0638019200 [MOLEX]
Pneumatic Bench Top Wire Stripping Machine Operation Manual; 气动台式剥线机操作手册
| 型号： | 0638019200 |
| 厂家： | 
Molex |
| 描述： | Pneumatic Bench Top Wire Stripping Machine Operation Manual |
| 文件： | 总20页 (文件大小：1942K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
Pneumatic Bench Top Wire Stripping Machine
WS-1000
Pneumatic Bench Top Wire Stripping Machine
Operation Manual
Order No. 63801-9200 (AWG wire)
Order No. 63801-9250 (Metric wire)
ꢀ Description
ꢀ Operation
ꢀ Maintenance
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
UNCONTROLLED COPY
Page 1 of 20
Pneumatic Bench Top Wire Stripping Machine
Table of Contents
SECTION
1
2
3
4
5
Safety Warnings
General Description
Setup and Adjustments
Maintenance
Parts List, Assembly Drawings and Troubleshooting
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
1. WARNING
MOLEX CANNOT BE RESPONSIBLE FOR DAMAGE OR INJURY RESULTING FROM UNSAFE PRODUCT
USE, LACK OF MAINTENANCE, OR INCORRECT PRODUCT AND SYSTEM APPLICATION.
All WARNINGS must be carefully observed to help prevent personal injury.
NEVER
NEVER
USE THIS TOOL WITHOUT GUARDS OR SAFETY DEVICES THAT ARE INTENDED TO
PREVENT HANDS FROM REMAINING IN THE STRIPPING SPACE.
OPERATE, SERVICE, INSTALL OR ADJUST THIS TOOL WITHOUT PROPER INSTRUCTION
AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS
MANUAL AND ALL APPLICABLE AIR POWERED CRIMPING TOOL MANUALS.
NEVER
INSTALL OR SERVICE THIS MACHINE WHILE CONNECTED TO THE COMPRESSED AIR
SOURCE.
WARNING THE PNEUMATIC BENCH TOP WIRE STRIPPING MACHINE IS NOT INTENDED FOR THE
PROCESSING OF MATERIALS OTHER THAN THOSE NORMALLY USED IN INSULATION
AND JACKET MATERIALS FOR WIRES AND ELECTRICAL CONDUCTORS.
WARNING THE PNEUMATIC BENCH TOP WIRE STRIPPING MACHINE IS ALSO NOT INTENDED FOR
THE PROCESSING OF MASSIVE SHIELDS MADE OF COPPER OR HARDER MATERIALS,
STEEL WIRE NETWORKS ETC.
WARNING MOLEX SPECIFICATIONS ARE VALID ONLY WHEN USED WITH MOLEX TERMINALS AND
TOOLING.
WORK SAFELY AT ALL TIMES
For Service, Contact Your
Local Molex Sales Office
Molex Application Tooling Group
2200 Wellington Court
Lisle, Illinois 60532, USA
Tel: 630-969-4550
Fax: 630-505-0049
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
Section 2
General Description
2.1
2.2
2.3
2.4
2.5
Description
Features
Technical Specifications
Delivery Check
Tools
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
Principal Mechanical Parts of the WS-1000 (63801-9200 / 63801-9250)
FILTER
REGULATOR
GAUGE
HOOK UP
ADJUSTING WHEEL FOR
CABLE CROSS SECTION
SAFETY COVER
WIRE / CABLE
ADJUSTING WHEEL FOR
STRIP LENGTH
BLADES
ADJUSTING SCREW FOR
STRIP LENGTH / PARTIAL
Figure 2-1
Order No: TM-638019200 Release Date: 10-01-09
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Revision: B
Revision Date: 04-07-11
Pneumatic Bench Top Wire Stripping Machine
Operating Parameters
Cycle Time
General Description
0.5 seconds
Operating Air Pressure 3 to 6 bar (43 to 87psi )
2.1 Description (See Figure 2-1)
The WS-1000 Pneumatic Bench Top Wire Stripping
Machine, Order no. 63801-9200 for AWG wire and
63801-9250 for metric wire, is a semi-automatic,
pneumatic table instrument for the stripping of
cables and wires with insulations of different natural
and synthetic materials, such as; rubber, PUR,
Teflon etc.
maximum
6 bar (87psi)
Air Consumption per cycle
0.15l (0.005 cubic feet)
Sound Level
< 70 dB(A)
Cable
Round cables up to 5.0mm (.196") O.D.
