SW Alpha 4xx Zinc en

Software Manual
for E480 / D901

Wire processing machines
alpha 4xx
Art.No. 035722 - Version 3
SWA alpha 4xx 1

Editor:
komax AG
Industriestr. 6
CH-6036 Dierikon-Luzern
Telefon 041 - 455 0 455

Telefax 041 - 450 15 79
Telex 868 291
As of date January 1997, subject to change
The reproduction of these manual or parts thereof, in whatever form, is prohibited without the
express written permission of the publisher.
© 1997 by komax AG, Wire processing systems
2 SWA alpha 4xx

Table of contents
1. Introduction and notes ..................................................................................................... Page 7
1.1 Validity of this manual ...................................................................................................... 8
1.2 Changes in this software .................................................................................................. 8
1.3 How to use this manual ................................................................................................... 8
2. Safety .......................................................................................................................................... 9
2.1 Safety notes ................................................................................................................... 10
3. Overview of operating elements .............................................................................................. 11

3.1 Controls for alpha 411 / 421 / 422 .................................................................................. 11
3.2 Controls for alpha 432 .................................................................................................... 11
3.3 Keyboard operation of alpha 432 ................................................................................... 12
4. Screen layout ............................................................................................................................ 13

4.1 Control window symbols ................................................................................................ 14
4.2 Control elements used ................................................................................................... 15
4.3 Control keys and their functions ..................................................................................... 16
5. Office and training software .................................................................................................... 17
6. Switch-on and starting ............................................................................................................ 19

6.1 Switch-on ....................................................................................................................... 19
6.2 Log-in ........................................................................................................................ 19
6.3 Switch-off ...................................................................................................................... 20
7. Software concept ..................................................................................................................... 21

7.1 Production process ........................................................................................................ 21
7.2 All set-up values are stored ........................................................................................... 23
7.3 Processing of data even during production .................................................................... 24
8. Wire and processing data ........................................................................................................ 25

8.1 Processing the wire data ................................................................................................ 26
8.2 Processing the main processing data ............................................................................ 27
8.3 Processing the preliminary processing data ................................................................... 28
8.4 Deleting data ................................................................................................................. 29
8.5 Storing and loading data ................................................................................................ 30
9. Article data ............................................................................................................................... 31

9.1 Processing the article ..................................................................................................... 32
9.2 Assigning the wire and the preliminary processing ........................................................ 34
9.2.1 Assigning the wire and the preliminary processing on the alpha 432 ................ 34
9.3 Assigning main processing for side 1 ............................................................................. 35
9.4 Assigning main processing for side 2 ............................................................................. 36
9.5 Establishing wire sequences ......................................................................................... 37
9.6 Ink-jet interface preliminary processing field .................................................................. 38
9.6.1 Defined marking ................................................................................................ 38
9.6.2 Scatter marking ................................................................................................. 38
SWA alpha 4xx Table of contents 3

9.7 A1 preliminary processing field (Auxiliary 1) ................................................................... 39
9.7.1 Hot-stamp marking during cutting ..................................................................... 39
9.7.2 Hot-stamp defined marking .............................................................................. 39
9.7.3 Intermediate stripping ....................................................................................... 40
9.8 Deleting the article data ................................................................................................. 40
9.9 Storing and loading the article data ................................................................................ 40
10. Set-up ..................................................................................................................................... 41

10.1 Set-up procedure ......................................................................................................... 41
10.2 Setting up the processing stations ............................................................................... 44
10.2.1 Open and closed contact ................................................................................ 44
10.2.1.1 Crimp force anlayser komax 325 PC .................................................. 44
10.2.2 Seals ............................................................................................................... 46
10.2.3 Tinning ............................................................................................................ 46
10.2.4 Twisting .......................................................................................................... 47
10.2.5 Sleeves ........................................................................................................... 47
10.2.6 IDC and komax 521 ........................................................................................ 48
10.2.7 Positioning the wire with the swivel unit .......................................................... 49
10.3 Setting up the modules ................................................................................................ 50
10.3.1 Double crimping of wires ................................................................................ 50
10.3.2 Fluxing ............................................................................................................ 50
10.3.3 Post-processing of trailing end ....................................................................... 50
10.4 Setting up the preliminary processing stations ............................................................. 51
10.4.1 Setting up the ink-jet marker ........................................................................... 51
10.4.1.1 Ink-jet scatter marking ...................................................................... 51
10.4.1.2 Ink-jet defined marking ...................................................................... 51
10.4.1.3 Set-up window ................................................................................... 51
10.4.1.4 Defining the typeface and position ..................................................... 52
10.4.2 Setting up at Auxiliary 1 .................................................................................. 52
10.4.2.1 Defined marking ................................................................................. 52
10.4.2.2 Marking during cutting ........................................................................ 53
10.4.2.3 Intermediate stripping ........................................................................ 53
10.5 Setting up the belt drive and the cutting head .............................................................. 54
10.5.1 Belt drive ........................................................................................................ 54
10.5.1.1 Belt drive on the alpha 432 ................................................................ 55
10.5.2 Cutting head ................................................................................................... 55
10.6 Special settings ........................................................................................................... 56
10.6.1 Transfer on the alpha 421, 422 and 432 .......................................................... 56
10.6.2 Wire deposition on the alpha 411 .................................................................... 57
10.7 Threading the wire in and out ....................................................................................... 58
10.8 Single step ................................................................................................................... 59
10.8.1 Single step side 1 ........................................................................................... 60
10.8.2 Single step side 2 .......................................................................................... 62
10.9 Single stroke ................................................................................................................ 63
10.10 Quick programming .................................................................................................... 64
10.11 Other commands in set-up mode .............................................................................. 64
4 Table of contents SWA alpha 4xx

11. Producing ...................................................................................................................... Page 65
11.1 Input of piece number and batch size .......................................................................... 66
11.2 Commands prior to starting production ........................................................................ 66
11.3 Starting production ....................................................................................................... 67
11.4 Automatic post-production ........................................................................................... 68
12. System settings ..................................................................................................................... 69

12.1 Ink-jet interface ............................................................................................................ 69
12.2 komax 325 crimping force analyser .............................................................................. 70
12.3 Machine options ........................................................................................................... 71
12.4 Timing settings ............................................................................................................. 73
12.5 Printer settings ............................................................................................................. 74
13. Managing the personnel list .................................................................................................. 75

13.1 Editing a personal entry ............................................................................................... 76
14. Quality data record ................................................................................................................. 77
15. Error messages ...................................................................................................................... 79

15.1 Machine errors ............................................................................................................. 79
15.2 Errors from external monitoring devices ....................................................................... 80
15.3 Warnings and messages .............................................................................................. 80
16. Annex ...................................................................................................................................... 81

16.1 Cleaning the mouse ..................................................................................................... 81
SWA alpha 4xx Table of contents 5

6 SWA alpha 4xx
1. Introduction and notes
Dear Customer,
These automatic CNC-controlled komax alpha wire processing machines usher in a new generation of
wire processors.
The software manual describes the komax alpha software. This mouse-operated windows software is
very convenient to operate and features symbol-based input aids, on-line language change and on-line
data review of wire and machine parameters.
Carefully read through the software manual. It will guide you step by step through the programming of
the komax alpha software and have you successfully using the program in no time at all.
Yours truly,
komax AG
SWA alpha 4xx Introduction and notes 0.1 7

1.1 Validity of this manual
This software manual is valid for the alpha models 411, 421, 422 and 432.
It is valid for the software versions E480e and D901e and higher.
Although most photos in this manual are of English screen masks for the alpha 422, they differ only
slightly from photos for the other alpha models.
Figures and information in this manual are subject to technical changes that improve the software.
The programming of the optional komax sigma block loading module for the alpha 432 is not described
in this manual. This system is covered in a separate software manual.
1.2 Changes in this software

The following changes were made in relation to the predecessor versions E480/D901 a, b,c and d:
The complete operations and analysis functions of the komax 325 crimp force sensor are integrated into
the alpha user interface (Chapter 10.2.1.1).
The installation of office and training software has changed (Chapter 5).
The creation of sequences for markers has been eliminated (Chapter 9.5).
A "calibration limit" feature has been added to the recording of quality data (Chapter 14).
1.3 How to use this manual

This software manual is available in German, English, French, Italian, Spanish and Portuguese. Other
languages are also available on request.
The manual is an integral part of the machine. It should be kept within easy reach of the machine at all
times. Only then can the operator make maximum use of it, especially for quick reference.
The first section of the manual, from Chapter 1 to 7, helps you become acquainted with the software
and familiarizes you with the user interface.
The middle section, from Chapter 8 to 11, describes the actual software used for daily work involving
operating data, set-up and producing.
The last section, Chapter 12 to 14, contains chapters you need only refer to occasionally, e.g. to change
the machine configuration, assign passwords, error messages, etc.
Read through the manual carefully, paying very close attention to the next chapter on
safety notes.
8 Introduction and notes SWA alpha 4xx
0.1
2. Safety
It is crucial that you read the chapter on safety (Chapter 2) in the operating instructions.
You must understand the machine's safety concept if you are to prevent accidents while
operating the komax alpha.
Always keep the following points in mind when using the software:
Emergency stop switch

There is an emergency stop switch on the operators panel at the front of the control
console. Pressing it immediately stops all machine movements and cuts off the power
to the processing stations. The emergency stop switch may only be used in an
emergency, when a person or the machine is in danger.
To release the pressed button, press it again and turn.
Operating mode selector switch

The machine control system distinguishes between two production modes: set-up and production (also
called automatic mode). The operator can switch from one mode to the other with the selector switch.
Setup mode
- The set-up window appears on the screen (see Chapter 10 ).
- The safety shields can remain open, but the approval key has to be pressed along
with
any command which results in a machine movement.
Production mode
- The production window appears on the screen (see Chapter 11).
- The safety shields must be closed. Opening a safety shield in automatic mode triggers
an emergency stop. The approval key has no function in this mode.
Approval key
If you are in setup mode and select a command which triggers a machine movement,
the movement is only carried out if you press the approval button at the same time with
your other hand.
SWA alpha 4xx Saftey 9

2.1 Explanation of the safety notes
The note boxes in this manual are marked with three different symbols, each having a different meaning.
This symbol marks a safety note on work procedures that may be dangerous for you or
other people. Heed these warnings and be very cautious when performing this work.
Pass these warnings on to all other users.
This symbol marks work steps that must be performed correctly to prevent damage to
the machine. Pass these safety notes on to all other machine users, too.
This symbol prefaces useful tips and information on how to proceed and act correctly
around the machine. Observe these notes and you will save yourself time as well as
needless headaches.
10 Saftey SWA alpha 4xx

