Alpha 550 Operating Instruction

EN
OPERATING INSTRUCTIONS
ALPHA 550
TOPWIN
Art. No. 0349573 – Version 3
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
Publisher
Komax AG
Industriestrasse 6
6036 Dierikon
Switzerland
Phone +41 41 455 04 55

Fax +41 41 450 42 66
info.din@komaxgroup.com
komaxgroup.com
Reproduction of these instructions or parts of them in whatever form is not permitted without express
written permission from the publisher.
The figures and information in these instructions are subject to technical changes that become neces-
sary to improve the machine.
© January 2020 by Komax AG

CONTENTS
1 Introduction 9
1.1 About the machine 9
1.1.1 Machine description 9
1.1.2 Machine identification / voltage version 9
1.1.3 Technical data 11
1.1.4 Space requirements 12
1.1.5 Conformity 13
1.2 About the instructions 13
1.2.1 Structure of overall documentation 13
1.2.2 Layout conventions 14
1.2.3 Saving the instructions 14
2 Safety 15
2.1 Explanation of warning notices 15
2.2 Intended use 15
2.3 General safety instructions 16
2.4 Technical condition of the machine 16
2.5 Sources of danger and warning stickers on the machine 17
2.5.1 Sources of danger 17
2.5.2 Description of sources of danger 17
2.5.3 Warning stickers on the machine 20
2.6 Personal protective equipment 21
2.7 Modes of operation 21
2.8 Work areas 21
2.9 Safety installations 22
2.9.1 Emergency stop button / approval button / main switch / manual shut-off valve
22
2.9.2 Safety cover 23
2.9.2.1 Protective plate side 2 23
2.9.3 Warning light 24
Alpha 550 TopWin – 0349573 – Version 3 – EN 3 / 156

2.10 Personnel qualification 25
2.10.1 Trained personnel 25
2.10.2 Qualified personnel 26
2.10.3 Specialized personnel 26
3 Machine view 27
3.1 General view 27
3.2 Mechanical components 28
3.2.1 Straightener unit (optional) 28
3.2.2 Belt drive 29
3.2.3 Guide parts 29
3.2.4 Swivel unit side 1 30
3.2.5 Cutting and stripping unit 31
3.2.6 Blade holder 31
3.2.7 Deposit gripper (optional) 33
3.2.8 Swivel unit side 2 33
3.2.9 Wire deposit basic module (2 m or 4 m) 33
3.2.10 Safety cover 35
3.3 Electrical components 35
3.3.1 Control cabinet 35
3.3.1.1 Identification of machine PC 37
3.4 Pneumatic components 38
3.4.1 Maintenance unit 38
3.4.2 Other pneumatic components 38
3.4.3 Pressure regulator, belt drive 39
3.5 Operating consoles 40
3.5.1 Main operating consoles 40
3.5.2 Secondary operator console 40
3.6 Tool drawer 41
3.7 Waste container 41
3.8 4 LED tower light (option) 42
4 Transport / scope of delivery 43

4.1 Safety instructions 43
4.2 Auxiliary equipment and tools 43
4.3 Transporting the packaged machine 44
4.3.1 Handling symbols 44
4.3.2 Corrosion protection 45
4.4 Unpacking the machine 45
4.4.1 Removing packaging 45
4.4.2 Screw in mounting feet 46
4.5 Moving the machine 46
4.6 Scope of delivery / reception inspection 48
4 / 156 Alpha 550 TopWin – 0349573 – Version 3 – EN

5 Installation and start-up 49
5.2 Installation location 50
5.3 Auxiliary materials and tools 50
5.4 Setting the machine in place 51
5.4.1 Leveling the machine 51
5.4.2 Adjusting the table height 52
5.4.3 Straightener unit / wire changer 52
5.4.4 Attaching wire deposit basic module 53
5.4.4.1 Mechanical assembly of wire deposit basic module 53
5.4.4.2 Electric / pneumatic assembly of wire deposit basic module 57
5.4.5 Attaching the console 57
5.4.6 Position machine PC in control cabinet 58
5.5 Connecting machine to electrical power source 58
5.6 Pneumatic connection of machine 60
5.7 Setting the positions of the safety cover 60
5.8 Modules and accessories 61
6 Operation 63
6.2 Checks prior to operation 63
6.3 Operating elements on the machine 64
6.4 User interface 66
6.5 User name and password 67
6.6 Switching on the machine 67
6.7 Switching off the machine 68
6.8 Setting up the machine 70
6.8.1 Adjusting the punched disk 70
6.8.2 Adjusting the straightener 70
6.8.3 Guide parts 70
6.8.4 Setting contact pressure of belt drive 71
6.8.5 Setting the encoder 73
6.8.6 Replacing the guide hose 73
6.8.7 Guide tube on swivel unit side 1 74
6.9 Drawing in the wire 75
6.10 Designate V stripping blades 76
7 Maintenance 77
7.2 Maintenance notes 78
7.2.1 Cleaning agents 78
7.2.2 Lubricants 78
7.3 Maintenance plan 79

7.3.1 Maintenance intervals 79
7.3.2 Maintenance table 79
7.4 Maintenance work 81
7.4.1 Cleaning entire machine 81
7.4.2 Check the entire machine for damage 82
7.4.3 Empty the waste container 83
7.4.4 Clean the crimp modules 84
7.4.5 Clean the seal modules 85
7.4.6 Emptying maintenance unit water separator 86
7.4.7 Check and clean straightener unit 87
7.4.8 Check and clean belt drive 88
7.4.9 Check and clean guide tube and guide hose 89
7.4.10 Check and clean swivel unit side 1 90
7.4.11 Check and clean swivel unit side 2 91
7.4.12 Cleaning stripping unit blades 92
7.4.13 Checking and cleaning the conveyor belt and tipping tray 93
7.4.14 Testing and cleaning of crimp modules 94
7.4.15 Checking and cleaning seal modules 95
7.4.16 Checking piece counter operation 96
7.4.17 Cleaning and lubricating the cutting and stripping unit 97
7.4.18 Checking and lubricating the swivel unit 97
7.4.18.1 Checking belt tension. 97
7.4.18.2 Lubricating the gripper 98
7.4.18.3 Lubricating the linear guides 100
7.4.18.4 Lubricating the pinion 101
7.4.19 Cleaning and lubricating the safety cover guide 102
7.4.20 Checking, cleaning and lubricating the crimp modules 103
7.4.21 Cleaning the filter mats 104
7.4.22 Checking guide parts and bearings 105
7.4.23 Checking toothed belts 106
7.4.24 Checking, cleaning and greasing the gripper seal 107
7.4.25 Crimp modules 108
8 Servicing and repairs 109

8.2 Auxiliary equipment 110
8.2.1 Adjustment tools and gauges 110
8.2.2 Recommended frequency-measuring devices 111
8.3 Basic settings 111
8.3.1 Two-hand operation 112
8.3.2 Setup work with two-hand operation 112
8.3.3 Record the blade range of movement 112

8.3.4 Adjusting the zero position for swivel unit side 1 113
8.3.5 Adjusting the zero position for swivel unit side 2 116
8.3.6 Adjusting the deposit gripper 119
8.3.7 Adjusting thread-in support 120
8.4 Replacement tasks 122
8.4.1 Replacing the blade holders 122
8.4.2 Replacing blades 124
8.4.3 Tensioning and replacing conveyor belt 125
8.5 Setup work 133
8.5.1 Tensioning the toothed belt 133
8.5.1.1 Tensioning the belt drive belts 133
8.5.1.2 Tensioning drive belt of belt drive motor 134
8.5.1.3 Tensioning drive belt of swivel unit side 1 141
8.5.1.4 Tensioning drive belt of swivel unit side 2 142
8.5.2 Adjusting the hold-up unit 143
8.5.3 Basic settings of straightener 145
8.5.3.1 Standard straightener 145
8.5.3.2 Straightener, pneumatic 146
8.5.4 Adjusting the conveyor belt position 147
8.6 Troubleshooting 150
8.6.1 General malfunctions 150
8.6.2 Malfunctions of toothed belt 150
8.6.3 Special cases in the software 151
8.6.3.1 Clearing the machine 151
8.6.3.2 Handling of wires in gripper side 2 after restart 151
8.6.3.3 Handling wires in gripper of double gripper module after restart 151
8.6.3.4 Faults 152
9 Decommissioning / storage / disposal 155

9.1 Decommissioning 155
9.2 Storage 155
9.3 Disposal 156

CONTENTS

INTRODUCTION
1 INTRODUCTION
1.1 ABOUT THE MACHINE
1.1.1 Machine description

The Komax Alpha 550 is an expandable, fully automatic wire processing machine for processing sin-
gle-wire leads.
1.1.2 Machine identification / voltage version

1 Name plate
2 Voltage version sticker
3 Sticker 3×400/230 V machine

2
Fig. 1: Base machine, view from above
Name plate
1 Komax article number
1 Part.No.: 0341000 Alpha 550 2
2 Machine type
3 Ser. No.: 550.0001
3 Machine number
4 3×208-480VAC 50/60Hz 5.6kVA 5
4 Voltage (possible range)
5 Power input
Fig. 2

INTRODUCTION
Voltage version sticker

The actual voltage version of the machine is
shown on this sticker.
Fig. 3
Sticker 3×400/230 V machine

Power supply
For this voltage version, an additional sticker is
L... - L... 400V 50/60Hz
applied to machines with a 400 V transformer. N - L... 230V 50/60Hz
Four wire systems only, neutral required!
L1
WYE
Machine
L2
WARNING PEN N
PE
L3
For other power supply voltages

refer to manual !
Fig. 4

INTRODUCTION
1.1.3 Technical data
Conductor cross sections* 0.13 – 6.0 mm2 (AWG26 – AWG10)

Up to 10 mm2 (AWG8) as an application on request
Length range 60 – 65 000 mm (2.35 in – 213 ft)
Optional 30 – 60 mm (1.18 in – 2.36 in)
Length accuracy Repetition accuracy: ± (0.2% + 1.0 mm [0.039 in])
Outer diameter of wire Max. 5.1 mm (0.2 in)
Strip length, full stripping Outer diameter of Side 1 (S1) Side 2 (S2)
(depending on outer diameter of wire In-line Out-of- In-line Out-of-
wire) line line
In-line: in-line blade 1 mm (0.04 in) 15 mm 29.5 mm 16 mm 29.5 mm
Out-of-line: out-of-line blade (0.6 in) (1.16 in) (0.6 in) (1.16 in)
2 mm (0.08 in) 14.9 mm 29.4 mm 16 mm 29.4 mm
(0.6 in) (1.16 in) (0.6 in) (1.16 in)
4 mm (0.16 in) 14.5 mm 29.2 mm 15.5 mm 29.2 mm
(0.6 in) (1.15 in) (0.6 in) (1.15 in)
Strip length with half strippingOuter diameter of Side 1 (S1) Side 2 (S2)
(depending on outer diameter of wire In-line Out-of- In-line Out-of-
wire) line line
In-line: in-line blade All 15.5 mm 35.5 mm 15.5 mm 35.5 mm
Out-of-line: out-of-line blade (0.6 in) (1.4 in) (0.6 in) (1.4 in)
Wire feed-in speed max. 12 m/s (39 ft/s)

Process module 4
Noise level < 80 dB (without crimp tool)
Ambient temperature 10 – 45 °C (50 – 113 °F)
Air humidity 30–90% non-condensing
Electrical connection 3 × 208 – 480 V 50/60 Hz; 5.6 kVA
or
3 × 400 V, 50/60 Hz, neutral required, 5.6 kVA
Compressed-air connection 5–8 bar (73–116 psi)
Recommended operating pres- 6 ±0.5 bar (87 ±7.25 psi) ***
sure **
Air consumption with lead Crimp / crimp: Seal crimp / seal crimp:
length of 500 mm (19.7 in) < 7 m3/h (247 ft3/h) < 11 m3/h (388.5 ft3/h)
Weight (including 2 crimp mod- approx. 1300 kg (2866 lbs)
ules)
Dimensions (w x h x d) With deposit basic module 2 m
(height with safety cover closed) 3825 × 1790 × 1525 mm (150.6 × 70.5 × 60 in)
Height with safety cover open: With deposit basic module 4 m
2790 mm (110 in)
5770 × 1790 × 1525 mm (227 × 70.5 × 60 in)

INTRODUCTION
* In the case of very hard, ductile, or thick-stranded wires, processing might not be possible even
within the cross-section range. If you are in doubt, Komax will be happy to provide processing
samples of your wires. Larger cross sections up to 10 mm² (AWG 8) are possible on request fol-
lowing a feasibility test.
** Non-compliance with the recommended operating pressure can restrict the proper functioning of
peripheral devices. Please also observe the technical data for peripheral devices.
*** The maximum permitted operating pressure depends on the ambient temperature: 6.5 bar up to
40 °C / 6 bar above 40 °C.
1.1.4 Space requirements
Wire deposit basic module 2 m: 3825 mm (150.6 in)

Wire deposit basic module 4 m: 5770 mm (227 in)
1525 mm (60 in)
Height with closed cover: 1790 mm (70.5 in)

Height with fully open cover (maximum opening): 2790 mm (110 in)
Fig. 5

INTRODUCTION
1.1.5 Conformity
Manufacturer / authorized representative for Komax AG

compilation of technical documents Industriestrasse 6
6036 Dierikon
Switzerland
Phone: +41 41 455 04 55
Fax: +41 41 450 42 66
The product conforms with the relevant provi- n Machinery Directive 2006/42/EC
sions laid down by these guidelines. n EMC Directive 2014/30/EU
n RoHS Directive 2011/65/EU
Applied harmonized standards n EN 61000-6-2

electromagnetic compatibility (EMC), Generic
standards - Immunity standard for industrial
environments
n EN 61000-6-4
electromagnetic compatibility (EMC), Generic
standards - Emission standard for industrial
environments
1.2 ABOUT THE INSTRUCTIONS
1.2.1 Structure of overall documentation

The complete documentation of the machine consists of the following documents:
n Operating instructions
n Pneumatic diagram
n Wiring diagram
n I/O list
n Software instructions, TopWin
n Installation instructions, TopImage
n Documentation for process modules (customer specific)
n Documentation for quality-monitoring modules (customer specific)
n Documentation for accessories (customer specific)
n Replacement parts catalog (electronic)
n EC declaration of conformity / machine inspection protocol

INTRODUCTION
1.2.2 Layout conventions

These instructions are laid out as follows:
TIP
Designates user tips and other useful information.
Tip is not a signal word for hazards.
Instructions
Instructions consist of one or more optional requirements, one or more action sequences, and op-
tional results.
Requirements
n This is a requirement for an action.
u This is an action sequence.
Ú This is an intermediate result from a single action sequence.

