Machine Model SSC500‐PC Sealer Crimper Owner’s Manual Rev ...€¦ · Artos Engineering Company ... potential bad crimping terminal need to be judged by manual, as CFM alarm acknowledge

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Machine Model SSC500‐PC Sealer Crimper Owner’s Manual

P/N 6‐119937 Rev. 1.0 Date 25 Jan 2017

Artos Engineering Company

21605 Gateway Court

Brookfield, WI 53045

Phone 262‐252‐4545 Fax 262‐252‐4544

www.artosnet.com

[email protected]

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Scope:

1 Instruction

2 Technical Data

3 Operation

4 Setting

5 Maintenance

6 Technical Requirement

7 Troubling Shooting

8 Circuit Diagram

9 Pneumatic Diagram

10 Spare parts list

11 Appendix

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1. Instruction:

SSC500 machine applies to assembly seal, strip wire insulation , crimp terminal ,it combined

3 functions in one machine.

Features:

◆ Multi-Function: Applies with seal load, wire strip ,terminal crimp 3 functions.

◆ Application filed: Applies to single , dual 0.15 to 2mm² insulation wire.

◆ Flexible: seal load, wire stripping, terminal crimping as three moulds be set with required

◆ Quality: Applied with wire color sensor & CFM function.

◆ Maintenance: No tooling changeover

◆ Friendly HMI : HMI easy to put into operation

2. Technical Data

Type SSC500

Connection Power Supply AC220V 50HZ

Pneum. Connection 0.6 MPa 12m3/h

Power 2 KW

Parameter Size L800*W680*H1880mm(with no post)

Weight 285 Kg

Crimping Terminal

Force 20 KN

Stroke 30 或 40 mm

Capacity Cross Section Range 0.15~ 2.0 mm²

Seal Option HardShell /Mini seal

Cycle time 3 S

Strip-Cut Stripping Length A A≤6mm

Break-out length B

Note: Single Wire 20mm

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3. Operation

1) Preparation

① Are all electrical installations complete?

② Applicator are properly installed, Not

Interfere with wire jaws.

③ Pneumatic hose are properly connected, pneumatic are applied on 0.6Mpa.

④ Correct Voltage Available according to technical data ( Note: Actuator should be off fully

stroke position. Appendix 3.)

⑤ Language: click icon on HMI ,click to choose language (below figure)

2)PC Touch Screen

① Main page(Production)

Tab page Switch Bar

Performance Data Func. Keys

0.6MPa Power On

Function Status

No interference

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● Tab page switch bar: click the button to switch to the screen needed.

● Performance Data: This area show parameter type, output volume, NG volume,

cycle time, blade times. Hold press CLR 5seconds to clear the number to zero, number of

blade used times can clear to zero in setting page “ “screen, to press CLR 5seconds.

⊙Operator Number：this column will be input the operator number.

⊙Process ( ID/Name)：Input process ID, terminal number, applicator ID, and seal tracker

number to verify correct material and tooling are applied.

⊙Running state：it show the status of machine, running , EMG etc.,

● Function Status: In this area, we can know the status of each function. Background

color ” ”is ON, Background color ” ”is OFF.

● Function Button:

⊙ CFM alarm acknowledge: if CFM alarm acknowledge is OFF, click CFM alarm acknowledge

potential bad crimping terminal need to be judged by manual, as CFM alarm

acknowledge is on, potential bad crimping terminal will be cut directly.

⊙ system reset: after shooting trouble ,click this button to be ready to start (F. 2)

⊙ Start: click this button to start run machine.

⊙ Wire color Learning: first wire will learn color automatic, Color Learning ,click this button

will learn color also.

