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Lead Makers and Harness Makers

Lead Makers and Harness Makers

Application Tooling and Equipment Portfolio

Applicators Board Processing Equipment Crimp Machines and Equipment Equipment for Electrical Testing FFC-FPC Equipment Hand Tools IDC Machines Insertion Machines for Single Contacts Lead Makers Magnet Wire Equipment MOST Equipment SOLARLOK Equipment Installation, Inspection and Service as well as Training and Short Term Rental Crimp Applicators within EMEA region

MOST is a trademark of SMSC Europe GmbH.

For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

Lead Makers and Harness Makers

Efficiency and Flexibility in Cable Production

High quality demands are placed on modern cable production. Shorter production cycles require increasingly flexible manufacturing processes. TE Connectivity ensures economic cable assembly at all times. Small batch sizes and just-in-time production are the order of the day. As a result, fast and easy retooling of the machines is an increasingly important consideration. Fully automatic crimping machines have been designed to meet this requirement. Based on state-of-the-art technologies the machines are designed to process single strands, twisted wire pairs, double crimp connections and to load housings. The modular design and integrated quality controls with good/poor handling enable maximum flexibility and process reliability. Due to the latest, multi-lingual user software the equipment can be widely networked. From compact machines with two processing systems, to flexible fully automatic machines with six stations and double gripper units up to variably upgradeable linear transfer systems, TE Connectivity offers a wide range of easy to network fully automatic crimping machines. For more information please contact your TE Connectivity Application Tooling (AT) representative.

For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

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Lead Makers and Harness Makers

Table of Contents

Page

Lead Makers

Gamma 255 Lead Maker

Fully Automatic Crimping Machine

3 4 5 6 7 8 9 10 11 12

Gamma 333 PC / 333 PC B Lead Maker

Fully Automatic Crimping Machines

Alpha 355 / Alpha 355 S Lead Maker

Fully Automatic Crimping Machines

Alpha 356 Lead Maker

Fully Automatic Crimping Machine

Alpha 358 Lead Maker

Fully Automatic Crimping Machine

Alpha 433 S / Alpha 433 H Lead Maker

Fully Automatic Crimping Machines

Alpha 455 Lead Maker

Fully Automatic Crimping Machine

Alpha 477 Lead Maker

Fully Automatic Crimping Machine

Alpha 488 Lead Maker

Fully Automatic Processing Machine

Zeta 633 and Zeta 633 L Lead Maker

Fully Automatic Processing Machine

Harness Makers

Zeta 651 Harness Maker

Fully Automatic Processing Machine

13 14

Zeta 656 Harness Maker

Fully Automatic Processing Machine

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For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

Lead Makers

Gamma 255 Fully Automatic Crimping Machine

Gamma 255 Lead Maker

The Gamma 255 lead maker is a flexible fully automatic crimping machine for efficient wire processing. It processes cross sections in a range from 0.0123 mm2/AWG 36 to 2.5 mm2/ AWG 14. It is compatible with all commercially available applications. It also handles double-sided crimped wires as short as 20 mm. The entire cross section is processed using programmable, highly dynamic servo-drives and V stripping blades. As part of its standard equipment, the machine has a prefeeder, splice, wireend and knot detection, as well as two wire straightening units. A bad wire handling system with automatic postproduction is also integrated in the Gamma 255 lead maker. To verify quality, you can also integrate devices for measuring crimp height and pull-out force right into the production process. The compact layout is carefully thought-out and allows you to change over from crimping to twisting, fluxing and tinning very fast.

TopWin is a trademark of Komax AG.

Technical Data: With its vertically opening safety cover, the Gamma 255 lead maker is readily accessible from all sides. Operations and material handling are convenient and simple. The reliable TopWin software user interface adds to this high level of user convenience in over 20 different languages. Key features: Reliable processing of a larger range of cross sections Double side crimping or twisting, fluxing and tinning (even lead-free) Can handle double side crimped wires as short as 20 mm Minimal footprint thanks to a compact design High equipment standards TopWin software with graphical user interface Readily accessible Over 20 different languages available

Length range 15.0­10,000 mm Length accuracy [0.2% +1.0 mm (0.04 in)] Stripping lengths 0.1­15.0 mm Wire cross section* 0.0123­2.5 mm2 (AWG 36­AWG 14) Wire draw-in speed max. 3 m/s Noise level <75 dB (without crimp module) Electrical connection 3x 208­400 V 50/60 Hz 1x 230 V 50/60 Hz Pneumatic connection 5­6 bar / 500­600 kPa Air consumption 3 m3/h Weight 870 kg gross (with packaging)

