RBK-PROC-MK3 Raychem MK3

Operating Manual
RBK- ILS Processor MK3

PN529535-1
412-94235-1 / 5-744015-9
October 2013, Rev. A3
Operation and Maintenance Manual
Tyco Electronics AMP GmbH

Ampèrestraße 12-14
64625 Bensheim
+49-6251-133-0
+49-6251-133-1600
http://www.te.com/europe

a TE Connectivity Ltd. Company.
RBK- ILS Processor MK3 Rev. A3 October 2013 1

RBK-ILS and RAYCHEM are trademarks of TE/Tyco Electronics.
All of the information in this manual, including illustrations, is believed to be reliable. Users,
however, should independently evaluate the suitability of each product for their application.
TE Connectivity /Tyco Electronics/Raychem make no warranties as to the accuracy or com-
pleteness of the information and disclaim any liability regarding its use.
TE Connectivity /Tyco Electronics/Raychem only obligations are those in the Standard Terms
and Conditions of Sale for this product and in no case will TE Connectivity/Tyco Electron-
ics/Raychem are liable for any incidental, indirect or consequential damages arising from the
sale, resale, use or misuse of the product.
TE Connectivity/Tyco/Raychem Specifications are subject to change without notice. In addition

TE Connectivity /Tyco Electronics reserve the right to make changes in materials or pro-
cessing, without notification to Buyer, which do not affect compliance with any applicable
specification.
TE/Tyco Electronics 2013. No part of this manual may be reproduced or transmitted in any form
or by any means, electronic or mechanical, including photocopying, or recorded by any infor-
mation storage or retrieval system, without written permission from TE/Tyco.
The original operating manual has been written in English.

Disposal: RBK- ILS Processor MK3
This product must not be disposed of as municipal waste.
RoHS: RBK- ILS Processor MK3
ROHS Information
TE Connectivity/Tyco Electronics only produces products in conformity with RoHS.
Information on the occurrence and location of substances subject to RoHS guidelines (Restriction
on Hazardous Substances) can be found at the following website:
http://www.te.com/customersupport/productcompliance/
Amendment Record
Issue Content Amended By Date Change

No. Request No.
Issue A Complete Manual May 2013
Issue A1 One chapter removed Lipp June 2013
Issue A2 Adjustment of spare part PNs Lipp August 2013
Issue A3 Picture on page 1-8 replaced Lipp October

2013

Table of Contents
1. Introduction ............................................................................................................................... 1-1

1.1 About this Manual .................................................................................................................... 1-1
1.2 General Information ................................................................................................................. 1-2
1.2.1 Front Panel ................................................................................................................................ 1-3
1.2.2 Temperature Display Panel ..................................................................................................... 1-4
1.2.3 Process Time Display Panel .................................................................................................... 1-5
1.2.4 Rear Panel ................................................................................................................................. 1-6
1.2.5 Air Cooled Stub splice fixture. PN - 981721-000 .................................................................. 1-8
2. Safety ......................................................................................................................................... 2-1

2.1 General Warnings ..................................................................................................................... 2-1
2.2 Electrical Safety ........................................................................................................................ 2-2
2.3 Personal Safety ......................................................................................................................... 2-3
2.3.1 Eyes .................................................................................................................................. 2-3
2.3.2 Clothing .................................................................................................................................. 2-3
2.3.3 Fire Hazard ................................................................................................................................ 2-3
2.3.4 Hot Surfaces ............................................................................................................................. 2-3
2.3.5 Servicing .................................................................................................................................. 2-3
2.4 Warnings and Labels ............................................................................................................... 2-4
2.4.1 Important Symbols ................................................................................................................... 2-5
3. Installation and Operation ....................................................................................................... 3-1

3.1 Installation ................................................................................................................................. 3-1
3.1.1 Unpacking ................................................................................................................................. 3-1
3.1.2 Safety .................................................................................................................................. 3-1
3.1.3 Location .................................................................................................................................. 3-1
3.1.4 Electrical Connections ............................................................................................................. 3-1
3.2 Operation ................................................................................................................................... 3-2
3.2.1 Safety .................................................................................................................................. 3-2
3.2.2 Controls and Indications ......................................................................................................... 3-2
3.2.3 Processor States ...................................................................................................................... 3-2
3.2.4 Stand-by .................................................................................................................................. 3-2
3.2.5 Operating Modes ...................................................................................................................... 3-2
3.2.6 Local Operating Mode .............................................................................................................. 3-2
3.2.7 Sequenced Operation .............................................................................................................. 3-3
3.2.8 Remote Operation .................................................................................................................... 3-3
3.2.9 Initial Switch On ........................................................................................................................ 3-3
3.2.10 OPERATING CYCLE ................................................................................................................. 3-5

3.2.11 Switching Off ............................................................................................................................ 3-6
3.2.12 Emergency Stop ....................................................................................................................... 3-6
3.2.13 Emergency Heater Chamber Release..................................................................................... 3-8
3.2.14 Heater Carriage Jammed ......................................................................................................... 3-9
3.2.15 Operator ................................................................................................................................ 3-10
3.2.16 Fault Indications ..................................................................................................................... 3-11
3.2.17 Routine Maintenance ............................................................................................................. 3-12
4. Service and Repair ................................................................................................................... 4-1

4.1 Processor Parameters ............................................................................................................. 4-1
4.1.1 Selecting Processor Parameters ............................................................................................ 4-1
4.1.2 Password Selection.................................................................................................................. 4-2
4.1.3 RBK- ILS Processor MK3 Parameters .................................................................................... 4-3
4.2 Defining Operating Modes ....................................................................................................... 4-5
4.2.1 Local Operating Mode .............................................................................................................. 4-5
4.2.2 Sequenced Mode ...................................................................................................................... 4-5
4.2.3 Selecting and Operating the Sequenced M ........................................................................... 4-5
4.2.4 Remote Operating Mode .......................................................................................................... 4-6
4.2.5 RS232 Data Format ................................................................................................................... 4-7
4.2.6 Keypad Lock Mode ................................................................................................................... 4-8
4.3 Calibration ................................................................................................................................. 4-9
4.3.1 Automatic Calibration Procedure ........................................................................................... 4-9
4.3.2 Manual Calibration Procedure .............................................................................................. 4-12
4.4 Gaining Access ....................................................................................................................... 4-13
4.5 Troubleshooting ..................................................................................................................... 4-15
4.5.1 Fault Analysis ......................................................................................................................... 4-15
4.5.2 Preliminary Checks ................................................................................................................ 4-16
4.5.3 Abbreviations .......................................................................................................................... 4-16
4.5.4 Troubleshooting Table ........................................................................................................... 4-16
4.6 Repair....................................................................................................................................... 4-22
4.6.1 Circuit Protection Devices ..................................................................................................... 4-22
4.6.2 External ................................................................................................................................ 4-22
4.6.3 Internal ................................................................................................................................ 4-22
4.6.4 Heater Element Replacement. ............................................................................................... 4-23
4.6.5 Upper Element ........................................................................................................................ 4-23
4.6.6 Lower Element ........................................................................................................................ 4-25
4.6.7 Load (Front) Proximity Sensor Adjustment ......................................................................... 4-27
4.6.8 Home (Rear) Proximity Switch .............................................................................................. 4-27
4.6.9 Proximity Switch Replacement ............................................................................................. 4-28
4.6.10 Motor Assembly Replacement .............................................................................................. 4-28
4.6.11 Motor Removal ........................................................................................................................ 4-29

4.6.12 Motor Assemble Fitting.......................................................................................................... 4-30
4.6.13 Cooling Fan Replacement ..................................................................................................... 4-32
4.6.14 24V DC Power Supply Replacement/Motor PSU Assembly ............................................... 4-33
4.6.15 Generic Controller PCB/EPROM Replacement ................................................................... 4-34
4.6.16 GC PCB EPROM Replacement .............................................................................................. 4-35
4.6.17 Thermocouple Compensating Cable Replacement ............................................................ 4-36
4.6.18 Power Switching PCB Replacement..................................................................................... 4-37
4.6.19 Isolation Relay Replacement ................................................................................................. 4-38
4.6.20 Solid State Isolator Replacement ......................................................................................... 4-38
4.6.21 Mains Filter Replacement ...................................................................................................... 4-38
4.6.22 Temperature Display Panel Replacement ............................................................................ 4-39
4.6.23 Process Time Display Panel Replacement .......................................................................... 4-40
4.7 Maintenance ............................................................................................................................ 4-41
4.7.1 Electrical Safety Checks ........................................................................................................ 4-41
4.7.2 Maintenance ............................................................................................................................ 4-43
4.7.3 Temperature Calibration ........................................................................................................ 4-43
4.8 Recommended Spares ........................................................................................................... 4-44
4.8.1 Supplier- web-sites ................................................................................................................. 4-50
5. Technical Details ...................................................................................................................... 5-1

5.1 Specification ............................................................................................................................. 5-1
6. Address "After" Sales. ............................................................................................................. 6-1

1. Introduction
1.1 About this Manual

This manual contains full information about the RBK- ILS Processor MK3 and comprises 6 sec-
tions:
Section 1 - Introduction
This section contains general information regarding the RBK- ILS Processor MK3.
Section 2 – Safety
This section contains important safety information and details of equipment labelling.
Section 3 - Installation and Operation
Describes how to unpack, install and operate the equipment and information on how to look
after it.
Section 4 - Service and Repair

This section contains details of setting the operating parameters, troubleshooting, repair and full
maintenance information with details of recommended spares and technical support.
Section 5 - Technical Details
This section contains a technical specification and standards compliance information.
Section 6 - Wiring Diagrams
This section contains detailed internal wiring diagrams of the equipment.
Note:
You do not need to read the whole document in order to install and operate the equipment but you should
read and understand the whole of this introduction, Section 2 - Safety and Section 3 - Installation and
Operation.
RBK- ILS Processor MK3. Rev. A3 - October 2013 1-1

1.2 General Information
Fig. 1-1: General View

The RBK- ILS Processor MK3 is semi-automatic units using an infrared process to heat shrink
Tyco Electronics ILS-125, ILS-85 and QSZH products onto ultrasonically welded or crimped splic-
es.
The equipment is designed to operate in conjunction with ultrasonic welders, positioned adjacent
to the welding head.
The heat chamber takes ILS and QSZH products from size 1 to 3A and has electrically heated
1
quartz glass elements which provide the heat source, up to 600°C . Operation of the chamber is
prevented until its temperature is within 10°C of t he set operating temperature.
Activated by two start buttons, the heating chamber moves forward, enclosing the joint area. It
remains in place for the set timed period, and then returns to the rear rest position, automatically
ejecting the wire assembly with the RBK-ILS splice sealing product installed.
In the event of a power failure the heating chamber is retracted to the rear rest position.
The RS232 interface, allows Time, Temperature and Product size to be transferred from a remote
machine (e.g. ultrasonic welding equipment) or control computer.
Fifteen pre-set memory buttons can be programmed for local storage of Time, Temperature and
Product size. These can be selected individually by the operator, or selected in a set sequence.
Note:
500°C is the maximum recommended set temperature.
ACCCESSORIES:
RBK-ILS-Proc-STUP-SP-FX: Used for installing stub splice tubing’s.
The Air Cooled stub splice fixture is used in conjunction with RBK-ILS-Proc-Air-Cool-Kit.
RBK-ILS-PROC-TERMFIX-08MM 8mm ring terminal fixture that can be fitted to the RBK-ILS-Proc-
Air-Cool-Kit: to install 8mm ring terminals.
Calibration tools required to Auto – calibrate the RBK- ILS Processor MK3.
CLT-Equip-UHI-250A-1-PRB 288869-000 Standard UHI temperature calibration probe
CLTEQ-UHI250-EXT-CABL 952687-000 Extension cable

Controls and Major Components
1.2.1 Front Panel
1 3
4
4
6 8 7
7
Fig. 1-2: Controls and Features - Front Panel
1. Temperature Display Panel

(Allows process selection using the 15 pre-programmed buttons, provides five Processor
condition indicators and presents the actual heater chamber temperature.)
2. Process Timer Display Panel

(Indicates process time and temperature; product size and process. Four buttons allow pa-
rameter selection)
3. Emergency Stop
(cuts power to machine)
4. Cycle Start Push buttons

(both buttons to be pressed simultaneously)
5. Grippers
(hold cable splice in heating chamber)
6. Calibration Socket
(allows connection of the UHI temperature probe for Processor calibration)
7. Dual Release
(allow removal of splice by hand)
8. Heater Chamber
(heat shrinks product over splice)

1.2.2 Temperature Display Panel
Fig. 1-3: Temperature Display Panel Features
1. Displays actual Heater Chamber Temperature and fault indications ( when warming up,
when cooling down.
2. Power I/O Switch. Illuminated (Green) when ON. Flashes when cooling fan is off and when
warming up.
3. Process Selection Buttons (15). Illuminated when selected.
4. Power Indicator (Blue). ON when Processor is in stand-by. Flashes during cooling to stand-
by
5. Heater Chamber Indicator (Yellow – warming up; Green – OK; Red – heater fault).
6. Calibrate Indicator (Amber). Flashing – Processor calibration required.

