Komax AG, Industriestrasse 6, CH-6036 Dierikon/LUTel. +41 41 455 04 55, Fax +41 41 450 42 66, info@komax.ch, www.komax.ch

Professionals in Advanced Automation

Twisted pairs – a technology with a bright futureAlpha 488

Your benefits

– Complete processing of continuous stock into twisted pairs with processed ends

– Gentle handling of base stock to ensure high-quality end products.

– Also possible to process different open ends up to 125mm in length on side 1 (as an option)

– Usable as well for two-end crimping and seal loading on two identical single wires

– High degree of flexibility and reduction of conversion times thanks to the mci 722 und mci 712

– Integrated quality monitoring (DLA, CFA, SPA-iL), also during twisting (TFA)

– Active good/bad sorting– Accommodates up to six processing stations – Great ease of operation thanks to TopWin software– Networking possibilities with reliable WPCS and

TopNet

Technical dataLength range700mm–4000mm (27.6 in–157.5in)700mm–7000mm (27.6 in–275.6in)700mm–10000mm (27.6 in–393.7in)Optional from 150mm (5.9 in)Final length of twisted pairsLength accuracy±0.3% (min. ±1.5mm)Stripping lengthsSide 1: 0.1–18mm/side 2: 0.1–35mmWire cross sections*2×0.22mm2–2×2.5mm2 (AWG24–AWG14)Open wire ends30–99mm (optionally. 30–125mm on side 1), depends on pitch, cross section, and end processingPitch lengthProgrammable from 5mm to 80mm Wire draw-in speedmax. 5m/sNoise level<75dB Electrical connection3×208–480V/50–60Hz; 10kVAPneumatic connection5–6barAir consumption12m3/hWeightIncluding two crimping modules and two seals modules

4. A

lpha

488

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Alpha 488 / 4m: approx. 3000kgAlpha 488 / 7m: approx. 3700kgAlpha 488 / 10m: approx. 4400kg* Certain extremely hard, tough wires may not be able to

be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

AccessoriesThere are a number of different accessories available with which you can adapt the Komax Alpha 488 to your own specific needs and expand its capabilities as desired.Preliminary wire processing– Ink jet marker– Hot stamp marker– Wire feed systemsCrimping module accessories– Height adjustable lift pedestals– Paper winder– Carrier strip chopper– Valve set for pneumatically

operated advance– Pressure regulation set– Monitoring of length-wise and

cross-wise transport of terminals Process monitoring– Twist force analyzer (TFA)– Delta length analyzer (DLA)– Crimp force analyzer (CFA)

– Seal presence analyzer (SPA-iL)– Splice detection– Quality assurance

Komax 331, 341, 351, 371Options– Short lengths (starting at 150mm)– Different open ends up to 125mm

in length on side 1– Tower light– Wire measurement table– Magnifying glass– Keypad– Uninterruptible power supply

(UPS)– WPCS networking and TopNet

Services Komax also provides superb after-sales support:– Commissioning– Training courses for different levels

of users – Production coaching and assis-

tance– Worldwide customer service net-

work with complete range of spare parts

– Professional consulting services

Processed samples

Alpha 488 / 4m8250mm (312.83in)

19

50m

m (7

6.77

in)

Reference values for piece output of Alpha 488Piece number [pieces/h]

Height with cover closed: 1790mm (70.5in)Height with cover open: 2670mm (105.1in)

Wire draw-in

Twist force analyzer (TFA)

Wire length [mm]

Set valuesConductors: 2×FLRY 0.75mm²Pressure: 6barDraw-in speed: 5m/sAcceleration: 50m/s²Pitch: 20mmOpen ends S1 + S2: 50mmCrimping module: mci 722Seals module: mci 761Quality monitoring: cfa, SPA-iL active

Optionally: different open ends on side 1

Alpha 488 / 7m11750mm (462.6in)

Alpha 488 / 10m15250mm (600.4in)

TopNet

0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1000 2000 3000 4000 5000 6000 7000 8000 1000090000

Economical production of twisted pairsAlpha 488

Drawing on continuous stock, the Alpha 488 fully automatic twister produces twis-ted pairs completely cut to length and ter-minated with all quality controls included. The modular design of the system ensures maximum flexibility. Four processing stati-ons at the lead termination and two at the trailing end open up an array of processing possibilities.

