2 SW TopTouch Kappa SimpleGUI EN

EN
TopTouch
Software instructions
TopTouch Kappa
Valid for
Kappa 310 / 315 / 320 /
322 / 330 / 331 / 350
Art. No. 0346365 – Version 2.0

EN
Translation of the original software instructions
Publisher
Komax AG
Industriestrasse 6
6036 Dierikon
Switzerland
Phone +41 41 455 0 455

Fax +41 41 450 4 266
E-mail info.din@komaxgroup.com
Internet www.komaxwire.com
Date issued Version Modified pages

August 2014 0 -
January 2015 1
December 2017 2
Reproduction of these instructions or parts of them in whatever form is not permitted

without express written permission from the publisher.
Komax reserves the right to make technical changes necessary to improve the ma-
chine that could diverge from figures and information in these instructions.
© 2017 by Komax AG pp
Table of contents
Table of contents
EN
1 Introduction ............................................................................................................. EN – 7
1.1 Software instructions (SW) ........................................................................... EN – 7
1.2 Updating the instructions ............................................................................. EN – 7
1.3 Additional documents................................................................................... EN – 7
2 Explanation on safety instructions ........................................................................ EN – 9
3 Operational concept ............................................................................................. EN – 11

3.1 TopTouch-screen ....................................................................................... EN – 11
3.2 Touch Control Interface (TCI) ...................................................................... EN – 13
3.3 The TopTouch Product Designer ................................................................ EN – 14
3.4 Recurring controls ...................................................................................... EN – 15
3.5 Active and inactive functions ...................................................................... EN – 16
3.6 Possible entries .......................................................................................... EN – 16
3.6.1 Buttons ......................................................................................... EN – 16
3.6.2 Alphanumerical keypad ................................................................ EN – 17
3.6.3 Numerical keypad......................................................................... EN – 17
3.6.4 Check box .................................................................................... EN – 18
3.6.5 Radio button ................................................................................. EN – 18
3.7 Lists ............................................................................................................ EN – 19
3.7.1 Adjusting depiction of lists ........................................................... EN – 19
3.7.2 Buttons for list processing ........................................................... EN – 19
3.7.3 Buttons for processing the cable lists .......................................... EN – 20
3.7.4 Buttons for processing product lists ............................................ EN – 21
3.8 Wizard ......................................................................................................... EN – 22
3.9 Coloring ...................................................................................................... EN – 23
3.10 Cables and products .................................................................................. EN – 24
3.11 Data model ................................................................................................. EN – 25
4 Initial steps ............................................................................................................ EN – 27

4.1 Switching the machine ON ......................................................................... EN – 27
4.2 Shutting down the machine ........................................................................ EN – 29
4.3 Password/login .......................................................................................... EN – 31
4.3.1 Logging in as different user .......................................................... EN – 31
4.3.2 User categories/passwords.......................................................... EN – 32
4.3.3 Changing the password ............................................................... EN – 32
4.4 Choosing the language ............................................................................... EN – 35
4.5 Defining a product ...................................................................................... EN – 36
SW TopTouch Kappa – Version 2.0 EN – 3

Table of contents
5 Configuration......................................................................................................... EN – 39
EN
5.1 Selecting the options .................................................................................. EN – 40

5.1.1 List of options ............................................................................... EN – 41
5.2 Managing pieces of auxiliary equipment .................................................... EN – 45
5.2.1 Recording a piece of auxiliary equipment .................................... EN – 45
5.2.2 Configuring the piece of auxiliary equipment ............................... EN – 46
5.2.3 Activating the piece of auxiliary equipment ................................. EN – 48
5.2.4 IOCS interfaces (Input/Output Communication Standard) ........... EN – 49
5.2.5 Settings for cable feeding system ................................................ EN – 52
5.2.6 Settings for notching/slitting machines ....................................... EN – 54
5.2.7 Settings for inkjet markers (license required) ............................... EN – 55
5.2.8 Settings for hot stamp markers .................................................... EN – 56
5.2.9 Settings for coilers........................................................................ EN – 58
5.2.10 Settings for deposit systems ........................................................ EN – 59
5.2.11 Settings for take-over grippers (license required) ........................ EN – 61
5.2.12 Settings for switches (license required) ........................................ EN – 63
5.3 Recording the licenses ............................................................................... EN – 65
5.4 Adjusting the axles ..................................................................................... EN – 66
5.5 Configuring the blades ............................................................................... EN – 68
5.5.1 Blade icons ................................................................................... EN – 68
5.5.2 Blade replacement and configuration ......................................... EN – 69
6 Defining the product ............................................................................................. EN – 71

6.1 Defining a new product with the TopTouch Product Designer ................... EN – 71
6.2 Defining cable characteristics .................................................................... EN – 74
6.2.1 Defining general cable characteristics ......................................... EN – 74
6.2.2 Flat ribbon cable........................................................................... EN – 81
6.2.3 Multi-pole cable with processing of inner conductors
(Kappa 322 only) .......................................................................... EN – 83
6.2.4 Multi-layer cables ......................................................................... EN – 88
6.2.5 Setting up the circular cutting unit (on Kappa 331 only) .............. EN – 91
6.2.6 Determining the cable parameters using cable learning .............. EN – 94
6.2.7 Cable length correction ................................................................ EN – 96
6.3 Defining the types of cable processing ...................................................... EN – 99
6.3.1 Stripping, full strip ...................................................................... EN – 102
6.3.2 Stripping, half strip ..................................................................... EN – 104
6.3.3 Slitting ........................................................................................ EN – 107
6.3.4 Trimming ..................................................................................... EN – 109
6.3.5 Inkjet marking (license required) ................................................. EN – 110
6.3.6 Hot-stamp marking .................................................................... EN – 113
EN – 4 SW TopTouch Kappa – Version 2.0

Table of contents
6.3.7 Notching ..................................................................................... EN – 115
EN
6.3.8 Short mode................................................................................. EN – 117
6.4 Importing CSV data .................................................................................. EN – 118
6.4.1 Table structure for cable data ..................................................... EN – 118
6.4.2 Table structure for product data ................................................. EN – 119
6.4.3 Recording CSV data ................................................................... EN – 120
6.4.4 Importing CSV data into Kappa ................................................. EN – 121
7 Production ........................................................................................................... EN – 123

7.1 Control buttons ......................................................................................... EN – 123
7.2 Piece counter............................................................................................ EN – 126
7.2.1 Layout......................................................................................... EN – 126
7.2.2 Operating states ......................................................................... EN – 126
7.2.3 Follow-up production ................................................................. EN – 128
7.3 Cyclic operation (license required) ........................................................... EN – 128
7.4 Producing samples ................................................................................... EN – 129
7.4.1 Defining sample parameters ...................................................... EN – 129
7.4.2 Producing in single step mode ................................................... EN – 130
7.4.3 Producing samples..................................................................... EN – 130
7.5 Starting production ................................................................................... EN – 131
8 Archive/error list ................................................................................................. EN – 133

8.1 Opening the archive/error list ................................................................... EN – 133
8.2 Error message........................................................................................... EN – 134
8.3 Consistency warning ................................................................................ EN – 135
9 System administration........................................................................................ EN – 137

9.1 System menu ............................................................................................ EN – 137
9.1.1 Opening the system menu ......................................................... EN – 137
9.1.2 Functions of the system menu ................................................... EN – 138
9.2 Emergency login ....................................................................................... EN – 140
9.3 User management .................................................................................... EN – 142
9.3.1 Recording a new user................................................................. EN – 142
9.3.2 Editing a user.............................................................................. EN – 143
9.3.3 Deleting a user............................................................................ EN – 144
9.4 Data backup ............................................................................................. EN – 145
9.4.1 Creating a backup ...................................................................... EN – 145
9.4.2 Restore from backup .................................................................. EN – 146
9.5 Software update ....................................................................................... EN – 147
9.6 Calibrating TouchScreen........................................................................... EN – 148
9.7 Show I/O ................................................................................................... EN – 148

EN

Introduction
1 Introduction
EN
1.1 Software instructions (SW)
These software instructions are valid for TopTouch for the Komax Kappa 310 / 315 / 320 /
322 / 330 / 331 / 350 from software version 16.3.1 onward.
These software instructions contain complete information on operating the TopTouch soft-
ware and certain general information on wire processing.
The software instructions form an integral part of the operating instructions for your Kappa
3xx. Keep the instructions within easy reach so you can refer to the information in them
any time you need it. Tab 13 in the operating instructions is the intended place for storing
software instructions.
Read through these software instructions carefully. Everyone responsible for installing,
operating and servicing the machine must understand these instructions and follow them
to the letter.
1.2 Updating the instructions

You will find a version number in every footer of these instructions, e.g. Version 0.0.
The number 0.0 indicates the first edition of the software instructions.
Main number Subordinate number
If changes are made on certain pages of the instructions, only the subordinate number on
the given page will be increased, e.g., from 0.0 to 0.1.
If the entire operating instructions are reissued, the main number also changes, e.g. from
1.3 to 2.0.
1.3 Additional documents

The overall documentation for the machine is divided into various sets of documents/in-
structions that can be filed in the operating instructions (OI).
Documentation/instructions OI tab
Electrical diagram (delivered separately) 11
I/O list (delivered separately) 12
TopTouch software instructions 13
Options/accessories (customer-specific) 14
Training documents (customer-specific) 15

EN

Explanation on safety instructions
2 Explanation on safety instructions
EN
NOTE
Read the chapter on safety in the operating instructions for the device used. Under-
standing the safety concept is an essential prerequisite for operating the machine
safely.
DANGER
Indicates a danger involving a high risk.
If this danger is not avoided, it can result in death or extremely grave injuries.
WARNING
Indicates a danger involving a medium risk.
If this danger is not avoided, it can result in injuries.
CAUTION
Indicates a danger involving a slight risk.
If this danger is not avoided, it can result in property damage.
NOTE
Indicates tips for users and other useful information.
It is not a word that signals dangers.

EN

Operational concept
3 Operational concept
EN
3.1 TopTouch-screen
After you switch on the Kappa, the main menu appears. From the main menu, you can ac-
cess all menus and functions needed for machine setup and cable production.
2 3 4
6
5 7
10 11 12
13
fig 3.01 TopTouch main menu
1 Information bar
The information bar shows:
- the loaded product - the product list key

- the selected cable - the cable list key
- the logged-in user
2 The product list key

Opens the list of all products already recorded. The products are managed here.
3 The system menu key

Opens the system menu. The system menu, in turn, contains the following main func-
tions:
- User management - Data backup

- Language selection - Software update

Operational concept
4 The cable list key

EN
Opens the list of all cables already recorded. The cables are managed here.
5 Touch-sensitive cable view (product menu)

A click on the touch-sensitive cable view opens the cable processing menus (product
definition). A click on the right side of the cable opens the cable processing menu for
side 1; a click on the left side of the cable opens the cable processing menu for side 2.
The blue fields are entry fields. These values can be adjusted without having to leave
the main menu (e.g., cable length).
6 TopTouch «Product Designer» key

Opens a menu where you can quickly define and name new products. When defining
new products, you can either use already existing cables or define new cables.
7 Cable menu key

Opens the menu for editing a cable.
8 Piece counter
The piece counter lets you define the total piece no. and the batch size for production.
The piece counter shows the number of products already produced.
9 Control buttons for production

The control buttons appear only if the on-load voltage is switched on.
10 Selector for auxiliary equipment (pre-station)

Here you can select the pieces of auxiliary equipment you want to use just upstream
of the Kappa (pre-stations). This equipment could be a marker or a feeding system, for
example. In this menu, you also set all the parameters needed for operating the pieces
of auxiliary equipment you selected.
11 Quick Links menu

The Quick Links menu lets you access important machine setup menus quickly. These
menus include:
- Cable transport speed - Configure blades

- Sample parameters - Configuration
- Corrected wire length (selection of options and pieces of
auxiliary equipment)
- Adjustment - Error list
12 Selector for pieces of auxiliary equipment (downstream devices)

Here you select the pieces of auxiliary equipment you want to use just downstream of
the Kappa for production. This equipment could be a deposit system, for example, or a
coiler. In this menu, you also set all the parameters needed for operating the pieces of
auxiliary equipment you selected.
13 Status bar
The status bar shows important information on the current operating status of the ma-
chine.