* The Gamma 255 lead maker may also be able to process wires outside the indicated cross section range. Certain types of extremely hard, tough wires may not be able to be processed even though they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

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Lead Makers

Gamma 333 PC and 333 PC-B Fully Automatic Crimping Machines

Technical Data:

Length range 60.0­65,000 mm (2.36 in­213.3 ft) Optionally from 30.0 mm (1.18 in) Length accuracy (Repeat) [0.2% + 1 mm (0.04 in)] Stripping lengths Side 1: 0.1­15.0 mm (0.004­0.59 in) Optionally from 28.0 mm (1.10 in) Side 2: 0.1­15.0 mm (0.004­0.59 in) Wire cross section* 0.22­5.0 mm2 (AWG 24­AWG 10) Optionally from 0.13 mm2 (AWG 26) Wire draw-in speed 6 m/s ­ Gamma 333 PC 10 m/s ­ Gamma 333 PC-B Noise level <75 dB (without crimp module) Electrical connection 3x 208­480 V 50/60 Hz Pneumatic connection 5­6 bar (73­87 psi) Air consumption 6.5 m3/h / 500­600 kPa (230 ft3/h) Weight 1,200 kg (2,649 lbs) gross Dimensions (W x D) 3,137 x 1,377 mm (123.5 x 54.2 in) Height with cover closed: 1,790 mm (70.5 in) Height with cover open: 2,670 mm (105.1 in)

* Certain extremely hard, tough wires may not be able to be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires

Gamma 333 PC / 333 PC-B Lead Maker

The Gamma 333 PC lead maker is a flexible fully automatic crimping machine for efficient wire processing. It processes cross sections in a range from 0.13­5.0 mm2 (AWG 26­AWG 10). Short conversion times, additional applications and a user-friendly user interface with multiple-language capability. The Gamma 333 PC and Gamma 333 PC-B lead makers (B-version with beltdrive) makes it all possible! With its third processing station and state of the art control software, you are provided high flexibility and an even more efficient way of meeting your wire processing needs. With an additional processing station on side 1, the Gamma 333 PC lead maker enables you to crimp both ends of the wire, to create double crimp connections with three different contacts, to carry out one-ended seal application, tinning or ink-jet marking. In addition, process monitoring is all integrated to ensure that the wire is cut to length and stripped perfectly.

Key features: Exact reproducible settings for processing stations Maintenance-free step and servo motor of top quality Very short conversion times thanks to integrated processing modules Highly comfortable and convenient to operate thanks to graphic-based TopWin software User specified language ­ more than ten different languages to choose from Integrated good/bad sorting Can be networked with additional WPCS (Wire Processing Communication Standard) software

TopWin is a trademark of Komax AG.

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For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

Lead Makers

Alpha 355 and Alpha 355 S Fully Automatic Crimping Machines

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

Technical Data:

Length range 60.0­65,000 mm (2.36 in­213 ft) Optionally from 30 mm (1.18 in) Length accuracy (Repeat) [0.2% +1.0 mm (0.04 in)] Stripping lengths 0.1­35.0 mm (0.004­1.38 in) Stripping lengths with partial pull-off Beginning of wire: 47.0 mm 1 mm (1.86 in 0.04 in) End of wire: 35.0 mm 1 mm (1.38 in 0.04 in) Wire cross section* 0.22­6.0 mm2 (AWG 24­AWG 10) Optionally from 0.13 mm2 (AWG 26) Wire draw-in speed max. 12 m/s (39 ft/s) Noise level <75 dB (without crimp module) Electrical connection 3x 208­480 V 50/60 Hz, 5 kVA Pneumatic connection 5­8 bar / 500­800 kPa (73­116 psi) Air consumption 9 m3/h (318 ft3/h) Weight 1,300 kg (2,866 lbs) including two crimp and seal modules

* Extremely hard, tough wires may not be able to be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

Alpha 355 Lead Maker

The Alpha 355 lead maker is designed for one and two-sided crimping and seal loading. It even handles doublecrimp connections involving varying lengths and the same wire types without any problem. The precise dualchannel blade system allows for a large range of wire sizes without blade changes. With options like the manual wire selector and/or the quick-change system for crimping tools, materials and tools can be prepared for the next job while the machine is running. Key features: Short changeover times Reliable process monitoring High production output Setup of next job while production of current job is underway WPCS (Wire Processing Communication Standard) Q-monitoring, CFA+ (Crimp Force Analyzer), SPM (Seal Position Monitor)