Maximum flexibilityDrawing on continuous stock, the Alpha 488 fully automatic twister produces twisted pairs completely cut to length and terminated. It can handle wire cross sections ranging from 2×0.22mm2 to 2×2.5mm2 with no trouble at all. Four stations on side 1 and two stations on side 2 open up flexible processing possibilities such as two-ended seals loading and crimping. Of course, the Alpha 488 is also ideal for the processing of individual conductors.

TechnologyThis machine’s high output of twisted pairs results from the parallel processing of the two conductors and a division of overall processing into three

main processes, all optimally synchronized with each other. The linear wire draw-in unit with integrated delta length analyzer (DLA) assures the gentle handling of the wires. The twisting head with AC servo-drive is the heart of the Alpha 488. The integrated twist force analyzer (TFA) guarantees uniform twisting by analyzing the forces exerted during twisting and regulating the subsequent adjustment movements of the twisting head.

Maximum user friendlinessThe system is extremely user friendly. Its stations swivel in a radius of 400mm, making them readily accessible to the operator. Elements like a wire deposit tray with integrated batch sorting

and post-production of defective wires are part of the standard equipment. The TopWin user interface and the sliding operator’s console along the pull-out unit further increase the convenience of this system. In combination with the Komax mci 722 or the mci 712 crimping modules and the mci 761 seals module plus the quick-change systems and the integrated monitoring units, the Alpha 488 offers maximum process reliability and ultra-short conversion times. Its modular design assures unbeatable flexibility.

TopWinTopWin is a Windows®-based graphical user interface designed for quick, easy data input. Thanks to its simple and logical structure, users can fully master the machine in no time at all. Pitch length, open conductor ends, pull force, and a host of other key parameters can be conveniently set and saved. Error messages are presented in clear, uncluttered graphics. A special editor (Permission Editor) can be used to manage access rights for all entry parameters. With the optional WPCS (Wire Processing Communication Stan-dard) interface, Komax

machines can be networked together and easily integrated into existing production processes. The supplemental networking software known as TopNet is the ideal tool for achieving optimum production management.

mci 722 crimping modulePress with programmable crimp height, integrated crimp force analyzer (CFA) for crimping forces up to 20kN (short conversion times)– Just one teach crimp required– Controls for the most important

functions, e.g. creep speed, are right on the press.

– Split-cycle function

mci 712 crimping modulePress with integrated crimp force analyzer (CFA) for crimping forces up to 20kN – Just one teach crimp required– Controls for the most important

functions, e.g. creep speed, are right on the press.

– Split-cycle function

mci 761 seals moduleChangeover times are ultra-short thanks to two great features: quick-release locks used consistently for all seal-related application parts and a software-assisted function for approaching special setup positions. Setup and adjustment work is eliminated entirely. The mci 761 seals module can be tipped back on its height-

adjustable module base, allowing ready access. An optional seal presence analyzer (SPA-iL) can be integrated directly into the mci 761 seals module and the TopWin user software.

Terminal feedThe swiveling terminal-roll holder allows the use of applicators with right or left infeed. It is as easy as can be to switch from side feed to back feed. The tidy disposal of carrier strips is assured by a paper winder and a carrier strip chopper.

Cost-optimized total solutions Modern wire processing requires cost-optimized total solutions. Komax offers you just the technologies you need to achieve this goal.

Alpha 488 with three crimping modules and one seals module

Straight-forward setup menu Production menu with all relevant information

Parallel gripper systems for both wires Two crimping modules and two seals modules on side 1

mci 722 crimping module with programmable crimp height

mci 712 crimping module Holding gripper for twisting operation mci 761 seals module with op-tional seal presence analyzer (SPA-iL)

Economical production of twisted pairsAlpha 488

Drawing on continuous stock, the Alpha 488 fully automatic twister produces twis-ted pairs completely cut to length and ter-minated with all quality controls included. The modular design of the system ensures maximum flexibility. Four processing stati-ons at the lead termination and two at the trailing end open up an array of processing possibilities.

