Operating Instructions

Automatic Wire Stripper

Kappa 230

OI Kappa 230 – Version 4 1

Art.No. 0043806 – Version 4
Published by:

Komax AG
Industriestrasse 6
CH-6036 Dierikon-Lucerne, Switzerland

Phone +41 41 455 0 455

Fax +41 41 450 15 79
e-mail [email protected]
Internet http://www.komax.ch

As of May 2001, subject to revisions

Reproduction of these instructions or parts of them in whatever form is not permitted without
express written permission from the publisher.

Komax reserves the right to make technical changes necessary to improve the machine that could
diverge from figures and information in these instructions.

2
© 2001 by Komax AG, Wire Processing Systems OI Kappa 230 – Versiongu4
Contents
1. 1. Product description ...................................................................................................... Page 5
1.1 The operating instructions (OI) .......................................................................................... 6
1.2 Machine identification ...................................................................................................... 6
1.3 Technical data / performance range ................................................................................. 7
1.4 Accessories ..................................................................................................................... 9
1.5 Personnel qualifications and training .............................................................................. 11
1.5.1 Personnel qualifications .................................................................................... 11
1.5.2 Training ............................................................................................................. 11

2. Safety ........................................................................................................................................ 13
2.1 Explanation of notes ...................................................................................................... 13
2.2 Safety notes ................................................................................................................... 13
2.3 Safety features ............................................................................................................... 15

3. Transport / items included in the delivery .............................................................................. 17

4. Machine overview .................................................................................................................... 19

5. Startup ...................................................................................................................................... 21
5.1 Checks prior to startup .................................................................................................. 21
5.2 Switching the machine ON and OFF .............................................................................. 21
5.3 Settings prior to production ............................................................................................ 21
5.3.1 Wire straightening unit (optional) ....................................................................... 21
5.3.2 Feed rollers ....................................................................................................... 22
5.3.3 Wire guides ....................................................................................................... 22
5.3.4 Blades .............................................................................................................. 23
5.3.4.1 Blade types ......................................................................................... 24
5.3.4.2 Changing the blades ............................................................................ 25

6. Machine operation .................................................................................................................. 27

6.1 Basic operator station .................................................................................................... 27
6.2 Display concept ............................................................................................................. 28
6.3 Short overview of user menus ........................................................................................ 29
6.4 MAIN - main menu ......................................................................................................... 30
6.5 LANG - language ............................................................................................................ 30
6.6 Brief instructions on the three most important menus .................................................... 30

OI Kappa 230 – Version 4 Contents 3

 6.6.1 TEACH - programming ...................................................................................... 30
6.6.2 PPARA - process paramet. ............................................................................... 32
6.6.3 PROD - production ........................................................................................... 33
6.6.4 Programming example ...................................................................................... 33
6.7 PPARA - further process parameters ............................................................................. 36
6.8 TEACH - further processes ............................................................................................ 41
6.8.1 IM - intermediate stripping ................................................................................ 41
6.8.2 PS - multiple-step stripping .............................................................................. 41
6.8.3 Parameters for processing double-sheathed wires ........................................... 42
6.9 CONF - configuration ..................................................................................................... 44
6.10 LIST - wire list .............................................................................................................. 45
6.11 SEQU - sequential ....................................................................................................... 46
6.12 REMOT - remote .......................................................................................................... 47

7. Malfunctions / error messages ............................................................................................... 49

7.1 Malfunctions .................................................................................................................. 49
7.2 Error messages on the display ...................................................................................... 50

8. Maintenance / repairs .............................................................................................................. 57

8.1 Maintenance .................................................................................................................. 57
8.2 Calculating the reference positions ................................................................................ 57
8.2.1 Reference blade ............................................................................................... 57
8.2.2 Reference gap (rollers) ...................................................................................... 58
8.2.3 Test functions ................................................................................................... 58
8.2.4 Non deletable total piece counter ..................................................................... 59

9. Description of connections ..................................................................................................... 61

9.1 Preliminary processing connection ................................................................................. 61
9.2 Post-processing connection ........................................................................................... 62
9.3 Stop input connection .................................................................................................... 63
9.4 RS232 interface connection ............................................................................................ 63

10. List of accessories ................................................................................................................. 65

Wiring diagram .................................................................................................................................

4 Contents OI Kappa 230 – Version 4

1. Product description
Die Komax Kappa 230 is an automatic stripper intended for the following applications in line with the
technical data (see Chap. 1.3):

Applications Kappa 230

Cutting to size

Stripping with semi pull-off

Stripping with full pull-off

Multi-step stripping

Multi-step cutting (double sheath)

Multi-pole round conductors

Flat ribbon cables

Interface for hot stamp marker

Ink jet marking/PC software

Equipment

Blade cleaning kit

Length measurement with encoder

Horizontal and vertical wire straightener

Wire deposition/winding system

Microsoft
PC software with Windows 9x/NT/2000
Windows 95

Standard

Optional

fig 1.1

This list is exhaustive.

Please take time now to read carefully through the operating instructions. They will guide you step by step
through the operation of your Kappa 230 so that you will successfully operating it yourself in no time.

OI Kappa 230 – Version 4 Product description 5

1.1 The operating instructions (OI)
These operating instructions are valid for the Komax Kappa 230 - software version G018c - and are
available in German, English, French, Italian, Spanish and Portuguese; other languages are available on
request. These instructions have 68 pages numbered consecutively throughout.
The instructions contain complete information on the controls, handling, maintenance and setting
procedures as well as all technical data. They also contain wiring diagrams and a list of accessories.
The operating instructions for the accessories (e.g. marker) are enclosed with the individual devices.
Take care not to lose them when you unpack and set up these devices.
The operating instructions constitute an integral part of the Kappa 230. Keep them within reach so you
can refer to the information in them any time you need it.
The instructions must be understood and heeded in full by everyone responsible for installing, operating
and repairing the machine.
Pay special attention to Chapter 2 and the safety notes it contains.

Please contact your Komax representative if you need further copies of the documen-
tation.

1.2 Machine identification

There is a nameplate on the back of the machine
bearing the following information: Part.No. : 050000 Komax 230
n Machine type
Ser. No.: 230.0001
n Machine number 115V/60Hz; 230V/50Hz 250 VA
n Voltage version 6036 Dierikon
n Power input

fig 1.2 Sample nameplate

6 Product description OI Kappa 230 – Version 4

 1.3 Technical data/performance range
Kappa 230

Length range 1mm– 200000mm

Length accuracy +/-1mm or <0.2depending on the wire length

Stripping lengths
Full and semi pull-off 0.5– 50mm
Side 1
Multi-step cutting up to 999.9mm

Full pull-off 0.5– 46mm

Side 2
Semi pull-off or
0.5–999.9mm
multi-step cutting

Pull-off lengths
Side 1 0–99.9mm

Side 2 0–50mm

Short mode <60mm, can be switched off

Wire cross-sections* 0.22–16mm² (stranded conductors)

AWG24–AWG5

Flat ribbon cables Maximum width up to 40mm in width

Minimum length 60mm (28mm, optional) + stripping length

Max. outside diameter 15mm

Piece number output See figure

Selectable piece numbers 1–60 000 pieces

Noise level <70dBA

Electrical connection 110V±15%/50–60Hz

230V±15%/50–60Hz
automatic changeover

Dimensions (W×H×D) 630×340×400mm

Weight ~43kg

* The Kappas can accommodate many wires with cross sections outside the indicated range yet may not be able to process
extremely hard, tough wires even if they are within this range. If you are in doubt about your wires, we are happy to process
samples of them.