Cross section from 0.15 - 4mm² (26 - 12 AWG)
Flat cables up to 8mm wide (.315")
Partial stroke from 1.0 – 15.0mm (0.04 – 0.59")
Stripping length of 1.5-15.0mm (.06 - .59”)
(total stripping)
The use of special blades, adapted to the cable to
be processed, allows the processing of nearly all
common round and flat cables.
The Pneumatic Bench Top Wire Stripping Machine
can handle extremely short wire leads, less than
9mm in length. It can adjust to change wire strip
diameter settings, easily without tools, to process a
full range of wire sizes. The V-shaped blades can
be adjusted for the full range of wire sizes, quickly
in seconds, without tools, for quick production run
changeouts. Self-centering clamping jaws and
release sensors ensure high quality strips, safely
and efficiently.
Removal length of 0 – 15.0mm (0 - .59”)
Safety covers
Order No.
Standard.
63801-9228
4.0mm (.157”) maximum insulation diameter
Cover with safety collar (optional)
63801-9229
8.0mm (.315”) maximum insulation diameter
2.4 Delivery Check
2.2 Features
Carefully remove Wire Stripping Machine from
its shipping container and determine that the
following items are included in the package.
ꢀ
Extremely short stranded wire ends can be
processed (distance cover to stripping blades
<= 9 mm)
ꢀ
ꢀ
Exact parallel guide of the blade heads
Processing with die-blades, prismatic blades
and flat stripping blades
Blade change within seconds and without tools
Sensor release of the stripping process
Self-centering clamping jaws
Air blow-out
Guard cover for safety
Putting in the cable from above
Description
63801-92*0 Pneumatic Bench Top Wire
Stripping Machine
63801-9243 Hex Wrench 5mm
63801-9271 pair of prismatic blades
(installed at the factory)
63801-9230 pair of rubber pads
for clamping jaws
Quantity
1
1
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
1
1
63801-9201 Air regulator & shut-off assy 1
TM-638019200 Instruction Manual
1
2.3 Technical Specification
2.5 Tools
Dimensions
The following tools are recommended for setup
and adjustments.
ꢁ Metric standard hex wrench set
ꢁ Adjustable wrench
Width
Depth
Height
Weight
95.0mm (3.74”)
280.0mm (11.02“)
165.0mm (6.50”)
4.3kg (9.5lbs)
ꢁ Wire stripper / cutter
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
Section 3
Set-Up and Adjustments
3.1.
3.2.
3.3.
3.4.
3.5.
Setup
Operation
Adjustments
Installing and Replacing Blades
Adjustment of the Brakes
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
3.1 Set-up
Caution: Always disconnect the air pressure until the system is ready to operate.
Note: Detail nos. in parenthesis ( ) are shown on the Assembly Drawing in Section 5. These are not order nos.
Air Supply Hook-Up
1. Read the following instructions before attempting to operate the
tool.
2. An Air Regulator assembly, order no. 63801-9201, is included
with this tool. It includes a filter / regulator unit with air shut-off
and supply hose.
Connect the assembly to the back panel of the machine, with the
two included cap screws. See Figure 3-1.
3. Adjust the regulator to an operating pressure of 3 - 6 bar (43 –
87 PSI). The maximum operating pressure is 6 bar (87 PSI).
Operating the tool above the maximum pressure may cause
injury or damage to the tool.
4. Before using the machine, make sure the clear plastic safety
cover is installed.
Figure 3-1
Safety Devices
The WS-1000 Bench Top Wire Stripping Machine is equipped with all necessary safety devices. However,
no system can be completely protected against misuse. All changes and amendments not made by the
manufacturer, or other modifications that are not granted in writing by the manufacturer, will void all
guarantees and liability claims.
When the safety cover is removed a safety switch will prevent the machine from operating.
The clear plastic safety cover supplied with the unit, order no. 63801-9228 (028.0071), is for cable or wire
insulation outer diameters up to 4.0mm.
In addition to the standard safety cover, an optional safety cover, order no. 63801-9229 (028.0072), is
available for cable or wire insulation outer diameters over 4.0mm.
The safety cover protects the operator from the hazardous area of the Wire Stripping Machine. Please check
regularly that the safety cover functions correctly by unscrewing the safety cover's two knurled screws, and
sliding the cover forward (towards the operator)
Note: If the machine works correctly, the safety switch will interrupt the air supply and the machine will
not function. If the safety device does not function properly, operation of the machine should be avoided
until the safety switch is repaired.
