DELTA
540
crimper
EN
DELTA
540
The Delta 540 is a semi-automatic BenchTop
machine equipped with all the necessary func-
tions to process IDC connectors. It is available
with several optional connector-specific kits.
The Delta 540 is equipped with a cable clamp
that securely holds the hand-fed wires, allowing
the cutting unit to precisely cut them to the de-
sired length. The machine also includes a com-
ponent feeder, which automatically supplies the
connectors from trays, and a component holder
to position the connectors for termination with
the wires. An IDC unit simultaneously presses all
the wires into the connectors’ slots, establishing
an insulation displacement connection. Once
the process is complete, the finished product is
transported to the take-out position.
SEMI-AUTOMATIC SOLUTION
The Delta 540 also offers several optional com- START TO AUTOMATE INSULATION DISPLACEMENT CONNECTIONS
ponents to improve the process and integrate
quality control into the workflow, such as con-
nector-specific kits, a vision sensor for compo-
nent monitoring, remote access, and a table for
setup.
Options
− Several connector-specific kits
− Vision sensor for component monitoring
− Remote access
− Table
Smart cable clamp,
manually insert wires
one by one or all at once.
From connector manufacturer straight
into the machine
Manually insert your supply of trays with
connectors directly from the manufacturer
HIGH FLEXIBILITY into the machine. Connector-specific car-
tridges are available to adapt the machine to
FOR A VARIETY OF CONNECTORS different types of trays.
Fully automatic connector feeding
Manually provide the machine with a tray of
connectors and the machine will do the rest.
The component feeder automatically feeds,
orients and positions the connectors for
termination.
Quality control conform the connector
manufacturer’s quality specifications
Standard equipped with force and wire
monitoring. Optionally expandable with
component monitoring. All integrated and
fully automated, ensuring consistently high
quality products. The orientation, color and
state of each connector, and the color and
quality of each wire is monitored before
termination even starts. Any disturbance in
the force curve during pressing is detected
and the faulty product is eliminated by the
bad-part cutter.
Achieve shortest possible changeover
times to increase efficiency
Exchangeable parts are bundled in connec-
tor-specific kits tailored specifically for a par-
ticular connector. All parts are engraved and
conveniently equipped with quick-change
systems. Program settings can be accessed
on the user interface with clear graphics.
Quickly change to another connector and
change the wire sequence. Access the
programmed settings from the memory for
simple handling and quick changeover.
Additional options for your convenience
Setup the machine on any table or choose
our optional height-adjustable table. Use
the lockable drawer to store the connec-
tor-specific kits and documentation. With the
remote access option you benefit from an
Conveniently set up on the
extended range of service. This gateway for
optional height-adjustable
table with drawer sustainable machine support will make you
future-ready for digital services.
03
The bad part cutter cuts the wires
off a faulty product. Any disturbance
in the force curve during pressing
is detected and the faulty product
is eliminated. The bad part cutter
prevents faulty products from being
processed further.
04
The vision sensor of the optional
component monitoring checks the
orientation, color and state of a
connector. If the sensor detects that
anything is wrong with the connector,
it is rejected and termination won’t
even start. Programming and viewing
the results of the vision check is done
on the laptop.
01 03
02 04
01
Insert trays from the connector man-
ufacturer straight into the machine. In
order to handle the different types of
connectors, connector-specific car-
tridges are available. Each cartridge
is adapted to fit the different types of
trays.
02
The component feeder processes
one of the connectors. It automati-
cally feeds, orients and positions the
connectors for termination. In order
to handle the different types of con-
nectors, the unit can be equipped with
connector-specific adapters and parts.
Application examples with a
variety of connectors
05
Changing one of the adapters of the
component feeder. Easy and quick
thanks to the magnetic quick-change
system. All exchangeable parts
specifically tailored for a particular
connector are bundled in connec-
tor-specific kits.
06
Programming on the user interface
with clear graphics. Quickly change
to another connector and change the
wire sequence. Load, edit, save and
backup programs in the database
environment for simple handling and
quick changeover.
Technical data
Wire cross section* 0.35 mm² (AWG 22)
Zero cut 2 – 4 mm (0.08 – 0.16 in)
Wire length** Single wire: min. 60 mm (2.36 in)
Bridging: min. 60 mm (2.36 in)
Twisted pairs: 70 – 90 mm (2.75 – 3.54 in)
Processable connectors Erni MicroBridge 90° connector 4 – 14 pin
Erni MicroBridge 180° connector 6 pin
05 Pressing force max. 7500 N (1686 lbf)
06
Electrical connection 3 × 230 / 400 V, 50 / 60 Hz
Power 2500 W
Compressed-air connection 6 bar (87 psi)
Dimensions L × W × H*** 1895 × 958 × 904 mm (74.6 × 37.7 × 35.6 in)
Weight ca. 250 kg (ca. 551 lb)
Noise level < 70 dB
Ambient temperature 10 – 40 °C (50 – 104 °F)
Humidity (non-condensing) max. 90%
Installation site Level, stable surface free of vibration
Table size: min. L × W = 1240 × 820 mm (49 × 33 in)
Loading capacity of the table: min. 250 kg (551 lb)
(e.g. optional table)
Scrap rate max. 2%
Cycle time**** max. 7.5 s
Technical availability 85% based on VDI3423
Processing outside the Processing outside the specifications upon request. In
specifications case of doubt, we will be happy to provide processing
samples for your connetors and wires.
*Specified by the connector manufacturer.
**For ergonomic reasons, longer lengths are recommended.
***With the safety doors open and the tray feeder out.
****Adding certain options will increase the cycle time of the machine.
Komax – leading the field now and in the future
As a pioneer and market leader in automated wire processing,
Komax provides its customers with innovative solutions. Komax
manufactures series and customer-specific machinery, catering to
every degree of automation and customization. Its range of quality
tools, test systems, and intelligent software and networking
solutions complete the portfolio, and ensure safe, flexible, and
efficient production.
Komax is a globally active Swiss company with highly qualified
employees and development and production facilities on several
continents. It provides local support to customers worldwide
through its unique sales and service network and offers services
that help them get the most out of their investments.
Komax Belgium nv
Ketelaarstraat 8
2340 Beerse, Belgium
Phone +32 14 61 86 66
[email protected]
Delta 540 V1 11-2023
Subject to change
komaxgroup.com
