IDEAL INDUSTRIES 45-930, 45-935 User Manual
Shielded Twisted Pair(STP)
Cable Stripping System
For 115V or 230V
Operation Manual
#45-930
#45-935
2
Table of Contents
Introduction..................................................................... 2
Caution and Safety Instructions....................................... 3
Environmental Conditions ............................................... 3
Warranty & Service Policy ............................................... 3
Unpacking........................................................................ 3
STP Service Setup ........................................................... 3
Electrical Connection Requirements ............................... 4
Air Connection Requirements.......................................... 4
System Controls.............................................................. 4
Heat Adjustment......................................................... 4
Thermal Head Rotation Speed Adjustment.................. 5
Pull Grip Pressure Adjustment................................... 5
Strip Length Adjustment............................................. 5
STP Operation
Head Adjustment........................................................ 6
Thermal head Rotation Speed Adjustment.................. 6
Pull Grip Pressure Adjustment................................... 6
Strip length Adjustment.............................................. 7
Cycle Mode................................................................ 7
Slug Removal ............................................................ 8
Program Mode................................................................. 9
Set Mode.........................................................................10
STP Service .....................................................................11
Batching...........................................................................11
Recommended Spare Parts..............................................12
Parts Replacement
Gripper Pad Replacement...........................................13
Front Gripper Pad Replacement..................................13
Rear Gripper Pad Replacement...................................14
Tension Springs.........................................................14
Blade Replacement...............................................15-16
CPU Module Replacement..........................................17
Power Module Replacement.......................................17
Maintenance....................................................................18
Changing Slug Tray Location ..........................................18
Trouble Shooting.............................................................18
Machine Schematic & Parts List................................19-21
Electrical Schematic.........................................................22
Introduction
The IDEAL Shielded Twisted Pair Cable Stripping System (STP) is a programmable bench top machine that accurately removes the outside jacket from
shielded twisted pair cable. The STP addresses occupational ergonomic needs by offering an alternative to manual stripping methods which are known
to have contributed to cumulative tissue trauma.
The STP system automatically adjusts to the size of the cable being stripped up to a maximum diameter of 0.3125 inches. Cable strip length is
programmable by inches or millimeters. The strip length is adjusted in preset increments from a minimum of 1-1/4 inches to a maximum of
6.00 inches. A strip operation cycle can be completed in as little as five seconds.
The large, easy-to-read display shows the operating function status and facilitates program entry. A memory module stores up to 500 user defined
“batch” programs and incorporates a battery back-up system. A service machine message can be programmed for display when the machine completes
a preset amount of operations. All operating parameters can be secured from unauthorized modifications by a programmable security code. The
intuitive front panel keypad provides tactile feedback and is highly resistant to harsh industrial environments.
The STP stripping system consistently produces quality levels achieved in the aerospace industry. With its wide array of powerful features, the IDEAL
STP is extremely flexible, simple to program and easy to use.
Shielded Twisted Pair (STP) Cable Stripping System
Caution and Safety Instructions
Please read, understand and follow the warnings and instructions in this manual. Failure to do so can result in serious personal injury.
• Do not alter, modify or misuse the machine.
• Do not operate the machine using an ungrounded electrical system.
• Do not perform any maintenance on the machine unless both the electrical power and air supply are disconnected.
• Do not operate the machine in a damp, wet, gaseous, hazardous or poorly ventilated work environment.
• Do not obstruct any ventilation or air flow around the machine.
CAUTION – Hazardous parts inside, refer servicing to qualified service personnel.
CAUTION – Blade area can create high temperatures; refer servicing to qualified service personnel.
CAUTION – Use proper heavy lifting procedures.
Environmental Conditions
Indoor use only
Altitude up to 2,000m
Temperature 5°C to 40°C
Maximum relative humidity 80% for temperatures up to 31° decreasing linearly to 50% humidity at 40°C
Mains voltage fluctuations not to exceed±10% of normal voltage
Insulation Category II
Pollution degree 2
Unit can produce sound levels greater than 85 dB, proper hearing protection is required.
Warranty & Service Policy
Each unit is warranted to be free from defects in materials and workmanship under normal use and service for a period of 12 months after the date of
purchase. The obligations of IDEAL under this warranty shall be limited to repairing at the Sycamore, Illinois manufacturing facility any unit which
shall, within the 12 month period, be returned to us with the transportation charges prepaid, and with our examination shall disclosed to our satisfaction to have been defective. This warranty shall not aply to any model which has been altered or repaired outside the factory in any way so as to affect
its operation nor which has been subject to misuse, negligence, accident or installed or operated in any other way than in accordance with our instructions, nor shall this warranty extend to repairs or replacement made necessary by the use of accessories not recommended by IDEAL.
