s n r a h e r i w applicationtooling andequipment · and semi automatic bench equipment can be...

All specifications subject to change. Consult Tyco Electronics for latest specifications.1 1For more detailed information please visit our websitestooling.te.com, tooling.te.com/china and tooling.te.com/europe

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WireHarness

Application Toolingand Equipment

Complete Solutions from Start to Finish

2

Complete Solutions from Start to Finish

ApplicationToolingandEquipment

Application Tooling and Equipment Portfolio

� Applicators

� Crimp Machines and Equipment

� Electrical Test Equipment

� FFC-FPC Equipment

� Hand Tools

� IDC Machines

� Lead Makers

� Magnet Wire Equipment

� MOST Equipment

� Pin Insertion and Press-Fit Machines

� SOLARLOK Equipment

� Tooling for RaychemHeat Shrink Products

� Wire Preparation Equipment

� Installation, Inspection and Serviceas well as Training and Short TermRental Crimp Applicators withinEMEA region

MOST is a trademark of SMSC Europe GmbH.

1Detailed information can be found at www.tooling.te.com www.tooling.te.com/europe

Introduction

Complete

Solutions

from

Startto

FinishTE Application Tooling is dedicated to providing high quality equipment options to meet all levels of

our connector products specifications. We are also able to provide a broad range of equipment forother manufacturer’s products.

Our equipment range is vast and is almost unmatched by others operating in the same industrysegments, as is our global presence and is support network in the form of field service engineersand product managers. You will see from browsing this catalogue; we supply everything from simplehand tools to the most complex automated systems – you name it, we supply it!

Equipment is segregated into two types and managed accordingly:

Generic equipmentWhere we can supply you with sufficient information referenced by Part Number such that you canidentify and order what you need yourself.

Specialised EquipmentWhere you will need help from our specialist product managers to identify what is right for yourapplication.

www.tooling.te.com/europe – a dedicated European Tooling Website with:

� Powerful searches to find generic equipment options (Hand Tools / Applicators)� Brochures and more detailed flyers for the specialised equipment along with local contact information.

It’s quick, easy and more importantly the latest and most up to date information is available online.

Finding Equipment online

Whatever your Product Volumes are we

Detailed information can be found at www.tooling.te.com www.tooling.te.com/europe2

Complete

Solutions

from

Startto

Finish

Hand Tools 4

Power Tools 12

Applicators 15

Bench Terminators 19Wire Preparation

Equipment 25

Lead Makers 26

Crimping Machinesfor Loose Piece Terminals 14

Harness Makers 34

ProductionVolume


have the optimal Application Solution

Complete

Solutions

from

Startto

Finish

Function Test Solutions 40

Equipment forHeat Shrink Products 39

Pin Insertion Machines 41Board Processing Equipment 43

Magnet Wire Equipment 46FFC Equipment 48

Application Tooling forProcessing Small Wire Sizes 49

High Voltage Application Tooling 50Application Tooling forAluminum Conductors 52

Service 54


Hand Tools

WireHarnessEquipment

Hand Tool Kits

TE Connectivity provides standard kits that contain all the necessaryequipment to carry out specific tasks to high professional standards.We can also provide custom kits for volume requirements containingonly tools, or a combination of tools and terminals tailoredto your specific requirements.

Please visit our tooling website to view our online hand tool cataloguefor standard kits, or find your local contact to discuss custom kits.

Hand Tools


Hand Tools


Hand Tools

Hand Tool Kits for the Aerospace Industry



Hand Tools

Insertion and extraction tools are used for inserting discrete terminals into connector housingsor removing them, without causing damage to either the terminals or housings.

Our new standard design features a comfortable handle and snap-in/out protective coverthat allows users to stow the business end of the tool to help protect from inadvertentpersonal injury when the tools are not in use.

Many different design types currently exist for ourvast terminal product range, which we continueto convert. If you would like the tool you useconverted to the new design, want a custom kitor tools in this design for other manufacturersproducts – contact us, and where volumes permitwe will be pleased to provide you with a quotationfor your requirement.

Insertion and Extraction Tools


Hand Tools


Hand Tool Kits MOST Sets

The MOST kits are simple and inexpenisve solutions for repair workin the workshop. To meet your requirements we offer several differentversions of sets.

The basic version is equipped with two hand tools. One for stripping andcutting of POF (Plastic Optical Fibres), another one for crimping of POFand an additional spare cutting unit.

A further version contains such items as a 20 meters POF, some male andfemale contacts and one position inline couplings. Other accessories areavailable in different equipment versions.



Hand Tools

Hand Tool Kits for SOLARLOK Interconnecting Systems

A large share of the primary energy demand is covered by utilising solar energy.A significant part of photovoltaic installations are interconnection devices,featuring SOLARLOK terminals. TE Application Tooling offers the requiredtools and machinery for the production of related wiring.

Prior to the termination of the contacts to the wires (crimping),the solar cables must be stripped. This operation is performedeither by hand tools or semi-automatic bench equipment,depending on the volume and the location.

For the termination of the screw machined contacts, hand toolsand semi automatic bench equipment can be used.The deciding factor for the selection of the appropriateequipment are again the location and the volume of leads to beprocessed. TE Application Tooling provides their customerswith a wide range of tooling to apply SOLARLOK products.

Heavy Head Hand Tool (HHHT)� Designed to terminate most large coaxial cable and

heavy-gage wire� Dies close in a straight line� Locator and wire stop when applicable� Insulation adjustment on tools for PIDG and

PLASTI-GRIP terminals� Approx. weight 0.95 kg [2.1 lb]

T-Head Hand Tool� Dies close in a straight line� Locator� Quick take-up on handle for holding terminal or splice in place� Adjust insulation crimp with a four-position screw� Approx. weight 0.59 kg [1.3 lb]

Double Action Hand Tool (DAHT)� Dies travel in arc-like path� Locator on tools for FASTON, MATE-N-LOK, PIDG and

PLASTI-GRIP terminals� Insulation adjustment on tools for FASTON, MATE-N-LOK,

PIDG and PLASTI-GRIP terminals� Approx. weight 0.54 kg [1.2 lb]

C-Head Straight Action Hand Tool� Dies close in a straight line� Dies are interchangeable� Locators and other applicable features included with dies� Approx. weight 0.86 kg [1.9 lb]

IDC Hand ToolsIDC or Insulation Displacement Crimping is based on an entirelydifferent concept to conventional crimping and requires thesespecial types of tool.

We provide a large range of tools for connector families like:MQS, AMP DUOPLUG 2.5, AMP DUOPLUG 2.5 Mark II,AMP DUOPLUG 2.5 power and AMP multifitting Mark II.

CERTI-CRIMP IIStraight Action Hand Tool (SAHT)� Dies close in a straight line� Contact locator and support� Wire stop� Insulation crimp adjustment (4 positions)� Ejects crimped contact� Approx. weight 0.59 kg [1.3 lb]

Detailed information can be found at www.tooling.te.com www.tooling.te.com/europe 9


Hand ToolsOur comprehensive hand tool portfolio ranges from service tools over to tools for commercialapplications and to premium hand tools for special wiring applications. Premium hand toolsare designed to exact specifications to produce consistent, high-quality terminations.

SDE Standard Die Envelope

SDE Crimp Tools

SDE dies are interchangeable in tools from portable hand tools(manually or battery-powered) to pneumatic hand tools andelectric bench terminators. It's a family of tools that you can takefrom bench to production or into the field, without the need fordifferent dies to fit each kind of tool.

You can rely on SDE to provide for your long term needs because ofour commitment to continued development of dies and the tool range.

SDE is a flexible approach to crimp toolingthat allows the use of the same dies withtooling across a range of application platforms.A large selection of die options are alreadyavailable for crimping a broad range ofterminals and wire sizes. Many die sets havemultiple cavities for crimping more than onewire or terminal size and we can providecustom designs where volumes permit.


Hand Tools



Hand Tools


The extensive hand tools programm also contains a selection of heavy-duty hand toolsfor crimping wire diameters up to 120 mm2 (AWG 4/0) and cable cutters for copper andaluminum wire up to 500 MCM.


Power Tools


With the vast improvement of battery life and smallmotor power, the practicality and convenience ofbattery powered tools is now well-proven.

These high quality hand tools are fitted witha protected retract switch. This ensuresthat the crimp cycle is completed consistently.

All battery tools are supplied witha battery charger and with a housedin a durable plastic case.

Each case includes:

� Battery tool� Battery charger� Two batteries

Lithium-Ion Battery Tools

The kits are supplied in a durable carry case and include:

� Battery tool� 4 t latched head� Battery charger� Two batteries

Lithium-Ion Battery Tool 4 t Latch Head

� Effortless crimping for a broad range of terminals� Either bench-mounted or handheld for working in cramped quarters

626 and Micro Pneumatic Tool forCERTI-CRIMP II, Straight Action (SAHT)and Double Action (DAHT)



Power Tools

Hydraulic Foot Pump, Manual� Pump action operation� Clicker valve pressure regulation� Supplied with male quick-coupling

Battery-Hydraulic Tool Kit12 t U-Die� Complete kit with battery charger� Suitable for all 'U' dies with the exception

of U-die assembly (14 t)� Rotating head 320°� Excellent power to weight ratio� circa 10,000 cycles

Kit includes:

� Crimp tool� Battery charger 110 V

Battery charger 220 V� Rechargeable battery� Carry case with strap

Electric Hydraulic Pumps,Heavy DutySuitable for continuous use

� Two speed cycle reduces cycle time forimproved productivity

� Pump shuts down after pressure-switchsetting is reached

� Easy to read integrated oil level sight glass� Totally enclosed fan-cooled motor –

ideal for use in any environment� Quiet operation 70-79 dB(A)� Swivel wheels provide easy manoeuvrability

U-Die line up, including #8–#2 SOLISTRAND tool head,for 68,950 kPa [10,000 psi] systems providingup to 14 t [125 kN] of crimp force

Shank-Die line up, for wiring sizes requiringmore than 14 t [125 kN] of crimp force

Hydraulic Equipment

Hydraulic Equipment Options



Crimping Machines for Loose Piece Terminals

Maximum ease of use with optimum safety was the challenge whendeveloping this pneumatic crimping machine for loose contacts.

