Komax kappa 220 Operating Instructions Manual

Operating

I nstructions

Automatic

striPPing

machine

lsomnax

koppo

220

Operating

Instructions

Automatic

striPPing

machine

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Art.No.

040986

-

Version

3

Publisher:

komax

AG

Industrrestrasse

6

CH-6036

Dierikon-Luzern

Phone

041-455

0

455

Fax

041-450

15

79

As of

May

1996,

subiect

to change

The reproduction

of

these

instructions

or

parts

thereof

,

in whatever

form,

is

prohibited without

the express,

written

permission

of

the

publisher'

3

2,

2
3
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1996 by

komax

AG,

Wire

Processing

Systems

Table

of

contents

1. lntroduction

and

notes.........

.....-'...'.."'

Page5

6

1 1 Operatrng

instructrons

tOl)

1 2 l,lachrne

tdenttf

icat;on

1

3

-i-echnrcal
speciirca:rons

per'forrnance

range

1

4 Accesso|es

'1

.5 Personnel

quaiificalicns

and

tratntng

6
6
8

I

11
11

2. Safety

2.1

Explanatton

of

ncies

2 2 Safety

notes

,

.

? ?

(:f

otv faalr rroq

3. Transport

/

ltems

included

in the

delivery

""""""""""

13

4. Overview

of machine

""""""""

15

5.

Start-up

procedure

17

17
17

5

1 Cf ecks

pnor

to start-uP

5.2 Swrtch

on

and

otl

5

3

AClustments

and

seitings

prior

to

productton

... .

. ..... ........

17
17

5 3.1

Stratghteier.

5 3.2

Punched

drsk

5 3 3

Feed

rolie.s

.

5.3.4

\ /tre

gurdes

.

5

3.5

Biades

..

...

5 3.5.1

Blade

tyPes

.

5.3.5.2

Cnangtng

the

blades

6.

Operating

the machine........'.....

6.1

Ccntrols

6.2

D splay

concept

'1

1

la

la

io

18

to

IJ

10

20

21

ai

al

22

6.3 Snorl

overvievr

of

operator's

menus

23
24
24

6.4

lvlAlN

-

marn

men!...............

.

6.5

LANG

-

language

selectron

. .

Ol kappa

220

-

Verston

3

Table

of

contents

6.6

Brief

rnstructrons on the three most rmpodant

menus

6.6

1 TEACH

-

programming

menu

6.6.2

PPARA

-

process parameter

menu

.

. ..,..

6.6

3

PROD

-

production

menu .

6.6

4 Programming

example

.. ...

24

a+

26

27

G
J
G
2
J

J

-

6.7

PPARA

-

other

processtng

parameters

6.8 TEACH

-

Further

types

of

processing

.

6.8.1

lf/ - Intermediate

stripptnq

6.8.2

PS

-

Stripprng

with multiple cuts

6.8.3

Parameters

for double-sheath

processing

6.9

CONF

-

configuration

6.10

LIST

-

wtre ltst

J
f

-

f

f

I
J

30
32
33

34

JO

20

6.11

SEQU

-

sequence

menu

6.12

REMOT

-

remote mode

7.

Malf unctions

/ error

messages

............

'.'.... 41

7.1 Malfunctions

..........

........-

41

7 .2 Error

messages on

the display

.

.

.. ... ' .... 42

8. Maintenance

/

repair

"'.'......'.....47

8..1

Maintenance...........

47

8.2

Determining

reference

positions

. .

47

8.2.1

Feference

blades

.. .... ... ...47

8.2.2

Feference distance

(rollers)

'.

48

8.2.3

Test functions

............ . .....

48

9. Description

of

connections

................

........ 49

9.1

Connectron

for subsequent

processing

.... . .

...

49

9.2 Connection

for

preliminary

processing

50

9.3 Connection

for stop

inout

. .......

.......51

9.4 Connection

for RS232

interface

-........52

10. List of

accessories

............

..'..

53

1'1. lndex

.............'.......

55

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7
J

Table

of contents

Ol

kaooa 220

-

Version

3

1 . lntroduction

and

notes

Dear

Customer

The

komax

kappa

220

is an

automatic

stripping

machine. designed

to

perform

the

following

wlre

nrocessino aoolrcatrons

in

accordance

with

the

technical specif

ications listed

in

Chapter

1.3:

'Y

*tsr""..

-'

This list is

complete

please

read the

operatrng

insiructions

caref

ully.

They

will

gurde

you

through

the

operatrons

of the

kappa

220

step

by

step

so

you

car

De

uslng

the

machine

successfully

in

no ttme at all.

Yours

trulY

komax

AG

e

G

a

Cuttrng

lo

lenoth

Strrpprng

wrth

half

Pull-off

Stripprng

with

fuli

oull-ofl

tr'*.rt1:t"

,_:

Multiple-step

cuttrng

(double sheaths)

#

H^t-at2mn markrnn

',ts '''.'''''

J

re

Multi-core

wtres

Illl''"'"111"1__

Passive

wire dePcsit

system

tt

'u

o

Ribbon

cable

Ink-1et

rnarker

Wire

staci<er

Horizontal

and';ertical

strai

ghtener

PC soflrvare

with

Wtndows

95

Microsoft
Windows 95

Ol

kappa 220

-

Versron

3

Introduction

and

notes

1.1

Operating

instructions

(Ol)

These operating

instructions

apply

to the

komax

kappa

220

-

software

version F103b

and are available

rn

German,

English.

French. ltalian.

Spantsh

and Portuguese:

other

languages

are available on

request

Thorr cnnqrqt nf 67 n:r

_,,*3€S,

nUrnoereo

consecutlvety.

The

instructions

contain

complete

rnformation

on the

controls.

the operation of the entire

machine.

maintenance and

adlustments as

well

as technical specificatrons.

Electrical diagrams

and a

Iist

of

accessories are also

rncluded. The operating

instructions forthe

various accessories are delivered with

each device.

Make sure they are

not

lost when

the device

is unpacked and set

up.

The

operating

instructions are an

integral

pad

of the kappa

220. Keep them

near

at

hand so

you

can

readily refer

to

the

rnformation in them

at any time.

The instructions

must

be understood and all

items in

them

followed bv anvone

responsible for

the

transport, rnstallation.

operation and

repair

of

the machine.

Pay special attention

to Chapter 2 and the safety notes included

there.

komax reseryes the

right

to

make

technical changes

in

the system

depicted and

indicated in

these

instructions

if

such changes are

necessary

to

improve

the

komax kappa.

lf

you

need additional

copies

of

the

documents,

please

contact

your

komax represen-

tative.

2
Y

a

3

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I

=

f

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r

1.2 Machine

identification

A

nameplate containrng

the followrng information is

affixed

to the back of the

machine

Machrne type

Machine

number

Voltage version

Power input

fjq 1 1

Nameplate affixed to the back ol the

machine

1.3

Technical specifications /

performance

range

f
f,
C
T

f

r

E
E

t

t

f

xt x6 xz

Stripprng lengths Side

1

Strrpprng

length

Pull-off

length

Side

2

Stripprng

length Pull-off

length

rq!

pull

9lr

Half

pull-off

,

Mullip]glcutstripprng

lntormodiaio

qtrinn

_.,,r_rt-le

i

sg.srt

99,9mm
40mm

.

36mm

.999,9mm

,

999,pqq

999,9mm

40mm
40mm

999,9mm

B0mm

40mm
40mm
40mm

f

r

]

T

f,

r.
r

lntroduction and

notes

Ol kappa

220

-

Version

3

LUr

19Lr I rOrrys

1mm - 99 999mrn

Lengln

accuracy

+r-

0.2?o or

1mm.

dependrng

on

the

wrre

Iength

Shorln

ode

Length

of remarnrng insulation

<

50

mm

Remaining

insulation

=

wire

length

minus stripped

Iengths

Wire cross-secttons

0,06

-

6mm'

(stranded

wires)

AWG 1O - AWG 30

Ribbon cable: up

to

12 mm

rn width

Omm

Max o.rtsrde

dtameter

Pioco nrrtntrt

qoo

nr:nh lin 1 )

Preselectable

ptece

numbers

1

-

60

000

pieces

Noise

level:

Electrical

connecttons:

1 10V t

15ol. / 50-60

Hz

230V

t 15ozo / 50-60

Hz

Dimensrons

(WxHxD)

480x340x390mm

Wergni

28kg

(without

deposition

untt)

''----

Standard

values

komax kappa

220

i

"'"..

)

D'ocessed

wire

S

geec.

li).lc . nanian

r

/a

vbac

k.

FLFY 0 5mm'
max.
3 5mm

0.2mm

I

-

r--

o

@

o

)o

I

t--

l

-+

l--

I

--

--r

I

Ol kappa 220 - Version

3

lntroduction and

notes

Tila

wrre

length

lmml

lin 1 ? Piona nr rlnrt

1 .4 Accessories

You can use any

of a

number of

accessones

to optimize

the

komax

kappa

220 to

your

specif

ic

application

while

remainrnq completelv

flextble

to

meet

future requirements

Wire

feed systems:

Various wire feed and

de-

reelrng

systems

Preliminary

wire
processing:
Ink-jet and

hot-stamP

marker

Wire

deposition

system:

Various:

t

?

t
I
t
D

I
I
f

f,
T

r

f
f
D
f

f
I

t

I

l

I

D
I

f

r.ln

l-

.l

'l

.'l

r

PC

software

runs under

Windows 95

(required

for

ink-jet marker)

I

Set for ribbon cable

processrng

r

Set

for

parallel processing

Exte

rnal

strai

ghteners

(for

vertical

and

horizontal

posrtion)

2

!i---

..:

":

'-;

-J

ggx
gtrnl

r

Large

assortment

of

quick-re-

lease

gurde

parts

r

Various

V and

radius

blades

r

Special

blades

and

wire

guide

parts

for

ribbon

cable

r

Speoal

blades

and

wire

guide

parts

for

parallel

Processtng

-

?tr

.\t

i

'\\'

I {i,

I
I

t

l

e.o.

hol

stamo-marker

komax 24

komax

107

Wire

stacker

komax 260

Wire deoosit svstem

komax 215

Refer to

the list of

accessories

(Chap.

10) or the

spare

parts

catalog

(Art. No.

041787)

for the corresponding

article

numbers.

3
J

,

s

f

lntroduction

and

notes

Ol

kaPpa

220

-

Version

3

1.5 Personnel

qualifications

and

training

Machine

operator

Tne

machine

operaior

must be

familiar

enough

with

ihe machrne to be

able

io operaie it

piLrs

its

accessores

and

peripheral

units

without difficulty

in normal

production.

Thrs

requrres a

good

understanding

of the

technical aspects o{ the

machine as well

as a

knowledge

of

the

software

for

operating

the

machine.

The

operator

can

attain this

level of

knowledge by attendrng

komax's Level I Training course.

In

the

course.

parlictPants:

I

Bef

resh

and

enhance

their

basic

knowledge

of the

machtne

r

Learn

about

the bastcs

of

operatrons

(software)

r

Perform

oractical

procedures

on the

machine

Training

courses

tailored

to customer

needs

t

'

Asrde

f rom the trarn

ing

courses

mentioned above,

komax also

off ers

Level S Training cou

rses to cover

specific

needs customers

may

have.

The

information

below

applies

to both

levels of

training:

:'

I

Duration:

max.

3 days

r Location:

Training Center

at

komax Dierikon

or in-house

at customer's

,:

r

Language:

German

or English

r

Srze of

group: The number

of training

participants

rs limited to a

maximum

of 3

,

Ol

kappa 220

-

Version

3

Introduction

and notes

Nofes

c

2

3
1

t
t

J

t

I
E

E

-

E

I
E
E
E
E
E

E
E
E
E
f

]

f
f

I
I
I

r

I
J

J

Ol kappa

220

-

Version

3

10

Z*\

\rI2

2. Safety

2.1

Explanation

of

notes

ln the

note ooxes

throughout

these

instructions,

you

will see

three

different

symbols

which

must be

obeyed

T^e

symbols

are useC

as

follows:

This

symbol

indicates

a safety

note

lor any

work

procedures which

pose

a danger

of

injury

to

you

or

olher

people.