Steady – calibration mode selected.
7. Cycle Indication (Amber). Steady – heater chamber is forward and a timed process is being
carried out. Flashing – heater chamber movement fault.
8. Sequence Indicator (Amber) Indicates that a sequenced process is selected.

1.2.3 Process Time Display Panel
Fig. 1-4: Process Time Display Panel
1. Selected Process and Set Time/Temperature Display (Displays parameter values in adjust-
ment mode.)
2. Process Selection Display (Displays parameter names in adjustment mode.)
3. Product size. (Displayed on first 2 digits)
4. Selected Process Button Number. (Displayed on last 2 digits)
5. SELECT Button
a) Selects time/temperature and Processor cycle hour’s information.
b) Selects parameter adjustment mode (used with ENTER button).
c) Selects required digit when adjusting Processor parameters.
6. UP Selection Button
a) Steps up through process 1 to 15.
b) Increases the value of the selected digit.
7. DOWN Selection Button

a) Steps down through process 15 to 1.
b) Decreases the value of the selected digit.
8. ENTER Button
a) Selects parameter adjustment mode (used with SELECT button).
b) Stores the adjusted parameter.
c) Operate for 3 seconds to exit parameter adjustment mode.

1.2.4 Rear Panel
Fig. 1-5: Controls and Features -Rear Panel
6
1
7
2
3 8
4
9
5
1. FAN Fuse
(240V, 100mA anti-surge)
2. HEATER Fuse
(240V d.c. 2A anti-surge)
3. Mains Isolation Switch (used to turn off power to the Processor, when in Stand-by Mode).
Do not use the Mains Isolation switch (3) to turn off the Processor, as
this will cause a significant reduction to the life of the heater element.
Turn off the Heater using the I/O Switch (2) on the Temperature Display
Panel. (See Figure 1.3.). The temperature will drop and cooling will
continue, once below 200º C, the fan will turn off and the Processor will
enter the stand-by mode. The power can now be switched off using the
Mains Isolation Switch.
4. Power Input Socket

(220/240V, 50Hz)
5. Mains Fuses
(2 x 240V, 3.15A anti-surge)
6. Cooling Fan
(operates above 200°C heater temperature)
7. Air Cooling Socket.
8. “0” volts output (n/c and n/o)
9. RS232 Connector

EMC Protection for connecting external devices to the MK3 Processor.
Connecting any external device to the following outputs below a ferrite core must be clamped to
every connection used. The ferrite clamp must contain one loop.
Ferrite Type 742 712 22/WÜRTH
Connection requiring ferrite clamp WITH ONE LOOP.

7. Air Cooling
8. “O” Volts output (n/c and n/o)
9. RS232 connector
1 x ferrite core to every connection on the interfaces "one loop" as shown...
742 712 22

1.2.5 Air Cooled Stub splice fixture. PN - 981721-000.
The Stub Splice Fixture is an accessory designed for use with the RBK- ILS Processor MK3 and is suita-
ble for the installation of TE/Tyco/ Raychem stub splice sealing products. It is also suitable, provided that
the appropriate tooling set is fitted, for use in installing heat shrinkable tubing onto ring terminals for both
insulation and sealing.
By removing the front guard the fixture may be fitted to any RBK- ILS Processor MK3. An adaptor plate is
supplied with the fixture which should be permanently fitted to the RBK- ILS Processor MK3. The
adaptor plate provides a quick release feature and once fitted allows ‘instantaneous’ assembly and re-
moval of the fixture from the machine. The Air Cooled stub splice fixture is used in conjunction with RBK-
ILS-Proc-Air-Cool-Kit.
The fixture is supplied with quick release tooling sets for use with stub splices. Tooling sets for ring ter-
minals and other applications must be ordered separately.
The fixture should be fitted to the machine whenever the need arises to process stub splices or ring ter-
minals. Once the fixture is in position the heat- shrinkable product should be assembled to the work
piece and the work piece located into the tooling fixture. The work piece can then be moved forward into
the correct position by the operator and once in position the machine cycle can be initiated
At the end of the heating cycle the work piece is automatically returned to the loading position where it
may be removed by the operator. The fixture should be removed from the machine whenever in-line
splices are being processed. Fit the front safety guard before use for inline splices.
RBK-ILS-Proc-Air-Cool-Kit PN 1-529533-7

2. Safety
In common with all electrical equipment, the RBK- ILS Processor MK3 must be used in accord-
ance with established safe working practices.
Prior to using the equipment, carefully read the Installation and Operating instructions (Section 3),
together with the following safety warnings.
2.1 General Warnings
Incorrect use of this equipment may cause injury.
This equipment must be operated and maintained only by fully trained and
qualified personnel.
Do not leave the equipment unattended during the process cycle.
Jamming of the operating mechanism may prevent the auto retraction of

the heater chamber. In this event the RBK processor heaters will switch off
automatically. Follow “Heater Carriage Jammed 3.2.14 page 3-10 and the
Emergency Heater Chamber Release” on page 3-9
Failure to follow the manufacturer’s instructions may affect the equipment

warranty.
Do not use the equipment for cooking food or heating products other than
those recommended by TE/Tyco Electronics.
Do not operate the Processor near combustible liquids or gasses.
Ensure adequate ventilation around the cooling fan intake and output grills
a minimum of 75mm clear space, when the equipment is in use.

2.2 Electrical Safety
The equipment is connected to an AC mains electricity supply. Before

undertaking any maintenance or repair, always turn off the equipment and
ensure it is isolated from the AC supply.
Allow the equipment to cool.
Electrical safety checks are described in 4.7. DO NOT CARRY OUT AN

INSULATION RESISTANCE CHECK USING A PORTABLE APPLIANCE
TEST UNIT AS THIS WILL RESULT IN DAMAGE TO THE EQUIPMENT.
FLASH TESTING - Do NOT Flash Test (protection circuits fitted to this

equipment may be damaged)...
INSULATION RESISTANCE TESTING - Do NOT exceed 250V DC (protection

circuits fitted to this equipment may be damaged).
Power connections for the Processor must conform to local standards and
regulations.
UK installations must be fitted with a 13A plug conforming to BS1363

(Green/Yellow-Earth; Blue-Neutral; Brown-Line), containing a 5A fuse to
BS1362.
Potentially hazardous voltages will be exposed if the equipment’s panels

are removed while it is powered-up. Do not use the equipment unless all
external panels are securely in place.
The equipment input supply has double pole fusing (Line & Neutral) and
must be connected to an earthed power supply. The power supply must be
protected by a 30mA residual current device.
Use only specified fuse types and ratings.

2.3 Personal Safety
2.3.1 Eyes
Eye protection must be worn at all times when the tool is in use.
2.3.2 Clothing
Care must be taken to ensure hair or loose clothing does not come into
contact with the Processor.
2.3.3 Fire Hazard
Parts of the tool will be hot during use. Special care must be taken to
avoid heating materials other than the pieces being worked on.
2.3.4 Hot Surfaces
Do not touch the Processors heating chamber - during use, it will become
extremely hot.
Special care must be taken when handling finished wiring assemblies

immediately after ejection from the heating chamber.
Special care must be taken when handling the calibration UHI probe
immediately after ejection from the heating chamber.
It is recommended that protective clothing and gloves are used when
operating this tool
2.3.5 Servicing
When carrying out repairs, always follow the instructions contained in this manual or contact Ty-
co Electronics for further advice. A record should be kept of the maintenance and servicing of the
equipment.
Do not use substitute components, use only TE/Tyco Electronics approved parts. If the mains
(utility) power supply cord is damaged it must be replaced only by a special cord or assembly
available from the supplier or its agent.

2.4 Warnings and Labels
The RBK- ILS Processor MK3 carries a label (shown below) which displays the product part num-
ber (PCN), product description, electrical rating information.
Year of Manufac-
ture.
The following conventions are used in the manual.
Information to prevent personal injury.
Information to prevent damage to the equipment.

2.4.1 Important Symbols
The following graphic symbols are used on the RBK- ILS Processor MK3.
Stand-by Indicator Heater
Calibration Process Cycle
Sequenced Process Process Interrupt
Time Temperature
Fault Code Read Manual for Code Function
Product size Process Button Number
Symbols used for parameter selection buttons.
Function Select Increment Selection
Decrease Selection ENTER Store Selection

3. Installation and Operation
3.1 Installation
3.1.1 Unpacking
Remove the RBK- ILS Processor MK3 from its packing. If there is any sign of damage, return the
equipment to TE/Tyco Electronics in its original container.
Note:
The Serial Number on machine must correspond with the Serial Number on the packaging.
3.1.2 Safety
RBK- ILS Processor MK3 must be installed in accordance with established

safe working practices. Incorrect use can cause injury.
Installation requirements must conform to local regulations.
3.1.3 Location
RBK- ILS Processor MK3 is designed to be installed and operated in

industrial environments. However it should not be used near explosive or
flammable materials or in a location where it would be subject to moisture.
The Processor is a manually operated device and should be sited on a flat

level surface, at a height suitable for an operator - a sturdy workbench is
ideal.
Take care to ensure that the ventilation fan on the back panel is not
obstructed.
3.1.4 Electrical Connections
The Processor is designed for operation from a 230V 50Hz mains supply
and is supplied with a 2 meter power with an IEC connector. UK
installations must be fitted with a 13A plug conforming to BS1363
(Green/Yellow-Earth; Blue-Neutral; Brown-Line), containing a 5A fuse to
BS1362.
Power connections for the machine must conform to local standards and
regulations.
The mains supply to the equipment must be protected by 30mA residual

current device.

3.2 Operation
3.2.1 Safety
Note:
Before any operation is carried out using the RBK- ILS Processor MK3, ensure that the Safety
Instructions contained in Chapter 2 of this manual, have been read and are fully understood.
The RBK- ILS Processor MK3 must be operated in accordance with safe
working practices.
Operators must not put their hands near the heating chamber...
Hair or loose clothing must not come in contact with the machine.
Wear safety glasses at all times.
3.2.2 Controls and Indications
Details of the Processor controls can be found in Chapter 1 Figure 1.2. To

Figure 1.5. Where appropriate the controls and indications are further
described in the following procedures.
3.2.3 Processor States
Note:
The term ‘process’ is used within this manual to describe the application
of a RBK-ILS splice sealing product, onto a cable assembly.
3.2.4 Stand-by
In stand-by, no power is connected to the heater, fan and motor circuits.

The blue Stand-by LED is ON, the Processor is ready to power up. A
flashing LED indicates that the Processor is cooling down and will switch
to Stand-by when the chamber temperature drops below 190ºC.
3.2.5 Operating Modes
The Processor can be configured in one of the following operating modes,

which define the actions of the pre-set selection buttons available to the
operator. Operation of the processor is similar for each mode. Further
information can be found in Section 4.2.
3.2.6 Local Operating Mode
[off ]
The process selection button parameters (time; temperature; product size)
have been assigned and stored in memory. The selected process button will be
illuminated and can be used repetitively until the next is selected from either
the off Temperature or Process Time Display panels. During the process the
Amber Cycle LED will be lit.