Operational concept
3.2 Touch Control Interface (TCI)
EN
TopTouch is controlled from the Kappa TCI (Touch Control Interface). In other words, it is
controlled from a touch screen.
Example: Changing the cable cross section
1 2
fig 3.02 Press the entry field for cable cross section fig 3.03 Enter the cable cross section
3 4
fig 3.04 Confirm your entry fig 3.05 New cable cross section is recorded

Operational concept
3.3 The TopTouch Product Designer

EN
The TopTouch Product Designer 1 is one of

the most important tools in TopTouch.
The Product Designer is an easy way for
you to define new products and to start
producing them in no time at all.
TopTouch helps you to define new products 1
with default values.
fig 3.06 Main menu with TopTouch

Product Designer key
When defining new products, you can resort

2
to the currently loaded cable 2 or to another
already recorded cable 3 or you can define
a new cable 4 in the same work step. 3
fig 3.07 Cable selection for a new product

Operational concept
3.4 Recurring controls
EN
Control Function
OK Confirms and saves the entered values.
Aborts the wizard (without saving the values).

Abort
The display changes to the previous window.
Forward Moves you to the next window in the wizard.
Backward Moves you to the previous window in the wizard.
Default values Reverts changed values to the default values.
Scrolls the screen upward.

Upward Selection switches to the previous value in a list.
Increases the entered value in defined increments.
Scrolls the screen downward.

Downward Selection switches to the next value in a list.
Decreases the entered value in defined increments.
Increases the entered value with a slide in defined

Add
increments
Decreases the entered value with a slide in defined

Subtract
increments

Operational concept
3.5 Active and inactive functions

EN
In the menus, you can only select entries that do not disrupt correct processing.
Functions may be inactive (not selectable) for a variety of reasons:
No authorization
Incomplete preliminary settings
Action impossible (e.g. going back on first page)
Inactive functions appear grayed out on the display.
fig 3.08 Active buttons (administrator) fig 3.09 Inactive buttons (operator)
3.6 Possible entries
3.6.1 Buttons
1 Opens the alphanumeric keypad for 1

entering text.
2 Opens the numeric keypad for entering

numbers. 2
2
3 The entry value is increased/decreased
in defined increments.
3
4
4 Switches function on and off.

Operational concept
3.6.2 Alphanumerical keypad
EN
If you open the alphanumerical keypad, you can enter letters and numbers.
1 Entry field
Touch the desired place in the text to set
the cursor position. 1 2
2 Information about entry (if necessary)
5
3 Keypad
Press the key several times until the 3 6
character you want appears. The cursor 7
jumps ahead after a short pause.
8
4 Special characters
Operate as you would a keypad. 4
fig 3.10 Example of an alphanumerical keypad
5 Press to switch between letters and
numbers.
6 Pres to switch between upper-case and
lower-case.
7 Press to delete the entire entry.
8 Press to delete individual characters.
3.6.3 Numerical keypad

If you open the numerical keypad, you can enter only numbers.
1 Entry field
Touch the desired place in the text to set
the cursor position. 1
2 Possible range for an entry. 2
Any entry outside the possible range is
displayed in red. The entry cannot be
confirmed.
3 Keypad 4
4 Press to delete the entire entry.

3 5
5 Press to delete individual characters.

fig 3.11 Numerical keypad

Operational concept
3.6.4 Check box

EN
In the configuration menu, you can use

check boxes to select options and activate
pieces of auxiliary equipment.
Check boxes are used in cases where you
can select from several options.
fig 3.12 Check box
3.6.5 Radio button

In the configuration menu, you can use
radio buttons to make selections.
Radio buttons are used if you can select just
one option from a group of items.
fig 3.13 Radio button

Operational concept
3.7 Lists
EN
TopTouch lists recorded cables and products as well as error messages in alphabetic order.
3.7.1 Adjusting depiction of lists

1 Sorting 1
If you select the column heading, the
content is sorted in ascending or de-
scending order.
2
2 Adjust column width
The cursor changes if you put it on the
lines between the columns, allowing you 3
to shift the column width in whichever 4
direction you wish.
3 Scrolling
You can select the up and down arrows fig 3.14 Lists
or make direct use of the scroll bar to
view lists that extend beyond the screen
display.
4 Selecting
The selected article is appears in a blue
bar. The remaining processing pertains
to this article.
3.7.2 Buttons for list processing
Icon Designation Function
Creates a new product/cable/piece of auxiliary equip-

New
ment, etc.
Copies the selected product/cable/piece of auxiliary

Copying
equipment, etc.
Deletes the selected product/cable/piece of auxiliary

Deleting
equipment, etc.
Opens the selected product/cable/piece of auxiliary

Processing
equipment, etc. for processing.

Operational concept
EN
Searches for products and cables. While you enter the

Searching keyword for the search, the search machine begins
filtering according to the letters entered.
Continuing
Opens the next entry according to the keyword.
to search
Saves the data for the selected product or cable at a

Exporting
selectable location.
Imports the data for a product or cable from a select-

able location
Importing Product data can only be imported by Kappa machines
of the same type. In other words, product data from a
Kappa 320 can only be imported to a Kappa 320.
Importing CSV Imports the CSV data for a product or a cable from a
data USB flash drive.
3.7.3 Buttons for processing the cable lists
Cable Designates a cable that is on the cable list.
Loaded cable Designates the cable currently loaded on the cable list.
Cable list Opens the cable list.
Cable from Designates on the cable list a cable that was created in
TopWin TopWin.
Cable loaded Designates on the cable list the currently loaded cable
from TopWin that was created in TopWin.

Operational concept
3.7.4 Buttons for processing product lists
EN
Product Designates a product in the product list.
Designates the product currently loaded in the product

Loaded product
list.
Product list Opens the product list.
Product from Designates on the product list a product that was cre-
TopWin ated in TopWin.
Product loaded Designates on the product list the currently loaded

from TopWin product that was created in TopWin.

Operational concept
3.8 Wizard
EN
The wizard simplifies all software settings

involving multiple sequential steps.
It guides the user step by step through the
installation and setting procedures and
wherever necessary, gives instructions on 1
what to do.
1 Controls
2 Instructions
Certain individual controls may be inactive.
You can end the wizard anywhere you wish
by pressing «OK» unless there is still a step fig 3.15 Controls
you have to carry out on another page.
You can end the wizard at any step along
the way by pressing the cancel button.
fig 3.16 Instructions

Operational concept
3.9 Coloring
EN
Color Menu Type of use Meaning
Red Production White text on Current error message

red background
Production Red text The mounted and configured blades

do not match those deposited with
the cable.
Error list Red text Archived error message

Notice along with error message
Miscellaneous Red text next Unacceptable entry

to entry field
Yellow Production Black text on yel- Consistency warning

low background
Software points out illogical
sequences at the start of production.
No error
Blue Error list Blue text Details on error messages and

consistency warnings
Production Blue dimensions Indicates correction values for

(during procedure processing cable side 1 and cable
for defining the side 2.
products)
Production Black font on blue Entry field

background
The value in the entry field can be
changed.
Gray Production Black font on gray Blocked entry field

background
The value in the entry field cannot
be changed (e.g. due to lack of
authorization).
Green Error list Green text Notes on error messages and

consistency warnings

Operational concept
3.10 Cables and products

EN
TopTouch distinguishes between cables and products. With the TopTouch Product Design-
er, you have cables and products well under control.
Cables Products
fig 3.17 Cables and products
Cables
«Cables» are fed into the Kappa for processing. Cables are coiled onto cable reels or
stored in cable drums.
The data important for processing a specific cable can be saved in TopTouch. This in-
cludes, for example, cable diameter, the number of insulation layers on a cable or the
blades being used for cutting. This data remains unchanged for a given cable regardless of
the product it ends up being after subsequent processing.
Product
The term «Products» refers to cables stripped and cut by the Kappa. Once finished, the
products are deposited in a tray.
Important product data items include, for example,the length of the cable being produced,
the stripping length or the type and manner of stripping (full strip, half strip).
TopTouch Product Designer

The TopTouch Product Designer allows you to define a product easily and quickly based on
a new cable or on an already recorded cable.

Operational concept
3.11 Data model
EN
TopTouch saves the data for cables and products separately in a cable database and a
product database.
NOTE
A cable is deposited for each product. Any change in the parameters for a given
cable affects all products that used this cable.
Cable data Product data
Cable name Product designation
Cable type Cable used
Cable cross section (gauge) Cable length
Blades used Side processes
Parameters for individual

Marking procedures, etc.
cable layers
Process parameters
(cable drive, speeds, etc.)
One cable can be deposited for several different products. In other words, multiple prod-
ucts can be made from one cable.
Example:
Cable 3 is used for the products 2, 3 and 5. Any changes in the parameters for cable 3 af-
fect the products 2, 3 and 5.
Cables created Products created
Cable 1 Product 1
Cable 2 Product 2
Cable 3 Product 3
Product 4
Product 5

EN

Initial steps
4 Initial steps
EN
4.1 Switching the machine ON
Procedure
f Turn machine ON at the main switch 1.
1
fig 4.01 Main switch
The user interface opens automatically. This

procedure may take several minutes.
fig 4.02 TopTouch in the process of starting
f Select the corresponding user 2.
fig 4.03 Selecting the user

Initial steps
The following passwords have been preset at the factory for the different users:
EN
User category Operator Administrator Setup

User OPERATOR ADMINISTRATOR SETUP
Password 123 123 123
f Enter password 3.
f Press the OK button 4.
The software opens the last menu the 3
user was processing before the machine
was switched off.
fig 4.04 Entering the password
f Wait until the message «Power can be

switched on» 5 appears in the status
line. 5
fig 4.05 Status line regarding power
f Press the button 6 to switch on the

power. 6
Push button lights up.
fig 4.06 Switching on the power.
f Click on the reset button 7.

The machine is reset mechanically and is
then ready for operation. 7
fig 4.07 Resetting the machine

Initial steps
4.2 Shutting down the machine
EN
CAUTION
If you switch off the machine directly at its main switch, data and/or programs could
be lost.
f Never switch off the machine directly at the main switch. Always use the procedure
below.
Procedure
f Click on the user 1 to proceed to the
system menu.
fig 4.08 Selecting the system menu
f Select shutdown 2.
fig 4.09 System menu

Initial steps
The user interface shuts down.

EN
f Wait till the message «System halted» 3

appears.
33
fig 4.10 «System halted» window
f Switch off the machine at the main

switch 4.
fig 4.11 Main switch

Initial steps
4.3 Password/login
EN
4.3.1 Logging in as different user
Procedure
system menu.
1
f Select login 2.
f Select the desired user category 3.
fig 4.14 Selecting the user
f Enter password 4.
f Click on «OK» 5.

Initial steps
4.3.2 User categories/passwords

EN
TopTouch has three user categories. Each user category has different rights. At the factory,
a user is recorded and given a standard password in each user category. Additional users
can be added at any time.
User category Operator Administrator Setup
User OPERATOR ADMINISTRATOR SETUP
Password 123 123 123
NOTE
The indicated passwords are preset.
f Change the passwords to attain optimum protection against misuse.
4.3.3 Changing the password
Procedure
f Log in with administrator rights.
system menu.
1
f Select «User management» 2.

Initial steps
f Select user 3 for whom the password is
EN
to be changed.
f Select the edit user button 4.
3
fig 4.18 User management
f Select «Change password» 5 (*un-

changed*).
fig 4.19 Changing the password
NOTE
Each password should be at least four characters long for security reasons!
f Enter a new password 6.

f Follow the wizard’s instructions and con-
firm the password.
6

Initial steps
The password was changed successfully

EN
and assigned the notice (*changed*).
fig 4.21 Password changed

Initial steps
4.4 Choosing the language
EN
Procedure
system menu.
f Press «Choose language» 2.
f Choose the language.
fig 4.24 Choosing the language

Initial steps
4.5 Defining a product

EN
In this chapter, you learn how to set up a product and start production quickly and easily in
TopTouch.
Go to Chapter 6 for a detailed description on how to set up a product.
Procedure
1
f Press the button for the TopTouch Prod-
uct Designer 1.
fig 4.25 Production menu
f Select the desired product from the list.