Unpacking
The IDEAL Shielded Twisted Pair (STP) Cable Stripping System is shipped in
protective foam packaging. You may wish to save this packaging for future
transportation.
The STP unit is equipped with a power cord, air hose, slug tray, IDEAL T
®
-Cutter
Lite wire cutter, keys, key chain, air regulator kit and an operation manual.
Lifting Instructions for the STP
Locate the front and rear of the machine. The front of the machine has the keypad
and display. Position the machine so the front of the machine is pointing to your
left and the rear of the machine is to your right. Also position the machine as close
to your body as possible. Place your left hand underneath the bottom plate and
center it between the two front rubber feet. Place your right hand underneath the
bottom plate and center it between the two rear rubber feet. Pull the machine up and
toward your body. When carrying the STP, always keep the machine as close to your body as possible.
Note: Where ever possible, lift with your legs slightly bent and your back straight (vertical). Lift the load by straightening your legs not by pulling up
with your arms.
STP Service Setup (Qualified Service Personnel)
The STP front cover is secured with two (2) screws for shipping. Remove the
screws from lower right and left sides of cover before opening lid.
Gripper pad pins are secured with plates for shipping. Remove these plates
from both front and rear gripper pad housings before machine use.
NOTE: Do not invert the unit after shipping plates have been removed. Gripper
retaining pins will fall out when inverted.
Close cover and replace screws removed.
Install slug tray - Insert the long screws provided, tighten.
Description Cat. No.
STP, 115 VAC, 60 Hz 4A 45-930
STP, 230 VAC, 50 Hz 2A 45-935
Power Cord K-6773
T®-Cutter Lite 45-260
Air Hose K-6865
Slug Tray IA-3124
Air Regulator 45-906
Operation Manual ND-3514
Security keys 1301.012
IDEAL Key Chain 99-020
3
Front
Rear
4
STP Service Setup Continued
Electrical Connection Requirements
Voltage Selection
The STP operates on either 115V/230V AC; 45-930, 115V AC 4A 60 Hz ; 45-935, 230V AC 2A 50 Hz. Proper voltage will be preset at the factory.
Fuse Replacement
Disconnect power cord and remove the fuse cartridge using a small blade screwdriver or similar tool. Replace two fuses with recommended fuses.
45-930, 4AT 250V, 1/4” x 1-1/4”; 45-935, 2AT 250V, 5 mm x 20 mm, insert the fuse cartridge back into the unit making certain the proper voltage is
selected.
On-Off Switch — Located on the back of the unit, the on/off switch controls the main
electrical power supply.
Air Connection Requirements
Connect 1/4" coiled air hose to the air inlet fitting located on the back of the unit. This is a reusable compression type fitting.
To connect air hose:
1. Disconnect electrical power supply.
2. Connect the air hose by inserting it firmly into compression fitting.
Air must be clean, dry and pressure regulated to 100 PSI.
The STP consumes approximately 50 cubic inches (about .03 cubic feet) of compressed air per cycle. Total air volume consumed depends on frequency
of operation.
To disconnect air hose;
1. Disconnect electrical power supply.
2. Disconnect air supply.
3. Depress the red ring
and pull on the air hose.
STP Operating Principles and Terms
The following section describes the basic principles of operation of the 45-930, STP.
The STP uses a combination of four variables to perform each strip. It is important to
understand each of these four control parameters and how they interrelate to obtain
the desired stripping results. The four variables are HEAT, SPEED, PRESSURE
and STRIP LENGTH. Each variable is described in terms of settings, ranges and
effects on stripping. The individual variable settings may affect the other variables
and the final stripping results. Please refer to the “Electrical Controls” section for
instructions on how to regulate each setting via the control panel.
HEAT: Thermal Blade
The HEAT setting controls the level of power (heat) directed to the blades during the thermal cutting phase of the stripping cycle, with 10% being
lowest heat and 100% highest. The STP may also be operated with a heat setting of 0%, which runs the unit through a complete cycle without using
the blades. This is intended to pull off a slug that has already been cut either by the STP or manual methods.
Since the STP is a thermal stripper, heat plays a very important role in the stripping process. Insulation materials have a wide variety of melting
temperatures, requiring the STP to produce a full range of blade HEAT settings. The melting temperature of an insulation material, high or low, must be
consistently matched by the STP blade heat setting for a successful stripping operation.
Another important factor is the rate at which the blade heat penetrates the insulation material. A tendency may be to strip at the highest blade heat available. This produces two undesirable results. First, the higher blade HEAT setting is inversely proportional to blade life. Second, the blade may
displace the insulation material too quickly, producing an excessive amount of contact with the inner shield. For these reasons it is important to
correlate the blade HEAT setting with the blade rotation SPEED setting.