OI Kappa 230 – Version 4 Product description 7

 Pieces/h Recommended values for Komax Kappa 230

Conductor: FLRY 0.5mm2

Blade opening: 3.5mm
Wayback: 0.2mm

Short mode
Cutting to size only
Cutting to size and stripping

Entire wire length [mm]

fig 1.3 Piece number output

8 Product description OI Kappa 230 – Version 4

1.4 Accessories
A variety of accessories can be added to the Komax Kappa 230 to adapt it exactly to your needs.

Wire feed:

fig 1.4 Komax 102 wire pulling fig 1.5 Komax 104 wire de-reeler fig 1.6 Komax 105 wire de-reeler
machine

fig 1.7 Komax 106 wire feed unit fig 1.8 Komax 107 wire de-reeler fig 1.9 Komax 109 wire de-reeler

Preliminary wire processing:

fig 1.10 Hot stamp marker fig 1.11 Ink jet marker fig 1.12 Ink jet marker
Komax 26 Komax 201AE TSSG 207 SPAK

OI Kappa 230 – Version 4 Product description 9

Wire deposition:

fig 1.13 Komax 270 fig 1.14 KA 3000 fig 1.15 KRI 400-T

Miscellaneous:

fig 1.16 External straightening station fig 1.17 PC software under Windows fig 1.18 Guide parts, blades, rollers

fig 1.19 Kappa 230 on workbench with K102 wire-pull unit and K270 wire
deposit unit

10 Product description OI Kappa 230 – Version 4

1.5 Personnel qualifications and training
1.5.1 Personnel qualifications
Machine operator
The machine operator must be sufficiently familiar with the machine to be able to operate it and its
accessories and peripheral devices in production on his own without difficulty.
This requires a good technical understanding of the machine and knowledge of the software for machine
operation.

Service technician
The service technician should have an extensive knowledge of the machine. Apart from machine
operations, he must be able to locate errors and take suitable measures to remedy them. A service
technician must also be able to maintain the machine correctly so as to increase its service life and
availability. He must also know the software very well so the machine can be optimally used in
production.
For this work, the service technician must have wire processing experience. He must also have
completed mechanical or electronic training and be able to demonstrate solid knowledge of the machine.

1.5.2 Training
Komax offers training specially tailored to your needs, whether you are an operator, machine installer,
maintenance technician or service technician. You get to know your product, its accessories and
peripheral devices better and learn how to make optimum use of them in production. A greater
knowledge of maintenance and repairs helps you to increase the service life and availability of the
machine. Every participant who passes the training course is given a certificate.

Courses offered and their contents

The training offerings are divided into machine and module-specific units. Basically, the training covers
the following:
n Company tour
n Machine layout
n Machine maintenance
n Mechanical system
n Electrical system
n Pneumatic system
n Software
n Practical exercises
n Trouble shooting
n Wrap-up discussion

General information on how training courses are organized

n Duration of training:Depends on machine, from 1 to 5 days or as agreed
n Venue of training: Komax Training Center in Dierikon or at customer’s premises
n Accommodations: We are happy to book rooms for you in a hotel (in downtown Lucerne).
n In charge of training: Customer Service at Komax Dierikon
n Languages: German or English
n Class sizes: No more than 3 persons per course.
n Training materials: All materials are distributed on the first day of training.

OI Kappa 230 – Version 4 Product description 11

12 OI Kappa 230 – Version 4
2. Safety

2.1 Explanation of notes

The note boxes in these operating instructions contain one of three symbols to which you must pay close
attention. The symbols are used as follows:
This symbol is found next to safety notes about work procedures posing a hazard to you
or other persons. Pay attention to these warnings and proceed with particular caution
in these instances. You should pass these warnings on to other users.

This symbol is placed next to notes about work procedures during which special care
must be taken to prevent damage to the machine. Pass these safety instructions on to
other users, too.

This symbol signals useful tips on correct procedures and behavior. Follow this advice
and you will save yourself time and unnecessary headaches.

Komax AG assumes no liability whatsoever if the machine operator ignores the instructions
marked on the machine or in this set of instructions.

2.2 Safety notes

Safety of persons

Prior to each startup, check to make sure all safety features, particularly the covers, are
attached and working correctly.

Danger!
Touching live parts is DANGEROUS!

Protective guards may be removed only when the machine is

stopped and the power to it is switched off. Housings and covers,
in particular, may be removed by duly trained persons only.

Danger of injury!

There is a danger of being cut in the area around the blades. Before
working on the cutting head or the blades, ALWAYS turn off the
machine at the main switch.

OI Kappa 230 – Version 4 Safety 13

 Danger of pinching!

There is a danger of being pinched if you come too close to the moving parts
of the machine.
Whenever doing installation, maintenance and repair work on the Komax
Kappa 230, ALWAYS switch the machine off and secure it against unautho-
rized switch-on.

Potentially dangerous parts/areas

W En D Sw C D
ire co riv iv ut riv
dr e el t in e
de ro g ro
aw rr lle gu h lle
-in ol rs id ea rs
le , le e d ,r
rs ft ig
(E ht
nc
od
er
is
op
tio
na
l)

fig 2.1 Machine movements on the Kappa 230

Machine protection

Thorough training of personnel is crucial to protecting the machine from damage.

Personnel’s failure to comply with work procedures can result in damage to parts
of the system. This training includes reading these operating instructions.

14 Safety OI Kappa 230 – Version 4

General safety instructions

The Komax Kappa may be operated, serviced and repaired only by duly authorized and
trained personnel familiar with the safety precautions for the machine.

If you have reason to believe the machine can no longer be operated safely, you must
put it out of commission and secure it against being unintentionally switched on.

Read through these instructions carefully before working on the Komax Kappa for the
first time.

Apart from the notes in these instructions, always observe general rules of safety and
accident prevention.

2.3 Safety features

Emergency stop switch

The front control panel has an emergency stop switch which can be pushed
to stop all machine movements and cut off power to the machine.

Machine main switch

The main switch at the rear of the
machine cuts off the power
supply.

Accessible controls
All controls are readily accessible.

Low noise level of <70dB

The machine can be hazardous if operated incorrectly by untrained personnel.

OI Kappa 230 – Version 4 Safety 15

16 OI Kappa 230 – Version 4
3. Transport/items included in the delivery

When transporting the machine, always follow the instructions below and observe
general rules of safety and accident prevention.

The Komax Kappa 230 is packed in a wooden crate.

Dimensions of the crate (L×H×D): 800×490×490mm, Weight: approx.65kg

The machine is front-heavy!

The Kappa 230 housing has fold-out grips for carrying the machine.

Always pay attention to the handling symbols on the packaging:

40˚C
-20˚C 104˚F
-4˚F

Do not use hand Store in a dry place Do not expose to Sensitive electronic
hooks at less than 40°C direct sunlight components

0
Top Do not load cover Protect against Fragile
moisture

Observe the following points when transporting the system:

Be careful when transporting the machine to prevent damage from impacts or careless loading and
unloading.

Check the machine immediately upon arrival for shipping damage. Report any shortcomings to us
immediately.