This pneumatic crimping machine features a newly developed safetymechanism. Due to a special safety valve, crimping is not permittedif the size of the opening between the dies exceeds 5.9 mm.Due to this special feature it is not necessary to fit safety guardsto protect the operator and is in accordance with legal requirements.

� Parallel closing mechanism� Variable closing speed� Electronic piece counter� Safety system

AT-SC MK II Pneumatic Safety Crimping Machine

AT-60 Pneumatic Crimping Machine

This is a powerful pneumatic machine with a handy quick change system.Due to the control of the return stroke, cycle times are shorter with the benefitof reduced energy consumption.

With increased productivity and an operation simplified with the use ofa foot pedal the operators hands remain free to terminate the contacts and wire.

Adapter changeover is easy andquick as no tools are required.A strategically placed LED worklightilluminates the work area, with thisfeature failures can be avoided.

The AT-60 offers manyapplication possibilities.

AT-66 Hydraulic Crimping Machine

The AT-66 hydraulic crimping machine features an extremely compact designresulting in low space requirement. The hydraulic power is provided by a separatehydraulic unit with main switch, power distribution and pump. The machine offerspossibilities for various applications with a crimp force of 150 kN and an openoperating space of 100.0 mm in height.

A key operated switch protects the basicand operation data. It permits adapting andsafeguarding the particular procedure forthe application. The fitted memory moduleallows 250 different programs to be stored.

� Programmable� Key operated switch protected user interface� Fast changeover times� Compact design� Short cycle time



Applicators

OCEAN Applicator Series

Crimping standards continue to rise to higher levels ofquality and repeatability. Taking customer input andmarket demands into consideration, TE ApplicationTooling has created the OCEAN applicator series tomeet those higher demands and to take terminalcrimping to a new level. By consolidating our applicatoroffering, TE can provide design consistency and toolingstandardization to the market.

� One applicator platform – modular family design� Two ram interface styles� Three interchangeable feed options

Mechanical FeedThe new mechanical feed design has a 50% faster setupand service and a single tool adjustment. Unlike the HDIor the competitive applicators, the feed cam and camfollower remain in constant contact to offer superiorfeeding performance.

Pneumatic FeedUnlike the competition, the OCEAN pneumatic feedhas independent forward and back stroke settings.If only a forward adjustment is needed the terminalcan be advanced by as little as 0.04 mm withouttouching the back stroke setting.

Servo FeedImproved feed accuracy and repeatability help to improvespare part life. Motorized feed allows for slow, controlled, andaccurate terminal placement repeatability.This is done without slowing the speed of the machine.

One of the resulting benefits to customers of this consoli-dation is flexibility in the choice of feeding options: newand improved mechanical and pneumatic feeds along withthe innovative and precise servo feed option. The OCEANapplicator series design also allows customers to performfield upgrades to system III technology. It provides an up-grade path for terminal intelligence that allows the machineto obtain set up features as the applicator is upgraded.



Applicators

Smart Applicator in any OCEAN Applicator Feed Style

Data Management Software (DMS)

The smart applicator offers the ability to exchangeOCEAN applicator information with a lead maker.An integrated data chip stores and relaysset up and maintenance information.

The smart applicator data can beviewed and utilized on a leadmaking machine. This full inte-gration provides the ability toverify the following informationrelated to the terminal:

� Easy and safe programming� Verification of lead maker settings

with smart applicator data� No manual typing of terminal name

is needed for software set up� Errors through manual data input are minimized� Reduction of applicator set up times� Self Adjustment� Better crimp quality, especially in difficult and small

terminal applications� Increase in productivity

The software is used on a personal computerto read and analyze the smart applicator dataeither offline or away from the lead making machine.

Applicator Maintenance� The integrated cycle counter offers the possibility

to set maintenance intervals to maintain the applicatoror to exchange wearable parts,

� All OCEAN applicator wearable tooling PNs are stored inthe data chip and visible on the leadmaker screen if needed.



Applicator Wear Parts Stocking ProgrammeTo ensure the support of our installed applicator base, we have establisheda stocking programme for wear parts. Subsequently, all crimpers and anvils foryour applicator are normally available ex stock, ensuring very short lead times.

Applicators

Pneumatic Mid Wire Size Mini-Applicatorsfor Strip Form Terminals� Dedicated to Crimpmatic 970 crimpmachine

with base plate for conventional TE applicators� Wire range: 6.0–10.0 mm2

� Fine adjustment� Press stroke: 40.0 mm� Shut height: 135.8 mm� Applicator feed: Side/end feed terminal up to 45.0 mm

HD-M Applicators� Fit TE terminator-style presses� Wire range: 0.20–8.0 mm2

� Fine adjustment pneumatic feed available� Press stroke: 40.0 and 30.0 mm

(cam change, as OCEAN applicator)� Shut height: 135.8 mm� Applicator feed:

Side feed terminal 26.5 mm [1.043"]End feed terminal up to 34.5 mm [1.358"]

Pneumatic Large Wire Size Applicatorsfor Strip Form Terminals� Dedicated to Crimpmatic 971 crimpmachine� Wire range: 25.0–50.0 mm2

� Fine adjustment� Press stroke: 44.0 mm� Shut height: 158.0 mm� Applicator feed: side/end feed terminal

up to 55.0 mm

Applicators for Loose Piece Terminals� Used on traditional TE bench presses� Wire range: up to 10.0 mm2

� Fine adjustment� Press stroke: 40.0 mm� Shut height: 135.8 mm� Moveable table with dedicated terminal seat

(according to terminal geometry) to load and unload terminals� Custom designs available for nearly any terminal

Applicators for Loose Piece Terminals� Dedicated to Crimpmatic 971 crimpmachine� Wire range: up to 50.0 mm2

� Press stroke: 44.0 mm� Shut height: 158.0 mm� Applicator feed: terminal loading manually



Applicators

Crimp Machine Gauge� Dynamic measuring of press shut height and direct display� Enormous time savings� Gauge is supplied in a handy transport case,

complete with power supply and manual� Software to generate measuring result

reports is available on request

Applicator Gauge� Ideal instrument to assure correct

positioning of all TE Connectivityapplicators

� Simple installation and use

Transporting Applicators SafelyAlthough they are manufactured to withstand the impact ofcrimping, crimpers and anvils do not fare well when theycontact each other. Such contact can scrape the platingor the crimping surface, causing a friction point.Such a friction point can form metal buildup, ultimatelycausing reject crimps and even tool breakage.

This problem is easily avoided. Always leave a terminal in the crimptooling when moving the applicator from one location to another.This allows the terminal to receive any possible contact andprotects the tooling.

GaugesCompatible with TE Connectivity and commerciallyavailable crimping presses, using quick changes style applicators.

Specifically designed for thru-splice and short lead length applications,the AMP 5/K-40 splice terminator combined with a splice applicatorprovides open access in front of and behind the crimper for controlledwire placement close to the crimping area in order to maximizeproduction efficiency.

The splice terminator is offered in two versions, with and withoutcrimp quality monitoring (CQM II). Equipped with optional CQM II,five different crimp analysis methods, including crimp height,can be used during every crimp cycle, providing real-time monitoring.

Each unit includes fine crimp height adjustment, total/batch countersand capabilities for jog operation.

The splice terminator is CE approved.

AMP 5/K-40 Splice Terminator



Bench Terminators

AMP 3/K-40 and AMP 5/K-40 Terminators

The AMP 3/K-40 and AMP 5/K-40 terminators use a DC motor withgearbox drive. The result is a small-footprint design that is fast and quiet.Cycle time is less than 0.4 seconds.

Standard features such as tool-less precision crimp heightadjust, CQM capability, batch counter and a work lightare integral parts of this equipment range.

By offering options the AMP 3/K-40 and AMP 5/K-40terminators can be tailored to the specific applicationrequirements without inflating the price for unwanted features.

The AMP 3/K-40 is for 0.03–2.5 mm2 [32-14 AWG] wire size.The AMP 5/K-40 is for 0.03–6.0 mm2; [32-10 AWG] wire size.

AMP 3/K-40 and AMP 5/K-40 terminators are CE approved.

� Tool-less removal of applicators and guards for quickand simple maintenance and product change over

� Universal electrical input

Crimp height measurement is a proven non-destructiveway to meet the stringent mechanical and electricalproperties of the crimp. The CQM II with touch screen isa crimp monitoring system that offers continuous crimpheight analysis for every crimp produced.

In fact, the new CQM II features five different methods ofprocess analysis to give you more choices to observe andmonitor the process than ever before.

Now, for the first time, the CQM II can be used on non-TEterminators, allowing you to standardize and provideTE crimp quality monitoring across your production area.