Observe

these

warnings

and

proceed with

special

care

in

these

instances.

Pass

these

warnings

on

to other

users'

This

symbol

is f ound

next

to all

work

procedures

of

special

importance

in

preventing

damage

to

the machine.

Pass

these

safety

instructions

on

to other

users'

too'

This

symbol

marks

helpfultips

and

instructions

on

correct

procedures and

behavior'

Observe

these

notes

caref

ully,

too. This

will

save

you

time

and

unnecessary

problems'

komax

AG

accepts

no

liability

whatsoever

il machine

users

disregard

the

instructions

marked

on the

machine

or

in

these

instructions.

2.2

Safety

notes

Protection

from

Personal

iniurY

7}

prior

to each

start-up.

check

that

all saf

ety

features,

especially

the

covers,

are

attached

..hllll

and

in

proper working

order.

Safety

features

may

be

removed

only

when

the

machine

is stopped

and

the

power to

the machine

is switched

ofl.

Housings

and

covers

in

particular may

be

removed

only

by

properly trained

personnel.

lt is

dangerous

to

touch

current-carrying

parts

!

,|*

Whenever

carrying

out

assembly,

maintenance

and

repair

work,

always

switch

off

the

.,Sf,

entire

komax

kappa

and

secure

it against

unauthorized

switch-on.

Protection

for

the

machine

@

Thorough

training

of

the

machine

users

is

the

best

way

to

protect

the

machine

from

damage

since

disregarding

the

operating

instructions

can

destroy

parts

of

the system

'

This

tiaining

includes

reading

these

operating

instructions.

11

Ol

kappa

220

-

Verston

3

Safety

General safety

instruclions

J,

t
3

]

J

J

Only

authorized

and

trained

personnelfamiliar

with

kappa 220 safety

procedures

are

permitted

to operate.

maintain

and service

the machine.

lf there

is reason

to believe that the machine can

no

longer be operated

safely, it must

be shut

down and

secured against accidental

switch-on.

Read these

instructions

carefully all

kappa

220 tor

the f irst time.

the

way through

before

operating

the komax

f

E

f

.

f

f

E

Aside from

the instructions

in this manual, always

observe

general

rules of safety and

accident

prevention.

2.3

Safety

features

Main switch

for machine

Pressrng the

marn

switch

on the rear

panel

of

the

machine cuts off

the

power

supply

Emergency

stop switch

Pressino the emeroencv

stnn

qwr'nh

on the

frnnt oneratnr's narlgl

STOOS all

maChine

I

rErrilry

rrrL ur

rvJ r.vv

movements and cuts off the

power.

Access to controls
All

controls are

readilv

accessrble.

Low noise level:

less

than

75 dBA

f

E

E

E

E

E

E
F
E
E
l

D
E
E

F
I
f
F

r

@

The

machine can

be dangerous

if improperly operated by untrained

personnel.

t.

j

12 Safety

Ol

kaooa

220

-

Version

3

3.

Transport

/

ltems

included

in the delivery

@

When

transporting

the

komax

kappa,

observe the

instructions

below

as

wellas

general

rules of

safety

and

accident

prevention.

i"e xappa 220

ts

pacKageo

r

a carciboard

box

Drmensions

of

the ocx

(WxHxD):

60

x

44 x 48 cm

Werght:

approx.

35kg

Always

observe

the

handling

symbols

on

the

package:

t

an'a

1 04'F

)

\

Delicate

electronic

appliance

Do

not

stack

anything

on

the cover

Keep

dry

Fragile

Note the

f ollowing

points

when

transporting

the system:

Always

transpon

tne system

careiully

to

prevent

damage

f

rom

impact or

careless

loading

or

unloading

lmmediaieiy

check

the

machtne

on

delrvery

foranytransport

damage.

Shortcomings

should

be

reported

rmmediately.
Items

included

in the

deliverY:

Don't

use

hand

hooks

Store

in

a dry

Place

at

less than

40'C

Keep

out

of

direct

sunlight

ffi

<cmax

kaopa

220 strrpper

with integrated

vertical

straightener,

safety

cover

and

:assive

',^;,.9

lgPosli

svstem

Power cable

and

electric

f ine-wire

f

uses

Set

of

V-blades

(2

blades)

Set

of

f

i'e

rollers

r4

rollers)

Swiveiirng

wire

guide.

6mm

\y'/rre

gurce, rtght.

6mm

Set

of

Allen

wrencnes

Blade

caltoratlon

wlres

operatrn

g

Instrucllons

Transport

Items

included

in

the

delivery

Ol kappa

220

-

Verston

3

13

Nofes

O
2
t

]

I

t
t

f
I
f

f

=

E
E
C
E
E
G
f

f

r

f
E

]

3

r

E

ts

I

3

r

t

7

?

Ol

kappa

220

-

Version

3

14

4. Overview

of

machine

I

I

I

i

I

I

i

-l
tlr

i.

t-

I

I

I

I

I

',1

o

.z';"'=

-

i

!l

o

a

ilof{)f

IJ

(-(:ftrf,

-

_

(D(D(E

utEt-

€ {::- 6t-Iffi

(DmE(E15lnm

lig 4 1 kappa 220

from abcve

1

Display

2

Function

keys

3

Keypad

4

Emergency

stop button

5

Wire

feed-in

6

Straightener

7

Punched

disk

8

Feed

roller

for

processing

side

1

9

Swivelling

wtre

gulde

{ n ^,,++;^^ h^^,

I u

vutul

lg lluau

11

Wire

guide,

rtght

12 Shaft

for feed

roller,

processing

stde

2

13

Trough

for

insulation

scraps

14

Wire deposit

system

trough

15

Swrtch

for

raisrng the

feed rollers

Ol kaooa

220

-

Versron

3

Overview

of

machine

15

0

n

l-e-f

o

lu.

tDl

lul

o

l

ia

t."

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I.,\=r/oi

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i

xt x? w $r7

l

1t-.1

Srnnhl

;

lLJl

bF-d

v-a

v v

l,*,

'tm;nt

ffi m,a, tlB

ll-lb-d

rJ

v

I

xi

x5 d

I

fig 4.2 Back of

the

machine

J

a

2

]

2
J

­=

J
2

-

j

-

E

-

3
E
E
I

f
f
f

E
3
3
f,

f

r

]

3
t
I

r

;

1

Main switch

2

Fuses

3

Power

connection

4 Connection

X2: subsequent

processtng

(e.g

5

Connection

X3:

preliminary

processing

(e.9.

6

Connection

X4:

reserve

7 Connection

X5: stop

input

8 Connection

X6: R5232-interiace

9

Connection

X7: reserve

10 Compressed

air

connection

11. Nameplate
12 Adhesive

lettering

for connectors

wire stacker)

wire

marker)

Consult

Chapter

9

'Description

of connections'

ments.

for information

on

terminal assign-

16

Overview

of machine

Ol

kaooa 220

-

Version

3

5.

Start-up

procedure

5.1 Checks

prior

to start-uP

Power connection:

Compressed

air connection:

(used

to blow

away

insulatton

scraps)

-

110 V t

15%/ 50-60

Hzor 23OV

*

159'o I 50-60

Hz

Devrce switches

over automatically

-

Length of

power

cabie 2,5

m

-

Use

a seoarate

mains

socket

I

Air

pressure

must not exceed

7

bar

I

Compressed

air

f

ree

of

water and

oil

fig 5.2

Examcle

of a strarghtener

r'v'th I rollers

lnstallation

site:

5.2

Switch

on

and off

Switch

on the

machine at

rnain switch 1 on

the

back

panei

of the

machine

lf nothing

happens,

check

to see

if

the

emergency

stop

switch

on the

front

operator's

panel

is

pressed

in

or

if fuse 2

underneath

the

main switch

rs

defectlve.

After start-up,

the

last active

menu appears

in the

preselected

language

5.3

Adjustments

and

settings

prior

to

production

5.3.1 Straightener

The

setting

shown

here

is suitable

for

most types

ol

wire. The

imporlant

thrng

ts

that the

ma;or

straightening

of the

wire

takes

place

at the begin-

ning of the straightener,

allowing

thewireto simply

run

out through

the

final

straightentng

roller

(xcy).

Adjustment

procedure:

Turn

the

retaining

screws

'1

and 2 to adlust the

inclination

of

the

straightening

rollers.

Close the straightener

by

turning

eccentric thumb

screw 3 and

set

to

wtre

drarreter

on turnrng

scale

4.

-

f lat.

stable

and

non-vibratrng sur{ace

-

protected

against

moisture

-

moderate ambtent temperature

(not

too

hign

nor

too

low)

-

ventilation slots

must be kept uncovered

-

suf{icient

space

for wire f eed-rn

and

wire depostt

systems

fig.5l Mainswitch

Eerci|W

t--

-

­G

d

LJ

Ol kappa 220

-

Version

3 Start-up

procedure

17

5.3.2

Punched

disk

Turn the

punched

disk to

find a

wire

hole

that

is

neither

too

small

nor too

large.

The

punched

drsk

need only

be cnanged

f

or special types

of

processtng tnvoiving. f

or example,

ribbon

cable or

double

V-blades.

To

switch dtsk,

proceed

as

follows:

r

Open

feed

rollers by

presstng

swttch 1

r Femove top

f eed

roller 2

r

Loosen

punched

disk 3 by

unscrewing screw

4

with hexagon

socket

head

wrench and remove

r

Insert new

punched

dtsk and

retrghten

screw

r

Flemount feed

roller

fig 5.3

Punched disk and

feed

roller

5.3.3

Feed

rollers

Use the appropriate

type of

feed

rollers for the wlre type being

processed.

To

change

rollers,

proceed

as

follows:

f
f
T
J

t

t

I
I
I

J

t

E

I

I

t

f
E

3
I
f
f

I

T
I

Open feed

rollers

1

Loosen f astening

screws

2 on

feed rollers and

pull

off

rollers

Slrde on the

appropriate

feed

rollers

for

the

wire

being

processed,

pushing

tt all the

way to the stop

Prior

to

tightening

the screws,

check

to make sure

the screws

are

pressing

against

surfaces 3 of

the

drive shafts; otherwtse

they

cculd

damage the

shafts

r:n

(6-

tE-

Giz-r r;-

GGFI Gio-

I

I

5.3.4

Wire

guides.

You may

have to adlust the

swivelling

wire

guide

(in

f ront of the blade) and

the

right-hand

wire

guide

(behrnd

the blade)

depending

on the outside

diameter

of the

wire

being

processed.

To do so,

proceed

as

follows:

Remove any drawn-ln

truire

Pull

off the swivelling

wire

gutde

1 and attach

the

:nnrnnririo nrrido

*HH'"Y'

Make

sure the

gurde

has a

{irm

axial

seat

on

the

swivel shaft.
Pull

off the

right-hand

wire

gurde

2 and attach

the

appropriate

guide.

I
f

t

I
I
T
t
I

t

T

t

r

;

fig.54Feedroller

fig. 5.5

Guide

Parts

18

Start-uD

procedure

Ol

kaPPa

220

-

Version

3

l{

there

is

axral

play

rn the

gurde

pa11s,

loosen

hexagon nut 3 on ball

thrust

prece 4

(f

ig

5.6

and

5

7;

and

readjust

rt. After

adjustrng

rt

retrghten

the

nul

frg

5 5

Rrght-hand

wtre

gurde

,l

I

frg. 5.7 Swivelling

wtre

guide

5.3.5

Blades

5.3.5.1

Blade

tyPes

Standard

blades

t

.

V-blades
This blade

type

ts suitable

for

most diameters

and

types

of

wire.

Problems

wtth

stripping

the

remaining

insulation

can occur

with cerlain

insulation

materrals

where

.

I

-

:

the

V

shape

does

not encompass

the stranded

wires

preclsely.

l'l

Radius

blades

These

biades

have a

rounded

cutttng

edge

and

are

adjusted

to

the cross

section

of

the stranded

wrres.

This

makes

rt

possible

to

process

wires

with extremely

thin

or

hard

1r7pes

of

'nsulation.