OI Kappa 230 – Version 4 Transport/items included in the delivery 17

Items included in the Komax Kappa 230 delivery:

1 Komax Kappa 225 automatic stripper with safety cover

1 Power cable and electrical fine-wire fuses

1 Set of R2 radius blade (mounted on blade blocks)
1 Set of drive rollers (8 rollers, mounted)
1 Swiveling wire guide, 10mm
1 Wire guide, right, 10mm
2 Guide parts, 10mm
1 Set of hexagon socket screw keys
2 Blade calibration wires
1 Set of calibration plates
1 Operating instructions and spare parts list

18 Machine overview OI Kappa 230 – Version 4

4. Machine overview

fig 4.1 Kappa 230 from above

1 Display
2 Function keys
3 Keypad
4 Emergency stop key
5 Wire draw-in
6 Feed rollers for processing side 1
7 Swiveling wire guide
8 Cutting head
9 Wire guide, right
10 Feed roller for processing side 2
11 Switch to open the feed rollers
12 Optional encoder
13 Guide part, left

OI Kappa 230 – Version 4 Machine overview 19

 fig 4.3 Back panel of the machine

1 Main switch
2 Fuses
3 Power supply
4 Connection X2: post-processing (e.g. wire collector)
5 Connection X3: preliminary processing (e.g. hot stamp marker)
6 Connection X4: reserve slot
7 Connection X5: stop input
8 Connection X6: RS232 interface
9 Connection X7: reserve slot
10 Air connection
11 Nameplate

See ‘Description of connections’ in Chapter 9 for connection assignments.

20 Machine overview OI Kappa 230 – Version 4

5. Startup

5.1 Checks prior to startup

Power: - 110V±15%/50–60Hz or 230V±15%/50–60Hz

Device switches automatically from one voltage to another
- Length of power cord: 2.5m
- Use a separate mains socket for the machine!

Compressed air supply: - Air pressure at most 7bar

(to blow out insulation scraps) - Compressed air is water and oil free

Setup location: - Level, stable surface free of vibration

- Keep free of moisture
- Ambient temperature between 0° and 40°C
- Do not cover the vents
- Sufficient space for wire feeding and depositing equipment

5.2 Switching the machine ON and OFF

Switch the machine on at the main switch 1 on the
back panel of the machine. If the machine does not
go on, check whether the emergency stop switch
on the front control panel is pressed down or the
fuses 2 under the main switch are defective:

Following switch-on, the last active menu appears

on the display in the previously selected language.

fig 5.1 Main switch

5.3 Settings prior to production

5.3.1 Wire straightening unit (optional)
The setting shown is ideal for most wire types. It
is important that the wire is straightened more at
the front part of the wire straightening unit so that
it just runs out straightened at the last straightening
roller (x<y).

Setting:
Turn holding screws 1 and 2 to adjust the inclina-
tion of the straightening rollers (basically already
factory-set).
Turn eccentric thumbscrew 3 to close the wire
straightener and turn dial 4 to set the wire diameter.
fig 5.2 Example of a wire straightening unit with 9 rollers

OI Kappa 230 – Version 4 Startup 21

 5.3.2 Feed rollers
Procedure for changing the rollers:
n Open feed rollers 1 with switch 2.
n Now you must switch off the machine!
n Loosen the fastening screws 3 for the feed rollers
and remove the rollers.

n Attach new rollers to the shafts and retighten

the fastening screws.
4x

fig 5.4 Feed rollers

5.3.3 Wire guides

The swiveling wire guide (in front of the blade) and the wire guide to the right (after the blade) must be
adjusted to the outer diameter of the wire being processed.

Procedure:

n Remove any wire that has been drawn into

the machine.

n Pull off the swiveling wire guide 1 and attach

the appropriate guide.

n Make sure the axial seat on the swivel shaft

is good.

n Also pull off the wire guide, right, 2 and attach

the appropriate guide.

fig 5.5 Pulling off the guide parts

If there is axial play in the wire guides, loosen the hexagon nut 3 on the ball-thrust device 4 (fig 5.6 and
5.7) and adjust the device. Retighten the nut after making the adjustment.

fig 5.6 Wire guide, right fig 5.7 Swiveling wire guide

22 Startup OI Kappa 230 – Version 4

5.3.4 Blades
5.3.4.1 Blade types

Standard blades

Radius blades
These blades have a round cutting edge and fit the cross section of stranded
conductors. This allows you to process especially wires with very thin or hard
insulation.

Kappa 220 blades (optional)

V-blades
This blade type is ideal for small diameter wire. Difficulties might arise with the
pull-off of residual insulation with certain types of insulation materials because the
V-shape does not fit precisely around the stranded wires.

Customer-specified blades

Blades for flat cable

These blades can be used for stripping flat ribbon cable with or without
intermediate supporting pieces.

Special versions
Blades can be made to customer specification and specially designed for a
certain type of wire.

fig 5.8

OI Kappa 230 – Version 4 Startup 23

Use of Kappa 220/225 blades

When using Kappa 220/225 blades, make sure they are correctly installed!
(See fig. 5.8 and 5.9)

Correctly installed fig. 5.8

Incorrectly installed fig. 5.9

24 Startup OI Kappa 230 – Version 4

 5.3.4.2 Changing the blades

You must change the blades to process certain types of wire or when their cutting performance begins
declining.

Procedure:

Danger of injury!

There is a danger of getting cut if you get too close to the blades!
Prior to working on the cutting head and blades, always switch off the
machine at the main switch.

fig 5.10 Cutting head fig 5.11 Blade blocks

n Loosen screws 1 and remove the entire blade blocks.

n Loosen fastening screws 2 on blades 3.
n Remove blades and insert new blades.
n When tightening the screws, press the blades against the stop pins 4 in the blade blocks.
n Reinstall blade blocks and loosely tighten screws 1.
n Manually close the cutting head and make sure the blade tips do not collide and block each other.
n Tighten the blade blocks.

OI Kappa 230 – Version 4 Startup 25

26 OI Kappa 230 – Version 4
6. Machine operation

6.1 Basic operator station

Cursor block
Number block

Stop key
Function keys Start key
+/- keys

fig 6.1 Basic operator station for Kappa

Keys Function

Function keys for selecting the various menus and functions

Pressing the MAIN key always returns you to the main menu.

Arrow keys for selecting the entry fields

The active entry field is depicted inversely.

+/- keys
For changing numerical inputs by a defined increment
For changing a parameter (text) in a selection field, e.g. wire type
(norm/doub), preliminary processing options, etc.

For entering numerical values

BACKSPACE key [bs]
For deleting the last character
MINUS/DECIMAL POINT key with double function [-/.]:
If you press this key before entering a number, the number will be negative (e.g. -2mm)
If you press this key after entering a number, a decimal point will be placed in
the number (e.g. 7.5mm)

ESC key
For undoing an input (old value appears on the display again).

ENTER key
The entered or selected value is accepted and the next entry field is selected.
Selecting another entry field has the same effect as pressing ENTER.
Selecting another menu (function key) has the same effect as pressing ENTER.

START/STOP keys
Pressing START commences processing.
Pressing STOP causes processing to stop after the current wire is completed.

OI Kappa 230 – Version 4 Machine operation 27

6.2 Display concept
The display is laid out as follows:

Function key labels

for the current menu
Number of the current
wire data record

Current menu

fig 6.2 Sample programming window

Function key labels:

All caps (e.g. PROD) Menu selection (change)
Lower-case (e.g. load) Function being carried out

Information or possible inputs for the current

menu, e.g. wire display with the parameters
necessary for the selected type of processing

28 Machine operation OI Kappa 230 – Version 4

 6.3 Short overview of user menus
OI Kappa 230 – Version 4

Main menu Most frequently Wire anagement Special

used menus settings
29

OI Kappa 230 - Version 4 Machine operation 29

 6.4 MAIN - main menu
All menus can be activated from the main menu:

n Using the function keys (most frequently used

menus);

n Using the arrow keys to move the cursor and then

pressing ENTER.
Press the MAIN key always switches you to the
MAIN menu. When the device is switched on, the
last active menu appears.
fig 6.3

6.5 LANG - language

The following languages can be selected in the
main menu under the item „Language“:

English Dutch
German Swedish
French Polish
Italian Japanese
Spanish Korean
Portuguese Chinese

The selection is retained when the machine is

fig 6.4
switched off.