The CQM II is an effective crimp quality monitor giving100% real time crimp heightmeasurement whenused on applicatorstyle terminators.



Bench TerminatorsBench Terminators

The BT 752 delivers three processes in a single device: stripping,seal loading and crimping. Reliability and top production performancecoupled with the user friendly TopTouch interface are the featuresthat make this semi-automatic device such a compelling product.The BT 752 is an economical alternative to fully-automatic machines.

BT 752 Stripping, Sealing and Crimping Machine

BT 712 Bench Top Crimping Machine

This all-purpose press accommodates the useof all common commercial crimping tools.

The software (in 12 languages)can be operated from a smalltouch screen interface (TCI).The benchtop press also includesa service tool with a datamemory for storing up to500 articles, for makingbackups and for uploadingupdates. The crimp force analyzerthat comes with the press detectsgood and bad wires reliably and givesa detailed description of errors.

Proven and useful options such as short projectingcable, bad contact cutter (BCC), fine adjustment and acontact strip chopper can all be integrated in the pressto boost efficiency and process quality even more.

� Ultra-short setup and cycle times� Ultra-simple changeovers� Active quality control� Integrated crimp force analysis� Simple operation with TopTouch� Seal applications compatible

with mci 761, mci 762 and bt 700

� Simple and intuitive controls (TopTouch, TCI)� High daily output due to ultra-short cycle time and changeovers� Reliable bad part detection thanks to integrated quality monitoring� Integrated crimp force analysis� Good value for the money



Bench Terminators

The BT 722 crimping machine is used for the manual crimpingof contacts. The BT 722 is operated from a touch screen.The new TopTouch user interface allows jobs to be set upquickly and easily. Even during production set up, themachine operator is prompted to conduct quality measure-ments. Following the input of the calculated values in theuser interface, the crimp height is automatically corrected.This prevents errors arising from the manual setting of thecrimp height.

Only one crimp is needed for referencing the integrated crimp force monitoring.This reduces waste material consumption and minimizes set up time. The qualityvalues measured during production are saved and can therefore always becalled up later. This ensures traceable quality at all times.

The programmable DigiStripper (option) is an ideal accessory to the BT 722 crimpingmachine. This can be set up without any mechanical adjustment. Thanks to the functionszero cut and pull back, as well as the pre-programmablecutting depth, the perfect stripping is ensured.

BT 722 Crimping Machine

� Short setup and cycle times� Active quality control� Simple operation with TopTouch� Integrated crimp force analysis� Integrated handling of bad terminals

SC 15 QC Stripper Crimper

With the SC 15 QC, you can strip and crimp solid and stranded wire.The machine processes side-feed contacts with 1 or 2 carrier stripsup to a max. 0.5 mm material thickness.

With the cam control system, a high level of crimping force and repetitiveaccuracy can be attained. The pneumatic control allows for product-independent, individual settings of the remaining machine functions.

The tool holder of the machine was conceived for a three-piece interchangeabletool. When a non-specified crimp connection is recognised by the crimping forcemonitoring system, the cable clamping device remains closed. It will only openif the reset button on the crimp quality monitor is pressed. The starting require-ments and the complete cycle sequence can be monitored with the LED displayon the front of the machine.

When the guard door is opened in automatic mode, the electrical and pneumaticenergy supply is interrupted by means of the emergency-off function. The design ofthe machine is service-friendly. There are interfaces for the parameter remote diagnosis.

� Automatic bare wire detection during crimping to deactivatestripping and suction and to switch the CQM at this level.

� Crimp force monitoring with statistic analysis (optional).� Individual parameter setting via software.� Testing and setting the various functions in setup creep speed.� Wire sizes range from 0.09 to 4.00 mm2� Insulation diameter: 0.5 to 3.6 mm� Stripping length: 12 mm and less, depending on the number of wires� Wire insertion depth: 10 mm� Flexible work light� Excellent work area visibility� Low operational noise


Hand Tools


Hand ToolsIDC Bench Terminators

Bench Machine for AMP DUOPLUG 2.5 Connectors

TE Connectivity offers the IDC semi-automatic bench machine that appliesAMP DUOPLUG 2.5 connectors (application specification 114-18049)which are widely used within the household appliance industry.The connectors are delivered on trays. Depending on the machineversion the tray feeding can either be manually or automatically.Both machine versions with manual or automatic tray feed canbe equipped with keying rib test and/or wire insertion length testas an option. The testing stations help to detect badly terminatedconnections and/or badly keyed connectors.In case of a bad detected connector/connection the IDC bench topmachine gives the operator a clear text message and instead of closing thecover, the machine waits for the operator to remove the unclosed connectorby hand. The operator may have to remove a complete sequence evenif only one bad connector/connection has been detected.

� Termination of single wires to AMP DUOPLUG 2.5 IDC connectors� The connectors are loaded either semi-automatically or automatically from the tray.

The image shows a machine version with automatic feed.� Testing stations are available optionally. They help to ensure termination quality

according to the respective specification.

SIM 25C and SIM 50C Compact Semi-Automatic IDC Machinesfor RAST Connectors

Both the SIM 25C and SIM 50C are compact semi-automatic stand-alonebench machines for processing RAST connectors which are widely usedwithin the household appliance industry. They are a cost-effectivealternative to the SIM E machines with better labor utilization andcomparable functionality at the same time.

The SIM 25C machine applies AMP DUOPLUG 2.5 Mark II and/orDUOPLUG power connectors whilst the SIM 50C machineprocesses AMP multifitting Mark II connectors.

These machines separate the foremost connectors from theinlayed chains, cut the latches and position the connectors for termina-tion. The wires are placed into the machine manually by the operator,the machine will then check the wire insertion length, separate thecover from the connector and place them into the housing, cut thecoding-ribs in accordance with the input coding and present the finishedconnectors for removal by the operator via the outfeed.

The machines can be loaded with up to 2 chained connector-chains with differentnumbers of positions into one sequence. All required data input can be doneconveniently over a 4 inch color touch screen.

� Compact stand-alone machines for single wire IDC termination� Cost-effective base machines for market entrance into RAST business

with medium labor utilization� Newly designed software� User-friendly human machine interface



This semi-automatic machine can process dependent on version AMP-LATCH or Micro-MaTch connectorswith ribbon cables. The housings are fed into the bench machine from a reel and terminated onto ribbon cable.Female connectors with and without center polarisation can be processed, oriented in both directions, utilisingthe integrated turn-table.

A completed harness assembly is ejected from thebench machine and a new connector is automaticallyfed into position. In this simple way, over 1000 con-nections can be produced per hour. The sensor-controlled operation of the machine ensuresease of use and high-quality ribbon cable assemblies.

Semi-Automatic Bench Machine for Micro-MaTch Connectors

IDC Bench Terminators

CHAMPOMATOR 2.5 Semi-Automatic Bench Machine

The CHAMPOMATOR 2.5 terminating machine is a compact, semi-automatic bench machine for terminatingmulticonductor, jacketed cable with a variety of TE Connectivity connectors having insulation displacement contacts.

� Low applied costs� Terminates most jacketed cable� Straight (180°) or right-angle (90°) wire dress� Microprocessor controlled� Programme storage capability� Selective termination of connector positions� Rapid tooling changeover for different connector types



Hand ToolsIDC Bench Terminators

MT-Matic Mark III for IDC Connectors

Dependent on type the machineis able to terminate different IDCconnectors semi-automatically.Placement of the connectors inthe magazine and positioningof the wires is a manual process,termination of the wires into theconnector is automatic.The connector and wire layout isprogrammable via keyboard ortouch screen.

As a help to the operator thewire insertion sequence is dis-played in color on the monitor.

Different machines are availableto terminate different connectors.

Operation without too much difficulty is a feature of this manual pressfor the application of AMP-LATCH connectors and ribbon cables.

A ribbed cable guide plate in the die ensures an exact positioningof the ribbon cable during processing. The swiveled cable stopensures that the cable end finishes flush with the housing.

Hand Operated Bench Machine for AMP-LATCH Connectors



Wire Preparation Equipment

Kappa Cut and Strip Family

The Kappa family strippers are ideal for cutting individual and special wiresto length and stripping them. They can strip in sections, allowing themto strip even extremely long length in perfect quality. The machines coveran extraordinarily broad range of cross sections.

Kappa 310, 320, 322, 330 and 350 strippers support a variety of processingoptions such as wire marking with hot-stamp or ink jet markers.Hot stamp marking can even be done on the Kappa 310 stripper,the entry-level model.

New Kappa Generation:

� Dynamic, flexible cutting and stripping unit� New intelligent sensors� New electronic and software� Optional TopWin connection

AT-FE 0400 Strip Box

The strip box is an electric driven machine to strip standard PVC(polyvinylchlorid) wires up to an outside diameter of 4.2 mm.Due to the low weight the AT-FE 0400 machine can be placedon nearly every workplace.

� Electrically driven� Simple adjustment� Easy handling� Stepping switch for manual operation� Small space required� Practically maintenance-free� Clear cut through insulation by special shape of cutting blades / 4 cutting blades� Continues adjustment of wire size and stripping length

Kappa and TopWin are trademarks.



Lead Makers

Gamma 255 Fully Automatic Crimping Machine

The Gamma 255 lead maker is a flexible fully automaticcrimping machine for efficient wire processing.It processes cross sections in a range from 0.0123 mm2/AWG 36 to 2.5 mm2/AWG 14. It is compatible with allcommercially available applications. It also handles double-ended crimped wires as short as 20 mm. The entire crosssection is processed using programmable, highly dynamicservo-drives and V stripping blades.