Ú This is the result of a complete set of instructions.
Numbered lists
1. This is a numbered list.
List
n This is a non-numbered list.
– This is a second-level bullet point.
Markup elements
Legend numbers for images are designated as in the following example:
Place setup gauge [1] into guide-tube holder [2].
Software elements are designated as in the following example:
Press OK.
1.2.3 Saving the instructions

These instructions are a component of the product. Keep the instructions at hand so that they are al-
ways readily accessible for any needed information.

SAFETY
2 SAFETY
2.1 EXPLANATION OF WARNING NOTICES
DANGER
Indicates a hazard of high risk.
Death or serious injury will result if it is not prevented.
WARNING
Indicates a hazard of medium risk.
If not prevented, death or serious injury can result.
CAUTION
Indicates a hazard of low risk.
If not prevented, injury can result.
NOTICE
Designates useful information
If not followed, property damage may result. Notice is not a signal word for hazards.
2.2 INTENDED USE

The machine shall only be used for wire processing in accordance with specifications in the technical
data. Any other use is prohibited and considered improper.

SAFETY
2.3 GENERAL SAFETY INSTRUCTIONS

System boundaries
The machine encompasses the area from wire multi spool dereeler to wire deposit. Responsibility for
the wire feed lies with the machine operator.
Personal safety
Personal safety is only ensured for a single operator. Make sure that your actions do not expose any-
one to danger. Any person who initiates a command input automatically becomes an operator and is
thereby responsible for all other persons at the machine.
Personnel qualification
Only persons with the relevant qualifications are allowed to operate, configure, and maintain the ma-
chine.
Instructions
These instructions form part of the product. Read the instructions before working with the product.
Observe the safety and warning notices.
Other instructions
Also observe the safety and warning notices in the instructions for the associated products.
2.4 TECHNICAL CONDITION OF THE MACHINE

Safe operation
If safe operation of the machine can no longer be guaranteed, disconnect the machine from the
power supply system and secure against inadvertent activation.
Safety installations
Operate the machine only with functioning safety installations. Do not remove, bypass or manipulate
any safety installation.
Maintenance
Service the machine within the indicated time intervals. If you do not regularly service the machine,
damage may result and the smooth operation of the safety installations cannot be ensured.
Spare parts
Replace defective parts only with original spare parts. You can obtain original spare parts from Ko-
max.
Backfitting
The machine must not be backfitted.
Software
The software must not be modified.

SAFETY
2.5 SOURCES OF DANGER AND WARNING STICKERS ON THE MACHINE
2.5.1 Sources of danger
1 2 3 4 5 6
7 4 8 9 10 7 11
Fig. 6: General view
1 Straightener unit / linear changer 7 Control cabinet
2 Belt drive / roller drive 8 Cutting and stripping unit
3 Swivel unit side 1 9 Safety cover
4 Process modules 10 Center of gravity of the machine
5 Swivel unit side 2 11 Wire deposit
6 Maintenance unit
2.5.2 Description of sources of danger
Wire drive
There is risk of burns in the area of the wire drive. Always keep the safety cover closed during pro-
duction. Keep hands away from the belts of the belt drive and away from the drive rollers during
setup work.

SAFETY
Swivel units side 1 and side 2

There is risk of injury in the area of moving machine parts. Always keep the safety cover closed dur-
ing production. Keep hands away from moving machine parts when setting up.
Process modules
There is risk of injury in the area of moving machine parts. Always keep protective covers closed dur-
ing production. Keep hands away from moving machine parts when setting up.
Cutting and stripping unit

There is risk of being cut in the area of the cutting and stripping unit when the safety cover is open.
Prior to working on the blades, disconnect the machine from the power supply system and take mea-
sures to prevent inadvertent activation.
Control cabinet
Touching live parts can be fatal. Prior to working on the control cabinet, disconnect the machine from
the power supply system and take measures to prevent inadvertent activation.
Wire draw-in
In front of the wire draw-in there is risk of injury from wire loops and wires under tension. Make sure
there are no persons in the hazard area of the wire draw-in.
Straightener unit / linear changer

There is risk of injury to fingers and hands at the straightener unit and linear changer. Keep hands
away from from the rollers and from moving machine parts while they are in motion. Be especially
careful when setting up a new wire at the linear changer during operation. Keep fingers and hands
away from wire line during operation.
Main air supply

There is risk of injury at the main air supply from compressed air. Switch off the compressed air and
the load voltage before removing parts of the main air supply.
Safety cover
When opening and closing the safety cover there is risk of crushing. When opening and closing keep
hands away from under the safety cover and from the safety cover guides. Keep hands away from
under the safety cover during operation.
Center of gravity of the machine

The center of gravity of the machine is not in the center. There is a tipping risk when moving the ma-
chine. When moving the machine, position the lifting truck or forklift according to specifications and
lift the machine only as high as necessary. When unpacking the machine, the position of the lifting
truck or forklift is indicated on the packaging.
Wire deposit
There is risk of crushing in the area of the wire deposit. Keep hands away from the deposit tray until it
has extended and is no longer moving.
There is risk of burns in the area of the conveyor belt. Keep hands away from the conveyor belt dur-
ing operation.
In the area of the conveyor belt there is risk of flying parts. Wear safety goggles when working in the
area of the conveyor belt.

SAFETY
Wire deposit basic module 2 m

The wire deposit basic module 2 m is not supported prior to assembly. There is risk of injury from
heavy loads during assembly and disassembly, as well as during packing and unpacking, of the wire
deposit basic module 2 m.
Assembly, disassembly, packing and unpacking of the wire deposit basic module 2 m must always
be done by at least two persons.

SAFETY
2.5.3 Warning stickers on the machine

Warning stickers on the machine also indicate hazards.
Procedure
u Heed the warning stickers attached to the machine.
Fig. 7: Front side
Fig. 8: Back side Fig. 9: Swivel arm

SAFETY
2.6 PERSONAL PROTECTIVE EQUIPMENT

Procedure
u Wear safety goggles when safety covers are open.
2.7 MODES OF OPERATION

Normal operation
Wires are processed in this mode of operation.
All safety covers must be closed in order to work in this mode of operation.
Special operation
In this mode, basic settings and setup work are performed on the machine.
The safety covers can be open for setup, but two-hand operation is active and moving machine parts
are moved at lower torque and reduced speed. Use the approval button and the start button to real-
ize two-handed operation. The approval buttons and start buttons are arranged to make one-handed
operation impossible.
2.8 WORK AREAS

The machine is worked with and on in the work areas. Depending on the activity carried out, work ar-
eas can become hazard areas.
2 1
Fig. 10
1 Work area during production 2 Additional work area during setup

SAFETY
2.9 SAFETY INSTALLATIONS
2.9.1 Emergency stop button / approval button / main switch / manual shut-off
valve
Fig. 11
Emergency stop button

Pressing the emergency stop button stops all machine movement and cuts off the power and com-
pressed-air supply. The machine is immediately switched to safe mode. If the emergency stop button
is pressed, the machine cannot be restarted until the emergency stop button is unlocked and load
voltage is switched back on.
Main switch
The main switch disconnects the power supply from the machine.
Approval button
The approval button, together with an actuation button (start button on the base machine or control
buttons on the modules), is needed to carry out machine movements with the cover open.
The approval button lights white when it should be pressed, and extinguishes when it should no
longer be pressed.
Start button
The Start button starts production.

SAFETY
2.9.2 Safety cover

The safety cover is closed all around and monitored with two redundant safety switches.
During special operation, machine movements are carried out with the safety cover open. Two-
handed operation makes it impossible for the machine operator to reach into the hazardous area of
moving machine parts.
Forcing open the safety cover during production leads to immediate stoppage of the machine and in-
terruption of load voltage. In this situation the approval button is not enabled.
2.9.2.1 Protective plate side 2

If side 2 of the machine is supplied without side
feed and without the optional MTC (mobile termi-
nal quick changer), a protective plate is attached
at the factory.
This protective plate forms part of the protective

cover and may only be removed if a side feed is
attached, or an MTC is being used.
If the machine is subsequently refitted for opera-

tion without side terminal feed and without MTC,
the protective plate must be ordered from Ko-
max (see Replacement parts catalog for article
number).
Fig. 12: Protective plate side 2
WARNING
Risk of injury due to openings in the safety cover
u Do not start production until all openings in the safety cover have been covered.

SAFETY
2.9.3 Warning light

Orange color lighting in the cutting and stripping unit indicates blade movements in setup mode with
the cover open:
n Warning light blinks: The cutting and stripping unit will move in two seconds.
n Warning light illuminates: The cutting and stripping unit moves.
The warning light is monitored. If the warning light malfunctions or is cut off from the electric circuit,
the machine will halt. Production can no longer take place.
1 Warning light on the cutting and stripping

unit (front side)
Fig. 13
1 Warning light on the cutting and stripping

unit (back side)
Fig. 14

SAFETY
2.10 PERSONNEL QUALIFICATION

Komax applies minimum requirements to operating personnel and differentiates between the follow-
ing user groups:
n Trained personnel (e.g. operators)

n Qualified personnel (e.g. setup technicians, maintenance technicians)
n Specialized personnel (e.g. service technicians, shift supervisors)
Overview of tasks
Specialized personnel
Tasks
Qualified personnel
Trained personnel
Positioning, aligning and leveling of machine × ×
Installing and setting up process modules and applications × ×
Carrying out mechanical basic configuration of machine × ×
Setting up and configuring the machine × ×
Preparing machine for production × × ×
Loading and charging ready for production × × ×
Safely operating machine during production × × ×
Performing daily maintenance × × ×
Maintaining and servicing the machine × ×
Carrying out trouble-shooting, malfunction diagnosis, and fault correction ×
Correct selection of replacement parts ×
Storage and disposal ×
2.10.1 Trained personnel
Requirements
n Technical knowledge
n Read and write (national language)
Product knowledge
n Technical data and intended use
n Sources of danger and safety installations
n User interface and its functions (normal operation)
n Proper action in the case of malfunctions

SAFETY
2.10.2 Qualified personnel
Requirements
n Requirements and product knowledge corresponding to “trained personnel”
n Mechanical training
n Electrotechnical knowledge
n General knowledge of wire processing
Product knowledge
n In-depth knowledge of user interfaces and their functions (special operation)
n Knowledge of areas of application and processing options
n In-depth knowledge of components (mechanical, electrical, pneumatic) and their function, set-
tings and maintenance
2.10.3 Specialized personnel
Requirements
n Requirements and product knowledge corresponding to “trained personnel” and “qualified per-
sonnel”
n Knowledge of spoken and written English
n Electrotechnical continuing education/training
n In-depth knowledge of wire processing
Product knowledge
n Reading and interpreting of wiring diagrams, I/O list and pneumatic diagram
n In-depth knowledge of PC hardware, operating system (Windows), periphery and applications
n In-depth knowledge of process options (applications and Q tools)
n Systematic approach for troubleshooting and fault diagnosis

MACHINE VIEW
3 MACHINE VIEW
3.1 GENERAL VIEW
1
10 6 7
3 10 4 5 10 9 8
Fig. 15: View from above
1 Machine side 1 (processing of first wire 2 Machine side 2 (processing of second wire
side) side)
3 Straightener unit (optional) 4 Belt drive
5 Swivel unit side 1 6 Cutting and stripping unit
7 Swivel unit side 2 8 Wire deposit with batch separation
9 Table, operator console 10 Emergency stop button

MACHINE VIEW
4 1 3
8 5 6 10 9 7 2
Fig. 16: View from front
1 Safety cover 2 Main switch
3 Main operating console 4 Secondary operator console
5 Pressure regulator, belt drive 6 Waste container
7 Maintenance unit 8 Tool drawer
9 Komax PC M TopImage 10 Komax PC O RT Linux
3.2 MECHANICAL COMPONENTS
3.2.1 Straightener unit (optional)

The straightener unit straightens the wire in front of the wire drive. It consists of one or several
straighteners.
There is no straightener unit included in the basic configuration of the machine.

MACHINE VIEW
3.2.2 Belt drive

The belt drive transports the wire and measures the exact length.
The belt drive has a brushless AC servo motor

with length measurement and slippage monitor-
ing. Slippage monitoring ASC (Anti-Slip Control)
compares the values of the motor encoder and
the length-measurement encoder.
Encoder
Motor Controller
Continue
Stop
No Yes
Encoder
Fig. 17
1 Safety cover 2 3 5
2 Wire draw-in
3 Belt drive with toothed belt 1

4 Contact cylinder
5 Revolving encoder contact wheel 7

4
6 Encoder wheel for length measuring
10
7 Wire guide at back (take-up for guide 6
hose) 8
9
8 Manometer
9 Pressure regulator (contact pressure of

belt drive / roller drive)
11
10 Adjusting screw (contact pressure of en- Fig. 18
coder wheel)
11 Adjusting screw for gap between en-

coder wheel and encoder contact wheel
3.2.3 Guide parts

The guide parts ensure that the wire is fed smoothly and securely into the machine and they must be
selected according to the diameter of the wire being processed.
Selection of correct guide parts for belt drive
Outer diameter of wire Wire guide, center Wire guide, back
up to 2.3 mm Ø 2.5 mm Ø 2.5 mm

2.3 – 5.1 mm Ø 6 mm Ø 6 mm

MACHINE VIEW
Guide parts, belt drive 1 2 4 7 6

1 Wire draw-in, long
2 Holder, wire draw-in
3 Wire guide, center

n Ø 2.5 mm (standard)
n Ø 6 mm (in drawer content)
4 Spacer, wire guide, center
5 Wire guide, back

n Ø 2.5 mm (standard)
n Ø 6 mm (in drawer content)
3 5
6 Spacer plate, wire guide, back
Fig. 19
7 Stop bar
3.2.4 Swivel unit side 1

Swivel unit side 1 swivels the wire and positions
2
it on the process modules of machine side 1. It 1
determines the pull-off length on the first wire 3
side.
4
1 Swivel arm
2 Wire gripper
3 Guide tube holder
4 Thread-in support
5 Motor, swivel axis

6 5
6 Motor, pull-off axis
Fig. 20

MACHINE VIEW
3.2.5 Cutting and stripping unit

The cutting and stripping unit cuts the wire and
strips it using the swivel unit. It cuts off bad ter-
minals.
6
1 Cutting and stripping unit complete
2 Warning light 1
3 Top blade holder
2
4 Bottom blade holder
5 Chute for bad parts side 2 3 7

6 Motor
4 5
7 Deposit gripper (optional)
Fig. 21
Automatic conductor detector ACD (optional)

The incision monitoring, Automatic Conductor
Detector (ACD), is a highly sensitive measuring
system. It has been developed to indicate the
slightest contact of the stripping blades with the
wire strands and to separate the relevant wire
end in accordance with the quality requirements
of the operator.
Incision monitoring performs the following moni-

toring:
n Incision monitoring during cutting

n Incision monitoring during stripping
Fig. 22
3.2.6 Blade holder

The blade holders are optional. The following blade holders can be configured:
n Blade holder with one blade line

n Blade holder with two blade lines
n Blade holder of form blade with two blade lines

MACHINE VIEW
Blade holder with one blade line
1 Cutting blade
2 Bad part blade
3 Stripping blade 3
1
3
Fig. 23
Blade holder with two blade lines
1 Cutting blade
2 Bad part blade
3 Stripping blade in-line 3 4

4 Stripping blade out-of-line
1
4
3
Fig. 24
Blade holder form blade
This blade holder is suited to special blades such

as form blades, X-blades and similar.
1 Cutting blade 4
3
2 Bad part blade
3 Stripping blade in-line

2
4 Stripping blade out-of-line
1
4
3
Fig. 25

MACHINE VIEW
3.2.7 Deposit gripper (optional)

The deposit gripper [1] is available as an option
and is easily turned upwards, without tools, to
better access the blades.
Fig. 26
3.2.8 Swivel unit side 2

Swivel unit side 2 swivels the wire and positions
it on the process modules of machine side 2. It
4 3
determines the pull-off length on the second wire
side.
1 Swivel unit side 2
2 Wire gripper
3 Motor swivel axis
4 Motor pull-off axis
1 2
Fig. 27
3.2.9 Wire deposit basic module (2 m or 4 m)

The wires produced are laid in the tipping tray using the conveyor belt. When the batch size has been
reached, the tray tips the wires into the extendable tray. The extendable tray moves out from behind
the safety cover for easy removal of the wires. For wires above a certain wire length, the extendable
tray no longer moves out.