3. Machine overview
3.1 Controls for alpha 411 / 421 / 422

pic 3.01
pic 3.02
1 2 3 11
8 9 10
4 5 6 7
3.2 Controls for alpha 432

1 Screen
fig 3.03
2 Keyboard
3 Mouse, refer also to Chapter 16.2 on cleaning
the mouse
4 Approval button: Press to trigger a machine
6 7 10 movement in setup mode
5 'O' button: Press to turn off operating voltage
6 'I' button: Press to turn on operating voltage
7 Operating mode selector switch: machine
setup or producing
8 Emergency stop button Stops the entire
machine in the event of an emergency
9 Stop button for current production
10 Start button for production
11 PC with external disk drive to save and load
5 4 9 3 1 2 8 data
SWA alpha 4xx Machine overview 11

3.3 Keyboard operation of the alpha 432
The oil-proof sealed keyboard is not sensitive to dirt and can be cleaned off with a cloth. It is used to
operate the software and to make alphanumeric inputs.
With F1, the control keys to operate the software without a mouse can be called up anywhere in the
program (refer also to the next page).
Many keys are assigned multiple functions; for example, the letters A to Z have to be entered over the
numeric field.
For example to enter PC:
Press these two keys
and then these two keys
12 Machine overview SWA alpha 4xx

4. Screen layout
The window user interface has a very clear, user-friendly layout. The alpha software utilizes ten main
symbols (also called icons or pictographs). Clicking one of them opens the corresponding work window
which contains input fields, scrollable list fields or other control elements.
The photo below shows a typical screen layout:
Command field with other symbols

Title of the work window
Control bar with the ten main symbols to select the work window
Display of HELP text for the current input field

Action fields to perform a command directly
This symbol is only activated in conjunction with the optional sigma block loading system.
The actual work field with input, control and text fields
SWA alpha 4xx Screen layout 13

4.1 Control window symbols
New log-in with personal number and password or language change ..................................
....................................................................................................... see Chapters 6 and 13
With the office software only! Exit program; this window is used to end the program in the office
and training software ....................................................................................see Chapter 5
Setting up and producing the article ............................................. see Chapters 10 and 11
Recording the article; the various components of the wire to be produced are recorded here,
e.g. the wire itself and the main and preliminary processing involved .......... see Chapter 9
Wire list; the wires to be processed are recorded here .............................. see Chapter 8.1
List of preliminary processes; for recording the devices used in marking and stripping ......
.................................................................................................................. see Chapter 8.3
List of main processes; for recording the types of processing on the stations, e.g. contacts,
seals, sleeves, tinning, etc. ....................................................................... see Chapter 8.2
Defining the machine settings and the options to be used ..................................................

................................................................................................................... see Chapter 12
Personal number and password management ............................................ see Chapter 13
The alpha automatically creates a production log which also contains all the measured values
from the komax 325 crimp force sensor ...................................................... see Chapter 14
This window displays the current version of the PC and machine program, the name of the user
who has logged in, and information about the PC memory.
14 Screen layout SWA alpha 4xx

4.2 Control elements used
The program inputs are made using different control elements depending on the window in which the
user is working. The table below summarizes all the control elements and their functions.
Element Name of the element What it is used for
Symbol fields The symbol fields are used to call up a sub-

menu in which further inputs can be made.
Action fields Clicking this field with the mouse triggers an

action at the push of a button.
For actions with serious consequences such
as Delete the program asks for confirmation to
prevent unintentional data loss.
Alphanumeric fields The fields are used to input text and numeric
values for settings.
Scrollbar lists The scrollbar opens when the upper right-hand

corner is clicked. One item must be selected
from the list that appears.
Selection fields One function must be selected from a list of

settings.
ON/OFF switch fields A function is switched on or off by clicking the

switch field.
Multi-column tables Display of recorded data. Select the item you

would like to edit. The entire table can be
viewed by pressing the right/left cursor keys.
SWA alpha 4xx Screen layout 15

4.3 Control keys and their functions
The user interface can be controlled by either the mouse or the keyboard. This window can be opened
in the software by pressing the F1 HELP button.
Key Function
Tab and Moves the cursor from one group to the next (boxes)
Shift-Tab
Arrow keys Moves the cursor within the groups
Alt-Space Switches the program between the main window and the current work window
Alt Switches the program between the toolbar (also command field, gray area along
the top of the window) and the white area of the window.
Enter Completes the entry, makes a selection or opens the scrollbar list
F1 Opens the HELP window
ESC Closes the HELP window
16 Screen layout SWA alpha 4xx

5. Office and training software
A special office and training software is also available for the komax alpha.
It simulates the alpha software and can be used as a training tool or for entering operating data when
work preparations are carried out on an external PC.
The office and training software is identical to the machine software except that the machine commands
for set-up and producing are not included. Please note the following:
System requirements
IBM-compatible PC, 386 or higher
3½ external disk drive
approx. 5 MB of hard disk memory
VGA graphics adapter
4 MB RAM
and DOS 5.0 or higher
Installation
Switch on the PC and proceed to the DOS input.
Insert the ALPHA Office+Training F018 diskette into the 3½" drive.
Enter a: or b: to switch to this drive.
The software can now be installed as follows:
install a: or install b: The software is installed in c:\alpha.
install a: /c or install b:/c The software is installed in c:\alpha and a new config.sys and the
autoexec.bat file are created at the same time. A backup copy of the old
system files is created with config and autoexec.old. Use this installation
procedure only if simple installation cannot be run.
Starting the software

The software can be started as follows:
- Leave the diskette in the drive and restart the PC or
- Switch to the c:\alpha directory in DOS and input alpha-Enter.
The login window will appear.
After keying in the password (not required the first
time), select the desired language and machine
type and click OK. The software will be started
accordingly.
SWA alpha 4xx Office and training software 17

Operations
Note the following points when operating the office
and training software:
The set-up and producing commands are not
shown; otherwise, the functions are identical to
those of the machine software.
Use F10 to switch back and forth between the
production and the set-up windows.
The Exit window is used to end the program and
return you to DOS.
Adaptations in the config.sys file (for experienced DOS users only)

You are not permitted to install an EMS driver (emm386, 386max, etc.).
There must be at least 80 open files (files=80)
A mouse driver must be installed (device=mouse.sys)
autoexec.bat may is not permitted to have a share.exe.
18 Office and training software SWA alpha 4xx

6. Switch-on and starting
Before switching on the machine for the first time, check that it is connected to the power
and that all installation work has been done correctly in accordance with the operating
instructions.
If you have reason to believe that the machine cannot be operated safely, DO NOT switch
it on.
6.1 Switch-on
Proceed step by step:
Turn the red main switch on the control cabinet to the right to ON. - The PC then starts and loads the
software.
Shortly thereafter, the log-in window for entering the password appears on the screen.
6.2 Log-in
The following inputs must be made in the log-in
window:
Language Either German, English, French, Italian,

Spanish, Portuguese, Swedish or Dutch can be
selected.
Personal number and password The password

input prevents unauthorized access to your data.
You should enter your own personal data imme-
diately after the first switch-on (see Chapter 13,
Managing the personnel list).
To eliminate the required input of a password on start-up, delete all personal numbers
except the supervisors.
After successful log-in, a connection is established between the PC and the machine control system
(the motor regulator and the inputs and outputs are triggered).
To make the machine ready for operation, the on-load voltage must be switched on with Power On. A
corresponding request appears on the screen.
But first the control system checks to see whether the machine is ready for operation, i.e. that:
- No emergency stop switch is pressed
- Safety doors are not open
- Other machine errors such as no compressed air, etc. are displayed in a separate error message
window
SWA alpha 4xx Switch-on and starting 19

After the on-load voltage is switched on, the machine must still be reset.
Important: For set-up and producing, the machine must be reset, i.e. the machine is returned to a state
defined by the software and all its functions are checked.
The machine is not permitted to be reset when the system setting is being changed (see Chapter 12).
The machine is now ready for operation. You can start recording operating parameters or start production
or set-up; read the next chapter to find out how to proceed.
6.3 Switch-off
Return to the log-in menu,
switch off the on-load voltage by pressing Power Off,
and turn the red main switch to the left to OFF.
The production data and machine configuration that have been entered are not deleted
on switch-off. They remain stored in the databases of the PC.
20 Switch-on and starting SWA alpha 4xx

7. Software concept
7.1 The production process

A wire that is to be processed, also known as an Article, is made up of three different components: the
wire itself, the types of main processing and the types of preliminary processing. The program has four
separate input windows to record these components (refer also to Chapters 8 and 9).
In practice, all components can also be recorded and revised directly in the set-up window, enabling
the user to carry out all the tasks in the set-up window except producing.
The following flowchart shows the entire production process in the set-up window:
Record Wire Record Main processing Record Pre.processing
Open the belt drive / cut- Open the window for the Open the preliminary
ting head window. station or the module. processing / ink-jet in-
terface window.
Accept the current wire; Accept the current type of Accept the current type of
do not record a new one. main processing; do not preliminary processing; do
record a new one. not record a new one.
Record a new wire; Record new processing; Record new prelimin. pro-
see Chapter 8.1 see Chapter 8.2 cessing; see Chapter 8.3
Change the current wire; Change current proces- Change the current preli.
see Chapter 8.1 sing; see Chapter 8.2 processing, see Chapter
8.3
Once the wire is defined, Once the main processing Once the preliminary pro-
set up the wire in the belt is defined, set up the processing is defined, set up
drive / cutting head win- cessing in the station/mo- the marker / the interme-
dow; dule window; see Chapter diate stripper; see Chap-
see Chapter 10.5 10.2 / 10.3 ter 10.4.
Record Article
see next page
SWA alpha 4xx Software concept 21
0.1
Record Article
Set up article by entering the

wire and stripping lengths,
the setting for the transfer,
deposition, etc.
see Chapter 10
Now store all article settings.
Store all settings under the Store settings under a new

current article ID. article ID.
Thread in the wire;

see Chapter 10.7
Produce the wire in single

step, making any adjust-
ments that may be required;
see Chapter 10.8
Change to automatic mode,

indicate the piece numbers
and start production;
see Chapter 11.
22 Software concept SWA alpha 4xx