As part of its standard equipment, the machine has aprefeeder, splice, wire-end and knot detection, as well astwo wire straightening units. A bad wire handling systemwith automatic post-production is also integrated in theGamma 255 lead maker. To verify quality, you can alsointegrate devices for measuring crimp height and pull-outforce right into the production process. The compactlayout is carefully thought-out and allows you to changeover from crimping to twisting, fluxing and tinning very fast.

With its vertically opening safety cover, the Gamma 255 leadmaker is readily accessible from all sides. Operations andmaterial handling are convenient and simple. The reliableTopWin software user interface adds to this high level of userconvenience in over 20 different languages.

Although compact in size, this fully automatic crimping machinecombines simplicity and functionality with economy and processreliability to deliver a high piece output. It is a real hit when it comesto obtaining excellent value for money. Whether you opt for the

roller or belt drive, you can adjustthe use of this device to yourindividual needs and be doingso yourself in no time at all.

� Small investment for high production output� Belt or roller drive in one machine for gentle

wire handling� Well known and proven crimping press technology� Compact and user friendly on small floor space� Highly ergonomic thanks to the

touch screen control

Gamma 263 Fully Automatic Crimping Machine

The machine is designed for one and two-sidedcrimping and for one-sided seal loading. The wiretransport system ensures gentle processing ofvarying conductors with cross-sections rangingfrom 0.13 mm2 to 4 mm2 (26–12 AWG). Proven qual-ity monitoring systems are integrated. A secondintegrated encoder ensures maximum length andrepetition accuracy for stripping and wire length.




Lead Makers

Gamma 333 PC and Gamma 333 PC-BFully Automatic Crimping Machines

The Gamma 333 PC lead maker is a flexi-ble fully automatic crimping machine forefficient wire processing. It processescross sections in a range from0.13–5.0 mm2 (AWG 26–AWG 10).

Short conversion times, additional appli-cations and a user-friendly user interfacewith multiple-language capability. TheGamma 333 PC and Gamma 333 PC-Blead makers (B-version with beltdrive)makes it all possible! With its thirdprocessing station and state of the artcontrol software, you are provided highflexibility and an even more efficient wayof meeting your wire processing needs.

With an additional processing station onside 1, the Gamma 333 PC lead maker en-ables you to crimp both ends of the wire,to create double crimp connections withthree different contacts, to carry outone-ended seal application, tinning orink-jet marking.

In addition, process monitoring is allintegrated to ensure that the wire is cutto length and stripped perfectly.

� Exact reproducible settings forprocessing stations

� Maintenance-free step and servomotor of top quality

� Very short conversion times thanks tointegrated processing modules

� Highly comfortable and convenient tooperate thanks to graphic-basedTopWin software

� User specified language – morethan ten different languages tochoose from

� Integrated good/bad sorting� Can be networked with additional

WPCS (Wire Processing Communica-tion Standard) software




Lead Makers

Alpha 355 Lead MakerThe Alpha 355 lead maker is designedfor one and two-sided crimping and sealloading. It even handles double-crimpconnections involving varying lengths andthe same wire types without any problem.The precise dual-channel blade systemallows for a large range of wire sizes with-out blade changes. With options like themanual wire selector and/or the quick-change system for crimping tools,materials and tools can be prepared forthe next job while the machine is running.

� Short changeover times� Reliable process monitoring� High production output� Setup of next job while production of

current job is underway� WPCS (Wire Processing Communica-

tion Standard)� Q-monitoring, CFA+ (Crimp Force

Analyzer), SPM (Seal Position Monitor)

Alpha 355 S Lead MakerThe Alpha 355 fully automatic crimpingmachine is a proven performer and nowavailable in a model offering the flexibleselection of modules. The high safetycover and the flat table design is the moststriking difference between this versionand the Alpha 355 lead maker. It allowsprocessing modules not specifically de-signed for certain machines to bemounted. One of the two module slots oneach processing side is fitted with specialmounting tables to accommodate thevarious mounting methods. Combinedwith the ingenious open-ended softwareinterface, the flexibility of the Alpha 355 Slead maker can be increased.

� Flexibility in module selection� Reliable basic machine� Open-ended software interface� WPCS� Q-monitoring, CFA+ (Crimp Force

Analyzer), SPM (Seal Position Monitor)

Short setup and changeover times, integrated quality measurements,and top performance are the three main features of the Alpha 355fully automatic crimping machines.

Alpha 355 and Alpha 355 S Fully Automatic Crimping Machines

Alpha is a trademark.



Lead Makers

Alpha 356 Fully Automatic Crimping Machine

The Alpha 356 fully automatic crimpingmachine has room for up to sevenprocessing stations.

A wide variety of configurations arepossible, in fact, almost any combinationof crimping, seal loading, fluxing/tinning,twisting, fitting with insulating sleevesand end sleeves for strands as well as bulkturned contacts and customer-specificprocesses. In a configuration featuringthree crimping presses, for example, youcan crimp the three wire ends for double-crimp connections with different contactsor select different articles without amachine changeover.

With the rotating wire selector and theTopWin user software, you can completemost of the preparations for the next jobwhile the current one is still being pro-duced on the machine.

Crimping tools, contact rolls and otherapplication-specific parts can be changedwithout tools. Thanks to the use of themodern technology, the productionoutput – and the degree of processcontrol – is extremely high in this machinegeneration.

� High flexibility with up to sevenprocessing stations

� Both standard and customer-specific processes can beintegrated

� Wide choice of different processingconfigurations

� High productivity thanks to thelatest technology

� Integrated quality measurements� Next job can be prepared while

machine is processing current job� Can be used in a networked system

by using WPCS (Wire ProcessingCommunication Standard ) interface.

Alpha and TopWin are trademarks.



Lead Makers

Alpha 433 H Fully Automatic Crimping Machine

� High flexibility with up to fiveprocessing stations

� Short changeover times� Maximum ease of operation thanks

to TopWin user software� Networkable with WPCS interface� Modern quality monitoring� Belt drive for high processing speed� Extensive range of accessories

The Alpha 433 lead maker is a flexiblefully automatic crimping machine forefficient wire processing. Large wiresno longer pose a problem. The machineis capable of processing large wiresfrom 0.20–16 mm2 / AWG 24-6 (fine-wire conductors). The P104 crimpingpress delivers the required force toprocess large terminals. Terminalscan be crimped on both ends butseals can also be loaded at one end.Wire processing to very exactingstandards – great versatility withoutconversion. The Alpha 433 fullyautomatic crimping machine is basedon state of the art technology andis designed for processing singleconductors as well as double crimpconnections.




Lead Makers

Alpha 477 Fully Automatic Crimping Machine

The Alpha 477 fully automatic doublecrimping machine allows you to processtwo different wires simultaneously toproduce your choice of double crimpor single wires. The two wire drivesare fitted with highly dynamic AC-servoaxes and an integrated anti-slip system.With this sophisticated handlingtechnology, two wires can be fed inparallel and their ends cut to lengthand terminated in a controlled process.Wires are handled gently throughout.

With four processing stations at the leadtermination and two at the trailing end,you have a large number of possibleprocesses at your command.

� No conversion required when switch-ing from double crimp to single wireproduction

� Double crimp connections can beproduced side-by-side or one abovethe other

� Integrated head separation and batchsorting

� Active good/bad wire sorting� An ergonomic layout assures the

operator optimum accessibility andminimal walking/reaching distances

� mci 722/mci 712 module ensure superbflexibility and shorter changeovertimes

� Integrated quality monitoring– CFA (Crimp Force Analyzer),– SPM (Seal Position Monitor)with automatic post-production ofdefective parts

� Accommodates up to six processingstations

� Great ease of operation thanks toTopWin software

� Networking possibilities with reliableWPCS and special software



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Lead Makers

Alpha 488 S Fully Automatic Crimping Machines

The Alpha 488 S produces fully automati-cally twisted-pairs out of two single bulkwires completely cut-to-length and termi-nated, with all quality controls included.The modular composition of the systemprovides superb flexibility. Four process-ing stations at the wire beginning and twoat the wire end offer extensive processingpossibilities. The machine layout accom-modates up to six processing stations.The system can also be used for the pro-cessing of two untwisted isometric singlewires and is available in the versions offour, seven and ten meters.

In combination with the crimping modulesmci 722 or mci 712 and the seals modulemci 765 C as well as with the quick-changesystems and the integrated quality moni-toring systems the Alpha 488 S ensureshigh process reliability and extremelyshort changeover times.

The optional interface WPCS (Wire Pro-cessing Communication Standard) allowsthe machine to be networked under Top-Win. With this open interface, the ma-chine is easy to integrate into existingproduction sequences.

� Complete processing of two singlebulk wires into twisted pairs withprocessed ends

� Fully automatic twister featuring well-proven as well as innovative qualitymonitoring systems formaximum process control

� Highly reliable and proven TopWingraphical user interface on touchscreen for efficient machine use

� Networking possibilities with reliableWPCS




Lead Makers

Zeta 633 and Zeta 633 L Fully Automatic Crimping Machines

Zeta 633 harness maker is a highlyflexible fully automatic crimping machineused for just-in-time production.With its flexible machine concept, theZeta 633 harness maker opens up manypossibilities for handling small jobs andwire sequences.

Up to 36 conductors are available for wirefeed without changeover. Wire transportcan be adapted to the specific propertiesof each conductor. Applying the looptransfer principle, the device feeds thetwo wire ends of the loop individually oneafter the other to the appropriate pro-cessing station.