Custom-ordered

blades

"%'

Blades

for

ribbon

cable

These

blades

can

be used

to strip

ribbon

cable

with or

r,rrithout

intermediate

tie

Special

models

Custom

blades

for

special

wire

types

can

alsc

be

manufactured

on

requesl

Double

V-blades

The

piece

output

can

be doubled

with

these

blades

They are

installed

lust

as

V-

blades

are.

Ol kappa 220

-

Version

3

Start-uo Drocedure

19

5.3.5.2

Changing

the

blades

Blades must be changed

in order to

process

cerlaln

types

of

wire or

rf the

qualtty

of

the cuts begins

to

decline.

To

do

so,

proceed

as

follows:

r

I

T

I

T

;||}r;\

ALWAYS

turn the

main

switch

on the

machine

to OFF

prior

to working on the

cutting

Ul,

head and the blades.

Remove right-hand wire

guidel

and.

if necessary.

the feed rollers
Loosen fastening screws 2 on

blades 3

Remove

blades

and insert new blades

When retightenrng

the

screws,

press

the blades

against the stop

pins

of the

blade

holder

Close

the cuttrng

head manually

and make sure

the

tips

of the blades do

not

collide

and block each

other

fig

5.8 Cutting head

T

I

I

t

I

t

!

t

r

I

?

t
t

,,

I

E

t

I

r

I

ts

20

Start-up

procedure

Ol

kappa 220

-

Version 3

6.

Operating

the

machine

6.1

Controls

Cursor

pad

in

)aD

iU

nnEl

.-

t1--llllllllllllllll

f5---l G----)

i r/

ri---l ro--.1 fe-r

f

Fi-] t6--'l

tE--"t

I

Numbers

pad

o

f*-l tFc

I

€ Cf) '

GEn f'rs------l

\

\L

Srop

key

Function

keys

-\
\

*r_

keys

Start

Key

fFr-l

fFr-]

lE--l

fF:-l Ir-sr

fZ-f

grm

|

l--

-

fig.

6

1 kappa 220 control unrl

Keys

Function

t-t

f-

Function

keys

for selecting

various menus

and f uncttons

Arrow

keys

for selecting

tnput f ields

The active

rnput

field is

displayed

inversely

on the

screen.

For changrng

numerical

inputs

at

predef

ined

increments

l.

It,_
t I i--l
T_- [.-_.

t.-lj-j l--i

i.

._)

II
:_l

r _l

For entering

numerical

values

BACKSPACE

key

[bs]

For deleting

the

last

character

MINUS/POINT

key with double

function

[-/.]:

Press

the

key before

entering

a

number

to create a

negative number

(e.9.

-2mm)

Press the

key after

entering

a

number

to create

a number

with a decimal

place

(e.9.

7.5mm)

Press

MAIN

key for

returning to the

main

menu.

For changing

a

parameter

(text)

in a selection

field, e.g.

wire type

(norm/

doub

r,

preliminary

processing

options.

etc.

t'-= -l

ESC

key

Fcr

cancelling

rnputs

(previous value

is dtsplayed

agatn)

ENTER

key

For accepting

the

entered

or selected

value

and selecting the

next

input

f ield

is

selected.

Selecting

another

input field

corresponds

to

ENTER.

Seiectrng

another

menu

(f

unction

key) corresponds

to ENTER'

it

START'STOP

keys

Press START

to commence

processtng.

Press STOP

to stop

machine

after

the

processing

of the current wire is

comoieted.

Ol kaooa

220

-

Version 3 Operating

the

machlne

21

T
I

5.3.2 Punched

disk

Turn

the

punched

disk

to

f

ind a wrre hole

that

is neither

too

small

nor too

large.

Tne

punched

disk

need only

be changed

for

specral

types

of

processing involving.

for

example.

ribbon

cable

or double

V-blades.

To switch disk,

proceed

as

follows:

I

Open feed

rollers by

pressing

swttch'l

r Bemove

top

f

eed

roller

2

r

Loosen

punched

disk

3

by unscrewing

screw 4

with hexagon socket

head

wrench and

remove

r

Insert new

punched

drsk

and

rettghten screw

I

Remount

feed roller

5.3.3

Feed

rollers

Use the appropriate

type

of f eed

rollers

for

the

wtre

To change rollers,

proceed

as

follows:

Open feed

rollers 1

Loosen f

astening

screws

2 on f eed

rollers and

pull

off

rollers

Slrde on the appropriate

feed

rollers for the

wire

being

processed,

pushing

rt

all

the

way to the stop

Prior

to tightening

the screws.

check

to

make sure

the screws are

pressing

against

surfaces

3

of the

drive shafts. otherwrse

they

could

damage the

shafts

fig.54Feedroller

5.3.4

Wire

guides,

You may have to adjust

the swrvellrng

wire

guide (in

f ront of the blade)

and

the

right-hand

wire

gutde

(behind

the blade)

depending

on the outside

diameter

of the

wire being

processed.

To do so,

proceed

as follows:

Remove

any di'awn-in

wire

Pull

off the swivelling

wire

guide

1 and attach

the

annrnnrieto nrrir{o

Make

sure the

guide

has a

ftrm axial

seat

on

the

swivel shaft.
Pull

off the right-hand

wire

gurde

2 and

attach

the

appropriate

guide.

fig 5.3

Punched

disk and

feed

roller

type

berng

processed.

I

U

I n

r-.t-

G;-

i

U

r.1.aa r-

t-

€

r-E-

a.r-Ga

..i6--

J
I

2
J
I
I
t

I
t

­=

a

I

E
E
T

C
C
T

I

r

f
f

f

]

T
I

r

3

t,
t
t

r

r

t
T

fig 5.5

Guide

Parts

18

Start-uo orocedure

Ol

kappa

220

-

Version

3

lf

rlrere

rs

axial

play

rn

the

gurde

parts

loosen

hexagon

nut

3

on

ballthrust

prece

4

(f

ig 5.6 and 5

7)and

readJust

;t

After adlusttng

ri

retighten

the

nut

I

-')

frg

5 5

Right-hand

wrre

gurce

irg

5.7 Swrvelling

wrre

guide

5.3.5

Blades

5.3.5.1

Blade types

Standard blades

V-blades
Thrs blade

type

ts

surtable

for

most drameters and types

o1 wire. Problems

with

strrpping

the

remarning

rnsulation

can

occur with cefiain

insulation

materials where

the V shape

does

not

encompass

the stranded

wires

precisely.

Radius

blades

These blades

have a

rounded

cutting edge and

are adlusted to

the

cross

section ot

the

strandeC

lvrres. This makes

rt

possrble

to

process

wires wrth extremely

thrn

or

hard

tyoes of

tnsulation.

Double

V-blades

The

prece

output can be doubled

wtth these blades. They are

installed

just

as

V-

Dlaoes

are.

Custom-ordered

blades

'{4e"

Blades

for ribbon cable

Tnese Draces

can be used Io strip

riboon cable

wrth

or

without intermedtate tte.

Special

models

C;stom

: ades

for

special

wtre

types

can arso be

manufactured

on

request

tr.

Ol kaooa

220

-

Version 3

Stad-up

procedure

19

5.3.5.2

Changing

the

blades

Blades

must be changed

in

order

to

process

certain

types

of

wire

or

rf

the

qualtty

of

the

cuts

begtns

to

0eclrne.

To do

so,

proceed

as

follows:

/

.

ALWAYS

turn

the

main switch

on the machine

to OFF

prior

to working on

the

cutting

qry

head and

the

blades.

t

]

t

3
L

T
I
I
I

t

I
D
t

t

r

t

g

t

I

I

r

l
I

?

{

i

f

r Remove

nght-hand

wire

guidel

and,

if necessary,

the

feed

rollers

r

Loosen

fastening

screws

2 on

blades

3

l

Remove blades

and

insert

new blades

r

When retrghtenrng

the

screws,

press

the blades

anainst thp stnn nins

of the

blade

holder

r

Close the

cutting

head

manually

and

make sure

the tios

of the blades

do not collide

and block each

other

a'.

\

F=_rl

g

'

----'
//

r i7

'-\- A

ffi

'/)'

o

--1:-

'//

,9

t*-

i

=€

+1

t,-,

frg58Cuttrnghead

'i.
I

!

(.

f
&

20

Start-uo

procedure

Ol

kaooa 220

-

Version

3

6.

Operating

the

machine

6.1

Controls

Cursor

pad

ill

\i

U

)

(---r

rn

IU

Nrrmhor< nerl

i.--\

(,1

€

(-

E

Function

keys

__

Fj

"l

fFr-] fFJ-l

fFa--f

G5-l fFi-]

[Utr-l

6rqil

6r@

.

--]

\

\-

stop

kev

keys

-

Starl

kev

bffi-

fig.

6

1 kappa 220 control unrt

Function

Function

kevs

for

selectinq

various

menus and f unctions

Press

MAIN key

lor returning to the

main menu.

Arrcw

keys for selecting

input fields

The active

input

f ield is displayed

inversely

on the screen

+r-(8YS

For cnanging

numerical inputs at

predef

ined

increments

For cnanging

a

parameter (text)

in a selection

field, e.g.

wire type

(norm/

dou:

,

prelrmrnary

processing

options,

etc,

i .l t

For

F.tering

numerrcal

values

BACKSPACE

key

[bs]

For Celeting

the

last character

MINUSi

POINT key

with double

function

[-/.]:

Press the

key before

entering

a

number

to create

a negative

number
(e.9.-2mm)
Press the

key after entering

a

number

to

create a number

with

a decimal

place

ie

g.

7.5mm)

t Ii i
t I i'__l

t.,r i.

.,

r'J

[_l

a, -j

[_-

ESC

kev

For

cancelling

inputs

(previous value

is

dtsplayed

again)

t --_

_l

ENTER

key

For

accepting

the entered

or

selected

value

and selecting the

next input f

teld

is seiected.
Selectrng

another

input f ield

corresponds

to

ENTER.

Seiectrng

another

menu

(function key)

corresponds

to ENTER.

STAIT

STOP

keys

Press STAFT

to commence

processing.

Press STOP

to

Stop

machine

after

the

processing

of the

current

wire is

cor.'oleted.

Ol kappa

220

-

Version

3 Operating

the

machine

21

Labelrng

of f unction

keys

in current

menu

e

2

2
3
2
2
2

6.2

Display

concept

The

drsplav

is

set

up as

follows

Number

ol current

wire

data

file

Current

meni.t

Labelrng of

funclror

keys:

Large

(e.9.

PROD)

menu

selectton

(change)

Small

(e.9.

load

t

f

unction to

be

performed

Informatron

or rnput options

for current

menu,

e.g.

wire

depictron

v,r:n

parameters

required

for the

pro-

cess,l'g

that

ha:

:een selected

2
f,
2
E
E
T

C
E
E
E
C

E
F
F
F

r

t

r

I

r

J

t

E

t

r

;r:'1.r;r,lt'..3t1itititig

# 1

TEFI]H

rr---

4_-_

"iu.g

5. B

28.8-TEher

zEg

[:R:j 1 . rlti1

DST B.

F*18

ltt'lE

E. 88

F,RI]I[I L

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SEftU

st.r i;:'p

i 1-1'=l l err::tLl-r

r'Ertge

I B. B

Eide 1

4A.FJl

rTrrll

fig

6.2 Sample

programmrng

window

j

t

22

Ooeratino

the

machine

Ol

kaopa 220

-

Version

3

CJ

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c
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o
o

E

q

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o

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o

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o

3

.9

o)
o

o

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- ,+s' e

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t1

a

6.4

MAIN

-

main

menu

All menus can

be

activated

f rom

the main menu:

by

pressrng

the

{unction

keys

(most

frequently

used

menus)

by

pressrng

the

arrow

keys

to move

the cursor

and

then

pressing ENTER

Pressrng the

MAIN

key always

returns

you

to the

main

menu.

When

the

device

is switched

back

on.

lhe

last

active

menu

rs

drsPlaYed

f.lg

I n

L

J

2

L
3
2

2

e

2
E

E

e

E
E

f
E

E
E

F
E

E

r

E

F
3

f

t

r

l

I
l

)

l

T

f

F.ognamm

I

nql

Lrire

l ist

ijiocess

Pararnet

'

corr

i

t'tr-r

r.3L :,,-rtr

--a'Ir rFr,l I .a I

I atr9trage

rernot'e

FROTJ

TEFCH

LIST

ppFRH

r: r:rf

iF

F'PITRH

l-'l:lNF

::;EllU

I

LFt'lrl

REI,lOT

6.5

LANG

-

language

selection

The

following

languages

can

be selected

under

the

item

"language".