6.6 Brief instructions on the three most important menus

6.6.1 TEACH - programming

The processing data (length dimensions and cross
sections) for the wire is entered in this menu. A
picture of the wire appears on the display with an
indication of the direction and type of processing
involved. The corresponding entry fields are ex-
plained in an information box, with the admissible
range indicated where applicable. If an input is
above or below this range, the corresponding limit
value will be selected automatically and an acou-
stic signal will go off.

1 Wire fig 6.5

2 Wire length
3 Type of processing and stripping lengths
4 Data on wire (CRS) and blade values
(cutting depth and wayback)
5 Box with explanations of selected entry field

30 Machine operation OI Kappa 230 – Version 4

Types of processing:

NO Cutting only

HS Stripping with semi pull-off

FS Stripping with full pull-off

PS Multi-step stripping

IM Intermediate stripping

Explanation of further abbreviations:

CRS
CRS
Cross section of core [mm2] or [AWG]

DST
Delta stripping value

Correction value for cutting depth, based on

core diameter d
(d is calculated on the basis of CRS)
Negative value for DST: d + (-DST)
—> deeper cut
Positive value for DST: d + DST
—> shallower cut
Standard value: 0.30

DWB
Delta wayback

Amount that blades open after cut is made or

while pull-off is underway to prevent damage
to the litz wires when insulation is stripped off.
Standard value: 0.60

OI Kappa 230 – Version 4 Machine operation 31

 6.6.2 PPARA - process paramet.
This menu is used for changing data specific to the wire, primarily roller pressure, roller gap, speeds,
etc. The menu has several pages. The first cover the values for wire processing; the ones thereafter cover
the values for the preliminary processing and post-processing of wires.

n First page:
Roller pressure
Pressure exerted to press together feed rollers (10 - 100 %)
Roller gap
Gap between the feed rollers (important for wire check and correct wire transport)

Determining the roller gap:

n Take wire being processing and lay it between
rollers.
n Select ‘Roller gap’.
n Press start.
n The rollers are pressed together and the measured
value is accepted.
The roller gap can also be changed with a manual
input.

nWire check fig 6.6

Check for determining whether there is wire between the feed rollers

Komax recommends you switch off the wire check when processing thin wires.
Otherwise, an error could be detected when there is none.

Wire feed speed

Speed of wire feed
Pull-off speed 1
Speed at which insulation is pulled off on side 1
Pull-off speed 2
Speed at which insulation is pulled off on side 2
Cut speed
Speed at which the blades open and close

Rule of thumb: Do not begin processing at too high a speed and always reduce the
speeds if problems arise.

Wire acceleration
Governs the approach during wire draw-in

32 Machine operation OI Kappa 230 – Version 4

n Following pages: see Chap. 6.7

For large-diameter wires, the „blade start position“ (Chap. 6.7) must be increased
because the default value is 12mm.

6.6.3 PROD - production

After entering the wire data and process parame-

ters, you can begin processing by pressing the
START key.
Piece number and batch size are set here. The
lengths and processes can also be changed here.

F5 (-1):
Piece number and batch size number are reduced
by one.

F6 (reset):
fig 6.7
Piece number and batch size number are reset to
zero.

6.6.4 Programming example

Prerequisite:
All setting procedures must be completed as described in Chapter 5.3.
Stipulated values:
Wire cross section: 0.75mm2

Processing side 1: semi pull-off (HS)

Processing side 2: full pull-off (FS)

Piece number: 100

Batch size: 50

Side 2 Direction of processing Side 1

fig 6.8 Processing lengths

OI Kappa 230 – Version 4 Machine operation 33

Possible order of inputs:

2 5

30

3 6

200

4 7

20 10

34 Machine operation OI Kappa 230 – Version 4

8 11

0.75

9 12

0.1 100 50

10 13

OI Kappa 230 – Version 4 Machine operation 35

6.7 PPARA - further process parameters
Push F6 (next) to select the subsequent pages in the process parameter menu; push F5 (prev) to move
back to the previous page.

Wire type
norm = normal wire
doub = double sheathed wire
Short processing (short mode)
on: Device switches automatically to short mode
depending on the wire length
off: Device does not switch to short mode
Cut start pos.
Starting position for blade during wire advance
Cut wait time
Wait time after cut is made in wire insulation
Corr. blade s. 1 fig 6.9
Cut correction for blade on side 1; allows different blade values to be used for sides 1 and 2
(Definition based on DST)
Blade cleaning
Here insulation scraps can be blown off the machine (optional/on a machine hooked up to compressed air)
Clean after cut
Here the insulation scraps can be blown off the blade during cutting (on a machine hooked up to
compressed air)
Lifter clearance
Wire is reversed before the swivel wire guide is moved upwards (important with large cross sections
where the wires could get stuck at the cutting head)

Wire length actual value

Input of measured wire length
Cor. factor length
Automatically calculated based on the relationship
between the stipulated wire length and the measu-
red wire length
Offset length
Constant correction value
Example: Desired wire length = input wire length +
1mm
Blade radius (info)
Input of blade type used (radius) - for information fig 6.10
only

36 Machine operation OI Kappa 230 – Version 4

Range monitoring
Ensures that the processing length is within the set limits
on: Standard settings on (based on technical data)
off: Standard settings off (A warning icon appears in the PPARA men, and in the PROD and TEACH
menus.) (See fig 6.11 - 6.13)

Keep in mind that when the range monitoring is off, values can be entered which render
correct processing impossible for certain wires.

fig 6.11 fig 6.12

fig 6.13

If range monitoring is switched from OFF to ON, the pertinent limit values apply again
automatically.

OI Kappa 230 – Version 4 Machine operation 37

Preprocessing
off: Preliminary processing OFF
pos: Preliminary processing active, positional
marking
cut: Preliminary processing active during cut-
ting
Feedback signal
off: Ignore feedback signal
high: With feedback in the event of a high signal
low: With feedback in the event of a low signal
Distance
Distance between upstream unit and Kappa, e.g. fig 6.14
with a Komax 26 hot stamp marker:
From middle of marker head to cutting axis of Kappa
Pulse time
Time for which the triggering signal is applied
Wait time
Wait time after triggering signal or maximum wait time till feedback signal
Output 2
off: No wire pulling machine connected
K102_1: K 102 wire pulling machine stops during processing on side 2 for each wire
K102_2: K 102 wire pulling machine does not stop until batch is completed
cut: Pulse time an K 102 until blade cuts

See preliminary processing connection, Chap. 9.2.