② Setting page

click to pop-up password input screen, then click ,input the password which

level ≥2

Figure 1

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● Seal parameter setting :

Click to modify(Fg.4). Detail explain: ⊙ Vacuum On Time: the time the vacuum absorb seal up from the bottom of tank ⊙ Vacuum Off time: the time the vacuum wait to next absorbing ⊙ Vibrator Width: the amplitude of vibrator ⊙ S15 jammed time: the time of check whether the seal is jammed in front of S15 sensor in the

track ⊙ S15 below time: the time of air blow , which to clear the jammed seal. ⊙ Seal on tube delay: the time of seal on tube, then PIN go up from the tube ⊙ Seal on pin delay: the time of seal on PIN, then PIN go up from the track ⊙ Pick wire time: the time after crimping ,then wire jaws actuator start to move back.

● Stripping Crimping Parameter Bar

Click to modify(fg.4), Detail explain: ⊙ Stripping closing: the time stripping blade closing, if necessary, set longer time to get good

stripping quality. ⊙ Crimp cycle: the interval time between two times of crimping ⊙ Motor speed: the motor speed, active for all A,B,C motor.

图 4

Seal parameter setting Stripping crimping parameter setting

Count setting Bar Function Key

Fg.4

Func

tion

Sett

ing

bar

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Function setting bar：Freedom of choice to open/close the function

⊙ S11 Detection: Detection whether there is seal in the S11 position of track. ⊙ S14 Detection: Detection whether seal is move to tube correctly. ⊙ S15 Detection: check the time between two continuity seals. ⊙ SEAL function: open/close load seal function. ⊙ Stripping Function: open/close wire strip function . ⊙ Wire Color Check Function: open/close wire color sensor detection function. ⊙ Crimp Function: open/close crimp terminals function. ⊙ Crimp Detection Function: open/close CFM to monitor quality of wire terminal crimping. ⊙ CFM Confirmation Function: open/close whether cut automatically when CFM sense bad

crimping. ⊙ Dual Function: switch two-wires and single-wire production mode selection, selection for

dual-core wire display dual function, select single wire display for single-function (Note: The single wire work at the right hole)

● Counting Set The Bar: Peeling, cutting blades and yield count, click CLR cleared.

( Note: Only the use of the tool in the tool can only be cleared after replacing)

● Function Keys:

⊙ 中文/English: User interface language support， Chinese and English switch.

⊙ Normal login: to distinguish remote login or normal login . ⊙ Restore Factory Setting: Click this button, seal and stripping

crimping parameters set to factory settings

③ Mode Selection Screen

Click the pop-up password input notes, the input LEVEL 2 user password entry mode selection screen.

Working Mode: click Working Mode automatically switch to production page. Slow Mode: Select the slow mode, and then click Run starts, the device runs a slow loop Stepping Mode: Select Stepping progressive mode, and then insert the harness or click Run to

start the action carried out step by step Multi-cycle mode: Select the multi-cycle mode and then click Run starts normal operation

multiple loops, click again to start the machine stops running multi-cycle operation

One cycle Mode: Select one cycle mod and then insert the wire harness or click Run to start the device running a loop

Manual Mode: Click to enter manual mode proofread debugging interface,

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④ Calibration screen

( Note: Machine will work as open safe door in this Mode

for adjust handy)

Click Calibration to pop-up password input screen(fg.8),after input correct password will show adjust screen. (fg.9) Note: LEVEL 3, original password is “3”.

● Manual mode bar: click the accordingly button to act, the movement is interlocked to avoid

interference . for example :fg.10and fg.11,as pin up is on, pin forward and sensor can be activation, as Pin down is on ,pin forward and sensor backward can not be active, it show Lock.

● Actuator position column : click the button, actuator will move to the accordingly position. The

actuator position is interlocked to avoid interference. For example:fg.9 VS fg.10,if stripping motor(B) Wire gripper is on,tube backward and Blade open will show as Lock, to avoid interference

( Note：to click the button of actuator ,pay attention to safety operation )

LEVEL 3 Pw: 3

Fg. 8

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● Actuator position adjust bar: act the one position of actuator, the coordinate of the actuator will

display,(fg.10),click two side tap to +/- the coordinate of actuator.