MACHINE VIEW
1 3 2 1 3 2
4 5 6
4 5 6
Fig. 28: Wire deposit basic module 2 m Fig. 29: Wire deposit basic module 4 m
1 Conveyor belt 4 Extendable tray
2 Conveyor belt motor 5 Fixed tray
3 Tipping tray 6 Wire deflector

MACHINE VIEW
3.2.10 Safety cover

The safety cover protects users from danger points in the area of moving parts during ongoing pro-
duction.
The maximum safety cover opening/top position can be set to three different heights.
The safety cover is opened and closed with the button Open / close safety cover («Operating ele-
ments on the machine», p. 64).
1 Column 3
2 Safety screens
3 Frame
2 1 2
Fig. 30
3.3 ELECTRICAL COMPONENTS
3.3.1 Control cabinet
DANGER
Live parts
Coming into contact with live parts can be fatal.
u Open the control cabinet only if you have been trained at least to the level of “Qualified person-
nel”.
u Only open the control cabinet if absolutely necessary and only when the power supply has been
cut using the main switch.

MACHINE VIEW
View: “Control cabinet, left” 1

1 ACSe regulator
2 Frequency converter
3 Transformer 4
4 Terminal block
(mounting plate «load») 3
2
Fig. 31
View: “Control cabinet, right”

8 6 7
10
3
2 9
5
Fig. 32 Fig. 33
1 Komax PC TopImage 2 Komax PC RT Linux
3 Terminal block 4 Terminal block

(mounting plate «controls») (base plate «periphery»)
5 SMe PCB 6 Print I/Oe
7 Power supply unit 8 Mains filter
9 Piece counter 10 Main switch

MACHINE VIEW
3.3.1.1 Identification of machine PC

A label is affixed to every machine PC. The data
on the label allows for unambiguous configura-
tion and confirmation of the machine PC series.
The label contains the following information:
1 Type of machine PC
2 Article number 5
3 Serial number
4 Bar code with all information
5 Ports, connections and assignment of

plug-in positions
1 2 3 4
Fig. 34: Label on machine PC type «M»
1 2 3
Fig. 35: Label on machine PC type «R»

MACHINE VIEW
3.4 PNEUMATIC COMPONENTS
3.4.1 Maintenance unit

1 Manual shut-off valve
5 4 2 1
2 Pressure regulator
3 Manometer
4 Solenoid valve
5 Pressure switch
6 Reducing nipple
7 Filter
3 7 6
Fig. 36
TIP
Manual shut-off valve
The manual shut-off valve completely cuts off compressed air to the machine.
3.4.2 Other pneumatic components

1 Proportional pressure regulator
Fig. 37

MACHINE VIEW
1 Valve terminal
1
Fig. 38
1 Compressed air storage
Fig. 39
3.4.3 Pressure regulator, belt drive

1 Pressure regulator
2 Manometer
Fig. 40

MACHINE VIEW
3.5 OPERATING CONSOLES
3.5.1 Main operating consoles

1 Load voltage on/off
4 1
2 Approval button
3 Open / close safety cover
4 Emergency stop button 9

5 Start button
6 Stop button
7 Keyboard
8 Mouse
2 3
9 Monitor with touchscreen operation 7 6 5 8
Fig. 41
3.5.2 Secondary operator console

1 Emergency stop button
2 Approval button
3 Open / close safety cover
4 Switch load voltage on / off
5 Wire advance 1 4 7
6 Open / close belt drive
2 5
7 Start button
3 6
Fig. 42

MACHINE VIEW
3.6 TOOL DRAWER

1 Drawer insert, top
2 Drawer insert, bottom
3 Drawer insert, guide tube
1 2 3
Fig. 43
1 Wire guide, back 3 4

2 Wire guide, center 5
3 Allen key SW4
2 6
4 Wire guide complete, diameter 6.5
5 Wire guide complete, diameter 4 7

1
6 Allen key set 8
11
7 Side cutter 9
8 Pin insert 4 mm socket wrench 1/4
10
9 Key for control cabinet
Fig. 44
10 Hexagonal socket wrench SW13
11 Ratchet 1/4 inch
3.7 WASTE CONTAINER

1 Waste container for insulation waste
from wire side 2
Fig. 45

MACHINE VIEW
3.8 4 LED TOWER LIGHT (OPTION)

The optionally available tower light clearly shows
the state of the machine. Even at greater dis-
tances, such as in a workshop with many ma-
chines, the operator can request assistance from Red
machine-maintenance and quality-assurance
personnel.
Green
Red light
Constantly lit
Blue
n Load voltage switched off
n Emergency stop button pressed
Orange
Blinking
n Machine malfunction
Green light
Constantly lit
n Machine producing
Blinking
n Batch size has been reached, operator must

confirm batch size
Blue blinking light

The blue blinking light is manually switched on
with switch [1] on the operator console.
n Optical call-up of machine maintenance
Orange blinking light

The orange blinking light is manually switched on
using switch [2] on the operator console.
n Optical call-up of quality assurance

1 Call-up of machine maintenance
2 Call-up of quality assurance
Fig. 46

TRANSPORT / SCOPE OF DELIVERY
4 TRANSPORT / SCOPE OF
DELIVERY
4.1 SAFETY INSTRUCTIONS
Personal safety
Make sure that your actions do not expose anyone to risk.
Only Komax service technicians and transport specialists may transport the machine.
More information: («Personnel qualification», p. 25)
Handling symbols
Observe the handling symbols on the packaging.
More information: («Handling symbols», p. 44)
General
Transport the machine with care in order to prevent damage from external forces or careless loading/
unloading.
4.2 AUXILIARY EQUIPMENT AND TOOLS

Auxiliary equipment
n Forklift
– Lifting capacity at least 2000 kg
– Fork length at least 2000 mm
n Two lifting trucks or one lifting truck with fork length 2000 mm
Tools
n Battery-powered screw gun

n Torx insert bit T25
n Wrenches size 24 and 19

n Side cutter
n Blades
4.3 TRANSPORTING THE PACKAGED MACHINE

The machine and accessories are delivered in a sturdy wooden crate.
Packaging unit Dimensions (l×w×h) Gross weight
Basis incl. console and con- 247 × 231× 203 cm (97 × 91 × 1700 kg (3748 lb)
veyor belt, basic module 2 m 80 in)
Conveyor belt, basic module 445 × 77 × 150 cm (175 × 30 × 320 kg (706 lb)
4m 59 in)
Table 1: Packaging
4.3.1 Handling symbols
Do not use hand-hooks. Center of gravity not in the cen-

Weight ter.
is not in
balance
Sensitive electronic components Do not use forklift at this spot.
This side up. Keep dry.
Do not place weight on lid. Store in a dry place at below

0
40° 40° C and above -20° C.
-20°
Fragile Do not expose to direct sunlight.

4.3.2 Corrosion protection

The packaging includes a special mat to protect against corrosion. The inhibitors evaporate, thereby
protecting the metal surfaces.
Procedure
u Prevent leakage of the protective atmosphere.
u Immediately reseal any damaged packaging.
u Do not open packaging until contents are to be used.
NOTICE
Damage to the machine
The machine can rust due to lack of corrosion protection.
u Open the packaging only briefly for purposes of inspection and reseal it immediately. The protec-
tive atmosphere renews itself after every closing.
4.4 UNPACKING THE MACHINE
4.4.1 Removing packaging
WARNING
Risk of injury from tipping of machine
The center of gravity of the machine is not in the center. The machine can tip when it is being
lifted.
u Use a forklift with a lifting capacity of at least 2000 kg and 2000 mm long forks.
u Use a lifting truck to assist if needed.
u Lift the machine only as high as necessary.
WARNING
Risk of injury from tipping of components.
The machine is packaged together with additional components. The components are not
bolted together. There is danger of tipping when unpacking the machine and the components.
u Follow the sequence below when unpacking the machine.
Procedure
u Remove covers from pallet.
u Release all protective bands and remove packaging materials.
u Remove all boxes and loose machine parts from the pallet and set aside.
u Carefully lift individual components out of the packaging.
u Carefully lift machine out of the packaging.

4.4.2 Screw in mounting feet
Procedure
u Release the machine attachments to the pallet.
u Lift machine with forklift.
u Remove pallet using a lifting truck.
NOTICE
Disturbance-causing vibrations
The more stable the machine stands, the less disturbance-causing vibration is generated.
u Screw in mounting feet evenly to at least halfway.
u Make sure that the mounting feet can still be turned after screwing in.
Procedure
u Screw in all mounting feet [3] evenly with the
hex nut [2] at least halfway into the machine
frame.
u Lower the base machine onto the mounting
feet.
u Tighten the counternuts [1].
1
2
3
Fig. 47
4.5 MOVING THE MACHINE
WARNING
Risk of injury from tipping of machine
The center of gravity of the machine is not in the center. The machine can tip when lifting.
u Use a lifting truck with a lifting capacity of at least 2000 kg and 2000 mm long forks.
u Lift the machine only as high as necessary.
NOTICE
Machine damage due to moving the machine with console
The console and the machine are not connected to one another. Moving them simultaneously
can lead to damage.
u Always remove the console prior to moving the machine.

NOTICE
Machine damage due to moving with wire deposit
Simultaneously moving the machine and wire deposit can lead to damage.
u Always remove the wire deposit prior to moving the machine.
Procedure
u Position the lifting truck [1] as illustrated. 1
u Push machine to desired place.
Fig. 48

4.6 SCOPE OF DELIVERY / RECEPTION INSPECTION

The delivery notes are affixed to the outside of the crate in a plastic envelope.
Procedure
u Check delivery against paperwork to ensure supply is complete.
u Upon delivery, immediately check product for transport damage.
TIP
Immediately notify Komax AG or the nearest representative if there are any missing or defec-
tive parts.
u Use the delivery feedback form included with the delivery notes.

INSTALLATION AND START-UP
5 INSTALLATION AND START-UP

Only Komax service technicians are permitted to install the machine.
Electrical connection
Observe the voltage data on the sticker attached to the machine. Incorrect voltage leads to serious
machine damage.
Operate the 400 V machine only with connected neutral conductor. Operating the machine without a
neutral conductor can result in destruction of individual devices.
When connecting several machines, the line conductors should be switched in rotation for symmetri-
cal mains load.
Wire protection / ground

The supply line must be secured with 32 A. The machine can only be operated with connected
ground.
Process modules / accessories

Installation work for process modules and accessories must follow the corresponding instructions.
Observe all safety and warning notices.

5.2 INSTALLATION LOCATION

Procedure
u Ensure the following conditions in accordance with technical data prior to installation:
n Space requirements
n Floor conditions
n Floor load capacity
n Compressed-air connection
n Electrical connection
n Network connection
n Exhaust connection
n Ambient conditions
n Sufficiently space in transport path: passage route, door openings, drops, cable-tray heights,
ramp heights, maneuvering space around corners
n Sufficiently large lifting tools: forklift, lifting truck
5.3 AUXILIARY MATERIALS AND TOOLS

Tools
n Lifting truck with 2-m-long fork

n Komax PC connection diagram document
n Clamping set
n Pneumatic diagram
n Wiring diagram
n Toolbox Alpha 5XX
Tools
n Wrenches size 24 and 19

n Hexagonal socket wrench set
n Allen key set
n Screwdriver size 3
n Ratchet
n Level
n Tape measure

5.4 SETTING THE MACHINE IN PLACE
5.4.1 Leveling the machine

Procedure
u Use the lifting truck to place the machine in
the intended location.
u Level the machine using a spirit level.
Fastening plate [1] of swivel unit side 2 serves

as a bearing surface for the water level.
1
Fig. 49
If the height of the mounting feet need adjusting:
u Release the counternuts [1] on the mounting

feet [3].
u Adjust the mounting feet [3] at the hexagonal
nut [2] until properly leveled.
u Make sure that all mounting feet are equally
loaded.
u Make sure that all mounting feet are screwed
1
out no more than halfway.
2
u Tighten the counternuts [1].
3
Fig. 50

5.4.2 Adjusting the table height

If the table is set too high or too low it is not pos-
sible to work with the MTC (mobile terminal
quick changer) option.
Procedure
u Adjust the table height [1].
900 mm ± 5 mm (35.4 in ±0.2 in)
Fig. 51
5.4.3 Straightener unit / wire changer
2 2
Fig. 52 Fig. 53
Procedure
u Attach straightener unit box [1] to base frame front with four screws M6×10 (bore holes [2]).
Procedure
u Connect the ground [1].
Fig. 54