Modules can be configured as desiredalong the entire length of the Zeta 633harness maker. That means total flexibilityfor each area of application. The Zeta 633standard machine accommodates up tofive processing stations, the Zeta 633 LVersion even 8 processing station.If need be, both Zeta versions can besuccessively expanded and still havespace for additional processing stations.

The wires can be bundled or deposited inpredefined order as a chain.

� Up to 36 different conductors can beprocessed without changeover

� Station layout can be definedas desired

� Full integration of existing processingstations

� High processing quality� TopWin software: Existing user

expertise can be applied immediately.� Excellent accessibility and safety� Expandable� Prepared for Zeta 651 and Zeta 655

machines� Fully integrated quality monitoring

with good/bad sorting� Customer specified special applica-

tions possible

Zeta and TopWin are trademarks.



Zeta 651 Fully Automatic Processing Machine

Teamed with the highly flexible Zeta 633fully automatic crimping machine, theZeta 651 can produce harnesses with sin-gle and double-row blocks using single-sided loading.

The Zeta 633 basic machine with inte-grated wire feed accommodates up to36 wires without changeover. Modules canbe configured as desired along the entirelength of the machine. That means totalflexibility for each area of application.

The Zeta 633 fully automatic crimpingmachine applies the loop transfer principleto feed the two wire ends of the loopindividually one after the other to theappropriate processing station. With theZeta 651, the contacts are mechanicallycentered prior to loading and optionallyrotated, if need be. The use of the reliableloading head and the process monitoringsystems of the Zeta 656 ensure optimumloading. The entire loading process ismonitored, from insert in chamber tocorrect locking. Blocks are fed auto-matically and can be replenished whilethe machine is running.

Feed and deposit can be adapted tomeet the respective needs of the specificcustomer.

Blocks are automatically fed using acustomer-specific vibratory bowl feederor linear feeder. You can replenish themwithout interrupting processing whilethe machine is running.

� Fully automatic block loading� Full integration into TopWin software� Integrated process monitoring with

good/bad separation� Automatic block feed� Blocks can be replenished while

machine is running.� Economical production of harnesses

undergoing single-sided loading

Harness Makers

Zeta and TopWin are trademarks.



Zeta 656 Fully Automatic Processing Machine

The Zeta 656 harness maker is a blockloading robot designed to take intoaccount the ever smaller sizes of pro-duction batches. Thanks to its machinedesign, the Zeta 656 harness makerallows investment costs to be amortizedin parallel on different types of wireharnesses, markedly reducing the costper lead set. The Zeta 656 harness makerallows new applications to be sub-sequently incorporated. With the flexiblepallet carousel, the most varied types ofwire harnesses can be produced just-in-time and changeover times are very short.All the operator has to do to change overto a new type of block is switch the twopallets. The loading of each and everyblock is monitored and controlled by aforce sensor.

The Zeta 633 basic machine has a36-wire changer and several crimpingstations with automatic crimp heightadjustment, allowing far more than300 different wire/terminal variations

to be processed without any changeoverat all. In combination with a machineextension, another four processingstations can be accommodated.Moreover, wire marking systems can beconnected, allowing different wireswithin the same harness to be markedwith the operator’s choice of black orcolored text.

� Extremely broad variety ofharnesses on one machine –no application-specific parts

� New applications can be easilyadded later on

� Economical even for tinyproduction batches

� Non-contact position recognitionfor the terminals

� Uniform top quality processing –high degree of process reliability

� Integrated quality monitoringwith good/bad sorting

� Short amortization period

Harness Makers

Zeta is a trademark.



IDC Harness Makers

IHM Mark III Fully Automatic IDC Mass Termination Machine

The IHM Mark III is a flexible high performance fully automatic machine for mass jumper production.Interchangeable IDC workstations ensure the processing for different IDC connector systems within short set up time.

The complete manufacturing process includes

� Mulitple wire feeding (up to 21 different wires)� Connector loading (2.5 mm and 5.0 mm pitch)� Mass termination of the wires� Connector polarization and key cutting� Quality control� Cover closing and colour marking

The quality control system is integrated in the IDC connector stations and includes bothinsertion length and electrical continuity testing.

� Modular processing equipmentwith interchangeable IDC stations

� Possibility to process 2.5 mm and5.0 mm pitch in the same harness

� Extremely high output for processingup to 21 parallel wires in mass termination

� Very low set up times thanks to the fullymodular design of the machine

� Modular processing equipmentwith interchangeable IDC stations

� Possibility to process 2.5 mm and5.0 mm pitch in the same harness

� Extremely high output for processingup to 21 parallel wires in mass termination

� Each connector processing module isfully independent and contains all theprocess features necessary for theparticular product (i.e. polarization/coverclosing etc.)

� Easy maintenance� Production assistance and trouble

shooting via modem� Simple and ergonomic operator

interface with touch screen control



IDC Harness Makers

The FHM IDC offered by TE Connectivity isa fully-automatic machine for cost effectiveharness production. Used in conjunctionwith our well known interchangeableSIM XX E work stations, it is able to processRAST 2.5 and RAST 5 connector systems atthe same time, specifically designed for thehousehold appliance market.

The machine excels in the flexibility itoffers. It is capable of processing crosssections in a range from 0.22–1.5 mm2.The wire selector allows as standardto have 6 different wires loaded.

This modular designed fully-automaticmachine is capable of producing IDC-harnesses, featuring, apart from parallelwiring, also crossovers and bridges.

It is specifically designed to meet cus-tomer’s demands for minimal set up andchangeover times, while providing highoutput including various quality assurancechecks.

FHM IDC Flexible Harness Maker

Flexible Harness Maker-IDC consists of:

� FHM IDC base machine with operating interface via touch screen� Universal wire selector up to 12 positions, prepared for 6 wires� Servo controlled transport gripper system� Possibility to run with one or two SIM E Workstations

Applicable semi-automatic IDC Machines economy orflexible Versions and Connectors:

SIM 25 E or F for AMP DUOPLUG 2.5 Mark II and AMP DUOPLUG 2.5 powerSIM 26 E or F for AMP DUOPLUG 2.5SIM 50 E or F for AMP multifitting Mark IISIM 52 E or F for AMP MONO-SHAPE

The following harnesses can be manufactured:

� Parallel designs� Crossovers� Bridges� Loose end connections� Connections with varying wire lengths and sizes.

Both, RAST 5 and RAST 2.5 connectors can be processed simultaneouslywith all of these options, depending on the SIM workstation.



SIM 50E / 51E / 52E / 25E / 26E Modular IDC Workstations

These semi-automatic machines have been designed to apply all TE Connectivity RAST 2.5 and RAST 5connectors used within the Household Appliance Industry. The machines are configured as base machineswhich can be extended through a variety of production enhancing options. The machines configurability leadsto an economical and application specific solution.

Connectors are separated automatically within the machine. Key cutting and checking are all automaticprocesses. The wires are inserted one by one manually and the machine controls the wire insertion lengthautomatically. Any rejects are separated automatically. One sequence can contain up to 12 positions in a5 mm pitch or up to 23 positions in a 2.5 mm pitch. The SIM Economy Series are designed to be used eitherwith the FHM IDC fully-automatic machine or as stand alone machines.

These Machines are compatible with followingIDC Connector Systems:

� AMP DUOPLUG 2.5� AMP DUOPLUG 2.5 Mark II� AMP DUOPLUG 2.5 power� AMP DUOPLUG 2.5 power 10A� AMP multifitting Mark II� AMP MONO-SHAPE

Available options

� Active wire clamping� Electrical continuity test� Wire bending (not for SIM 25E)� Cover marking� Conversion kit for AMP DUOPLUG 2.5 Mark II

(only for SIM 25E)� Conversion kit for AMP DUOPLUG Power

(only for SIM 25E)� Conversion kit FHM IDC machine� Modem remote maintenance

Basic configuration

� Automatic product feeding� Latch-cutting and separation� Key cutting and checking� Wire termination� Wire length checking� Cover closing� Good bad sorting� Simple and ergonomic operator interface

with touch screen control

Workstations for FHM IDC Flexible Harness Maker



Equipment for Heat Shrink Products

AD-3050 Seal Test Equipment

Raychem RBK-ILS Processor MKIII

The AD-3050 seal test equipment is a manually operated pneumatic device,intended for use as a convenient ‘inprocess’ sampling technique for checkingsealed splices.3 versions available: a standard “Bubble-Tester”, an AD-3050 withintegrated timer and a special-tester for big cable-/wire-diameter up to 35 mm2.

� Fast determination of sealing integrity and multiple test fixtures� Easy load and release of test samples� timer also as retrofit kit only

CV-Obhat 1600 W Stub-System /On-Board Splice Sealing Stub-Splice and Inline-Splice Variant

IR-1891 Shuttle and IR-1891 Shuttle-AIR

The CV-Obhat system is a lightweight, portable hot air tool,used to install Raychem Splice Sealing products such as QSZHand ES-CAPS on-board.

� Capable of producing sealed stub and in-line splices on-board� Wire support and cap holding fixtures integral part of pistol� 6 pre-sets for free programming available� Lightweight pistol connected to controller with 6 m umbilical

The IR-1891 is suitable for the installation of a wide range of Raychem heat-shrinkable tubing productsonto a variety of small components, e.g. ring terminals, FASTON terminals and small connectors, etc.