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
3.2. Operation
The cable is put into the machine through the opening in the
safety cover from above or from the front and is pushed
against the sensor. This sensor starts the working cycle,
which functions as follows:
SENSOR
1. The starting position is where the Clamp Jaws
(028.0010 and 028.0011) and blades are open and the
Blade Head (028.0014) with sensor is in the front
position. Front position is when the Blade Head is
placed directly behind the Clamping Jaws
2. The back position is when the Blade Head is placed at
the end of its way towards the Front Plate (028.0001).
3. Insert the cable or wire into the slot of the safety cover
until the end touches the Sensor (028.0035). See
Figure 3-2.
CLAMP
JAWS
BLADES AND
BLADE HOLDERS
Figure 3-2
WIRE
4. The Clamp Jaws will come together and then clamp
and center the cable.
5. The blades move together and cut into the insulation of the cable or wire.
6. The complete slide, with blade head and blades, moves backwards to the adjusted removal length. At
the same time, the sensor moves backwards.
7. After the slide and the blade head have reached their final
ADJUSTING WHEEL
position, the clamp jaws open and then the blades. The
slide moves backwards to the initial position. At the same
time, a small air jet blows the stripping debris into the waste
shaft (028.0028).
3.3. Adjustments
1. Cable / Wire diameter (See Figure 3-3)
The adjusting wheel for the conductor diameter of the wire to be
Figure 3-3
stripped, is located in the front at the top of the machine.
(028.0015 for metric or 028.0083 for AWG)
Note: While using die blades, the adjusting wheel has to be put in the position marked
.
While using prismatic blades or flat stripping blades, the adjusting wheel has to be opened wide enough.
Adjust the necessary diameter step by step, until satisfactory stripping results are obtained - otherwise, there
is risk that the blades will cut into the wires.
The scale values on the adjusting wheel are related to the diameter of the conductor, when prismatic blades
are used.
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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2. Stripping length (See Figure 3-4)
The desired stripping length 1.5 – 15.0mm (.059” to .590”) is adjusted
with the adjusting wheel (028.0046) on the right side of the machine in
increments of 0.5mm.
Note: The middle scale line is valid when using the Prismatic Blades.
The front and rear scale lines are used when using the Flat Blades;
The front line is used when the draft angle of the flat blade is facing
out and the rear scale line is used when the draft angle of the Flat
Blade is facing in (not visible)
3. Removal length / Partial stroke (See Figure 2-1)
The removal length also can be adjusted as required, (from 0 –
15.0mm). This is done by using a 5mm hex wrench to adjust the
screw (028.0041), located through the hole on the lower left side of
the front plate.
ADJUSTING
WHEEL
Figure 3-4
3.4. Installing and Replacing Blades
This machine will accomadate 2 different interchangable blade sets. The 63801-9200 includes the standard
prismatic blades, order no. 63801-9271. There are also optional flat stripping bades available, order no. 63801-
9272. Follow the steps below to install and replace them.
Figure 3-5
63801-9271 PRISMATIC BLADES
63801-9272 FLAT STRIPPING BLADES
1. Remove the safety cover. This is done by loosening (2) knurled screws on each side of the cover and
then sliding the cover forward, up and off the machine.
2. Push back the guide pin on the swing lever that is located behind each blade holder, (one side at a time)
and pull out the blade from the side. See Figure 3.6.
3. Make sure that the guide slots are clean and free of debris.
4. To Install new blades, push back the guide pin and slide in the blade until the blade clicks onto the guide
pin. Make sure that the guide pins catch in the corresponding holes of the blades. See Figure 3-7.
GUIDE
PINS
PUSH BACK
GUIDE PIN
PUSH IN
THE BLADE
Figure 3-7
Figure 3-6
Note: The prismatic blades must be installed so they overlap when closed.
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
3.5 Adjustment of the Brakes
The correct function of this machine is dependent on two adjustable brakes. Improper adjustment or wear of
the brakes can influence the function of the machine and cause faulty stripping results.
The following two malfunctions are possible, due to improperly adjusted brakes:
1. The blades move together before the clamp jaws close - this means that the cable is not
sufficiently clamped and centered.
Correction:
The brake, below the cylinder (028.6001), requires readjustment:
1. Unscrew the button head screw (028.8033) on the side plate (028.0002).
2. Turn the screw, located behind the side plate (028.0002), with a 3mm hex wrench, approximately 1
to 3 turns clockwise (CW).