7.2 All set-up values are stored
If you change settings during set-up, e.g. the wait time at the station or corrections at the cutting head,
the following occurs:
1. The new parameters are accepted by the machine control system and
2. the changed parameters are stored under the corresponding ID.
All settings in set-up are stored under an ID and are therefore always retained.
Settings in the Station window are stored under the main proces-
or in the Module window . . sing ID.
Settings in the Preliminary proces- are stored under the preliminary pro-
sing or Ink-jet window . . cessing ID .
Settings in the Belt drive/cutting

are stored under the wire ID.
head window
Settings in the Transfer window (al- are stored under the article ID.
pha 421, 422 and 432 only)
Settings in the Wire deposit window are stored under the article ID.
(alpha 411 only)
The wire length, the stripping and pull-off length,

the wire sequences, the piece number and the are stored under the article ID.
batch size . .
SWA alpha 4xx Software concept 23

7.3 Processing of data even during production
The alpha software allows you to continue to record article, wire and processing data
even during production. Simply select the main symbol you desire and the correspon-
ding window will open above the production window.
With this software you can also continue to record article, wire and processing data
even when production is interrupted.
The alpha software also enables you to continue to record article, wire and processing
data even when the on-load voltage is switched off, e.g. during an emergency stop.
24 Software concept SWA alpha 4xx

8. Wire and processing data
After this symbol is selected, the corresponding work window
appears on the screen. These windows are used to record the data
which will constitute the finished wire.
The example below shows the work window for recording main processes. It differs only
in name and inputs from the two other work windows. The displayed names are simply
suggestions; feel free to adapt the inputs to your own needs.
1 Title of the work window with display of current drive

2 Only a certain group or all recorded data is listed in the table
3 Display of marked ID
4 Backup symbol; a backup copy of all stored work window data is saved on the diskette. This
safeguards you against a possible loss of data.
5 Hard disk symbol; lists the data from the hard disk C: ; see Chapter 8.5
6 Copy symbol; to store or load the data on a disk; see Chapter 8.5
7 Disk drive symbol; to list the data from the A: drive; see Chapter 8.5
8 To change the marked ID; see Chapters 8.1 to 8.3
9 To enter new data; see Chapters 8.1 to 8.3
10 To delete existing data; see Chapter 8.4
11 Vertical scroll bar, to scroll the table up and down with Page Up and Page Down
12 Information about the current cursor or mouse position (HELP text)
13 Table with the data. The entire table can be viewed by using the right/left and Home/End arrow
keys.
SWA alpha 4xx Wire and processing data 25

8.1 Processing the wire data
To record a new wire or to change an existing one, select the field New or Change in the work window.
The window Processing the wire will appear with the following input fields:
1 - Group
Wires with the same features, e.g. insulation,
cross section, manufacturer, etc. can be put toge-
ther in the same group.
These groups can be listed separately in the
overview table.
2 - ID
Unique identification of such things as the article
number or the manufacturer designation, etc.
3 - New wire
This field enables you to enter a new wire without
leaving the window or reopening it. The existing
data of the active wire is accepted.
Type
Scroll list with a choice of
single sheath and double sheath wires
Color
To input wire color/s
Insulation
To input the type of wire such as FLKD, FLKR etc.
or the type of insulation such as PVC, PTFE etc.
Cross section
To input the wire cross section in mm2 or AWG.
Input range 0.1 - 6.0mm2 or 10 - 26AWG.
The machine accepts these values and sets the
cutting head accordingly during stripping and
cutting. For certain types of insulation, you may
have to correct the values again during setup (see
Chapter 10.5.2).
Name
For wires assigned their own name, this name can
be recorded here.
Info
To input additional information such as setting of
the straighteners or information on the dereeling
system, etc.
For processing large and problematic sizes of wire, komax has an optional conversion
kit available with special blades and grippers (refer also to the section on blade types in
Chapter 12.3 ).
26 Wire and processing data SWA alpha 4xx

8.2 Processing the main processing data
To record data for a new type of main processing or to change the existing data, select the field New
or Change in the work window. The window Edit main processing will appear with the following input
fields.
1 - Group
Types of processing can be put together in a single
group, e.g. the same manufacturers, same parts,
etc. These groups can be listed separately in the
overview table.
2 - ID
3 - New type of main processing
This field enables you to enter a new type of
processing without leaving the window or reope-
ning it.
Station / module
Choice of various types of processing at a module
or a processing station.
The module processes and several of the following station processes are not available
for the alpha 411 model with its just two processing stations.
Type ( with module )

Post processing of trailing end
Joining wires (double crimp)
and fluxing
Type ( for station )

These types of main processing are possible on all
processing stations:
Twisting
Tinning
Applying seals
Open contact
Closed contact
Fitting sleeves
The two types of main processing below are

possible only on the last transfer station:
IDC (insulation displacement connection)
K521 (single-row block loading)
Name
A name can be recorded here (optional).
Info
To input additional information such as the required processing stations, tools, setting of the swivel unit,
etc.

8.3 Processing the preliminary processing data
To record data for a new type of preliminary processing or to change the existing data, select the field
New or Change in the work window. The window Edit preliminary processing will appear with the
following input fields:
1 - Group
Identical types of preliminary processing are put
together in a single group. These groups can be
listed separately in the overview table.
2 - ID
3 - New type of main processing

This field enables you to enter a new type of
processing without leaving the window or reope-
ning it.
Preliminary processing / ink-jet interface

Choice of preliminary processing via the preliminary processing station (Auxiliary 1) or via the optional
komax ink-jet interface board (refer also to Chapter 12.1)
Preliminary processing at Auxiliary 1:

Marking during cutting
Continuous printing with a hot-stamp marker. The
marking is carried out simultaneously to the trigge-
ring of the cutting heads.
Defined marking
Positioned marking with hot-stamp marker. The
number of possible texts is determined mechani-
cally by the marker, e.g. komax 25 hot-stamp
marker has a maximum of 12 texts.
Intermediate stripping
Intermediate stripping at up to six different positi-
ons, e.g. with the komax 38.
Types of preliminary processing with the ink-jet

interface:
Defined marking
Marking of up to 5 different texts (4x positioned, 1x
continuous) with an ink-jet marker.
Scatter marking
Continuous wire marking of individual texts with an
ink-jet marker.

Name
If a type of preliminary processing has a special name, that name can be recorded here.
Info
To input additional information such as the required processing stations, tools, or other settings, etc.
Confirm the inputs with OK. The recorded data appears in the table, which means it is
stored. To conclude an input without storing the data, select the cancel field.
Assign each ID to a group you designate. This will help you maintain an overview when
a large number of IDs are recorded.
8.4 Deleting data

Data stored on the hard disk of the PC and on the floppy disk can be deleted.
For safetys sake, only the data in the current window is deleted. The wire, processing
and article data must always be deleted separately.
Deleting data from the computer hard disk:

Mark the entry to be deleted and click the Delete
field.
This window appears. Delete the marked item or
the entire group.
Click OK. For safetys sake, the deletion must be
reconfirmed. If the deletion is reconfirmed, the
data is lost.
Deleting data from the floppy disk:

Insert the disk into the disk drive and click disk
symbol 1 in the main window.
1 2
All data stored on the disk appears. Mark the item
to be deleted and click field 2 - Delete.
The same window appears as when deleting data

from the hard disk. You can delete the marked item
or all data.

8.5 Storing and loading data
Storing data on a floppy disk:

Insert a formatted disk in the external disk drive.
Go to the table and mark the item to be stored.

1
Click copy symbol 1.
The copy window appears.

Do you want to store just the marked item or the
entire group?
If the same data has already been stored, should
it be overwritten with or without confirmation?
Make the selection and click the OK field. The

selected data is copied onto the disk in drive A.
Make back-up copies of recorded data periodically to eliminate the possibility of losing
data. Use the backup command when doing so (see page 29, item 4). The data is stored
much more quickly with backup than with Store data.
Loading data from a disk:

Insert the disk with the stored data into drive A.
1 2
Click the disk drive symbol 1; the data on the disk
is listed.
Mark the entry for loading in the table and click

copy symbol 2.
The copy window appears.

Do you want to load just the marked item or the
entire group?
If the same data has already been loaded, should
it be overwritten with or without confirmation?
Make the selection and click the OK field. The

selected data is loaded in the C directory on the
hard disk.
To work with the loaded data, click the hard disk 3

symbol 3 after copying is completed.

9. Article data
Selecting this symbol causes the window for selecting the article to appear. The wire you
wish to produce can be created in this window from the three components wire, types
of preliminary processing and types of main processing. (It is also possible to create an
article consisting only of the component wire).
1 Title of the work window with display of the current drive

2 You can list either a certain article group or all article groups
3 ID of the current article
4 Backup symbol; a backup file of the stored data is stored on the floppy disk to eliminate the
possibility of losing data.
5 Hard disk symbol; lists the articles in the C: drive; see Chapter 9.9
6 Copy symbol; to store or load article on a floppy disk; see Chapter 9.9
7 Disk drive symbol; lists the stored articles on the A: drive; see Chapter 9.9
8 To change a marked article; see Chapter 9.1
9 To input new articles; see Chapter 9.1
10 To delete existing articles; see Chapter 9.8
11 Vertical scrollbar; scrolls the article table up and down using Page Up and Page Down
12 The marked article is produced, i.e. either the set-up or the production window is opened,
depending on where the operating mode switch is set.
13 Information about the current cursor or mouse position (HELP text)
14 Table with the articles. The entire table with all the data can be viewed on the monitor using the
right/left and Home/End arrow keys.
SWA alpha 4xx Article data 31

9.1 Processing the article
To record a new article or to change the data for an existing one, select the field New or Change in the
work window. The window Processing the article appears as shown below.
1 Window title
2 Input of article group, articles with the same features (customer, subassembly, etc.) can be put
together in a group. These groups can be listed separately in the overview table.
3 Input of article ID, unique identification of the article, e.g. article number
4 Display of the current wire (in a wire sequence) or determining the number of wires in a
sequence; refer also to Chapter 9.5
5 Increase and reduce the actual wire in a wire sequence, see Chapter 9.5
6 Record a new article A new article can be entered in this field. The current article is stored and
a new article can be recorded.
7 Display and process wire sequence list, see Chapter 9.5
8 Assigning the wire and preliminary processing, clicking this item causes a window to appear
for selecting the wire and preliminary processing (see Chapter 9.2). The wire ID, the color and the
cross section of the desired wire appear under the symbol field.
The wire is recorded directly in this window for the alpha 432 model with double belt drive and
optional wire changer (see Chapter 9.2.1) .
32 Article data SWA alpha 4xx