SPEED
HEA T
PRES SURE
PRGM.
HIGH
STRIP
LENG TH
COUNT
CLEAR
ENTER
BATCH
5
STP Operating Principles and Terms (continued)
SPEED: Thermal Head Rotation
SPEED refers to the rate of rotation by the Thermal Head of the STP. This is the rate at which the blades are rotated about the wire being stripped. The
slowest speed is 1 and 10 the highest.
Running at a faster speed requires a higher blade heat setting which may shorten the blade life. A superior strip quality is obtained at lower blade HEAT
and SPEED settings. However, the various types and thicknesses of insulation material requires a wide variety of HEAT and SPEED setting
combinations (to avoid touching the inner braid).
PRESSURE: Rear Grip Mechanism
The PRESSURE setting regulates the air pressure delivered to the internal, rear grip mechanism. This mechanism is used to pull the stripped slug off
the wire. Based on a line pressure of 100 PSI, which is required for operation of the unit, the internal rear grip can be set to operate from 5 PSI to
100 PSI in increments of 5 PSI. Various insulation materials and shield types require varying grip pressures to obtain optimal slug removal results.
The rest of the machine runs on a constant 100 PSI line pressure.
Having air pressure controlled electronically allows the STP to use a variable amount of grip force to hold the insulation slug while trying to pull off the
slug. This is important for three reasons. First, various materials adhere to the braid differently and require more or less grip pressure to be pulled from
the shield. Excessive grip pressure increases internal friction between the slug and shield, preventing removal of the slug. Second, different materials
have varying coefficients of friction with the grip pads. This creates the need for a wide variety of grip PRESSURE settings. Finally, the strip length
affects the amount of grip pressure required.
STRIP LENGTH
The strip length range of the STP is from 1.25 to 6.00 inches (31 to 150 mm). It can be set in increments of .01 in. or 1 mm. The strip length
required for a given wire is a user-defined variable.
Longer or shorter strip lengths may require varying grip PRESSURE settings. Once the STP is set to strip 3.00 inches or longer the grip PRESSURE
setting remains fairly constant for a given wire type. However, when stripping less than 3.00 inches it may be necessary to increase the grip
PRESSURE setting. This is due to the fact that the internal, rear grip mechanism is about 4.00 inches long and consists of separate pressure points.
When less than 3.00 inches is to be removed, the grip mechanism is not fully utilized and may require a higher PRESSURE setting to accomplish the
task.
Any given wire may be successfully stripped over a range of setting combinations. It is important to look at all of the variables and resulting
performances in order to select the combination that best suits the specific stripping requirements.
IDEAL INDUSTRIES, INC. offers free application assistance... for immediate assistance, call our technical service hotline at 1-800-338-4495.
STP Operation
When the machine is turned on, the software version is briefly displayed followed by
the machine initializing.
Then the Machine Status display appears showing the present settings. During
operation there are three different status displays: READY MODE, “ENTER VALUE”
(a value is being entered or the machine is adjusting to a new value) and “CYCLE IN
PROGRESS” (the machine is in a strip cycle).
At this point, you can proceed stripping wire, enter new values or retrieve a preset batch
with different settings.
Use the following procedures to change the machine settings via the
control panel keeping in mind the “Operating Principles and Terms”
described on page 4, while selecting process variables.
All control settings can be set by either using the arrow keys or setting
discrete values on numeric key pad.
Example: Ready Mode Display
HEA T
SPEED
PRES SURE
PRGM.
HIGH
STRIP
LENG TH
COUNT
CLEAR
ENTER
BATCH
6
STP Operation continued
Heat Adjustment
Heat can be adjusted by pressing [0] through [9] producing corresponding heat values of 0% through 90%. Pressing HIGH sets the heat at 100%. If
the heat is set at 0%, the machine completes the cycle without using the blades. The heat can also be adjusted by pressing HEAT and using the [ ]
and [ ] keys. The heat is adjusted from 0% to 100% in increments of 10%. Pressing the ENTERkey exits from the heat entry mode and returns to the
ready mode.
If CLEAR is pressed during a HEAT entry, it returns to the beginning of the HEAT entry mode. If CLEAR is pressed at the beginning of the HEAT entry
mode, it exits the HEAT entry mode and the previous settings are returned.
Thermal Head Rotation Speed Adjustment
Speed can be adjusted by pressing [1] through [9] corresponding to speeds 1 through 9, and pressing HIGH for speed 10.The speed at which the
thermal blades rotate around the wire being stripped can also be adjusted by pressing SPEED and using the [ ] and [ ] keys. The speed is set from 1
to 10, the fastest setting being 10. Pressing the ENTER key exits from the speed adjustment mode and returns to the run mode.