Maximum flexibilityDrawing on continuous stock, the Alpha 488 fully automatic twister produces twisted pairs completely cut to length and terminated. It can handle wire cross sections ranging from 2×0.22mm2 to 2×2.5mm2 with no trouble at all. Four stations on side 1 and two stations on side 2 open up flexible processing possibilities such as two-ended seals loading and crimping. Of course, the Alpha 488 is also ideal for the processing of individual conductors.

TechnologyThis machine’s high output of twisted pairs results from the parallel processing of the two conductors and a division of overall processing into three

main processes, all optimally synchronized with each other. The linear wire draw-in unit with integrated delta length analyzer (DLA) assures the gentle handling of the wires. The twisting head with AC servo-drive is the heart of the Alpha 488. The integrated twist force analyzer (TFA) guarantees uniform twisting by analyzing the forces exerted during twisting and regulating the subsequent adjustment movements of the twisting head.

Maximum user friendlinessThe system is extremely user friendly. Its stations swivel in a radius of 400mm, making them readily accessible to the operator. Elements like a wire deposit tray with integrated batch sorting

and post-production of defective wires are part of the standard equipment. The TopWin user interface and the sliding operator’s console along the pull-out unit further increase the convenience of this system. In combination with the Komax mci 722 or the mci 712 crimping modules and the mci 761 seals module plus the quick-change systems and the integrated monitoring units, the Alpha 488 offers maximum process reliability and ultra-short conversion times. Its modular design assures unbeatable flexibility.

TopWinTopWin is a Windows®-based graphical user interface designed for quick, easy data input. Thanks to its simple and logical structure, users can fully master the machine in no time at all. Pitch length, open conductor ends, pull force, and a host of other key parameters can be conveniently set and saved. Error messages are presented in clear, uncluttered graphics. A special editor (Permission Editor) can be used to manage access rights for all entry parameters. With the optional WPCS (Wire Processing Communication Stan-dard) interface, Komax

machines can be networked together and easily integrated into existing production processes. The supplemental networking software known as TopNet is the ideal tool for achieving optimum production management.

mci 722 crimping modulePress with programmable crimp height, integrated crimp force analyzer (CFA) for crimping forces up to 20kN (short conversion times)– Just one teach crimp required– Controls for the most important

functions, e.g. creep speed, are right on the press.

– Split-cycle function

mci 712 crimping modulePress with integrated crimp force analyzer (CFA) for crimping forces up to 20kN – Just one teach crimp required– Controls for the most important

functions, e.g. creep speed, are right on the press.

– Split-cycle function

mci 761 seals moduleChangeover times are ultra-short thanks to two great features: quick-release locks used consistently for all seal-related application parts and a software-assisted function for approaching special setup positions. Setup and adjustment work is eliminated entirely. The mci 761 seals module can be tipped back on its height-

adjustable module base, allowing ready access. An optional seal presence analyzer (SPA-iL) can be integrated directly into the mci 761 seals module and the TopWin user software.

Terminal feedThe swiveling terminal-roll holder allows the use of applicators with right or left infeed. It is as easy as can be to switch from side feed to back feed. The tidy disposal of carrier strips is assured by a paper winder and a carrier strip chopper.

Cost-optimized total solutions Modern wire processing requires cost-optimized total solutions. Komax offers you just the technologies you need to achieve this goal.

Alpha 488 with three crimping modules and one seals module

Straight-forward setup menu Production menu with all relevant information

Parallel gripper systems for both wires Two crimping modules and two seals modules on side 1

mci 722 crimping module with programmable crimp height

mci 712 crimping module Holding gripper for twisting operation mci 761 seals module with op-tional seal presence analyzer (SPA-iL)

Economical production of twisted pairsAlpha 488

Drawing on continuous stock, the Alpha 488 fully automatic twister produces twis-ted pairs completely cut to length and ter-minated with all quality controls included. The modular design of the system ensures maximum flexibility. Four processing stati-ons at the lead termination and two at the trailing end open up an array of processing possibilities.