( Note：please pay attention to safety operate when adjust actuator position )

Manual mode bar

Actuator position colum

n

Actuator position adjust bar

Stripping Motor coordinate

Interlock

Fg.9

Fg.10 Fg.11

Interlock

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⑤ Product selection

click to pop-up the screen(fg.8),input LEVEL 3 password to enter the product selection screen. (fg.12)

( Note：before do some setting in product selection screen, should press EMG button. After

setting, release EMG button, press Reset button.)

● Process ID bar: show currently process ID, or click the tab to create new I（Detail

see item 2-②）

● Choose Process ID: click the tab to choose the process have stocked.

● Parameter: It show the actuator coordinate according the activate process

（ Note :Parameter can not be setting in the screen, go to Setting screen to if change the

parameter）

● Factory setting: hold 5s this key, all parameter override to factory setting.

● Set as default: set the parameter as factory setting.(only AST can have the high level password to

set)

⑥ ALARM LIST

Click to check the alarm record list, show as below figure.

Process ID Bar Choose Process ID

Fg.12

Parame

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⑦ I/O STATUS

This function only be acted by A.S.T.

⑧ HELP

Click“ ”，will find the instruction of machine.

⑨ PASSWORD LEVEL

User should input premission to enter the setting bar with the distinguish premission

level. Level 2 is “2”,Level 3 is “3”which is in factory setting.

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⑩ CHANGE PASSWORD

Click “ “ to show figure As below, enter password in “Old password ”bar, key new

password in “New password ”bar.

⑾ CFM

if SSC500 applied with net-work CFM, click ” “ ,then can be processed in remote.( Detail

see. Appendix 1)

⑿ LIGHT

Click “ “ to turn on or off light on the machine.

3) CFM Monitoring Screen

① function of CFM：to monitor the quality of terminal crimping.

② setting of CFM：if change over terminal , setting the applicator or replace new applicator

need to setting the CFM, show as below

(detail see appendix 1)

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4. Basic Mechanical Setting

1)Note:

⊙Before changeover terminal, power off the machine.

⊙Check no interference after setting before power on.

⊙press unit setting see ( Appendix 2)

2)Setting process:

① Press and Applicator shut height adjustment： Turn the press 360°,by supplied wrench,to

avoide break the applicator with overshort shut height of press，ajustment process see

fg.13 (Note:press post should be upper position, will adjust later )

② Add process ID：

a. click “ “ to enter this screen, then press EMG button.

b. Key in new Process ID and Process name (Fg.14)，all parameter are“0”(fg.15)

c. click factory setting，parameter will be set (fg15)，then will enter the calibration screen

to fine-tuning the parameter.

Enter process ID and name All parameters are 0,press Factory Setting tab 5S all parameters are set rough

Fg.14 Fg.15

Loosen two screws before

adjust the spindle

Press post

Fg.13

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③ 3 small principles: for shortest wire broken-out length needed, machine are set

according to this rule. a. Set the gap between wire gripper and seal jaws is 0.5~1mm(right figure)

b. Set the gap between wire gripper and applicator is 0.5~1mm(F.g17)，

ensure theapplicator do not interference with wire gripper as press go down. The press adjust way see ( Fg. 18)

c. set the stripping motor(B) coordinate (F.g9)，zero cut of wire be about

0.5mm(right figure)

Fg.17 Fg.18

④ unfit situation ：Please follow below action to shoot the issue after we according

to“3 small pricinple”( Note: Adjustor need trained by AST)

Gap 0.5mm Loosen 4 screw Turn the screw

Gap 0.5mm

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a. Core wire extruded：Increase Stripping coordinate of the stripping motor(B) “△X”

(Note: if△X＞0.5,need to adjust press backward accordingly)

b. Core wire lower：Decrease Stripping coordinate and Wire gripper coordinate of the

stripping motor(B) coordinate “△X”

c. Seal extruded：Increase Seal coordinate of stripping motor(B)“△Y”

d. Seal is lower：Decrease Seal coordinate of Stripping motor(B)“△Y”