2
For the new product, you can resort to
the currently loaded cable 2 or to anoth-
3
er already recorded cable 3 or you can
define a new cable 4 in the same work
step.
4
5
fig 4.26 TopTouch Product Designer

Initial steps
f Click on product name 6 and name the
EN
product.
6 7
f Click on cable name 7 and name the
cable.
f Adjust the cable cross section 8.
12 13 9 11 10 8
f Adjust the cable length 9.
f Adjust the stripping length 10 and pull-
off length 11 on side 1.
fig 4.27 Defining the product
NOTE
Additional parameters may have to be defined or adjusted depending on the selected
product.
f Press the sample button 14 to produce

samples.
f Check the sample and correct entries if
need be.
f Enter the piece No. 15 and batch size 16.
17 15 14 16
f Press the start button 17 to start produc-
tion.
fig 4.28 Starting production

EN

Configuration
5 Configuration
EN
fig 5.01 Configuration of Kappa options and pieces of auxiliary equipment
In the configuration menu, you define the functional scope of the Kappa. This includes:
Selecting the built-in options
The options built into the Kappa must be activated in TopTouch before they are able to
be used in production. They include, for example, the slitting unit or selecting between a
belt drive or a roller drive.
Selecting the display options
In the configuration menu you decide, for example, whether TopTouch displays the
length dimensions in millimeters or inches.
Selecting the pieces of auxiliary equipment
You can expand the functionality of the Kappa with additional pieces of equipment. In
the configuration menu, you select pieces of auxiliary equipment you wish to have avail-
able at your company. After that, you select the pieces of auxiliary equipment you will
use for production and define the parameters for its interaction with the Kappa.
Recording of licenses
Several options and pieces of auxiliary equipment require licenses. They can only be
operated on the Kappa if they are duly enabled with a valid license key.

Configuration
5.1 Selecting the options

EN
In the configuration menu, you select the options that are built into the Kappa and select
the display options for the Kappa.
Built-in options
Select from the list of options the options that are built into the Kappa. This activates the
options in TopTouch so they can be used in production.
Display options
Select the display options you need. You determine, for example, whether TopTouch dis-
plays the length dimensions in millimeters or inches.
Procedure
f Open the Quick Links menu 1.
f Select the configuration icon 2.
fig 5.02 Quick Links menu
f Select the desired options using the

check boxes 3 and the radio buttons 4.
3 5
fig 5.03 Selecting the options

Configuration
5.1.1 List of options
EN
Icon Designation Kappa type Function
Length 320 / 322 / Additional encoder for length measure-

measurement 330 / 331 / ment measures the required cable length.
system 350
– Keep swivel All For ensuring that the swiveling cable guide
guide down always remains at the lower position.
Recommended for flat ribbon supplemen-
tary set for short lengths
– Keep wire All For ensuring that drive side 2 is closed

drives closed while the cable is being reeled in.
If this function is deactivated, the drive
side 2 does not close until the tip of the
cable is under the drive.
– Cable 310 / 315 / Wire-end detection and wire jam monitor-

monitoring 320 ing with roller drive on side 1
Transport system
For monitoring with roller drive, side 2
– Cable end 320 / 322 / For detecting when cable has run out
detection switch 330 / 331 / (empty cable reel, empty cable drum)
350
Material change detection (optional Top-
Win production logistics module)
After the out-of-cable switch detects that
there is no more cable, the user has to
scan in the bar code of the new cable to
be able to resume production.
Cable detector 310 / 315 / Initial cut optimization

320 / 330 / For minimizing the initial cut into the cable
331 / 350 using sensors
Cable monitoring
Laser light barrier for detection of even the
tiniest cable diameters and of cable jams
at the discharge point
Tolerance
The tolerance data refers to cable monitor-
ing

Configuration
EN
Conductor All Conductor detector

detector For measuring the diameter of electrically
conducting materials with insulation
Unit of measure All For choosing millimeters and inches
– Staggered 320 / 330 / For using with the «Offset blade axes» op-
blade axle 331 tion for short-length cables
– High controller 310 / 315 / For optimizing the movement for placing
accuracy 320 the cutting blades. The movement for plac-
ing the cutting blades can be optimized for
accuracy or for speed.
– Hard cable 322 / 350 For processing two cables with hard con-
ductor or hard insulation. The blade opens
after a failed attempt to cut and closes
again at the same spot until it has cut
through the cable.
Blade cleaning 310 / 315 / For blowing out insulation scrap, select-
320 / 322 / able after stripping and/or cutting
330 / 331
Slitting unit 320 / 322 / For switching the slitting unit on/off
330 / 331 /
350
Different feed 322 / 330 / Different settings can be entered for pres-
and process 331 sure applied in cable transport and during
pressure stripping if a proportional air regulator set
is mounted for side 2.
– Roller or 310 / 322 / For selecting type of cable drive (belt or

belt drive 330 / 331 / roller) on side 1 / 2 (mechanical conversion
350 set needed)
Kappa 310: Side 2 for option «Short cable
lengths» (mechanical conversion set
needed)
Second propor- 350 Different settings can be entered for pres-

tional valve sure applied in cable transport and during
stripping if a proportional air regulator set
is mounted for side 2.

Configuration
EN
– Other pull-off 322 / 331 The pull-off offset on sides 1 and 2 vary in
offset on side 2 adjustability.
– Parallel 310 / 315 / For parallel processing of two identical

processing 320 / 322 / cables
330 / 331
– Guides 331 For choosing between swivel guide and

split guide
RIU stops at 331 The RIU rotary incision unit stops after the
batch size batch size is reached.
– Post production All Button for activating / deactivating post

production; refer to Chapter 7.2.3.
– Disable job All When operated with TopWin, no confir-

confirmation mation is needed after individual jobs are
completed.
– Additional 331 For allowing the recording of cables with

cable layers more than two insulation layers
Standard for Kappa 331; license required
on all other Kappas (refer to Chapter 5.3)
CSV data All CSV = Comma separated values

import
See Chapter 6.4 on how to create cable
and product data in a program such as
Excel® or in a text editor and import it into
TopTouch.
Cyclic operation All For defining the cycle time in the produc-
tion menu (refer to Chapter 7.3)
License required (see Chapter 5.3)
Show pieces All For additionally displaying the output rate

per hour in piece no./hour in the production menu
Touch screen All Touch-activated function for switching

buzzer buzzer on/off

Configuration
EN
– IOCS extension All For enabling interface expansion for Y-

cable
Kappa 310 / 315 / 320 / 322:
For expanding from 2 to 4 interfaces
Kappa 330 / 331 / 350:
For expanding from 3 to 6 interfaces
ATTENTION: Not all pieces of auxiliary
equipment can be operated from expand-
ed interfaces.
– Homing sensor 310 / 315 / For detecting the top stop in the drive
closing drives 320 axes.
- Use an optical All The optical length measurement system

length measure- offers better resolution than its magnetic
ment system counterpart.

Configuration
5.2 Managing pieces of auxiliary equipment
EN
5.2.1 Recording a piece of auxiliary equipment
Select from the list the pieces of auxiliary equipment you have available to you at your
company. All pieces of auxiliary equipment recorded in this manner can be configured for
working with the Kappa and activated for production.
Procedure
f Use the check boxes 3 to activate the

pieces of auxiliary equipment you desire.
3
4
fig 5.05 Activating the piece of auxiliary equipment

Configuration
5.2.2 Configuring the piece of auxiliary equipment

EN
Configure the pieces of auxiliary equipment so they work correctly with the Kappa. A piece
of auxiliary equipment must be recorded before you can configure it.
Procedure
For configuring pre-stations:
f Open the «Aux. equipment» menu 1.
f Press «Edit» 2.
To configure downstream devices:

f Open the «Aux. equipment» menu 3.
f Press «Edit» 4. 2 4
1 3
fig 5.06 Auxiliary equipment menu
f Press the button for new device 5.
fig 5.07 Recording a new piece of auxiliary equipment
f Select the piece of auxiliary equipment 6

to be configured.
fig 5.08 Selecting a piece of auxiliary equipment

Configuration
f Name the piece of auxiliary equipment 8.
EN
f Press the «>>» button 9.
8
fig 5.09 Naming the piece of auxiliary equipment
f Select the IOCS interface 10 to which

the piece of auxiliary equipment is con-
nected.
f Press the «>>» button 11. 10
11
fig 5.10 Selecting the interface
f Set the parameters 12 specific to this

device (refer to following chapters for
details).
12 13
fig 5.11 Parameters specific to the device

Configuration
f Activate the newly configured piece of

EN
auxiliary equipment 14 if required.

14
15
The configured and activated piece of

auxiliary equipment appears in the auxil-
iary equipment window 16.
16
fig 5.13 Configured and activated piece of

auxiliary equipment
5.2.3 Activating the piece of auxiliary equipment

Activate the pieces of auxiliary equipment you wish to use for production. A piece of auxil-
iary equipment must be recorded and configured before you can activate it.
Procedure
f Click in the auxiliary equipment win-
dow 1.
f Activate the piece of auxiliary equip-
ment 2 you desire.
2
1

Configuration
5.2.4 IOCS interfaces (Input/Output Communication Standard)
EN
Most pieces of auxiliary equipment communicate with the Kappa over the IOCS interface.
One piece of auxiliary equipment can be connected at each IOCS interface.
With the IOCS extension, you can connect up to two pieces of auxiliary equipment to each
IOCS interface using a Y-cable.
NOTE
Because of the number of inputs and outputs a piece of auxiliary equipment needs,
there are device-specific restrictions on how the device can be connected.
Contact your Komax agent to order a Y cable.
Available interfaces
IOCS1 IOCS1_ExA IOCS1_ExB

Kappa Kappa
Device Safety IOCS2 IOCS2_ExA IOCS2_ExB
Inputs Outputs
IOCS3 IOCS3_ExA IOCS3_ExB
Komax 102 In3 (stop) Out1 No
ads 112 In3 (stop) Out1 Yes
ads 115 In3 (stop) - No
ads 117 In3 (stop) - Yes
Komax 26 In1 (ready) Out1 No
Komax 62 In1 (ready) Out1 No
CSU In1 (ready) Out1 No
dps 375 - Out1 + Out2 No
KA 3000/6000 In1 (ready) Out1 Yes
dps 272 In1 + In3 Out1 Yes
KRI 400/800 In1 (ready) Out1 Yes
Return stop - Out1 No
Take-over gripper Out1
Depends
(non-Komax In1 (ready)
Out1 + Out2 on device
device)
Hand-/foot- Depends
In1 Out1
operated switch on device
Direct Inkjet
- Out1 No
Interface
Connection available Connection not available

Configuration
Activating the IOCS extension

EN
NOTE
When selecting the port, heed the table with available ports on the previous page.
f Activate the IOCS extension 1 in the

«Configuration» menu.
fig 5.15 Activating the IOCS extension
f When configuring a piece of auxiliary

equipment, select the desired inter-
face 2.
Once you have activated the IOCS
extension, you have not only the ports
IOCS1, IOCS2, IOCS3 available to you
but IOCS1_ExA, IOCS1_ExB, etc. as
2
well.
fig 5.16 Extended selection of ports

Configuration
Diagram of IOCS ports
EN

Configuration
5.2.5 Settings for cable feeding system

EN
Cable feeding systems feed the cable out of a cable reel or a cable drum to the Kappa for
processing. The following cable feeding systems can be connected to a Kappa:
ads 112 ads 123

ads 115 K 102
ads 117 F1150
ads 119 Non-Komax devices
Settings for ads 112 / 115 / 117 / 119 / 123 und K 102
1 Port:
IOCS port
2 Coil diameter: 1
Outside diameter of the cable coil
2
3 Follow-up time (only for ads 112 and
K 102): 3
After the desired length of cable has
been drawn in, the cable pulling machine
continues to run for this period of time.
fig 5.17 Settings for ads 112 (example)
4 Storage unit (for ads 123 only):

− Simple
Without linear storage unit; the cable
comes directly out of the ads 123
− Linear
With linear storage unit (buffer effect) 4
The Kappa automatically limits the speed
during cable transport to values suitable for
the ads 123, the storage unit and the cable
reel.
With the linear storage unit, the software fig 5.18 Settings for ads 123 (example)
allows greater speeds than with the simple
storage unit.

Configuration
Settings for F1150 and non-Komax
EN
devices
1 De-reeler type:
TopTouch enters different settings de-
1
pending on which device is selected.
2 Port:
2
IOCS port 3
3 Max. rotation speed: 4
The maximum rotation speed of the
cable reel is specified for most devices. 5
4 Coil diameter: 6
Outside diameter of the cable coil
fig 5.19 Settings for non-Komax devices
5 Maximum cable speed:
Depends on the rotation speed and
diameter of the cable coil. TopTouch
shows the possible maximum value for
the selected device in the bar.
6 Max. wire acceleration:
TopTouch shows the possible maximum
value for the selected device in the bar.