Maximum flexibilityDrawing on continuous stock, the Alpha 488 fully automatic twister produces twisted pairs completely cut to length and terminated. It can handle wire cross sections ranging from 2×0.22mm2 to 2×2.5mm2 with no trouble at all. Four stations on side 1 and two stations on side 2 open up flexible processing possibilities such as two-ended seals loading and crimping. Of course, the Alpha 488 is also ideal for the processing of individual conductors.

TechnologyThis machine’s high output of twisted pairs results from the parallel processing of the two conductors and a division of overall processing into three

main processes, all optimally synchronized with each other. The linear wire draw-in unit with integrated delta length analyzer (DLA) assures the gentle handling of the wires. The twisting head with AC servo-drive is the heart of the Alpha 488. The integrated twist force analyzer (TFA) guarantees uniform twisting by analyzing the forces exerted during twisting and regulating the subsequent adjustment movements of the twisting head.

Maximum user friendlinessThe system is extremely user friendly. Its stations swivel in a radius of 400mm, making them readily accessible to the operator. Elements like a wire deposit tray with integrated batch sorting

and post-production of defective wires are part of the standard equipment. The TopWin user interface and the sliding operator’s console along the pull-out unit further increase the convenience of this system. In combination with the Komax mci 722 or the mci 712 crimping modules and the mci 761 seals module plus the quick-change systems and the integrated monitoring units, the Alpha 488 offers maximum process reliability and ultra-short conversion times. Its modular design assures unbeatable flexibility.

TopWinTopWin is a Windows®-based graphical user interface designed for quick, easy data input. Thanks to its simple and logical structure, users can fully master the machine in no time at all. Pitch length, open conductor ends, pull force, and a host of other key parameters can be conveniently set and saved. Error messages are presented in clear, uncluttered graphics. A special editor (Permission Editor) can be used to manage access rights for all entry parameters. With the optional WPCS (Wire Processing Communication Stan-dard) interface, Komax

machines can be networked together and easily integrated into existing production processes. The supplemental networking software known as TopNet is the ideal tool for achieving optimum production management.

mci 722 crimping modulePress with programmable crimp height, integrated crimp force analyzer (CFA) for crimping forces up to 20kN (short conversion times)– Just one teach crimp required– Controls for the most important

functions, e.g. creep speed, are right on the press.

– Split-cycle function

mci 712 crimping modulePress with integrated crimp force analyzer (CFA) for crimping forces up to 20kN – Just one teach crimp required– Controls for the most important

functions, e.g. creep speed, are right on the press.

– Split-cycle function

mci 761 seals moduleChangeover times are ultra-short thanks to two great features: quick-release locks used consistently for all seal-related application parts and a software-assisted function for approaching special setup positions. Setup and adjustment work is eliminated entirely. The mci 761 seals module can be tipped back on its height-

adjustable module base, allowing ready access. An optional seal presence analyzer (SPA-iL) can be integrated directly into the mci 761 seals module and the TopWin user software.

Terminal feedThe swiveling terminal-roll holder allows the use of applicators with right or left infeed. It is as easy as can be to switch from side feed to back feed. The tidy disposal of carrier strips is assured by a paper winder and a carrier strip chopper.

Cost-optimized total solutions Modern wire processing requires cost-optimized total solutions. Komax offers you just the technologies you need to achieve this goal.

Alpha 488 with three crimping modules and one seals module

Straight-forward setup menu Production menu with all relevant information

Parallel gripper systems for both wires Two crimping modules and two seals modules on side 1

mci 722 crimping module with programmable crimp height

mci 712 crimping module Holding gripper for twisting operation mci 761 seals module with op-tional seal presence analyzer (SPA-iL)

Komax AG, Industriestrasse 6, CH-6036 Dierikon/LUTel. +41 41 455 04 55, Fax +41 41 450 42 66, info@komax.ch, www.komax.ch

Professionals in Advanced Automation

Twisted pairs – a technology with a bright futureAlpha 488

Your benefits

– Complete processing of continuous stock into twisted pairs with processed ends

– Gentle handling of base stock to ensure high-quality end products.