German

English
French
Italian
Spanishvvqr

rrer I

The

selection

is saved

when

the

machine

is swit-

ched off

.

6.6

Brief

instructions

on

the

three

most

important

menus

6.6.1

TEACH

-

Programmlng

menu

The

processing

data

for the

wire

(lengths and

cross

sections)

are

entered

under

this

menu.

The

wire appears

on

the

display

with the

processtng

drrection

and type.

An

inf ormation

box

explains

the

corresponding

input

fields.

The

input

range

might

also be

indicated,

where

applrcable.

lf

you

enter

a

value

higher or

lower than

this

range' the

limit

value is automatically

selected

and

a signal

sounds.

1 Wire
2 Wire length
3

Type of

processing and

strrpprng

Iengths

4

Data

on

wire

(CRS)

and

blade

values

(cutttng

depth

and

waYback)

5 Box

with explanations

on

selected

rnput

field

Portuguese

lan:noqa

Korean
Chinese

fig63

Irnsr.rase

engl

ish

LFHG

EEIIE

ueuLScn

franqa

I 5

rtallano

esPano

I
Port-ugue5
r.f l''

4t+ttJ

Ll-'r

+.;
+.):..

PROD

TERCH

L

I ST

PPHRP

IJOi.IF

fig64

f,t^,:r,-,Jf-.3nrttn,:t \

*

I

18r.8

5.

B

zaa@

CRS

1.

FJB

tr:lT

B.

r'-18

;:[a:oi"nr

t.E]ln-='!8.

E1:

n'

6

PRO! LIST

PPFTRR

CONF

SEAU

frnAi

24

Operating

the

machine

Ol

kaopa

220

-

Version

3

Types of

processtng

NO

Cuttrng

onlY

HS

StrrPPrng

Yrtth

t"aif

Pull-off

FS

StrrPPrng

wrth

f

ui1

Pull-off

PS

StrrPorng

lvrth

rrultiPle

cuts

lM

Intermedtate

sirrPPlng

Bffiffiwffiwlffi ffia $sxtffi

Explanation

of

other

abbrevtattons:

CRS

wire

cross

section.

core

wire

CRS
fmm']or

[AWG]

n^l|^ ^+.;^^i^^ ,,alr ra
L,/ertd Dil

rPPil

r9 vqrus

Correction

value

f

or cutttng

depth.

based

on

the core

wire diameter

d

1d

is

calculatel

on

the casrs

of

CRSt

Negative

value

for DST

d

+

(-DST)

-->

0eeper cuI

Positive value

for

DST:

d

+

DST

-->

shailower

cut

DWB

Delta

wa'rback

Blade opens

after

cut

or

durtng

pull-off

to

prevent

damage

to

stranded

wires during

;^^,,t^+;^^ ^,,lt ^{{
il tSutditutr

PUil-u1r

DWB

_'--.

l

ra]l

r

\r'

tl

a

Ol kappa 220

-

Version

3

Operating

the

machine

25

6.6.2

PPARA

-

process

parameter

menu

Wire specif

ic data

can

be

changed

in this menu;

e,g.

pressure applied,

roller

distance.

speeds, etc.

The

menu

is several

pages

long.

the

f

irst

covering

wire

processrng and

ihe

others,

the values

f or

orelirntnary

and

subsequent

processing

of

the

wire
Page one:
Roller

pressure

Pressure

wrth

whtch

the

feed rollers are

pressed

togetner

t1O

-

100'.)

Roller

gap

Distance

between

the

feed rollers

(imporlant

for wire monttoring

and correct

feed)

7A

t;3

5A

T66

e

?

To determine

roller

distance:

r

Take wire

to be

processed

and

lay

it

bet-

ween

the

rollers.

r

Select

'roller

distance'.

I

Press

Start.

r

The

rollers

wtll

move together

and

the

measured

value

is accePted.

To change

the

pressure

being

applied,

you

must

repeat

the above

Procedure.

The

roller distance

can also

be

changed

by

ma-

king

manual

inputs.

Wire

check

Check

that

there

is wire between

the

feed rollers.

Pr'ocesg

Pan;mei-.

rol 1*r

PresEure

r'ol1er

9eP

wire

check

r,r

i re

f eed

EPeed

slniP

speed

1

Et-rip

sPeed

2

crrl

sPeed

PROD

TEHCH

L I5T

COI'IF

Preu,

nexl

2
J

2
I

1.
l

t
2

E
3

E
E
E

E
E
C
T

E

r

E
E

x

t

l

We

recommend

turning

off

the monitoring

wise

it will

detect

an error.

unit when

working

with

thin

wires. Othet-

Wire feed

speed

Speed

with

which

wire

is fed

in

Strip

speed

1

Speed

with

which

insulatton

on

Strip

speed

2

Speed

with

which

insulatton on

srde

1 rs

strrpped

off

srde

2 is stripped

off

Cut

speed

Speed

with

which

the blades

open

and close

In

general, avoid

starting

the

processing

at

excessively

high speeds

and

reduce

the

speeds

il

problems

occur.

I

Following

pages:

see

Chapter

6.7

When

processing

large

diameters,

you

must

increase the' blade

start

position'

(Chap'

6.7)

from

the

default

value of 5mm.

l

r

t

I

,

26

Operating

the

machine

Ol kappa

220

-

Version

3

6.6.3

PROD

-

production

menu

After entering

the

wtre

dala and

the

processlng

oarameters.

you

can

Dress

tr,e sTART

key

lo

start

processl

ng

Prece nun ber ano

batch

srze are

set

here

The

^ - ^.L^ ^^! ...^^^ ^, ^,ocpqq,^n

Can alSO t-le

Chan-

lel'9tl lb

dl

lu

tyPEJ u urvuLJJ' y

wqr I srJv

vu

\

geo

nere.

F6

(reset)

For resetting

piece

number and batch

stze counter

\') Lt: l U

6.6.4

Programming

example

Requirements:
All

adJustment

and

setting

work described

in

Chapter 5

3

nrust

be

frnrshed.

Desired values:

Wire cross

section: O.75mm'

Processing

side

1: haif

puli-or{

(HS)

Processing

side

2: f ull

cuil-cff

iFS)

Piece

number:

100

Batch size: 50

TEFICH L I5T

PPRRR C0l',lF

SEQU rsl

fig67

side 2

nroncqqinn rlirectron

>

side 1

20

<->

10

*)

200

fig

6.8

Processing

lengths

Ol kaooa 220

-

Verston 3

Ooeratino the

machine

27

C

2
2
3
2

2
t

T
I

E
2
3
T

f
E
E

E
C

I
I

r

f

t

l

t

I
I
B

l

r

I

T

t

?

i)

.:^-,\

\ r:--

"'

il:,-,..---,:

-t-

@

30

Possible

order

of

making

inPuts:

v

PS2

=

Process

stde

2

N0

=

nc,

process

ut

.\ 20

1t

:)

ProceEs

Paramet-..
configuralron
sequent

1 3 I
I anguage
remoLe

TEF]CH

LIST

PPNRF

CONF

FrLagr'amm

I

n'l

i:|.E.]'nntin

1 - eeeeer

mm

PROII LIST

PPFRF

CONF

SEAU

Progntsrnmlng

$ I

TEICH

Fil

lrlta

CRS

1.Sg

DST

8.OB

DI,IB B.OS

slr

rPPrng-

lqn?Lh

=Ide--

ranqe t

,J.6

-

Jb.uJ

mm

Frogramm

1

ng

zAB

r . 80

DST

g.

8B

Dl,lE

g.

9s

PSl

=

Pnocess

Eide

I

HS

=

half

slrtp

28

v

Operating

the

machine

Ol

kappa

220

-

Version

3

l

t,,

l I

-o

f

. 1.q, gt-r

st:+

I

rz..qe

I Z,Z

-

a8,i,

I'r

PRl:]D L I5T

PPFRF iC]NF

IEHLN LI)I

'

1..

.:.'.

l

l

it-,

-tr-

w

-,"

''")

.---.-

L)

U./5

I

n

-i-s-t,si-lsc=r

-----

------T

ProceSS ParSrtF!,
roI

Ier

Pressune

roI Len

gaF

uire check
rJ

1

ne f

eed speed

str r.

P speed 1

strip

Epeed 2

cr-LL

sPeed

* 1

PPPRF

,:gffiffi

ffiT

..-

D

-

.-\

n t

- '-./

u.

I

L

t l:)

i

-r100d>

,1.

, ,. ,

t.,,

cu

I

:nl

18.8 2g.ii

:l'

r

r)

I

._R9

FrSE tsr

8./e

1S.6 2A.A

DI,IB B. 8B

l

F'

l---

i

_

;:

._r

.

T:

'.)r

B ,

.:z-

n!18 Erl

!

Ol

kappa

220

-

Version

3 Operating

the

machine

t,.l

29

6.7 PPARA

-

other

processing

parameters

Press

F6

(next)

to

go

one

page

ahead in

the

processrng parameter

menu; F5

(prev)

to

go

one

page

DACK.

Wire type

flOrffi

=

normal wire
doub = double sheathed wire
Short

mode

on. machine switches automatrcally

to short

pro-

cessing

if wire length

so

warrants

off

: machine

does

not

switch to short

processing

Cut start

position

Basic

setting of blades during

wire

advance
Cut wait time
Wart

time aftercuts are made

in

the

wire insulatron

Correction blade

S.1

Cutting

depth

correction for

blades on side

1

:

allows for

dif{erent blade

values

on side 1

and 2

(defined

according

to

DST)

Blade

cleaning

Insulation

scraps can be blown away

(machine

is hooked up to compressed air supply)

Clean after

cut

Here wire

can be blown off the blade durrng

cutting

(machine

is

hooked

up to compressed arr supply)

Lifter

clearance

Wire

is

transported

in reverse

before the

swivelling

wire

guide

is raised

(important

for

large

cross

sections where wire could

be

right

up against

the cuttrng

head)

Length

correction factor

Correction value

as a

percent

of

wire

length

Example: Desired wire length = input wire

length

+

'109o

of

rnput

wire length,

i.e.

enter

1.i

Offset length

Constant

correction

value

Example:

Desired

wire length

=

inpul wire length + 1mm

Upstream

device

off

:

switches off

preliminary process

^^+;r,^+^^ ^,^li

pos:

acrvares

prerrrnrnary process. posrtron

markrng

cut:

prelrmrnary process

is active during

cutting

Feedback

signal
off : feedback ignored
hrgh:

with feedback

at a

high

signal

iow:

with feedback

at a low sionai
Distance
Drstance

between

the

upstream device and kappa

220,

e.g.

for komax

24 hot-stamp marker:

Middle

of

marker head

to cutting axis of the

kappa
220
Pulse

time

Time for

which

the tripprng signal

is

applied

t

t

t

t

,

l
T

?

I

F

t

?

f

I

!

t
t

t

l

t

l

r
t

T

r

l

r

f

prErcPSE

Fer.3rnet-.

*

I

r*r

t re

L,JPe

shont--mode
cuL

stanL

Pas.

cui.

urait tirne

cor'r'.

b I ade s. 1

blade

cleanin9

cleen

aft-en

cul

]rfLer

cleararrce

cor.

f

.:cL,:r

i engtlr L.

UJBA

offsel

len9th I mm

PR0D TEPCH LIST C0NF

Prev

nexl

llEltrrl

on

5,0 mm

8ms

,s.88

nn

off
off

5. I rni'n

fig69

PnocessFaramet,

* 1 PPRRF

PrePnocess i n,;t

Fln

feedback

sign;I of{'

,l

i sl:nce i20 mnr

Puis

time

58 ms

uait, Lirtte

E rrrs

PROD TEIII]H

L I ST CONF

PrE',I

NEXt

fig

6

1O

30

Operating the

machine

Ol kappa 220

-

Version

3

Wait time
W2it rimp eftpr t!'rnnrnn

qrnnal

rq rssrrcd or maxrmum wait

time

unttl

feedback

See

connection

for

preliminary

processing

Chap.