9 Assigning the types of main processing for side 1, clicking this item causes a window to appear
for selecting the main processing on side 1 (see Chapter 9.3).
10 Assigning the types of main processing for side 2, clicking this item causes a window to appear
for selecting the main processing on side 2 (see Chapter 9.4).
11 Input of the wire length, Input range from 82 to 65535 mm for the alpha 421/422/432
Input range from 60 to 65535 mm for the alpha 411
12 Input of the stripping, pull-off and sheath-stripping length, the bottom input field sheath-
stripping length is only activated in conjunction with double-sheathed wires (see Chapter 8.1).
The input range is determined by the machine and the installed options. If the input is
not in the valid range, the display turns RED.
13 Ink-jet interface, this field is only activated when one of the two types of preliminary processing
ink-jet defined or ink-jet scatter marking is assigned (see Chapters 8.3 and 9.2). Clicking this item
opens the window for entering the marking text and its position (see Chapter 9.6).
14 Auxiliary 1, this field is only activated if it is switched on under machine options (see Chapter 14.2)
and one of the following types of preliminary processing is assigned: hot-stamp cut marking, hot-
stamp defined marking or intermediate stripping (see Chapters 8.3 and 9.2). Clicking this item
causes the window to appear for the marker and intermediate stripping inputs (see Chapter 9.7).
15 Switching the assigned types of processing on and off on machine side 1. The ID of the
assigned type of main processing is shown for each station field.
16 Switching the assigned types of processing on and off on machine side 2. The ID of the
assigned type of main processing is shown for each station and module field.
For alpha models 421/422 and 432, processing can also be carried out at the modules. Module
processing (see Chapter 8.2) can only be assigned if the module is switched on under machine
options (see Chapter 12.3).
If IDC is selected as the type of main processing for the last station, an input field for the chamber
number appears. The chamber number must be entered in ascending order for each sequence
wire.
17 Article name, a special article name can be recorded here.
18 Information field, for recording additional information or comments.
19 Revision status, for entering the recording date or the date a change was made. An index letter
should be added to the date so it is identifiable as a new change, e.g. 28.05.95 A.
20 Information field on the current mouse or cursor position (HELP text).

9.2 Assigning the wire and the preliminary processing
Wire; In the top field the wire to be processed is
assigned to the article. Start by determining the
group, and then select the desired wire from this
group. The recorded inputs such as cross section,
color and the symbol for the wire type are then
displayed.
Preliminary processing; In the bottom field, the

wire is assigned possible types of preliminary
processing. You have your choice of two fields:
Ink-jet interface: The two types of preliminary
processing ink-jet defined marking and scatter
marking can be assigned here.
Auxiliary 1: The types of preliminary processing
intermediate stripping, hot-stamp defined mar-
king and hot-stamp marking during cutting can be
assigned here.
IDs can be assigned for both preliminary processing fields. The application is then limited
to intermediate stripping at A1, because a hot-stamp and an ink-jet marker cannot be
used at the same time.
9.2.1 Assigning the wire and the preliminary processing on the alpha 432
The alpha 432 model has a double belt drive as part of its standard equipment. This drive can be fitted
with an optional wire changer for up to 24 different wires. For this reason, the assignment of wire IDs was
changed for the alpha 432 software.
The IDs are assigned directly in the window for

processing the article. The two scrollbar lists
are used to select first the group and then from
the group, the desired wire ID.
Clicking the wire symbol opens the input win-

dow for preliminary processes shown here.
The possible inputs correspond to those indi-
cated in Chapter 9.2.

9.3 Assigning main processing for side 1
The following types of main processing can be assigned to the two processing stations 1 and 2 on side
1: twisting, tinning, seals, open contact, closed contact and sleeves.
Enter the type/s of processing you desire in the

correct chronological order, from top to bottom.
The example shown here: The first side of the wire
is first crimped with a closed contact and then
fitted with a sleeve.
The station at which the process is carried out need not be entered here; it will be
assigned during set-up. However, the chronological order must be correct.

9.4 Assigning main processing for side 2
No module processing can be done with the alpha 411.
Given the above limitations, the processing stations on side 2 and the modules can be assigned the
following types of main processing:
At the modules: Trimming trailing end, joining wires and fluxing
At the stations: Twisting, tinning, seals, open contact, closed contact, sleeves, IDC and k521
(single-row block loading)
The IDC and k521 processes can be assigned only to the last station on side 2.
The modules can be assigned only the types of processing switched on in the window
System settings under Machine options (see Chapter 12.3).
Enter the types of processing you wish, doing so

in chronological order from top to bottom.
Example shown here: First a seal is applied to the

2nd wire end, then it is crimped with an open
contact. No processing is carried out at the modu-
les.
In the 'Join wire' module processing mode, you must create a wire sequence with at least
2 wires. A sequence may consist of several double crimp and individual wires, too. You
must always switch on module processing if there are two consecutive wires. If you enter
the wrong input, an error message appears.

9.5 Establishing wire sequences
It is possible to create a wire sequence (also wire set or wire harness) of up to 100 different wires all based
on a single wire. Each of the wires can have different properties; that is:
different wire lengths, processing on a station, different stripping dimensions or even up to 24 different
wires on the alpha 432.
Establishing a wire sequence

Click the symbol Sequence list main processing data. The window Sequence list
appears with the recorded wire data.
The table shows the number of sequence wires, the overall length, the stripping and pull-
off length, and the types of processing at the stations, modules and preliminary processing
stations.
Pressing OK concludes the input

Insert causes another sequence wire to be inserted at the point marked
Add causes another sequence wire to be added at the end of the sequence list
Delete causes the marked sequence wire to be deleted
Single wire causes all sequence wires except the one marked to be deleted
The wire data cannot be changed in this table; it is only possible to add or delete wires.

9.6 Ink-jet interface preliminary processing field
This field is active if one of the two types of preliminary processing ink-jet defined or scatter marking
is selected (see Chapter 12.1). The field varies depending on the type of preliminary processing:
9.6.1 Defined marking

If ink-jet defined marking is selected for prelimi-
nary processing, this field appears.
The marking text is listed in the scrollbar list to the
right. Clicking the left symbol field opens the input
window:
4
5
7
2 6
1
Up to six positioned and one continuous text can be entered. Observe the following points:
1 Input field for marking texts side 1 5 Input of marking text

2 Input field for marking texts side 2 6 Input of text position
3 Input field for continuous text 7 Selecting upside-down text Yes/No
4 Selecting the sequence wire 8 Display residual length/wire length
9.6.2 Scatter marking (continuous) 1

If this type of preliminary processing is selected,
a continuous text is printed by the ink-jet marker.
1 Input of marking text
2 Input of distance between one text and the
next
3 Selecting upside-down text; Yes/No
3 2

9.7 A1 preliminary processing field (Auxiliary 1)
This field is activated only in conjunction with one of these three types of preliminary processing: hot-
stamp defined marking, marking during cutting, or intermediate stripping (refer also to Chapter 8.3
Editing preliminary processing). The input varies depending on the type of preliminary processing:
9.7.1 Hot-stamp marking during cutting

In cut marking, the marker is always triggered at the same time as the cutting head of the komax alpha
4xx. The position of the text is determined by the distance of the marker from the cutting head.
The following display appears:
1 Input of marking text

2 Switching marker ON/OFF
2 1
The hot-stamping marker cannot accept the marking text. This input is only for the
machine operator during setup.
9.7.2 Hot-stamp defined marking

If this type of processing is assigned (e.g. with komax 25 wire marker), the following display appears.
The entered marking text is listed in the scrollbar

list on the right.
Clicking the left symbol field opens the following input window:
The inputs are the same as for positional marking with ink-jet markers (see Chapter 11.6).
The marking texts cannot be accepted directly by the hot-stamp marker. They must be
specially set on the marker.

9.7.3 Intermediate stripping
If intermediate stripping (with the komax 38) has
been assigned as one of the processes, this
display will appear.
The recorded data is listed in the scrollbar list on
the right.
Clicking the left-hand symbol field opens the following input window:
3
4
2 1
Up to six intermediate stripping processes can be determined.
1 Input field for intermediate stripping side 1 4 Selecting intermediate stripping during wire cut.
2 Input field for intermediate stripping side 2 Yes/No (see note below)
3 Selecting the sequence wire 5 Display of residual length/wire length
The ON/OFF switch field 4 determines whether the first intermediate stripping process
on side 1 is carried out when the initial cut is made in the wire (used for extremely long
intermediate stripping lengths).
The intermediate stripping width is determined mechanically by the stripper.
9.8 Deleting the article data

To delete an existing input, mark it in the article table and select the Delete field. For safetys sake, the
deletion must be reconfirmed before it is carried out. This recorded article is then lost unless it is first
stored on a floppy disk.
9.9 Storing and loading the article data

The procedure for storing and loading article data is identical to the one used for wire and
processing data. It is described in detail in Chapter 8.5 Storing and loading data.

10. Set-up
After the article has been recorded, the machine is prepared for production in the set-up
window. Click the symbol shown here and turn the operating mode switch to set-up.
setup
Be very cautious when working in set-up mode because machine movements can be
carried out in this mode even when the safety covers are open. Be especially careful that
no other people are working on the machine during set-up.
Also observe the instructions in Chapter 2. Safety in this manual and in the operating
instructions.
The article, wire and processing data can also be recorded and processed in the set-up
window. As a result, all procedures except producing can be carried out in the set-up
window ( see Production sequence, Chapter 7.1).
Successful set-up requires

the machine to be in proper operating condition,
the operating mode selector switch to be at set-up,
the processing stations and any monitoring devices to be set up and the wire to be drawn in up to the
belt drive.
The set-up window
Example of a set-up window for the alpha 422
SWA alpha 4xx Set-up 41

10.1 Set-up procedure
Proceed as follows when setting up the alpha:
1. Define and assign wire and types of processing (only when article has not yet been recorded)
The set-up window can be used to record new wire and processing data, change existing data and
assign them to an article (see Chapter 7.1 Production procedure). Once all the data has been assigned,
proceed as follows:
2. Assign the types of processing to the correct stations
When recording the article to be produced, the

types of processing must be entered in chronolo-
gical order (see Chapters 9.3 and 9.4). The types
of processing are then assigned to the stations in
the set-up window; the various types of proces-
sing may be switched.
The arrow symbol is used to change the types of
processing to the way they are actually set up on
the stations.
3. Set up the processing stations

Start by checking the symbol fields of the processing stations. Enter settings according to the display.
The station has never been set up for this type of processing before. Open the window
and make the settings required (see Chapter 10.2 Setting up the processing stations).
The station has been set up for this type of processing before, but something has been
changed at the station (station assignment has changed). Make any settings that may be
required (see Chapter 10.2 Setting up the processing stations).
The station has been set up for this type of processing before and no changes have been
made. This type of processing does not have to be set up. (Unless the processing station
was not set correctly or was changed.)
4. Set up types of processing for module (does not include alpha 411)
Check the symbol fields for the modules. They can only be selected if they are switched on under
machine options (see Chapter 16.3). Three types of processing are possible at the modules: double
crimp, fluxing and cut trailing end (see Chapter 10.3 Setting up the modules).
5. Set up the preliminary processing stations

Check the symbol field for the preliminary processing station. The display is the same as the one for
the processing stations. Make any settings required (see Chapter 10.4 Setting up the preliminary
processing stations).
42 Set-up SWA alpha 4xx

6. Set up the belt drive and the cutting head
Check the symbol field for the belt drive and the cutting head. The wire to be processed may or may
not have already been set up depending on what appears on the display.
The wire to be processed is being newly recorded; i.e. the machine has never been set
up to produce it. The window must be opened and the settings made (see Chapter 10.5
Setting up the belt drive and the cutting head).
The wire has been set up before, but something has been changed. The belt drive and
the cutting head may have to be readjusted (see Chapter 10.5 Setting up the belt drive
and the cutting head).
The belt drive and the cutting head have already been set up and no changes have been
made. No set-up is required. (Unless the belt drive and the cutting head were set
incorrectly or changed.)
7. Special settings ( transfer, wire deposit, etc.)

