molex 63800-7950 Instruction Manual

Crimp Force Monitor

63800

-

7950

Doc. No: TM-638007950 Release Date: 03-21-13 UNCONTROLLED COPY Page 1 of 21
Revision: A Revision Date: 03-21-13

Crimp Force Monitor

Instruction Manual

Order No. 63800-7950

Crimp Force Monitor

Read

and

understand

all of the instructions and safety information in this

CAUTION:

WARNING

WARNING

Never

install or service this

unit while

WARNING

WARNING

Do not use

compressed air to clean

WARNING

WARNING

Never

operate a press

without safety devices

Do

not

expose

this equipment to moistur

e.

This symbol is used to call your attention to hazards or unsafe practices which could result in an injury
or property damage. The signal word, defined below, indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.

DANGER

WARNING

Safety Warnings and Information

manual before operating or servicing this tool.

Keep this manual available when using this tool.

Replacement manuals are available for download at no charge at

SAFETY ALERT SYMBOL

DANGER:

Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.

WARNING:

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

www.molex.com.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION may also be used to alert against unsafe practices associated with events that could lead

to personal injury.

Always wear proper eye protection when
operating or servicing a press.

Failure to wear eye protection could result
in serious eye injury from flying debris during test.

Never operate, service, install, or adjust this
equipment without proper instruction and without
first reading and understanding the instructions
in this manual and all applicable press and/or
wire processing machine manuals.

that are intended to prevent hands from remaining
in the tool.

Failure to observe this warning could
result in severe injury or death.

connected to any electrical power source.
Disconnect power by unplugging the AC adapter.

Failure to observe this warning could result
In severe injury or death.

this equipment. The forces created by
compressed air can force debris into the unit.

Failure to observe these precautions may
result in injury or property damage.

To prevent fire and shock hazard,
always unplug the AC line cord prior to servicing.

Failure to observe this warning could result
In severe injury or death.

Doc. No: TM-638007950 Release Date: 03-21-13 UNCONTROLLED COPY Page 2 of 21
Revision: A Revision Date: 03-21-13

Crimp Force Monitor

WARNING

Do not

exceed the rated force capacity

of the sensor

. The unit may be damaged,

and the operator or others in

CAUTION

Never

perform any service or maintenance other than as described

in this manual.

the immediate vicinity injured under extreme force conditions.

Do not remove the disassemble the display module. Disassembly will void the warranty.

Never modify, alter or misuse this equipment

Failure to observe this precaution may result in injury and / or property damage.

Application Tooling Technical Assistance

Application tooling technical assistance is available for customers who may need some guidance for tooling
adjustments. This support can be accessed by calling either of the two numbers listed below and asking for the
Molex Tooling Group.

Call Toll Free 1-800-786-6539(US) 1-630-969-4550(Global).

This assistance is limited to the operation and set-up of a customer’s Molex tool. Questions with regard to Molex
connector products or how to identify the proper tooling and/ or tooling documentation should be directed to your
local Molex personnel or Customer Service Representative.

When calling for service on the crimp force monitor it is recommended to have the following: a copy of this Tooling
Manual and a person familiar with the crimp force monitor should be present. The following information is also
recommended to supply:

1. Customer name

2. Customer address

3. Person to contact such as (name, title, e-mail, and telephone number)

4. Crimp force monitor part number (638007950)

5. Urgency of request

6. Nature of problem

Molex Application Tooling Group

2200 Wellington Court

Lisle, IL 60532, USA
Tel: [phone]
Fax:[phone]

Visit our Web site at http://www.molex.com

Doc. No: TM-638007950 Release Date: 03-21-13 UNCONTROLLED COPY Page 3 of 21
Revision: A Revision Date: 03-21-13

Crimp Force Monitor

Table of Contents

Contents

Safety Warnings and Information .................................................................................................................................................2

Application Tooling Technical Assistance .....................................................................................................................................3

Section 1 .......................................................................................................................................................................................5

General Description ..................................................................................................................................................................5

1.1 Features .........................................................................................................................................................................5

1.2 Technical Specification ...................................................................................................................................................5

1.3 Description .....................................................................................................................................................................5

1.4 Delivery Check ...............................................................................................................................................................6

1.5 Tools ..............................................................................................................................................................................6

Section 2 .......................................................................................................................................................................................7

Setup and Installation ...............................................................................................................................................................7

2.1 Controls Overview of the Crimp Force Monitor ..............................................................................................................7

2.2 Set-Up ............................................................................................................................................................................8

2.3 Ram Sensor Installation .................................................................................................................................................8

2.4 Mounting the Control Module .........................................................................................................................................8

2.5 Cable Connections .........................................................................................................................................................9

2.6 Power Supply Connection ..............................................................................................................................................9

Section 3 .....................................................................................................................................................................................10

Operation................................................................................................................................................................................10

3.1 Learning a Process ......................................................................................................................................................10

3.2 Auto-Gain Feature ........................................................................................................................................................10

3.3 Information Screen .......................................................................................................................................................10

