Soltec CFM-Lite Instruction manual
CFM-Lite General instruction manual
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CRIMP FORCE MONITOR
CFM-Lite
Ver 1.4
General
I
nstruction
M
anual
CFM-Lite General instruction manual
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UPDATED HISTORY
Version Date Updated by Details
Version 1.0 2017.10.24 Masato Sato
Version 1.1 2017.11.13 Masato Sato 1. Overview is updated
Version 1.2 2018.12.14 Masato Sato 1.2 description for dongle is
updated
Version 1.3 2020.01.22 Suzuki Tomomi Update functions of CFM-Lite
(FW V1.17, SW V1.0.4.5)
Version1.4 2023.4.26 Tatsuya
Yanagawa
Update functions of CFM-Lite
(FW V1.35, SW V1.0.6.2)
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INDEX
1. Overview ................................................................................................................................................................. 5
1.1. Introduction ............................................................................................................................................ 5
1.2. Main Unit and Accessories ............................................................................................................ 5
1.3. CFM-Lite Specifications .................................................................................................................. 7
1.4. I/O pin assignment ............................................................................................................................. 7
1.5. Detectable Defects ............................................................................................................................ 8
1.6. Wire size................................................................................................................................................ 12
2. Tolerance .............................................................................................................................................................. 13
3. CFM-Lite Operation ......................................................................................................................................... 14
3.1. Main Unit ............................................................................................................................................... 14
3.1.1. Start up .............................................................................................................................................. 14
3.1.2. TEACH .............................................................................................................................................. 14
3.1.3. OPE (Operation) .......................................................................................................................... 17
3.1.4. Auto Trigger Check ..................................................................................................................... 18
3.1.5. Error screen .................................................................................................................................... 18
3.1.6. Sensor Error ................................................................................................................................... 19
3.1.7. Tolerance Setting ......................................................................................................................... 20
3.1.8. Parameter Screen ....................................................................................................................... 21
3.1.9. Reset Counting ............................................................................................................................. 21
3.1.10. Initialize Parameter ..................................................................................................................... 22
3.1.11. Other Icons ...................................................................................................................................... 22
3.1.12. Other Functions ............................................................................................................................ 23
3.2. PC software（Pro-Lite） .............................................................................................................. 23
3.2.1. Pro-Lite Start up ........................................................................................................................... 23
3.2.2. Example of Force Curve Display ......................................................................................... 24
3.2.3. Tolerance Setting ......................................................................................................................... 25
3.2.4. Parameter Settings (Logged on).......................................................................................... 25
3.2.5. Parameter Settings (Logged off) .......................................................................................... 30
3.2.6. Configuration Settings ............................................................................................................... 31
3.2.7. Utility Settings ................................................................................................................................ 32
3.2.8. Display Force Curve Data ....................................................................................................... 33
3.2.9. Area Modification ......................................................................................................................... 34
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3.2.10. Brightness Adjustment .............................................................................................................. 35
3.2.11. Preload Setting ............................................................................................................................. 35
3.2.12. Auto Trigger Check ..................................................................................................................... 36
3.2.13. Capture raw force data ............................................................................................................. 37
3.2.14. Head Room ..................................................................................................................................... 39
3.2.15. Communication Error ................................................................................................................. 44
4. Technical Description ...................................................................................................................................... 45
4.1. Good / Bad Judgement (T1/T2/T3/TD) ................................................................................. 45
4.2. Maintenance for Applicator and Crimping tools. ............................................................... 48
5. Troubleshooting .................................................................................................................................................. 50
5.1. Major defects which must be detected are not detected ............................................. 50
5.2. Small defects are not detected .................................................................................................. 51
5.3. Defect of large wire is not detected ......................................................................................... 52
5.4. Detecting defect of equal to or smaller wire than AWG30 is unstable .................. 52
5.5. False alarms occur frequently, which affects the production process................... 53
5.6. No force curve is captured when the terminal is crimped ............................................ 55
5.7. The power of the main unit does not turn ON when the power switch is ON. .. 56
5.8. Communication with PC cannot be established. .............................................................. 56
5.9. Electrical noise enters and the force curve shows strange behavior. ................... 56
5.10. No terminal crimp is detected after crimping ...................................................................... 56
6. Index ....................................................................................................................................................................... 57
7. Warranty ................................................................................................................................................................ 58
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1. Overview
1.1. Introduction
Crimp Force Monitor CFM-Lite is integrated into manual crimping machine or semi-
automatic crimping machine, to check the crimp quality through monitoring crimping force.
All operations are performed via the LCD touch panel on the main unit. Standard
settings and operations are simplified with only crimping force curve display and some
buttons on the main screen, so that customers can handle it easily.
For further parameter settings, it is possible to set up from the PC software.
1.2. Main Unit and Accessories
Front
Rear
Operations are performed via the LCD touch panel. Only the power switch locates at
the bottom of the main unit.
Bracket Mounting
Screw Holes （M5）
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Bottom
FG (Frame Ground) must be connected firmly to the earth via e.g. the earth terminal of
the table tap, crimping machine, the formal earth terminal prepared by the factory in order
to prevent the external noise.