Set up and adjust specific devices, consult the instructions for each. The settings specific to the
machine, such as setting the transfer on the alphas 421, 422 and 432 or the deposit unit on the alpha
411, are described in Chapter 10.6 Special settings.
8. Set up the article

Enter the wire length, the stripping and pull-off length and possibly the sequence wires (see Chapter
9.1, Processing the article).
9. Thread in the wire

After all settings have been made in the software, the wire/s can be drawn into the machine (see
Chapter 10.7 Threading the wire in/out).
10. Produce wire in single step

After completing the work steps for the stations, the belt drive with cutting head and the special settings
and after assigning the types of processing to the correct stations, you can produce a wire on the
machine in single step mode (see Chapter 10.8 Single step). This mode gives you complete control over
the production procedure and allows you to make any changes and adjustments you desire.

10.2 Setting up the processing stations
Clicking the station symbol field opens the set-up window.
All settings in the set-up windows are stored under the main processing ID and are
therefore always retained (refer also to Chapter 7.2).
10.2.1 Open and closed contact

Work process Chosen according to crimp press
and feedback log.
Supply monitor on / off / k194 / k495
Crimping force sensor (barred for users)
Crimp force sensor (barred for users) Select a
crimp force sensor. If switched on, the monitoring
symbol appears near the station window. For
information on setting and calibration, please
consult the corresponding instructions. With the
komax 325 PC, you can enter all the inputs directly
into this software (see the next chapter).
Press optimization The press is triggered during
the swivel movement in/out
Wait time at the station, front and rear. Input will depend on what press is used.
Speed (for Side 1 only) Set the swivel and pull-off speed of the gripper. Reduce the values when
processing thin wires with heavy contacts; otherwise the value is 10.
Hold gripper (on the transfer only) The type of hold gripper that is mounted must be indicated here
(refer also to Chapter 12.3 Machine options).
Wire extension (only with alpha 411, Side 2) Wire extension out of the gripper. Standard and
With the alpha 411, you set the swivel and pull-off speed for Side 2 in the window 'Wire
deposit' (see Chapter 10.6.2).
10.2.1.1 komax 325 crimp force analyser

If you have selected the 'komax 325 PC' crimp force analyser in the station window,
a small symbol field appears next to the station field. If you click it with the mouse,
the following window opens.
The installation and operations of the komax 325 are thoroughly described in the
installation and operating instructions for this unit. Read these instructions first. You
will find other commands for the crimp force sensor in these instructions in Chapter 11,
Producing and in Chapter 12. System settings.
The four limit values below are saved under the main processing ID, the settings for the
recording mode and analysis range are under the machine configuration.

Teach limit If this limit value is exceeded during
calibration, the calibration must repeat.
Production limit If this value is exceeded, the
processing was bad.
Drift limit The reference curve may drift by this
value.
Damage limit The machine stops immediately
when this value is reached. This prevents the
tools from being damaged!
Capture mode The standard setting is -Encoder sync-. If the measuring time is recorded by a sensor,
select -Fixed measuring times - and indicate the speed of the presses in rpm.
Analysis range The standard setting is -Automatic measuring range-; the measuring range can be
manually adjusted if constant measurement errors occur.
Vpp Measured voltage from piezo element of the transducer.
Press angle The press must be turned for a

display to appear; otherwise the display is 0.
Measured value station The measured production

values are depicted graphically and numerically.
Teach limit The setting is displayed

Production limit The setting is displayed
Minimum Smallest measured value
Maximum Largest measured value
Mean value Mathematical mean value
Mean value+3r Statistical value; it can serve as the
approximate production limit.
CPK -----
Number of measured values in the batch produced
Station measuring curve The crimp

force curves are recorded.
Green curve Reference curve

Red curve Last measurement
Display of production limit and the last measured
value.
The two green, vertical lines show the set measu-
ring range.
The monitoring is calibrated in the production production window using the command
Sample CFA (refer also to Chapter 12.2)
SWA alpha 4xx 45

10.2.2 Seals
Work process To select seal module
Supply monitor ON/OFF
Wait time at the station, front and rear.
Enter 0 values for komax 136.
Speed (only for swivel units) Setting the swivel
and pull-off unit of the gripper. The maximum
input value for the komax 136 seals module is 10.
Hold gripper (only at transfer) The hold gripper
type that is mounted must be indicated (refer also
to Chapter 12.3 Machine options).
Wire extension (only alpha 411, Side 2) Wire
extension out of the gripper. 30 mm is the stan-
dard value and also the optimum.
10.2.3 Tinning
Work process determined by the wait time or via
feedback from the I/O interface.
Wait time at the station, front and rear. Values
depend largely on tinning process and wire cross
section.
Speed (only for swivel units) To set the swivel
and pull-off speed of the gripper. These values
must be reduced for tinning. Depends on the
tinning process and wire cross section.
Hold gripper (only at transfer) For dip tinning at
transfer, for example, the hold gripper must be
able to be swiveled out of the way (refer also to
Chapter 12.3 Machine options).

10.2.4 Twisting
Work process determined by the wait time and
speed or via feedback at the I/O interface.
Wait time Values depend largely on specific
device, see instructions for twisting unit.
Speed (only for swivel units) The actual work
process during twisting can be determined using
the forward/backward speed for the gripper.
Hold gripper (only at transfer) For twisting at the
transfer, for example, the hold gripper must be
able to be extended (refer also to Chapter 12.3
Machine options).
10.2.5 Sleeves
Work process Chosen according to device. The
komax 134 sleeve shrink-fit module can also be
selected under this work process.
Wait time Fitting period depends largely on the
specific device. Consult corresponding operating
instructions.
Speed (only for swivel units) Setting the swivel
and pull-off speed of the gripper. Maximum input
value is 10.
Hold gripper (only at transfer) For sleeve fitting
at the transfer, for example, hold gripper must be
able to be extended (refer also to Chapter 12.3
Machine options).

10.2.6 IDC and k521
Work process The software supports the work
processes for IDC attachment with the komax 621
and for block loading with the komax 521.
Wait time Select 100 ms at the front and 0 ms for
the rear with both modules.
Hold gripper Hold gripper The correct grippers for
these two types of processing must be mounted
on the station and selected in the system settings
(see Chapter 12.3). If an incorrect setting is made,
an error message appears when production is
started.
48 SWA alpha 4xx

10.2.7 Positioning the wire with the swivel unit
There is a crosshair symbol in the upper right-hand corner in the set-up windows on side 1 and, for the
alpha 411, also on side 2.
Clicking the crosshair symbol causes an input window to appear for entering the position and
the approach path to the processing stations.
The swivel movement can be divided into three steps:

1. The swivel and pull-off unit swivels to the processing station and moves with the pull-off unit to the
approach position in front of the processing station.
2. The pull-off unit advances to the processing position; the wire is processed at the station.
3. When the processing at the station is completed, the pull-off unit returns to the withdrawal position.
The processing at the station is ended and the regular processing is resumed.
Positioning at station 1
Note that processing station 1 can be approached from the left or the right. That is why
there are more input fields than for station 2.
1 3
1. Swivel angle in relation to the station
2a. Approach position from the left (if the wire
is first processed at station 2).
2b. Approach position from the right (if the wire
is swivelled in from the cutting head).
3. Processing position
4a. Withdrawal position to the right (if the wire
is swivelled back to the cutting head).
4b. Withdrawal position to the left (if the wire is
swivelled to station 2 for further processing).
4b 2a 4a 2b
The approach, withdrawal and processing positions are identical in the mask photo
above. The processing position can therefore be approached directly with open crimp
contacts. We strongly advise against this for other types of main processing.
The position of the processing station cannot be determined exactly in this set-up
window because the machine does not carry out these changes directly. The station is
not positioned exactly until single step mode(see Chapter 10.8).
Inputs are based on previous experience. Note however that the smaller the position
value, the further forward the pull-off unit advances and the greater is the possibility of
it colliding with the station. It is thus better to enter somewhat larger values.

10.3 Setting up the modules
Modules can be mounted between the transfer stations for further types of processing with the alpha
machines 421, 422 and 432. To be able to assign the various types of processing to a module, the
module must be switched on under machine options (refer also to Chapter 12.3).
All settings in the set-up windows are stored under the module processing ID and are
therefore always retained.
10.3.1 Doubling crimping of wires
Work process Select horizontal or vertical double

crimp
Wait time Input approx. 100 ms for values on top
and bottom with komax double crimp module.
10.3.2 Fluxing
Work process Choice of swivelling away module

gripper for dip fluxing or no gripper action.
Wait time Input depends on specific work pro-

cess and device.
10.3.3 Post-processing of trailing end
Work process Choice of cutting off wire or strip-

ping sheath from wire.
Wait time Input depends on the work process.