5.4.4 Attaching wire deposit basic module

The wire deposit of the basic module 2 m / 4 m is delivered separately. Before the machine can be
used, the wire deposit must be attached to the base machine.
5.4.4.1 Mechanical assembly of wire deposit basic module
WARNING
Risk of injury from heavy loads
Wire deposit basic module 2 m is not supported prior to assembly.
u Always have at least two persons assemble the wire deposit basic module 2 m.
u Secure wire deposit basic module 2 m against tipping or falling.
The holding arm for wire deposit [1] must be re-

moved in order to move the wire deposit
smoothly into the machine base. Alternatively,
the hold-up unit can also be removed, in which
case the holding arm base on the column can be 3
left in place. 2
Procedure
u Release counternut [2] and adjusting
1
screw [3].
u Remove holding arm of wire deposit [1] from
the column. Fig. 55
u Remove bracket [4] from base frame.
Fig. 56
NOTICE
Machine damage due to collision
A collision between base machine and wire deposit can damage the machine.
u Carefully raise the wire deposit basic module 2 m to the machine.
u Carefully slide the wire deposit base module 4 m against the machine.
u Make sure that the wire deposit does not drag over the deposit table.
u Make sure the wire deposit does not collide with swivel arm side 2.

u On a carriage, push the wire deposit 2 m as close to the machine as possible.
u Push the wire deposit 4 m on rollers up to the machine.
To better approach the machine without collision, the horizontal angle of the wire deposit can be ad-
justed by adjusting the transport rollers at the end of the deposit.
Wire deposit basic module 2 m must be lifted by at least two persons.
WARNING
Cutting hazard
There is a cutting hazard in the blade area.
u Prior to working on the blades, disconnect the machine from the power supply system and take
measures to prevent inadvertent activation.
u Turn off the main air using the manual shut-off valve.
u Do not reach into the blades.
u Remove blade holders («Replacing the blade

holders», p. 122).
Fig. 57
u Attach setup gauge of swivel arm [5].
u Push the setup gauge of the swivel arm up as

far as possible in the blade holder.
5
Fig. 58

u Attach setup pin [6] to setup gauge of swivel

arm [5].
The hold-up unit must be at the topmost po-
sition.
5
u Push the wire deposit toward the blade 7
holder until the setup pin [6] (flush with the 6
setup gauge of the swivel arm) is against the
hold-up unit [7]. This specifies horizontal ori-
entation.
Fig. 59
u Loosely attach bracket [4] to the base plate.
Fig. 60
u Loosely attach holding arm of wire deposit [1]
to column and tighten counternut [2] and ad-
justing screw [3].
3
2
Fig. 61
u Loosely attach wire deposit with sliding
blocks in the carrier and cylinder screws [8]
8
(M8×20) and flat washers to the holding arm
of the wire deposit [1].
Fig. 62

u Adjust height on base with adjusting

screw [3] on holding arm of wire deposit [1].
Adjust the height so that the sliding blocks of
3
the wire deposit can be fastened to the
bracket [4] using M6×16 screws and flat
washers.
Fig. 63
u Loosely attach screws [9] (M6×16).
9
9
4
Fig. 64
u Orient (visually) the wire deposit horizontal to
the wire line of the machine. 7
u Orient the wire deposit vertically so that the
setup pin [6] comes to lie in the left bore hole
of the hold-up unit [7].
6
Hold-up unit [7] and setup gauge of the
swivel arm [5] must be in the topmost posi-
tion, and the setup pin 6 must lie flush on the
setup gauge of the swivel arm [5]. 5
Use the adjustment screw [3] and transport
rollers for height adjustment.
Fig. 65
u Orient wire deposit by adjusting the height at
the transport rollers using a spirit level.
u If the horizontal and vertical orientation, as
well as the lining-up to the wire line are cor-
rect, the wire deposit can be screwed tight
onto the holding arm of the wire deposit and
to the bracket on the base plate.
Fig. 66
u Screw down the mounting feet of the machine until they rest on the floor.
u Screw transport rollers up until they are suspended over the floor.

5.4.4.2 Electric / pneumatic assembly of wire deposit basic module
Procedure
u Connect wire deposit to base machine in accordance with pneumatic diagram.
All connecting parts are already provided and are either on the wire deposit or on the base ma-
chine.
u Guide the electric lead of the wire deposit into the control cabinet and connect in accordance
with the wiring diagram.
u Connect loose sensor cable to sensor of wire deposit.
The sensor is located next to the pneumatic cylinder which moves the wire tray out.
5.4.5 Attaching the console

Procedure
u Position the console as close as possible to
the back of the machine, as illustrated.
u Use the lifting truck to raise the console high
enough to lift it over the wire deposit.
Fig. 67
u Place console so that it does not rest on the
wire deposit.
u Adjust height by adjusting the feet.
Fig. 68

u Insert plug [1] into console and secure.
Fig. 69
5.4.6 Position machine PC in control cabinet

1 Komax PC TopImage
2 Komax PC RT Linux
Procedure
u Position the machine PCs in the control cabi-
net “right”.
u Connect the machine PCs according to the
attached PC label.
1 2
Fig. 70
5.5 CONNECTING MACHINE TO ELECTRICAL POWER SOURCE
DANGER
Live parts
Touching live parts can be fatal.
u Ensure that the power is disconnected during installation.
u Ensure that the main switch is set to OFF.

Procedure
u Observe country-specific voltage.
2
u Check machine voltage version [1]. 1
u Secure connection lead.
u Guide connection lead into control cabi-

net [2].
u Connect electrical cable in accordance with
wiring diagram.
Fig. 71

5.6 PNEUMATIC CONNECTION OF MACHINE
NOTICE
Machine malfunctions due to kinked compressed-air hoses
Kinks in compressed-air hoses lead to machine malfunctions.
u Lay compressed-air hoses so there is no kinking.
u Fasten the hoses in place in the area of moving parts.
Procedure
u Connect compressed-air supply to mainte-
nance unit [1].
Fig. 72
5.7 SETTING THE POSITIONS OF THE SAFETY COVER

The maximum opening of the safety cover can be adjusted using three different sensor positions.
WARNING
When opening and closing the safety cover there is risk of crushing.
u When opening and closing, keep hands away from under the safety cover and from the safety
cover guides.
NOTICE
Damage to sensor from improper installation
u Open the safety cover only as far as needed to position the sensor. The sensor must not be dam-
aged when closing the safety cover by the downward moving inner column.

Fig. 73 Fig. 74
Procedure
u Open the cover far enough to access the sensor positions [1].
u Attach sensor [2] with two screws M4×12 at the desired sensor position.
u Push the sensor into the clamping unit [3] until it is against the inner column.
u Pull sensor back approximately 0.5 mm.
If the LED extinguishes, the sensor has been pulled too far back.
u Tighten screw [4].
Ú The maximum opening of the safety cover is now set.
5.8 MODULES AND ACCESSORIES
TIP
Consult the mounting instructions for information on assembly of modules and accessories.


OPERATION
6 OPERATION
Only qualified personnel are permitted to operate the machine.
Personal safety
Make sure that your actions do not expose anyone to risk.
Technical condition of the machine

Only operate the machine if it is in technically sound condition.
6.2 CHECKS PRIOR TO OPERATION

Check the following items prior to each operation:
Electrical connections
u Check that all cables are correctly plugged in and not damaged. Replace defective cables.
Pneumatic connections
u Check that all compressed-air hoses are correctly connected and not damaged. Replace defec-
tive hoses.
u Check whether operating pressure is set correctly according to the technical data.
Safety installations
u Check function with machine switched on.
Ú Pressing the emergency stop button switches the load voltage off.
Safety covers
u Check integrity and function with machine switched on.
Ú Recesses must be covered with the included protective plates.

OPERATION
Ú Opening the safety cover causes the machine to stop.
6.3 OPERATING ELEMENTS ON THE MACHINE
TIP
User interface
The machine is primarily operated using the user interface.
u Also observe the software instructions.
On the entire machine and on the modules, only the buttons active in the current operating condi-
tions are lit and can be pressed.
Deactivated buttons have no function in this moment. They cannot be selected.
Color Behavior Status / cause / action
White permanently lit Active

Red lights / blinks Error
Yellow lights / blinks Dangerous action
Approval button
The approval button must be pressed simultaneously with the actuation button in order to carry out
machine movements with the safety cover open.
The approval button lights white when it must be pressed. It extinguishes when it must be released.
Color Behavior Status / cause / action
White permanently lit Approval button is active.

u In order to carry out the desired action, press the approval button
together with the actuation button.
White blinks quickly Action has concluded.
u Release the approval button.
Button is held pressed for more than 0.5 seconds without pressing
another button.
u Release the approval button.
u Press the approval button again.
White blinks slowly User has forgotten to press button.

u In order to carry out the desired action, press the approval button
together with the actuation button.
Main switch
The main switch disconnects the power supply from the machine.

OPERATION

Pressing the emergency stop button stops all machine movement and cuts off the power and com-
pressed-air supply. The machine is immediately switched to safe mode. If the emergency stop button
is pressed, the machine cannot be restarted until the emergency stop button is unlocked and load
voltage is switched back on.
Load voltage button

This button switches the load voltage on and off.
The button lights green when load voltage is switched on.
The button lights red when load voltage is switched off.
Start button
The Start button starts production.
The Start button lights green if it supports a function.
The corresponding function is displayed on the buttons on the user interface.
Stop button
The Stop button stops production.
The button lights red if it supports a function.
The corresponding function is displayed on the buttons on the user interface.
Button Safety cover

The button opens and closes the safety cover.
Briefly pressing the button opens the safety cover to the top position.
If the button is held pressed, the safety cover moves up until the button is released.
Button Open/close belt drive

The button opens and closes the belt drive.

OPERATION
6.4 USER INTERFACE

The machine is primarily operated using the user interface TopWin.
This chapter contains only a short description of user interface TopWin. See the software instructions
and online help for more information.
8
9
Fig. 75: User interface TopWin
1 Configuration 2 Definition
Machine-dependent settings and configu- The article to be produced is assembled
rations are carried out on the configuration on the Definition page.
page.
3 Sample 4 Production
The article is optimized for production on The article is produced on the Production
the Sample page. page.
5 Quality 6 Archive
The statistical production data of the ma- Errors that arise are displayed on the Ar-
chine are displayed on the Quality page. chive page.
7 Help 8 Options editor

You will find detailed information on menus Options are added or removed in the Op-
and functions on the Help page. tion editor.
9 Leaving TopWin

OPERATION
6.5 USER NAME AND PASSWORD

The table below shows the default setting when the machine leaves the plant.
User name Password Group Function
Administrator Komax Administrator This user has all rights. He is responsi-

ble for setting up and maintaining the
system. He can also change the Per-
mission editor and set up new users.
Komax recommends, in addition to the default settings, using the groups listed in the table below.
These groups can be imported from the TopWin USB stick.
User name Password Group Function
KomaxFull This user has all rights that affect the

functions of TopWin. He can select
and change all parameters.
KomaxSetup This user looks after the machines dur-
ing production and can carry out all
Freely selectable
Freely selectable
necessary settings. However, he can-

not access the operating system.
KomaxOperator This user produces with the machine.
This user has no access to settings
and cannot enter new articles.
6.6 SWITCHING ON THE MACHINE

Procedure
u Turn main switch [1] right to “ON”.
Ú The operating system loads.

Ú The loading procedure takes approxi-
mately 2 minutes.
Fig. 76

OPERATION
u Enter user name [1] and password [2] User

name and password.
Ú The Windows® interface and user inter-
face are loaded.
1
2
Fig. 77
u Switch on the load voltage [1].
Ú The machine has been switched on and is

ready for operation.
Fig. 78
6.7 SWITCHING OFF THE MACHINE
NOTICE
Data loss
Using the main switch to directly switch off can cause data and / or program loss.
u Never switch off the machine directly with the main switch.
u Switch the machine off following the procedure below.
Procedure
u Press button Leave TopWin [1].
Fig. 79

OPERATION
u Activate PC-herunterfahren [1].

Shut down the computer
Ú TopWin is shut down. The machine PC

powers down. 1
u Wait until the machine PC has completely
shut down.
Fig. 80
u Turn main switch [1] left to “OFF”.
Ú The machine is now switched off.
Fig. 81

OPERATION
6.8 SETTING UP THE MACHINE
6.8.1 Adjusting the punched disk

Procedure
u Turn the punched disk [1] until the opening 1
fits on the wire cross-section.
- Vertical wire feed from drum: select slotted
opening.
- Horizontal wire feed from dereel system:
select closed opening.
The opening must be neither too narrow nor too
wide.
Fig. 82
6.8.2 Adjusting the straightener

The two straighteners must be set to the wire diameter so that the wire is optimally oriented.
TIP
The rotating scale serves to roughly set the selected wire diameter. Different factors such as
insulation material, temperature, and wire feed influence the setting.
u Check process reliability during production and readjust the straighteners if needed.
Procedure 2 2
u Set the basic parameters at the straighteners 1 1
(«Basic settings of straightener», p. 145).
u Close the straightener rollers with eccentric
wing screws [1].
3
u Set the selected wire diameter according to
the scale on the turning knob [2].
The last rollers [3] must not turn at the same
time.
Fig. 83
6.8.3 Guide parts

Guide parts ø 2.5 are installed as standard equipment. They must be selected according to diameter
of the wire to be processed, and thus replaced when necessary.

OPERATION
Procedure 2 6
u Release cylinder screw [2] M5×25. 3
u Remove the attached wire guide, center [1]. 5
u Attach selected wire guide, center, using a
cylinder screw [2].
u Release two cylinder screws [3] M5×25.
u Remove wire guide, back, [4] including

spacer plate [5]. 1 4
u Push selected wire guide, back, against the
stop [6].
u Lay the spacer plate [5] on wire guide, back,
and attach with screws [3].
Fig. 84
Selecting correct guide parts
Outer diameter of wire Wire guide, center Wire guide, back
Up to 2.3 mm Ø 2.5 Ø 2.5

2.3 – 5.1 mm Ø6 Ø6
6.8.4 Setting contact pressure of belt drive

Contact pressure of the wire drive is factory preset to 4 bar. The pressure depends on the wire to be
processed and must be appropriately set.
The manometer [2] shows the contact pressure

of the belt drive.
Contact pressure depends on:
n Wire type
n Type of insulation
n Strip length
Contact pressure must be selected to convey the

wire without slipping, but not put too great a load 2
on the belts. 1
Procedure
u Pull the pressure regulating valve [1] up.
- Turn left = increase pressure Fig. 85

- Turn right = decrease pressure
u Produce and test wires.

OPERATION
NOTICE
The belt drive settings greatly influence the quality of the wire produced.
u Select the lowest possible contact pressure; this will protect the drive belt.
u Check the wire produced after changing the contact pressure.
u For stable production of wires with large cross-sections and long pull-off lengths, it may be nec-
essary to reduce the pull-out speed.