Alpha 355 S Lead Maker

The Alpha 355 fully automatic crimping machine is a proven performer and now available in a model offering the flexible selection of modules. The high safety cover and the flat table design is the most striking difference between this version and the Alpha 355 lead maker. It allows processing modules not specifically designed for certain machines to be mounted. One of the two module slots on each processing side is fitted with special mounting tables to accommodate the various mounting methods. Combined with the ingenious open-ended software interface, the flexibility of the Alpha 355 S lead maker can be increased. Key features: Flexibility in module selection Reliable basic machine Open-ended software interface WPCS Q-monitoring, CFA+ (Crimp Force Analyzer), SPM (Seal Position Monitor)

For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

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Lead Makers

Alpha 356 Fully Automatic Crimping Machine

Technical Data:

Length range 60.0­65,000 mm (2.36 in­213 ft) Optional 30.0­60.0 mm (1.18­2.36 in) Length accuracy (Repeat) [0.2% +1.0 mm (0.04 in)] Stripping lengths 0.1­35.0 mm (0.004­1.38 in) Stripping lengths with partial pull-off 47.0 mm (1.85 in) on side 1 35.0 mm (1.38 in) on side 2 Optionally up to 80.0 mm (3.15 in) Wire cross section* 0.22­6.0 mm2 (AWG 24­AWG 10) Optionally from 0.13 mm2 (AWG 26) Wire draw-in speed max. 12 m/s (39 ft/s) Noise level <75 dB (without crimp module) Electrical connection 3x 208­480V 50/60 Hz, 5 kVA Pneumatic connection 5­8 bar / 500­800 kPa (73­116 psi) Air consumption 9 m3/h (318 ft3/h) Weight approx. 1,400 kg (3,090 lbs)

* Certain extremely hard, tough wires may not be able to be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

Alpha 356 Lead Maker

The Alpha 356 fully automatic crimping machine has room for up to seven processing stations. A wide variety of configurations are possible, in fact, almost any combination of crimping, seal loading, fluxing/ tinning, twisting, fitting with insulating sleeves and end sleeves for strands as well as bulk turned contacts and customer-specific processes. In a configuration featuring three crimping presses, for example, you can crimp the three wire ends for double-crimp connections with different contacts or select different articles without a machine changeover. With the rotating wire selector and the TopWin user software, you can complete most of the preparations for the next job while the current one is still being produced on the machine. Crimping tools, contact rolls and other application-specific parts can be changed without tools. Thanks to the use of the modern technology, the production output ­ and the degree of process control ­ is extremely high in this machine generation.

Key features: High flexibility with up to seven processing stations Both standard and customer-specific processes can be integrated Wide choice of different processing configurations High productivity thanks to the latest technology Integrated quality measurements Next job can be prepared while machine is processing current job Combinable in networks using WPCS (Wire Processing Communication Standard) interface

TopWin is a trademark of Komax AG.

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For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

Lead Makers

Alpha 358 Fully Automatic Crimping Machine

Alpha 358 Lead Maker

The Alpha 358 fully automatic crimping machine sets new standards in the processing of long cables. Coiling and binding cables directly in the fully automatic crimping machine frees up substantial space and offers considerable quality advantages. Fitted with an ingenious coiling and binding system, this machine can save you the production space otherwise required for long deposit units. Cables up to 35 meters (27.34 yd) in length can now be processed at high speed on a machine just four meters (4.37 yd) long. The coiler is fully integrated in the machine. The coiling process can be optimally adapted to the material being processed in order to optimize the output. The Alpha 358 lead maker is designed for the two-sided crimping and seal loading of long cables. With options like the manual wire selector and/or the quick-change system for crimping tools, materials and tools can be prepared for the next job while the machine is running. Jobs can also be recorded and edited with TopWin software while the machine is running. The changeover time is displayed, providing an easy method for optimizing the workflow. Key features: Easy further processing of long cables No risk of damaged contact parts, even with long cables Only a small production area required High production output

Technical Data:

Length range 2,500­35,000 mm (98,0 in­114 ft) Length accuracy (Repeat) [0.2% +1.0 mm (0.04 in)] Stripping lengths 0.1­35.0 mm (0.004­1.38 in) Wire cross section* 0.22­6.0 mm2 (AWG 24­AWG 10) Optionally from 0.13 mm2 (AWG 26) Wire draw-in speed max. 10 m/s (33 ft/s) Noise level <75 dB (without crimp module) Electrical connection 3x 208­480 V 50/60 Hz, 5 kVA Pneumatic connection 5­8 bar / 500­800 kPa (73­116 psi) Air consumption 9 m3/h (318 ft3/h) Weight 1,300 kg (2,866 lbs) including two crimp and seal modules

* Extremely hard, tough wires may not be able to be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

TopWin is a trademark of Komax AG.