10.4 Setting up the preliminary processing stations
Various markers and intermediate strippers can be set up under preliminary processing. Ink-jet
markers are triggered via the special ink-jet interface; the hot-stamp marker and the intermediate
stripper are controlled directly via the standard interface auxiliary 1.
All settings in the set-up windows are stored under preliminary processing ID and are
10.4.1 Setting up the ink-jet marker

The two types of preliminary processing defined marking and scatter marking are triggered by the
ink-jet interface. The inputs for marking are usually entered when recording the article (see Chapter 9.6).
These inputs can also be entered directly in the set-up window.
10.4.1.1 Ink-jet scatter marking
Text field Empty text window for comments

ABC symbol field Opens the input window below
it which contains the work process and the di-
stance.
Numbers field To input continuous distance
ON/OFF switch field Print the text upside down?
10.4.1.2 Ink-jet defined marking
ABC symbol field Opens the input window below

it which contains the work process and the di-
stance.
Field wire symbol Opens the input window with
the text and the positioning (refer also to Chapter
9.6.1)
10.4.1.3 Set-up window
Work process The work process is indicated for

both types of preliminary processing.
Distance Distance from cutting blade on cutting
head to marker head

10.4.1.4 Defining the typeface and position
To define the typeface, click the crosshair symbol. Each change is displayed with the letter A. The
typeface options depend on the type of marker. The choice below applies only to this example.
Script type Normal (5x7), small (5x5), chimney

Character width Distance between each indivi-
dual point. From 0.24 to 0.36 mm.
Character height Can be changed in eight incre-
ments by up to +/- 20%.
Typeface design Bold1, Bold 2 or normal
Character spacing x2 To double the distance
between characters ON/OFF
Speed mode Allows speeds of up to 4m/s, but
with a sacrifice of quality.
Distance
Head - Wire The ideal spacing is 3 to 4 mm
Head 1 - Head 2 If the wire has to be marked from
above and below, the two marking heads have to
be offset.
10.4.2 Setting up at Auxiliary 1

The three types of preliminary processing marking during cutting and defined marking with a hot-stamp
marker and intermediate stripping are triggered and set up via interface A1.
10.4.2.1 Defined marking
Wire symbol The marking text is changed by

clicking the wire symbol in the set-up window.
Work process With or without feedback from the
marker.
Wait time Input depends largely on specific
device; see instructions for the marker.
Distance of the cutting blade at the cutting head
to the middle of the marking head. The software
automatically indicates the ideal value for which
no intermediate stop is required. Pressing the
arrow causes this value to be automatically ac-
cepted by the system and the marker to be
positioned accordingly.

10.4.2.2 Marking during cutting (continuous marking)
-0- Switching processing ON/OFF

marker
Wait time Input depends largely on specific type
of device; see instructions for the marker.
to the middle of the marking head. The software
cepted by the system and the marker to be
positioned accordingly.
10.4.2.3 Intermediate stripping
Wire symbol The intermediate stripping data is

changed by clicking the wire symbol.

device
Wait time Input depends largely on specific type

of device; see instructions for the intermediate
stripper.

to the middle of the stripping blade. The software
cepted by the system and the intermediate
stripper is positioned accordingly.

10.5 Setting up the belt drive and the cutting head
The belt drive and the cutting head are adjusted to accommodate the specific features of the wire.
All settings in the Belt drive/cutting head window are stored under the wire ID and are
10.5.1 Belt drive
Wire To display the cross section, the color and

the insulation
Length correction Input range from -10 to +10
per thousand (1/10 %). The wire length can be
selected to be either somewhat too short (-X) or
somewhat too long (+X). The standard value is 0.
Note that a correction will affect the optimum
marker distance (see Chapter 10.4.2).
The length can also be corrected simple and quickly in the quick window in set-up and
producing.
Speed Belt drive speed from 1 to 10m/s. Standard

value is 10. The speed must be reduced for thin
wires and for ink-jet marking.
Acceleration Input range 1-10 (x 5 ms2). The
standard value is 10. This value may have to be
reduced in conjunction with special surfaces.
Slip Input range 1-10. The standard value is 3. Slip
is the difference in speed between the belt drive
and the blade system. The higher the value, the
larger the difference is allowed to be. An emergen-
cy stop is triggered if this value is exceeded.
Brake acceleration see information under accele-
ration.
Wait time cutting/stripping These values increa-
se for thick wires or tough insulation, enabling the 422
cutting head to build up more pressure. The
standard value is 0.
Pull-off speed Input range 1-10. The standard
value is 10. Reduce the value if the insulation is
not being completely pulled-off.
Set-up window for belt drive on alpha 411/421/

10.5.1.1 Belt drive on the alpha 432
There is an extended set-up window for the alpha 432 with double belt drive and the optional wire
changer for 24 wires with five guide tubes at the swivel unit.
1 - List of the wire IDs in the double belt drive

Up to 24 different wires can be assigned and
processed depending on which wire changer is 2
installed.
2 - Remove wire symbol

To remove a wire ID that was assigned.
3 - Guide tube 1
The guide tube must be selected to accommoda-
te the wire cross section. The tube number and
3
diameter are engraved on the guide tube part
(refer also to the operating instructions for the
alpha 432). Set-up window for belt drive on alpha 432
10.5.2 Cutting head

When recording the wire, the wire cross section is one of the things to be determined. This value is
transferred to the cutting head; it can also be adjusted in the following window by clicking the crosshair
symbol.
The blade position during stripping and the

withdrawal path for the insulation pull-off can be
adjusted in increments of 0.05 mm.
The value can be changed in increments of 5/10
mm or 5/100 mm in the (x10) field.
The blade position can also be changed simply and quickly in the quick window in set-
up mode or production mode.

10.6 Special settings
10.6.1 Transfer on the alpha 421, 422 and 432

The alpha transfer has an intelligent control system. The transfer can detect its position with the help
of three sensors and a switch plate, enabling it to control the transfer movement in an optimum manner.
Settings in the transfer window are stored under the article ID and are therefore always
retained.
Speed
Choice of two speeds: fast or slow. Fast is the
setting usually selected, but slow should be used
for thin wires with heavy crimps.
Wire extension
This determines the projecting wire length in the
station gripper at the transfer. 43 mm is the basic
value and the optimum value for stripping with full
pull-off. The input range is from 35 to 64 mm.
Side movement (alpha 421 and 422 only)

Two transfer grippers at the last transfer station
can move forward and backward (refer to the
machine). The movement of both transfer grippers
toward the rear is called transverse movement
and is used for example to approach a crimping
press with closed contacts without extending the
station gripper.
When selecting the scrollbar list, you can choose
from various types of movements. The transverse
movement is started before or after the transfer
movement (straight movement - time loss), or the
transverse movement is carried out at the same
time as the transfer movement (trapezoidal - less
time loss). The default setting is No transverse
movement.

10.6.2 Wire deposition on the alpha 411
The deposit window of the alpha 411 is also used to set the speed of the swivel and pull-off unit on
Side 2.
The settings in the wire deposit window are stored under the article ID and are therefore
always retained.
Side 2 - speed:
Extend / retract Speed of the pull-off unit at the
processing station. Input range 1-10. Standard
value 10.
Swivel to station The values depend on the type
of processing (refer also to Chapter 10.2).
Swivel to initial position The values depend on
the type of processing (refer also to Chapter 10.2).
The value on side 1 affects the wire deposition.
Gripper at deposit point:

Prior to opening / After opening Wait time of the
deposit gripper in ms. Standard values are 0.
Wire bolt Insertion and removal of pin under the
swivel unit on side 2. Default value on.
All of these values affect the quality of
wire deposition. You may have to adjust the standard values depending on the wire
length and size or the type of processing.

10.7 Threading the wire in and out
Prior to threading in the wire, all mechanical settings on the machine must be made and
the wire must be drawn into the machine up to the belt drive (see Chapter 7 in the
operating instructions). The machine must also be in proper operating condition.
If you select commands in set-up mode that result in machine movements, you must
press the approval button at the same time for these movements to be executed. You
are responsible for ensuring that no other people are around the machine when it is
carrying out movements.
Clicking the command field opens the following

window:
Display of the current wire ID, the wire cross

section, the color, the insulation and the length
correction factor.
1 - Threads the wire out of the machine
2 - Slowly withdraws the wire
3 - Slowly advances the wire
4 - Cuts the wire
Threading the wire in and out on the alpha 411/421/422
5 - Feeds the current wire to the outlet of the

wire changer
6 - Feeds the current wire to the wire separator.
7 - Feeds the current wire up to the cutting

head.
Threading the wire in and out on the alpha 432

10.8 Single step
Prior to producing with single-step mode, the wire must be drawn into the machine and
cut at the cutting head and the mechanical settings on the machine must already be
made (see Chapter 7 in the operating instructions). The machine must also be in proper
operating condition.
The safety shields can remain open in single-step mode. However, the approval button
must also be pressed whenever commands are made which trigger machine move-
ments.
The person setting up the machine is responsible for seeing that no other people are
in the vicinity of the machine while the machine movements are being carried out.
In single-step mode the entire production process is triggered in small single steps. The software
guides the operator through single step according to the type of processing involved.
The flow chart for the single-step mode on the next page is just an example. Certain
items would be eliminated if particular stations were not approached or certain
monitoring systems were not installed.

10.8.1 Single step side 1
Wire feed advance
Cutting, stripping lead termination
Complete processing Processing in small steps
Move blade into cut position

Move pull-off units into stripping position
Move blade into stripping position
Move pull-off units into pull-off position
Open blade
Move pull-off units into initial position
Approach station 1 on side 1
Stored position Target position New wire Complete processing

(basic value) (initially)
Trigger station Continue without triggering New wire Position the station
(initially)
Approach visual check unit

Continue New wire Position the visual check unit

(initially)

Approach station 2 on side 1

Trigger station Continue without triggering New wire Position the station
(initially)
see next page

10.8.2 Single step side 2
Wire feed: wire length
Cutting, stripping trailing end
Complete processing Processing in small steps
Move blade into cut position

Move pull-off units into stripping position
Move blade into stripping position
Move pull-off units into pull-off position
Open blade
Move pull-off units into initial position
Approach module 1
Approach Approach and process New wire

(initially)
Trigger module Continue without triggering New wire

(initially)
Approach station 1
Trigger station Continue without triggering New wire

(initially)
Repeat last step Continue New wire

(initially)
Approach module 2
same as above
Approach station 2
same as above
Deposit wire
End

10.9 Single stroke
Be especially careful when triggering individual machine components since machine
movements can be carried out with open safety shields in this mode. Only use the
Single stroke command when no other people are in the vicinity of the machine.
Also be careful not to damage machine components by triggering them carelessly. For
example, triggering a crimp press repeatedly without first removing the contact from
the anvil will damage the tool.
Single stroke on alpha models:
Station Preliminary station * Transfer Wire stacker* Guide tube
alpha 411
alpha 421
alpha 422
alpha 432
* The preliminary station and the wire stacker can only be selected if they are switched on under
machine options.
Each station and preliminary station output has 2 relays, which explains the designation
S1-1 and S1-2 at station 1. Only one relay is triggered for crimping presses; the second
has no function in this case. With a seals applicator, for example, both outputs are
triggered, either together or individually.