3.2.7 Sequenced Operation
[on]
The process selection button parameters have been set and programmed
to step through a required sequence. On completion of the current
process the selection button will change to the next in the preset
sequence (from 2 to 15). The position within the process sequence can be
altered by re-selecting the required process button from the Temperature
Display Panel.
3.2.8 Remote Operation
Process conditions are received through the RS232 Interface

socket. The Temperature Display Panel is disabled.
A moving arrow on the Process Time Display Panel lower display
10.0 indicates that the transmitted process has been received and
operator action is required. 3A identified.
During the process the arrow will be out until the next process is
transmitted.
3.2.9 Initial Switch On
1. Connect the power cord.
2. Release the Emergency Stop button.
3. Switch the rear panel Mains Isolation Switch to ‘I’...

a) Check that the Blue Stand-by LED on the Temperature Display Panel is ON.
b) The software issue and revision number will be displayed briefly, on the Process Time
Display Panel.
4. Switch on the Processor by pressing the I/O Start/Stop Switch for three seconds.
a) The green LED in the button will flash.
b) The Processor will initiate.
5. Check that the correct process button is selected for the task required.
a) The active button has a green illuminated circle.

The selected process button may also be changed from the Process Time Display Panel.
6. The actual chamber temperature will be indicated, and will increase towards the process
temperature.
7. The Heater LED will indicate Yellow while the temperature is outside the alarm bands.
a) When the process temperature is reached the LED will indicate green.
8. The Process Time Display Panel will indicate the set process temperature when outside the
alarm bands, and once within the alarm bands the display will change to time.
a) The selected process time display will change to selected temperature if the function se-
lect button is pressed once.
9. The Product size will be shown in the first two digits of the lower display.
10. The number of the active process button (1 to 15) will be displayed in the last two digits of
the display.
11. To change the active selection button from the Timer panel increment the number of the
process button using the UP or DOWN arrow keys.
12. Store the selection by pressing the ENTER key.
Note:
Ensure that the Processor has been at operating temperature for 30 minutes prior to performing
an operating cycle...
The MK3 RBK-ILS Processor is now ready to operate.

3.2.10 OPERATING CYCLE
Action of the Process Start buttons is inhibited until the heater LED has changed
to green.
Operation of any individual Start button during the timer count-down will manually
override the process and move the heater chamber to the rear.
1 6
4 3
Fig. 3-1: Initiating the Operating Cycle
1. Check correct process button has been selected for the cable assembly to be processed.
Note: This will be selected automatically if the Processor is being controlled remotely.
2. Select the correct size (ILS. / QSZH) product (Code 1; 2; 3; 3A) and position over splice to be
processed.
3. Insert the cable assembly into the Processor grippers.

Align the centre of the splice and product ends, with the guide markers on the Perspex
shield and Guard.
4. Press and release both START CYCLE buttons simultaneously when the heater carrier
reaches front position.
5. Check that the process Cycle LED illuminates.
6. Check that the Timer Display counts down.
7. When the Timer reaches zero, the heater will move to the rear and the processed splice will
be ejected.
TAKE CARE WHEN HANDLING THE EJECTED CABLE SPLICE AS IT WILL

BE HOT.
8. Repeat the same operation or change to the next process button as required.
Note:
If the Processor has been configured to operate in the Sequential Mode the sequence LED will be
lit and it will step to the next process selection button automatically after each cycle is completed.

3.2.11 Switching Off
Failure to use the following method will reduce Heater life.
1. Ensure that the Processor operating cycle is completed and the cable splice has been re-
moved.
2. Press the Start/Stop Switch on the Temperature Display Panel for three seconds.
a) The blue Stand-by LED will flash.
b) The actual chamber temperature indication will decrease.
c) The process button will be de-selected.
d) The right timer display will switch off.
3. Wait until the Temperature on the display falls to 190°C.

a) At this point the display will switch off...
b) The Blue Stand-by LED will stop flashing, indicating that the Processor is now in the
Stand-by mode.
c) The green LED in the Mains Isolation Switch will be OFF.
d) The cooling fan will turn off.
4. Switch the rear panel ON/OFF switch to 0.

a) The blue Stand-by LED will go out.
3.2.12 Emergency Stop

Note:
This is an EMERGENCY procedure used in the unlikely event of the Heater Chamber remaining
closed after the set time sequence.
HAZARDS FROM DAMAGED PRODUCT

Due to the nature of all heating tools, any product which is trapped or
inadvertently left in the oven can become damaged or even BURN. This may lead
to smoke; hence the machine must be used in a well-ventilated area.
If a fire occurs inside the heater the operator should actuate the machine’s
Emergency Stop button and then either extinguish the fire by correct use of a
CO2 filled fire extinguisher, or allow the fire to extinguish naturally. In both cases
care should be taken not to inhale any of the fumes which result from the
burning wires or splice tubing. If the heater chamber is forward when the STOP
is activated it will immediately move to the rear and eject the splice being
processed. Care should be taken in handling the splice as the splice nugget and
surrounding area may be hot. The splice/wires should then be safely disposed of
in a metal bin which contains no combustible material.
In the unlikely event the heater chamber does not retract during an emergency
stop operation, follow the “Emergency Heater Chamber Release” on page 3-8.

Activating the Emergency Stop
Fig. 3-2: Activating the Emergency Stop
1. To Power down the processor in an emergency, push the EMERGENCY STOP button (Fig
3.2.).
a) If the heater chamber is forward when STOP is activated it will move to the rear and eject
the splice being processed. All power to the Processor is then turned OFF.
2. To restore the processor to its normal working condition release the EMERGENCY STOP
button by rotating it clockwise.
a) The blue Stand-by LED will light.
3. Reset the Processor by pressing the Start/Stop Switch on the Temperature Display Panel for
three seconds until the green LED illuminates.
Once the heater chamber has returned to the selected temperature the Processor is then ready to
continue operation.

3.2.13 Emergency Heater Chamber Release
This is an EMERGENCY procedure used in the unlikely event of The Heater Chamber not opening
when the Emergency stop is activated. The equipment is connected to an AC mains electricity
supply. Before undertaking any maintenance or repair, always turn off the equipment and ensure
it is isolated from the AC supply. Allow machine to cool down before starting this procedure!
1. Push bottom heater guard to rear of machine until heater opens (Fig 3.3.).
Fig. 3-3: Manual movement of bottom heater
FRONT OF THE MACHINE CAN BE HOT TO THE TOUCH
2. Push down on GRIPPER RELEASE studs and remove splice (Fig 3.4.).
Fig. 3-4: Manual splice release

3.2.14 Heater Carriage Jammed
Heater Carriage Jams. ‘Cycle’ LED is (Yellow) flashes and the stand by indicator (blue)
flashes.
Power to the motor and to the heater removed.
• The RBK processor heaters will switch off automatically if the carriage has not reached
the front sensor in 700ms. Power to the drive motor removed
• Heater’s cool down and the RBK Processor will go into Stand-by mode, exactly as if the
operator were preparing to switch the machine off. The Cycle LED will continue to blink,
Indicating fault/Carriage jam.
• Allow machine to cool
The equipment is connected to an AC mains electricity supply. Before undertaking

any maintenance or repair, always turn off the equipment and ensure it is isolated from the AC
supply
• Clear the jam. Check for signs of damage to Processor. Ref Emergency Heater Chamber
Release: 3.2.13
To re-sett the Processor the operator must hold the Start/Stop switch (shown below) to bring the
RBK out of stand-by.
Switch on the Processor by pressing the I/O Start/Stop Switch for three seconds.
a) The green LED in the button will come on.
b) The Processor will initiate.
Check that the correct process button is selected for the task required.
a) The active button has a green illuminated circle.
Press both start buttons once the heater return to its home position “ref 3.2.10 Operating cycle”
This will move the mechanism back and reset the fault condition.
Processor is now ready to use.

3.2.15 Operator
Operator Indications and Alarms
Two types of indications and alarms are available to the operator:
• General Information
• Fault Indications
• These indications are shown on the Process Time Display Panel and are accessed by re-
peatedly pressing the Selection button, as described in Table i below.
Selection Displayed
Press Interpretation
button Code
First Selected Process Time

Note:
Temperature is displayed when outside of alarm bands.
2 Selected Process Temperature

(Display will revert after 10 Seconds)
Note:
Time is displayed when outside of alarm bands.
3 cycH Cycle counter high digit 10,000 to 99,990,000

Processor operating cycle count.
4 cycL Cycle counter Low digit 0001 to 9,999

Processor operating cycle count.
5 hrsH Operating hour’s high digit count.
6 hrsL Operating hours low digit count.
7 cycC Operating cycles remaining to next calibration.

Default starting parameter 010k.
8 hrsC Operating hours remaining until next calibration.

Default starting parameter 350 hours. (Not Used)
9 Scrolls back to first selection.
• Table i: Processor Operating Information
• The RBK- ILS Processor MK3 operating parameters are also viewed and entered from the
Process Time Display Panel. Access is protected by a password not normally available to
the operator.
• Setting these operating parameters is described fully in Section 4 - Service and Repair.

3.2.16 Fault Indications
During the operation of the RBK- ILS Processor MK3 a fault may develop which initiates an alarm
code. This code will be displayed as a 4 digit indication on the Temperature/Display panel.
Possible causes of a problem will fall generally into two categories:
• A fault with the heater chamber temperature.

• A fault with the mechanical movement.
A fault with the mechanical movement.
Fault / LED
Possible Fault Initial Action
Code indication
To/c Control thermocouple Turn off power to the Processor.

open circuit. Check the Heater and Fan Fuses re-
place if necessary.
Ts/c Flashing Control thermocouple Re-start the unit.
RED short circuit. Check that the cooling fan is running.
Starting the Processor will reset the
To/t Control thermocouple fault condition.
over temperature
675°C.
Table ii: Indicated Fault Codes

Note:
If the fault codes do not clear after carrying out the Initial Action in Table ii above, refer to the
“Troubleshooting” on page 4-15.
Fault Condition Indication Initial Action
Mechanical Jam REF.3.2.14 PAGE 3-10
Heater starts process Press both start buttons to reset fault

but returns to the rear Flashing every 0.5 condition.
position immediately. Sec. If fault persists, replace or adjust sen-
- Indicating a sor. Refer to the “Troubleshooting” on
Home/Load Sensor page 4-15.
fault.
Table iii: Heater Chamber Mechanical Failure
LED
Indication Reason Initial Action
Indication
CAL! Calibration of the This flashing LED indicates that the

flashing Processor is re- cycle count has exceeded the num-
quired. ber of operations, or set hours of
Flashing heater function. The indication can
AMBER only be cleared by carrying out a
calibration as described in “Calibra-
tion” on page 4-9.
Table iv: Calibrate Warning

3.2.17 Routine Maintenance
The RBK- ILS Processor MK3 requires only the minimum of maintenance. However, the following
checks must be carried out on a weekly basis:
1. Check the cooling fan is operating correctly and air is flowing through the rear vent panel.
2. Remove front cover. Check for correct clearance (a minimum of 75mm clear space) and ob-
structions.
Fig. 3-5: Maintenance Points
3. Wire Grippers. Check visually for correct operation and signs of wear.
4. Manual Release. Check that manual release levers operate freely.

4. Service and Repair
THE TASKS IN THIS SECTION SHOULD ONLY BE CARRIED OUT BY A
SUITABLY QUALIFIED TECHNICIAN. THE MACHINE MUST BE ALLOWED TO
COOL AND BE DISCONNECTED FROM THE MAINS SUPPLY BEFORE
CARRYING OUT ANY REPAIR OR REPLACEMENT.
THE MACHINE HAS A CAPACITOR AS PART OF THE AUTO-RETRACT
FEATURE. NORMAL PRECAUTIONS REGARDING DISSIPATION OF STORED
ENERGY MUST BE TAKEN PRIOR TO ANY SERVICE OR REPAIR.
AFTER COMPLETION OF A REPAIR OR REPLACEMENT, THE APPROPRIATE
SAFETY CHECKS MUST BE MADE. REFER TO THE “Electrical Safety Checks”
section 2.2
4.1 Processor Parameters
Fig. 4-1: Process Time Display Panel
4.1.1 Selecting Processor Parameters

The processor parameters are entered from the right hand Process Time Display Panel shown
above in Figure 4.1.
Two displays present the parameter information. The lower display indicates the parameter name
and the upper indicates its value.
Access is by using the four selection keys described below:
Button Description Function
Function & Both keys are used to enter parameter adjustment

Enter mode.
+
Function The select key selects the parameter digit for ad-
Select justment.
Increment Steps up through the parameter menu.