The IR-1891 Shuttle AIR comes with an additional forced cooling device.The installation temperature/power as well as the cooling time on the AIR-versioncan be varied according to product type/size and required cycle times.

� Automatic cycle start once heater is manually positioned over product,which gives improved process control (recommended for adhesive linedheat-shrinkable tubing e.g. sealing applications)

� Automatic heating head retraction at end of cycle prevents damageto components

� Multiple product fixture assemblies give increased process rates� Cooling fan above each fixture assembly maintains holding fixture

at an acceptable temperature

The RBK-ILS processor MKIII is a semi-automatic unit designed to installsplice sealing products onto ultrasonically welded or crimped splice jointsused in automotive harnesses.

� Long life heating elements� Installation times, temperatures, and product size information

(individual selection)� Sequenced installations� Automatic calibration (single cycle)� RS232 interface allows communication with a remote machine (e.g. an ultrasonic welding tool)� Signal output to exchange datas with any external customer device (PC, Server)� Air cooling can be provided to an optional stub splice fixture in the RBK-ILS processor Mark III – processor



Automated Testing Equipment for Electrical Wiring and Components

Customized testing solutions for aerospace, defense, marine andrailway as well as for automotive or industrial products, from themodule to the vehicle.

Coverage of the process chain from small part manufactureto pre- and final assembly and maintenance.

Test systems for fully automated wiring and function tasks areavailable from compact bench top testers up to distributed testsystems for large UUTs (Units Under Test) as well as high voltagetest tables.

Function Test Solutions

Detailed information can be found at www.tooling.te.com www.tooling.te.com/europe 41

PCBProcessingEquipment

Pin Insertion Machines

P 100 Pin Insertion Machine

The semi-automatic P100 machine belongs to the TE Connectivity pininsertion system line. Designed and manufactured with a focus on mid-volume level production, the P100 machine provides a broad range offeatures at a very competitive price. With the ability to apply productsfrom TE Connectivity and other manufacturers, the P100 machine doesnot limit your production to “TE Connectivity only” applications andprovides flexibility to address both current and future tooling needs.

The P100 machine uses a pneumatic power unit together with productspecific “quick change” tooling packs. The insertion heads can beequipped with a rotary insertion finger that can apply products atdifferent angles without decreasing the insertion rate. The toolingpacks can be exchanged within 30 minutes to meet your full rangeof application requirements.

CE approval is in process.� X/Y-Table with stepper motors� Database driven software for simple programming and automatic setup� “Quick change” tooling packs allow easy and fast setup� Wide range of tooling packs for TE and non-TE products available� Easy-to-use operator interface

P 50 Insertion Machine

The successful product line of single pin insertion machines has beenexpanded with the addition of a manual operated bench machine forlow volume production, repair work and sample production.

The P 50 manual bench insertion machine uses a tracer slide to positionthe PCB under the pneumatic insertion head. A regular PCB is usedas master to position the indexing pin above the insertion hole.When activating the two hand start, the indexing pin extracts.If a hole is detected, the terminal is inserted into the boardin production.

To fulfil automotive requirements, the P 50 insertion machinecan be equipped with an insertion force monitoring system.In cooperation with an optional barcode scanner, theinsertion forces can be stored for traceability purposes.

� Pneumatic insertion head can also be usedon other machines of the product line.

� Conversion kits can be changed without too muchdifficulty to run different terminal types.

� Conversion kits can also be installed on motor-driveninsertion heads used on P 200, P 300 and P 350 machines

� Terminal insertion is possible at different angleswithout the need to re-load the PCB indifferent orientations.



Pin Insertion Machines

M2000MC Automatic Insertion Machine for Fuses and Relays

With the CE approved M2000MC automatic insertion machineTE Application Tooling provides a high-quality solution forhigh-volume production within the automotive industry.

The M2000MC automatically inserts mini fuses intoa Junction Box (J/B) according to the programmedsequence, ensuring that the correct fuses are insertedin the correct location for consistent quality.The machine reduces the number of operators requiredin the production process, increasing productivity in thefactory whereat the operator needs to ensure that machineis supplied with junction boxes and fuses.

The M2000MC can also be optionally equipped withinsertion force monitoring and insertion depth control.

Outstanding Features deliver tangible Benefits

� Dependable high-volume production� Insertion depth checking by linear scale� Insertion force monitoring – checking maximum

force during insertion� OCR (Optical Character Recognition – vision sensor checks

color or characters on the components) of fuse beforeinsertion to prevent wrong fuse insertion

� No stopping of production during supply to the bowl feeder� Robot arm with ionizer that cleans inside the robot arm� XY table positioning� Up to 6 heads (fuse)

P 300 / P350 Fully-Automatic Machines for PCB Processing

For the automatic assembly of printed circuit boards, the basicP 300 machine is equipped with a product specific insertionhead. A speciality is the rotary insertion finger which allows theproducts to be inserted in different angles of rotation.

A XY table, powered by servo drives, positions the printedcircuit boards under the insertion head. Up to 4 motor driveninsertion heads, each equipped with a terminal specific conver-sion kit, allow the application of up to 4 different products.Available accessories like

� Insertion Force Monitoring� Vision System for position detection and program correction� Flip unit to insert terminals on both sides of a PCB� PCB transfer belts for an in-line installation� Pin length detection� Traceability features such as reel scan, board scan, etc.� Motor driven insertion head for continuous wire products� Tool changer for up to

4 Insertion heads andlower tools allows theP 300 to be adaptedto the most variedmanufacturing tasks.



Board Processing Equipment

TE Connectivity offers a wide range of machines for processingpress-fit connectors.

The range includes bench presses with a press capacity of 5 tas well as semi-automatic machines with automatic seating ofconnectors before pressing, including a number of qualityassurance systems.

All presses are servo driven, providing a constant press forceover the entire press range. In conjunction with the pressquality monitor, included with all presses, this ensures aconsistently high process quality.

Press-Fit Systems

CSP-3T Shuttle Electric Press

The CSP-3T servo electric press incorporates an automaticshuttle system to the proven TE press line for fast and simpleproduct presentation. Focused at the application of PCB’sonto compliant pin housings, this system is provided withfull control and monitoring of force, distance and speed forquality assurance of every product applied.

Each system is supplied with a servo electric drive withforce feedback control. Force capacity is available up to27 kN [3 t] to handle a range of compliant pin housings andconnectors on the market today. Compared to pneumaticor hydraulic systems, the CSP Press is quiet, efficient, anddoes not suffer from oil leaks that can damage PCBs.With PC control, the servo driven CSP Press provides aneasily programmed press system with automatic set upfrom press cycle to press cycle.

Force, distance and speed are the core parameters of anypress cycle. With feed back and PC control, CSP systemscan monitor and control each characteristic of every pressstroke run on the press in real-time. If any aspect of thatpress cycle is outside of specified limits, the system canstop the press, mid-stroke, to prevent damage to theproduct and reduce or eliminate scrap. This gives CSPsystems a distinct advantage over pneumatic or hydraulicsystems which can not offer the same level of control.Optional pin penetration sensing (PPS) tools also allowthe CSP to assure that every pin has properly penetratedthe PCB a predetermined minimum distance. Any missing,bent or improperly seated pins will be detected andillustrated to the operator.




The CBP-5T of servo electric pressprovides the ability to processmost compliant pin connectorapplications in a compactbenchtop system. Board sizecapacity and press force rangeallows the system to handle a wide range ofapplications for low to medium production volume operations.

Each system is supplied with a servo electric drive withforce feedback control. The CBP is available in 44 kN [5 t]force capacity to handle most compliant pin connectorson the market. With PC control, the servo driven CBPprovides an easily programmed press system with automaticset up from press cycle to press cycle. The system reacheslevels of precision and accuracy not available in a pneumaticor hydraulic press.

Force, distance and speed are the core parameters of any press cycle.With feed back and PC control, the CBP system can monitor andcontrol each characteristic of every press stroke run on the pressin real-time. If any aspect of that press cycle is outside of specifiedlimits, the CBP can stop the press, mid-stroke, to prevent damageto the PCB and reduce or eliminate rework and\or scrap.Common problems such as PCB holes out of tolerance, missingconnectors, improper connectors used and, in some cases, bentpins can be detected and reported to eliminate quality problems.

CBP-5T Electric Bench-Top Press

CMP-6T and CMP-12T Manual Electric Servo Presses

The CMP manual electric servo presses are designed with a rigid “H” frameto minimize deflection. The CMP-6T press provides 53 kN [6 t] of force andthe CMP-12T press provides 107 kN [12 t] of force. The operator is able tomanually adjust the press head and/or the PCB between connectorpress cycles.

An air bearing system provides effortless press head positioning.The PCB capacity of the CMP-6T press is 610 x 915mm [24 x 36”]and the PCB capacity of the CMP-12T press is 760 x 900mm [30 x 36”].The SPC feature within the CMP’s included software provides a presslog and in addition, allows press force plotting for every connector.

The product setup for these machines is accomplished without anyrequired hardware adjustments. The use of tool and connector databases,and a press sequence program, provides a fully data driven press cycle.

There is a wide range of insertion heads available for these machinesfor both TE and non-TE products.

Options for these machines include a bar code scanner, whichprovides fast PCB serial number entry, an air table option that assiststhe operator when positioning product under the press head, and atouch screen monitor for enhanced machine operation.