For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

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Lead Makers

Alpha 433 S and Alpha 433 H Fully Automatic Crimping Machines

Technical Data:

Length range 60.0­65,000 mm optional from 35.0 mm Length accuracy 1.0 mm or <0,2%, depend of the wirelength Stripping lengths 0.1­18.0 mm Stripping lengths with partial strip Side 1: 35.0 mm 1 mm (optional 50.0 mm) Side 2: 35.0 mm 1 mm Wire cross section 0,22­6,0 mm2 / AWG 24-10 0,22­16.0 mm2 / AWG 24-6 (Alpha 433 H) Optionally for Alpha 433 F from 0.13 mm2 / AWG 26 Wire feed speed max. 10 m/s Noise level <75 dB (without crimp module) Electrical power 3x 208­480 V 50/60 Hz, 5 kVA Pneumatic pressure 5­8 bar / 500­800 kPa (73­116 psi) Air consumption 9 m3/h (318 ft3/h) Weight Alpha 433 S: 1,080 kg (with 2 crimp- and 2 sealmodules) Alpha 433 H: 1,200 kg (with 2 presses and lifting pedestal)

The Alpha 433 lead maker is a flexible fully automatic crimping machine for efficient wire processing. The Alpha-S version can processes cross sections in a range from 0,20­6,0 mm2 / AWG 24-10 and the Alpha 433 H lead maker from 0,20­16 mm2 / AWG 24-6. Wire Processing to the most exacting standards ­ great versatility without conversion. The Alpha 433 fully automatic crimping machine is based on state of the art technology and is designed for processing single conductors as well as double crimp connections. With its two different versions ­ the Alpha 433 S lead maker (standard machine) and the Alpha 433 H lead maker (processing of large wires) ­ the Alpha 433 lead makers offers maximum possibilities.

Alpha 433 S Lead Maker

The Alpha 433 S lead maker accommodates up to four processing stations, making it the ideal machine for crimping both wire ends and loading seals on one or both wire ends. Other types of processes are also possible, i.e. double crimp connections, fluxing and tinning, as well as sleeve attachment. Key features: Incomparable flexibility with up to five processing stations Short conversion times Maximum ease of operation thanks to TopWin user software Networkable with WPCS interface Very modern quality monitoring Belt drive for high processing speed Extensive range of accessories

Alpha 433 H Lead Maker

Large wires no longer pose a problem. The Alpha 433 H lead maker is capable of processing large wires up to 16 mm2 (fine-wire conductors). The P104 crimping press delivers the requisite force to process large terminals. Terminals can be crimped on both ends but seals can also be loaded at one end. Key features: High flexibility with up to five processing stations Short conversion times Maximum ease of operation thanks to TopWin user software Networkable with WPCS interface Very modern quality monitoring Belt drive for high processing speed Extensive range of accessories

TopWin is a trademark of Komax AG.

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For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

Lead Makers

Alpha 455 Fully Automatic Crimping Machine

Alpha 455 Lead Maker

The efficient setup of the Alpha 455 fully automatic crimping machine is achieved due to the mci 722R module. This innovative new rotary press table was specially developed for the Alpha 455 machine and allows conversion during the production process. The tools and terminals for the next two jobs are changed while the current batch is still being produced. The manual wire selector further reduces changeover times. A wire for the next batch is set up while the current batch is still under production. If need be, the manual wire selector can be turned to feed the second wire into the machine in seconds so it is available for further production. The optional guide tube changer allows you to automate this step in the changeover and keep downtimes to a minimum. The Alpha 455 lead maker is specially designed for just-in-time production. Downtimes become crucial where batch sizes are relatively small and the machine requires frequent changeovers. The objective in these cases is to minimize the time needed for setup and changeover while always keeping the highest standards of quality. Key features: Short changeover times Fully automatic terminal change Integrated quality measurements Next job can be prepared while machine is still running. Combinable in networks using WPCS (Wire Processing Communication Standard) interface

Technical Data:

Length range 60.0­65,000 mm (2.36 in­213 ft) Optionally from 30.0 mm (1.18 in) Length accuracy (Repeat) [0.2% +1.0 mm (0.04 in)] Stripping lengths 0.1­35.0 mm (0.004­1.38 in) Stripping lengths with partial pull-off 47.0 mm (1.85 in) on side 1 35.0 mm (1.38 in) on side 2 Optionally bis 80.0 mm (3.15 in) Wire cross section* 0.22­6.0 mm2 (AWG 24­AWG 10) Optionally from 0.13 mm2 (AWG 26) Wire draw-in speed max. 12 m/s (39 ft/s) Noise level <75 dB (without crimp module) Electrical connection 3x 208­480 V 50/60 Hz, 5 kVA Pneumatic connection 5­8 bar / 500­800 kPa (73­116 psi) Air consumption 9 m3/h (318 ft3/h) Weight 1,300 kg (2,866 lbs) including two crimp and seal modules

* Extremely hard, tough wires may not be able to be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

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Lead Makers

Alpha 477 Fully Automatic Crimping Machine

Technical Data:

Length range 60,0­80,000 mm (2.36 in.­3149.61 in) Optional from 35.0 mm (1.38 in) Length accuracy (Repeat) [0.2% +1.0 mm (0.04 in)] Stripping lengths Both ends 0.1­35.0 mm (0.004­1.38 in) Optional 50,0 mm (1.97 in) on side 1 Wire cross section* 0.22­4.0 mm2 (AWG 24­AWG 12) Optionally from 0.13 mm2 (AWG 26) Cross section ratio > 1:4 Double crimp (wire A+B) < 6 mm2 Wire draw-in speed max. 10 m/s Noise level <75 dB (without crimp module) Electrical connection 3x 208­480 V 50/60 Hz, 7 kVA Pneumatic connection 5­8 bar / 500­800 kPa Air consumption 22 m3/h Weight Approx. 1,900 kg (including 2 m conveyor belt, two crimping modules and two seal modules)

* Certain extremely hard, tough wires may not be able to be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wire.

Alpha 477 Lead Maker

The Alpha 477 fully automatic double crimping machine allows you to process two different wires simultaneously to produce your choice of double crimp or single wires. The two wire drives are fitted with highly dynamic AC-servo axes and an integrated anti-slip system. With this sophisticated handling technology, two wires can be fed in parallel and their ends cut to length and terminated in a controlled process. Wires are handled gently throughout. With four processing stations at the lead termination and two at the trailing end, you have a large number of possible processes at your command.

Key features: No conversion required when switching from double crimp to single wire production Double crimp connections can be produced side-by-side or one above the other Integrated head separation and batch sorting Active good/bad wire sorting An ergonomic layout assures the operator optimum accessibility and minimal walking/reaching distances mci 722/mci 712 module assure superb flexibility and shorter changeover times Integrated quality monitoring ­ CFA (Crimp Force Analyzer), ­ SPM (Seal Position Monitor) with automatic post-production of defective parts Accommodates up to six processing stations Great ease of operation thanks to TopWin software Networking possibilities with reliable WPCS and special software

TopWin is a trademark of Komax AG.

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For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

Lead Makers

Alpha 488 Fully Automatic Processing Machine

Technical Data:

Length range 700­4,000 mm (27.6­157.5 in) 700­7,000 mm (27.6­275.6 in) 700­10,000 mm (27.6­393.7 in) Optional from 150.0 mm (5.9 in) Final length of twisted pairs Length accuracy (Repeat) [0.3% +1.5 mm (0.06 in)] Stripping lengths Side 1: 0.1­18.3 mm / Side 2: 0.1­35.0 mm Wire cross section* 2x 0.22 mm2­2x 2.5 mm2 (AWG 24­AWG 14) Optionally from 0.13 mm2 (AWG 26) Open wire ends 30.0­99.0 mm (optionally. 30.0­125.0 mm on side 1), depends on cross section and end processing Pitch length Programmable from 5.0­80.0 mm Wire draw-in speed max. 5 m/s Noise level <75 dB Electrical connection 3x 208­480 V 50/60 Hz, 10 kVA Pneumatic connection 5­8 bar / 500­800 kPa Air consumption 12 m3/h Weight Including two crimping modules and two seals modules Alpha 488 / 4 m: approx. 3,000 kg Alpha 488 / 7 m: approx. 3,700 kg Alpha 488 / 10 m: approx. 4,400 kg

* Certain extremely hard, tough wires may not be able to be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