3.4 Run Screens.................................................................................................................................................................11

3.4.1 Main Screen ...................................................................................................................................................11

3.4.2 Counter Screen ..............................................................................................................................................12

3.5 Operator Interaction .....................................................................................................................................................12

Section 4 .....................................................................................................................................................................................14

Process Setup ........................................................................................................................................................................14

4.1 Signature Analysis and Tolerances ..............................................................................................................................14

4.2 Part Number Database .................................................................................................................................................14

4.2.1 Loading a Part Number ..................................................................................................................................15

4.2.2 Creating a New Part Number .........................................................................................................................15

4.2.3 Deleting a Part Number ..................................................................................................................................15

4.2.4 Run Screen ....................................................................................................................................................16

4.3 Setup Menu ..................................................................................................................................................................16

4.3.1 Signature Capture ..........................................................................................................................................16

4.3.2 Learn Parameters ..........................................................................................................................................17

4.3.3 Machine Interface ..........................................................................................................................................18

4.3.4 Other Settings ................................................................................................................................................19

Appendix A – Configuration Worksheet ......................................................................................................................................20

Appendix B – Spare Parts ..........................................................................................................................................................20

Appendix C – Typical Force Signatures of Crimp Defects ..........................................................................................................21

Warranty .....................................................................................................................................................................................21

Doc. No: TM-638007950 Release Date: 03-21-13 UNCONTROLLED COPY Page 4 of 21
Revision: A Revision Date: 03-21-13

Crimp Force Monitor

Section 1

General Description

1.1 Features

 Accurate discrimination of crimp defects from normal production
 Simple operator function – easy to set up
 Graphics color changes for visual indication of crimp defect
 Audible alarm when defect is found
 Press can be inhibited when defect is found
 USB2.0 interface for PC software
 Password protected set up
 Mounts directly on the TM-3000 and TM-4000 presses
 Not for use on the TM-2000 press

1.2 Technical Specification

Environmental:

Operating temperature: 15° to 50°C

(60° to 120°F)

Electrical Input:

85-264VAC, 47-63Hz
(Adapter output 24VDC ±10% 350mA)

Sensor Input:
AC coupled, Inverting or Non-inverting
(selectable), SMA connector

Communication

USB 2.0 (Mini B connector)

1.3 Description

The crimp force monitor measures the force signature of a crimped terminal and compares it to a reference crimp.
Depending on the limits programmed, the measurement will pass, fail, or be suspect.

When a measurement is suspect, the display backlight will turn yellow to warn the operator. A failed measurement
will cause the backlight to turn red and an audible alarm to sound. The operator must press a button to silence the
alarm and reset the monitor. If connected, the crimp force monitor can inhibit the press foot switch when a failure
occurs.

The crimp force monitor can be set to display peak force in pound, kilograms, or newton units. A production
counter is also included as well as job storage.

Inputs and Outputs:

Input 1: 24VDC discrete input
Output 1: 1A @ 30VDC, 1A @ 240VAC
Output 2: 1A @ 30VDC, 1A @ 240VAC

Dimensions:

Height: 147mm (5.6in)
Width: 89mm (3.5in)
Depth: 25mm (1.0in)

Doc. No: TM-638007950 Release Date: 03-21-13 UNCONTROLLED COPY Page 5 of 21
Revision: A Revision Date: 03-21-13

Crimp Force Monitor

1.4 Delivery Check

Carefully remove the crimp force monitor from its shipping carton and determine the following items are included
in the package.

Decription: Quantity
Control Module 1
Force Sensor with Ram Mount 1
SMB sensor cable 1
Mini-USB cable 1
DC power supply 1
Foot switch cable 1
Press Mounting kit 1
CD for PC software 1
CD for operating manual 1
Crimp Force Monitor Manual TM-638007950 1
FoceView Software Manual TM-638007958 1

1.5 Tools

The following tools are recommended for installation of the crimp force monitor:

1. 3mm hex wrench (to install ram sensor)

2. 4mm hex wrench (to install mounting bracket)

3. Adjustable wrench (to install mounting bracket)

Doc. No: TM-638007950 Release Date: 03-21-13 UNCONTROLLED COPY Page 6 of 21
Revision: A Revision Date: 03-21-13

Crimp Force Monitor

BLACK BAR:

PEAK CRIMP

ANALYSIS

CRIMP

GROSS LIMIT (%)

SENSOR CA

BLE

24VDC INPUT

RS232 I/O

POWER SWITCH

Section 2

Setup and Installation

2.1 Controls Overview of the Crimp Force Monitor

FORCE

REGION

SIGNATURE

63800-7950

TARGET

PROCESS ERROR

MINI-USB PORT

INPUT

MENU KEY: Return to previous screen or cancel

DOWN KEY: Move down to next menu item or screen

UP KEY: Move up to next menu item or screen

ENTER KEY: Move to selected screen or select current item

Doc. No: TM-638007950 Release Date: 03-21-13 UNCONTROLLED COPY Page 7 of 21
Revision: A Revision Date: 03-21-13