Example: Komax 26 as upstream device

Settings feedback signal low
Pulse time 100
Wait time 600

Preliminary processing positions (e.g. marking, intermediate stripping, etc.):

> Position processing 1 side 2

>> Position processing 2 side 2
>>> Position processing 3 side 2
<> Distance for continuous processing
< Position processing 1 side 1
<< Position processing 2 side 1
<<< Position processing 3 side 1

1 Wire length
2 Remaining wire length without preliminary pro-
cessing fig 6.15

38 Machine operation OI Kappa 230 – Version 4

Example: Marker as upstream device

n The distances define the position of text on the

wire. If all the positions are set to 0 but processing
is activated, the marking is done at the lead end
of the wire.
n Possible input for the positions (fig 6.16) and the
result (fig 6.17):

fig 6.16

Side 2 Side 1
Direction of processing

fig 6.17

OI Kappa 230 – Version 4 Machine operation 39

Post-processing
off: Not activated, post-processing is OFF
process 1: Post-processing activated, standard se-
quence required, e.g. for K 260/K 270
process 2: Post-processing activated, special
process required, e.g. with Ramatech
KA 3000/KRI 400
Delay time
Delay time in relation to the commencement of wire
removal. Standard value: 400ms
Feedback signal
off: Ignore feedback signal fig 6.18
high: With feedback in the event of a high signal
low: With feedback in the event of a low signal (applies for example to the Komax 260 wire collector)
Pulse time
Time for which the triggering signal is applied (e.g. for Komax 260: 100ms). Standard value: 100ms
Wait time
Wait time after triggering signal or maximum wait time till feedback signal (e.g. for Komax 260: 200ms).
Standard value: 200ms

See post-processing connection, Chap. 9.2.

Special case for wait time 0ms:

If you enter 0ms as the wait time in the PPARA
process parameter menu, Kappa remains in a wait
state (infinite wait time), e.g. when barrel coilers or
a deposit system is used. The Kappa machine
does not proceed with processing until the down-
stream device has received a feedback signal.
The „@“ character appears in the title line of the
PROD production menu as an indication that 0ms
has been entered (arrow). This wait state can be
aborted by pressing the „stop“ key.
fig 6.19

Length measuring
Shuts length measuring ON/OFF
Stop tolerance
Length deviation permitted before wire advance
stops, indicated in percent.

Note: You must increase the stop tolerance when

producing in short mode!

fig 6.20

40 Machine operation OI Kappa 230 – Version 4

6.8 TEACH - further processes
6.8.1 IM - intermediate stripping
To achieve the result shown in fig 6.21, for example, you must enter the inputs indicated in fig 6.22.

Since the processing lengths are interdependent, the input range could change during
the input, especially for the stripping length (pos. 1, fig. 6.22) and remaining length (pos.
3, fig 6.22).

To arrive at a stripping length of 50mm (fig 6.22), for example, proceed as follows:
1. Enter a stripping length of 40mm (maximum value).
2. Enter the pull-off length (in this example: 20mm)
3. Enter the remaining length of the intermediate pull-off (in this example: 10mm).
4. Enter the pull-off length for the first sectional cut (in this example: 5mm).
5. Return to the stripping length position. You can now enter the value 50mm.

fig 6.21 fig 6.22

1 Stripping length side 1 3 Remaining length intermediate pull-off side 1
2 Pull-off length side 1 4 Pull-off length first sectional cut side 1

6.8.2 PS - multiple-step stripping

To achieve a result like the one in fig 6.23, for example, you must enter the values indicated in fig 6.24:

fig 6.23 fig 6.24

1 Stripping length side 1 3 Sectional cut side 1

2 Pull-off length side 1 4 Distance between the sectional cuts side 1

OI Kappa 230 – Version 4 Machine operation 41

6.8.3 Parameters for processing double-sheathed wires

To process double-sheathed wires, select „doub“ in the process parameter menu for „Wire type“.
Change to the TEACH menu and further entry fields will appear which are needed only for double-sheath
processing.

fig 6.25

1 CRS Cross section of core

2 DIA Diameter of inner insulation
3 DWB Delta wayback for core (inner wire)
4 DWB Delta wayback for inner insulation
5 DST Delta stripping value
6 Diameter of outer insulation (as measured with roller gap)

fig 6.26

42 Machine operation OI Kappa 230 – Version 4

IM - Intermediate stripping with double-sheathed wires
To achieve a result like the one in fig 6.27, for example, you must enter the values indicated in fig 6.28:

fig 6.27 fig 6.28

7 Stripping length outer insulation side 1

8 Stripping length side 1
9 Pull-off length side 1
10 Remaining length intermediate pull-off side 1
11 Pull-off length first sectional cut side 1

PS – Stripping in multiple steps with double-sheathed wires

To achieve a result like the one in fig 6.29, for example, you must enter the values indicated in fig 6.30:

fig 6.29 fig 6.30

12 Stripping length outer insulation side 1

13 Stripping length side 1
14 Pull-off length side 1
15 Sectional cuts side 1
16 Distance between the sectional cuts side 1

OI Kappa 230 – Version 4 Machine operation 43

6.9 CONF - configuration
This menu is used for recording data specific to the machine.

Unit of measure
mm or inch
Unit of cross section
mm2 or AWG
Sequential processing
Can be switched ON/OFF
on: Sequential processing is active. Execute start
in the PROD menu.
Note: No further changes can be made in TEACH,
PROD and PPARA! The piece number is determi-
ned in the SEQU menu and the data is drawn from
the LIST menu. fig 6.31
Sequential number
Two different sequences are possible:
1 or 2
Sequential stop
Intermediate stop in sequence
off: Sequential processing without stop until sequence is finished
on: stop at each sequential position
Input stop
(refer also to Chap. 9)
high: Machine stops in the event of a high signal
low: Machine stops in the event of a low signal
Single step
on: The machine executes the processing movements in single steps. To start, press the START key
in the production menu. Press any key to continue. When a production cycle is over, an acoustical
signal sounds. If the STOP key is pressed after this signal sounds, no zero cut is made in
subsequent production.
STOP key: Abort processing
‘Write from’ protection
0: All protected
150: None protected
Wire numbers greater than the input number cannot be overwritten in the wire list.
Machine ID
Device address for communication in the remote mode

44 Machine operation OI Kappa 230 – Version 4

6.10 LIST - wire list
Wire data can be saved in a list (maximum of 150 wires).

Commands:

Advance through wire list 10

wires at a time

Top entry

Bottom entry

135
Jump directly to wire number
+
135

F5 load Accept data, fig 6.32

i.e.
1 Number of loaded wire data
F6 save Save data,
2 Cursor position
i.e.
3 Wire number
Copy function through multi-
4 Information text (see label)
ple saving
5 Wire cross section
The label is also copied and
6 Wire length
can be changed prior to sa-
7 Processing side 1
ving.
8 Processing side 2

If the wire number is greater than the value of the write protection in the CONF menu,
no saving occurs; an acoustical signal is sounded instead.

F4 - Information text (label)

An information text (at most 8 characters in length) can be entered at the cursor position. The input is
completed by pressing F4 or by pressing one of the function keys and then carrying out the
corresponding function. The input can also be completed by pressing the ESC key, but the old
information text is then retained.
Commands:

Select letters

Accept selected letters

Input numbers

Delete the last character

fig 6.33

Change cursor position 1 Wire number

2 Label (information text)

OI Kappa 230 – Version 4 Machine operation 45

 6.11 SEQU - sequential
The wires defined in the wire list can also be processed as sequences on the Kappa 230. There are two
possible sequences. Select the desired sequence (sequence number) in the CONF menu. A sequence
consists of at most 100 positions.
Commands:

F5 Accept the loaded wire into

(ins) sequence.

Move cursor to desired

sequence position.

Select the entry field, 3, 4 or 5

(fig 6.34).
fig 6.34
1 Current sequence number
Select a data record from the 2 Sequence position
wire list or change the length 3 Number of the wire data record from the
and quantity. wire list
4 Wire length for this sequence position
F6 Delete wire from sequence. 5 Quantity of wires to be produced
(del) (multiplier)
6 Information text from the wire list
7 Number of wires in the sequence

Procedure for entering a sequence:

n F5 (ins): Insert the wire data record with the current

number in the sequence.
n Change the number of the wire data record as you
wish.
n Determine the wire length for this sequence posi-
tion (initial value is the length indicated in the wire
list).
n Set the multiplier.
n Repeat for the desired quantity of positions in the
sequence.

fig 6.35

46 Machine operation OI Kappa 230 – Version 4

 Since the wire length pertains to the sequence position, the same data record can be
used to produce different lengths very quickly. To do so, just change the length and the
rest of the wire data is transferred.