Alpha 488 Lead Maker

The high machine output of twisted wires results from the parallel processing of the two conductors and a division of overall processing into three main processes, all optimally synchronized with each other. The linear wire draw-in unit with integrated delta length analyzer (DLA) assures the gentle handling of the wires. The twisting head with AC servo-drive is the heart of the Alpha 488 lead maker. The integrated twist force analyzer (TFA) enables uniform twisting by analyse the forces during the twisting process. Drawing on continuous stock, the Alpha 488 fully automatic twister produces twisted pairs completely cut to length and terminated. It can handle wire cross sections ranging from 2x 0.13 mm2 to 2x 2.5 mm2 with no trouble at all. Four stations on side 1 and two stations on side 2 open up flexible processing possibilities such as two-ended seals loading and crimping.

Key features: Complete processing of continuous stock into twisted pairs with processed ends Gentle handling of base stock to ensure high-quality end products Also possible to process different open ends up to 125 mm in length on side 1 (as an option) Usable as well for two-end crimping and seal loading on two identical single wires High degree of flexibility and reduction of conversion times Integrated quality monitoring ­ DLA (Delta Length Analyzer), ­ CFA+ (Crimp Force Analyzer), ­ SPM (Seal Position Monitor), also during twisting ­ TFA (Twist Force Analyzer) Active good/bad sorting Accommodates up to six processing stations Great ease of operation thanks to TopWin software Networking possibilities with reliable WPCS (Wire Processing Communication Standard) and special software

TopWin is a trademark of Komax AG.

For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

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Lead Makers

Zeta 633 and Zeta 633 L Fully Automatic Processing Machine

Technical Data:

Length range 240­3,000 mm (9.45­118 in) standard tray 240­10,000 mm(9.45­394 in) optional Length accuracy 1.0 mm (0.039 in) or <0.2% depending on wire length Stripping lengths 0.1­25.0 mm (0.004­0.98 in) with full strip 0.1­42.0 mm (0.004­1.65 in) with partial strip Wire cross section* 0.22­6.0 mm2 (AWG 24­AWG 10) Optionally from 0.13 mm2 (AWG 26) Useable transfer length 1.800 mm ­ Zeta 633 (basic machine) 2.880 mm ­ Zeta 633 L (basic machine) 1.720 mm ­ Zeta 633/Zeta 633 L extension Wire draw-in speed max. 10.0 m/s (33 ft/s) Noise level <75 dB (without crimp modules) Electrical power 3x 208­480 V 50/60 Hz, 10 kVA (basic machine) Pneumatic pressure 5­6 bar / 500­600 kPa (73­87 psi) Air consumption 12 m3/h (424 ft3/h) Weight Approximately 1,560 kg (3,440 lbs)

* Certain extremely hard, tough wires may not be able to be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

Zeta 633 and Zeta 633 L Harness Maker

Zeta 633 harness maker is a highly flexible fully automatic crimping machine used for just-in-time production. With its flexible machine concept, the Zeta 633 harness maker opens up an almost unlimited number of possibilities for handling small jobs and wire sequences. Up to 36 conductors are available for wire feed without changeover. Wire transport can be adapted to the specific properties of each conductor. Applying the loop transfer principle, the device feeds the two wire ends of the loop individually one after the other to the appropriate processing station. Modules can be configured as desired along the entire length of the Zeta 633 harness maker. That means total flexibility for each area of application. The Zeta 633 standard machine accommodates up to five processing stations, the Zeta 633 L Version even 8 processing station. If need be, both Zeta versions can be successively expanded and still have space for additional processing stations. The wires can be bundled or deposited in predefined order as a chain.

Key features: Up to 36 different conductors can be processed without changeover Station layout can be defined as desired Full integration of existing processing stations High processing quality TopWin software: Existing user expertise can be applied immediately. Excellent accessibility and safety Expandable Prepared for Zeta 651 and Zeta 655 machines Fully integrated quality monitoring with good/bad sorting Customer specified special applications possible

TopWin is a trademark of Komax AG.