Configuration
5.2.6 Settings for notching/slitting machines

EN
Notching/slitting machines notch or slit flat ribbon cable before it is processed with the
Kappa. The following notching/slitting machines can be connected to a Kappa:
K 62
Settings
1 Port:
IOCS port 1
2 Distance:
2
Distance between the notching/slitting
blades and the cutting blades 3
3 Activation time:
Length of signal that triggers the notch- 4
ing process. 5
4 Wait time:
When feedback signal is switched off: fig 5.20 Settings for K 62 (example)
Wait time after notching until the Kappa
continues transporting the cable.
When feedback signal is switched on:
Wait time until the feedback signal must
arrive at the Kappa. A timeout appears if
this wait time is exceeded.
5 Feedback signal:
Select whether you want to operate with
or without feedback signal.
Activation time
Wait time
Feedback signal
Cable advance
(with feedback signal)
Cable advance
(without feedback signal)
fig 5.21 Time diagram notching/slitting process

Configuration
6 Tool ID:
EN
Name of the installed notching or slitting
tool
6
fig 5.22 Settings for K 62 (example)
5.2.7 Settings for inkjet markers (license required)

Ink-jet markers mark the cable before it is processed with the Kappa. The configuration
described here is necessary only if the ink-jet marker is operated with the Direct Ink-jet
Interface (without TopWin). The following ink-jet markers can be connected to a Kappa via
the Direct Ink-jet Interface.
Komax ims 295

WP 405
WP 407
Settings
1 Port:
IOCS port 1
2 IP address:
2
IP address of the ink-jet marker
3 Encoder output: 3
Encoder output to which the ink-jet
marker is connected. 4
4 Distance:
Distance between the marking head and
the cutting blades. fig 5.23 Settings for the Direct Ink-jet Interface

Configuration
5.2.8 Settings for hot stamp markers

EN
Hot stamp markers mark the cable before it is processed with the Kappa. The following hot
stamp markers can be connected to a Kappa:
K 26
Settings
1 Port:
IOCS port 1
2 Distance:
2
Distance between the marking head and
the cutting blades. 3
3 Activation time:
Length of the signal that triggers the 4
marking process.
5
4 Wait time:
When feedback signal is switched off: fig 5.24 Settings for K 26 (example)
Wait time after marking until the Kappa
continues transporting the cable.
When feedback signal is switched on:
Wait time until the feedback signal must
arrive at the Kappa. A timeout appears if
this wait time is exceeded.
5 Feedback signal:
Select whether you want to operate with
or without feedback signal.
Activation time
Wait time
Feedback signal
Cable advance
(with feedback signal)
Cable advance
(without feedback signal)
fig 5.25 Time diagram for marking process

Configuration
6 Color band, left:
EN
Color of the left color band installed in
the marker
6
7 Text left side:
The marking text on the right side set in 7
the marker with the daisy wheels.
8
8 Color band, right:
Color of the right color band installed in 9
the marker
9 Text right side:
The marking text on the right side set in
fig 5.26 Settings for K 26 (example)
the marker with the daisy wheels.

Configuration
5.2.9 Settings for coilers

EN
Coilers coil the cable after it is processed with the Kappa. The following coilers can be con-
nected to a Kappa:
dps 272
KRI 400
KRI 800
Settings
1 Port:
IOCS port 1
2 Encoder output: 2
Encoder to which the coiler is connected
for device synchronization. 3
3 Distance:
Distance between the Kappa cutting 4
blades and the position at which the
coiler can take the cable.
4 Mode: fig 5.27 Settings for coilers (example)
Type of cable transfer to the coiler.
− Eject:
The Kappa cable drive transport the
cable from the Kappa to the coiler.
− Pull-out:
The coiler pulls the product out of the
Kappa.
5 Inside diameter:
Inside diameter of the finished coil
6 Outside diameter: 5
Outside diameter of the finished coil
6
7 Pitch:
Increase in the diameter per rotation of 7
the coiler
8 Maximum wire feed speed: 8
Depends on the inside diameter of the
finished coil. 9
9 Maximum wire acceleration fig 5.28 Settings for coilers (example)
NOTE
Some of the parameters also have to be entered for the take-up stand because there
is no compensation between the Kappa and the take-up stand.

Configuration
5.2.10 Settings for deposit systems
EN
Deposit systems lay the cables in a tray after being processed on the Kappa. The following
deposit systems can be connected to a Kappa:
dps 375
KA 3000
KA 6000
Settings for dps 375

1 Port:
IOCS port 1
2 Deposit mode:
2
Defines the use of the two trays.
− Overlapping:
Once the batch size is reached, the
upper tray empties the batch into the
lower tray and production automati-
cally continues in the upper tray.
fig 5.29 Setting the deposit mode in the dps 375

− Sequential:
Once the batch size is reached in the upper tray, the batch has to be confirmed. Fol-
lowing confirmation, production continues and the upper tray empties the batch into
the lower tray.
− Upper tray:
The batch is deposited exclusively in the upper tray. The lower tray is not used.
− Lower tray:
The batch is deposited exclusively in the lower tray. The upper tray remains in tipped
position.
− No tray:
Setting in the event that no tray is mounted.
The time behavior of the tray and the ejector

are determined by:
3 Duration for deposit tray down 3
4 Duration for deposit tray up 4
5 Duration for deposit ejector out
5
6 Duration for deposit ejector in
7 Duration for deposit ejector start-up 6
fig 5.30 Setting the deposit tray in the dps 375

Configuration
Settings for KA 3000 and KA 6000

EN
1 Port:
IOCS port 1
2 Encoder output: 2
Encoder to which the deposit tray is con-
nected for device synchronization. 3
3 Distance:
Distance between the Kappa cutting 4
blades and the position at which the
cable is laid in the deposit unit.
4 Mode: fig 5.31 Settings for deposit systems (example)
Type of cable transfer into the deposit
tray.
− Eject:
The Kappa cable drive conveys the
cables from the Kappa to the deposit
tray.
− Pull-out:
The deposit tray pulls the product out
of the Kappa.
5 Maximum wire feed speed

6 Maximum wire acceleration
fig 5.32 Settings for deposit systems (example)

Configuration
5.2.11 Settings for take-over grippers (license required)
EN
These grippers take the cables after they are processed on the Kappa and transport them
onward.
Settings
1 Port:
IOCS port 1
2 Select whether the hand-over signal 2
«take» and «move» are to be sent over
the same output or separate ones. 3
3 Kappa ends its transport of the product
4
out of the system after this distance.
4 Wait time (t1, fig 5.34) until the take-over 5
gripper is in the ready position.
An error message appears if this wait fig 5.33 Setting the take-over gripper
time is exceeded.
5 Wait time (t2, fig 5.34) until the take-over gripper has taken the conductor.
An error message appears if this wait time is exceeded.
Process overview
Take-over signals are sent over the same outputs:
In1 Gripper is not Gripper is in Gripper takes Gripper moves the cable and Gripper is in
IOCS Pin 1 Gripper waits ...
ready feed position the cable goes back to feed position feed position
(Feedback 1)
produce
produce
release
move
take
t1 t1
Out1
Kappa produces Kappa releases Kappa produces
IOCS Pin 2-4 Kappa waits
a cable
Kappa waits
the cable
Kappa waits
a cable
...
(Relais 1) t2
fig 5.34 Take-over signals over the same outputs
Take-over signals are sent over separate outputs:
In1 Gripper is not Gripper is in Gripper takes Gripper waits Gripper moves the cable and Gripper is in
IOCS Pin 1 ...
ready feed position the cable goes back to feed position feed position
(Feedback 1)
produce
produce
release
move
take
Out1
IOCS Pin 2-4 ...
(Relais 1)
Kappa waits Kappa Kappa waits Kappa Kappa waits Kappa
produces releases produces
Out2 a cable the cable a cable ...
IOCS Pin 6-8
(Relais 2)
fig 5.35 Take-over signals over separate outputs

Configuration
Keep in mind the following points in this process:

EN
The take-over gripper is ignored in short mode because Kappa does not hold the con-
ductor on side 2 itself.
Before producing, the Kappa always waits for a signal from the take-over gripper, even
in short mode or in the event of rejects. The take-over gripper always has to be ready
even if there is no cable for it to take.
Electrical diagram for the take-over gripper
Peripheral Basic
device 1 1 machine
Feedback 1: high, low, off
2 2
3 3 Relais 1 to
4 4 control peripheral device
5 5
Feedback 2: high, low, off
6 6
7 7 Relais 2 to
8 8 control peripheral device
9 9
GND
24VDC 10 10
24VDC/0.5A
11 11
Stop input
12 12
13 13
Emergency stop
14 14
fig 5.36 Electrical diagram for the take-over gripper

Configuration
5.2.12 Settings for switches (license required)
EN
The IOCS ports can have a foot pedal or hand terminal for production control connected to
them, among other devices. Production can therefore be controlled from a remote location.
These switches allow you to control the following TopTouch buttons:
Start production
Stop production
Confirm batch size
NOTE
Switches directly connected to a deposit device (dps 272, KRI 400/800 and
KA 3000/6000) do NOT have to be configured in TopTouch.
NOTE
The switch functions must be assigned to ExA or ExB.
f Make sure the IOCS extension is switched on.
Example 1: Starting and stopping production using a hand terminal

The hand terminal has a green switch and a
red switch that light up analogously to the
TopTouch buttons. This means two switches
have to be configured.
f Assign the «Start production» function to
the port IOCS1_ExA.
fig 5.37 Configuring first port
f Assign the «Stop production» function to

the port IOCS1_ExB.
fig 5.38 Configuring second port

Configuration
Example 2: Confirming batch size with foot pedal

EN
You can confirm the achieved batch size by

pressing down the foot pedal.
f Assign the «Confirm deposit» function to
the port IOCS2_ExA.
fig 5.39 Configuring the foot pedal port

Configuration
5.3 Recording the licenses
EN
The Kappa works only with a valid license key. This license key is recorded at the factory.
Several options and additional devices require an additional license. They can only be op-
erated on the Kappa if they are duly enabled with a valid license key.
Procedure
f Open the Quick Links menu.
f Select «Configuration».
f Press the button for record license 1. 1
fig 5.40 Configuration menu
f Enter the license key 2.

The license key depends on the machine 3
and its hardware code 3.
2
fig 5.41 Entering the license key
TopTouch confirms the entry of a valid

license key with a green check mark 5.
The option requiring a license can now
be configured.
5 6
fig 5.42 Valid license

Configuration
5.4 Adjusting the axles

EN
You can use TopTouch to adjust the mechanically moved axles of the machine (blade axles,
delivery axles of the cable drive). This adjustment is required only after repairs, e.g., after a
motor is replaced.
Procedure
f Select the «Adjusting»button 2.
2
2
1
1
f Select the desired axle 3.

TopTouch shows which axles have al-
ready been successfully adjusted.
Axle has already been

successfully adjusted
Axle has not yet been

adjusted
3
fig 5.44 Adjust axles menu

(Kappa 322 shown as an example)
NOTE
To adjust blade axles, V-blades with a 0 radius must be installed.

Configuration
f Select desired action 4.
EN
f Follow the wizard’s prompts.
fig 5.45 Adjust axles menu

(Kappa 322 shown as an example)
CAUTION
If the safety cover is opened unsolicited during the adjustment process, the adjust-
ment stops immediately and an error is generated.
f Only open the safety cover during an adjustment if TopTouch instructs you to do so.
NOTE
You can find further information on the settings and adjustments in the correspond-
ing chapter of the operating instructions.

Configuration
5.5 Configuring the blades

EN
5.5.1 Blade icons
Icon Machine type Function
Kappa 310 / 315 / 320

To change blade configuration
/ 330 / 331
Kappa 310 / 315 / 320

To show the configured blade
/ 330 / 331
To change the blade configuration of the lower

Kappa 350
blade
To change the blade configuration of the upper

Kappa 350
blade
Kappa 350 To show the configured lower blade
Kappa 350 To show the configured upper blade
To change the blade configuration for standard

blades (inline blades).
Kappa 322
If only inline blades are configured, the machine
does not move to the outline position.
To change blade configuration for separation or

Kappa 322
special blades on side 1
To change blade configuration for separation or

Kappa 322
special blades on side 2
To show the configured standard blades (inline

Kappa 322
blades)
To show the configured separation or special

Kappa 322
blades (outline blades) on side 1
To show the configured separation or special

Kappa 322
blades (outline blades) on side 2

Configuration
5.5.2 Blade replacement and configuration
EN
CAUTION
The blades assigned to the cable must match the blades that are configured and
actually mounted.
Procedure
f Select «Configure blades» 2.
f Select the blades 3 you desire.