If CLEAR is pressed during a SPEED entry, it returns to the beginning of the SPEED entry mode. If CLEAR is pressed at the beginning of the SPEED
entry mode, it exits the SPEED entry mode and the previous settings are returned.
Pull Grip Pressure Adjustment
Pressure can be adjusted by pressing the numbers corresponding to pressures 05% through 95%, pressing HIGH sets the pressure at 100%.
EXAMPLE:
press [4] then [5] to get pressure at 45%.
The pressure can also be adjusted by pressing PRESSURE and using the [ ] and [ ] keys. Pressure can be
adjusted from 5 to 100 PSI in increments of 5 PSI. Pressing the ENTER key exits from the pressure entry mode and returns to the ready mode.
If CLEAR is pressed during a PRESSURE entry, the display returns to the beginning of the PRESSURE entry mode. If CLEAR is pressed at the
beginning of the PRESSURE entry mode, the display exits the PRESSURE entry mode and the previous settings are returned.
↑
↑
Example 1 Example 2
Example 1 Example 2
↑
↑
Example 1 Example 2
↑
↑
HEAT
Press
20%
10 40 3.10
ENTER VALUE
HEAT Field will Flash
Press
20%
ENTER
or
Press Press
HEAT
10 40 3.10
ENTER VALUE
HEAT Field will Flash
Press To
Enter Single
Digit Value
ENTER
BA TC H
PRGM.
HIGH
Or Press for
100% Heat
SPEED
Press
20%
ENTER VALU E
40 3.1010
SPEED Field will Flash
Press
20%
ENTER
or
Press
SPEED
Press
ENTER VALU E
SPEED Field will Flash
40 3.1010
Press To
Enter Single
Digit Value
PRGM.
HIGH
Or Press for
Speed 10
ENTER
BA TC H
PRESSURE
Press
20%
ENTER VALUE
PRESSURE Field will Flash
3.1010 40
Press
or
ENTER
Press
PRESSURE
Press
20%
ENTER VALUE
PRESSURE Field will Flash
3.1010 45
Press To
Enter Single
Digit Value
ENTER
BA TC H
PRGM.
HIGH
Or Press for
100%
Pressure
STP Operation continued
Strip Length Adjustment, by Discrete Value
METRIC LENGTH MODE (31 mm to 152 mm)
• Press STRIP LENGTH.
• The strip length display will blink.
• Enter the strip length and then press ENTER.
A strip length is automatically entered after a third digit is pressed.
ENGLISH LENGTH MODE (1-1/4 inches to 6.00 inches)
• Press STRIP LENGTH.
• The first digit will blink. Press the appropriate number key and it will be entered.
• Press the decimal point.
• The tenths digit will blink, press the appropriate number key.
• Next the hundredth position will blink, press the appropriate number key.
• After typing the hundredth position, the new strip length is set.
If at any time during the strip length entry ENTER is pressed, the current strip length will be set. If CLEAR is pressed during a strip length entry, it
returns to the beginning of the strip length entry mode. If CLEAR is pressed at the beginning of the strip length entry mode, it exits the strip length
entry mode and the previous settings are returned.
Strip Length Adjustment By Increment
While in the ready mode, the strip length can be changed up or down by increments using the [ ] and [ ] keys. Programming the increment is
explained in the Set section of Program.
In either of the strip length entry methods, the strip length is checked. If the strip length is invalid, an appropriate message appears and the previous
strip length is displayed.
Cycle Mode
NORMAL STRIP CYCLE
• To select a new cycle mode, press Program/High
• Enter in the 3-digit security code
Note: All units are factory preset to a 3-digit security code of “111.” To make any changes in the Program Mode the security
code must be entered.
• The display will show
1 - Test 2 - Set
3 - Mode Clear_Esc
• Select [3] for Mode
• Select [1] NORMAL CYCLE MODE
• Press count/clear on your key pad
• Self Check - Press enter and hold to display batch number and selected cycle mode.
• Insert wire for normal cycle mode
• Remove wire when cycle is completed
For Example Enter Value 3.25 Inches:
↑
↑
For Example Enter Value of 75 mm:
7
PRGM.
HIGH
Press
STRIP
LENGTH
Press
20%
ENTER VALUE
40 10 0
Digit Will Blink
Press Numbers
7 Then 5
ENTER
Press
STRIP
LENGTH
Press
20%
ENTER VALUE
First Digit Will Blink
40 10 0.00
Press 3
BATCH
Press
20%
ENTER VALUE
Second Digit Will Blink
40 10 3.00
Press 2
20%
VALUE
ENTER
Third Digit Will Blink
40 10 3.20
Press 5
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