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For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

Harness Makers

Zeta 651 Fully Automatic Processing Machine

Technical Data:

Wire cross section 0.22­4.0 mm2 (AWG 24­AWG 6)

Zeta 651 Harness Maker

Together, the Zeta 633 and Zeta 651 harness makers offer a reliable and attractively priced complete solution for the single-sided loading of single and double row blocks. The Zeta 633 fully automatic crimping machine applies the loop transfer principle to feed the two wire ends of the loop individually one after the other to the appropriate processing station. With the Zeta 651 harness maker, the contacts are mechanically centered prior to loading and optionally rotated, if need be. The use of the reliable loading head and the process monitoring systems of the Zeta 655 harness maker ensure optimum loading. The entire loading process is monitored, from insert in chamber to correct locking. Blocks are fed automatically and can be replenished while the machine is running. Feed and deposit can be adapted to meet the respective needs of the specific customer. The long deposit system with batch separation and integrated bad part cutter is used for producing harnesses with long conductors up to 3000 mm in length. Key features: Fully automatic block loading Full integration into TopWin software Integrated process monitoring with good/bad separation Automatic block feed Blocks can be replenished while machine is running. Economical production of harnesses undergoing single-sided loading

TopWin is a trademark of Komax AG.

Outside cable diameter 4.0 mm (0.16 in) Lengths of processed cables Single-sided processing 85.0­3,000 mm (3.35­118 in) Double-sided processing 85.0­110.0 mm (3.35­4.3 in) / 240.0­3,000 mm (9.45­118 in) Loadable blocks Single and double row blocks Piece output Cycle time: 1.5 s per loading operation* Block loading time: 1.5 s* Monitoring of loading process Collision End force for loading Contact locking Block feed Vibratory bowl feeder Linear rail Customer-specific solution on request Wire deposition Simple deposition for wires up to 1,000 mm (39.37 in) long Deposition for wires up to 3,000 mm (118 in) long Customer-specific solution on request Electrical/pneumatic connections Directly from Zeta 633 harness maker Accessories The Zeta 651 harness maker can be fitted with various accessories to meet specific customer requirements such as block closing, secondary locking, etc.

* Piece output depends on wire length and block/contact combination.

For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

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Harness Makers

Zeta 656 Fully Automatic Processing Machine

Technical Data:

Piece number output* One-ended loading 1.5 s per loading operation Two-ended loading 1.5 s per loading operation Shortest wire length With one-ended loading 240.0 mm For jumper connections at both ends 280.0­440.0 mm** For complex loading operations 280.0­640.0 mm** Cable cross section** 0.13­2.5 mm2 (4.0 mm2) Outside diameter of cable Maximum of 4.0 mm Wire end storage unit Rotary storage unit with a maximum of 30 storage slots Process monitoring (integrated) Collision monitoring (block cavities) Monitoring of loading force Monitoring of terminal interlocking Block feed Carousel with pallets customer specific solution on request Pallet system Loading field (WxHxD) 164.0 x 200.0 x 120.0 mm Connection electrical/pneumatic Directly from Zeta 633 harness maker

*** Piece number output depends on wire length and block/terminal combinations. *** Depends on wire harness structure *** Wires outside the indicated cross section range can also be processed on the Zeta. In case of doubt, we are happy to produce samples of your wires.

Zeta 656 Harness Maker

The Zeta 656 harness maker is a block loading robot designed to taken into account the ever smaller sizes of production batches. Thanks to its machine design, the Zeta 656 harness maker allows investment costs to be amortized in parallel on different types of wire harnesses, markedly reducing the cost per lead set. The Zeta 656 harness maker allows new applications to be subsequently incorporated. With the flexible pallet carousel, the most varied types of wire harnesses can be produced just-in-time and changeover times are very short. All the operator has to do to change over to a new type of block is switch the two pallets. The loading of each and every block is monitored and controlled by a force sensor. The Zeta 633 basic machine has a 36-wire changer and several crimping stations with automatic crimp height adjustment, allowing far more than 300 different wire/terminal variations to be processed without any changeover at all. In combination with a machine extension, another four processing stations can be accommodated. Moreover, wire marking systems can be connected, allowing different wires within the same harness to be marked with the operator's choice of black or colored text.

Key features: Extremely broad variety of harnesses on one machine ­ no application-specific parts New applications can be easily added later on Economical even for tiny production batches Non-contact position recognition for the terminals Uniform top quality processing ­ high degree of process reliability Integrated quality monitoring with good/bad sorting Short amortization period

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For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

Application Tooling Contacts

Americas

USA ­ Harrisburg, PA Tooling Sales Phone: +1-888-777-5917 Phone: +1-717-810-2080 [email protected] Technical Assistance Phone: +1-800-722-1111 Phone: +1-717-986-3434 Canada Rick Grawehr Phone: +1-908-612-6499 [email protected] Brazil Mauricio Oliveira Phone: +55-11-2103-6062 [email protected] Mexico ­ Mexico City Tooling Assistance Center Phone: +1-717-986-3434