Zero can be set as the number of positions but a sequence of this kind cannot be started.

Since the sequence is saved when you exit the menu, make sure you change to another
menu before switching off the machine.

Sample application:
Wires are to be produced with the same processes on side 1 and side 2, but are to be of different lengths.
The different wires are required individually and undergo further processing immediately (e.g. in a
production cell).

n Program wire processing and save in the wire list

(check processing).
n Insert the desired number of wires in the sequence
menu with F5.
n Enter different lengths per sequence position.
n Switch sequential processing and sequential stop
in the CONF menu to ON.
n Select the PROD menu.
fig 6.36
n Press START; every time a start command is
issued, the machine produces a sequence positi-
on and then waits. The current sequence number,
the sequence position and the quantity of wires in
the sequence are displayed above the wire in the
PROD menu.

6.12 REMOT - remote

A remote menu can be selected in the main menu.
The Kappa 230 is then operated from an external
PC on which the PC version of the Kappa software
has been loaded.

The Kappa software version has to be F103b/

F385a or higher. It is briefly displayed after the
machine is turned on.

fig 6.37

OI Kappa 230 – Version 4 Machine operation 47

48 OI Kappa 230 – Version 4
 7. Malfunctions/error messages

7.1 Malfunctions

Machine does not start when it is switched on.

n Check power connection.
n Release emergency stop switch.
n Check fuse at power cable inlet.

Machine is running but does not respond.

n Switch off the machine, wait a while and then switch it back on again.
n Check for possible blockage at upstream or downstream devices.
n Close safety cover.

Cutting quality
Poor quality cutting of insulation may be traced to a variety of factors:

Reason Remedy

Worn blades Replace old blades with new ones

Wrong blade type (e.g. V instead of radius blade) Change blade type

Processing speeds too fast Reduce speeds

Cut too shallow Correct values

Soft or tough insulation Enter wait times

Insulation scraps adhering to statically charged blades Connect blow-off device

Dimensional accuracy
If the dimensions of the produced wires do not match the entered values, check the following:

n Correct setting for straightening station

n Correct guide parts

n Appropriate and clean feed rollers

n Optimum roller pressure and roller gap; if not, correct the measured value

n Processing speeds too fast

OI Kappa 230 – Version 4 Malfunctions/error messages 49

7.2 Error messages on the display
If the machine detects an error, a self-explanatory error message appears on the display.

Wire feed messages

3 - Error wire removal check
Error in removing the wire. After wire removal, no wire should be present under
the feed rollers on side 2.
Cause:
Wire jam at feed rollers on side 2.
Wire is too thin for wire monitoring function.
Roller gap is incorrectly set in process parameters.

4 - Error in wire draw-in side 1 and side 2

Wire must be present under both feed rollers during wire draw-in.
Cause:
Device is out of wire.
The wire was deflected prior to reaching the feed rollers on side 2.
The wire was deflected prior to reaching the feed rollers on side 1.
Wire is too thin for wire monitoring function.
Roller gap is incorrectly set in process parameters.

5 - Error in wire draw-in on side 1

If the wire is not detected by the feed rollers on side 2, only the feed rollers on side
1 are monitored during wire draw-in.
Cause:
Device is out of wire.
Wire is too thin for wire monitoring function.
Roller gap is incorrectly set in process parameters.

Cover message
6 - Cover open
Cover is open or was opened during processing.

Reference position message

7 - Calibration check carried out
The device’s reference positions have not been calculated. Refer to the section
on maintenance.

Piece number message

8 - Piece number reached

50 Malfunctions/error messages OI Kappa 230 – Version 4

Pressure monitoring message
9 – Pressure monitoring unit responded
The roller pressure is too high. Reduce the roller pressure or reset/enter the roller
gap.

Message regarding processing length

10 - Residual insulation < 0
The pull-off lengths are excessive for the selected wire length. Correct the lengths.

Length measuring message

11 – Wire feed was stopped
The deviation of the length measuring system is too large. Set the stop tolerance
or check the wire feed. There may be a knot in the wire or the wire may have caught
on something.

12 – Hardware error in the length measuring system

Maybe the encoder is not plugged in.

Short mode messages

20 - Short mode not possible
The wire is being processed in short mode because of the length of the residual
insulation. In this case, it is not possible to run the processes IM and PS nor to
process double sheathed wires.
Possible remedy:
An attempt can be made to process the wire in normal mode by deactivating the
switchover to short mode in the process parameters.

21 - Stripping length too long

The wire is being processed in short mode because of the length of the residual
insulation. The stripping length is too long. The stripping length in short mode is the
sum of the stripping length on side 1 and the pull-off length on side 2.

22 – Pull-off length is too long

The wire is being processed in short mode because of the length of the residual
insulation. The pull-off length is too long. The pull-off length is the sum of the pull-
off length on side 1 and the pull-off length on side 2. This message cannot appear
because of the restrictions to the entries.

OI Kappa 230 – Version 4 Malfunctions/error messages 51

Processing length messages
30 - Stripping length inside > outside on side 1
With a double-sheathed wire the outside stripping length on side 1 is less than the
inside stripping length. This message cannot appear because of the restrictions
to the entries.

31 - Stripping length inside > outside on side 2

With a double-sheathed wire the outside stripping length on side 2 is less than the
inside stripping length. This message cannot appear because of the restrictions
to the entries.

40 - Stripping length on side 1 incorrect

The stripping length on side 1 is too long.

41 – Pull-off length on side 1 incorrect

The pull-off length on side 1 is too long.

42 - Sectional stripping length on side 1 incorrect

The sectional cut length or the length of the intermediate pull-off on side 1 is too long.

43 - Sectional distance on side 1 incorrect

The distance between the sectional cuts or the distance of the intermediate pull-
off on side 1 is too great.

44 - Pull-off length on side 1 is too long

While processing in sectional cuts PS, the pull-off length on side 1 has become
too long. The lengths must be reduced.

52 Malfunctions/error messages OI Kappa 230 – Version 4

45 – Maximum number of processes is too large
The number of processing steps for processing in sectional cuts on side 1 has
become too large. The sectional cut length must be reduced.

The error messages 40 to 45 are repeated under the numbers 50 to 55 for processing on
side 2.

Messages regarding external stop input

60 - Monitoring external stop input
The external stop input X5 has detected a stop.
Cause:
Device responded at stop input
The feedback signal for the stop input is incorrectly defined in the configuration.
No device is connected at X5 and the feedback signal for the stop input is set at
high instead of low in the configuration.

Messages regarding feedback signal from upstream device

70 - Timeout upstream at low
This input of the upstream device (X3) detected an incorrect feedback signal after
the wait time expired. Signal is high instead of low.
Causes:
Upstream device set the feedback signal incorrectly.
The wait time in the process parameters is incorrect.
The feedback signal in the process parameters is incorrect.

71 - Timeout upstream at high

This input of the upstream device (X3) detected an incorrect feedback signal after
the wait time expired. Signal is low instead of high.
Causes:
Upstream device set the feedback signal incorrectly.
The wait time in the process parameters is incorrect.
The feedback signal in the process parameters is incorrect.