Selection Increases the value of the digit to be changed.

Decrease Selec- Steps down through the parameter menu.
tion Decreases the value of the digit to be changed.
Enter Selection Stores the adjusted parameter value.

Holding for 3 seconds exits adjustment mode.
Table v: Selection Button Function Continued
4.1.2 Password Selection

A period of twenty five seconds elapses with no function key activated then the display will revert
to the normal operating mode. Entry of an incorrect password will revert to the normal operating
mode
Before access to the parameter mode is given, the selected password must be entered. The Pro-
cessor has a default Password 0000. This should be changed if secure adjustment of the RBK- ILS
Processor MK3 is required. Note:
Record any changed password. In the event of the password being lost the Processor parameters
can be reset to the default settings, by applying power to the Processor with the Select and Enter
buttons pressed. However this will result in the loss of previously entered parameters.
Upper and
Action Key
lower displays
1. Press the Function Select and Enter Keys

simultaneously.
+
2. Press the Select key to select the first digit.
3. Set the first digit by selecting the Up or Down key

for the first number of the password.
4. Press the Select key to step to the next digit.
5. Repeat the procedure to set each digit of the

password.
6. Confirm the selected Password by pressing the

Enter key.
The first parameter is now displayed.
7. To change the password the parameters must be

scrolled to the password select and the numbers
re-entered as above (See Table vi).
8. Adjustment of each parameter is carried out using the same key functions as for password selec-
tion.

4.1.3 RBK- ILS Processor MK3 Parameters
The parameters listed in Table VI below can be adjusted and set in the Processor memory after
the correct password has been entered.
Default Value
Units Range Function
Parameters
- (Off-On) Remote
on - enables remote operation through the RS232 Interface.
- (Off-On) Remote power On

on – enables the processor to be switched on from stand-by via the
RS232 interface. On receipt of valid process parameters.
min Off Automatic Power Off

or 1 to 240 – sets the time in minutes from the last key press, before the
1-240 Processor switches to stand-by (Always 60 mins for versions <1.7).
- (Off-On) Keypad Lock

off – keypad normal (1 to 15 process select buttons available to the
operator).
On – keypad operation is restricted to the last active process select
button before selecting ‘KEYL on’.
- Off Sequence Mode

1-15 1 to 15 – sequence mode selected.
See “Sequenced Mode” on page 4-5.
°C -99 Temperature Control Offset

to Calibration value to be added to the Heater chamber temperature after
+99 the Processor temperature has been measured.
°C 0-99 Temperature Alarm Band Low

Sets the ºC below the selected process temperature at which the Pro-
cess is Inhibited (LED yellow).
°C 0-99 Temperature Alarm Band High

Sets the ºC above the selected process temperature at which the Pro-
cess is Inhibited (LED yellow).
%of 000 Proportional Band

FS to Area around the selected process temperature where the output is at a
199 level other than 100% or 0%. Increasing this parameter increases the
width of this band.
Sec. 00-99 Integral

Corrects offset between selected process temperature and the propor-
tional band over time. Increasing this parameter increases the time it
takes to correct this offset.
Sec. 00-99 Derivative

Shifts the proportional band relative to the actual process temperature,
damping the process temperatures tendency to over/under shoot when
changing. Increasing this parameter will lengthen the time to change to
another process temperature.
These parameters have to be carefully adjusted together and are facto-
ry set.
Table vi: RBK- ILS Processor MK3 Parameters

Default Value Unit
Range Function
Parameters s
Sec. 00.0 Cycle Time

to Sets the process time for selector button Nº 1.
99.9
°C 00.0 Cycle Temperature

to Sets the process temperature for selector button Nº 1.
600
- 1 to 3 A Product Size
Sets the product code (1; 2; 3; 3A) for process selector
The next 14 parameters set the individual Time, Temperature and Product Size for the process selector but-
tons Nº 2 to Nº 15.
- 1 to 7 Brightness
Sets the level of the display brightness.
- (Off-On) Cycle Interrupt

On – during a product installation cycle operation of either Cycle Start
button will abort the cycle and the heating chamber is moved to the
rear position. The cycle is still recorded by the cycle counter.
Off – the interrupt function is disabled.
- 000 k Cycle Count

to The Cycle counter (cycC) counts down from the set level with every
150 k operation of the Processor. At the end of the count (000) the Calibra-
tion LED will be on, indicating calibration is required.
- 0 Operational Hours to Calibration

to Not Used
999
-99 Calibration thermocouple scale factor

to 107 for standard heating element.
+999
-99 Calibration thermocouple scale factor

to This parameter is factory set.
+999 Not present in software version 1.92 or later.
- -99 Calibration thermocouple scale factor

to This parameter is factory set.
+999 Not present in software version 1.92 or later.
- 0000 Enter/Change Password

to Allows the entry of new password.
9999
Table vii: RBK- ILS Processor MK3 Parameters

4.2 Defining Operating Modes
4.2.1 Local Operating Mode
The 15 process selection key parameters (time; temperature; product code) are assigned and
stored in memory using the Parameter settings outlined previously in Table vi. Each process may
be selected and used repeatedly.
SEQU OFF
REMT OFF
RPW1 OFF
KWYL OFF ON
Table viii: Parameter Settings for Local Operation

4.2.2 Sequenced Mode
Process selection keys are enabled. After each process the current selection is advanced to the
next, up to the selected number. The sequence is then restarted at Nº1.
SEQU 1 to 15
REMT OFF
RPW1 OFF
KWYL OFF ON
Table ix: Parameter Settings for Sequenced Operation

4.2.3 Selecting and Operating the Sequenced M
Before selecting the number of process keys to be used (for example 5), each selected key must
first have the time, temperature and product size parameters entered and stored in memory.
Note:
Setting SEQU selects the number of keys required starting with 1 and finishing with the required
number e.g. 5.
Action Key Display
1. Hold the Function Select and Enter...

+
2. Enter Password and step through to Set

Sequence mode.
3. Use the Function Select key to step from ‘off’ to

the Nº of keys to be included in the Sequence
e.g. 5.
4. Store this change into memory.

The display will revert to normal. The first 5
process selection keys will be lit, with key Nº 1 +
flashing. The Yellow Sequence LED is lit.

5. Initiate the first process cycle.
The heater chamber will move forward complete
the cycle and then move to the rear.
The Processor will then step to the next process
key Nº 2 which will flash. Key Nº 1 will extinguish.
6. This procedure is repeated stepping through

each process selection key in turn until the
Processor scrolls back to key Nº1.
7. Repeat the sequence as required.
8. To exit Sequence Mode

Reset SEQU to ‘off’.
Note:
While in the SEQU mode the operator may start the sequence from any point by pressing the ap-
propriate process selection key.
4.2.4 Remote Operating Mode
The remote operating mode allows the RBK- ILS Processor MK3 to be controlled by external de-
vices such as an industrial Computer or Ultrasonic Welding equipment.
Remote operation is enabled via the RS232 communication interface, through an RS232 cable
connected to the external device.
SEQU OFF)
REMT ON
RPW1 OFF / ON
KWYL OFF
Table x: Parameter Settings for Remote Operation

The initial process values will default to those set when the Processor was last used remotely.
Remote overrides local operation, all 15 process buttons and the UP and DOWN selection keys
will be disabled.
On receipt of new process values, two sequencing arrows 10 .0

pointing to the product size replace the sequence button number.
On completion of the cycle the arrows extinguish until further process values are received.
The current REMT parameters will remain in memory during power down of the Processor.
If the Processor Remote parameters are then set to ‘off’, the local values used prior to the Remote
selection are restored. The Processor will remain in the Remote condition permanently or until
manually reset to ‘off’.

4.2.5 RS232 Data Format
All data is transmitted in ASCII form. The Data format uses 8 data bits, 1 stop bit, no parity at 9600 baud.
Full duplex TX/RX exists, RTS/CTS is disabled. The RBK- ILS Processor MK3 Processor recognises the
following fourteen byte information packet structure.
BYTE 1 Start of Header (SOH) (always ASCII 01h)
BYTE 2 10’s of seconds (ASCII 30h to 39h (1 to 9))
BYTE 3 1’s of seconds (ASCII 30h to 39h (1 to 9))
BYTE 4 Always a decimal point (ASCII 2Eh)
BYTE 5 0.1’s of seconds (ASCII 30h to 39h (1 to 9))
BYTE 6 Always a NULL (always ASCII 00h)
BYTE 7 Product size code (ASCII numeric – (1 to 3) – see below)
BYTE 8 Product size code (ASCII numeric – (‘_’ or A)– see below)
BYTE 9 100’s of deg. C
BYTE 12 Checksum high hex nibble (ASCII value 0–9 A–F) F)
BYTE 13 Checksum low hex nibble (ASCII value 0–9 A–F)
BYTE 14 End of transmission (EOT) (always ASCII 04h)
The checksum hex (A-F) must be in ASCII lower case.

The RBK- ILS Processor MK3 Processor will ignore all RS232 data until a SOH character is recognised.
On receipt of a SOH, 10 additional characters or an EOT character is sought. For each character re-
ceived (including the SOH) the longitudinal addition (checksum) is maintained up to and including byte
11. Overflow of the checksum beyond a byte boundary is discarded; This single byte checksum is con-
verted to two ASCII characters and compared with bytes 12 and 13 of the received packet.
The RBK- ILS Processor MK3 responds 100ms after receipt of the above data packet with either a single
ACK (acknowledgement) (ASCII 06h) or a NAK (not acknowledgement) (ASCII 15h) character. An ACK
response will occur providing the following verifications are met:
a) The checksum Byte compares.
b) The packet format meets the above defined format. (i.e., The decimal point and
null characters occur in the correct positions and the expected numeric values
represented by ASCII 30–39 are present).
Failure to meet these requirements results in the RBK- ILS Processor MK3 responding with a NAK.
The only exception unchecked is product size value.
The two ASCII values designated product size are unchecked as part of the receive protocol other than
being included in the checksum calculation (i.e. any data received in these positions will not result in NAK
response). However, the software will only display product sizes for the following received ASCII charac-
ters in these positions: 1_/2_/3_/3A (where _ is a ASCII null (00h)). Any other data received results in a
blank product size display.

4.2.6 Keypad Lock Mode
The keypad lock selector parameter KEYL restricts operator process selection in local static and
sequential operating modes.
The keypad lock mode is set as follows:
Action Key Display
1. 1. Select the process selection key to be locked.

Check Time, Temperature and product code are
correct...
2. Hold Function Select and Enter Keys for

3 Seconds to enter Parameter Mode.
+
3. Enter Password and step through to Keypad

Lock Mode.
4. Use Function Select key to select KEYL ‘on’.
5. Store change into memory.

Display will revert to normal.
The process selection key selected prior to
setting KEYL will be the only one active.
6. Selected process cycle may now be carried out

as normal.
7. To exit Keypad Lock Mode, enter of the

parameters as before and Reset KEYL to ‘off’...

4.3 Calibration
Calibration of the RBK- ILS Processor MK3 is carried out by using a UHI probe (CLT-EQUIP-UHI-
250A-1-PRB 288869-000-PROBE and CLTEQ-UHI250EXT-CABL 952687-000-CABLE), plugged into
the ‘K’ type thermocouple socket. (See: Figure 4.2.)
LOAD the 250A UHI PROBE INTO

GRIPPERS
Fig. 4-2: Processor Calibration

Calibration of the Processor can be performed at any time, however when the calibrate LED is
flashing accompanied by ‘CAL!’ indicated in the Temperature Display Panel, a calibration is re-
quired. To extinguish the flashing indications, a calibration of the Processor must be carried out.
The calibrate LED will flash either when:
a) The Cycle count ‘calC’ set in the Parameters has counted down.
b) Or the number of hours that the Processor has been powered with the Heater on
has been exceeded. This parameter is factory set to 350 hrs.
Note:
Interrogation of the operating cycles remaining ‘cycC’ and hours remaining ‘hrsC’ can be read
from the Process Time Display Panel. (See Table i) on page 3-10.Section 3.2.15
c) The ‘calC’ LED will be on, when the calibration mode is selected.
4.3.1 Automatic Calibration Procedure

The following procedure describes how to calibrate the Processor, by comparing the expected
UHI probe peak temperature with the actual UHI peak temperature recorded after a 15 second cy-
cle. The MK3 RBK-ILS processor will automatically calculate the temperature Offset required to
correct any errors and automatically replace the existing Offset value in the parameter memory.
A negative Offset increases the heater actual temperature and a positive Offset will decrease it.
The automatic calibration procedure requires the processor to stabilise for 15 minutes after auto
calibration. Repeating this procedure within this time may cause a large offset value to be ob-
tained - do not repeat within 15 mins.