The CAP-6T automatic electric press is the latest addition tothe successful TE Application Tooling servo press line. It providesthe proven force control capabilities and quality assurance of theline in an automatic press. The automatic pressing capabilitiesof the CAP-6T press provide the end user with greater controland simplified processing to help improve quality, lower reworkand prevent rejects. This provides users with lower true appliedcost and higher end profits. The in-line version of the CAP-6Tallows the integration of the press into a fully automaticproduction line.

The CAP-6T press was designed to apply compliant pin con-nectors to a wide range of PCBs. It is fully capable of handlingthe most demanding applications today from daughter cardsto mid-planes to back-planes. The CAP-6T press is focused atall but very large board applications. This press can also holdup to 12 insertion tools and uses a lower support fixture.

Compliant pin technology has distinct advantages versus through hole solder products. A key advantage is the ability tomonitor and control the press cycle in real-time to provide 100% quality assurance. The CAP-6T Press gives your opera-tion the ability to maximize this advantage with higher quality, higher yield and lower applied cost production line.

The key is the CAP-6T’s ability to precisely and accurately apply each connector to the pre-programmed force, heightand speed requirements. Each parameter can be individually programmed for each connector. Connectors can bepressed to height or force based upon their individual specifications. If an error is encountered during the press stroke,the cycle is stopped immediately to help prevent damage to the PCB and allow for the minimum amount of re-work.

CAP-6T Automatic Electric Press

CSM-200 Connector Seating Machine

PCB and connectors are loaded manually into fixtures. Whenstarted, the machine checks the correct loading of the connec-tors before placing the connectors onto the PCB. The tool thenmoves under the press ram where the connectors get pressedone after the other onto the PCB. The BMEP 5-T servo-electricpress is used to seat the PCB which provides a force-distancecheck to ensure quality production.

A special tooling plate allows the sequential pressing of anumber of different pre-loaded connectors. An intermediateplate, positioned between the PCB with its pre-positionedconnectors and the flat rock press ram contains the connectorspecific press tools. For each connector a force distance curveis available after completion.


SpecialApplications

Magnet Wire Equipment

MAG-MATE and SIAMEZE Inserter Mark II

MAG-MATE Insertion Machine

Insertion Tools

Pneumatic Insertion Tool forMAG-MATE Terminals

The pneumatic tool for MAG-MATE terminals features a rotaryinsertion finger to facilitate different insertion angles.

This tool is designed for use in TE Connectivity standardinsertion machines such as P200 and P300 but can also beintegrated into customized production lines or assembly cells.

TE Connectivity magnet wire terminations are a perfectconnecting alternative to all soldering techniques usedin a lead-free environment. Special knowledge isrequired to design a mass manufacturing line for insula-tion displacement crimps on thin lacquerd insulatedwires with high yield. Design aspects of the terminal,the cavity and the machine all need to be harmonized.With the Inserter Mark II TE can offer an economicsolution especially for the application of MAG-MATEand SIAMEZE terminals.

� Magnet wire application� 1 to 4 contacts can be applied

per machine cycle� Can be used as bench machine or

can be integrated in an assembly line

� Insert loose piece terminals into molded cavities� Available quickly for prototyping application requirements� Available for each type of MAG-MATE terminal

This insertion machine provides a gastight, electrically correct connectionbetween magnet wires and contacts using the insulation displacementtechnique without the prior removal of the lacquer.

The MAG-MATE machine is designed to apply multiple different contactsand will be customized according to the customer or product specificrequirement. The machine can be used as a stand alone bench machineor may be integrated in an assembly line. A maximum of four contactscan be applied per machine cycle. This also gives the opportunity to usethe contacts as single contacts or in strip form (bridge function).


SpecialApplications

Magnet Wire Equipment

The machine was especially developed for processing magnet wireconnections. Different versions for end-feed and side-feed contactsare available. The design takes into account that the motorwindings and coils can be supplied directly tothe connectors. The exposed crimp positionpermits precise handling. In case of endconnections the projecting magnet wiresare cut off.

AMPLIVAR splices and terminals are specifi-cally designed to terminate magnet wiresor in combination with standard solid orstranded wire. In a one-step operation themagnet wire is automatically multiple ringstripped of its insulation as it is forced into theserrations during the precisely controlled crimpingoperation.

As many as three magnet wires can be terminated,simultaneously in one splice. Nearly the entireAMPLIVAR splice programme can be applied withthis machine in combination with suitable applicators.The comprehensive range of manufacturing possibilitiesdemands a specific machine and applicator combination.

AMPLIVAR Terminator for Parallel and End Connections

The newly designed APT-5A AMPLIVAR productterminator, magnet wire splicing machine for pigtailsplicing or direct connection of contacts to magnetwire. The APT-5A machine offers a fast and efficientsystem, with no need to strip magnet wire insulation.

The APT semi-automatic bench machines provideCE compliance and are available in two versions:

– APT-5A with automatic precision adjustmentcontrolled by the crimp quality monitor (CQM),and improved efficiency when runningcustomer-motor assemblies.

– APT-5E with manual precision adjustment.

In addition to providing 100% inspection and automaticadjustment of crimp heights as needed, the CQM also evaluatesthe quality of each crimp. In addition to the ability to auto adjustfor a given crimp height, the APT-5A also provides the ability to programvarious crimp heights and automatically sequence through them as requiredto terminate different wire combinations on a given motor.

The lower cost, manual adjust APT-5E is a simpler version without CQM capability,with the advantage of faster set up time. Both machines are built with the qualityand reliability our customers come to expect from TE Connectivity.

APT-5A AMPLIVAR Product Terminator


SpecialApplications

FFC Equipment

Hand Tool for FFC ConnectionsThis tool allows crimp connections to be made between foil andFFC terminals. Flexibility is built in, through the hand tools variablesettings. The settings have to correspond to the specification.The crimp height is adjustable according to the foil thickness.

The hand tool was designed for FFC loose pieceterminals with multi-crimp barrel.

� FFC foils with 2.54 mm pitch� Max. width of the foil 88 mm� Manual foil feed

by hand wheel� Table clamp for

ergonomic handling

The termination machine is an electrical driven semi-automatic assembly machine that usesdifferent applicators to terminate reel-feed FFC contacts to manually supplied FFC cables.

The machine terminates a predefinded number of contacts to the supplied cable end.Individual wire positions can be skipped during the assembly sequence.

� Alignment of the cable is effectedin the machine

� Number of pins can be programmed� Pitches between 1.27 mm and

5.08 mm can be programmed� Individual wire positions

can be skipped� Operator friendly interface

via touch screen� Interchangeable appli-

cators available fordifferent products

� Quick change ofthe applicator

FFC ApplicatorThe FFC applicator was desinged for the FFC termination machine.The adjustment of the crimp hight is similar to other TE ApplicationTooling crimp applicators. All wear parts are easy to change.

Different types are available for following terminals:� FFC MQS terminals� FFC Junior Timer terminals� FFC AMPMODU .100 terminals� FFC AMPMODU .050 terminals� FFC Card Edge� ACTION PIN contacts� FFC soldering contacts


SpecialApplications

Application Tooling for Processing Small Wire SizesA range of application tooling solutions is available toembrace the current trend in the automotive industry towardsusing wires with increasingly smaller cross sections.

Thinner stranded wires require crimp connections with smallercontacts such as the NanoMQS, MQS and other contactsystems that allow stranded wires to be processed up to aminimum of 0.13 mm2 cross section.

Miniaturization of the connectors place higher demand bothon the processing machines and tools as well as the machineoperator. The hand tool, crimp tool, and fully automaticmachine manufacturers have addressed the issue of process-ing small wire sizes by equipping the machines with tailoredcomponents to ensure reliable and secure processing.

To process crimp contacts both hand tools and applicatorswith pneumatic feed or motorized contact feed can be used.

For automatic processing the quality of the crimp connectioncan be recorded with standard commercial crimp monitoringsystems, modified to accommodate the small cross section.

Example:The Alpha 355 lead makercan be equippedwith specialapplicationtooling kits andapplicators forsmall wire sizes.

Available tooling and accessories for the processingof small wire sizes:� Hand tools for crimping NanoMQS and MQS contacts� OCEAN Applicator with pneumatic or servo-motor

contact feed� Fully automatic crimping machines, equipped with special

part kit to apply small wire sizes from 0.13–0.22 mm2.� Komax Zeta, with automatic housing loading, customized

for small wire applications

The crimp tool was developed specifically to process small wires. Using this tool ensures thatmanual work on the vehicle cabling – during repair work or low-volume production for instance –is done on the quality level of fully automated large scale original equipment manufacturing.

On top of these generally high quality standards this crimp tool was also tuned to offer excellentergonomics. To achieve this, the tool was designed as compact as possible, keeping in mind thatit needs to be handy for areas with limited handling space.

Among the many advantages are:

� Six crimp nests in a single tool head� Exchangeable crimp die head� Slideable crimp die ensures application of force in a straight line (no tilting of the dies)� Locator for proper contact positioning� Wire stop� Proven and durable tool body


SpecialApplications

High Voltage Application ToolingWith fossil fuels in increasingly short supply and a growing environmentalawareness, almost all car manufacturers are now offering electric poweredvehicles. The current focus is on hybrid technology. To direct the powercreated to the various units, the contact components need to be sizedaccordingly. The high voltage contact system covers the 16–50 mm2cross section range.

To date the batch totals have been relatively small, which means that themanufacturing process has been carried out by hand in several stages.

Special stripping devices with a coil mechanism are usedin the wire preparation, which consists of separatephases of marking the wire, stripping, trimming

and reeling. The challenge here is to handlethis kind of wire dimension, as the process

can quickly produce wire weighing in excessof 30 kg.