TopTouch opens the list of all blades.
If the correct blades are not configured

for the loaded cable, TopTouch displays
the required blades 4 in red.
3 4 5
The magic wand 5 opens the list of all
blades and shows the required blade.
fig 5.47 «Configure blades» menu

(Kappa 322 serving as the example here)
NOTE
For further information on changing the mounted blades, please consult the operat-
ing instructions for the Kappa you are using.
NOTE
Special blades are required for processing inner conductors on the Kappa 322.
Flat blades are recommended for thin sensor cables.
Special blades are required for cutting multi-pole cables that are difficult to process.

EN

Defining the product
6 Defining the product
EN
This chapter tells you how to define a product in TopTouch. Defining a product means set-
ting up the Kappa in such a way that a certain cable is processed the way you want it to
be.
6.1 Defining a new product with the TopTouch Product Designer

The TopTouch Product Designer lets you record a new product quickly and easily. In the
TopTouch Product Designer, you can define the characteristics of the cable being used and
all processing steps for the cable up to it being a finished product.
Procedure
1
uct Designer 1.
fig 6.01 «Production» menu
Select the desired product from the list:

f Select a new cable 2 with the desired
cable processing.
3
f Press the OK button.
or 4
f Open cable list 3.
2
f Select an existing cable from the cable
list.
f Select the cable processing you wish to
have done on the cable 4 from the cable fig 6.02 TopTouch Product Designer
list.

Selectable products
EN
1 Cutting material 1
2 Single-conductor cable with half strip 2
3 Single-conductor cable with full strip 3
4
4 Cutting single-conductor cable
5
5 Multi-layer cable with half strip
6
6 Multi-layer cable with full strip 7
7 Cutting multi-layer cable 8
8 Coaxial cable with half strip (Kappa 331) 9
9 Coaxial cable with full strip (Kappa 331) 10
11
10 Cutting coaxial cable (Kappa 331)
12
11 Multi-strand cable with half strip
13
12 Multi-strand cable with full strip 14
13 Cutting multi-strand cable 15
14 Multi-strand cable with half strip and in- 16
ner conductor processing (Kappa 322) 17
15 Multi-strand cable with full strip and in- 18
ner conductor processing (Kappa 322) 19
16 Cutting multi-strand cable and inner con- 20
ductor processing (Kappa 322) 21
17 Flat ribbon cable with half strip 22
18 Flat ribbon cable with full strip
fig 6.03 Selectable products
19 Cutting flat ribbon cable
20 Flat ribbon cable with double casing and
half strip
21 Flat ribbon cable with double casing and
full strip
22 Cutting flat ribbon cable with double
casing

Example of a single-strand cable with
EN
half strip
5 6
f Click on the product name 5 and name
the product.
f Click on the cable name 6 and name the
cable. 11 12 8 10 9 7
f Adjust the cable cross section 7.
f Adjust the cable length 8.
f Adjust the stripping length 9 and pull-off 13
length 10 on side 1.
fig 6.04 Defining the product
f Press the sample button B to produce a
sample with the current settings
NOTE
You can produce a sample at any time during setup using whatever the current set-
tings are.
f Press the cable editor button 14 to de-

fine further cable characteristics. 14
For details on this, see Chapter 6.2.
fig 6.05 Editing cable characteristics
f Click on button 15 to switch between full

strip, half strip and no strip. 16
f Press on the cable view 16 to define to
define further types of cable processing.
For details on this, see Chapter 6.3.
15 15
fig 6.06 Defining types of cable processing

6.2 Defining cable characteristics

EN
6.2.1 Defining general cable characteristics

This chapter describes how to define the cable characteristics that apply to all types of
cables. The settings exclusively applicable to a special type of cable are described in
Chapters 6.2.2 through 6.2.5.
Starting the cable editor

1
f Press the cable editor button 1 to define
cable characteristics.
fig 6.07 Opening the cable editor
Defining cable dimensions and way back
f Select the cable characteristics icon 1.

f Select the unit of measure 2 for en-
tering the conductor cross section 1 3 2
(mm² or AWG).
f Select the conductor cross section 3. 4
TopTouch automatically calculates new
5
specified values for the parameters that
are dependent on the conductor cross
section.
f Enter cable diameter 4 for each cable
layer. fig 6.08 Cable definition menu
f Enter blade opening (way back) 5 for
each cable layer.
Blade opening (way back) applies to the
pull-off of insulation or to cable advance
depending on the cable layer involved.
NOTE
Manually changed cable diameters and blade opening values are recalculated after
another wire cross section is entered.

Defining cable colors
EN
f Click on a cable layer 1 in the cable view. 1
fig 6.09 Cable definition menu
For single-colored cables:

f Select the color of the cable layer.
For multi-colored cables:

f Select first color of cable layer. 3 2
f Press button 2.
f Select the next color from the cable
layer.
You can choose at most five colors. fig 6.10 Cable color menu
Press button 3 to remove individual

colors.
f Define the color of all further cable layers
this same way.

Select blades for cable processing

EN
f Select the blade icon 1.

f Select blade 2 for cutting and stripping. 1
In machines with two blades, different
blades can be defined for cutting 2 and 2
stripping 3.
3
f Define the pull-off offset 4.
4
fig 6.11 Blade menu
If the pull-off offset ≠ 0 mm, the blades

will open after their incision 1 and the
1
cable backs up by the offset value 2.
Then the blades close again at the way
back position and the insulation is pulled
off 3. The blades now bite into the insu-
lation for pull-off. 2
fig 6.12 Pull-off offset
Defining correction values

f Select the correction icon 1.
f Define the diameter correction side 2 2
per cable layer.
Enables different stripping cut-in depths
on side 1 and side 2 of the cable. 1 2
fig 6.13 Correction value menu

With slitting unit activated
EN
f Enter the delta slit blade 4.
Define the distance from the slit blade to
the conductor. This distance is needed
so the conductor is not damaged during
slitting.
f Enter the opening of the slit blade for
4 5
cable transport 5.
5
4
fig 6.14 Defining the slit blade
Defining cable transport

f Select cable transport icon 1. 2
f Define wire feed speed 2. 3
f Define wire feed acceleration 3.
4
5
f Define feed out speed 4.
6
f Define insulation pull-off speed 5.
1
f Define blade speed 6.
fig 6.15 Cable transport menu

Defining process parameters

EN
(Kappa 310 / 320)

2
f Select process icon 1. 3
7
f Select wire drive pressure 2. 4
f Select close behavior 3 of cable drive: 5
− Pressure sensor: 6
The cable drive closes far enough so
1
that the pressure sensor detects the
attainment of the selected pressure.
− Cable diameter:
The cable drive closes to the defined fig 6.16 Pressure settings for Kappa 310 / 320
outside diameter of the cable.
f Define the maximum drawable insulation
length 4.
f Define pull over distance 5.
The distance beyond which the insula-
tion is pulled beyond the end of the
cable in full strip.
f Enter the corrected cable length 6.
Example: A cable has a defined length of
1000 mm. The subsequent measurement
yields a length of 1010 mm. Following
the entry of the corrected cable length,
TopTouch adjusts the length correction
factor.
NOTE
Use the standard values for the pressure settings if you find yourself in the following
situations.
You are working with unfamiliar cables.
You are uncertain about which settings you should enter.
f Press button 6 to select the default values.

Defining process parameters
EN
(Kappa 322 / 330 / 331 / 350)
2
f Select process icon 1. 3
f Select wire drive pressure for feed 2. 4
f Select wire drive pressure for process- 5
ing 3.
f Define the maximum drawable insulation
length 4. 1
f Define pull over distance 5.

The distance beyond which the insula-
fig 6.17 Pressure settings for
tion is pulled beyond the end of the Kappa 322 / 330 / 331 / 350
cable in full strip.
f Enter the corrected cable length 6.
Example: A cable has a defined length of
1000 mm. The subsequent measurement
yields a length of 1010 mm. Following
the entry of the corrected cable length,
TopTouch adjusts the length correction
factor.
Defining cutting and stripping

f Select the cut and strip icon 1. 2
f Switch on/off the function «Pull wire tip 3
back after cutting» 2. 4
If the function is switched on, the cable 5
is pulled back a bit after the blades
close. This prevents the opening blades
from pulling the cable upward. 1
f Define wait time before strip 3
Defines the wait time between the insula-
tion being cut into and it being pulled off. fig 6.18 Cut and strip menu
f Switch on/off the function for blade

cleaning after stripping 4 (not for Kap-
pa 350).
f Switch on/off the function for blade
cleaning after cutting 5 (not for Kap-
pa 350).

Enter processing instructions

EN
f Select the information icon 1.

f If need be, enter instructions 2 on use
and processing.
1 2 3
fig 6.19 Processing instructions menu
TopTouch shows this information for

the loaded product in the instructions
menu 4 under Quick Links.
fig 6.20 Hints and instructions

6.2.2 Flat ribbon cable
EN
Flat ribbon cable can be defined using the same procedure as described in Chapter 6.2.1.
Follow the description below to determine the few data items that differ for flat ribbon
cable.
Starting the TopTouch Product Designer

1
uct Designer 1.
f Select a flat ribbon cable 2 from the list.

f Press the cable editor button 4.

Defining flat ribbon cable

EN
f Select the cable characteristics menu 1.

f Define the number of conductors 2 in the 1 2
flat ribbon cable.
fig 6.24 Cable characteristics for flat ribbon cable

6.2.3 Multi-pole cable with processing of inner conductors (Kappa 322 only)
EN
Multi-pole cables with inner conductor processing can be defined using the same proce-
dure as described in Chapter 6.2.1. Follow the description below to determine the few data
items that differ for multi-pole cables.
In the processing of multi-pole cables, the inner conductors are untwisted (separately) and
stripped.
NOTE
Only the Kappa 322 offers inner conductor processing. You can use the separation
option to process the inner conductors of multi-pole cables even with extremely
short stripping lengths.

1
uct Designer 1.
f Select a multi-pole cable 2 from the list.



EN
Defining a multi-pole cable

f Define the number of inner conductors 2 1 2
in the multi-pole cable.
fig 6.28 Cable characteristics for multi-pole cables.
Selecting type of separation

2
f Select the separation menu 1.
f Press the type of separation 2.
fig 6.29 Separation menu

f Selecting type of separation:
EN
2 Separation at the stripping position.
3 Separation at a definable pre-sepa-
ration position and at the stripping
position. 2 3 4 5
4 Separation at a definable pre-separa-
tion position.
5 No separation. 6
If pre-separation is selected:
f Enter the distance 6 between cable end fig 6.30 Types of separation
and stripping blade. This defines the
cable position at the pre-separation.
Selecting insulation ring

1
Loose inner conductors can jam up when
inserted in the guide tube on side 2. This
can be prevented by putting insulation rings
over the inner conductors.
f Go to the separation menu and select
the ring type button 1.
f Selecting the ring type:

2 Insulation ring with standard width.
3 Insulation ring with selectable width.
4 No insulation ring. 2 3 4
If insulation ring with selectable width is
selected:
f Enter width 5 of the insulation ring.
5
fig 6.32 Selecting the ring type

Selecting the minimum separation dis-

EN
tance
A multi-strand cable needs a minimum sep-
aration distance in order to be separated.
This distance depends on the distance from
the separation blades to the separation roll-
ers and on the cable being processed. If the
rollers are not mounted in a standard way,
1
this parameter can be adjusted. Normally,
no change is needed.
f Go to the separation menu and press the
button minimum separation distance 1. fig 6.33 Separation menu
f Selecting the minimum separation dis-

tance:
2 Set the minimum separation distance
at the standard value of 15 mm.
3 Set the minimum separation distance 2 3
to another value.
If the minimum separation distance is not

the standard value:
4
f Enter the minimum separation dis-
tance 4.
fig 6.34 Selecting the minimum separation distance
Selecting the number of separation steps

f Go to the separation menu and press the
separation steps button 1.

f Define the number of separation steps 2.
EN
f Enter the starting diameter 3 for separa- 2
tion.
f Enter the wait time 4 between the sepa-
ration steps.
3 4
fig 6.36 Separation steps
D1 + 2 * W1
D3
D2
D4
....
1. 2. .... N.
fig 6.37 Separation process
D1: Cable parameter «Outside diameter»

W1: Cable parameter «Blade opening cable transport»
D2: Cable parameter «Layer diameter»
D3: Cable parameter «Max. separation diameter»
D4: Cable parameter «Conductor diameter»
N: Cable parameter «Separation steps»
With each separation increment, a given dimension is closed somewhat more or opened
somewhat less widely.
After each closing and opening, the machine waits in accordance with the cable parameter
«Wait time during separation».