Automatic Calibration Procedure
Note:
If the UHI probe is temporarily removed, or removed “too” soon, CAL! will continue to flash.
Action Display
1. Ensure that the Processor has been at 500ºC for 30 minutes

prior to performing a calibration. If the set temperature was
set higher or lower, allow a further 15 minutes after the probe
has been inserted into the front socket. This allows the heat-
ing chamber to stabilise.
2. Connect the UHI probe to the front panel socket.
a) This will automatically select calibrate mode (calibrate LED

on).
b) Calibrate mode may be selected or de-selected using the se-

lect key. Connection of UHI probe alters select key opera-
tion.
c) Upper timer display indicates pre-set calibration time (15 sec-

onds) and the lower shows UHI temperature.
d) Temperature display will flash if set temperature is outside the

range 500ºC to 550ºC. (Automatically set to 500ºC if outside of
this range 15 .0 for the duration of the calibration Procedure).
3. Place the UHI probe centrally into the Processor jaws.
a) The UHI probe temperature must be cooled to 23ºC, out-

side this, temperature will Flash until it 48C has reached
23ºC.
(No calibration is permitted)
b) A rotating bar to the left of the UHI temperature indicates

that a calibration cycle can be performed.
4. Initiate a process cycle.
a) Timer display counts down from the (15s).UHI temperature

will rise.
b) If after 5 seconds the Processor does not detect a 108C

UHI
increase of 5ºC the cycle will be aborted. i.e. If probe is not
inside heater during cycle.
5. Once the cycle is completed the UHI will be ejected.

DO NOT UNPLUG THE UHI PROBE AT THIS STAGE
Allow 15 seconds after UHI is ejected for machine to calculate and
adjust OFST before removing UHI from socket.

CAUTION HIGH TEMPERATURES
Take care when handling the ejected UHI probe after a calibration cycle.
It will be HOT.
a) UHI peak temperature is shown in the upper display. 111 C

(The reducing probe temperature will be displayed in the
lower display.
b) Processor calculates offset value. (timer displays are blank).
c) Offset value (‘OFST’) is shown briefly in the top -1 2C dis-

play and entered into memory, replacing the existing val-
ue. This value will be in the range -99ºC to +99ºC.
If actual UHI temperature is less than or greater than the expected UHI
temperature by more than 5ºC, then calibration mode will not clear (Cal! is
displayed). Another calibration is required as the offset value has
changed - wait 10 minutes to allow the UHI probe temperature to fall and
then repeat the Calibration procedure from Step 3.
Note:
If the UHI probe is temporarily removed, or removed too soon, CAL! Will
continue to flash.
If the result of the calculation is within the -99ºC to +99ºC

limit, the existing OFST is replaced.
(The new value is displayed in the upper display for
about one second, then the calibrate mode automatically
de-selects.)
6. Unplug the UHI probe (Cal! no longer displayed).
7. Normal machine operation can now be resumed.
If the result of the offset calculation is outside the -99ºC

to +99ºC limit, the Offset value is discarded and
calibration out of range (Co/r) will be displayed.
If Co/r is still shown, de-select the calibration mode by

pressing the select key, or unplug the UHI probe from
the Processor. It is recommended to replace the heater
set if the offset value is greater than ± 99°C. Aut o
calibration is then required.
(Offset value has not been replaced).

4.3.2 Manual Calibration Procedure
1. Set tool to 500°C and 15 second cycle time.
2. Set CalF to 107°C
3. Connect UHI probe to a calibrated meter.
4. Carry out 3 calibration readings (cool UHI to 23°C between each cycle).
Calculate average value.
5. Compare measured value (average) with desired value of 130°C ± 5°C.

If below, adjust OFST to desired value - measured value (negative result).
If above, adjust OFST to measured value - desired value (positive result).
6. Wait 25 minutes for temperature to stabilise.
7. Repeat 3 (and 4 if necessary).
8. After OFST has been adjusted correctly it is necessary to wait 15 minutes for temperature to
stabilise prior to normal use.
It is recommended to carry out an auto calibration after manual calibration in order to remove the
Cal!
Message in the display panel.
Note: If this does not disappear it is necessary to replace the heater set and auto calibrate.

4.4 Gaining Access

SUITABLY QUALIFIED TECHNICIAN. THE MACHINE MUST BE ALLOWED
TO COOL AND BE DISCONNECTED FROM THE MAINS SUPPLY BEFORE

FEATURE. NORMAL PRECAUTIONS REGARDING DISSIPATION OF
STORED ENERGY MUST BE TAKEN PRIOR TO ANY SERVICE OR
REPAIR.
AFTER COMPLETION OF A REPAIR OR REPLACEMENT, THE

APPROPRIATE SAFETY CHECKS MUST BE MADE. REFER TO THE
“Electrical Safety Checks” on page 4-36.
To gain access to the internal components, the side and top panels must be removed. Use the
correct size Key. (Figure. 4.3 & 4.4. below).
Fig. 4-3: Base Securing Screws
1 = Left Side Panel Lower Securing Screws

2 = Right Side Panel Lower Securing Screws
3 = Rear/Top Panel Lower Securing Screws
4 = Heater Side Panel Lower Securing Screw

1
2
3
1
Fig. 4-4: Side and Top Securing Screws

1 = Left and Right Side Panel Securing Screws
2 = Rear/Top Panel Top Retaining Screws
3 = Heater Side Panel Securing Screws
4= Front Guard retaining screws

4.5 Troubleshooting

SUITABLY QUALIFIED TECHNICIAN. BEFORE STARTING ANY REPAIRS,
THE MACHINE MUST BE DISCONNECTED FROM THE MAINS SUPPLY.
AFTER COMPLETION, THE APPROPRIATE SAFETY CHECKS MUST BE
MADE.
If a fault develops, the following tables will help in identifying the fault. Refer to the section on
“Repair” on page 4-22 for details on how to replace parts.
4.5.1 Fault Analysis

There are two types of fault condition:
a) Heater chamber
b) Mechanical movement.
Heater Chamber Faults:

Are detected by the control thermocouple, which is part of the lower heater.
Unexpected thermocouple readings will result in the heater LED flashing ‘Red’. One of three warn-
ing messages will then be shown on the temperature display.
i. 'To/c' - Control thermocouple open circuit.
ii. 'Ts/c' - Control thermocouple short circuit.
iii. 'To/t' - Control thermocouple over temperature.
Each of these faults causes the heater to be switched off.
Mechanical Movement Faults:

These are detected by the state of the ‘Home’ and ‘Load’ proximity sensors, located in the base of
the Processor. (Figure 4.12.)
Deviation from the expected sensor state results in the ‘Cycle’ LED flashing and removal of pow-
er to the motor and to the heater. Movement faults will either be detected immediately or when a
cycle is initiated.
A 700mS time out condition also exists, i.e. any jamming of the movement will result in a move-
ment fault. The fault condition is ‘latched’. Refer to 3.2.14 page 3-10 “Heater carriage jammed”

4.5.2 Preliminary Checks
Before investigating a fault condition check:
1. MAINS ISOLATION switch is in ON position.
2. EMERGENCY STOP switch is in OUT position.
3. All fuses are OK.
4. Power supply is ON.
4.5.3 Abbreviations
The following abbreviations are used:
PCB Printed Circuit Board
TI Thermocouple Interface
GC Generic Controller
PTDP Process Time Display Panel
TDP Temperature Display Panel
PS Power Switching
PSU Power Supply Unit
SSR Solid State Relay
Note:
For PCB circuit refer to diagrams in Section 6.
4.5.4 Troubleshooting Table
Problem Possible Cause Verification Solution
All LED’s OFF No power. Unplug mains power cable. Restore power
Check mains supply present. supply.
Mains Switch not in Blue stand-by LED is illumi- Set switches to

the 'ON' position nated when the Mains switch correct position.
and/or the Emergency and the emergency stop are in
Stop switch pressed... the correct position.
Mains input fuses Remove and check. Replace if neces-

failed sary. Refer to sec-
tion 4.6.1 for cor-
rect Item. Page
4.22
24V DC PSU Fault Check 24-32V is present on J2 Replace 24V DC

on PS PCB. PSU.
Internal Polyswitch R3 With input power connected to If 24V is present,

tripped or defective the unit check for 24V DC at switch off power to
socket J1 on the PS PCB. the Processor and
allow 2 mins for
the polyswitch to
reset.
Restart the unit if
the fault is still
apparent, replace
the PS PCB.

All LED’s OFF Check 24V dc present on Check 24-32V is present at Rectify connection
TI PCB. J9 on TI PCB. between PS PCB and
TI PCB.
Disconnected Connector Check disconnected lead Correct connection...

J2 on GC PCB. between GC PCB and J2 on
both front display panels.
Generic Controller fault. At least 1 red LED should Check EPROM in-
be flashing on the GC PCB. stalled. Replace GC
PCB.
Blue stand-by LED is I/O switch not pressed. Press I/O switch for 3 sec- Replace TDP.
permanently ON. onds until display illumi-
I Faulty I/O Switch... nates.
Faulty Isolation Relay Start the Processor and Replace if necessary.

(RL4) on the PS PCB. check the relay contacts (Section 4.5.19) Page
operate. (relay operation 4.38
can be heard with the co-
vers on)
‘To/c’ indicated. Control thermocouple Check thermocouple re- Check compensating

Heater LED RED open circuit sistance at connector J3 cable between J3 and
flashing. pins 1& 2. (should be ap- SK5. Replace cable as
proximately 2 ohms.) required.
If resistance is infinite, Check thermocouple.
thermocouple is defective. resistance at PL5. Re-
place lower heater as
required. Section
4.6.4/4.6.5 Page 4.23
‘Ts/c’ indicated. Blown Heater Fuse. Remove and check. Replace if necessary.
Heater LED RED Section 4.6 For correct
flashing. Item. Page 4.22
Defective thermocouple Check for short circuit Replace compensating

compensating cable. compensating cable. cable. Section 4.5.17
Control thermocouple Unplug control thermocou- Check that the ‘a1bL’ &
short circuit. ple at PL5, check for short ‘a1bH’ Parameters
circuit between J3 pins 1 & have been set correct-
2. ly.
Check for short circuit on Check that the thermo-
PL5 pins 1&2. couple resistance is
approximately 2 ohms.
Replace compensating
cable if required.
Replace lower heater if
required
Open circuit control sig- Red LED on TB PCB always Repair any fault as
nal between J10 and off. required.
SSR. Check for continuity be-
tween J10 pins 1&2 on the
TI PCB.