3. This tightens the brake and increases the brake power.
2. The slide blade head (028.0014) with blade holder and blade moves back before the blades have
moved together – this means that the insulation is removed too late or not at all.
Caution: Before re-adjusting the brake always disconnect the compressed air from the machine.
Correction:
The brake (028.0040) requires readjustment.
1. Remove the compressed air supply from the machine.
2. Unscrew the cover (028.5001).
3. Turn the screw (009.8050) with a 3mm hex wrench approximately 1 to 3 turns clockwise (CW).
4. Check the correct brake adjustment by pushing back (machine should have no compressed air) the
cylinder (028.6001) manually on the unscrewed carrier . The blades will first move together. Then,
the cone (028.0053) must move with its binding face against the adjusting screw (028.0036).
Finally, it pulls back the complete slide (blade head 028.0014) with blade holders and the blades.
5. In an opposite movement, the slide (blade head 028.0014) is pulled towards the front plate
(028.0001). The blades first have to open before the slide (028.0014) moves.
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
Section 4
Maintenance
4.1
Cleaning
4.2
4.3
4.4
4.5
Lubrication
Perishable Parts
Spare Parts
Storage
Order No: TM-638019200 Release Date: 10-01-09
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Pneumatic Bench Top Wire Stripping Machine
Maintenance
CAUTION: Always disconnect the compressed air supply before all maintenance
In order to insure the best operating condition and machine safety, a regular inspection of all relevant parts
and functions should be done, appropriate to the frequency of their use.
4.1 Cleaning
See Chart for recommended Preventive Maintenance Schedule.
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of
your machine or use this as a template to create you own schedule or use your company’s standard chart,
if applicable.
The following applies to this machine with tooling installed.
1. For efficient operation, the tooling should be cleaned daily with a soft bristle brush to remove any debris
from the tooling area.
2. All hose connections must be free of grit and grime.
3. Machine interior:
From time to time, the working area of the machine should be cleaned with a soft brush. An intermediate
cleaning is recommended in case of considerable dirt due to talcum and stripping scrap. Make sure that
there are no foreign parts or liquids getting into the case openings.
4. When it is necessary to change the tooling, care should be taken to remove any debris from tapped holes
or mounting surfaces. Debris can prevent tooling from being properly locked into position.
5. All rotating and other movable elements are equipped with antifriction bearings or maintenance-free slide
bearings. These parts are adequately lubricated and do not require any further maintenance.
CAUTION: Using compressed air to clean tooling is not recommended. Chips can wedge in the
tooling and/or fly at an operator.
4.2 Lubrication
Pneumatics
All control valves and cylinders have been adequately lubricated with pneumatic oil, and therefore, do not
require any further maintenance.
Filter-Regulator
It will be necessary to check the filter bowl at least once a month, depending on how dirty the air supply is,
and empty as required.
Preventive Maintenance Chart
Daily: Clean. See Section 4.1.
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
CHECK SHEET MONTH
YEAR _________
Days of the Week
Week
Daily Use
Solution
MON TUE WED THU FRI SAT SUN
1
2
3
4
Bleeding Air From
the System
Run the system thru
several cycles.
After prolong use
Hose connections free of grit
and dirt.
Cleaning
Use soft cloth
Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive
maintenance be kept with the tool.
4.3 Perishable Parts
Customers are responsible for maintaining the Pneumatic Bench Top Wire Stripping Machine. Perishable
parts are those parts that come in contact with the product and will wear out over time. Molex
recommends that all customers keep at least one set of the perishable parts in stock at all times. This will
reduce the amount of production down time.
4.4 Spare Parts
Customers are responsible for maintaining the The Pneumatic Bench Top Wire Stripping Machine. Spare
parts are available. Moving and functioning parts can be damaged or wear out over time and will require
replacement. Molex recommends that the customer keep some or all of them in stock to reduce production
down time. These parts are identified in the Parts List. See Section 5.
4.5 Storage
When storing the WS-1000 Pneumatic Bench Top Wire Stripping Machine, disconnect the air supply and
store in a dry location.
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
Section 5
Parts List, Assembly Drawings and Troubleshooting
5.1.
5.2.