76 - Feedback signal low: Level after pulse is low instead of high

The input of the upstream device (X3) detected an incorrect feedback signal after
the pulse time expired. Signal is low instead of high.
Causes:
Upstream device set the feedback signal incorrectly.
The pulse time in the process parameters is incorrect.
The feedback signal in the process parameters is incorrect.

77 - Upstream feedback signal: Level after pulse is high instead of low

The input of the upstream device (X3) detected an incorrect feedback signal after
the pulse time expired. Signal is high instead of low.
Causes:
Upstream device set the feedback signal incorrectly.
The pulse time in the process parameters is incorrect.
The feedback signal in the process parameters is incorrect.

OI Kappa 230 – Version 4 Malfunctions/error messages 53

Messages regarding processing lengths for upstream device
73 - Upstream device max. number of processes
Error in processing on upstream device. The number of processes on wire is too
large.
Cause:
The length for continuous processing ( <X> ) is too short.

74 - Sum of distances for upstream device > wire length

Error in processing on upstream device. The sum of the processing lengths is
greater than the wire length.

Messages regarding feedback signal downstream device

80 - Timeout downstream at low
This input of the downstream device (X2) detected an incorrect feedback signal
after the wait time expired. Signal is high instead of low.
Cause:
Downstream device set the feedback signal incorrectly.
The wait time in the process parameters is incorrect.
The feedback signal in the process parameters is incorrect.

81 - Timeout downstream at high

This input of the downstream device (X2) detected an incorrect feedback signal
after the wait time expired. Signal is low instead of high.
Causes:
Downstream device set the feedback signal incorrectly.
The wait time in the process parameters is incorrect.
The feedback signal in the process parameters is incorrect.

82 - Feedback signal low: Level after pulse is low instead of high

The input of the downstream device (X2) detected an incorrect feedback signal
after the pulse time expired. Signal is low instead of high.
Cause:
Downstream device set the feedback signal incorrectly.
The pulse time in the process parameters is incorrect.
The feedback signal in the process parameters is incorrect.

83 - Feedback signal high: Level after pulse is high instead of low

The input of the downstream device (X2) detected an incorrect feedback signal
after the pulse time expired. Signal is high instead of low.
Cause:
Downstream device set the feedback signal incorrectly.
The pulse time in the process parameters is incorrect.
The feedback signal in the process parameters is incorrect.

54 Malfunctions/error messages OI Kappa 230 – Version 4

Message regarding internal error
Error 0
Depending on the error, you can abort or advance to another page (more) to obtain
more detailed information.

Message regarding detailed system error

The detailed error message provides more precise information that helps Komax
pinpoint the error.

Blade axis message

Blade axis speed is too high. Machine must be switched off and back on again.
Reduce blade axis speed and start production.

OI Kappa 230 – Version 4 Malfunctions/error messages 55

56 OI Kappa 230 – Version 4
 8. Maintenance/repairs

Only duly authorized personnel is allowed to carry out all conversion, maintenance and
repair work on the Kappa 230. The machine must be shut off during this work.

If the housing has to be opened up, any detached and/or opened parts of it must be re-
attached and/or closed again immediately once the work is done.

8.1 Maintenance
The Kappa 230 requires no actual maintenance (e.g. lubrication, etc.). Since malfunctions are generally
caused by dirt, you are advised to keep the machine clean at all times.
Do not use fraying materials such as cleaning wool or the like to clean the machine.
Do not use compressed air; it will merely drive tiny bits of insulation into the machine and could lead
to malfunctions. A small brush is the best way of removing any wire remnants.

8.2 Calculating reference positions

8.2.1 Reference blade
During initial startup or after repairs (e.g. when toothed belts are replaced, new motor installed), the
blade’s zero position must be recalculated. Proceed as follows:

n Switch off device.

n Remove swiveling wire guide.
n Make sure the calibrating plates are inserted.
n Insert blade calibration wire 1 into the calibration
receptacle 2 and place the wire between the
plates.
n Close the safety cover.
n Switch on device.
n Press F6 after the software version is displayed.
n Select the Reference blade entry field (see fig 8.2).
n Press START; the new calibration position is auto- fig 8.1

matically saved.
If a whistle sounds, this means the calibration of
the cutting head did not succeed and you must
repeat the procedure.
n Press the MAIN key to exit the menu.
1 Temperature
2 Encoder test (turning the encoder changes the
value)
3 Total piece counter (reset by pressing the zero
key)
4 System time
fig 8.2

OI Kappa 230 – Version 4 Maintenance/repairs 57

 8.2.2 Reference gap (rollers)
Proceed as follows:

n Remove the wire from between the rollers.

n Switch on device.
n Press F6 after the software version is displayed.
n Select the entry field Reference gap 1 for feed
rollers on side 1 and the entry field Reference gap
2 for feed rollers on side 2.
n Press START and the new calibration position of
the rollers is automatically saved. fig 8.3

If a whistle sounds, this means the roller calibration was unsuccessful and you must repeat the
procedure.
n Press the MAIN key to exit the menu.

8.2.3 Test functions

Test functions can be activated on the same page as reference blades and reference rollers. These
functions are intended for commissioning at Komax or for Komax service staff. Here the functioning of
the machine’s motors and sensors can be individually tested.
Procedure:
Use the arrow keys to select the desired motor or output and trigger the function by pressing the +/- key.
To exit this page:
Press the MAIN key.
Abbreviations used:

SM1 Blade axis ST Stop input X5

(incrementally with +/- key) V1 Input Preliminary processing X3
SM2/3 Feed rollers, left V2 Input 2 Preliminary processing X3
(Processing side 1) SA Reserve (X5)
SM4/5 Feed rollers, right N1 Input Post-processing X2
(Processing side 2) N2 Input 2 Post-processing X2
(on/off with +/- key) S1 Calibration receptacle/wire monitoring S2
SM6 Drive for rollers open/close side 1 S2 Reference sensor, blade axis
SM7 Drive for rollers open/close side 2 S3 Reference sensor, roller gap S1
SM8 Drive for swivel guide up/down S4 Reference sensor, roller gap S2
Out 24_1 Fan S5 Safety cover
Out 24_2 Valve blade cleaning (optional) S6 Switch for feed rollers OPEN
Out 40_1 Reserve slot S7 Switch for feed rollers CLOSE
Out 40_2 Reserve slot S8 Calibration sensor/wire monitoring S1
VOut_1 Output 1 Preliminary processing X3 S9 Calibration sensor S2
VOut_2 Output 2 Preliminary processing X3 S10 Reference sensor for swivel guide
NOut_1 Output 1 Post-processing X2 S11 Monitoring of roller pressure
NOut_2 Output 2 Post-processing X2

58 Maintenance/repairs OI Kappa 230 – Version 4

 8.2.4 Non deletable total piece counter
Another control function involves a non deletable total piece counter 1. To call it up proceed as follows:

n Switch on device.
n After software version appears, press the F6 key.
n The non deletable total piece counter will appear
on the display.
n Press the MAIN key to exit the menu.