‘Ts/c’ indicated. Heater element open Check resistance of heater ele- Replace heater ele-
Heater LED RED circuit ment assembly at the terminal ment assembly. Sec-
flashing. block mounted at the rear of the tion 4.6.4/4.6.5/4.6.6
heat chamber. Resistance should Page 4.23
be >100 ohms, < 200 ohms across
terminals (2) and (8) (Fig 4.8.).
If not heater element assembly is
defective.
Defective wiring be- Check continuity between con- Replace Defective Wir-
tween solid state nector J4 socket pin 5(L) and pin ing...
relay and heater, or 11(N) on power switching PCB...
break in neutral line
to heater.
Isolation relay RL4 Start Processor and check relay Replace if necessary.
defective. contacts operate. (relay operation (page 4.37)
can be heard with the covers on)
Solid State Relay Start the Processor, check that If no AC Power is

RL3 defective. RL4 operates, check AC power at measured replace the
J4 on power switching PCB. power switching PCB.
(page 4-37)
‘To/t’ Displayed. Thermocouple over The control thermocouple has RL3 permanently on.
Heater LED RED temperature. detected a temperature of 675ºC in Replace PS PCB.
flashing the heater chamber. (page 4-37)
Co/r displayed Incorrect calibration Carry out factory reset. Calibrate Replace heater set if
following calibra- procedure carried according to correct procedure - correct calibration
tion. out particularly wait time. does not reset Co/r (or
(OFST > ± 99) Cal!) message.
Incorrect thermo-
couple contact on
element
Processor will not Actual temperature Check that the Heater LED is Adjust parameters.
cycle. outside set tempera- Green, indicating actual tempera- (page 4-1)
ture band. ture is within the alarm band.
Check that the ‘a1bL’ & ‘a1bH’
Parameters have been set correct-
ly.
One cycle start but- When pressing start buttons Replace button as
ton disconnected. check connections to S4 and S3 to required.
the SAFTEY RELAY and interface Correct wiring fault as
board. Check power LED is “ON” necessary
SAFTEY RELAY
Check RL1 -continuity. between
Wiring error "replace."
J1Pins 5 and 6
Safety Relay PCB
Replace defective
Check RL2 continuity. between J3
Safety PCB.
Pins 1 and 2

Heater chamber Heater not in rear posi- Check heater chamber Remove obstruction.
fails to move when tion. position. Press cycle start but-
start buttons Check for obstruction. tons to return heater to
pressed. Cycle LED the rear position.
flashes.
‘Home’ sensor failed or Check sensor gap and Adjust sensor position
stuck OFF. position. or replace if required.
Sensor should be illumi- (page 4-26)
nated. Check LED D27 on Rectify wiring fault.
GC PCB illuminates.
Check wiring and connec-
tions.
‘Load’ sensor failed or Check heating chamber is Check wiring and con-
stuck ON. in the ‘Home’ position. nections. Adjust sensor
Sensor should be illumi- position or replace if
nated. required. (page 4-26)
Check sensor gap and
position. Check LED D28
on GC PCB illuminates.
Relay RL1 not operating Check that when the start Replace the isolation
when the start buttons buttons are pressed there relay RL1. (page 4-38)
are pushed is a logic low (0V) present
at J1 pin 4 on the Power
Switching PCB.
Check that when the start Replace the Thermo-

button is pressed there is couple Interface and or
a logic low (0V) present at the Control PCB. (page
J9 pin 5 on the Thermo- 4-36)
couple Interface PCB.
Internal Poly switch R1 When the start buttons are If 24V is present switch
tripped or defective. pressed check RL1 opera- off power to the Proces-
tion and for 24V DC at sor and allow 2 mins for
socket J3 on the Power the polyswitch to reset.
Switching PCB. Restart the unit - if the
fault is still apparent
replace the Power
Switching PCB.
Motor Failure Check power to motor Replace motor. (page 4-

(24V dc) when start but- 29)
tons are operated. Rectify wiring fault.
Mechanical Jam. See section 3.214 page 3-

10

Heating chamber moves forward ‘Load’ proximity Check that the ‘Load’ Adjusting sensor
and returns immediately to the sensor permanently sensor internal LED position. (page 4-26)
Home position. Cycle LED flash- 'OFF' or defective. D28 is illuminated on Replace sensor if
es May be positioned the GC PCB. necessary. (page 4-
incorrectly. 27)
Check that the LED Replace Control

D28 on the Control PCB. (page 4-34)
PCB is lit with the
chamber in the load-
ed position.
Move heater to load-
ed position to check
the LED.
Pressing the cycle buttons will reset the sen-

sor control but will move the chamber to the
Home position if not correct.
Machine overheats. Covers and Switch off proce- Switch off at I/O Ensure correct
guards are warmer than normal. dure not being ob- switch switching proce-
served. Fan will continue to dures are carried out.
run until 190°C and (page 3-4 & page 3-7)
then switch off.
Blue stand-by led will
be lit.
Cooling fan failure Check fan function. Replace fan. (page 4-

32)
No 24V DC power to Carry out no power Identify fault and

Generic Controller condition checks. correct to restore
PCB. power.
Process Time Display Panel will Open circuit con- Check connections If fault clears Re-
not operate, malfunctions, will nection between between TDP and GC place PTDP (page 4-
not power up. PTDP and TDP. PCB. 40)
Substitute PTDP.
Defective TDP. Substitute new TDP. If fault clears Re-

place TDP. (page 4-
39)
Defective GC PCB Substitute new GC If fault clears Re-

PCB. place GC PCB. (page
4-34)
Temperature Display Panel will Keypad Lock Mode Check in parameter Reset KEYL to off
not operate but temperature dis- ‘KEYL’ selected on. for KEYL settings.
play is illuminated.

Temperature Display Panel not Open circuit con- Check connections Substitute New TDP.
illuminated. nection between between TDP and GC If fault clears Replace
TDP and GC PCB. PCB. TDP Refer to page 4-
39
Defective GC PCB. Substitute new GC If fault clears replace

PCB. GC PCB. (page 4-34)
RS232 Communication does not ‘REMT’ not on. Check parameters. Set ‘REMT’ to on.
function.
RS232 cable not Check interconnecting Reconnect...
connected to cable.
welder or Proces-
sor.
Internal intercon- Check wire between Connect wiring.

nection not made. rear interface socket Check links are set:
RS232 driver not PL2 and J7 on the GC
installed. PCB.
Check for correct link
settings on LK2, 3, 4, &
5. on the GC PCB.

4.6 Repair

SUITABLY QUALIFIED TECHNICIAN. THE MACHINE MUST BE ALLOWED
TO COOL AND BE DISCONNECTED FROM THE MAINS SUPPLY BEFORE

FEATURE. NORMAL PRECAUTIONS REGARDING DISSIPATION OF
STORED ENERGY MUST BE TAKEN PRIOR TO ANY SERVICE OR
REPAIR.
AFTER COMPLETION OF A REPAIR OR REPLACEMENT, THE

APPROPRIATE SAFETY CHECKS MUST BE MADE. REFER TO THE
“Electrical Safety Checks” on page 4-41.
4.6.1 Circuit Protection Devices
FAN Fuse (240V, 200mA anti-

surge))
HEATER Fuse (240V d.c 2A anti-
surge
Mains Fuses (2 x 240V,

3.15A anti-surge)
Fig. 4-5: Circuit Protection devices
1 = FAN Fuse (240V, 200mA anti-surge))
2 = HEATER Fuse (240V d.c. 2A anti-surge)
3 = Mains Fuses (2 x 240V, 3.15A anti-surge)
4.6.2 External
The Processor is protected by four external fuses fitted at the back of the unit, as shown in Figure
4.5.
4.6.3 Internal
Two protective ‘Polyswitch’ devices are mounted on the PS PCB.
a) ‘R3’ provides protection for the 24V DC supply to the PCB.
b) ‘R1’ is connected in the switched (RL1) supply to the motor.
Both switches will automatically reset once activated by removing the AC power from the Proces-
sor.

4.6.4 Heater Element Replacement.
ENSURE THAT MAINS SUPPLY IS DISCONNECTED.
The two heater elements are mounted within a protective cage. Each are removed separately, but
must be replaced as a set. REMOVE FRONT SAFTEY COVER
4.6.5 Upper Element
1. Loosen top and side covers (See “Compare measured value (average) with desired value of
130°C ± 5°C. If below, adjust OFST to desired value - measured value (negative result). If
above, adjust OFST to measured value - desired value (positive result).” on page 4-11) and
remove top cover and front cover.
2. Remove heater chamber cover.
REMOVE SCREWS X 2
Fig. 4-6: Heater Chamber in 1st Position Remove screws ref fig 4.3 page 4-15
1 = Bearing Assembly
2 = Heater Blade
Fig. 4-7: Heater chamber Fully Forward
3. Pull the heater chamber forward to the 1st position (Figure 4.6.). Pull the heater blades for-
ward to free the chamber and continue moving the heater until it is fully forward (Figure 4.7.).
4. Remove the upper bearing screws and bearing assembly (Figure 4.6. (1)).

Fig. 4-8: Electrical Connections
1 = Bottom Heater 3 = Top Heater 5 = Thermocouple ‘J’ Type Socket

2 = Bottom Heater 4 = Top Heater 6 = Thermocouple ‘J’ Type Plug
5. Disconnect the upper and lower heater electrical connections.
6. Remove the top cover from the heater thermocouple Connector Plug (Figure 4.8. (6)).
7. Disconnect wires from the plug. Note the polarity of the wires.
Note: There is only one thermocouple fitted to the lower heater which cannot be re-placed sepa-
rately.
Fig. 4-9: Heater Removal
Support the top heater element while screws are removed.
8. Remove the two retaining screws (Figure 4.9.).
9. Remove top heater element from top guard.
10. Replacing the upper heater element is the reverse of the removal procedure.
Note: Ensure wires to thermocouple connector plug are reconnected with the correct polarity.
Note: On replacement ensure that the earth lead is connected and cable ties are fitted. Calibration
must then be carried out.

4.6.6 Lower Element
Fig. 4-10: Gaining access to the lower retaining screws

1 = Access Grommets
2 = Heater Element Retaining Screws
1. Remove the top and heater chamber panels and position the heater chamber in the forward
position as previously described.
2. Disconnect the heater electrical connections (Figure 4.8.).
3. Disconnect the heater thermocouple Connector Plug and socket (Figure 4.8. (5)).
4. Remove the grommets from base plate (Figure 4.10.) to gain access to the two lower heater
element retaining screws.
5. Remove the retaining screws and withdraw the lower element.
Note:
If increased access is required remove the upper heater bearing assemblies as shown in figure
4.6. And open the heater jaws.
6. Replacement is the reverse of the removal procedure.
Note:
On replacement ensure that the earth lead is connected and cable ties are fitted.

Proximity Switch Adjustment
ENSURE THAT MAINS SUPPLY IS DISCONNECTED.
1. Remove the left, right and top covers. (Page 4-15).
2. Isolate the motor by disconnecting plug J3 from the PS PCB.
WHEN POWER IS SWITCHED ON, MAINS VOLTAGES ARE PRESENT

ON THE 24V DC PSU, AND POWER SWITCHING PCB.
3. Reconnect mains supply and switch on n.
4. Identify the short vertical red tab on the heater chamber; lower left side.
5. When in the sensing position, the gap between the relevant tab and the proximity switch
should be 1.5mm.
Fig. 4-11: Motor Disk Assembly

1 = Rotating Disk
2 = Vertical Red Tab (Approximate Position)

4.6.7 Load (Front) Proximity Sensor Adjustment
6. Rotate the motor disc (Figure 4.11.) until the heater chamber is 5° below ‘top dead centre’.
7. Set the gap between the front of the proximity switch and the tab by loosening the lateral
clamping screw (Figure 4.12.) and sliding the switch in or out.
8. If necessary, reposition switch mounting block to obtain correct setting by loosening the
block clamping screws (Figure 4.12.).
9. Switch off the Processor and disconnect the mains supply.
10. Refit connector J3.
Fig. 4-12: Proximity Switch Mounting

1 = Lateral Clamping Screw
2 = LED lit when the switch is sensing
3 = Mounting Block Clamping Screw
4 = Electrical Terminal Cap
5 = Load (Forward) Proximity Switch
4.6.8 Home (Rear) Proximity Switch
1. Move the chamber back to its rear position.
2. Adjust position of Home proximity switch as described previously for the Load switch.
3. Switch off the machine and disconnect the mains supply.
5. Refit all removed covers.