9.2.

Positions

for

preliminary

processing

(e.9.

marking,

intermediate

stripping,

etc.):

Position

processing

1 , srOe

2

Positron

prccessrng

2, stde

2

Pnqitinn nrrcessinr 3.

srde

2

Drstance

for

contlnuous

prccessing

Position

processing

1 stde

1

Pnsitron rrocpssinn 2

Side

i

I

tsi

vvvvv,i,Y

e

Prsrtion rirocessrnc 3

side

'

Wire

length

Remarning

wire

length

without

prelimlnary

pro-

cessing

1
2

Example:

Marker

as

uPstream

device

The

distances

define

the

pcsrtron

of the

text on

the wire.

lf all

positions

are

set

to 0 and

processing

ts

switched

on. the

markinq

rv' I

be

done

at the

beginntng

of the

wtre.

Possrbie

posttion

rn0uts

(f

r-:

6.12)

and their

effect

(f

rg 6.1 3)

ProceEE

Paramet.

S 1

FFosF,la

g<<

r nc{

PROD

TEFCH

LIST

fig611

Proces5

Par.:met,.

* 1

PPf'lFlF

t>

I

t)i)'l

K

)'1

l(((1.

l(l

O

lsa

Gl

--.o

o

PR0D

TERCH

LIST

COtlF

Frev

nexl

fig 6

12

(r0

ov

I

processing direction

@

,,j,*0

i30

>

v1n

<___::---+

:

lcNl zorl

eorj

side

1

side

2

lig

6

13

Ol kaooa

220

-

Version

3 Operatrng

the

machine

31

Downstream

device

on

qrthqenlrpntnrnaaacrnn:ntirratorl

,y

qvLrYq(eu

off

:

subsequent

processing

switched

off

Delay

time

Delay

time with

reference

to the

stan

of

wtre

removal

f

rom the machine

Feedback

signal
off : feedback ignored
hrgh:

with feedback

at

a hrgh

signal

low:

with feedback

at a low

srgnal

(applies,

for

example, to

the komax

260 wire

stacker)

Pulse

time

Time

for which

the tnpprng

srgnal is

applied

(e.g.

for

komax 260: 100 ms)

Wait

time

Wart

time after tnpping

signal rs issued

or maxi-

mum

wait

time untilfeedback

(e.9.

ior

komax

260:

200

ms)

Process

PararrreL.

*

1

P'f ELProcess r ng
dela! Lime

ieedback

signal

Fr.rIs

i-rme

rr.iit-

lime

PROD TEFCH

LIST

C0NF

prev

nexL

See

connection for

subsequent

processing

Chap.

9.1.

l

t

i
l

t

T

I

,

I

t

T

E
t,
t
E

E

?
E

v

E
F

E
E
E
t
E

E
E
F

F
3
F
F
F

r

32

Operating

the machine

Ol kappa

220 - Version 3

6.8

TEACH

-

Further types

of

processing

6.8.1

lM

-

Intermediate

stripPing

To

achreve

the

result

shown

in f iq 6.15. for example, the tnputs must

be

made as indrcated

rn

frq 6.16

Since

the

processing

lengths

are

interdependent.

the input

ranges

may change during

input, especially

the range

for stripping length

(ltem

1, fig 6.16) and

the remaining

length

(ltem

3,

fig 6.16).

To

arrive

at a stnpprng

length of 50

mm

(fig

6.16), forexample,

proceed

as

follows.

1.

Enter a stripprng

length of

40 mm

(maxtmum

value)

2. Enter the

pull-off

length

(in

this example:

20 mm)

3. Enter

the

remaining

length of

intermediate

pull-off (in

thrs example:

10 mm)

4. Enter the

pull-off

length

for first sectional

cut

(in

this

example: 5

mm)

5. Switch

back

again

to the

item

'stripping

length

;

50

mm can

now be entered

as a

value here.

*-**/

I

2

Strrpprng

length.

stde

'1

Pull-off

length. stde

.1

3
4

lig 6.16

Remaining

length

of intermediate

pull-off,

side

Pull-otf

length

for f irst sectional cut,

side

1

Sectional cuts.

side

.l

Distance

between

sectional cuts,

side

.1

6.8.2 PS - Stripping

with

multiple cuts

To

achieve the

result shown

in

fig

6.17,

for

example,

you

must enter

the

inputs

indtcated in fig 6.18:

o-'uo

3
4

1
2

Stripprng length. side

1

Pull-off

length, srde

1

Prognammlng

* 1

6o

, ,.*,

stripPins

lensLh

side I

nange I

A.A - 50.8]

mm

PROD LIST

PPRRR

COHF SEOU

{rn A 1(

2

____)<-

pnosrammins

* lGl

TITEFCH

cRS

1.sB

DST ,:ZZ

q'*rtr.rr-t

saP

belugen

Farflg-=Irce s.1

range L u.u - YY.:l

mm

PROD

L

I5T

PPFRI]

CONF

SEAU

fig

6

18

Ol kappa

220

-

Version 3 Operating

the

machine

33

6.8.3

Parameters

for

double-sheath

processing

To

process double-sheath

cables,

select doub

in

the

processing

parameter

menu under'wire

type''

on

entering

the

TEACH

rnenu'

you

wrll see additional

rnput

frelds

used

only

for double

sheath

o

rocessi

ne.

1 CRS

Wire

cross

sectlon

of core

wire

2

DIA

Diameters

for

inside

insulatton

3

DWB

Delta

wayback

f or the

core

wire

(inner

conductor)

4 DWB

Delta

wayback

for inner

insulation

5

DST

Delta

striPPing

value

6 Diameters

of

outer

insulation

(measured

by

means

of

roller

distance)

fin A

f

t

2

1
J

t
1

t
f

2
E

v

I

t

r

t

t

?
T

T

r

t

t

I

r

I

t

:

l

r

I
!
I

pr'rgremr,rir,'=t

s

6

TERCH

lll";

ot"[*b:6si!'

ra:ab1"ki""

PROD

LIST

PPRRF

CONF

SEAU

iig 6 20

34

Operating

the

machine

Ol

kappa

220

-

Version

3

lM - Intermediate

stripping

with double-sheathed

cables

-i
, achreve

the

resuit shown

rn f rg 6.21

,

for example,

you

must

enter

the

inputs

rndrcated

tn

tig

6.22.

,-fr

puIl-off

lerr. 1.

partiai

slr iP Eide

1

renge

I

l'].

8 - 84.

91 nrrn

rig 6 21

7 Stripping

length for outer

insulatton, side

1

8

Stripping

length,

side

1

9

Pull-off

length,

side

1

10

Remaintng

length of

intermedrate

pull-off

,

side

1

11

Pull-off

length

for f irst

sectional

cut,

side

1

PS - Multiple-step

stripping

with double'sheathed

cables

Tc

achie',,e

the

result

shown

in f

rq

6 23.

f

or example,

you

must enter

the

inputs

tnCicated

in f ig 6.24:

fig

6 23

12 Strrpprng

length

for outer

tnsulation.

side 1

13

Stripping

length,

side

1

14

Pull-off

length, stde

1

15

Sectional

cuts,

side

1

16

Distance between

the

sectional

cuts, stde

1

*---

3a

--l

+i

doo

o

Itrr'ogr:mrr

I

rr'l!

'(E

(D{encr

'

5.9

jre'

ETE

tr?Er

DSr B'86

6

BilE

fig 6.22

i:nogrEmffrl

ng

gaP

beLueen

ParLltt slrc: s.1

range

I B.B

-

99'9]

mm

PROD

L

I ST

PPFRI]

CONF

SEAU

fig 6 2.1

Ol kaooa

220

-

Version

3 Operating

the

machine

35

6.9

CONF

-

configuration

Machine-specjf

ic

data

is

recorded in

thrs

menu

Unit of

length

mm

or

rnch

Unit of cross

section
mm2 or AWG
Sequential

processing

can be

switched

oniofi

on: Sequence

processrng

is

acttvated. Stad

ts in

PROD menu.

Note: No f urther changes

can be

made

in

TEACH.

PROD

and

PPARAIThe

piece

number

is

determt-

ned in the SEQU

menu and the

data

is

drawn

f rom

the LIST

menu.

Sequential

number

Two

different sequences

are

possible'.

1

or

2
Sequential stop
Intermediate stop

on completion

of sequence

off : sequence

processing

wrthout stop before Ihe sequence

is ftntshed

on: sequence

processing

until a

new wire

position

number comes up

Stop input

(refer

also to Chap

9)

high: machine stops at

hrgh srgnal

low:

machine stops

at

low signal
Single step
on: the

machine

perf

orms the

processing

movements

rn

single steps.

Start

by

pressing

the START

key

ln the

production

menu.

Proceed by

pressrng

any

key.

An

acoustical

srgnal

ts

sounded

afler a

production

cycle ends.

lf

the STOP

key

rs

pressed

after

thrs srgnal,

no

zero

cut

is

made during tne

^.^i,,^+;^^ +L-t +

proouclron

rnar

rollows.

STOP

key:

abort

Write

protection

from

0: everythrng

is

protected

150: nothrng is

protected

Wrre numbers which are

larqer

than

the number entered

cannot be overwritten

in

the

wtre

ltst.

Machine lD
Address of the device

within a

network

(remote

mode)

I

I
t
I
l
t
I
t

l

t

I

r

t

I

*

t

I

r

I

T
I
f
F

t

l

t
t
t

I
l

;
j

r

f

L-:C,rr

i I':Jur

.3l-

I,lrl

111^1

1i-.

r:r

{ rfiea55ur-e

r-r.rr

i

i, r:

f

cro55

Eei:;t, 1,:irr

Ee.luerrlial

Pr'rcegsrr,g

':,

if

segrterrf

r.:l-number

I

se4uential

stoP

off

EtoP

r

nPuf

fr r

gl'r

stngle

sLeP

off

r*rr

i

i,e

ProLecL

f r'crn

l3B

mechrne

iD

il

PROD

TERCH

L I ST

SEI]U

Jig

6 25

36

Ooeratino

the

machine Ol

kappa 220

-

Version

3

t

I

,

!

6.10

LIST

-

wire list

The wrre

data

ca. :e saved

in

a

ltst

(maximum

cf

150

wires)

Commands:

!

IID

I

7.^

cppd, thrn,,nh the

list

rn

.-":ps

of

ten

items

each

I

c t_)

I

i:0 entry

:

-:iom en,|ry

l:

llrectly

[o

w're

+

il

I

I

F5 load

F6

save

^

^^^^1 .l^f-

duuEyt uora.

ie

o>o

- - ,^ A^t^
:: /u udta.

'.

o>e

; : oy f unct

on

by

multiple

sa-

'"E

T^e

label

is also copted

and

- - ^ h^ ^h-^aan nriar

:=1 Oe

Cnangeu

Prlor

IO Sa-

!.lE

1

Number o{ loaded wire

data

2

Cursor

position

3 Wire

number

4 lnformation text

(see

label)

5 Wire cross

section

6 Wire

length

7 Processing

srde

1

I

Processing

side

2

r*,ire

I ist

*

S---?:>

Ef-[ISr

PROD

TERCH

SEQU

label load

save

fig 6.26

:/

I

I

I

t

\

I

lf the

wire number

is

larger than

the value entered

for

write

protection

in the CONF

menu.

it is not saved

and

an acoustical

signal

sounds.

F4 label

-

information

text

An information tex:

iup

to B characters)

can be entered

at the

cursor

position.

The tnput

is completed

by

pressrng

F4

or:',

pressing

one

of the f unction

keys.

The

corresponding

f

unction

is

then

carried out.

Pressing

ESC als:

:ompletes

the

rnput

but

the old

information

text

ts retained.

Commands:

I

I

I

I

0

L]D

!

Serect

letters

f-l

I ^^^^. ^^l^^+^! l^++^-^

-

_-eu[ 5etcLttru

rgtrctJ

): :'.

,

l-_i;

'

li: -.