For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

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Application Tooling Contacts

Europe, Middle East, Africa and India

Austria Phone: +43-1-90-560-0 [email protected] Belarus - Russia - Ukraine Phone: +7-910-452-3571 [email protected] Belgium - Netherlands - Luxemburg Phone: +31-73-6246246 [email protected] Bulgaria - Hungary - Latvia Lithuania - Poland - Romania Phone: +48-601-522-935 [email protected] Czech - Slovakia Phone: +420-541-162-150 [email protected] Denmark - Norway - Sweden Phone: +46-8-507-250-00 [email protected] Egypt - Ireland - United Kingdom Phone: +44-1237-42-8657 [email protected] Finland - Estonia Phone +358-9-5123-4224 [email protected] France - Morocco - Tunisia Phone: +33-1-34-20-87-70 [email protected] Germany - Slovenia - Turkey Phone: +49-6251-133-1376 [email protected] India - Middle East Phone: +91-990-240-0577 [email protected] Italy - Greece Phone: +39-011-401-2272 [email protected] Switzerland Phone: +41-71-447-02-84 [email protected] Spain - Portugal Phone: +34-93-291-03-96 [email protected] Product Information Center France Phone: +33-134208943 Fax: +33-134208623 [email protected] Product Information Center Germany Phone: +49-6251-133-1999 Fax. +49-6251-133-1998 germany-[email protected] Product Information Center Netherlands Phone: +31-736246999 Fax: +31-736246931 [email protected] Product Information Center Poland Phone: +48-224576704 Fax: +48-224576720 [email protected] Product Information Center Spain Phone: +34-932910330 Fax: +34-932017879 [email protected]

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For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

Application Tooling Contacts

Asia / Pacific

China

Shanghai Phone +86-21-24071588 Fax +86-21-24071599 Beijing Phone +86-10-65693488 Fax +86-10-65693208 Shenzhen Phone +86-755-25154700 Fax +86-755-25980416 Wuhan Phone +86-27-85778391 Fax +86-27-85778390 Changchun Phone +86-431-88964709 Fax +86-431-88961143 Taibei Phone +886-2-87682788 Fax +886-2-87681866 Hongkong Phone +852-27351628 Fax +852-27350243

Others

Japan Phone +81-44-900-5027 Fax +81-44-900-5037 Korea Phone +82-2-3415-4636 Fax +82-2-3486-6873 Malaysia Phone +60-3-7906-7688 Fax +60-3-7805-3066 Thailand Phone +66-2-834-6271 Fax +66-2-955-0515 Singapore Phone +65-64164567 Fax +65-6482-1012 Australia Phone +61-2-95542612 Fax +61-2-9554-3859

While TE Connectivity and its affiliates referenced herein have made every reasonable effort to ensure the accuracy of the information contained in this catalog, TE Connectivity cannot assure that this information is error free. For this reason, TE Connectivity does not make any representation or offer any guarantee that such information is accurate, correct, reliable or current. TE Connectivity reserves the right to make any adjustments to the information at any time. TE Connectivity expressly disclaims any implied warranty regarding the information contained herein, including, but not limited to, the implied warranties of merchantability or fitness for a particular purpose. TE Connectivity's only obligations are those stated in TE Connectivity's Standard Terms and Conditions of Sale. TE Connectivity will in no case be liable for any incidental, indirect or consequential damages arising from or in connection with, including, but not limited to, the sale, resale, use or misuse of its products. Users should rely on their own judgment to evaluate the suitability of a product for a certain purpose and test each product for its intended application.

For more detailed information please refer to our website at www.tooling.te.com www.tooling.te.com/europe www.tooling.te.com/china

TE Connectivity Tyco Electronics AMP GmbH Ampèrestr. 12­14 64625 Bensheim / Germany Phone +49-6251-133-0 Fax +49-6251-133-1600 www.te.com Tyco Electronics AMP GmbH certified acc. ISO 14001 and ISO/TS 16949:2002 © 2011 Tyco Electronics AMP GmbH, a TE Connectivity Ltd. Company. All rights reserved. SOLARLOK, TE Connectivity, TE connectivity (logo) are trademarks. TopWin is a trademark of Komax AG. MOST is a trademark of SMSC Europe GmbH. Other products, logos and company names mentioned herein may be trademarks of their respective owners. 5-1773444-9 issued 5-2011 in Germany.

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