6.2.4 Multi-layer cables

EN
NOTE
Double-sheathed cables can be processed with all Kappas.
Only the Kappa 331 has the standard capability of processing multilayer cables (with
more than three cable layers). For all other Kappas, this process requires a license.
Multi-layer cables can be defined using the same procedure as described in Chapter 6.2.1.
Follow the description below to determine the few data items that differ for multi-layer
cables.
TopTouch automatically designates the lay-

ers as shown in the figure to the right in the
Layer 3
procedure for defining multi-layer cables. (outside sheath)
The parameters for the definition of indi-
vidual layers are also designated with these Layer 2
names. Layer 1
Example (conductor)
A parameter that defines the stripping of
the conductor is designated as «Layer 1».
In other words, the layer being exposed is
always mentioned.
fig 6.38 Structure of a multi-layer cable (example)

1
uct Designer 1.

f Select a multi-layer cable 2 out of the
EN
list.
2
Defining a multi-layer cable

f Press the button 2 (for additional cable 1 2
layers) and select the number of cable 3
layers.
f Define the diameter 3 for all cable layers. 4
f Define the blade opening 4 for all cable
layers.
fig 6.42 Define the cable diameter and way back
NOTE
A double-sheathed cable consists of three layers as shown in fig 6.42 (2+1 layers).
For a cable with four layers, parameter (2) for additional cable layers has to be at 2
(2+2).
This parameter is available only on the Kappa 331 or with the corresponding license.

f Select the blade menu 5.

EN
f Select the cutting blade 6. 5

f Define the stripping blade 7 for each
cable layer.
6
f Define the pull-off offset 8 for each cable
layer. 7
fig 6.43 Defining the stripping blade.

f Defining diameter correction side 2 10
for each cable layer
Enables different stripping/cut-in depths
on side 1 and side 2 of the cable.
9 10
fig 6.44 Defining correction values

6.2.5 Setting up the circular cutting unit (on Kappa 331 only)
EN
Cables can be cut very gently and precisely with the rotary incision unit of the Kappa 331.
The circular cutting unit is therefore especially suitable for cutting coaxial cables. Follow
the description below to determine the few data items that are additionally needed for the
setup of the circular cutting unit.
Coaxial cables consist of several layers.

TopTouch automatically designates the lay-
Layer 4
ers as shown in the figure to the right in the (outside sheath)
procedure for defining multi-layer cables.
Layer 3
The parameters for the definition of indi-
vidual layers are also designated with these Layer 2
names. Layer 1
(conductor)
Example:
A parameter that defines the stripping of
the conductor is designated as «Layer 1».
In other words, the layer being exposed is
always mentioned. fig 6.45 Structure of a coaxial cable (example)

1
uct Designer 1.
f Select the desired product 2 from the

list.


EN
Setting up the circular cutting unit

f Select the cable characteristics icon 1.
f If need be, press button 2 for additional 1 2
cable layers and select the number of
additional cable layers.
f Enter the incision diameter of the RIU 3.
The incision diameter of the RIU can be 3
defined for each cable layer and inde-
pendent of the conductor diameter to
obtain optimum cutting results.
fig 6.49 Cable characteristics menu
f Select the blade icon 4.

f Select the cable layers 5 to be cut into 4
with the circular cutting unit.
Insulation is always pulled off with the
linear blades regardless of this setting. 5
f Pull-off offset side 1, define 6 per cable
layer. 6
f Pull-off offset side 2, define 7 per cable
layer (if activated in the configuration).
7
fig 6.50 Blade menu

EN
f Define the diameter correction on side 2 8
9 for each cable layer.
Enables different stripping/cut-in depths
9
on side 1 and side 2 of the cable.
fig 6.51 Entering the correction values
f Select the icon for the circular cutting

unit 10.
11
f Set the blade rotation speed 11. 12
f Set the blade closing speed 12. 13
f Set the blade resting time 13. 14
The resting time determines the resting 15
time for the blades in closed position. 16
f Set the «Feed way back correction
knives» 14 (i.e. correction of the blade 10
opening distance while cable is being
fed). fig 6.52 Circular cutting unit menu
Defines the opening distance of the

blades (way back) in the circular cutting
unit for wire feed.
f Set centering jaws pressure 15 in such a
way that the cable does not turn during
the incision and the centering jaws do
not leave indentations behind.
f Set «Centering jaws feed way back» 16
in such a way that the centering jaws
are certain not to touch the cable during
cable feed.

6.2.6 Determining the cable parameters using cable learning

EN
Instead of entering the conductor diameter and outside diameter of the cable manually, the
Kappa can measure these values with sensors and enter them in TopTouch. To make opti-
mum use of this function, the optional conductor detector and cable detector are recom-
mended.
Procedure
f Draw a cable into the Kappa.
f Press the cable learning button 1.
The Kappa measures the drawn-in cable
using sensors.
1
fig 6.53 Cable learning
The sensors of the Kappa measure the con-

ductor diameter and the outside diameter
automatically.
f Check the measured cable data.
f Define further cable characteristics
(see Chapter 6.2).
fig 6.54 Cable learning process

f Press the sample button 2 to produce a
EN
cable.
f Check the produced sample.
f Press the OK button 3 to save the cable
data.
f Press the cancel button 4 to leave the
2 3 4
menu without saving.
fig 6.55 Producing samples
NOTE
If you press cancel to leave cable definition, TopTouch does not save any cable data.
f Repeat the cable learning procedure.

6.2.7 Cable length correction

EN
The actual length of the produced cable can deviate slightly from the programmed cable
length. Slight slip between cable and cable drive can be one possible reason for this devia-
tion. The deviation between programmed and actual cable length tends to become larger
with long cables.
This deviation can be compensated with the function known as cable length correction.
The best results are achieved if the cable length correction is learned in two steps; first with
the length measurement system switched off and then with it switched on.
TopTouch saves the calculated correction values in the cable database.
Procedure
f Switch off the length measurement sys-

tem 3.
3
fig 6.57 Switching off the length measurement system

f Define a cable without wire-end process-
EN
ing.
f Set the cable length 4 to 1000 mm.
f Press button 5 to produce a sample.
f Measure the length of the sample. 4 5
fig 6.58 Producing the sample cable

f Select corrected cable length 7.
fig 6.59 Corrected cable length menu
f Enter the measured length 8 of the

sample cable.
8
fig 6.60 Entering the length of the sample cable


EN
10
f Switch on the length measurement sys-

tem 11.
11
f Produce a further sample with the length
measurement system switched on.
f Measure the sample and enter the mea-
sured value.
TopTouch saves the calculated correc-
tion values in the cable database.
fig 6.62 Switching on the length measurement system

6.3 Defining the types of cable processing
EN
Cuts the insulation and pulls the ring of insulation all

Stripping, full strip
the way off.
Cuts the insulation and pulls the ring of insulation

Stripping, half strip
off a defined distance.
Cuts the insulation at two positions and cuts the

Slitting
insulation lengthwise between these incisions.
Trimming Cuts the cable end again after a side is processed.
Marks the cable with a selectable text. An external

Ink-jet marking
ink-jet marker is needed for this function.
Marks the cable with a selectable text. An external

Hot-stamp marking
hot stamp marker is needed for this function.
Puts notches in the cable. Is mainly used to sepa-

Notching
rate the individual conductors in flat ribbon cable.
Procedure
f Enter the cable length 1.
f Click on the cable view 2.
1 2

f Select the processing side 1 3 button.

EN
f Define cable processing on side 1.

You will find details on this on the follow-
ing pages.
fig 6.64 Cable processing side 1
f Select the processing side 2 4 button.

f Define cable processing on side 2.
You will find details on this on the follow-
ing pages.
fig 6.65 Cable processing side 2
f Press the information button 5.

f If need be, enter instructions 6 on use
and processing.
5 6 7
fig 6.66 Product information

TopTouch shows this information for the
EN
loaded product in the Quick Links ->
Instructions menu 8.
fig 6.67 Hints and instructions

6.3.1 Stripping, full strip

EN
During stripping with full strip, the Kappa cuts into the insulation and pulls it completely off
the cable. Full strip can be carried out just once on each cable side and cable layer.
Procedure
5
f Press stripping full strip 1.
f Enter the stripping length 2.
The stripping length is measured from
the end of the cable. 2
f Select the waste cut 3 if need be. 3 1
The waste cut removes any insulation 4
bits from the blades.
f Select slitting 4 if need be.
f Press the button 5 to define the over- fig 6.68 Full strip
length/under-length for slitting.
f Define the over-length/under-length for

slitting 6.
slitting 7 on the insulation ring at the end
of the cable. 6 7
The insulation ring is completely re-
moved from the cable in the case of full
strip.
fig 6.69 Slitting for full strip
NOTE
If slitting over-length is activated for stripping, full strip, this can affect the preceding
and following cables, which can then also be cut into.
NOTE
Heed the over-length distance assigned to the cable.

Full strip with multi-layer cables
EN
f Press stripping full strip 1 once for each
cable layer.
f Enter the stripping length 2 for the first
cable layer.
2 5
f Select the waste cut 3 and slitting 4 for
3
the first cable layer if need be. 1
4
f Use the arrow keys 5 to select the next
process (the full strip of the next cable
layer).
f Define the stripping of the next cable fig 6.70 Full strip for multi-layer cables
layer the same way.
Full strip in multiple steps

In order to achieve extremely long stripping Initial situation:
length, the insulation is divided into several 300
rings and the rings are then stripped indi-
vidually.
Example Desired strip:

Cable length = 300 mm 100
Desired stripping length = 100 mm
Max. drawable insulation length = 40 mm
TopTouch calculates the insulation rings and

Procedure:
carries out a stripping length of 100 mm 20 40 40
taking into account the maximum drawable
insulation length and maximum projecting
length.
Result: 100
fig 6.71 Full strip in multiple steps

6.3.2 Stripping, half strip

EN
During stripping with half strip, the Kappa cuts into the insulation and pulls it off a defined
distance. However, the insulation ring remains at the cable end to protect the strands. Mul-
tiple half strips (insulation rings) can be cut per cable side and cable layer.
Procedure
5
f Press stripping half strip 1.
2

3
f Press the button 5 to define the over-
length/under-length for slitting. 4 1
fig 6.72 Half strip
f Define the over-length/under-length at

the incision position 6.
slitting 7 on the insulation ring at the end
of the cable.
6 7
fig 6.73 Slitting with half strip
NOTE
If slitting over-length left is activated for stripping, half strip on side 2, this can affect
the following cable, which can then also be cut into.

Multi-step half strip
EN
f Press stripping half strip 1 once for each
insulation ring desired.
f Enter the stripping length 2 for the first 2
insulation ring.
f Enter the stripping length 3 for the first 5
3
insulation ring.
4 1
f Use the arrow keys 5 to select the next
process (half strip of the next insulation
ring). fig 6.74 Multi-step half strip
f Define half strip for the next insulation

ring the same way.
Half strip with multi-layer cables

To process a multi-layer cable (e.g. a coaxial Half strip
cable) as shown in this figure, a full strip Full strip
and a half strip is needed for the outermost
layer.
In the full strip the part of the cable layer no
longer needed is completely stripped off.
The half strip produces the insulation ring fig 6.75 Insulation ring on multi-layer cables
that remains on the cable.
f Press stripping full strip 1.

f Select the outermost cable layer 2.
2 1
fig 6.76 Full strip of outermost cable layer

f Press stripping half strip 4.

EN
f Select the outermost cable layer 5.

6
f Enter the stripping length 7 for the insu-
lation ring.
7
5 4
fig 6.77 Half strip of outermost cable layer
f Press stripping full strip 8 twice.

f Define the full strip for layers 1 and 2.
fig 6.78 Full strip of the inner cable layers

6.3.3 Slitting
EN
In slitting, the Kappa cuts into the insulation at two positions and cuts the insulation length-
wise between the two incisions. However, the insulation remains on the cable to protect the
strands. Several slitting procedures can be carried out on each cable side and cable layer.
Large stripping lengths can be achieved with slitting. Before the cable can be further pro-
cessed, the insulation has to be pulled off manually. Slitting can also be used for intermedi-
ate stripping and for separating strands in flat ribbon cable.
Slit over-length/under-length
You can define a slit over-length to ensure
that the insulation is neatly stripped from
the conductor. The slitting blade lengthens
the cut by the desired amount beyond the
incision position.
fig 6.79 Slitting over-length
You can also define a slitting under-length.
fig 6.80 Slitting under-length
NOTE
If slitting over-length is defined for stripping, half strip, this can affect the preceding
and following cables, which can then also be slit.