. ,' -:

E-ier

numbers

- = ele

the

rast character

t

1
2

Wire

number

Label

(information

text)

rrine

IisL

S

I

'l.->

2 LIST

HSCDEFGHi;, II

NNOPQRSTUUI.]X
VZabcdefgl-rr.J

klrnnopqrst'rv

w^Yacou_-

pR0D

TERCH

SEQU

labe

I

load save

fig 6 27

Ol

kaooa 220

-

Version 3 Operating

the

macnlne

37

6.11

SEQU

-

sequence

menu

The wires defined

in

the

wire list can also

be

processed

as sequences

by

kappa 220. There

are

two

nnqqrhlo

qaarr

ronaAq The r-lec,rrpd

qanljpnae

.-r

(sequence

numberl

rs

selected

rn

the CONFIG

rnenu

A

sequence

consists

of a

max. of

100

entries.

Commands:

2

]

t
t

I
l
I
l

t

tl

ll

!r

It

iI

f;
!r

?t
t

rI

,tr

rt

,f

F5

(ins)

Insert loaded wire

in

sequence

I

c

t_::)

I

!

--

U

Shift cursor

positron

to desi-

red

sequence

positron

Select

the input f ield;

3,

4, or

s

(fig.

6.28)

Select

a set of data

from

the

wire

list

orchange

length

and

numoer

F6

(del)

Delete wire from sequence

Procedure for sequence

input:

F5

(ins):

Wrre

data set

with

its

current

number

is inserted in the sequence.

Chanoe the nrrmber

of the

wire data

set

as

desired
Set the

wire length for

thrs

sequence

position

lrnitial

value is

the

length from the wire

list)

Set the multiplier

Repeat

for

the desired

number of

posrtions

in

tho

qonronno

1

Current

sequence

number

2

Seouence oosition

3 Number of wire data set

from wire lisi

4 Wire length for this sequence

position

5 Number of

wires to be

produced (multiplier)

6

Information

text

f rom wire list

7

Number

of

wires in

the

sequence

!t
t7

t

.t

I

.rl

se'-luarrllal

A 1: 6,' 6 SEG-

I

4

d

o

I
1
I

1

1

-

o

ITI|TI

100
188
10u
lt38
n8
taa

@

I
1
1
1
1
i

o

IADET

KHBEL 8B
KABEL 8fl
KEBEL A8
KABEL 86
KHBEL

B8

KIqBEL

88

@

fin 6 2R

sectr.reni- i

.=

I

fi^ A rO

l

,l
a

J

E,

I

_1

3
2

1

i

r't'l r't'l

188

3ea

1BB
304
2BB
258

5

10

7

25

?

IB

KI]BEL 8A
l'lusLer-2
l'luster-2
Schran k
KHBEL 88
Schran k

,T

Y

38

Operating

the

machine

Ol

kappa 220 - Version

3

Since

the

wire length

refers to the sequence

position,

the same

data set

can be used

to very

quickly

produce

wires ol

different

lengths. To do so,

lhe

length is simply

changed

and

the other wire data

is

taken

over.

I i I

The number

of

positions

can

be zero. A

sequence of this

kind cannot

be

start.

t:l

Since

the sequence

is

saved

when the menu is

exited,

a menu

change

must be

made

prior

to switching

ofl the

machine.

Example

of an

application:

A

wire is

supposed

to be sub1ect

to the same

types of

processing

on

side 1 and side

2 but

produced

tn

different

lengths.

Tne

drf{erent

wires are

requrreo

rnoividually

and

go

into f urther

processing

immediately

(e.9.

in

a

production

cell).

Program

wire

processing

and save

in

the

wtre

ltst

(check

the

Drocessrng)

lnsert

the

wrre

In

tne sequence

^lenu

in

the desrrec

quantrty

by

presstng

F5

Enter dif f erent

lengins

f

or

each sequence

positlon

-r'

''^ .\t\l

arnctrqqlnn and SeOttence

I

ull

|

\Jr\ 5ut-lugIuc

PrvvLrJ

stop

in

the CONF

menu

Select

PROD menu

Press

STAFT:

v,,*eneversla'1

rs

pressed.

the

-rachrne

produces

a

sequence

pcsilion

and

then

waits.

The current sequence

numDer, sequence

position

and the

number

of

wires rn

the

sequence

are

drsplayed above

the

wire

tn tne

PROD

men-

6.12 REMOT

-

remote

mode

You can select

a

remote

menu

in

tne

maln menu.

kappa 220

is then operated

f rom an external

PC

loaded wrth a PC

version

ol the

kappa software.

The kappa software

must be the

F103b version or

higher.

Thrs information

is oispiayed brief

ly when

the

machine is

turned on.

tig

6 31

seguenf

i a I

KFBEL
KFBEL
KFEEL
KABEL
KRBEL
KRBEL

88
8B
8B
8B
88

od

PROD

TEFTCH L I ST

C0l]F i ns

de I

fig

6 30

Ol

kappa 220

-

Version

3 Operating

the

machine

39

Nofes

J

2
2
3

2
2
2

]

t
2
2

j

I

t
t
E

E

G
T
f

r

F
E

I

r

I

t

t

r

t

F

!
I

]

I

Ol kaooa

220

-

Version

3

40

7.

Malfunctions

/

error

messages

T.l

Malfunctions

Machine

does

not start

after

switch-on

r Check

power

conneclion

r Belease emergency

stop

swltch

r

Check

f

use on

power

cable

lnpul

Machine

runs

but

does

not

resPond

r

Swrtch

off the

machine.

wait awhile.

and switch

back

on

r

Check

1or

possrble

blockage

by

upstream

or downstream devices

r

Close

safety

cover

Cut

quality

There are several

possrble

explanations

f or the

insulation

being

poorly

cut:

Dimensional

accuracy

lf

the dimensions

of the

wires berng

produced

differ

f rom

those

entered,

check

whether:

r

Setting

ol straightentng

station

ls correct

I

Guide

pans

are

correct

I

Feed rollers are

appropriate

and clean

I

lf

applied

pressure

or

distance

between

rollers

is not

ideal,

correct

any

measured

value

r

Processing speeds

too

htgh

Reason

Remedy

Worn blades

Incorrect

type of

blade

(e.9.

V-blade

instead of

radius

blade)

Replace

with

new blades

Change

type of

blade

Excessiveiy

hrgh

processtng

speeds

Reduce speeds

Cut too shallow
Insulation

mater al soft

or tough

Correct

the

values

Enter

wait

times

Rlrdoc cteiinellv .h2rnad 42, !crn.

u!q(rvql'_/

insulalron scraps

to adhere

to the-

Hoox

up blow off device

t

Ol

kappa 220

-

Version

3

Malfunctions

I

error

messages

41

7.2 Error

messages

on

the

display

lf

the

machine detects

an error.

a

self

-explanatory

errcr

n'essage

appears

on

the dlsplay

f
2
2
J

*

l

t

Messages

regarding

wire

leed

3

-

Error

removal monitoring

Frror

in removing

the

wire.

Following the

removal, no !i'ire may be uncer

the

leec

rollers

on side

2.
Cause.
Wire is

lammed

at

teed rollers on

side

2.

Wrre is

too

thin tor

wtre

monttorlng

luncllon.

Dislance betvveen

rollers

is rncorrectly set

in the

processlng pararnete-s

4 - Error in

wire draw-in

on side

1 and side

2

There must

be

wire

under

both

feed

rollers when the

wtre ts

drawn

tn

Cause:

End of

wire reached.

The wire was drverted

prior

to

feed

roller on side 2.

The wire was diverled

prior

lo

feed roller on

side

1.

Wire is

loo thrn

lor

wrre

monitoring

function.

Distance between

rollers

is

Incorrectly

set

in

lhe

processlng

parameters

5 - Error

in wire draw-in

on side

1

l{

the

wire

is nol registered

by the

feed

rollers

on side

2 oniy the

feeC

rcrler cn

stde

1 will

be

monrtored

durrng

wire feed-in.

Cause

End ol

wire reached.

Wire is

too

thin

for wire

monitoring

tunction.

Distance between

rollers

is incorrectly set

in the

processlng

pararnele's

Message

regarding

cover

6 - Cover

opened

Cover is open or

was opened

during

the operatlng

cycle

Message regarding

reference

positions

7 - Monitoring calibration

carried

out

The re{erence

positions

have

not been determlned

for

the

machine

See

mainte

nance Inslrucllons.

Message regarding

piece

number

8 - Piece number

reached

/-

\r

.l-

I

I

il

rSl:

ii

,\

i ,

I

enlea

j

I

t

I
I
l

I

I

I

I

s
r

t'-

I

I

r

''.

$s

fFn-tr--.l

I

il
'il

il
I

I

t

I

I

f i------., i ,'

42

Malfunctions

I error

messaqes

Ol

kaooa

220

-

Version

3

Messages

regarding

shorl

processing

20 - Short

processing not

possible

The

wlre s oerng

processec n

s^cn

Tcde

due

to the

length

ol lhe remainrnq

-

sulatror

il'1 and

PS

process

ra

)'2

ra'.3cssrLre

.or is

rre

0rccess

1_!

cf

double

:neathed

,!

res

2.sstbrlrl/
Ar

attemot

can be

made to

proc?ss

lhe

w'rre

rn

standard

mOdp

i:; l.rnrng

off the

s,^jitchover

tc short

mcde tn lhe

:':cess

iq

pararneters

F!

I

FS

r5.

I

lB.0 |

5.6

{:

45

2l - Stripping

length

too

great

-fle
lvlre s berng

processed

n

^sulatror

5.Jt the strrpp

ng

lenqtr

s

fhe

srjr

:,t

strrpptng

lengtns

ar

::ori

rcde

due

to the

length

o{ the

remarning

:

:.o

:'eal

The strroolng

lerglh n

lhe

short mode

: ae

:

and srde

2

29.6

58.e ) 4L:,8
shorl

'

22 - Pull-oft

length too

great

-l^e
wrre

is

berng

processed

In

sro(

-ode

due

to there.gth of the'emaining

nsulation.butthepull-off

lenglh:s':c

jreat TheDUll-orf lenglf'tst'esumof

thepull'

-i,tenqtFs

:.. Side

1

and S,de

2

--

-.

r:eSSage

caTnOt aOpea'CUe

ro rhe

irpUt

lrmiis

Messages

regarding

processing

lengths

30 - Stripping

length

rnside

> outside

on side

1

The ouler stflpping

lengtn ol d

ocubl€ sneathed

wtre on stde

I

ls smaller than

the

nner

slripprng

length

Thls

messale ca"nol

appear due

lo the

Inpui

rmlts

31

-

Stripping

length

inside

>

outside

on side

2

-le
outer stilpping

lengih of

a acuCle

sneathed

wire on side

2

rs smailer

than the

nner

strrcDrng

length.

This

fnessala ca'not

appear

due to ll'e

lnput

ilmrts

40 - Stripping

length

on side

1

ts

incorrect

The

stnpDing

length

on

srde

'l

rs ::o

qreai

4e.g

> 35.8

lg. I

t5. B ) 38,9

I

td -.

Y''

I

en!er

5u.e ) 48.8

ff

'S

on

I

enler

41

-

Pull-of1

length on

side

1 is lncorrecl

i.e

pull'al

iength

on side

i

is

ia':

lrea:

Ol kaooa 220

-

Version

3 Malfunctions

I error

messages

::.n , 4d.n

43

J

2
2
J
2
2
2

42 - Partial stripping

length

on side

1 is ancorrect.

The

partial

cut

lengths or

the

length ot the

lntermediate pull-ot{

on srde

1

rs:o.

l.eat

43 - Partial

distance

on side

1 is

incorrect

The

dtstance

between

the

partial

cuts

or the distance ol the

Intermediate

cull-ol1

on

slde

1

rs

too

qreat.

44 - Pull-off

length

on side

1 is too

great

The

pull-off

length

on

side

t has become too

great

during

PS

partial

cut

processrng

The lenoths

must be

reduced.

45 - Maximum

number

of the

types of

processing

is too large

The number of

processing

steps

has

become too

large

during

Dartial

cut

orocesslng

on side

1. The

partial

cut

length must be

reduced.

t

,.,4.-

rl"-

L

enter

158.

B

!:8. e

!'':. l

t

i.rl.-

l

I

:

2

J
I
f

E

E
E
E

laa.

a

5. E

..