⑤ Adjustment for press post：turn press to dead bottom by means of supplied wrench after

press EMG button, move the wire gripper under the press post, adjust press post to push

wire gripper down to correct position( hole for insert wire of wire gripper is same level to

applicator guider. Lock the press post. It will be checked or fine-tuned .( Note：Press

post has been adjusted in correct position before outgoing factory)

⑥ FINE-TUN SECTION OF TERMINAL

a. Applicator Structure: generally applicator can be adjusted to get correct B dimension &

D dimension (Above figure),Detail see applicator instruction.

b. B dimension adjust: turn C.H. knob to adjust the dimension B(for example：AST E4

adjustment stork is 2mm，turn one pitch is 0.02mm),also we can adjust press spindle,

1.Applicator in dead bottom

2.turn down post

3.hole is same level to guide

of applicator

4.loosen nut and

fix screw

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one pitch is 0.03mm (Fg.13)

c. D dimension adjust : turn I.H. knob to adjust the dimension D(for example： AST E4

adjustment stork is 2mm，one pitch is 0.02mm)

AST E4 applicator other brand applicator

C.H. knob I.H. knob One pitch is 0.02mm

I.H. knob

C.H. knob

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5. Maintenance

1) Maintenance for Press and Applicator：Detail refer to press manual ( Appendix 2)

2) change parts( Note：switch off power and pneumatic before change parts)

a、change Pin b、change Tube

①

②

②

①

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c、Change Jaws d、change seal feeding unit

e、Change Blade and Spacer f、change wire gripper

3) Apply grease and cleaning ① General : to avoid accident happen and ensure SSC500 is good condition, it should be maintained

according to below instruction. The maintenance technician is an employee of or a person explicitly trained by AST. Operator is not allowed to maintain with no authorized.

② Instruction: The maintenance work instruction and intervals must be strictly followed.

②

②

①

③

③

④

①

①

③

⑤

②

①

②

①

Unfix the screw to take off spacer ②

①

②

③

④

⑤

Clean gripper once a week

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③ greasing instruction

NO. Location Name Type of oil To the oil and inspection

Remarks Mar Oil name and Interval Oil Responsible

1 Figure a Linear Guides 1 Shell Grease S2 6Months 1g Technician

2 Figure b Linear Guides r 1 Shell Grease S2 6Months 2g Technician

3 Figure c Linear Guides 1 Shell Grease S2 6Months 1g Technician

4 Figure d Pin swing 1 Shell Grease S2 3Months 1g Technician

5 Figure e Linear Guides 1 Shell Grease S2 6Months 2g Technician

6 Figure f Flip tube structure 1 Shell Grease S2 3Months 2g Technician

7 Figure g Jaw sliding 1 Shell Grease S2 3Months 1g Technician

8 Figure h Press 2 Grease HP-R 1Months 5g Technician

图 a 图 b

① ①

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Fg. c Fg. d Fg. e

Fg. f Fg. g Fg. h

① ①

①

①

① ②

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6.Technical Requirement

Need to provide cable drawing before order SSC500.(detail Appendix 5)

1)cable requirment：

①applicator not modification：B≥33mm

②if B＜33mm，need to check as below to evaluate whether need to modify applicator.

B=x+y+9 （x---end of conductor to cut-off tab；y--- thickness of holder part）

For example : y=6.5，then B=x+6.5+9=x+15.5， also B should ＞20 without seal ，or＞25 with seal

2)seal requirement：diameter should less＜8mm 。

3）Applicator requirement：

The center distance of two wires is 8mm, so to avoid the forming part injured another wire,

the width of forming part of applicator should match below requirement：

a≤(8-b/2)*2

a--- width of forming part；

b--- diameter of seal or wire

mostly if a ≦ 12mm, will match

the requirement。

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7. Trouble Shooting

1) General

The HMI can show all necessary information. It allows users to quickly and effectively exclude minor malfunctions. If the user could not exclude a particular malfunction by himself/herself, he/she could use the information in the shown help text when consulting service technicians.