10.10 Quick programming
The most important machine settings can be changed using the quick window in the
set-up window and production window.
The quick programming window for the alpha 422
Setting the Input range Comment
Length of projecting wire at transfer 35 - 64 mm (see Chapter 10.6.1)
Blade position during stripping 0 - 4 mm +/- 0.05 mm (see Chapter 10.5.2)
Blade position during insulation pull-off 0 - 4 mm +/- 0.05 mm (see Chapter 10.5.2)
Length correction factor -10 to +10 o/oo (see Chapter 10.5.1)
Processing position at the stations 0 - 40 mm (see Chapter 10.2.7)
10.11 Other commands in set-up mode

Display of the last production log that was printed. The symbol is active only when a
printer has been selected under machine options (see Chapter 12.5).
Return to the login window to select another language.
Confirm that the article is set-up in the indicated way. The exclamation points on the
symbol fields disappear.
Store changes and settings in the article ID.
Open a new article.

11. Producing
Production can commence as soon as the article setup has been successfully
completed.
auto
Successful producing requires:
The machine and all processing stations and their accessories to be in proper operating condition,
the entire production process to be properly set-up,
the safety shields to be closed,
and the operating mode selector switch to be set at production (automatic)
The production window, example for alpha 411
1 Display of the article group and the article as well as loading of a new article
2 Graphic depiction of the wire to be produced and display of the wire ID
Input of the wire length and stripping data.
3 Symbol fields with additional commands such as Save article and Quick programming (refer also
to Chapter 10.11).
4 Display field of the crimp force sensors which have been installed. With the komax 325 crimp force
sensor, the current measured value, the production limit and the symbol field for adjusting the
monitoring unit will appear (see Chapter 10.2.2.1).
5 Display of piece number output and wire consumed and
Field to set the counter for consumed wire to zero.
6 The production cycle can be executed at normal speed (quickly) or in slow motion (slowly).
7 Input of total piece number and batch size Input of total piece number and batch size and display
of total pieces and batch size as well as a field to set the two counters to zero; see Chapter 11.1
8 Start production; see Chapter 11.3 and further production commands; see Chapter 11.2
SWA alpha 4xx Producing 65

11.1 Input of piece number and batch size
The total piece number and the batch size are determined prior to starting production.
Total piece number and batch size

Input range 1 - 65535 wires
For alpha 421s, 422s and 432s with wire stacker, the batch size is limited by the capacity of the wire
stacker. The max. batch size varies according to the wire cross section:
0.5 mm2 approx. 200 wires 2.5 mm2 approx. 50 wires

1.0 mm2 approx. 150 wires 4.0 mm2 approx. 25 wires
1.5 mm2 approx. 100 wires
11.2 Commands prior to starting production

Turn wire stacker (alpha 421, 422 and 432 if wire stacker is installed)
The wire stacker with the produced wires turns, the small safety shield rises, and the produced wires
can be removed.
Clear transfer (alpha 421, 422 and 432 only)

The wires on the transfer are completely processed at the stations and then deposited.
Clear deposit (alpha 411 only)

The wires are tipped into the transport tray and moved out of the machine for removal.
Sample
A single specimen of the article is produced.
Sample short
A single, short specimen of the article is produced. The length of the short wire is set in the System
settings window (see Chapter 12, Item 8).
Thread in/out
The belt drive window for transporting the wire appears (see Chapter 10.7).
Sample CFA Crimp force analyser

If a crimping force sensor is installed at a press, this sensor is calibrated. The average value of these
wires serves as the reference value for subsequent production. The number of calibrations is set in the
System settings window (see Chapter 12, Item 9).
Note that all wire samples for calibration are deposited as good wires. You must
therefore always check all sample wires manually.
66 Producing SWA alpha 4xx

11.3 Starting production
New articles can be recorded and processed while the machine is producing. Simply
select the corresponding symbol in the control window.
To start production, proceed as follows:

Press the START key on the operators console
or select the Start production field in the production window
The following commands are available during production:
Stop
Stops production immediately starting with the next wire.
Stop at batch size
Stops production when the batch is completed.
-1 (0) alpha 411 only
The piece counter is reduced by one and the machine produces one additional wire. This is used, for
example, if a wire is removed for a manual check. The number in parentheses indicates the number
by which the counter was reduced.
A display can be switched on in the alpha 411 to indicate the number of bad wires (bad
processing on Side 2) in the deposit system. Thanks to this feature, you always know
how many wires you have to sort out of the deposit system ( see Chapter 12, Point 14).
SWA alpha 4xx Producing 67

11.4 Automatic post-production
If one of the check units (komax 324, 325 etc.) detects defective processing, the bad wire is
automatically post-produced whenever possible. In this way, the full piece number of good wires is
achieved by the end of production.
Automatic post-production is not activated when test wires are being produced. When the crimping
force sensors (komax 323 or 325) are being calibrated, only the bad processing reported by the Wire
check are post-produced.
Automatic post-production is switched off when the wire is being marked or intermediately stripped.
This is done because these processes are carried out prior to cutting and unplanned pieces are
therefore not allowed to be cut from the wire.
The design of the machine creates certain differences between post-producing on side one and
on side two:
Post-producing on side 1
Post-production always occurs automatically with unmarked wires. The badly processed wire is cut
off immediately and the process repeated on the new wire lead. The wire scrapped in the process is
always 150 mm.
If the wires are processed by a preliminary station, only individual wires (sequence size 1) can be post-
produced. When marking is done by an ink-jet, individual wires are not post-produced either. Due to
the processes involved, the entire wire must be cut out and the next wire end replaced.
Post-producing on side 2
Automatic post-production is only possible at the transfer if a wire sequence is not being processed.
One more wire is produced, replacing the bad one in the current batch.
This is not possible in sequence operating mode because the bad wire cannot be replaced by the one
immediately following it. Automatic post-production is therefore switched off in this mode.
The double crimp function is also treated like a sequence which is why no automatic
post-production occurs in conjunction with it on side 1.
68 Producing SWA alpha 4xx

12. System settings
Selecting this symbol in the control window causes the System setting work window to
appear. The machine settings can be recorded here.
This work window can be opened only if you are logged in as the supervisor or the set-
up person and if the machine is not reset.
1 Input of a name for the machine

2 Opens the Timing settings window; see Chapter 12.4
3 Opens the Machine options window; see Chapter 12.3
4 Opens the window for print-out of production data; see Chapter 12.5
5 Produce one test wire prior to each production start? Yes/No
6 The sample wires for calibration are the length indicated in item 9.
7 Optimisation of the calibration of the crimping force for sequence wires? Yes/No
8 Input of the number of sample wires for calibrating a crimp force sensor
9 Input of fixed wire length for a short sample wire
10 The memorisation of article modifications can be locked for the user level.
11 alpha 411: Message on the number of bad wires in the deposit tray On/Off.
alpha 421/422/432: Option for cutting bad wires.
12 Input of the number of badly produced wires before the machine stops. Top example: Three in ten
can be bad; the machine stops production when the fourth of ten is bad.
13 Input of system time and the date
14 Selection of unit of measure for length, either mm or inch.
15 Selection of drive for saving and loading data (disk- and network drives)
16 Input field for networking the komax 325 crimp force sensors; see Chapter 12.2
17 Input field for an installed ink-jet interface; see Chapter 12.1
SWA alpha 4xx System settings 69
0.1
12.1 Ink-jet interface
The ink-jet interface is an optional I/O board installed in one of the plug-in slots of the komax alpha PC.
It triggers various ink-jet markers with great precision and gives the operator virtually unlimited marking
options. The lowest field is only activated if an interface board is inserted in the PC.
Address
The storage address assigned to the interface in
the PC memory is indicated on the left-hand
margin. The standard value is Hex-C000. If this
address has already been assigned to another
board (network board, etc.), the address has to be
changed. This is done on the interface board at DIP
switch X17 (refer also to instructions for interface).
Marker selection
Choice of current printer types, Alpha Jet, Imaje or
Wiedenbach (as of January 1997).
12.2 komax 325 crimping force analyser

The komax 325 is an optional crimping force sensor. Several komax 325s can be networked with each
other for quality evaluations, etc. Each device must then be assigned its own address.
Assigning the address

Enter the new network address.
If several devices are connected by means of a
network line, disconnect the network plug from all
other devices.
Are all other devices disconnected from the net-
work? Click the Change address field. The new
address will be assigned to the komax 325.
Never assign the same address to two difference devices. This error causes the program
to crash. For this reason, you must be especially careful when changing the network
addresses. Please make a note of the addresses.
70 System settings SWA alpha 4xx

12.3 Machine options
Various accessories can be added to the alpha machine to expand its functions. This window is used
for the software activation and setting of the accessories.
All installed options are already set on delivery. Inputs in this window need only be
changed if new options are installed.
alpha 411 - Machine options alpha 421 - Machine options
alpha 422 - Machine options alpha 432 - Machine options
Blade type - all alpha models

Choice between form blade and V blade. The standard is the V blade.
Select the form blade with special process (alpha 421, 422 and 432) only if the appropriate conversion
kit is mounted for large wire sizes (special blades and grippers).
Blade distance side 1 and side 2 - all alpha models

The distance between the cutting blade and the stripping blade. The standard is 18.5 mm. A cutting head
for greater stripping lengths is available as an option on side 1. If it is used, the value for side 1 must
be 30 mm.
Wire selector - alpha 432

The expansion of the wire changer is indicated here for the alpha 432 with double belt drive and the
optional wire changer (no changer, 4, 8 or 12 wires).

Holding gripper type - alpha 421, 422 and 432 only
A simple hold gripper comes as standard equipment on the transfer stations. There are three types of
optional hold grippers available which can be extended and/or swivelled, e.g. for submersion tinning.
Special hold grippers must be used for the housing equipment on the komax modules 521 and 621; they,
too, can be entered here.
Strip cutter interval - alpha 411 only

The optional komax 455 komax contact strip chopper is triggered after a set number of crimp cycles.
Adjust swivel unit - alpha 411 only

When you select this field, you can readjust the zero position of the two swivel units in the setup window.
The exact sequence is explained in the operating instructions, Chapter 10. Setting procedures.
Safety cover - alpha 421, 422 and 432 only

The standard input is 'mounted'. If no safety flap is mounted on the wire stacker, the stacker must be
switched off.
Optional DZIO - alpha 421, 422 and 432

The optional DZIO must be installed and switched on under this item if the alpha is equipped with a
module or with an optional wire stacker.
Deposit - alpha 421, 422 and 432

Choice between no wire deposit system, deposit tray and wire stacker. If you choose no wire deposit,
the wire is released at the last transfer gripper (for further processing). If you choose deposit tray, the
wire is taken by the transfer gripper and placed in the wire tray. The standard is wire stacker.
Wait time for wire length feed - alpha 421, 422 and 432
The wait time for a batch size change is entered here for a mounted feed belt with batch size sorting.
The input range is 0 - 10000 ms.
Wire feed check - all alpha models

The check unit for wire feed, e.g. for a komax 106 dereeling system, can be switched on here.
Optical check - all alpha models

Determines the location of the komax 324 stripping and seals check unit on side 1 and 2. The
corresponding symbol appears in the set-up window when the check unit is switched on.
Modules - except alpha 411 and preliminary stations - all alpha models
The A1 preliminary processing station and the transfer modules between the stations can be switched
on and off here. Select the preliminary station and the modules only if they are actually installed. This
will ensure you a better overview in the set-up window.
Conveyor belt
Switch on the activ wire conveyor belt komax 408 or 409.