fig 8.4

OI Kappa 230 – Version 4 Maintenance/repairs 59

60 OI Kappa 230 – Version 4
9. Description of connections

9.1 Preliminary processing connection

fig 9.1

Feedback = off

Pulse time Wait time

Feedback = low

Pulse time Wait time

Error 76 Error 70
Feedback = high

Pulse time Wait time

Error 77 Error 71
fig 9.2

Reset pulse

Pulse time

fig 9.3

OI Kappa 230 – Version 4 Description of connections 61

9.2 Post-processing connection

fig 9.4

Feedback = off

Delay time Pulse time Wait time

Feedback = low

Delay time Pulse time Wait time

Feedback = high Error 82 Error 80

Delay time Pulse time Wait time

Error 83 Error 81

fig 9.5

Reset pulse

Pulse time

fig 9.6

62 Description of connections OI Kappa 230 – Version 4

 9.3 Stop input connection

fig 9.7

Stop input = low

Stop input = high

fig 9.8

9.4 RS232 interface connection

fig 9.9

OI Kappa 230 – Version 4 Description of connections 63

64 OI Kappa 230 – Version 4
10. List of accessories
Art. No. Designation
Blades
0044211 Set of hard-metal blades R2 (Standard)
0044212 Set of hard-metal blades R2.5
0044213 Set of hard-metal blades R3
0044214 Set of hard-metal blades R4
0044215 Set of hard-metal blades R5
0044216 Set of hard-metal blades R6

Art. No. Designation

Wire guides
0044016 Swiveling wire guide 2mm
0044017 Swiveling wire guide 3mm
0044018 Swiveling wire guide 4mm
0044019 Swiveling wire guide 5mm
0044020 Swiveling wire guide 6mm
0044021 Swiveling wire guide 7mm
0044022 Swiveling wire guide 8mm
0044023 Swiveling wire guide 9mm
0044024 Swiveling wire guide 10mm
0044025 Swiveling wire guide 12mm
0044026 Swiveling wire guide 14mm
0044027 Swiveling wire guide 16mm

0044101 Wire guide, right, 2mm

0044102 Wire guide, right, 4mm
0044103 Wire guide, right, 6mm
0044104 Wire guide, right, 8mm
0044105 Wire guide, right, 10mm
0044106 Wire guide, right, 12mm
0044107 Wire guide, right, 14mm
0044108 Wire guide, right, 16mm

0044109 Wire guide, left, 2mm

0044110 Wire guide, left, 4mm
0044111 Wire guide, left, 6mm
0044112 Wire guide, left, 8mm
0044113 Wire guide, left, 10mm
0044114 Wire guide, left, 12mm
0044115 Wire guide, left, 14mm
0044118 Wire guide, left, 16mm

OI Kappa 230 – Version 4 List of accessories 65

 Art. No. Designation
Miscellaneous parts 0040506 External, horizontal straightening
station, complete
0043984 Integrates length measuring system
with encoder
0024340 PC software
0041437 Blade cleaning kit

See spare parts catalog for further components!

66 List of accessories OI Kappa 230 – Version 4

 1 2 3 4 5 6 7 8

Jumper: gesetzt / set

X7
9
nicht gesetzt / not set
8
7
6
G1 A3 Bedienerfrontplatte kpl. / Operator's panel cpl.
5
Speisung Leistungsteil 2 S1 Not-Aus 5
Jumper auf Tastaturprint 1: 4
Power supply power part 2 emergency stop J3, J6 3
A Jumper on keyboard PCB 1: 3 A
X1 1 2 3 4 A1 2
2
1 RS422-1 Encoder 1 2 Rechnerprint H8/532 / PCB H8/532
5A T 1
P 2
+5V 1
3 Reserve
5A T GND 2
N 4 N 4 BR1 D-SUB Buchse 9pol
+24V 3
3 P 4 D_SUB socket 9 pole
PE1 GND
2 1 RS422-2
+40V 5
PE 1 PE 2 X6
GND 6 9
3 X4
8
Netzstecker mit Filter P4 P6 4 VRB LT2 K24 24pol
7
Main plug with filter X3
6
2 GND 5
5
1 +24V 4
SM21 SM22 SM23 3
BR2 10pol 3
1 #NAME?
8 1 #NAME?
8 1 #NAME?
8 2
2
PE2 PE3 X5 1
Mechanik Frontplatte Mechanik Bedienerfrontplatte K21 K22 K23 X1 20pol X3 60pol
Mechanics front plate Mechanics operator's panel Remote
RxD
TxD
Gnd

K3
X4 4 1 #NAME?
8 1 #NAME?
8 1 #NAME?
8 3 5 9 D-SUB Buchse 9pol
3 D-SUB socket 9 pole
2
1 SM6 SM7 SM8
(SM21) (SM22) (SM23) K1 K2
CPC 4pol
Reserve
Rollen Distanz Seite 1 Rollen Distanz Seite 2 Wippe auf/ab
A2
Roller distance side 1 Roller distance side 2 Lifter up/down
5-mal 2Phasen SM-Endstufe
X2 14 5-times 2 phase SM final stage
B 13 24V 1 2 3 4 5 6 7 8 9 10 1112 B
12 12 IO_2 Sens InOut
11
11
10
10
9 Power 5/24/40 V
9
8 GND
8
7 N1
6 7
6 K4
8
8

5 5
4 Rollen Seite 2 oben
#NAME?

4
#NAME?

3 N2 SM5 Rollers side 2 up

3
2
1
1

2
SM5

1
1
K5
8
8

CPC 14pol
Nachschaltgerät Rollen Seite 2 unten
#NAME?

Downstream device SM4 Rollers side 2 down

1 #NAME?
1

SM4

X5 4
3 K6
8
8

2
1 Rollen Seite 1 oben
#NAME?

SM3 Rollers side 1 up

CPC 4pol
1 #NAME?
1

SM3

Stop
K7
8
8

C X3 14 Rollen Seite 1 unten C

JP01 JP06 JP07 JP05 JP08 JP09 JP02 JP03 JP04 JP10 JP11
#NAME?

13 24V SM2 Rollers side 1 down

12
1 #NAME?
1

12 IO_1
SM2

11
11
10 K8
10
8
8

9
9
8 8 GND Messerachse
#NAME?

7 V1 SM1 Blade axis

7 24V VCC
6
1 #NAME?
1

6
SM1

5 Out24V_1 Out24V_2 Out40V_1 Out40V_2 GND

5 24V 24V 40V 40V
4
4
3 V2
3
2
1 2
1
CPC 14pol S01 S06 S07 S05 S08 S09 S02 S03 S04 S10 S11 T2
Vorschaltgerät 1 2 1 2 1 2 1 2 GND 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
Upstream device

K11 K12 K13 K14 K15 K16 K17 K18 K19 K20
S3 SM3 SM5
21
Rückansicht kappa 230
Back view of kappa230 E1 22
Haubenüberw. + O - + O - + O - + O -
X6 X7 Cover check B1 B2 B3 B4
X1 X2 X4 Lichtschranke Lichtschranke Lichtschranke Lichtschranke
Light barrier Light barrier Light barrier Light barrier S7/1 S7/2
S2 SM2 SM4
D Lüfter E2 D
Fan

9p fmale
9p fmale
S6/1 S6/2
Messereichung Messerachse Distanz S1 Distanz S2 Wippe Anpressdrucküberwachung SM1
X3 X5 Kabelüberwachung S.2 S4/1 S4/2 S5/1 S5/2 Blade axis Distance S1 Distance S2 Lifter Roller pressure check
Blade calibration Wippenschalter Rollen auf/zu
Wire check S.2 Switch rollers open/close
Ausblas-Ventil Seite 2 Kalibriersensor Elektroschema / Electrical diagram kappa 230 4WD copyright by
Blow-off valve Side 2 calibration sensor Komax AG
Seite 1 Industriestr.6
Kalibriersensor und Kabeküberwachung Size: A3 Doc-Nr: F427c Art.Nr.: 024735 Datum/Visum: 19.01.2012 CH-6036 Dierikon
Side 1 Switzerland
Abt./Ersteller: EA / B.Renggli Sheet 1 of 1
Calibration sensor and wire check
1 2 3 4 5 6 7 8