1.1 Safety instructions

Warning! Before removing any component of the machine to carry out repair operation, please shut down SSC500 and disconnect the electrical and pneumatic power supplies.

2) Spare Parts

Usually, the spare parts will not be delivered in the first batch of the cargo with SSC500. Negotiate with the service technicians about the spare parts or purchase from AST company specially.

3) Trouble shooting

Most malfunctions could be detected by the controller. According to different types of malfunction, SSC500 will either stop at the current operation steps or complete the entire operation cycle.

If there is one malfunction happened, HMI screen will show the relevant error information. This information will tell operator the wrong type and initial condition that cannot be reached. After correcting the error, press RESET(START) to confirm receiving the error information. Then, SSC500 can start working again.

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4) Possible malfunctions can be displayed as follows:

S/N DESCRIPTION REASON & SHOOTING

1 Alarm01: Emgerence stop! Release the EMG button

2 Alarm02: CFM monitoring alarm! Cancel CFM,detail see champer 5.1

3 Alarm03: the front door was open! Door-1 Close Door 1

4 Alarm04: the right door was opened! Door-2 Close Door 2

5 Alarm05: the back door open! Door-3 Close Door 3

6 Alarm06: electric cylinder reset timeout! Reset electrical cylinder or remove the block.

7 Alarm07: PLC Battery runs out,change it in 10 days! Change PLC Battery in 10 days.

8Reminder08:Please press the start button to enter the

ready to run state,or reset

9Reminder09:Stripping blade usage exceeds the set value,please timely replacement

Replace stripping blade and set the counter to zero

10Reminder10:Cutting blade usage exceeds the set value, please timely replacement!

Replace cutting blade and set the counter to zero

11Reminder11:wire color is error, please reinsert or re-learning!

12Alarm12: No detected Sensor S21 signal (top position sensor of crimping machine)

13Alarm13: not detected S14 signal, please re-learn or re-set it!

1)reset the machine to re-learn. 2)Check feeder kit works well. 3)Tube is correctly in its position. 4)Reset S14 amplifier.

14Alarm14: No detected Sensor S00 signal (tube cylinder forward sensor)

Check S00 whether in correct position or was broken.

15Alarm15: No detected Sensor S01 signal(tube cylinder backward sensor)


16Alarm16: No detected Sensor S02 signal (trigger cylinder,forward)


17Alarm17: No detected Sensor S03 signal (trigger cylinder,backward)


18Alarm18: No detected Sensor S04 signal(back and forward cyclinder of Pin, Forward one)


19Alarm19: No detected Sensor S05 signal(back and forward cyclinder of Pin, Back one)


20Alarm20: No detected Sensor S06 signal(up and down cylinder of Pin, upper one)


21Alarm21: No detected Sensor S07 signal(up and down cylinder of Pin, middle one)


22Alarm22: No detected Sensor S08 signal(up and down cylinder of Pin, bottom one)


23 Alarm23: No detected Sensor S09 signal(jaws open) Check S09 whether broken.

24 Alarm24: No detected Sensor S10 signal(jaws close) Check S10 whether broken.

25Alarm25: No detected Sensor S11 signal(end of feeding track)

Check the hole for S11 whether was chocked or seal in correct position.

26 Alarm26: No detected Sensor S12 signal(air pressure)Check whether pneumatic valve was switch on or the pressure was match requirement.

27Alarm27: No detected Sensor S19 signal(stripping cylinder, open one)


28Alarm28: No detected Sensor S20 signal(stripping cylinder, close one)


29Alarm29: NO detected sensor S15 signal(middle of feeding track)

Check whether seal was block to arrange in the track or no seal in feeder tank.

30 Alarm30: Crimp timeout! Check whether the crimpper was block.

31Alarm31:detected sensor (S22) signal、crimping machine handle is inserted into the!

Take out the handle.

32 Reminder32:After switching function, you need to reset! Reset.

33Alarm33: No installation pin, or no SEAL on Pin!(From the S11 sensor)

Check the hole for S11 whether was chocked or no seal in the track.