OPERATION
6.8.5 Setting the encoder
Adjusting the contact pressure

The contact pressure of the encoder wheel has been preset at the factory and does not generally
need to be adjusted.
Adjustments may be necessary if there are errors in encoder measuring, or for special wires.
Procedure
u Set contact pressure with threaded pin [1].
Turn clockwise = increase pressure 3

Turn counterclockwise = decrease pressure
Adjusting the end stop 2

The gap between the encoder wheel [2] and con-
tact wheel [3] is factory preset to 0.5 mm. This
gap can be adjusted if it is no longer correct.
u Adjust the end stop with screw [4].
The end stop is correctly set when there is a

gap between the encoder wheel [2] and con- 1 4
tact wheel [3] of 0.5 mm.
Fig. 86
6.8.6 Replacing the guide hose

The machine includes a guide hose [1] with a diameter of 5 mm as standard equipment. The tool
drawer contains hoses with inner diameters of 4 mm and 6.5 mm for adapting to the respective wire
diameters.
Procedure 2
u Release the clip seal [2].
1
Fig. 87

OPERATION
u Open clamp [3] by releasing knurled nut [4].
u Remove hose [1] and replace with a new

hose.
u Retighten clip seal [2] and knurled nut [4].
3
4
1
Fig. 88
6.8.7 Guide tube on swivel unit side 1

Select the guide tube according to the wire to be processed. Guide tubes are available in the follow-
ing diameters:
1.3 mm 1.5 mm 1.7 mm 2.0 mm

2.3 mm 2.5 mm 3.0 mm 3.5 mm
4.0 mm 5.0 mm 5.5 mm
Procedure
u Pull the ring [1] of the coupling toward the
gripper and hold pulled.
u Pull out guide tube [2].
u Install new guide tube.
u Release the ring [1].
Ring [1] must slide entirely to the front after

the guide tube is inserted. 2 1
Fig. 89

OPERATION
6.9 DRAWING IN THE WIRE

Setup work must have concluded before the wire can be pulled in.
Procedure
u Press Feed in Feed out in TopWin on the
Feed in Feed out
2
configuration page. 1
u Open the straighteners [1].
u Pull wire through punched disk [2] and

straighteners [1].
u Close the straighteners [1].
Fig. 90
u Push wire to belt drive [1].
u Press the feed button [2] and hold it pressed

until the wire has been completely threaded.
Ú The wire is transported forward into the guide
tube and automatically stopped. TopWin au-
tomatically leaves the thread-in menu as 1
soon as enough wire material is threaded in.
Ú The wire is ready to be processed.
2
Fig. 91

OPERATION
6.10 DESIGNATE V STRIPPING BLADES

Different stripping blades are used depending on wire type. V-stripping blades are usually used. Spe-
cial blades are available for specialty wires; e.g. wires with thin insulation. Further help is available in
the Komax machine software or directly from Komax.
Recommended V stripping blade radii:
Conductor cross section

[mm²] V radius, R
0.08 0.10
0.13 0.10
0.22 0.30
0.35 0.50
0.50 0.50
0.75 0.50
1.00 0.75
1.50 0.75
2.50 1.00 Fig. 92
6.00 1.50

MAINTENANCE
7 MAINTENANCE
Proper maintenance is required for ensuring processing quality. It prevents malfunctions and their
consequences. This chapter shows you the maintenance tasks for the base machine. Maintenance of
the process modules and accessories is described in the corresponding instructions.
Depending on how the machine is used, Komax recommends regular inspection by a Komax service
technician. He checks quality-relevant components and adjusts them if needed.
Recommendation
n 1- to 2-shift operation: annual inspection by Komax service technician.

n 3-shift operation: semi-annual inspection by Komax service technician.

Daily maintenance work may be conducted by instructed personnel. The work carried out at other
maintenance intervals may only be conducted by qualified personnel.
Personal safety
Prior to carrying out maintenance in the hazardous zone of moving and energized electric parts, dis-
connect the machine from the power supply system and take measures to prevent inadvertent
switching on.
Switch off the compressed air supply at the shut-off cock and secure it against inadvertent switch-
ing-on.
Compressed air
The machine shall not be cleaned with compressed air, otherwise insulation waste will be blown into
the guides. Insulation waste increases wear and affects accuracy.
Maintenance intervals
The maintenance intervals apply to one-shift operation. If multiple shifts are worked, the maintenance
interval decreases proportionally.

MAINTENANCE
7.2 MAINTENANCE NOTES

Compressed air
u Do not use compressed air to clean the machine. Tiny fragments of insulation waste can be blown
into the guides. This increases wear and impacts production accuracy.
u If it is necessary to use compressed air, deinstall the parts to be cleaned.
Pointed or sharp tools

u Avoid the use of pointed or sharp tools on rail elements, conveyor belts and bowl feeders. They
can damage the profile or coating.
7.2.1 Cleaning agents
Procedure
u Use soft, lint-free cleaning cloths to clean the machine.
u Do not use cellulose thinners to clean the safety cover.
u Ensure proper ventilation.
u Wear protective goggles.
u Do not use solvents which corrode the metal.
u Oil or lubricate parts which have been cleaned with solvent.
7.2.2 Lubricants
NOTICE
Material damage from wrong grease and oil
The wrong grease and oil can lead to premature wear and thereby material damage.
u Use only the grease and oil mentioned.
u Do not use lubricants containing silicone.
All conventional bearing greases can be used for all bearing positions. High-pressure paste must be
used for contact areas that are subject to pressure.
Designation Type Use
Klüber Microlube GL 261 Grease Gripper, pinion

Mobil Vactra 2 ISO VG 68 Oil Guide rods
Arcanol MULTI2 Grease Linear guides
SMC GR-S-020 Lubricant Pneumatic units and assemblies
The lubricants are supplied in the grease-gun and oil press included with delivery.
Other possible grease: Molykote DX

MAINTENANCE
7.3 MAINTENANCE PLAN
7.3.1 Maintenance intervals

All maintenance intervals refer to one-shift operation:
n 8 hours / day
n 40 hours / week
n 160 hours / month
Use of the machine in multi-shift operation proportionately shortens the maintenance intervals indi-
cated. Likewise, the type of material to be processed and ambient conditions can shorten mainte-
nance intervals.
Maintenance work shall be performed following the instructions and within the maintenance intervals
indicated.
Weekly maintenance presupposes daily maintenance.
Monthly maintenance presupposes daily and weekly maintenance, etc.
7.3.2 Maintenance table
Maintenance du-
Semi-annually
As necessary
Monthly
Weekly
Yearly
ration
Daily
7.4.1 Cleaning entire machine 1 10 minutes

7.4.2 Check the entire machine for damage 1 5 minutes
7.4.3 Empty the waste container 1 2 minutes
7.4.4 Clean the crimp modules 1 2 minutes
7.4.5 Clean the seal modules 1 15 minutes
7.4.6 Emptying maintenance unit water separator 2 2 minutes
7.4.7 Check and clean straightener unit 2 5 minutes
7.4.8 Check and clean belt drive 2 5 minutes
7.4.9 Check and clean guide tube and guide hose 2 5 minutes
7.4.10 Check and clean swivel unit side 1 2 5 minutes
7.4.11 Check and clean swivel unit side 2 2 5 minutes
7.4.12 Cleaning stripping unit blades 2 2 minutes
7.4.13 Checking and cleaning the conveyor belt and tipping 2 5 minutes
tray
7.4.14 Testing and cleaning of crimp modules 2 2 minutes
7.4.15 Checking and cleaning seal modules 2 15 minutes
7.4.16 Checking piece counter operation 2 5 minutes

MAINTENANCE
Maintenance du-
Semi-annually
As necessary
Monthly
Weekly
Yearly
ration
Daily
7.4.17 Cleaning and lubricating the cutting and stripping unit 2 10 minutes
7.4.18.1 Checking belt tension. 2 5 minutes
7.4.18.2 Lubricating the gripper 2 5 minutes
7.4.18.3 Lubricating the linear guides 2 5 minutes
7.4.18.4 Lubricating the pinion 2 5 minutes
7.4.19 Cleaning and lubricating the safety cover guide 2 10 minutes
7.4.20 Checking, cleaning and lubricating the crimp modules 2 5 minutes
7.4.21 Cleaning the filter mats 2 5 minutes
7.4.22 Checking guide parts and bearings 3 15 minutes
7.4.23 Checking toothed belts 3 15 minutes
7.4.24 Checking, cleaning and greasing the gripper seal 3 10 minutes
7.4.25 Crimp modules 3 2 minutes
7.4.25 Crimp modules 3 2 minutes
1 - Operating personnel; 2 - Maintenance personnel; 3 - Service personnel

MAINTENANCE
7.4 MAINTENANCE WORK
7.4.1 Cleaning entire machine
Maintenance interval Daily
Maintenance personnel Operating personnel
Maintenance duration 10 minutes
Tools n All-purpose cleaner

n Soft, lint-free cleaning cloth
n Brush
n Industrial vacuum cleaner
NOTICE
Damage to machine from harsh solvents and compressed air
Harsh solvents damage the finish and plastic parts. Compressed air blows insulation waste
into the guides. Insulation waste in guides increases wear and affects processing accuracy.
u Do not use harsh solvents.
u Do not use compressed air.
Procedure
u Use the brush to clean production remains and dirt from all the process modules.
u Clean the storage containers for the individual process modules.
u Remove the longer wire remains (bad wires).
u Vacuum the process modules with an industrial vacuum cleaner.
u Rub the casing parts / safety cover with a soft cleaning cloth. Use an all-purpose cleaner to re-
move any stubborn dirt.

MAINTENANCE
7.4.2 Check the entire machine for damage
Tools n None
Procedure
u Visually inspect the machine components for signs of damage.
u Notify the maintenance crew promptly of any damage to the machine.
u Do not operate machine.

MAINTENANCE
7.4.3 Empty the waste container
Tools n None
Procedure
u Empty the waste container.
Fig. 93

MAINTENANCE
7.4.4 Clean the crimp modules

Procedure
u Remove insulation and wire remains.
u Lightly clean the module.
u Empty the catch tank.

MAINTENANCE
7.4.5 Clean the seal modules

n Cleaning set for sleeve application
Procedure
u Lightly clean entire module.
u Remove dust and insulation waste from stripper.
u Clean the transport rails.
u Check operation of SPM lighting and clean, if needed.

MAINTENANCE
7.4.6 Emptying maintenance unit water separator
Maintenance interval Weekly
Maintenance personnel Maintenance personnel
Tools n Drip pan
Requirements
n The compressed-air supply must be switched
on.
Procedure
u Open drain plug [1].
u Drain water into a drip pan.
u Close drain plug [1].
Fig. 94

MAINTENANCE
7.4.7 Check and clean straightener unit
Tools n Industrial vacuum cleaner
Procedure
u Check freedom of movement of the rollers.
u Remove insulation waste from rollers using

an industrial vacuum cleaner.
u Check basic settings.
Fig. 95

MAINTENANCE
7.4.8 Check and clean belt drive
Tools n Wrench set

n Allen key set
n Frequency measuring device
n Soft copper brush
Procedure
u Check belt drive belt for wear and insulation-
material deposits (inner and outer sides).
u Clean the encoder wheel with a soft copper-
wire brush.
u Check tension of belt drive belt («Tensioning
the toothed belt», p. 133).
Fig. 96

MAINTENANCE
7.4.9 Check and clean guide tube and guide hose
Tools n None
Procedure
u Check guide tube and guide hose for wear
and deposits.
u Remove guide tube and guide hose and
clean with compressed air.
Fig. 97

MAINTENANCE
7.4.10 Check and clean swivel unit side 1
Tools n None
Procedure
u Check gripper jaws for wear and deposits.
u Check free movement of grippers.
u Clean or replace gripper jaws.
Fig. 98

MAINTENANCE
7.4.11 Check and clean swivel unit side 2
Tools n None
Procedure
u Check gripper jaws for wear and deposits.
u Check free movement of grippers.
u Clean or replace gripper jaws.
Fig. 99

MAINTENANCE
7.4.12 Cleaning stripping unit blades
Tools n Soft, lint-free cleaning cloth
WARNING
Cutting hazard
Procedure
u Check blades for wear.
u Clean the blades with a soft, lint-free cloth.
u Replace blades, if necessary («Replacing

blades», p. 124)
Fig. 100

MAINTENANCE
7.4.13 Checking and cleaning the conveyor belt and tipping tray
Tools n None
Procedure
u Check the belt tension («Tensioning and re-
placing conveyor belt», p. 125).
u Check lateral running distance.
u Check the functioning of the tipping tray.
Fig. 101

MAINTENANCE
7.4.14 Testing and cleaning of crimp modules

Procedure
u Check and set the carriage guidance play.
u Clean and check the carriage.

MAINTENANCE
7.4.15 Checking and cleaning seal modules

n Klüber Microlube GL 261
Procedure
u Check pneumatic, mechanical and electrical machine parts for damage and wear. Replace if
needed.
u Thoroughly clean the module.
u Clean and lightly oil the guide shafts and sliding guides.
u Clean and lightly oil insertion tools and surfaces that join with the basic unit.
u Clean the seal drum.

MAINTENANCE
7.4.16 Checking piece counter operation
Maintenance interval Monthly
Tools n None
Procedure
u Check the quantity on the piece counter [1]
on the control cabinet.
u Produce a batch of ten pieces.
u Re-check the piece counter.
Ú The quantity on the piece counter [1] must

have increased by 10.
Fig. 102

MAINTENANCE
7.4.17 Cleaning and lubricating the cutting and stripping unit
Tools n Klüber Microlube GL 261

n Allen key set
Procedure
u Remove cover plate of cutting and stripping
unit.
u Clean and lubricate linear guides.
u Lubricate gear rack, pinion, and guides.
Fig. 103
7.4.18 Checking and lubricating the swivel unit
7.4.18.1 Checking belt tension.
Tools n Frequency measuring device
Procedure
u Check the belt tension.
Fig. 104

MAINTENANCE
7.4.18.2 Lubricating the gripper
Tools n Grease gun

TIP
For optimal lubrication, the grippers must be lubricated with a grease shot in the closed posi-
tion.
u Open and close the grippers several times after lubrication in order to ensure good distribution of
the lubricant.
Side 1
u Lubricate the lubricating nipples [1]. 1
Fig. 105
u Lubricate the lubricating nipples [1].
Fig. 106

MAINTENANCE
u Lightly oil the guide bars [1] with lubricating

oil.
u Push gripper down several times in order to
optimally distribute the lubricant. 1
Fig. 107
Side 2

2
1
Fig. 108
u Lightly oil the guide bars [1] with lubricating
oil.
1
u Push gripper down several times in order to
optimally distribute the lubricant.
Fig. 109

MAINTENANCE
7.4.18.3 Lubricating the linear guides
Tools n Nozzle for grease gun 1/8 in

n Grease gun
n Arcanol MULTI2
TIP
For optimal lubrication, push the stripping unit during and after lubrication from the back to the
front stop.
Procedure
u Remove the sealing plug. 1
u Lubricate the lubricating nipples of the linear

guides [1] with one or two grease shots.
Fig. 110
u Remove the sealing plug.
u Lubricate the lubricating nipples [1] with one

or two grease shots.
Fig. 111

MAINTENANCE
7.4.18.4 Lubricating the pinion
Tools n Nozzle for grease gun 1/8 in

n Grease gun
TIP
For optimal lubrication, push the stripping unit during and after lubrication from the back to the
front stop.
Procedure
u Lubricate the pinion with one or two grease
shots [1].
1
Fig. 112
u Lubricate the pinion [2] with one or two
grease shots.
Fig. 113

MAINTENANCE
7.4.19 Cleaning and lubricating the safety cover guide
Tools n Grease gun

n Wrench set
n All-purpose cleaner
n Mobil Vactra 2 ISO VG 68
n Arcanol MULTI2
n Allen key set
Procedure
u Loosen and remove four M5 cylinder screws.
u Slightly loosen two M6 cylinder screws.
u Remove fastening plate [1].
u Check three rollers [2] for deposits and clean

them.
u Grease three rollers [2].
u Clean and lubricate linear guide with oil-

soaked cloth.
u Attach fastening plate [1].
2 1
u Tighten two M6 cylinder screws.
u Insert and tighten four M5 cylinder screws.