Slitting without incision function

EN
If desired, the incisions in the cable can be

switched off individually.
fig 6.81 Slitting without incision function
This is an easy way to separate the strands

at the ends of twin cables for example.
fig 6.82 Separating strands of twin cables
Procedure
5
f Press slitting 1.
f Enter the slitting position 2.
f Enter the slit length 3. 2
f Select the layer 4 to be slitted (only in 3
multi-layer cables). 4
1
f Press the button 5 to define the over-
length/under-length for slitting.
fig 6.83 Slitting
f Switch the incision function 6 on or off at

the ends of slitting.
slitting 7 at the incision positions.
6
The over-length/under-length for slitting
defines the length beyond which the slit-
ting blade has to cut beyond the incision
positions.
f Press the «>>» button 8. 7 8
fig 6.84 Defining slitting

f Select the continue mode 9.
EN
The possible settings for the selected
mode become activated.
f Select number 10 of slits.
f Select distance 11 between the slits.
9
f Press the OK button 12. 10
11
12
fig 6.85 Defining the continue mode
6.3.4 Trimming
Trimming is always the last processing steps on a cable side. In trimming, the Kappa trims
the cable end at the position defined by the user. Trimming can be carried out only once on
each cable side.
Trimming ensures that the cable end is cut straight through the conductor and all insulation
layers. Any projecting insulation layers (half strip) can be cut away with trimming.
It is technically possible to use the trim function to cut off the entire processing of a cable
side as a final step.
Procedure
f Press trimming 1.
f Enter the trimming position 2.
The trimming position is measured from
the end of the cable (conductor).
2
1
fig 6.86 Trimming

6.3.5 Inkjet marking (license required)

EN
Ink-jet markers can be connected to the Kappa. With these markers, freely selectable texts
can be marked on the cable.
Defining marking at the cable end

5
f Press ink-jet marking 1.
f Enter the marking position 2.
f Enter the marking text 3. 2
f Select the direction of marking 4. 3
f Press the button 5 to select the type of 4
font. 1
fig 6.87 Ink-jet marking
f Select the size of the marking matrix 6.

f Select the character width 7.
6
f Select the relative character height 8.
7
f Activate bold 9 if need be.
8
10
fig 6.88 Selecting the type of font
NOTE
The selected font is for marking at all positions on the cable (side 1, middle of cable,
side 2). If the font for marking one of the positions is changed, the font also changes
for the other positions.
NOTE
The font height can be varied with the height parameter (8) from approximately
1.1 mm to 2.1 mm. However, the font height also depends on the distance from the
marking head to the cable and on the marker and the ink used.

Defining marking in the middle of the cable
EN
NOTE
Marking in the middle of the cable can only be started from the menu for marking
cable side 1.
f Click on button 1.
5
f Press the button for inkjet marking 2 1
twice to define marking in the middle of
the cable.
f Enter the marking text 3.
3
f Select the direction of marking 4.
4
f Press the button 5 to select the type of 2
font.
fig 6.89 Defining second marking operation
f Select the size of the marking matrix 6.

f Select the character width 7.
6
f Select the relative character height 8.
7
f Activate bold 9 if need be.
8
f Press the «>>» button 10. 9
10
fig 6.90 Selecting the type of font for marking in the

middle of the cable
f Select the distance between prints (i.e.

marking operations) 11.
f Select whether the defined text should
be marked with alternating orienta-
tion 12.
12
13
fig 6.91 Selecting the distance between prints

If no marking is desired on cable side 1:

EN
f Press button 14 to proceed to marking

on side 1.
f Press the delete button 15.
15 14
fig 6.92 Deleting marking on cable 1
Defining marking on side 2

f Select cable side 2 1.
f Press inkjet marking 2.
f Define marking on cable side 2 in the
same way as you defined marking on
cable side 1.
1 2
fig 6.93 Defining marking on cable side 2

6.3.6 Hot-stamp marking
EN
Hot stamp markers can be connected to the Kappa. With these markers, you can mark
freely selectable texts in a selectable color on the cable.
Procedure
3
f Press hot stamp marking 1.
f Enter the stamping position 2.
The stamping position is measured from
the end of the cable.
f Press button 3 to define color band and 2
text for the marking operation. 1
fig 6.94 Hot-stamp marking
f Select the color band 4 and the text 5 for

marking on the left side.
f Select the color band 6 and the text 7 for
marking on the right side.
4
5
8
6
fig 6.95 Defining color band and text for

hot stamp marking
NOTE
The color bands configured in the marker must match the ones assigned to the mark-
ing process.
The machine issues a consistency warning if colors not configured on any marker are
assigned to the marking process.
f Make sure the marker configuration matches the installed color bands.


EN

f Select the count (i.e. number of marking
operations) 10.
f Select the distance between prints (i.e.
9
marking operations) 11. 10
11
12

6.3.7 Notching
EN
In notching, notches are put in parts of the
cable by a notching tool specially made for
this application. Notching is used mostly to
separate the individual conductors in flat
ribbon cables.
Notched cable parts
fig 6.97 Notching
Procedure
3
f Press notching 1.
f Enter the notch position 2.
f Press the button 3 to select the notching
tool.
2
1
fig 6.98 Notching
f Press button 4 and enter the identifica-

tion number of the notching tool used.
4 5
fig 6.99 Notch tool ID
NOTE
The notching tool configured in the notching machine must match the notching tool
assigned to the notching process.
f Make sure the configuration matches the installed notching tool.


EN

f Select the count 7 (number of notching
positions).
6
f Select the distance 8 between the notch-
ing positions. 7
8
9

6.3.8 Short mode
EN
You define the cable length and the stripping positions for side 1 and side 2 in the course
of the wizard’s instructions on product definition.
The Kappa uses this data to calculate the minimum residual cable length (cable length
minus largest stripping positions on side 1 and side 2). The minimum residual cable length
refers to the cable length for which the machine can still process cable side 2. The mini-
mum residual cable length depends on the machine.
When processing on side 2 becomes no longer possible, the Kappa automatically activates
the short mode.
1 Short mode ON/OFF

TopTouch automatically makes this but-
ton available as soon as the machine-
specific minimum residual cable length
has been exceeded. 1
fig 6.101 Short mode function
If the short mode is switched on, the Kappa

strips the total of both stripping lengths on S1+S2
side 1. The Kappa then pushes the insula-
tion in the direction of side 1 until both sides
have the defined stripping lengths.
S2 S1
fig 6.102 Stripping with short mode

6.4 Importing CSV data

EN
Cable and product data can be created as a CSV data set in a program such as Excel® or
in a text editor and then imported into TopTouch.
If the data is recorded with Microsoft Excel® and saved as *.csv, a correct CSV file is gener-
ated for the import into TopTouch.
If a text editor is used, the creator of the CSV data must personally make sure that the CSV
data is correct.
All columns must be separated using the same separator (character, letter). TopTouch
recognizes the separator automatically.
The first row must contain the column headings.
All the following rows must contain the product data or cable data.
6.4.1 Table structure for cable data

Column Cable name Cross section Color
Column designation CableName CrossSection Color
Use Required Required Optional
2
Unit --- mm ---
Value Alpha-numerical Numerical RGB format or color
name 1)
1)
The following color formats are possible
#RGB
#RRGGBB
#RRRGGGBBB
#RRRRGGGGBBBB
Name of a predefined color as per:
http://www.w3.org/TR/SVG/types.html#colorkeywords
Transparent (color designated as transparent)
TopTouch cannot correctly display all the entered color values.
If no color is defined, TopTouch selects red as the cable color.

Column Product name Cable name Cable length Strip length S1 Pull-off length S1 Strip length S2 Pull-off length S2
Column ProductName CableName CableLength StrippingPositionS1 PullOffLengthS1 StrippingPositionS2 PullOffLengthS2 6.4.2
designation
Use Required Required Optional Optional Optional Optional Optional
---
Unit --- mm mm mm mm mm
Value Alpha- Alpha- Numerical Numerical Numerical Numerical Numerical
numerical numerical
Prerequisites for the recording of product data
SW TopTouch Kappa – Version 2.0

No stripping or a type of stripping can be defined for each cable side.
Other processes such as marking or slitting are not supported.
Only cables with a single conductor and with one insulation layer are supported.
Definition of types of stripping

Table structure for product data
Desired result Entry in the field Entry in the field

«StrippingPositionS1» «PullOffLengthS1»
No stripping on S1 Leave empty Leave empty
Half stripping on S1 Value > 0 Value > 0
Full stripping on S1 Value > 0 Leave empty
EN – 119
EN
6.4.3 Recording CSV data

EN
Procedure
f Record product data or cable data (e.g. with Excel®).
fig 6.103
f Save file in CSV format.
fig 6.104
f Copy CSV data onto a USB flash drive.
NOTE
Cable data and product data must be saved in separate files.

6.4.4 Importing CSV data into Kappa
EN
Procedure
f Plug the USB flash drive into the Kappa.
f Open the Quick Links menu.
f Select «Configuration».
f Activate «CSV data import» 1.
f Press «OK».
1 1
fig 6.105
f Open the product list or cable list.

f Press the CSV button 2.
fig 6.106
f Select the data on the USB flash drive

that you wish to import.
f Follow user guidance.
fig 6.107

EN

Production
7 Production
EN
7.1 Control buttons
The main menu of TopTouch is also the pro-
duction menu. Whenever you finish enter-
ing a setting and return to the main menu,
the control buttons 1 are available to start
production.
fig 7.01 Control buttons
Start For starting production.
For executing the initial mechanical reset

Initial mechanical reset after the machine is started.
The machine is put into a defined state.
For executing a mechanical reset; can be

Mechanical reset carried out at any time.
The machine is put into a defined state.
The cable keeps moving in the direction of

Wire advance
processing as long as this button is pressed.
For producing sample cables in single step

Single step
mode.

Production
EN
Samples For producing a sample cable.
For quick cable learning.

Cable learning Outside diameter and conductor diameter
are calculated by sensors.
For interrupting production as soon as the

Break
current movement is finished.
For resuming production after a break.

Continue production Resumed at the point at which it was inter-
rupted.
Cancel production For discontinuing production after a break.
For interrupting production as soon as the

Stop
cable currently being processed is finished.
Batch size is reached.

Confirm batch size Production continues automatically following
confirmation.
Applies only if a dps 375 deposit unit is con-

figured.
First batch done.
Sequential setting:
Upper tray full Following confirmation, the batch is emptied
from the upper tray into the lower tray.
Overlapping setting:
The batch is automatically emptied from the
upper tray into the lower tray.

Production
EN

figured.
Second batch is achieved.
Both trays full
Empty lower tray, then confirm in order to
empty the upper tray into the lower tray and
resume production.

figured.
Lower tray full A further batch can be produced.
Following confirmation, both trays are empty
again.
Reset counters Resets all counters to «0» (zero).
Only Kappa with TopWin.

Suspend job
Skip an item in the parts list.
Only Kappa with TopWin.

Confirm job
Confirm parts list item.

Production
7.2 Piece counter

EN
Use the piece counter 1 to determine the

following:
f Quantity of cables to be produced
f Size of the individual production batches
1
While production is going on, the piece
counter indicates the following:
f Quantity of cables already produced per
production batch
f Total quantity of cables already produced
fig 7.02 Piece counter
7.2.1 Layout
1 For defining the desired output
2 Total number produced
3 For resetting the counter
4 For defining the desired batch size
1 2 3 4 5
5 Number produced in current batch
fig 7.03 Layout of the piece counter
7.2.2 Operating states

The information provided by the piece counter depends on the operating status of the
machine.
Prior to production
All counters to 0.
Here, you can record/change the desired
piece no. (here 100) and desired batch
size (here 10).
fig 7.04 Prior to production
Ready to start production.