34Reminder34:Zero Cut blade usage exceeds the setting value,please timely replacement!

Replace the Zero Cutter with new pair set.

35 Alarm35: Motor Set the speed too low! Check whether Motor speed set was too low.

36 Alarm36: Applicator's life exceedCheck applicator works well,and reset the number to zero.

37 Alarm37: Start trigger signal (S16) abnormal

38 Alarm38: Start trigger signal (S17) abnormalSee chamfer 5.2

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7.5.1 CFM Alarm

The system captures the crimp force signature over time, and compares this signature to the reference or “learned” signature using OES’s patented CDA algorithm.

The malfunction maybe caused below:

S/N CFM Alarm Possible Causes Shooting

1Applicator is not installedsteady in the press

Check whether some stand,insulation,or chippings areunder the applicator.

2 Applicator is not steady.Forming blade of applictor is not assembliedcorrecttly,or forming blade is wrapped.

3Carrier feeder of applicator donot work well.

Make it work well.

4 Missing of strands.

1)Check closed position of blade is appropriated.2)Check whether the blade is worn.3)Check whether the wire jaws is in correct position.4)Whether wire is too bend or too long in the stand outof jaws.

5 Insulation is peeling out fully.

1)Check closed position of blade is appropriated.2)Check whether the blade is worn.3)Check whether the wire jaws is in correct position.4)Whether some scrap was hold between the peelingcylinder arm or under Micrometer head guage.

6 Strand was cut

1)Check closed position of blade is appropriated.2)Check whether the blade is worn.3)Check whether the wire jaws is in correct position.4)Whether wire is too bend or too long in the stand outof jaws.

7Some strands were out ofterminal

1)Check whether wire jaws is in correct positionaccoringly to applicator.2)Whether the press post is in correct height.3)Forming blade of applicatin is well shaped.4)Other reason.

8 CFM setting is not correct. See CFM instruction.

9 Other apperances It will be judged by detail facts.

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7.5.2 S16,S17 Alarm

Trigger mechanism as below:

S16 , S17 are two sensors to sense the wires are inserted in start

position. As machine are ready to start, two wires insert in the holes of tube to

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push two trigger levers which hide in backside hole of tube, as the two levers are

sense by S16, S17, the machine will start a cycle.

Detail mechanism showed as above figure. If S16, S17 alarm frequently ,maybe

caused as below chart.

S/N S16，S17 malfunction causes Shooting

1Tube is not horizontal when ready for start.

Tube motion tracking is determined by a groove part,if the groove parts was loosed,the trigger lever will interference in the hole of tube. Should adjust the groove parts.

2 Scrap was in the tube hole Clean the inner hole of tube.

3Scrap blocked the trigger lever.

Clear the scrap which block the trigger lever.

4S16，S17 is not corrected assemblyed

The sense distance of S16,S17 is 0.6mm, so the gap between S16,S17 to the trigger lever shoube 0.8~1mm.

5Spring force it too light for small compressed.

If force is too light, the trigger lever can not spring back steady.

6 Other apperance Judge by the detail facts.

7.5.3 other malfunction

8. Circuit Diagram

S/N Other malfunction Shooting

1 Seal was piecred.

1)check whether pin is aligned with end seal position in the track. 2)check whether seal is exhausted. 3)Check whether too seals in seal kit tank.

2 Seal was cut.

1)May it caused for seal was piecred prior. 2)over one seal in the jaws. 3)2 seals pick by pin.

3Machine run with no wire automaticly.

S16,S17 issue.

4Not smoothly to insert wire in the jaws.

Check whether the jaws position is aligned with tube hole,may it caused by some scrap stock to block the electrial cylinder to reset to Zero position.

5 Color sensor malfuntion1) too white particle in the wire 2)Wire is not same length.

Documents

Machine Model SSC500‐PC Sealer Crimper Owner’s Manual Rev ...€¦ · Artos Engineering Company ... potential bad crimping terminal need to be judged by manual, as CFM alarm acknowledge