Another challenge is to process the braid.Here we now apply the processing conceptdeveloped by TE Application Tooling, thusmaking the process steps of crimping the

wire and shield into a semi-automated and checked process operation.

The crimping machine uses applied encodings to detect whether the righttool has been used. The operator now joins the contact part to the wirein the specified crimp position and fixes the wire with a clamping device.The crimping process can now begin through two-handed operation.When the wire has been crimped, the crimp cavity carriage is movedto crimp the braid.

Monitoring the crimping process with proven crimp monitoring systems andusing a PLC ensures a high quality crimp connection. It also ensures that theoperator carries out the processing stages in the right order using all thecomponents. Only when the crimp monitoring system certifies a good crimpand the programmed process stages have been observed can the fullycrimped wire be removed.

The crimping machine used has been designed to allow the applicator to bereplaced by another without too much effort. This allows all the latest highvoltage contact systems to be processed.

Depending on the contact being used, crimping force monitoring can beused for checking the wire crimp. The PLC that is used ensures that allthe processing steps are performed in the specified sequence and withthe necessary care.


SpecialApplications

High Voltage Application ToolingOwed to the increasingly limited fossil fuel resources and a generally growingenvironmental awareness, practically all vehicle manufacturers offer vehiclemodels with electric drive train components. The current focus in Europe,for instance, is on hybrid electric cars.

To conduct the necessary high voltages and currents to the individual compo-nents within this type of application, the terminals need to have a sufficientdimension. Therefore the current high voltage interconnection system coverswire sizes between 16 and 120 mm2. The hydraulic application tools are suitedfor the ultimate interconnection quality.

TE Application Tooling together with renowned tool manufacturers offersapplication tooling based on a hand tool in order to support the economicproduction of high voltage harnesses in low volumes. During developmentof the hydraulic manual crimp tool and crimp dies for connections of a veryhigh quality, tool ergonomics ranged particularly high. The portfolio includesdies with contact locator for the wire crimp and shield crimp. In addition themanual hydraulic crimp tools can be mounted on a rack which is equippedwith a cable clamp. The rack can be fixed onto the workbench.

Among the many advantages of this design are:

� High-quality crimp connections� High-precision contact and

crimp barrel positioning� Easy set up� Safe and simple operation� Cable clamp prevents tensile loads

during crimping� Economic and flexible production

of small lots

With the bt 214 shield processing machine, extremelydemanding requirements for the processing of highvoltage (HV) lines can be satisfied.

A specially developed technology is used to cut backthe braided shield and slip it over the sleeve, which isloaded manually for the time being. The insulation ofthe inner conductor is not demaged in the process.

Cable specific blade sets can be changed quickly and easily.

� Reliable controlled process for cutting back braidedshield on high voltage cables

� Processing of multiple core cables� Short processing times� Large outputs� Consistent quality


SpecialApplications

Application Tooling for Aluminum ConductorsAluminum is a good conductor of electricity. In the carindustry, within many areas this lightweight material is inthe process of replacing copper in power cables. Thereare two key advantages in using aluminum: lower materialcosts and – even more importantly – considerably lessmass than copper.

A fully automated process uses a specially tailored crimp-ing tool to create contacts with the aluminum strandedconductors. This results in productivity comparable to whatis achieved in processing conventional copper conductors.

Some special requirements of aluminum processingapplies to the entire manufacturing process:

wire de-reeling, align the aluminum stranded lead, strip-ping, positioning the lead in the applicator and crimpmonitoring system. The special crimp design calls fora new crimp monitoring system.

All of these challenges are fully satisfied thanks to theinnovative design of the crimping tools, specially adaptedstandard machinery and optimum coordination of theindividual processes involved.

The aluminum-F-crimp can be processed fully automatically usingstandard machines.


SpecialApplications

Application Tooling for Aluminum ConductorsAt TE Connectivity, aluminum is a familiar material to us.For high-voltage applications, we have successfully devel-oped the COPALUM crimp connector for contacts withaluminum conductors. The connector has proven itself inthe field. For stranded conductors made of aluminum weoffer tried and tested solutions with AMPLIVAR crimping

technology and the related group of products. The under-lying findings based on these products went into thedevelopment of the new aluminum F-crimps byTE Connectivity. Our development goal: Process-stable,reliable contact using aluminum stranded connectors,with the kinds of cross-sections found in automobiles.

� Secured electrical connection� Effective corrosion protection� Fully automated processing� Tailored termination equipment

Proven during extensive use:COPALUM crimp connector forcontacts with aluminum conductors.

The applicator, similar for aluminumand copper, is individually adjustedfor crimping.


FieldService

ServiceTE Connectivity provides global field service support on our application tooling. Field specialists are locatedacross every continent to provide timely response to customer needs. In addition to installation, warranty andrepair service, TE Connectivity field specialists can help you with equipment choices, training of maintenanceand operation personnel, troubleshooting assistance and spare parts. Service contracts to cover all yourapplication equipment needs are also available. We have implemented a service management tool thatprovides standardization of reporting that gives us the ability to continuously improve our global serviceorganization. Throughout the year we educate our field service engineers on the latest industry technologiesand equipment. See for yourselves the advantages of our professional consultation and individual services.Our qualified service teams are ready to assist you.

Service Offerings:

Standard ServiceIncludes troubleshooting problems, making repairs,and/or installing parts.

Express ServiceProviding express service form Monday to Friday,apart from official holidays to start service inter-ventions within the express service time frame.

Equipment InstallationsProviding installation, set up and training of applica-tion equipment at the time of delivery.

TrainingProviding customers with practical training programsaddressing machine operation, set up, maintenance,inspection, and connector application. Trainingprograms can be scheduled at the customer’s siteor a TE Connectivity training center. A trainingcertificate will be issued upon the completion ofeach formal training course.

We are proud to be able to offer a comprehensiverange of customer training programs. The followingare some of the standard training programs we offer:

� 4901 Basics Seminar Crimp Technology� 4902 Basics Seminar Working with Applicators� 4904 Working with Hand Crimping Tools� 4906 Flexible Flat Cable (FFC) Crimp Technology� 4907 Basics Seminar of Crimp Technology

for Machine Operators� 4910 Enamelled Wire Connection Technology� 4911 Advanced Seminar in Crimp Quality� 4912 Advanced Seminar in Crimp Force Monitoring� 4913 Advanced Seminar on Microsections� 4914 Pin Insertion Technology� 4930 IDC Technology

Repair in HouseProviding repair capabilities in the TE workshop forsmall equipment and hand tools.

Hand Tool CertificationProviding hand tool certification capabilitiesin the TE workshop.

Service Contracts:

Service AgreementProvides service at attractive service terms forperiodic visits to perform preventive maintenance,inspection calibration, installation, set-up, training,spare parts management, equipment processevaluation and technical assistance on applicationtooling and/or product related problems orconcerns.

Hand Tool ContractProvides hand tool certification on customer site.Hand tools certification is recommended within aninterval of 6 months or 5000 cycles, whicheverthe sooner.

“A service agreement and/orhand tool contract ensures

equipment optimization, improvesproduction quality and reduces

quality complaints”

Short Term Rental of Crimping ApplicatorsApplicators are being increasingly required at shortnotice for a limited period. This may include prepro-duction runs, prototype series, and the subsequentproduction of single part requirement or simply smallseries production. It is often uneconomical to pur-chase a crimp tool or to rent it on a long-term basis,when it is only required for a few weeks in the year.Our short-term rental service has applicators readilyavailable for you, which you can return whencomplete with your rental period.Your local TE Connectivity representative will gladlyinform you about the availability of an appropriateapplicator for your specific need.


Engineering Notes

CompleteSolutionsfromStarttoFinish

While TE has made every reasonable effort to ensure the accuracy of the information in this catalog, TE does not guaranteethat it is error-free, nor does TE make any other representation, warranty or guarantee that the information is accurate,correct, reliable or current. TE reserves the right to make any adjustments to the information contained herein at any timewithout notice. TE expressly disclaims all implied warranties regarding the information contained herein, including, but notlimited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions in this catalog arefor reference purposes only and are subject to change without notice. Specifications are subject to change without notice.Consult TE for the latest dimensions and design specifications.

Disclaimer

CompleteSolutions

fromStartto

Finish

ACTION PIN, AMP, AMP DUOPLUG, AMP-LATCH, AMPMODU, AMPLIVAR, AMP MONO-SHAPE, CERTI-CRIMP,CHAMPOMATOR, COPALUMG, FASTON, MAG-MATE, Micro-MaTch, MQS, NanoMQS, Raychem, SIAMEZE, SOLARLOK,TE Connectivity and TE connectivity (logo) are trademarks.

KOMAX and MOST are trademarks.

Other products, logos and company names mentioned herein may be trademarks of their respective owners.

Tyco Electronics AMP GmbHa TE Connectivity Ltd. companyAmpèrestr. 12–1464625 Bensheim / GermanyPhone +49-6251-133-0Fax +49-6251-133-1600

www.te.com

Tyco Electronics AMP GmbH certifiedacc. ISO 14001 and ISO/TS 16949:2002

© 2013 Tyco Electronics AMP GmbH, a TE Connectivity Ltd. company.All rights reserved.

1654180-5 Revised 10-2013.

FOR MORE INFORMATION PLEASE REFER TO

www.tooling.te.com

FOR REGIONAL ASSISTANCE PLEASE REFER TO

www.te.com/support-center

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