Fig. 114

MAINTENANCE
7.4.20 Checking, cleaning and lubricating the crimp modules
Tools n Klüber Microlube GL 261

n Grease gun
n Molykote DX white batch no. Z W0Z8147
n All-purpose cleaner
Procedure
u Clean and lightly lubricate the guides on the crimp module carriage with Molykote.
u Check the fastening screws on the crimp module carriage for wear and replace if needed.
u Lubricate eccentric bearing with Klüber Microlube GL261.
u Check sensor cable for wear and replace if needed.

MAINTENANCE
7.4.21 Cleaning the filter mats
Tools n None
Procedure
u Remove covers [1] from ventilator.
u Remove the filter mats and check for soiling.
u Clean the filter mats or replace, if needed.
u Reattach covers with filter mats.
1 1
Fig. 115

MAINTENANCE
7.4.22 Checking guide parts and bearings
Maintenance interval Semi-annually
Maintenance personnel Service personnel
Tools n None
Procedure
u Check all guide parts and bearings for damage, wear and corrosion.

MAINTENANCE
7.4.23 Checking toothed belts
Tools n Frequency measuring device
Procedure
u Check all toothed belts for wear.
u Checking the correct tension on all toothed belts («Tensioning the toothed belt», p. 133).
TIP
Replacing the toothed belt as a preventive measure
Komax recommends replacing the toothed belt of the swivel unit, side 1 after 20 million cycles
as a preventive measure.

MAINTENANCE
7.4.24 Checking, cleaning and greasing the gripper seal
Tools n Lubricant SMC GR-S-020

n Allen key set
TIP
Regular checking of gripper seal.
ü The machine uses oil-free air.
u Regularly check, clean and grease the seal on gripper side 2.
Procedure
1
u Release four screws [2].
u Remove the gripper cover [1].
Fig. 116
u Check and clean the quadring [3].
u Lightly lubricate the quadring with lubricant

SMC GR-S-020. 3
u Remount the gripper cover [1].
Fig. 117

MAINTENANCE
7.4.25 Crimp modules
Maintenance interval As necessary; Yearly
Tools n None
Procedure
u Check sensitivity and stability of the device with the Crimp Module Analyzer (see operating in-
structions for Crimp Module Analyzer).
u Check shut height of carriage with shut height gauge (see operating instructions for crimp mod-
ule).
u Clean linear length measurement (if needed).
u Orient tool fixture, set shut height and execute reference move (if needed).

SERVICING AND REPAIRS
8 SERVICING AND REPAIRS

Only qualified personnel are permitted to perform repair and maintenance work.
Personnel safety
Prior to carrying out repair work, disconnect the machine from the power supply system and take
For tasks controlled via the user interface, switch the machine on.
Make sure that your actions do not pose a hazard to other persons.
Wear protective goggles for all set-up and maintenance work.

8.2 AUXILIARY EQUIPMENT
8.2.1 Adjustment tools and gauges

All tools and gauges needed for adjustment are in the toolbox. A detailed list can be found in the re-
placement parts catalog.
Setup gauge for swivel unit Setup gauge for crimp module
Article number 0342377 Article number 0048069
Included:
n Arbor for universal gauge, art.
no. 0343713
n Spacer shaft, art. no. 0046398
Level Setup gauge for seal module

Hexagonal pin insert 5 mm Nozzle for grease-gun 1/8 in

Pin adjustment mandrel Measuring tip with alligator clip

Article number 0347227 for ACD
Article number 0335221
Dowel pins Grease-gun with Klüber Microl-

Article number 0335163 ube GL 261
Article number 0054914
Grease-gun with Arcanol Multi 2 Extension 1/4 in 150 mm

NOTICE
Risk of collision from calibration tools and gauges
Collisions with calibration tools and gauges cause damage to the machine.
u Remove all calibration tools and gauges from the machine prior to production.

8.2.2 Recommended frequency-measuring devices
Gates 507 C CONTI VSM-1

Frequency measuring device Optoelectronic measuring device
Converts frequency into a voltage measurement. Precise optoelectronic measuring device for con-
Very noise sensitive and thus not suited to use in tactless measurements.
production environments. Insensitive to noise and thus suited to use in pro-
duction environments.
8.3 BASIC SETTINGS
NOTICE
Open protective covers.
During setup, machine errors can be caused if protective covers are left open.
u Take one of the following actions to ensure a safe and error-free setup:
u To close the protective covers: Close all the protective covers on the machine before entering
commands which will trigger machine movements.
u Two-hand operation: When a protective cover is open, commands, which trigger machine move-
ments, can only be executed in two-hand operation (approval button). Only release both of the re-
quired buttons once this is displayed in the software.

8.3.1 Two-hand operation

During set-up, machine movements are executed with the protective cover open. So that the ma-
chine operator cannot reach into the dangerous area of moving parts, machine movements can only
be executed with two-hands. Two-hand operation takes place by simultaneously pressing the Confir-
mation button and the Start or Stop button. The buttons are arranged to make one-hand operation
impossible.
If two-hand operation is necessary, then the buttons are displayed as follows:
Green button with hand symbol

Call up a function by simultaneously pressing the Confirmation button and Start
button.
Red button with hand symbol
Call up a function by simultaneously pressing the Confirmation button and Stop
button.
Gray button with hand symbol
This function cannot be accessed directly with the Confirmation button and the
Start/Stop button. The button must first be pressed to come into focus and turn
green on the screen. It can then be executed by simultaneously pressing the
Confirmation button and the Start button.
8.3.2 Setup work with two-hand operation

When setting up the machine (special operation), machine movements can only be performed with
the protective covers closed or with two-hand operation. Two-hand operation requires simultaneous
pressing of the start and approval buttons.
The start and approval buttons are arranged to make one-handed operation impossible.
If a light-green “S” appears in the background of a button, this function can be exe-
cuted by simultaneously pressing the approval button and the start button.
If a red “S” appears in the background of a button, this function can be executed by
simultaneously pressing the approval button and the stop button.
If a dark-green shaded “S” appears on a button, the start button (without approval
button) must first be pressed in order to change the focus to this button. If the focus
changes, the “S” turns light-green in the background and the function can be exe-
cuted by simultaneously pressing the approval button and the start button.
8.3.3 Record the blade range of movement
TIP
Recording the travel range with software
The travel range is recorded with the software. No mechanical settings need to be made.

Procedure
u In the Configuration menu press Setup Configuration
mode [1].
Setup Mode
Fig. 118
At first startup:
u Press Seek reference points [1]. seek points of reference
u Press Adjust machine [2]. Adjust Machine
1 2
Fig. 119
u Activate Teach cutting unit range [1]. Teach cutting unit range
1
Ú The blade opens and closes twice and
records the range of movement of the
blades.
Ú Press Finish. Finish
Fig. 120
8.3.4 Adjusting the zero position for swivel unit side 1

Equipment
n Setup gauge, swivel arm

n Pin adjustment mandrel 0347227
n Allen key size 4
n Set of open-end wrenches
n Set of screwdrivers

WARNING
Cutting hazard
Procedure
u Release lever [2].
u Flap the deposit gripper [1] up.

2
Fig. 121
u Remove blade holder («Replacing the blade
holders», p. 122).
Fig. 122
Fig. 123

u Remove guide hose [1] from swivel arm.
Fig. 124
u In the Configuration menu press Setup Configuration
mode. Setup Mode
u Press Adjust machine. Adjust Machine

1
u Swivel arm side 1: Activate Adjust zero po-

sition [1].
swivel Side 1: adjust zero position
Ú You are led step by step through the ad- Fig. 125
justment procedure.
u Press Next. Next
Ú The swivel arm moves to a specified posi-

tion.
u Attach the pin adjustment mandrel [1].
1
u Continue with the user guidance.
Fig. 126
u Push the swivel unit by hand until the pin ad- 2
justment mandrel [1] comes to lie in the bore
hole of the setup gauge of the swivel arm [2].
u Adjust the height of the swivel unit side 1, if
needed. 1
Fig. 127

Adjusting the height

u Adjust the height of the swivel unit side 1 by
turning the screw [1].
Fig. 128
u Push the pin adjustment mandrel into the
bore hole to the stop.
Ú The machine saves the zero position of

the swivel arm side 1.
Fig. 129
TIP
If the zero position of the swivel arm side 2 is to be adjusted next, the setup gauge of the
swivel arm can be left in place on the stripping unit.
u Remove all gauges.
u Reattach the blade holder.
8.3.5 Adjusting the zero position for swivel unit side 2

Equipment
n Setup gauge, swivel arm

n Pin adjustment mandrel
n Allen key size 4
n Allen key set
n Set of open-end wrenches
n Set of screwdrivers

WARNING
Cutting hazard
Procedure
u Open deposit gripper [1] upwards.

2
Fig. 130
u Remove blade holders («Replacing the blade
holders», p. 122).
Fig. 131
Fig. 132

u In the menu Configuration press Setup Configuration
Mode. Setup Mode
u Press Adjust Machine.

1
Adjust Machine
u Activate Swivel side 2: adjust zero position swivel Side 2: adjust zero posi-
[1].
tion
Ú You are led step by step through the ad- Fig. 133
justment procedure.
u Press Next. Next
Ú The stripping unit closes and the swivel

arm moves to a specified position.
u Open gripper side 2 with Allen key.
u Attach arbor of universal gauge (0343713) [1]

to gripper side 2.
The flange must lie flush on the gripper jaws.
u Continue with the user guidance. 1
u Push swivel unit by hand until the pin adjust-
ment mandrel comes to lie in the bore hole of
the setup gauge of the swivel arm.
u Adjust the height of the swivel unit side 1, if
needed.
Fig. 134
Adjusting the height

u Adjust the height of swivel unit side 2 by turn-
ing the screw [1].
u Push the pin adjustment mandrel into the
bore hole to the stop.
Ú The machine saves the zero position of

the swivel arm side 2.
Ú The grippers open and the universal 1

gauge is allowed to fall on the wire de-
posit.
u Remove all gauges.
u Reattach the blade holder.

Fig. 135

8.3.6 Adjusting the deposit gripper

Equipment
n Allen key set

n Arbor of universal gauge
Procedure
u Switch on the machine and the load voltage.
u In the Configuration menu [1], press AdjustConfiguration

1
process modules [2].
adjust Process Modules
Fig. 136
u Activate checkbox [3].
u Press Next.Next
3
u Follow the user guidance.
Fig. 137
u Loosely attach the deposit gripper [4] with
screws [5].
Ú Swivel arm side 2 swivels into the deposit 5

position.
Ú The gripper closes. 4
Fig. 138
u Open gripper with Allen wrench.
u Lay the arbor of the universal gauge [6]

(0343713) between the gripper jaws.
Make sure that the flange lies against the
gripper jaws.
u Continue with the user guidance. Gripper 6
side 2 swivels into deposit position and de-
posit gripper closes.
Ú Gripper side 2 swivels into deposit posi-
tion.
Ú The deposit gripper closes. Fig. 139

u Orient the deposit gripper on swivel unit side

2.
- The deposit gripper and the gripper head 6
must not come into contact.
- The gap between the deposit gripper and
the arbor of the universal gauge [6] must
be approximately 1 mm.
1 mm
Fig. 140
u Press Open and close deposit gripper [7]. open and close deposit gripper
Ú Deposit gripper opens / closes.

The swivel unit side 2 must not move.
u Tighten screws [5].
Ú Gripper position is verified.

7
u Press Finish.finish
Ú Gripper side 2 opens.

Ú Arbor falls into the tray.
u Remove arbor of universal gauge. Fig. 141
8.3.7 Adjusting thread-in support

Equipment
n Allen key set

n Spacer shaft gap to setup gauge
Procedure
u In the Configuration menu, press Adjust Configuration
process modules. adjust Process Modules
1
u Activate checkbox [1].
Ú You are led step by step through the ad-

justment procedure. Fig. 142

u Unthread the wire.
u Remove the guide tube and flexible guide

tube on swivel unit side 1.
u Loosely attach thread-in support [2] or, if al-
ready attached, loosen screws [3].
2
Fig. 143
u Attach spacer shaft [4] (0046398) in place of
the guide tube.
Ú Swivel arm side 1 moves to thread-in po-

sition.
u Roughly orient the thread-in support [1] so
that the spacer shaft [4] can be gripped by
the grippers of the thread-in support. 1 4
Fig. 144
u Press Open/close wire guide. open / close wire guide
Ú Thread-in support opens and closes.

The gripper side 1 must not move.
u Orient the thread-in support.
Thread-in support is correctly set if the gap

between gripper and front plate is approxi- 3 mm
mately 3 mm.
u Tighten screws [4].

Fig. 145
u Remove spacer shaft.
u Reinsert guide tube and flexible guide tube.

8.4 REPLACEMENT TASKS
8.4.1 Replacing the blade holders

Equipment
n Allen key size 4
WARNING
Cutting hazard
Procedure
u Flap the deposit gripper [1] up.