– Also possible to process different open ends up to 125mm in length on side 1 (as an option)

– Usable as well for two-end crimping and seal loading on two identical single wires

– High degree of flexibility and reduction of conversion times thanks to the mci 722 und mci 712

– Integrated quality monitoring (DLA, CFA, SPA-iL), also during twisting (TFA)

– Active good/bad sorting– Accommodates up to six processing stations – Great ease of operation thanks to TopWin software– Networking possibilities with reliable WPCS and

TopNet

Technical dataLength range700mm–4000mm (27.6 in–157.5in)700mm–7000mm (27.6 in–275.6in)700mm–10000mm (27.6 in–393.7in)Optional from 150mm (5.9 in)Final length of twisted pairsLength accuracy±0.3% (min. ±1.5mm)Stripping lengthsSide 1: 0.1–18mm/side 2: 0.1–35mmWire cross sections*2×0.22mm2–2×2.5mm2 (AWG24–AWG14)Open wire ends30–99mm (optionally. 30–125mm on side 1), depends on pitch, cross section, and end processingPitch lengthProgrammable from 5mm to 80mm Wire draw-in speedmax. 5m/sNoise level<75dB Electrical connection3×208–480V/50–60Hz; 10kVAPneumatic connection5–6barAir consumption12m3/hWeightIncluding two crimping modules and two seals modules

4. A

lpha

488

00

5438

3 Ve

rsio

n 3

Sub

ject

to c

hang

e/gu

Alpha 488 / 4m: approx. 3000kgAlpha 488 / 7m: approx. 3700kgAlpha 488 / 10m: approx. 4400kg* Certain extremely hard, tough wires may not be able to

be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

AccessoriesThere are a number of different accessories available with which you can adapt the Komax Alpha 488 to your own specific needs and expand its capabilities as desired.Preliminary wire processing– Ink jet marker– Hot stamp marker– Wire feed systemsCrimping module accessories– Height adjustable lift pedestals– Paper winder– Carrier strip chopper– Valve set for pneumatically

operated advance– Pressure regulation set– Monitoring of length-wise and

cross-wise transport of terminals Process monitoring– Twist force analyzer (TFA)– Delta length analyzer (DLA)– Crimp force analyzer (CFA)

– Seal presence analyzer (SPA-iL)– Splice detection– Quality assurance

Komax 331, 341, 351, 371Options– Short lengths (starting at 150mm)– Different open ends up to 125mm

in length on side 1– Tower light– Wire measurement table– Magnifying glass– Keypad– Uninterruptible power supply

(UPS)– WPCS networking and TopNet

Services Komax also provides superb after-sales support:– Commissioning– Training courses for different levels

of users – Production coaching and assis-

tance– Worldwide customer service net-

work with complete range of spare parts

– Professional consulting services

Processed samples

Alpha 488 / 4m8250mm (312.83in)

19

50m

m (7

6.77

in)

Reference values for piece output of Alpha 488Piece number [pieces/h]

Height with cover closed: 1790mm (70.5in)Height with cover open: 2670mm (105.1in)

Wire draw-in

Twist force analyzer (TFA)

Wire length [mm]

Set valuesConductors: 2×FLRY 0.75mm²Pressure: 6barDraw-in speed: 5m/sAcceleration: 50m/s²Pitch: 20mmOpen ends S1 + S2: 50mmCrimping module: mci 722Seals module: mci 761Quality monitoring: cfa, SPA-iL active

Optionally: different open ends on side 1

Alpha 488 / 7m11750mm (462.6in)

Alpha 488 / 10m15250mm (600.4in)

TopNet

0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1000 2000 3000 4000 5000 6000 7000 8000 1000090000

Komax AG, Industriestrasse 6, CH-6036 Dierikon/LUTel. +41 41 455 04 55, Fax +41 41 450 42 66, info@komax.ch, www.komax.ch

Professionals in Advanced Automation

Twisted pairs – a technology with a bright futureAlpha 488

Your benefits

– Complete processing of continuous stock into twisted pairs with processed ends

– Gentle handling of base stock to ensure high-quality end products.