12.4 Timing settings
Movement sequences not inquired about by the machine control system can be changed and thus
optimized for each work process. However, these inputs should be made only by staff who are very
familiar with the machine control system.
alpha 411 - Timing settings
alpha 421, 422 and 432 - Timing settings
Example: Closing the transfer grippers, input 90 ms

The machine control system issues the command to close the transfer grippers. The control system
waits 100 ms before issuing the command for the next movement.
If this value were set at 20, the next movement would follow 20 ms after the command Close the transfer
gripper regardless of whether the transfer gripper had actually closed. At this setting, the wire would
probably be lost or transferred incorrectly.
Changing these values can increase the piece number output, but it can also cause
problems with machine operations. A lot of knowledge about the movement sequences
and a lot of time is required to discover the optimum values. The default values suffice
perfectly under standard operating conditions.

12.5 Printer settings
A printer can be connected to the PC of the komax alpha for automatic print-out of the production data.
This enables you to print a log for each job.
The following settings and inputs are available:

Should no data be printed out or should all the data
be printed out when a batch is complete or the
preset piece number is reached?
A header and a footer can be added that will
appear on each print-out.
The following example shows a sample print-
out with all data:
Wire processing systems Defined header line (see above)

-----------------------------------
Date : 14.2.1995 - date
11,34 - time
Machine : ALPHA_03 - machine number; see Chapter 12. Item 1
Article ID : AIRBAG 563 - article ID
Bundle size : 60 - quantity produced (batch size or piece number)
Wire ID : WIRE 1083 - wire ID
Side 1 - main processing IDs on side 1
S1 (CFA) ID : FASTON 6.3 (CFA) stands for crimping force sensor
S2 ID : SEAL RED 46
Side 2 - main processing IDs on side 2
S3 ID : SLEEVE PP42
S4 (CFA) ID : FLAT PLUG 035
----------------------------------- Defined footer line (see above)
komax Switzerland
Industriestrasse 6
6036 Dierikon

13. Managing the personnel list
After selecting this symbol in the control window, the work window Managing the
personnel list appears with an overview table of the list.
1 To change a personal entry. An existing entry can be marked in the table and corrected on clicking
this field; see Chapter 13.1
2 To record a new personal entry; see Chapter 13.1
3 To delete the marked entry. For safetys sake, the deletion procedure must be confirmed a second
time. These personal data are lost on deletion.
4 Table with the personal data. The entire table can be viewed by using the left/right and up/down
arrow keys.
To change the personnel list, you must be logged in as the supervisor.
SWA alpha 4xx Managing the personnel list 75

13.1 Editing a personal entry
Personal number and password

Since these two inputs must be entered on log-in,
it is essential that you remember them.
The personal number supervisor cannot be deleted but the password can be changed.
Write down this password just in case.
Last name and first name

The users last name or first name can be entered here. The program does not ask for this input during
log-in and it can be omitted if you prefer.
Language
You can use any of the following languages with this software: German, English French, Italian, Spanish
and Portuguese. The text on the screen will appear in whatever language you choose.
Level
Access to several windows can be barred by assigning user levels. The supervisor can assign one of
three levels:
Level Restrictions
Supervisor No restrictions; only supervisors can edit the personnel list.

Set-up person Access to the personnel list is barred.
User Access to the personnel list, the system settings and the entire setting of the crimping
force sensor is barred.
You can adapt the entire personnel list to meet your needs. However, komax recom-
mends that you define only one supervisor and write down the password just in case.
If you can no longer log in as the supervisor, you cannot change the personnel list.
If you want to skip the password input on start-up, delete all personal entries except the
supervisors. You can now go through start-up without having to enter a password.
76 Managing the personnel list SWA alpha 4xx

14. Quality data record
The komax alpha automatically keeps a production log containing the following data: article
ID, machine name, user, date, time, piece number produced and all quality data.
This data can be viewed, automatically deleted or saved on a diskette for further data processing.
The log is newly recorded whenever you change the settings of the komax 325 or any ID, or
whenever you log in again or reset the piece number to zero.
Pay close attention to the data protection regulations in your country when you process
your data.
The data are stored as ASCII files with the filename extension .RSP and can be processed further with
a table calculation program (e.g. Excel©). The columns are created by TABs, lines by CR/LF. The following
table shows how the production log is structured.
Article
Machine ID User ID
Date Time
Actual pieces
Quality data record (only with komax 325 PC crimping force analyser):
Teach limit station 1 Teach limit station 2 Drift limit station 3 Station 4 . . .
Production limit station 1 Production limit at station 2 Production limit at station 3 ..........
Drift limit at station 1 Drift limit at station 2 Drift limit at station 3 ..........
1. Measured value station 1 1. Measured value station 2 1. Measured value station 3 ..........
4. . . . . . . . . . . 4. . . . . . . . . . . 4. . . . . . . . . . . ..........
5. . . . . . . . . . . 5. . . . . . . . . . . 5. . . . . . . . . . . ..........
x. . . . . . . . . . . x. . . . . . . . . . . x. . . . . . . . . . . ..........
SWA alpha 4xx Quality data record 77

78 SWA alpha 4xx
15. Error messages
The alpha software has three different types of messages for indicating an error: machine errors,
errors from monitoring systems and safety messages.
15.1 Machine errors

Machine errors are displayed in a separate error window.
Column 1
Five-digit, internal error code
Column 2
Possible cause and location of error
Column 3
Address on the I/O board
There are up to three different commands for

resuming operations depending on the severity of
the error. All wires in the machine are lost.
Abort
The window closes and the machine must be reset
once again.
Retry
The action that triggered the error is repeated.
Ignore
The error is ignored and the program process
continues.
If only the 5-digit error code appears in the error window, it is usually a severe error. If
you cannot remedy the error yourself, contact your representative or Customer Service
at komax.
SWA alpha 4xx Error message 79

15.2 Errors from external monitoring devices
Errors from external monitoring devices such as the k325 crimping force sensor, the k324 stripping check
unit or the wire and contact feed check units are displayed in RED at the bottom of the screen.
The machine stops production and issues the error

message from an external monitoring system only
when the defined number of bad wires has been
exceeded (see Chapter 12. System settings, Item
10).
If the maximum number of bad wires is not rea-
ched, the bad wires are separated out from the
rest and post-produced.
15.3 Warnings and messages

Warnings or safety messages are displayed in a separate window.
These messages are not really error messages.

They are the means by which the software points
something out so the machine can be started and
the full safety for the user is safeguarded.
80 Error message SWA alpha 4xx

16. Annex
This annex contains additional information on the alpha software.
Add any further information of your own to the instructions by writing them in the space
provided.
16.1 Cleaning the mouse

The mouse has a mechanism for self-cleaning the ball housing. This feature prevents dirt build-up around
the ball and rollers under normal conditions.
If the ball needs cleaning despite this feature, proceed as follows:
Turn off the computer.

Turn the mouse over.
Loosen the lock dial covering the ball housing by
turning it counter clockwise and remove it.
Take out the ball.
Clean the ball with regular tap water or a mild
cleaning agent and dry it with a lint-free cloth.
Check for abraded particles on the roller in the ball
housing and remove any you find there with a
cotton swab.
Remove the rest of the dust by blowing into the ball
housing.
Place the ball back into the housing and turn the
lock dial clockwise until it locks again.
SWA alpha 4xx Annex 81

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Software Manual

for E480 / D901

Art.No. 035722 - Version 3

SWA alpha 4xx 1

Telefon 041 - 455 0 455

As of date January 1997, subject to change

© 1997 by komax AG, Wire processing systems

2 SWA alpha 4xx

3. Overview of operating elements .............................................................................................. 11

4. Screen layout ............................................................................................................................ 13

5. Office and training software .................................................................................................... 17

6. Switch-on and starting ............................................................................................................ 19

7. Software concept ..................................................................................................................... 21

8. Wire and processing data ........................................................................................................ 25

9. Article data ............................................................................................................................... 31

SWA alpha 4xx Table of contents 3

10. Set-up ..................................................................................................................................... 41

4 Table of contents SWA alpha 4xx

12. System settings ..................................................................................................................... 69

13. Managing the personnel list .................................................................................................. 75

14. Quality data record ................................................................................................................. 77

15. Error messages ...................................................................................................................... 79

16. Annex ...................................................................................................................................... 81

SWA alpha 4xx Table of contents 5

SWA alpha 4xx Introduction and notes 0.1 7

1.2 Changes in this software

1.3 How to use this manual

8 Introduction and notes SWA alpha 4xx

Emergency stop switch

Operating mode selector switch

an emergency stop. The approval key has no function in this mode.

SWA alpha 4xx Saftey 9

10 Saftey SWA alpha 4xx

3.1 Controls for alpha 411 / 421 / 422

3.2 Controls for alpha 432

SWA alpha 4xx Machine overview 11

For example to enter PC:

Press these two keys

and then these two keys

12 Machine overview SWA alpha 4xx

The photo below shows a typical screen layout:

Command field with other symbols

Display of HELP text for the current input field

SWA alpha 4xx Screen layout 13

Setting up and producing the article ............................................. see Chapters 10 and 11

Defining the machine settings and the options to be used ..................................................

Personal number and password management ............................................ see Chapter 13

14 Screen layout SWA alpha 4xx

Element Name of the element What it is used for

Symbol fields The symbol fields are used to call up a sub-

Action fields Clicking this field with the mouse triggers an

Scrollbar lists The scrollbar opens when the upper right-hand

Selection fields One function must be selected from a list of

ON/OFF switch fields A function is switched on or off by clicking the

Multi-column tables Display of recorded data. Select the item you

SWA alpha 4xx Screen layout 15

Arrow keys Moves the cursor within the groups

F1 Opens the HELP window