4.6.9 Proximity Switch Replacement
1. Pull electrical terminal cap off the proximity switch.
2. Slacken clamping screw and mounting block and withdraw switch.
3. Adjust Proximity Switch. (page 4-26 and 4-27)
4. Switch off the machine and disconnect the mains supply.
6. Refit all removed covers.
4.6.10 Motor Assembly Replacement
MASTER SAFTEY
RELAY
Fig. 4-13: Motor Assembly (Viewed from Rear) before fitting master relay
1 = Motor Electrical Connections
2 = Motor Support Bracket Screws
3 = Top Plate Retaining Screws
4 = Motor Assembly
5 = Motor Mounting Blocks
6 = Motor Position Adjustment Screws
2 = Motor support Bracket

screws

4.6.11 Motor Removal
With reference to Figure 4.13. And Figure 4.14.
1. Remove the side and top covers.
2. Slacken motor support bracket screws. (Do not remove).
3. Remove (de-solder) the motor electrical connections (red & black).
4. Remove the 4 top plate retaining screws and carefully remove the top plate from the proces-
sor chassis.
5. Rotate the motor crank to move the heater chamber fully forward to the (Load) position.
6. Remove the forward motor crank pivot pin retaining screw. Gain access through the hole
shown in (Figure 4.14. (2).
7. Release the M6x40 lock nuts from the adjustment screws in the motor mounting blocks and
remove the screws.
8. Release the two screws which retain the motor assembly mounting plate.
9. Lift the mounting plate and remove the motor assembly from the processor.
10. Remove the rear, motor crank arm pivot pin from the motor assembly crank disk.
BLACK
RED
Fig. 4-14: Motor Assembly (viewed from front)

1 = Motor Crank Arm
2 = Forward Pivot Pin Access Hole
3 = Motor Assembly Plate Screws
5 = M6x40 Lock Nuts
7 = Motor Electrical Connections
8 = Cable Chain

4.6.12 Motor Assemble Fitting
1. Fit the rear motor crank arm pivot pin to the motor assembly crank disk. Use Loctite 222 on
the securing screw.
2. Position the motor assembly mounting plate onto the chassis and fit the plate securing
screws. Leave the screws finger tight.
3. Fit the M6x40 motor position adjustment screws and locking nuts loosely through the motor
mounting blocks and mounting plate.
4. Move the heater chamber fully forward to the (Load) position.
5. Fit the forward motor crank pivot pin retaining screw to the heater chamber. Gain access
through the hole shown in (Figure 4.14. (2). Use Loctite 222 on the securing screw.
6. Rotate the motor crank to move the heater chamber to the rear (Home) position with the
crank in the top dead centre position.
Fig. 4-15: Heater Carrier Assembly Adjustment. (Shown fully forward)

1 = Upper Bearing
2 = Chassis Bearing slots
3 = Heater carrier assembly
4 = Lower Bearing
5 = Heater Chamber Jaw Gap

7. Adjust the motor assembly until the top and bottom bearings on the heater carrier assembly,
are approximately 2 to 3mm from the rear of the chassis bearing slots.
8. Tighten the M6x40 position adjustment screw locking nuts finger tight.
9. Rotate the crank until the heater carrier assembly is fully forward (Load).
10. Check that the gaps from the upper and lower bearings to the forward chassis bearing slots
are equal left and right. The clearance should be approximately the same as in the rear posi-
tion, 2 to 3mm.
Fig. 4-16: Motor Assembly Position Adjustment (viewed from rear)

3 = Motor Assembly Crank Disk
4 = Motor Assembly Plate
11. Move the heater carrier to the Home and Load position as required. Adjust the setting of the
motor position adjustment screws until the left and right clearances are approximately the
same front and back.
12. Check that the heater chamber jaw gap is parallel in the Load position. Make fine adjust-
ments to the motor position screws if necessary.
13. Tighten the M6x40 motor assembly plate screws.
14. Tighten the M6x40 adjustment screw locking nuts.
15. Fit the top plate and secure. Position and tighten the motor support bracket screws. (Figure
4.13. 2 & 3).
16. Solder the red and black wires to the motor electrical connections. Insulate with a protective
sleeve.
17. Refit panels.

4.6.13 Cooling Fan Replacement
1 Fan and Grill is fixed as shown below
Fig. 4-17: Cooling Fan Location

1 Fan
1. Remove the top and back cover.
2. Locate the Fan power cables (blue & Brown). De-solder connections.
3. Disconnect earth connection to fan chassis.
4. Note the orientation of Fan. Label at bottom right indicates direction of air movement and
rotation.
5. Remove FAN unit and protection grill from top cover.
6. Replacing the Fan is the reverse of the removal procedure.
7. Ensure that the orientation of the fan is the same as in step 4.
8. Ensure air movement is from front to rear of Processor.
GROMMET FEA001 PAPST

4.6.14 24V DC Power Supply Replacement/Motor PSU Assembly
Fig. 4-18: 24V DC PSU Location

1 = PSU Assembly Retaining Screws
2 = Rectifier Bridge Earth Cable
3 = Chassis Earth Cable
4 = Power Switching PCB
1. Remove right side cover.
2. Identify the upper and lower connectors fitted to the PSU.
3. Depress retaining latch on each connector and disconnect.
4. Remove the wiring from the cable ties.
5. Remove the earth connection to the bridge rectifier.
6. Remove PSU mounting plate retaining screws and remove the PSU Assembly. (Figure
4.18.(1)).
Note:
The lower right screw also has the chassis earth connection wire.
7. On the new assembly check that the connected wiring is correct.
Transfer wiring from the old assembly as required, before fitting.
8. Fitting of the new PSU assembly is the reverse of removal.
Ensure that the chassis and rectifier bridge Earth are re-connected..
9. Re-secure the cables to the wiring loom.

4.6.15 Generic Controller PCB/EPROM Replacement
The Controller PCB contains static sensitive devices. Special handling

techniques must be observed, e.g. wrist strap connected to earth via
1M ohm resistor.
To gain access the “SafetyRelay pcb “must be removed.item 8.
8
J2
J3
8
J2
Fig. 4-19: Generic Controller PCB Removal
1 = Thermocouple Interface PCB
2 = PCB Retaining Nuts
3 = PCB Linking Connector Safety relay sits on top of Generic
4 = Generic Controller PCB controller PCB. The same fixing
5 = Software EPROM U3 screws /nuts used for the Generic
6 = Thermocouple Compensating Cable PCB. Identify connectors J2 and J3.
7 = Temperature Display Disconnect by depressing the retain-
ing latch on each connector. Remove
8 = Safety Relay PCB board.
1. Remove left side cover.
2. Identify connectors J2 (Temperature Display) and J7 (RS232 Interface) disconnect by de-

pressing the retaining latch on each connector.
3. Remove the six retaining nuts from the GC PCB.(Figure 4.19.(2)).
4. Remove the three retaining nuts from the TI PCB.
5. Ease both boards away from the securing studs.
6. When clear the inter-connecting plugs and sockets can be separated.
7. Replacement of the GC PCB is the reverse of removal.
8. Carry out a functional check of the Processor operation and check Parameters. (Refer to
“Operation” on page 3-2)
9. Calibrate the Processor to set the temperature offset value before returning it to normal op-
eration.

4.6.16 GC PCB EPROM Replacement
The Software EPROM (Figure 4.19.(5) can be replaced or upgraded without removing the GC PCB.
Ensure static electricity precautions are maintained and the correct removal/insertion tool is used.
Carry out a processor functional check from Step 9.) After replacement.
Thermocouple Interface PCB Replacement
The TI PCB contains static sensitive devices. Special handling

techniques must be observed, e.g. wrist strap connected to earth via
1M ohm resistor.
1. Remove the left side cover
2. Locate the TI PCB. (Figure 4.19.)
3. Disconnect the eight connectors to the PCB. (depress the retaining latch on each connector)
4. Remove the six retaining nuts from the GC PCB.
5. Remove the three retaining nuts from the TI PCB.
6. Ease both boards away from the securing studs.
7. Separate the inter-connecting plugs and sockets.
8. Replacement of the TI PCB is the reverse of removal.
9. Carry out a full functional check of the Processor operation and set Parameters. (Refer to
“Operation” on page 3-2)
10. Calibrate the Processor to set the temperature offset value before returning it to normal op-
eration.

4.6.17 Thermocouple Compensating Cable Replacement
1. Remove the power cord.
2. Remove top/back and heater chamber covers.
3. Remove the left side cover.
4. Rotate the motor disc to drive the heater chamber to the forward position.
5. Separate the two halves of the thermocouple connector (Fig 4.8. (SKT5)) And disconnect the
wires from the socket. Take note of the polarity of the connecting wires.
6. Trace the route of the thermocouple connecting cable from the SKT5 to connector J3 on the
thermocouple interface PCB (Fig 4.19.).
7. Remove the defective cable from the loom.
8. Fit and secure the new cable into the loom. Make the relevant connections at both ends en-
suring the correct polarity.
Note:
No cable ties should be within the cable chain.
9. Refit the machine covers.

4.6.18 Power Switching PCB Replacement
The Power Switching PCB contains static sensitive devices. Special

handling techniques must be observed, e.g. wrist strap connected to
earth via 1M ohm resistor.
Fig. 4-20: Power Switching PCB Removal

1 = Power Switching PCB and Mains Filter Mounting Plate
2 = Mains Filter
3 = Isolation Relays
4 = Power Switching PCB
5 = Solid State Relays
6 = Timer Display Assembly
1. Remove the right side cover.
2. Locate the PS PCB shown in Figure 4.20.
3. Identify connectors J1 to J4 and disconnect, depressing the retaining latch on each con-
nector.
4. Locate and remove the Earth connection.
5. Remove the four retaining nuts securing the PCB to the filter mounting plate.
6. Ease the PCB from the mounting studs.
7. Replacement of the TI PCB is the reverse of removal.
8. Carry out a full functional check of the Processor operation.

4.6.19 Isolation Relay Replacement
Two power isolation relays RL1 and RL4 are fitted to the PS PCB, these provide the power switching for
the Motor and Heater Elements.
The relays are of the plug in type located in holders.
1. To remove the relays the PCB does not have to be removed from the Processor.
2. Release the spring clip holding the relay to the base.
3. Pull the relay out of the base.
4. Fitting is the reverse of removal.
4.6.20 Solid State Isolator Replacement

The Solid State Isolators are encapsulated devices soldered directly to the PCB.
1. In the event of a failure replace the PCB, follow the “Power Switching PCB Replacement” on page
4-37
4.6.21 Mains Filter Replacement

The Mains Filter is a sealed unit fitted to the mounting plate shown in Figure 4.20.
1. Remove the right side cover.
2. Disconnect the two Line (brown) and Neutral (blue) wires from the filter by pulling off the fast-on
connecters.
3. Disconnect the larger Earth (yellow/green) connector.
Note:
It may be easier to first remove the filter plate by removing the four retaining screws from the right
side cover.
4. Remove the two retaining nuts from the filter. Remove filter from the filter plate.
5. Replacement of the Mains Filter is the reverse of the removal procedure. (Fit the device to the filter
plate before fitting the assembly to the right cover)
Ensure that when electrically connecting the Mains Filter the LINE
NEUTRAL and EARTH connections are on the correct terminals.

4.6.22 Temperature Display Panel Replacement
The Temperature Display Panel PCB contains static sensitive devices.

Special handling techniques must be observed, e.g. wrist strap
connected to earth via 1M ohm resistor.
Fig. 4-21: Temperature Display Panel Removal

1 = Temperature Display Securing Screws
1. Remove the left side cover.
2. Locate the TDP refer to Figure 4.19. (7)
3. Disconnect connectors J1 (GC PCB) and J2 (TDP).
4. Remove the four screws securing the TDP to the left hand cover (Figure 4.21.)
5. Remove the TDP carefully.
6. Replacement of the TDP is the reverse of the removal procedure.
7. Test the TDP by restoring power.
8. Operate the Processor for a normal cycle. Note the state of the LED indications.
9. Check that each one of the fifteen cycle selector keys operates normally.

4.6.23 Process Time Display Panel Replacement
The Process Time Display Panel PCB contains static sensitive devices.
Special handling techniques must be observed, e.g. wrist strap
connected to earth via 1M ohm resistor.
Fig. 4-22: Process Time Display Panel Removal

1 = Timer Display Securing Screws
1. Remover the right side cover.
2. Locate the PTDP assembly refer to Figure 4.20. (7).
3. Disconnect connector J1 (TDP).
4. Remove the four screws securing the PTDP to the left hand cover (Figure 4.22.).
5. Remove the PTDP carefully from the right cover.
6. Replacement of the PTDP is the reverse of the removal procedure.
7. Test the PTDP by restoring power to the Processor in the normal way.
8. Operate the Processor for a normal cycle. Note the time, temperature, product code and cy-
cle key number give the correct indications.