Parts Lists and Assembly Drawings
Troubleshooting
Order No: TM-638019200 Release Date: 10-01-09
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Pneumatic Bench Top Wire Stripping Machine
5.1 Main Parts List
WS-1000 Pneumatic Bench Top Wire Stripping Machine (63801-9200 or 36801-9250)
RSP / PP Parts
and notes
Order No Detail No
Description
Quantity
63801-9201 Not shown Filter Regulator and shut-off valve assy Pneumatic parts
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
0
1
1
1
63801-9202 003.6027
63801-9203 009.8050
63801-9204 028.0001
63801-9205 028.0002
63801-9206 028.0003
63801-9207 028.0004
63801-9208 028.0005
63801-9209 028.0010
63801-9210 028.0011
63801-9211 028.0014
63801-9212 028.0015
63801-9213 028.0017
63801-9214 028.0025
63801-9215 028.0028
63801-9216 028.0034
63801-9217 028.0035
63801-9218 028.0036
63801-9219 028.0037
63801-9220 028.0038
63801-9221 028.0040
63801-9222 028.0041
63801-9223 028.0046
63801-9224 028.0053
63801-9225 028.0054
63801-9226 028.0055
63801-9271 028.0060
63801-9272 028.0063
63801-9227 028.0064
63801-9228 028.0071
63801-9229 028.0072
Micro Ram Valve
Screw
Pneumatic parts
Front Plate
Side Plate (Right)
Side Plate (Left)
Back Plate
Bottom Plate
Clamp Jaw, Right
Clamp Jaw, Left
Blade Head
Adjusting Wheel (metric wire sizes)
Sleeve
On 63801-9250
Sensor Fork
Waste Shaft
Pipe For Sensor
Sensor
Adjusting Screw
Rubber For Ram
Swing Pin
Brake
Screw
Adjusting Wheel
Cone
Pedestal
Conus Guide
Prismatic Blades, Pair
Flat Stripping Blades, Pair
Centering Piece
Safety Cover, Standard
Safety Cover 8mm
PP
PP Optional part
RSP
Optional part
63801-9230 028.0075 Pair Of Rubber Pads For Clamping Jaws RSP Accessories REF 1
63801-9231 028-0083
63801-9232 028.5001
63801-9233 028.6001
63801-9234 028.6002
63801-9235 028.6034
63801-9236 028.8004
63801-9237 028.8005
63801-9238 028.8007
63801-9239 028.8008
Adjusting Wheel (AWG)
Cover
Short Stroke Cylinder
5/2 Sliding Valve
On 63801-9200
1
1
1
1
1
2
2
4
1
Pneumatic parts
Pneumatic parts
Pneumatic parts
Throttle Return Stroke Valve
Grooved Ball Bearing
Grooved Ball Bearing
DU-Sleeves
Sleeve (Sinter Bronze)
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
WS-1000 Pneumatic Bench Top Wire Stripping Machine (63801-9200 or 36801-9250)
RSP / PP Parts
and notes
Order No Detail No
Description
Quantity
63801-9240 028.8012
63801-9241 028.8013
63801-9242 028.8023
63801-9243 028.8025
63801-9244 028.8033
63901-9245 028.8034
Guide Pins
Swing Levers
Sleeve (Sinter Bronze)
Hexagon Socket Wrench 5mm
Button Head Screw
2
2
2
Accessories
REF 1
1
1
High-Grade Steel Strand
RSP - Part is a Molex Recommended Spare Part.
PP - Part is a Perishable Part.
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Pneumatic Bench Top Wire Stripping Machine
Assembly Drawing
Order No: TM-638019200 Release Date: 10-01-09
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Revision: B
Revision Date: 04-07-11
Pneumatic Bench Top Wire Stripping Machine
5.2 Troubleshooting
Symptom
Blades do not open.
Insulation is cut improperly.
ꢀ
ꢀ
ꢀ
Cause
Blade guide is dirty.
Dull blades.
Solution
Clean blade head.
Install new blades
Push safety cover
towards the front plate
See Section 3.5
Adjustment of the Brakes
See Section 3.5
Adjustment of the Brakes
Machine has excessive air leaking ꢀ Safety switch is not pressed in far
around the safety cover.
The cable is not sufficiently
clamped and centered.
The insulation is removed too late
or not at all.
enough by the safety cover.
ꢀ
Worn or improperly adjusted brakes.
ꢀ
ꢀ
Worn or improperly adjusted brakes
Cable scrap between clamp jaws
and safety cover.
Clamp jaws do not open.
Remove cable scrap.
http://www.molex.com
Order No: TM-638019200 Release Date: 10-01-09
Revision: B Revision Date: 04-07-11
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Order No: TM-638019200 Release Date: 10-01-09
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Revision: B
Revision Date: 04-07-11
相关型号：
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