6.4

The error

messages

40 to

45 are repeated under

the numbers

50

to

55

for

processing

side 2.

3
E
3
E
F

Messages

regarding

external stop

input

60 - Monitoring

ol external

stop input

-he
external stop

input X5

has

detected a stop
Cause:
Machine

at stop

input has

responded

The

feedback

for

stop

input in the conlrguration

is incorrectly

defined.

No machine

is connected

to X5 and

the leedback

lrom the stop

Incut

In

the

contiguration

's

hrgh instead of

row

I

!
3

llt=l

''.

,r

r

F

r

,

t

;

r

r

44 Malf unctions

I error

messaqes

Ol

kaooa 220 - Version

3

Messages regarding

feedback

related

to line-side

switchgear

70 - Time-out lor upstream

equipment at

low

T^o

r.nr rt

{nr

tnp I Inqtrpe-

o^,,,^6d.r

Y 1. hrc

.laro.to4

InCOr.eCt

f

eedbaCk

afle,

tl-e

, L I

iPU(

v' L'

'e

uPeU

us u9viPi

iv

wart

lrme

s cver

lt

is

I

an

insteac

:f c!!
C auses
l-ne

upsii'eam equipmerl

nas

nol

:41

lhe

leedback

correcil"

The

watt

trme

in

the

prccessrng

parameters

ts lncorrecl

rhe

feedback in the

processrnq

Ca'arnefers

rs

incorrecl

71

-

Time-out

for

upstream

equipment

at high

f

'le

Input

for

the upslrea'1 equtpment

X3r

has

detected

ncorect

teedback

afte'tl-e

wait

time

,s

o,/er.

lt ts

ic''!

rnsteao cl

h10h

The

upslrearn equiprne^l

has

ncl

s9l ltre

leedback

correcllj"

Ihe wart

trrne

rn

the

processrng

paramelers

ls

incorrect.

l-he leedback in

the

prlcessrng

pai'areters

is lncorrect

76 - Feedback is

low: Level after

pulse

is high instead ol low

The input of the upstream equipment

{X3)

has

detected

tncorrect feedback

after the

pulse

time ends.

lt is

hrgh instead ot

low

Reasons.

The

upstream equiprnen!

has not set the

feedback

correctlv

The

pulse

irme

in

the

crocesstn_q

0arameters

ts Incorrect.

The feedback In the

prccessing

pai'ameters

is tncorrect

77 - Feedback of upstream

equipment:

Level after

pulse

is low instead of high

The input cf the upstream

equipmenl

iX3)

has

detected

incorrect

{eedback

atter

the

pulse

lrme

ends.

lt ts

lc^

Instead ci

tlgh.
F easons
The

upstream equipmeat

has not sat the

feedback

correctly

The

puise

ilme in the o:ccessing

pararneters rs

Incorrect.

The

leedback

In

the

Di:iessrnq

parameters

is

incorrect

Messages regarding

processing

lengths from

upstream

equipment

73

-

Max. number

ol

processes lor upstream equipment

Error

rn

upstream equicrnent

cycle

ihere too many types

of

processing

on the

wlre

Cause:
The lenclh for

continuc!s

process':

icX>) ls too

small

74 - Total of the distances

at upstream

equipment

> wire

length

Error in

upsiream

equrcrent

cycle

-ne
sum of

the

processing lengths

is

greater than

tne

wire length.

t-'"

l

'

,:,u lller

-:rr-

a

.jj

-n

_r_

?iier

i

r:l

i-..

-

;.l

th 3tt-er

!3rl

{l

.o'-

Iou elte. Pulse

t

rfl

rr

I

e^tea

I

t

rB

a

?4r_ er

I

P-

ePr r: es9 1 a9

5B

t

,n

_.

=-.;

l

;I

.t

Ol kappa

220

-

Version

3 Malfunctions

I error

messages

45

Messages

regarding

feedback

from downstream equipment

80

-

Time-out

downstream

equipment

at

low

The

rnput of the

downstream

equipment

(x2)

has detected incorrect

teedback

aner

the

wait ttme

ls

over.

lt rs

hrgh

instead ot

low

C auses.
The

downstream

equtpment

has

not set the

{eedback

correctly

The wart lime

in

the

processing

parameters

ls lncorrect

The {eedback

in

the

processrng

parameters

rs

lncorrect.

81

-

Time-out

downstream

equipment

at high

The input

ot the downslream

equrpmenl

(X2) has

detected

incorrect

feedback

atter

the

wait ttme

rs

over.

lt

rs low Instead of

high

Causes.

The

downstream

equrpment

has

not

set

the

leedback correctly

The wait trme

In

the

processing

parameters

ls Incorrect.

The

feedback

in the

processing

parameters rs Incorrect.

82

-

Feedback

is

low:

Level atter

pulse

is high

instead of

low

The

input of the

downstream

equipment

(X2)

has detected

incorrect

feedback

after

the

pulse

lime

ends

lt is

high instead

ol

Iow
Reasons:
Downstream

equipmenl

dld

not set the

feedback correctly

The

pulse

time

In the

processrng

parameters ls

Incorrect

The ieedback

in

lhe

processing

paramelers ls

Incorrect.

83

-

Feedback

is

high:

Level

after

pulse is low

instead of

high

The input of the

downstream

equipment

(x2)

has detected

incorrect

feedback

attel

the

pulse

time

ends.

lt is low

instead

of

high

Reasons.
Downstream

equipmenl

did

not set

the

feedback

correctly.

The

pulse

time

in the

processing

pararneters ls

Incorrect.

The feedback

in the

processrng

parameters

ls Incorrect.

frr

','j

2

2

2

3

l"

t

l

t

L

r

j

T

t

E

7

r

F

t

r

r-l

.,:]

,_ ..-. ,t,t

1..'.

.'

||

tA -.

L

enlea I

X2

not_ ic0 afr,e-

Pulse

.t

l<l i'

iI

--

I

enle'

t

F

F

E

r

46

Malfunctions

I error

messages

Ol

kappa

220

-

Version

3

8.

Maintenance

/

repair

All conversion.

maintenance and

repair

work

on

the

kappa

220

must

be

done

by

duly

authorized

personnel

with the machine

of{.

6l

lf housing

has

to be removed, it should

be

put

back

in

place

as

soon

as

the

assembly

Yl,

work

is done.

8.1

Maintenance

The kappa 220

requires

nc

:eal

nraintenance

(lubricaticr.

eic.).

Since malf

unctions

are

usualiV caused

by dirt,

rt rs

advrsable

to

keec the

machine

clean at all times.

Do

not

use

f

raying materials

such as cleaning

wool

or ine like

to clean

the machine.

Avoid using compressed

arr:

il

can blow

mtnuscule tnsulation

scraps

into

the machine

and cause

mallunctions.

Wire scraps

are best

removed usinq a

small brush.

8.2

Determining

reference

positions

8.2.1

Reference

blades

The

zero

posrtron for

the

blaces

nrust

be

reset

for

con

nissioning

or

f

ollowing repairs

(e g replactng

toothed belts,

changing

the

motor). To do so,

proceed

as

follows:

l

Switch ofJ

machine

t

Bemove

swivelling

wire

g-

:e

I

Make

sure

that

V-blades a.

aoubie V-oiades are

rnsene0

I

insert

biade caiibration

wtre

1 tn caiibratron sleeve

2 and lav the end

of the

wire between the blades

I

Close safety cover

I

Switch

on the

machine

r

Afterthe

software

version

appears on

the

display,

press

F6

r

Select the rnput

f reld for reference

blade

(see

fig 7.2;

I

Press

START and

the

new calibration

position

is

^...^-^.:^^11., ^^.,fd
dururilcluudily

>dvr

lf vorr hpar a neen

tnnp thc .unrnn hparj

Calibfa-"

tve

I

'ron

farlprl and vorrmrst reneAt the orocedUre.

r

The

menu

can be exited

cv

pressing

tne

MAIN

key.

fiq 7 1

Cuttrng head

with

calibration

wire

83

Feference

bIa'le

:

Pe ierence

gap

i'

gtl

I

5N2

Sf'13 Sf'1.1

Sr'15

auL24-

I

0ut?4-2 cruf 48-

1 0ur,4B_2

U0r,Li,-

1

U0uf -2

l'ltltr-rt--

1 l'ltlr-rt-.---

5;

U1

U2 SH

N1 ll2
,Jlril111
I I

:i?

53

S.1 55 i€,

S-i 5rl

S3

:i

1E S I 1

g

a

6

Ll

t_1

g

_1

i._:t

rr:1

L1 B

tig7 2

Ol kappa

220 - Version

3

Marntenance

lrePatr

47

2

]

2
3
2
2
2

2

f

E

n

T
I
I

I

I

8.2.2

Reference

d istance

(rol

lers)

Proceed as

follows:

Remove

the

ulire

between

the

rollers

Swrtch

on the

machine

After the software

version

appears

on the display

press

F6

Select

the

rnput

f reld

for reference

gap

Press START

and

the

new calibration

position

for

the

rollers

is automatically

saved

lf

you

hear

a

peep

tone

the

roller caltbration

fatled

and

you

must

repeat

the

Procedure.

The menu

can

be exited

by

pressing

the

MAIN

KEV.

8.2.3

Test

functions

Test functrons

can

be activated

on

the same

page

as

reference

blades

and

relerence

rollers

These

f

unctlons

are used

in con.lunction

with commissioning

at

komax

or by

the

komax

service

team

to test the

functionrng

of the

motors

and

sensors

of the

machine

individually.

Procedure:
Use the

arrow

keys to

select

the desired

motor or

output

and

trigger

the

f unctton

by

pressing

the

+/-Key.
Exiting

this

page:

Switch off

machine

and

switch

back

on again.

Abbreviations

used:

SM1

Blade axts
(proceed

incrementallY

+

/

-

keY)

Roller

distance

Rnllor nraecr tra

Right-hand

feed

rollers

/nrnnoccinn c.iale 2\

Left-hand

feed

rollers

/nrnnoccinn c.i.le 1\

(on/offwith+/-key)
Fan

Valve

for

blade

cleantng

Swivelling

wire

guide
Reserve
Output

1

prelimrnary

Processing

X3

Output

2

preliminary

processing X3

Output

1

subsequent

Processing

X2

Output

2 subsequent

Processing

X2

SM2
SM3
SM4

SM5

Out 24

1

Oul24

2

Out

40 1
Out 40_2
VOut_1
VOut 2
NOut 1
NOut 2

ST
v.l
v2

SA
N1
N2
S1
S2
S3
S4
S5
S6

S7
S8
S9

s10
s11

Stop

input

X5

Input

for

preliminary

processing

X3

Input

2 for

preliminary

processing

X3

Reserve

(X5)

Input

for subsequent

processing

X2

Input

2 for subsequent

processing

X2

Calibration

sleeve

Ref erence

sensor

for blade

axis

Reference

sensor

for

roller distance

Reference

sensor

f or

roller

pressure

Safety

cover

Switch

for

feed

rollers OPEN

Switch

{or feed

rollers

CLOSE

Wire monitoring,

stde

1

Wire

monitoring,

side

2
Reserve
Reserve

9
E
I
2,
E
E

E
E

r

3
F

F
t
t

r

t

l
l

r

;

)

F
t

0ut,24-I

0r.r.t-.24-2

0ut46-1

0uf40-2

UOuf-1

U0uL-2

t,l0ql-I

Nrlul-'t

ST

U1

U2

SR

I.I 1 N2

8,

.1.8= 4o dt 8. sr

srr ee sltr

:,11

a'ri-

a-

i4

d-

,J-

6 A-

6 6

n

fig73

48

Maintenance

/ repatr

Ol

kappa

220

-

Version

3

9.