2
Fig. 146
u Release knurled nut [2].
u Push the waste chute [1] down.
Fig. 147

u Unplug cables [1] (four cables) for optional

1
ACD.
Fig. 148
u Release screw [1].
5 1
u Remove top blade holder [2].
u Release screw [4]. 2 4

u Turn bad-part terminal waste chute [4] up-
ward.
u Release the ACD wire chute [10] for optional 3
ACD.
Fig. 149
u Release screw [1].
u Remove bottom blade holder [2].
Fig. 150

TIP
Attaching blade holders
u Ensure bearing surfaces and guide bars are clean.
u Install blade holders by following the disassembly instructions in reverse.
u First, loosely attach the bottom blade holder and then the top blade holder.
u Move the blade holders together by hand.
u The blade holders will center themselves.
u Tighten the screws of the blade holders.
u After tightening the screws, move the blade holders together again by hand.
u Ensure that this functions smoothly and easily.
8.4.2 Replacing blades

Auxiliary materials
n Allen key set
WARNING
Cutting hazard
NOTICE
The blades must sit flush in the guides.
u Clean the blade holders before installing new blades.

Fig. 151 Fig. 152
Procedure
u Remove the blade holder.
u Release the fastening screw of the appropriate blade.
u Remove the blade.
In order to replace the upper cutting blade, the in-line stripping blade side 1 must be removed
first. Only then is the screw for the upper cutting blade accessible.
u Clean the blade holder.
u Install the new blade.
u Tighten the fastening screw.
While tightening the fastening screw, press the blade in the direction of installation to the stop.
- Top blade holder: The chamfer of the stripping blades faces inward.
- Bottom blade holder: The chamfer of the stripping blades faces outward.
8.4.3 Tensioning and replacing conveyor belt

Equipment
n Allen key set

n Two open-end wrenches size 13
n Ratchet with extension for Allen key size 3 (recommended)
WARNING
There is risk of injury in the area of moving machine parts.
u Prior to changing the conveyor belt, switch off the machine by using the main switch and secure it
against inadvertent switching-on.

WARNING
Cutting hazard
TIP
The tipping tray must be at the bottom position for better access.
u Switch off the compressed air of the machine using the manual shut-off valve.
Procedure
u Remove top and bottom blade holders («Re- 2
placing the blade holders», p. 122).
u Remove front cover plate [1] by releasing the
two M4 countersunk screws with counter-
sunk washers [2]. 1
For better access, use the ratchet with exten-

sion here.
Fig. 153
u Remove two M6 cylinder screws with flat
2
washers [1].
u Remove hold-up unit [2].
Do not entirely remove the hold-up unit, sim-

ply fold it to the side so that the conveyor belt 1
is free.
Fig. 154

u Remove cover panel of wire deposit rear 1 2

side [1] by releasing the two M4 cylinder
screws with flange [2].
Fig. 155
u Remove cover panel of wire deposit front
side [1] by releasing the two M4 cylinder
screws with flange [2].
1
2 2
Fig. 156
u Release two M4 cylinder screws with
flange [1].
u Unhinge and remove wire deflector [2].
1
Fig. 157
u Remove ramp at end of conveyor belt [1] by
releasing the two M5 cylinder screws [2].
Fig. 158

1 2
Fig. 159 Fig. 160
u Release the M8 hex nut [1] of the clamping screw on the front side.
u Release the M8 hex nut [2] of the clamping screw on the back side.
u Push motor block in the direction of the arrow

until the conveyor belt is untensioned.
Fig. 161
u First pull off conveyor belt [1] at the front (ma-
chine side) over the drive roller.
u Pull conveyor belt [1] out of the entire length
of the guide.
2
u Pull conveyor belt [1] off at the back over the
drive roller and bearing plate [2].
1
Fig. 162

u First guide the new conveyor belt [1] back

over the bearing plate [2] and the drive roller.
u Lay conveyor belt [1] over the entire length of 2
the guide.
u Guide the conveyor belt [1] at the front (ma- 1
chine side) over the drive roller.
Fig. 163
u Pull motor by hand as far as possible in the
direction of the arrow.
Fig. 164
1 2
Fig. 165 Fig. 166
u Set the tension.
u Set the tension using the M8 hex nut [1] on the threaded bar on the front side and using the M8
hex nut [2] on the threaded bar on the back side.

Conveyor belt 2 m
Fig. 167
The tension is correctly set when the slack [1]=10 mm.
Conveyor belt 4 m
2 1
Fig. 168
Belt [1] lies lightly on the support roller [2].
The tension is correctly set when the slack [3]=5 mm.
u Adjusting lateral running distance.
u Individually set the threaded bars to orient

the drive roller.
The lateral running distance during operation
is correctly set when the lateral edges of the
deflection rollers, bearing brackets and cov-
ers rarely touch the conveyor belt [1] and the
gap [2] on both sides is about equal.
u Turn conveyor belt [1] by hand.
2 1 2
The conveyor belt must easily move.

Fig. 169

u Secure settings with counternuts.
Fig. 170
u Attach ramp at end of conveyor belt [1] using
two M5 cylinder screws [2].
Fig. 171
u Attach hold-up unit [2] using two M6 cylinder
2
screws with flat washers [1]and adjust the
height («Adjusting the hold-up unit», p. 143).
Fig. 172
NOTICE
Damage to the hold-up unit and the swivel unit side 2 as a result of collision.
u Check hold-up unit height by moving the swivel unit side 2 by hand above the hold-up unit. The
gripper on swivel unit side 2 must not be in contact with the hold-up unit nor brush against it.

u Attach front cover panel [1] using two M4

countersunk screws with countersunk wash-
ers [2]. 2
u Orient height of front cover panel [1] so that
the panel lies below the rib of the conveyor
belt. 1
For better access, use the ratchet with exten-
sion here.
Fig. 173
u Switch on the machine and compressed air.
u In the configuration menu, press Manual IO

configuration
2
Settings [1].
Manual IO Settings
1
3
Ú The signal connections [2] window will signal connections
open.
u On the I/O board tab [3], press on the Out
1-8 plug [4].
4
u In the Valves [5] window, enable output 11
5
Valves
(tipping tray).
Fig. 174
u In the signal connections [1] window, press signal connections
the tab ACSe224-16-1 Wire drive servo No. 1

1.1 [2].
u Activate Output 8 (conveyor belt) [3].
Ú The conveyor belt runs. It should not 2

make noise while running and not drag
nor touch anywhere.
u Adjust tension of conveyor belt if needed. 3
Fig. 175

1 2
1
2 2
Fig. 176 Fig. 177
u If the conveyor belt is correctly set, reattach the cover plate of the wire deposit, front and rear [1]
using the two M4 cylinder screws with flange [2].
u Attach the wire deflector plate [2].
u Tighten the two M4 cylinder screws with

flange [1].
1
Fig. 178
8.5 SETUP WORK
8.5.1 Tensioning the toothed belt
TIP
Correct measurement of belt tension
u Hold the measuring head of the frequency-measuring device in the center of the strand (center
between cog wheels) and at a right angle to the belt surface.
u Hold the frequency-measuring device as close as possible but without touching the toothed belt
so that the toothed belt can still vibrate.
u Briefly tap the belt and read the measured frequency.
u Change the pretensioning until the required frequency is displayed.
u Move the belt by hand, if possible, through one complete turn between measurements and then
remeasure.
8.5.1.1 Tensioning the belt drive belts

Equipment
n Allen key set

n Wrench size 19
n Frequency measuring device or spring balance and ruler
Setting values
Measuring point 1
n Frequency = 170 ± 10 Hz
n F = 11.2 N / h = 2.5 mm
Measuring point 1
n F = 11.2 N / h = 1.8 mm
Requirements Measuring point3 1

n The belt [1] must only be tensioned in the
open position. 1
4
n The belt [2] must only be tensioned in the
closed position. 4
Procedure
u Release Allen screw [3].
3
u Release the eccentric [4].
u Tension the toothed belt with the eccentric [4]

until correct setting is reached. 2
u Tighten screw [3]. Measuring point 2
Fig. 179
8.5.1.2 Tensioning drive belt of belt drive motor

The motor sits on a plate which can be slid over slotted holes. The plate is slid using a screw in order
to tension the belt.
The belt drive must be removed to tension the drive belt.
DANGER
Live parts
Touching live parts can be fatal.
u Switch off the machine using the main switch and secure it against inadvertent activation.
Equipment
n Allen key set


Procedure
u Unplug the ground. 2
u Loosen four M6 lens-head screws [1].
u Unhinge and remove the straightener unit

box [2]. 1 1
1 1
Fig. 180
u Loosen four M5 cylinder screws with
flange [3].
u Flap the metal casing forwards [4]. 3
4
3
3
Fig. 181
u Disconnect plug [5] (operating elements,
front). 4
u Remove metal casing [4].
Fig. 182

u Loosen four M5 cylinder screws with

flange [6].
u Flap the metal casing forwards [7].
7
6 6
6
6
Fig. 183
u Disconnect plug [8] (emergency stop button,
back side).
u Remove metal casing [7].
Fig. 184
u Release three M3 cylinder screws [10].
u Remove safety cover of belt drive [9].

9
10 10 10
Fig. 185

u Release two M4 cylinder screws [12].
u Remove cover panel of wire draw-in [11]. 12
12
11
Fig. 186
u Disconnect two motor plugs [13].
13
Fig. 187
u Remove two compressed-air connec-
tions [14].
14
Fig. 188
TIP
So as not to have to thread the encoder wire out of the entire machine, it is recommended to
place a deposit table/small cart next to the machine for tensioning the drive belt.

u Release six M6 cylinder screws [15].

15 15
u Lift the entire belt drive unit with the base
plate out of the machine [16]. 15
15
u Place the belt drive upside-down on a table/
cart.
15
15
16
Fig. 189
Setting values Measuring point
n F = 30 N / h = 3.4 mm
u Adjust belt tension if needed.
Fig. 190
u Loosen four M8 cylinder screws [17].
u Tension the toothed belt with M8 cylinder

screw [18] until correctly adjusted.
u Tighten screws [17]. 17
17
17
17
18
Fig. 191

u If belt tension is correct, reinstall the belt

drive unit with base plate into the belt drive 15 15
box and attach with six M6 cylinder 15
screws [15]. 15
15
15
Fig. 192
u Connect motor plugs [13].
u Connect compressed-air connections [14].
13
14
Fig. 193
u Attach cover panel of wire draw-in [11] with
two M4 cylinder screws [12]. 12
12
11
Fig. 194

u Attach safety cover of belt drive [9] with three

M3 cylinder screws [10].
9
10 10 10
Fig. 195
u Connect plug [8] (emergency stop button,
back side).
u Attach metal casing [7] with four M5 cylinder
screws with flange.
7
Fig. 196
u Connect plug [5] (operating elements, front).
4
u Attach metal casing [4] with four M5 cylinder
screws with flange.
Fig. 197
u Fit the straightener unit box [2] onto the lens-
head screws [1].
2
u Attach the ground.
u Tighten four M6 lens-head screws [1].
1 1
1 1
Fig. 198

8.5.1.3 Tensioning drive belt of swivel unit side 1

Equipment
n Allen key set

Setting values
n Frequency 1 (new belt): 185 +20/0 Hz

n Frequency 2 (used belt): 160 ± 20 Hz
n Force 1 (new belt): F = 27.6 + 2.5/0 N / h = 2.7 mm
n Force 2 (used belt): F = 21.1 ± 2.5 N / h = 2.7 mm
Procedure 2 1
u Release five M5 cylinder screws with
flange [2].
u Remove cover [1].
Thread-in support need not be removed.
Fig. 199
u Adjust belt tension if needed.
Measuring point
Fig. 200

u Release four M8 cylinder screws [3].

4
u Tension the toothed belt with M6 hexagon
screw [4] until correctly set.
3 3
u Tighten four cylinder screws [3].
u Reattach cover. 3 3
u Set swivel unit zero position Adjusting the
swivel arms.
Fig. 201
8.5.1.4 Tensioning drive belt of swivel unit side 2

Equipment
n Allen key set

Setting values
n Frequency 1 (new belt): 185 +20/0 Hz

n Frequency 2 (used belt): 160 ± 20 Hz
n Force 1 (new belt): F = 27.6 + 2.5/0 N / h = 2.7 mm
n Force 2 (used belt): F = 21.1 ± 2.5 N / h = 2.7 mm
Procedure
Measuring point
u Adjust the belt tension if needed.
Fig. 202

u Release four M8 cylinder screws [1].
u Tension the toothed belt using M6 hexagon

screw [2] until the correct setting is reached.
u Tighten four M8 cylinder screws [1].
u Adjust swivel unit side 2 Adjusting the swivel

arms.
Fig. 203
8.5.2 Adjusting the hold-up unit

The hold-up unit is preset at the factory. It must only be readjusted if a component has been re-
placed. In this case, remove the conveyor belt to access and adjust the required parts.
WARNING
Cutting hazard
6 3
2 8
7
4
1
5
Fig. 204 Fig. 205

Prior to beginning with adjustment of the hold-up unit, check and set, if needed, the following mea-
surements:

n The preset stroke [1] with retracted hold-up unit (stroke = 23.5 mm).
n Gap [2] between guide plate [3] and wire ramp [4] with extended hold-up unit (gap = 7 mm)
n Surface [7] must lie approx. 1 mm under swivel unit side 2.
n Edge [8] must not touch the conveyor belt, gap approx. 1 mm.
n Guide plate [3] must move to upper position without colliding with ramp [4].
Setting the stroke

u Turn M6 nut [5].
Setting the wire ramp

u Release M5 cylinder screws [6].
u Set the wire ramp.
u Retighten screws [6].
2
1
Fig. 206 Fig. 207

u Switch off load voltage.
u Remove top and bottom blade holders («Replacing the blade holders», p. 122).
u Install the setup gauge of the swivel unit [1] with the spacer shaft [2].
u Push the wire-guide panel [3] and setup gauge of the swivel arm [2] by hand into the top position.
u Adjust the hold-up unit by releasing the two M6 cylinder screws [4] so that the spacer shaft [2] lies
in the bore hole of the wire-guide panel [3].
u Retighten the two M6 cylinder screws [4].
u Remove setup gauge of swivel arm [1] and spacer shaft [2].
u Install top and bottom blade holder.
u Check height of hold-up unit.
u Move swivel unit side 2 by hand above the hold-up unit.
The gripper on swivel unit side 2 must not be in contact with the hold-up unit nor brush against it.