– Also possible to process different open ends up to 125mm in length on side 1 (as an option)

– Usable as well for two-end crimping and seal loading on two identical single wires

– High degree of flexibility and reduction of conversion times thanks to the mci 722 und mci 712

– Integrated quality monitoring (DLA, CFA, SPA-iL), also during twisting (TFA)

– Active good/bad sorting– Accommodates up to six processing stations – Great ease of operation thanks to TopWin software– Networking possibilities with reliable WPCS and

TopNet

Technical dataLength range700mm–4000mm (27.6 in–157.5in)700mm–7000mm (27.6 in–275.6in)700mm–10000mm (27.6 in–393.7in)Optional from 150mm (5.9 in)Final length of twisted pairsLength accuracy±0.3% (min. ±1.5mm)Stripping lengthsSide 1: 0.1–18mm/side 2: 0.1–35mmWire cross sections*2×0.22mm2–2×2.5mm2 (AWG24–AWG14)Open wire ends30–99mm (optionally. 30–125mm on side 1), depends on pitch, cross section, and end processingPitch lengthProgrammable from 5mm to 80mm Wire draw-in speedmax. 5m/sNoise level<75dB Electrical connection3×208–480V/50–60Hz; 10kVAPneumatic connection5–6barAir consumption12m3/hWeightIncluding two crimping modules and two seals modules

4. A

lpha

488

00

5438

3 Ve

rsio

n 3

Sub

ject

to c

hang

e/gu

Alpha 488 / 4m: approx. 3000kgAlpha 488 / 7m: approx. 3700kgAlpha 488 / 10m: approx. 4400kg* Certain extremely hard, tough wires may not be able to

be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

AccessoriesThere are a number of different accessories available with which you can adapt the Komax Alpha 488 to your own specific needs and expand its capabilities as desired.Preliminary wire processing– Ink jet marker– Hot stamp marker– Wire feed systemsCrimping module accessories– Height adjustable lift pedestals– Paper winder– Carrier strip chopper– Valve set for pneumatically

operated advance– Pressure regulation set– Monitoring of length-wise and

cross-wise transport of terminals Process monitoring– Twist force analyzer (TFA)– Delta length analyzer (DLA)– Crimp force analyzer (CFA)

– Seal presence analyzer (SPA-iL)– Splice detection– Quality assurance

Komax 331, 341, 351, 371Options– Short lengths (starting at 150mm)– Different open ends up to 125mm

in length on side 1– Tower light– Wire measurement table– Magnifying glass– Keypad– Uninterruptible power supply

(UPS)– WPCS networking and TopNet

Services Komax also provides superb after-sales support:– Commissioning– Training courses for different levels

of users – Production coaching and assis-

tance– Worldwide customer service net-

work with complete range of spare parts

– Professional consulting services

Processed samples

Alpha 488 / 4m8250mm (312.83in)

19

50m

m (7

6.77

in)

Reference values for piece output of Alpha 488Piece number [pieces/h]

Height with cover closed: 1790mm (70.5in)Height with cover open: 2670mm (105.1in)

Wire draw-in

Twist force analyzer (TFA)

Wire length [mm]

Set valuesConductors: 2×FLRY 0.75mm²Pressure: 6barDraw-in speed: 5m/sAcceleration: 50m/s²Pitch: 20mmOpen ends S1 + S2: 50mmCrimping module: mci 722Seals module: mci 761Quality monitoring: cfa, SPA-iL active

Optionally: different open ends on side 1

Alpha 488 / 7m11750mm (462.6in)

Alpha 488 / 10m15250mm (600.4in)

TopNet

0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1000 2000 3000 4000 5000 6000 7000 8000 1000090000