4.7 Maintenance
4.7.1 Electrical Safety Checks
Tyco Electronics recommend a yearly, or a periodic servicing, and EARTH BONDING checks. Use
a Portable Appliance Tester (PAT).
Note:
The following procedure is intended as a guide only. Refer to the manufacturer’s literature for the
PAT tester, before proceeding with any testing.
Do not carry out an INSULATION RESISTANCE check using the PAT

tester, as this will result in damage to the equipment.
Checks are as follows:
1. Check that the twelve screws securing top and side covers to base (Figure 4.3.) are tight.
2. Connect the PAT to the mains supply. Select EARTH BONDING, 10A
Fig. 4-23:
Heater Element Test Points
a = Top heater element
b = Bottom heater element
3. Place test probe firmly on each of the four test points in turn, as listed below (see Figures
4.23., 4.24., 4.25.). Press TEST for 10 seconds, check resistance remains at not greater than
0.225 ohms for the 10 seconds.
a) Top heater element

b) Bottom heater element
c) Base-plate accessed from front of machine
d) Stud securing Perspex cover of heater chamber.
F) Check nuts are tight on earth bonding Studs.

Fig. 4-24: Base Plate Test Point
c = Base-plate accessed from front of machine
Fig. 4-25: Perspex Cover Screw d = Stud securing Perspex cover of heater chamber
F)

4.7.2 Maintenance
The RBK- ILS Processor MK3 requires only the minimum of maintenance. However, the following
checks must be carried out on a weekly basis:
a) Cooling Fan. Switch the Processor from the Stand-by to operating mode. Check
that fan starts working when 200ºC is reached on the Temperature display, and
air is flowing through rear vent panel.
b) Wire Grippers. Check visually for correct operation and signs of wear.
c) Manual Release. Check that manual release levers (Figure 1.2. page 1-3)
operate freely
4.7.3 Temperature Calibration

Processor Calibration is to be checked before first use, on monthly basis and after long periods of
not in use. Calibration is also required if the heater, GC PCB or TI PCB is replaced.
For Auto Calibration of the RBK- ILS Processor MK3 the tools required to do this are “highlight-
ed” in
YELLOW.
For Manual/Auto calibration a kit can be ordered from TE/Tyco//Raychem “highlighted” in Tur-
quoise
Order information below highlighted in GREY a complete kit with a needle probe can be pur-
chased to calibrate RBK- ILS Processor MK3 and other TE Application tooling. Example: CV-
OBHAT.
Ordering information:
RBK-Temp-Calibration-Kit 684947-000 Temperature calibration kit contain-

ing meter, UHI probe + cable & nee-
dle probe
RBK-TEMP-CAL-KIT-UHI A12192-000 Temperature calibration kit contain-

ing meter, UHI probe + cable
CLT-Equip-UHI-250A-1-PRB 288869-000 Standard UHI temperature calibra-

tion probe
CLTEQ-UHI250-EXT-CABL 952687-000 Extension cable
Follow the procedure described on page 4-9.for calibration.

4.8 Recommended Spares
The following list contains the spare parts available for the RBK- ILS Processor MK3.
Description Description Part-No. Supplier
RBK-Proc-Mk3-Processor Main Equipment * 529535-1 TE/Tyco

Electronics
RBK-ILS-MK2/3-VIEW-WINDOW Replacement lockable cover window 496043-000 TE/Tyco

Electronics
RBK-ILS-MK2/3-VIEW-
RBK-ILS-MK2/3-PROX-SW Replacement front and back proximity 492905-000 TE/Tyco

sensor Electronics
RBK-ILS-MK2/3-HTR-PIVT-ASSY Replacement heater pivot assembly 014395-000 TE/Tyco

Electronics
RBK-ILS-MK2/3-BEAR-REP-KIT Heater chamber replacement bearing kit 870779-000 TE/Tyco

Electronics

RBK-ILS-MK2/3-EJECT-BL-SET Replacement ejector blade set 690523-000 TE/Tyco
Electronics
RBK-ILS-MK2/3-ELEM-ASSY Replacement heating element 342551-000 TE/Tyco

Electronics
RBK-ILS-MK2/3-FAN Replacement cooling Fan 250145-000 TE/Tyco

Electronics
RBK-ILS-MK2/3-MECH-REP-KIT Mechanical repair kit 883491-000 TE/Tyco

Electronics
RBK-ILS-MK2/3-MOTOR-ASSY Replacement motor 858752-000 TE/Tyco

Electronics

RBK-ILS-MK2/3-PWR-SW-ASSY Power switching assembly 537221-1 TE/Tyco
Electronics
RBK-ILS-MK2/3-MOT-PSU-ASSY Motor PSU assembly 537221-3 TE/Tyco

Electronics
RBK-ILS-MK2/3-GEN-CONT-PCB Generic controller PCB 537221-2 TE/Tyco

Electronics
RBK-ILS-MK2/3-INTFC-PCB Thermocouple interface PCB 537221-4 TE/Tyco

Electronics
RBK-ILS-MK2/3/CV-OBHAT- Timer module 3-529533-3 TE/Tyco

TIMER-MODULE Electronics

RBK-ILS-MK2/3-TMP-CONT- Temperature control module 3-529533-4 TE/Tyco
MOD
Electronics
RBK-ILS-MK2/3-EL-COVR-ASSY Element cover assembly 478274-000 TE/Tyco

Electronics
RBK-ILS-Mk3-Eprom Software EPROM 1-537221-0 TE/Tyco

Electronics
Version 2
RBK-ILS-Mk2/3-EJ-Bush-Kit Ejector bush kit F20689-000 TE/Tyco

Electronics

RBK-ILS-MK3-PCB- Safety Relay PCB 537221-8 TE/Tyco
SAFETY-RELAY Electronics
RBK-ILS-MK2/3-PROC-PIN- The kit consists of 2 off moving pinch 924745-000 TE/Tyco Elec-
BLOC-REP blocks. Both fitted with spring anchor tronics
pins.

Description Description Part-No. Supplier
Mains inlet socket IEC Input Plug and fuse 151-747 Farnell
assembly
* Fuse 3.15A T (anti-surge) Mains input fuses x 2 - Rear 1123247 Farnell

panel mains connector
* Fuse 100mA T (anti-surge) Cooling fan fuse - Rear panel 1241961 Farnell
* Fuse 2A T (anti-surge) Heating element fuse - Rear 534-195 Farnell

panel
* Note: Only use fuses which conform to BS4265 or IEC127
EMC Filter FN610-6/06 Mains filter 230-560 Farnell
Emergency Stop Switch
Emergency Stop Push button ZB2-BS44 Telemechanique
Contact Block ZB2-BZ104 Telemechanique
Cycle Start Button
Switch Push Button 14-132.0252 Supplier see

below under
Aluminium Ring 704-6001 EAO
Green Cap 704-6015
Accessories
RBK-ILS-Proc-Termfix-08mm 08mm stub splice adaptor 049857-000 Tyco Electronics
SAFETY RELAY PSR-SCP- 24UC/THC4/2X1/1X2 2064570 Farnell
RBK-ILS-Proc-Air-Cool-Kit Air cooled stub splice support 1-529533-7 Tyco Electronics

fixture.
Comms Link Cable Cable required for comms link 758-7541 1m RS Components
between MK3 processor and 758-7545 RS Components
ultrasonic welder software. 2m
The required cable is a 9-pin
female ‘D’ type connector with
the pins wired 1 to 1

4.8.1 Supplier- web-sites
Farnell.
http://www.farnell.com/
Telemechanique
http://www.schneider-electric.co.uk
EAO
http://www.eao.com

5. Technical Details
5.1 Specification
RBK- ILS Processor MK3
Electrical Supply 220/240 V - 50 Hz
Power Consumption 1,7 A (Maximum)
Operating Temperature Range 200ºC to 600ºC Maximum

(Acc. ± 1ºC of set temperature)
500°C Recommended
Typical Machine Cycle Times for ILS-125 Range 0.1 to 99.9 seconds
Products used on typical range of automo- Typically 2-34 seconds, depending on
tive splices. QSZH product installs faster wire size and number of wires used.
than the ILS-125 Product
Mains Fuses 2 x 240V - 3.15A T (anti-surge) Line and

Neutral
Motor Internal Protection Device (Poly- 30V - Trip - 1.1 to 2.2 amp continuous < 30
switch) sec.
Power off reset - 1 minute.
Product Range RBK-ILS-125/QSZH Sizes 1 to 3A

RBK-ILS-85 Sizes 6/1 to 12/3
(For other Raychem/TE/TYCO Products
Discuss with TE Product Management)
Dimensions 390 mm (W) x 365 mm (D) x 225 mm (H)
Weight 18 kg
Noise 80dB Maximum (Cyclic, 1m from machine)
Power Failure Protection Capacitor activated ‘Electronic Spring’

Technology (Allows Heater Chamber to be
retracted automatically)
RS232 Interface Permits transfer of Time, temperature and

Product code from isolated STD. 1KV re-
mote device.

6. Address "After" Sales.
c/o Schenck Technologie- und Industriepark GmbH
Landwehrstr. 55 / Gebäude 83
64293 Darmstadt / Germany
GATD Kundendienst-Hotline: +49-6151-607-1518
RBK- ILS Processor MK3 Rev. A3 October 2013 6-1

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Operating Manual

RBK- ILS Processor MK3

Operation and Maintenance Manual

Tyco Electronics AMP GmbH

Tyco Electronics AMP GmbH

RBK- ILS Processor MK3 Rev. A3 October 2013 1

TE Connectivity/Tyco/Raychem Specifications are subject to change without notice. In addition

The original operating manual has been written in English.

RBK- ILS Processor MK3 Rev. A3 October 2013 2

This product must not be disposed of as municipal waste.

RoHS: RBK- ILS Processor MK3

Issue Content Amended By Date Change

Issue A Complete Manual May 2013

Issue A1 One chapter removed Lipp June 2013

Issue A2 Adjustment of spare part PNs Lipp August 2013

Issue A3 Picture on page 1-8 replaced Lipp October

RBK- ILS Processor MK3 Rev. A3 October 2013 3

1. Introduction ............................................................................................................................... 1-1

2. Safety ......................................................................................................................................... 2-1

3. Installation and Operation ....................................................................................................... 3-1

RBK- ILS Processor MK3 Rev. A3 October 2013 4

4. Service and Repair ................................................................................................................... 4-1

RBK- ILS Processor MK3 Rev. A3 October 2013 5

5. Technical Details ...................................................................................................................... 5-1

6. Address "After" Sales. ............................................................................................................. 6-1

RBK- ILS Processor MK3 Rev. A3 October 2013 6

1.1 About this Manual

Section 3 - Installation and Operation

Section 4 - Service and Repair

Section 5 - Technical Details

This section contains a technical specification and standards compliance information.

Section 6 - Wiring Diagrams

This section contains detailed internal wiring diagrams of the equipment.

RBK- ILS Processor MK3. Rev. A3 - October 2013 1-1

Fig. 1-1: General View

CLT-Equip-UHI-250A-1-PRB 288869-000 Standard UHI temperature calibration probe

CLTEQ-UHI250-EXT-CABL 952687-000 Extension cable

RBK- ILS Processor MK3. Rev. A3 - October 2013 1-2

Fig. 1-2: Controls and Features - Front Panel

1. Temperature Display Panel

2. Process Timer Display Panel

4. Cycle Start Push buttons

RBK- ILS Processor MK3. Rev. A3 - October 2013 1-3

Fig. 1-3: Temperature Display Panel Features

3. Process Selection Buttons (15). Illuminated when selected.

6. Calibrate Indicator (Amber). Flashing – Processor calibration required.

8. Sequence Indicator (Amber) Indicates that a sequenced process is selected.

RBK- ILS Processor MK3. Rev. A3 - October 2013 1-4

Fig. 1-4: Process Time Display Panel

2. Process Selection Display (Displays parameter names in adjustment mode.)

3. Product size. (Displayed on first 2 digits)

4. Selected Process Button Number. (Displayed on last 2 digits)

7. DOWN Selection Button

RBK- ILS Processor MK3. Rev. A3 - October 2013 1-5

4. Power Input Socket

7. Air Cooling Socket.

8. “0” volts output (n/c and n/o)

RBK- ILS Processor MK3. Rev. A3 - October 2013 1-6

Connection requiring ferrite clamp WITH ONE LOOP.

1 x ferrite core to every connection on the interfaces "one loop" as shown...

RBK- ILS Processor MK3. Rev. A3 - October 2013 1-7

RBK- ILS Processor MK3. Rev. A3 - October 2013 1-8

2.1 General Warnings