Accessories
Packed together Non packed together
CFM-Lite Main Unit PC software (Download from True Soltec website)
Sensor:
・Standard: PSS type
・Others: FTW or FTC model.
General instruction manual and Installation manual
(Download from True Soltec website)
BNC cable for sensor PC (prepared by users)
I/O cable for control USB-AB type cable (prepared by users)
AC adaptor USB memory (prepared by users)
Dongle key (optional item)
Mounting bracket
Basic instruction manual (print)
Power switch
USB
-
B type port for
USB-AB cable
USB-A type
port for USB
memory
Dongle key port
AC adaptor
port
Sensor input
D
-
sub 9 pin port
for I/O cable
Power LED
FG
Serial No. seal
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1.3. CFM-Lite Specifications
Outer dimensions W 137mm x H 84mm x D 50mm
Analog sensor
signal
Resolution 12bit
Max sampling rate 20kHz
Sensor FTW series (ring type force sensor, cable output, 0.1 to 10 ton)
PSS series (piezo strain sensor, high /middle / low sensitivity
models)
FTC series (ring type force sensor, connector output, 2 or 4 ton)
I/O cable Refer to “1.4. I/O pin assignment”
USB
communication
1) PC communication (USB2.0)
2) USB data memory （max 64GB saved）
Power Adapter Tec made, model ATM012T-W240U
(Input 100～240V AC、Output 24V DC・0.5A)
Other all AC adaptors are out of warranty if trouble should
happen.
Operating
temperature
0～40 degrees C, Humidity 90% or lower but no dew
Circumstances RoHS regulation is performed.
1.4. I/O pin assignment
The above is the relay output of I/O pin assignment when the main unit is powered off.
PIN No.
Description Wire color
1 Power 24V(output) Orange/Black 1
2 TRIGGER External trigger input Orange /Red 1
3 RESET External reset input Yellow/Black 1
4 TEACH External teach input Yellow/Red 1
5 STOP Stop signal (N.O) Green/Black 1
6 STOP Stop signal (COM) Green/Red 1
7 STOP Stop signal (N.C) Gray/Black 1
8 EJECT Eject output Gray/Red 1
9 GND Ground White/Black 1
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1.5. Detectable Defects
This section describes all the defects that CFM-Lite can and cannot effectively
detect, given the condition that crimping machines, applicators, and tools are in
good performance.
Defects that can be detected nearly 100% (major defects)
- No wire inside the crimp
- No strip crimp
- Double terminal crimp
Defects that can be detected depending on the working conditions
- Crimp height change +/-0.03mm
- 1 of 7 wire strands being cut or out: depending on the number of wires and
wire size.
- High insulation and low insulation (high feed and low feed)
Fitting part Wire barrel
W
ire
Insulation
Insulation barrel
Crimped terminal
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A) Defects that can be detected nearly 100% (major defects)
a) High feed (Wire barrel pinches the insulation)
This is the case where the wire barrel pinches the insulation (deep-feed defect).
The total force applied onto the wire barrel increases, which generates a change on
the crimping force curve. That’s why CFM can detect it.
b) Low feed (Total volume of wire inside the wire barrel decreases)
This is the case where the wire top position is pulled down and stays inside the wire
barrel (low-feed defect). The total volume of wire inside the wire barrel decreases,
which generates a change on crimping force curve. Therefore, CFM can detect it.
Fitting part Wire barrel
Wire
Insulation
Insulation barrel
Example of high feed (detectable)
Fitting part Wire barrel
Wire
Insulation
Insulation barrel
Example of low feed (detectable)
Wire top position
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B) Defects that are difficult to detect
a) High feed (Wire barrel does not pinch the insulation)
This is the case where the wire barrel does not pinch the insulation (deep-feed
defect). The total force applied onto the wire barrel does not change, which means
the crimping force curve does not change either. That’s why it is difficult to detect.
b) High feed (The insulation is under the bell mouth, but not pinched by the wire
barrel)
This is the case of deeper feed than usual. The insulation looks like being under the
bell mouth. It seems easy to detect this kind of deep feed but the insulation is not
pinched into the wire barrel. In this case, the total force applied onto the wire barrel
does not change. Neither do the crimping force curve. That’s why it is difficult to
detect.
c) Low feed (The total volume of wire inside the wire barrel does not decrease)
This is the case of lower feed than usual. The wire top does not appear between the
wire barrel and the fitting part window. It seems easy to detect this type of low feed.
However, as shown in the above picture, if the total volume of wire inside the wire
barrel stays the same, so does the total crimping force. That means the curve also
does not change, which is very hard to detect.
Fitting part Wire barrel
Wire
Insulation
Insulation barrel
Example of deep feed (hard-to-detect case)
Fitting part Wire barrel
Wire
Insulation
Insulation barrel
Example of deep feed (hard-to-detect)
Fitting part Wire barrel
Wire
Insulation
Insulation barrel
Example of low feed (hard-to-
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