Description

of connections

9.1

Connection

for subsequent

processing

\2

l4-pole CPC

\j- i

Ortprt

2.25ovt4A

/\l

(N

Input

24VDC

\6
t_

--)

\/ ^ i Outout1.25OV|4A

I

a

^rrn

,)-

vtru

1n

r

24VDC/1A

I'

ffi

ffio

GO
STOP

OUTPUT

1

f

I

DelaY

time

Feedback

-

low

Pulse

time

Wart

trme

GO

STOP

OU]-PUT

1

INPUT

Delay tirne

Puise

trme

Wait trme

I

I

Error 8O

Feedback

-

high

Error 82

I

STOP

OUTPUT

1

INPUT

Pulse time

Wart trme

I

-

Error

83

Error 81

I

ne5el uJr>tr

It

,

Ol kaooa

220

-

Version 3

Descriotion

of

connecttons

49

t

I
t

t

t

9.2

Connection

for

preliminary processing

14-pole

CPC

Output

2, 250Vi4A

Input 24VDC

Output

1,

250V.'4A

GND
24VDC/1A

ruo

ffi

lo\/ol

ffi

X3

t

^l

I

i-

\l

\5 f'-

A

\7 1
/----\

v

o

'r

l0

)-

r

t

ffi

Feedback

-

off

GO
STOP

OUTPUT

1

GO
STOP

OUTPUT

1

Pulse lime

Pulse time

Waat trme

Feedback

-

low

;{

INPUT

Feedback

-

high

Error

70

Error

76

GO
STOP

OUTPUT

1

INPUT

Wait time

"!{

Error

77

Error

71

50

Pulse

time

Description

of

connections

Ol

kappa

220

-

Version

3

,{

J

l

ll

I

;l
J

t

;l

l

"l

I
I

OUTPUT

:

Pulse lrrne

9.3

Connection

for stoP

inPut

Rp<el nr rlco

ffiffiH

mt

lo\/ol

ffi

lo\/ol

4-pole CPC

f+-

Input 24VDC

*-

24vDc

ffi

X5

a

I
I

_l

-I
il

I

;l

I

"I
:l

I

"t

I

.I

tl-

1
i
I

.I

t

vl

Stop

input

=

low

INPUT

Stop input

=

high

INPUT

Ol kappa

220

-

Version

3

Descriotion

of connections

51

9.4

Connection

for

RS232

interface

9-pole

DSUB

l-)ata lpnnth R

Baud

rate: 9600

Stop

Brt

1

Parity:

No

X6

J

2
2
3

2
2
2

2
!
2
E

r

\2
)-

)-

q

)-

TxD

Transmit

data

RxD

Recerve data

GND

ruffiH

mt

lN/"1

K]

M]

C

t
2
E

tr

v
n

j

*

F

F

!
!

t

i

f

I
I
F

fr

r

r

52

Description

of

connections

Ol

kappa

220

-

Version

3

10.

List

of

accessories

Blades

Art.No. Description
016497

Set

of

hard

metal

V-blades

(standardr

040555 Set

of hard

metal

blades

R0.5

035220 Set of

hard

metal

blades

R1.0

035222 Set of

hard

metal blades

R1.5

035224 Set of

hard metal

blades

R2.0

035351 Set of

hard

metal

blades

R2.5

041325

Hard-metal

double-V

blade

set

for

parallel processrng

Feed

rollers

Art.No.

Description

041

.1

17 Set of

feed

rollers,

f ine

(standard)

041 1

1B

Set

of

feed

rollers,

rough

041

1

19

Set

of

feed

rollers,

plasma-coated

041120

Set of

feed

rollers.

polyurethane

L

F

041

131 Swivelling

wire

guide

2mm

for

parallel

processing

041132

Swrvellrng

wire

gutde

3mm

{or

parallel

processing

041

133 Swivellrng

wire

guide

4mm

for

parallel

processing

040392

Right-hand

wire

guide

2mm

040393

Right-hand

wire

guide

4mm

040394

Right-hand

wire

guide

6mm

(standard)

040395

Right-hand

wire

guide

1Omm

041324

Right-hand

wire

guide 4mm for

parallel

processing

041128

set

for

ribbon

cable

processlng

wrtn

O41482

Set

for

parallel

processing,

2

mm with

Art.No.

Description

040261

Swivelling

wire

guide

1mm

040262

Swivelling

wire

guide

2mm

040263

Swivelling

wire

guide

3mm

040264

Swivelling

wire

guide

4mm

040265

Swivelling

wire

guide

5mm

040266

Swivelling

wire

guide

6mm

(standar0;

040267 Swivelling

wire

guide

7mm

040268

Swivelling

wire

guide

8mm

040269

Swivelling

wire

guide

9mm

041126

Swivelling

wire

guide

10mm

perlorated disk

wire

gurde,

swivelling

and

to

the

rtght

set

of

special

blades

(without straighiening

statron)

perforated

disk

wire

guide,

swivelling,

2

mm

and to

the

right

4 mm

set

of

double-V

blades

(without

straightening

statron)

o

Ol

kaooa 220

-

Version

3

List of

accessones

53

041127

Set

for

parallel

processing, 3

mm with

perforated

drsk

wire

guide,

swivelling'

3

mm

and

to the

right

4

mr

set

of

double-V

blades

(without strai

ghtening statron)

041483

Set

lor

parallel

processing,

4 mm with

perforated

disk

wire

guide,

swivelling,

4 mm

and

to the

right

4 rnr'

set of

double-V

blades

(without

straightening

statron)

Various

parts

Art.No.

DescriPtion

040506

External

straightener

for

horizontal

po-

sition

cPl.

041

130

External

straightener

for

vertical

posrtr-

on

{or

ribbon

cable

cPl.

041129

External

strarghtener

for

vertical

posttt-

on

f

or

Parallel

Processtng

cPl.

041

125

Wire

stacker

komax

260

024340

PC

Software

Y
2

2
3
?

,

2

l

L
2

*

3
I

I

]

other

components

can

also

be

found

in

the

spare

parts

catalog!

I

t

t

r

T

t

$

F

s

t

t

1

54

List

of

accessories

Ol

kaooa

220

-

Version

3

''r{:lerf

Atr

pressure 17

Applrcatrons

5

Arrow

keys 21

B

tr

L

'''

r:-'llcrSe

oc'y' :.i...4

sw,ir:1"

'-'

rN i rx

j<ey

.z )

Frrnr mocq:no 41

ESC key

21

Explanation

of

notes

11

F

Back of

the

machine

16

BACKSPACE

key

21

Blade cleaning

30

Blade

types

19

Blades

lor ribbon

cables

19

Blades

19

c

Feed rollers

15

1 8

Feedback

30 31
FS 25
Functron

keys

15 21

Fuse

16

G

Calibration

of

cutting

head

47

Calibration

of

rollers

47

Changing

the

blades

20

Cleaning

47

Compressed

air

connection

16,17

Compressed

air

17

CONF

-

configuration

36

Control

unit

21

Correction

of blades

S.1

30

cRS

25.34

Cursor

pad

21

Cut speed

26

Cut

start

position

26.

30

Cut

wait

trme

30

Cutting

head

.15

General

saletv

instructions

12

H

HS 25

I

tM 25
lnstallation

site

17

Items

included

in

the

delivery

13

K

Keypad

1 5

L

D

label - information

text

menu

37

LANG

-

language

selection

24

Language

6,24

Length

accuracy

7

Length

correction

factor

30

Length

range

7

Lifter

clearance

30

LIST

-

wire

lrst

37

M

t

.l

Decimal

place

21

Delay

time

32

Delta strrpping

value

25

Delta

wayback

25.

34

Device

rdentification

36

DIA

34

Dimensions

7,

13

Display

concept

22

Display

15

Distance

30

doub

30,34

Double

V-blades

19

Double-seath

Processing

34

Downstream

device

32

Draw-rn

speed

26

DST

25

DWB

2s.34

Machine

identification

6

Machrne

number 6

lvlachrne

operator

I

Machine

overview

15

Machine

protection

1'1

Machine

type

6

MAIN

-

main

menu 24

MAIN

key 21

Main

switch

for machine

12,16,17

Ol kappa

220

-

Version

3

lndex

55

11.

lndex

A

Accessorres

B,

53

AdJUstment

17

Air

pressure

17

Applications

5

Arrow

keys

21

B

Electrical connection

7, 16.

17

Emergency stoP

switch

12

ENTER

key 21

Error

message

41

ESC

key 21

Explanatron

of

notes

1 l

F

Back

oi

the

machine

16

BACKSPACEkey

21

Blade

cleaning

30

Blade

types

19

Blades

for

ribbon

cables

19

Blades

19

c

Feed rollers

15 1 B

Feedback 30

31
FS 25
Functron

keys

15. 21

Fuse 1 6

G

Calibration

of

cutting

head

47

Calibration

of

rollers

47

Changing

the blades

20

Cleaning

47

Compressed

air

connection

16.

17

Compressed

air

17

CONF

-

configuration

36

Control

unrt

21

Correction

of

blades

S.1

30

cRS

2s,34

Cursor

pad

21

Cut

speed

26

Cut start

position 26.

30

Cut

wait

trme

30

Cutting

head

.15

General

safetv

instructions

12

H

HS

25

I

tM 25
lnstallation

site

17

Items

rncluded

in the

delivery

13

K

Keypad

1 5

L

D

label

-

informatron

text

menu

37

LANG

-

language

selection

24

Language

6,24

Length

accuracy

7

Length

correction

factor 30

Length

range

7

Lifter

clearance

30

LIST

-

wire

lrst

37

M

t

.l

ll]ocim:l alzr a 21

yrsvv

-

Delay time

32

Delta

stripping

value

25

Delta

wayback

25,

34

Device

rdentificatton

36

DIA 34

Drmensions

7,

13

Display

concept

22

Display

15

Distance

30

doub

30,34

Double

V-blades

19

Double-seath

Processing

34

Downstream

device

32

Draw-in

speed

26

DST

25

DWB

25.34

Machine

identilication

6

Machine

number

6

Machine

operator

9

Machine

overview

15

Machine

protection

11

Machine

type

6

MAIN

-

main

menu 24

MAIN

key 21

Main

switch

for machine

12,16,17

Ol

kappa

220

-

Version

3

lndex

55

M

Maintenance

47

Malfunctions

41

MINUSIPO|NT

key

21

N

Nameplate 16
Negative

number

2'1

NO

2s

Noise level

7

norm

30

Nl,,-h^.^ ^^! 4r

r\ur

tuEr> pdu 4 r

o

Offset length

30

Operatrng

instructions

6

Operation

21

Outsrde

diameter 7

P

Pe'sonnel orralifir:atrnn

9

Piece

output 7

Power input

6

PPARA

-

olher

processtng

parameters

30

PPARA - process parameter

menu

26

Prelimrnary

processrng

8, 16

Pressure

applied

26

PROD - nrorirrr:tinn mgng

f/

Programming

example

27

Protection

f rom

personal

injury 11

PS

25

Pulse

time

30, 32

Punched

disk 15. 1B

R

Radius

blade 19

Rarsing

the feed rollers

Reference

blades 47

Beference

distance

48

REMOT - remote

mode
Repatr 47
Roller

distance

26

R5232 rnterface

16

S

Qafotrr {o)ft traa 1

'2

Safety

notes 1 1

Safety

11

SEQU

-

sequence

38

Qonrronno nrrmhcr ?A

Spnr rpncp nrocps.'rn

36

Sequence stop 3e

Shaft

for feed rollei

srde 2 15
Shortmode 7
Srngle step

36

Ql:r1-r rn nrnnorlr t.c 17

START/STOP kevs

21

Stop rnput 16.

36
Straightener 15, 1 7
Stripping length

6

Stripping

speed 25

Subsequent

processing

1

6

Switch

off 17

Switch

on 17

Swivelling

wire

gr.l'ie

15

9vmbols

+/-keys

21

T

TEACH

-

program,-ning

menu

24

Technical

data 6

Test

f unctions 48

Training

tailored

to customer

needs

9

Training

9

Transport

13

Trough

for insulation

scraps 15

U

l3

Unit

of

cross

secticrr

36

Unit

ol length

36

Upstream

devrce

3C. 31

V

V-blades

19

Voltage

version

6

56

Inoex

Ol

kaooa

220 - Version

3

w

Wait

time

30, 32

Weight 7,

13

Wire cross section

7

Wire deposit

system

trough

15

Wire deposit

8

Wire feed system

8

Wire feed-in

15

Wire

guide,

right

15

Wire

guides

18

Wire monitoring

26

Wire type

30

Ol kappa 220

-

Version

3

lndex

57