8.5.3 Basic settings of straightener
8.5.3.1 Standard straightener

The basic settings of the straightener are important for correctly orienting and processing the wires.
The following setting is considered ideal for most types of wire.
Auxiliary materials
n Allen key set
It is important that at the start the wire is more Wire draw-in direction
accurately oriented, and that it simply run out
straight from the last straightening rollers.
X<Y
X Y
Fig. 208
Procedure
u Release screws [1].
u Set the inclination of the plate [2] according

to the illustration.
The screw [3] serves as a pivot point.
u Retighten screws [1].
3 mm
1 mm
1 2 1 3
Fig. 209

u Close straightener by turning wing screw [1].
u Turn the turning knob [2] until the first 2 4

straightening rollers [3] touch one another. 1 0 9
u Release adjusting screw [4].
u Turn the turning knob [2] until the number 0

appears on the rotating scale exactly on the
front. 1
u Tighten adjusting screw [4].
3
Ú The straightener is now mechanically set.
Fig. 210
8.5.3.2 Straightener, pneumatic

Procedure
u Open the straightener [1].
u Take the wire to be processed [2] and pull it

3
through to the end of the straightener.
u Close the straightener [3].
2
1
Fig. 211
u Adjust roller gap in small steps with turning
knob [1].
u Move wire back and forth repeatedly.
1
The gap is correctly set if all the rollers turn
and only slightly touch the wire.
Fig. 212

Adjusting straightener pressure

u Adjust the pressure of the straightener using
the pressure regulator [1].
Observe guidance values on sticker:
Wire cross-section Pressure
0.13 mm2(AWG26) 3.5 bar (50.8 psi) 1
0.35 mm2(AWG22) 2.0 bar (29 psi)

1.50 mm2(AWG15) 1.5 bar (21.8 psi)
Fig. 213
8.5.4 Adjusting the conveyor belt position

In order to optimize deposit performance and/or to create more space on the table, the conveyor belt
can be displaced in the Y direction by 19 mm.
Procedure
u Disconnect plug [1] from console.
u Use lifting truck to remove console from the

1
machine.
Fig. 214
u Remove cover [2] (six screws).
2 9
Fig. 215

u Remove blade holder («Replacing the blade

holders», p. 122).
4
u Attach setup gauge for swivel arm [3] with
spacer shaft [4] in blade holder.
u Bring wire-guide panel [5] and setup gauge 5
for swivel arm [3] into topmost position. 3
The pictured position is the default position of
the conveyor belt.
Fig. 216
u Release two M8 cylinder screws [6].
u Screw out the transport rollers of the wire de-

posit (only 4 m).
Fig. 217
u Displace wire deposit in Y direction by
19 mm, until the tip of the spacer shaft [4]
comes to lie in the second bore hole of the
4
wire-guide panel [5].
Fig. 218
u Visually orient the wire deposit so that it
aligns with the wire line of the base machine.
u Screw the transport rollers of the wire deposit
upward (only 4 m).
u Tighten two M8 cylinder screws [6]. 6
Fig. 219

u Release two M8 cylinder screws [7] (front

side).
u Release two M6 cylinder screws [8] (back
side).
7 7
8
8
Fig. 220
u Displace tipping tray 19 mm in Y direction.
u Retighten screws [7] and [8].
Fig. 221
u Remove setup gauge for swivel arm with
2 9
spacer bolt.
u Install blade holder.
u Attach cover [2] (six screws).
u Attach console [9] and establish electrical

connection.
Fig. 222

8.6 TROUBLESHOOTING
8.6.1 General malfunctions
TIP
General malfunctions
The user interface displays general malfunctions.
8.6.2 Malfunctions of toothed belt
Type of error Possible cause Remedy
Excessive running noise Excess belt tension Decrease pre-tension

Cog wheels not aligned Orient cog wheels
Abnormal wear on the loaded Incorrect belt tension Correct the tension
tooth flank of the belt Surface of crown gears too Repolish or replace crown gears
rough
High wear in tooth root surface Belt tension too high Decrease tension
of belt Faulty crown gears Replace crown gears
High wear on the lateral shoul- Incorrect orientation of shafts Reorient parallelism and align-
ders of the belt Flanged wheels bent and / or ment of shafts.
have rough surface Replace flanged wheels
Soft shaft bearing Replace bearings
Torn belt or shearing of belt Acidic or caustic atmosphere Use suited belt quality
teeth
Apparent belt stretch Reduce axis distance by loos- Reset axis distance and check
ening the shaft bearing or tight- attachment
ening the crown gears Check for heat transfer from
Overheating of toothed belt, motor
crown gear or bearing
Premature tooth wear Pretensioning too high or too Correct the pre-tension
low Toothed belt cover
Excessive damage from foreign
objects
Bulking of toothed-belt back Strong oil penetration Protect belt from excessive oil-
ing

8.6.3 Special cases in the software
8.6.3.1 Clearing the machine

After an error, for instance an unexpected ‘Power off’ or ‘Emergency stop’, and after the operator has
confirmed the error message, the machine automatically clears all wires in the machine and pro-
cesses them according to ‘Good’-‘Bad’ status.
n Finished wires with no defects are deposited in the good-wire tray and counted as good wire.
n Unfinished wires and wires with defects are disposed of in a rejects bucket, if possible, or cut in-
correctly, deposited in the good-wire tray, and counted as bad wire.
8.6.3.2 Handling of wires in gripper side 2 after restart

If there is a wire in the gripper on side 2 after an unexpected ‘Power off’ or ‘Emergency stop”, the
user will choose whether to manually or automatically process the wire.
For manual removal, the user must open the cover and take the wire out by hand from the gripper.
In automatic removal, the wire is automatically processed during the subsequent resetting after
‘Power on’.
n If the wire is completely finished and all quality data are good, the wire is deposited into the tray
and counted as good wire.
n If the wire has not been finished or the quality data are not good, the wire is incorrectly cut on
side 2, deposited into the tray and counted as bad wire.
8.6.3.3 Handling wires in gripper of double gripper module after restart

If a wire remains in the gripper of the double gripper module after an unexpected “Power off” or
“Emergency stop”, it is cleared exactly as for swivel unit side 2. Here too, the operator’s preference
regarding manual or automatic clearing of the wire is taken into account. If the wires are automati-
cally discharged, the wire is cut as a bad part and placed in the tray.

8.6.3.4 Faults
Error Consequence Solution
Air failure (without Machine has no air. After the error message has been confirmed, the ma-
simultaneous load Goods in process chine autonomously clears itself («Clearing the ma-
voltage drop) may have been in- chine», p. 151).
correctly produced If the machine switches to ‘Power Off” status after con-
and could fall out of firmation of the error message, the machine will be man-
the grippers. ually or automatically cleared.
Power failure (load Goods in process After the error message has been confirmed, the ma-
voltage button may have been in- chine autonomously clears itself («Clearing the ma-
pressed) correctly produced chine», p. 151).
and could fall out of If the machine switches to ‘Power Off” status after con-
the grippers. firmation of the error message, the machine will be man-
ually or automatically cleared.
Voltage too high or Could lead to mal- After the error message has been confirmed, the ma-
too low function of machine autonomously clears itself («Clearing the ma-
chine, regulator or chine», p. 151).
motors. If the machine switches to ‘Power Off” status after con-
firmation of the error message, the machine will be man-
Emergency stop Machine stops im- If there are wires in the gripper of the swivel unit, they
button pressed mediately or in are removed either manually or automatically.
shortest possible Whether the wire has been produced without errors is
time. also differentiated («Clearing the machine», p. 151).
All wire data (quality, length, number of crimps, etc.) can
statistically continue.
Crash of user inter- Production no After restarting RT controller and based on the gripper
face longer possible. status, it will be decided whether any wire in the gripper
Necessary to restart must initially be cut as a bad part.
PC. A warning signal indicates that there may be an un-
known wire is in the gripper.
Prior to starting production, the swivel unit moves to the
bad-part blade to cut off any wire present.
If testing of the bad part cut fails, the swivel unit moves
outwards and the operator is prompted to cut the wire
by hand as a bad part.

Bad part side 1 Bad part end side 1 Wires marked as bad on side 1 are deposited from the
bent and not cut off could end up with conveyor belt into the waste container at the end of the
good wires. conveyor belt and not in the good tray.
To test whether the wire has been cleanly transferred to
side 2, the wire is “clamped in” prior to cutting with the
cutting blade. The swivel unit side 2 moves back a bit
with less torque. If the swivel unit can reach the target
position, the wire is clamped by the blade and can be
cut.
If the swivel unit can reach the target position, it is as-
sumed that the wire has not been clamped by the cut-
ting blade, or that the swivel unit side 2 does not have
the wire in the gripper. An error message is displayed
which advises the operator to remove the wire by hand
from the machine.
Bad part side 2 Bad part end side 2 Wire is laid in bad part blade and ‘clamped in’ by it with-
bent and not cut off could end up with out cutting. The swivel unit side 2 moves back a bit,
good wires. thereby pulling the wire.
If the intended target position cannot be reached, or the
required electricity exceeds a previously taught limit, the
wire lies in the bad part blade and can be cut.
If the specified position is reached without a noteworthy
rise in electricity, the blade does not clamp the wire and
the wire is thus bent. In this case the swivel unit swivels
to an easily accessible position for the user. An error
message is displayed with a prompt to remove the wire
by hand from the machine, or to bend the wire straight
and feed it back to the bad part blade.
The wire comes out Wrong insulation or After the error message has been confirmed, the ma-
of guide parts in wrong crimping po- chine autonomously clears itself, and all bad or unfin-
belt drive sition. ished wires are automatically cut as bad wires.
Finished wires with no defects are deposited in the
good-wire tray and counted as good wire.
If the machine switches to ‘Power Off” status after con-
Proportional valve Wrong insulation or After the error message has been confirmed, the ma-
defective (pressure wrong crimping po- chine autonomously clears itself, and all bad or unfin-
too high or too low) sition ished wires are automatically cut as bad wires. Finished
wires with no defects are deposited in the good-wire
tray and counted as good wire. If the machine switches
to ‘Power Off” status after confirmation of the error
message, the machine will be manually or automatically
cleared.
Blade holder: Insu- Shifted initial posi- After the error message has been confirmed, the ma-
lation snippet is tion of measuring chine autonomously clears itself («Clearing the ma-
stuck axis after resetting. chine», p. 151).
If the machine switches to ‘Power Off” status after con-

Hold wire side 1, if The wire may The gripper side 1 must be closed while the machine
waiting for batch- stretch during the awaits confirmation of batch size so that the wire cannot
size confirmation waiting time, lead- stretch.
ing to the wire
length, crimp posi-
tion, etc. no longer
being accurate.
Move blades to me- If the roller cage After a specified number of cycles (suggestion: after
chanical stop to ori- shifts during the 1,000), the blade moves to the top mechanical stop,
ent the bearings. cutting drive, the which reorients the rollers in the cage.
roller cage can wear
prematurely or be-
come stuck.

DECOMMISSIONING / STORAGE / DISPOSAL
9 DECOMMISSIONING /
STORAGE / DISPOSAL
9.1 DECOMMISSIONING
Procedure
u Close safety covers.
u Use main switch to switch off machine.
u Disconnect machine from power supply system.
u Disconnect machine from compressed-air supply.
u Make sure that no fluids leak out.
9.2 STORAGE
Procedure
u Decommission machine («Decommissioning», p. 155).
u Select suitable storage place. The same requirements as for the place of installation apply to the
storage place (floor conditions, space requirements, ambient conditions).
u Protect machine from soiling.
u Protect machine from corrosion (dry rooms, no direct sunlight).

DECOMMISSIONING / STORAGE / DISPOSAL
9.3 DISPOSAL
NOTICE
Legal provisions
It falls to the responsibility of the machine operator to provide for environmentally-friendly and
proper disposal of the machine and its operating fluids.
u Observe all national and local legal regulations and provisions.
The materials (metal, plastic) used to build the machine are largely recyclable.
Procedure
u Decommission machine («Decommissioning», p. 155).
u Disassemble the machine, sort according to material and dispose of the materials at the appropri-
ate recycling facility.
u Electric and electronic components, in particular printed boards, monitors, etc., must be disposed
of in an environmentally-friendly way.
u It is recommended to bring in specialized companies.

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Alpha 550 Operating Instruction

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EN

Phone +41 41 455 04 55

© January 2020 by Komax AG

Alpha 550 TopWin – 0349573 – Version 3 – EN 3 / 156

4 Transport / scope of delivery 43

4 / 156 Alpha 550 TopWin – 0349573 – Version 3 – EN

Alpha 550 TopWin – 0349573 – Version 3 – EN 5 / 156

8 Servicing and repairs 109

6 / 156 Alpha 550 TopWin – 0349573 – Version 3 – EN

9 Decommissioning / storage / disposal 155

Alpha 550 TopWin – 0349573 – Version 3 – EN 7 / 156

8 / 156 Alpha 550 TopWin – 0349573 – Version 3 – EN

1.1.1 Machine description

1.1.2 Machine identification / voltage version

2 Voltage version sticker

3 Sticker 3×400/230 V machine

Fig. 1: Base machine, view from above

Alpha 550 TopWin – 0349573 – Version 3 – EN 9 / 156

Voltage version sticker

Sticker 3×400/230 V machine

For other power supply voltages

10 / 156 Alpha 550 TopWin – 0349573 – Version 3 – EN

1.1.3 Technical data

Conductor cross sections* 0.13 – 6.0 mm2 (AWG26 – AWG10)

Wire feed-in speed max. 12 m/s (39 ft/s)

Alpha 550 TopWin – 0349573 – Version 3 – EN 11 / 156

1.1.4 Space requirements

Wire deposit basic module 2 m: 3825 mm (150.6 in)

Height with closed cover: 1790 mm (70.5 in)

12 / 156 Alpha 550 TopWin – 0349573 – Version 3 – EN

Manufacturer / authorized representative for Komax AG

Applied harmonized standards n EN 61000-6-2

1.2 ABOUT THE INSTRUCTIONS

1.2.1 Structure of overall documentation

Alpha 550 TopWin – 0349573 – Version 3 – EN 13 / 156

1.2.2 Layout conventions

u This is an action sequence.

Ú This is an intermediate result from a single action sequence.

Place setup gauge [1] into guide-tube holder [2].

Software elements are designated as in the following example:

1.2.3 Saving the instructions

14 / 156 Alpha 550 TopWin – 0349573 – Version 3 – EN

2.2 INTENDED USE

Alpha 550 TopWin – 0349573 – Version 3 – EN 15 / 156

2.3 GENERAL SAFETY INSTRUCTIONS

2.4 TECHNICAL CONDITION OF THE MACHINE

16 / 156 Alpha 550 TopWin – 0349573 – Version 3 – EN

2.5 SOURCES OF DANGER AND WARNING STICKERS ON THE MACHINE

2.5.1 Sources of danger

Fig. 6: General view

1 Straightener unit / linear changer 7 Control cabinet

2 Belt drive / roller drive 8 Cutting and stripping unit

3 Swivel unit side 1 9 Safety cover

4 Process modules 10 Center of gravity of the machine

5 Swivel unit side 2 11 Wire deposit

2.5.2 Description of sources of danger

Alpha 550 TopWin – 0349573 – Version 3 – EN 17 / 156

Swivel units side 1 and side 2

Cutting and stripping unit

Straightener unit / linear changer

Main air supply

Center of gravity of the machine

18 / 156 Alpha 550 TopWin – 0349573 – Version 3 – EN