Production
During production
EN
Display of piece number already pro-
duced (in example: total 24 pieces, 4th
piece in third batch).
fig 7.05 Machine is producing
Batch size reached (the third batch in

this figure).
Following a confirmation of the batch
size, the machine resumes production.
fig 7.06 Batch size reached
After production
Desired piece number reached.
Following a confirmation of the batch
size:
− Reset counter. fig 7.07 After production

Production
7.2.3 Follow-up production

EN
With the follow-up production function,

products can be subsequently produced,
for example, to replace ones that were re-
moved during production for quality control
purposes.
The follow-up production function must 2 1
be activated in the configuration (consult
Chapter 5.1).
1 Button for follow-up production. One
piece is added for each time you click
the button.
fig 7.08 Follow-up production
2 Display of the number of products sub-
sequently made in follow-up production.
During follow-up production

Display of piece number already subse-
quently produced (in this example: 2 of 4
pieces after a desired piece number
of 100).
fig 7.09 During follow-up production
7.3 Cyclic operation (license required)
In cyclic operation, the machine waits after

each piece it produces until the defined
cycle time has been reached.
This allows the production output to be
adjusted to the downstream manual work
stations.
2
The cyclic operation function must be ac-
tivated in the configuration (consult Chap- 1
ter 5.1).
If cyclic operation is activated, two new ele-
ments appear in the production menu:
fig 7.10 Cyclic operation
1 Display of actually measured cycle time
2 Button to change the cycle time

Production
7.4 Producing samples
EN
Samples are produced to check whether the machine is correctly set up for the product.
Samples can be produced even before the product is completely defined. That way the
settings entered can be checked step by step and corrected immediately if need be.
7.4.1 Defining sample parameters
Procedure
f Select sample parameters 2. 2
f Define the maximum possible distance 3

between blade and pre-station.
Only pre-stations in this area are consid-
ered and triggered in sample production.
3
f Define the maximum length 4 of the
sample cable. 4
Limits the length of the sample cable.
5
fig 7.12 Sample parameters

Production
7.4.2 Producing in single step mode

EN
Procedure
f Press the button for single step mode 1.
fig 7.13 Producing sample in single step mode
f Press buttons 2 to select the step size

(increment).
The smaller the step size (increment)
the more individual steps are needed to
produce a sample. The production of 2
samples can be examined more precise-
ly with small step sizes (increments) than
with large ones. 3 4
f Press button 3 to carry out one step.
f If need be, you can press button 4 to
discontinue sample production.
fig 7.14 Single step mode
7.4.3 Producing samples
Procedure
f Press the button for sample 1.
The machine now produces one sample.
fig 7.15 Producing samples

Production
7.5 Starting production
EN
Procedure
f Select a product from the product list 1. 1
f Enter the desired piece number 2.
f Enter the piece number for follow-up
production 3 if need be. 5 2 3 4
f Enter the batch size 4 if need be.
f Press the start button 5.
The machine will produce the selected
quantity of cables in the desired batch
size. fig 7.16 Production menu

EN

Archive/error list
8 Archive/error list
EN
TopTouch saves all error messages and consistency warnings in the error list.
8.1 Opening the archive/error list
Procedure
f Select error list 2.
2
1
TopTouch lists all error messages in chrono-

logical order.
3 Error numbers 3 4 5
4 Error code
5 Date and time of error events
f Click on an error message.
fig 8.02 Error list (example)

Archive/error list
TopTouch shows all information on this

6
EN
event.
7 8 9
6 Message
− Error text
− Consistency warning
7 Message
− Describes the process during which
the error was generated
8 Hints 10
− List of possible solutions
fig 8.03 Archived error message
9 Detail
− Precise time of error, error number,
etc.
− Indication of source path
10 Back to error list
8.2 Error message

If an error occurs, there are different ways of handling the error message depending on the
error involved:
1 «Abort»
The software goes to the previous page.
2 «Change config»
The software proceeds to the configura-
tion menu, where appropriate adjust-
ments can be made.
An «Ignore» or «Retry» button may also

1 2
appear depending on the error message
involved.
fig 8.04 Error message

Archive/error list
8.3 Consistency warning
EN
NOTE
The consistency warning is a message generated by the software that points out the
incompatibility of two settings. This warning is NOT an error message.
Example
A maximum drawable stripping length of 10 mm was defined in the cable parameters. Half
or full strip of more than 10 mm was deposited for the product.
If production is started anyway, TopTouch generates a consistency warning.
NOTE
To prevent confusion with similarly structured error messages, the error text is shown
in black on a yellow background.
If the software generates a consistency

warning, it can be handled in the following
ways:
1 «Abort»
The software goes to the previous page.
Production is not initiated and the user
has the option of adjusting the configura-
tion. 1 2
2 «Ignore»
The software ignores the warning and
production starts without the configu-
ration being started. This same warn- fig 8.05 Consistency warning
ing will not appear again as long as no
changes are made to the product or
cable.

EN

System administration
9 System administration
EN
9.1 System menu
The system menu is used for undertaking all settings and actions not directly connected to
cable production.
9.1.1 Opening the system menu
Procedure
system menu. 1
The system menu is displayed: 2 3

2 Logged-in user
For switching between system menu and
the main menus.
3 Clock
4 Program management 4
NOTE
A user may not be able to open all programs in the system menu depending on the
user category to which he belongs!

9.1.2 Functions of the system menu

EN
Designation Function
Cable production User software starts in the production menu.
Programs currently running are indicated by a

Running programs
green check mark.
The system logs out of the current user profile.

Log-in Another user can now be selected from the
list.
Software is shut down.

Shutdown After the shutdown message appears, the
power can be shut off at the main switch.
Choose language For choosing the language
Stop programs Stops all programs that are running.
Creating a new user

User management Editing a user
Deleting a user
For saving all product and cable data on a

Create backup
USB flash drive or a network
For loading a software update from a USB

Software update flash drive or network
Create backup
For transferring product and cable data

saved on a USB flash drive or in a network
Restore from backup
and inserting it into the current version of the
software
For setting the time and date.

Correct time recording is extremely important!
Date/time settings
For selecting date format and time zone
For selecting time server if need be

EN
For recording IP address

Network configuration
Record sub-network mask
Unique machine ID
(for operation in a network or creation of a
backup)
Machine identification
Komax recommends using the serial
number and machine type in the machine
designation to create a unique machine ID.
For adjusting the contrast in the user soft-

Display contrast
ware
Touchscreen calibration For calibration using the touch screen
For showing information on versions and

System information counters for individual software compo-
nents
Show I/O For showing all inputs and outputs

9.2 Emergency login

EN
If the administrator should forget his password, he has the option of logging in with admin-
istrator rights using the emergency login.
NOTE
Logging in with the emergency password is required only if no user with administra-
tor rights can remember his password. In all other cases, an administrator can issue
a new password.
Procedure
f Open the «Login» window in the system
menu.
f Press button 1.
fig 9.03 «Login» window
The software generates an individual ID

number 2.
f Contact the Komax customer adviser
and give him the ID 2.
fig 9.04 ID for emergency login

The Komax customer adviser issues an
EN
emergency password with which you can
log in once with administrator rights and
change passwords.
f Enter the emergency password.
You are now logged in once with admin-
istrator rights.
f Change the password (see Chapter
4.3.3).
fig 9.05 Entering the emergency password
NOTE
The emergency password only remains valid till the end of the given calendar day. In
other words, if the emergency password is issued in the evening, it will no longer be
able to be used the next morning. It is therefore important to set the time in the soft-
ware correctly. After the emergency password is issued, a new administrator must
also be created immediately.

9.3 User management

EN
9.3.1 Recording a new user
Procedure
f Open the «User manager» window in the
system menu.
f Select the button for recording a new
user 1.
1
fig 9.06 Recording a new user
f Enter user name 2.

f Select a user category. 2
f Enter the password for the new user and
enter it again to confirm it.
The new user can now be opened in the
user manager. 3
fig 9.07 Entering the user name

9.3.2 Editing a user
EN
Procedure
system menu.
f Select the user you wish the edit 1.
f Press the button for editing users 2.
2 1
fig 9.08 Selecting the user for editing
f Press user category 3.

f Select the user category to which the
user is supposed to belong.
f Press the password button 4 and change
the password. 3
f Press «Auto login» 5 to switch this user’s
4
automatic login on or off.
The next time the machine is started, the 5
user for whom auto login was switched
on is automatically logged in. No pass-
word has to be entered. fig 9.09 Editing a user
Auto login can only be switched on for

one user.

9.3.3 Deleting a user

EN
Procedure
system menu.
f Select the user 1 you wish to delete.
f Press the user deletion button 2.
f Confirm the question by pressing the OK
button.
2 1
The user has now been deleted from the
user manager.
fig 9.10 Deleting a user
NOTE
The user predefined as «Administrator» by Komax cannot be deleted!

9.4 Data backup
EN
9.4.1 Creating a backup
When you do a backup, all recorded product and cable data is saved on a USB flash drive.
You can transfer the backup back to the machine at any time.
Procedure
f Open the «Create backup» window in the
system menu.
f Insert the USB flash drive.
f Select a path for the backup (USB flash
drive).
fig 9.11 Creating a backup
Data can be backed up on a USB flash drive. Use the commands below to select the place
you wish to save the data backup.
Add new network For establishing a new network connection.
Delete network For deleting an existing network connection.
Create folder For creating a new folder in the selected path.
Delete folder For deleting the selected folder.
For updating the view if for example a USB

Update flash drive does not appear in the user inter-
face.

9.4.2 Restore from backup

EN
If you restore a backup copy, all recorded product and cable data is transferred from a USB
flash drive and inserted in the current version of the software.
Procedure
f Open the «Restore from backup» win-
dow in the system menu.
f Select the desired backup in the corre-
sponding path.
fig 9.12 Restoring from backup

9.5 Software update
EN
Procedure
f Open the «Software update» window in
the system menu.
f Select the desired software version in the
path.
fig 9.13 Software update
The software can be updated on any network drive or on a USB flash drive. Use the com-
mands below to select the data source.
Add new network For establishing a new network connection.
Delete network For deleting an existing network connection.
For updating the view if for example a USB

Update
stick does not appear in the user interface.
NOTE
The software automatically prompts you to create a backup of product and cable
data at every update (see Chapter 9.4.1).
CAUTION
Software downgrades are not permitted. Komax recommends that you never revert
to an older version of TopTouch.

9.6 Calibrating TouchScreen

EN
Procedure
1
f Open the «TouchScreen calibration»
window in the system menu.
TopTouch Kappa shows cross-hairs 1 on
the display.
f Touch the cross-hairs shown.
f Touch the cross-hairs at four other
places.
After you touch the five displayed cross-
hairs, the software reports on whether
calibration was successful. fig 9.14 TouchScreen calibration
9.7 Show I/O
TopTouch Kappa shows all inputs and out-

puts. The outputs can be changed if need
be.
Procedure
f Open the «Show I/O» window in the
system menu.
f Click on a check mark to set or remove it.
Top: Inputs (green)
Bottom: Outputs
fig 9.15 Show I/O
NOTE
Changes in outputs only function if cable production is activated and the user is duly
authorized to make changes.
WARNING
Always make a careful check before changing outputs so that no undefined states
occur!

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EN

Art. No. 0346365 – Version 2.0

Translation of the original software instructions

Phone +41 41 455 0 455

Date issued Version Modiﬁed pages

Reproduction of these instructions or parts of them in whatever form is not permitted

2 Explanation on safety instructions ........................................................................ EN – 9

3 Operational concept ............................................................................................. EN – 11

4 Initial steps ............................................................................................................ EN – 27

SW TopTouch Kappa – Version 2.0 EN – 3

5.1 Selecting the options .................................................................................. EN – 40

6 Deﬁning the product ............................................................................................. EN – 71

EN – 4 SW TopTouch Kappa – Version 2.0

6.3.7 Notching ..................................................................................... EN – 115

7 Production ........................................................................................................... EN – 123

8 Archive/error list ................................................................................................. EN – 133

9 System administration........................................................................................ EN – 137

SW TopTouch Kappa – Version 2.0 EN – 5

EN – 6 SW TopTouch Kappa – Version 2.0

1.2 Updating the instructions

Main number Subordinate number

1.3 Additional documents

Electrical diagram (delivered separately) 11

I/O list (delivered separately) 12

TopTouch software instructions 13

Training documents (customer-speciﬁc) 15

SW TopTouch Kappa – Version 2.0 EN – 7

EN – 8 SW TopTouch Kappa – Version 2.0

2 Explanation on safety instructions

SW TopTouch Kappa – Version 2.0 EN – 9

EN – 10 SW TopTouch Kappa – Version 2.0

- the loaded product - the product list key

2 The product list key

3 The system menu key

- User management - Data backup

SW TopTouch Kappa – Version 2.0 EN – 11

4 The cable list key

5 Touch-sensitive cable view (product menu)

6 TopTouch «Product Designer» key

7 Cable menu key

9 Control buttons for production

10 Selector for auxiliary equipment (pre-station)

11 Quick Links menu

- Cable transport speed - Conﬁgure blades

12 Selector for pieces of auxiliary equipment (downstream devices)

EN – 12 SW TopTouch Kappa – Version 2.0

3.2 Touch Control Interface (TCI)

Example: Changing the cable cross section

SW TopTouch Kappa – Version 2.0 EN – 13

3.3 The TopTouch Product Designer

The TopTouch Product Designer 1 is one of

ﬁg 3.06 Main menu with TopTouch

When deﬁning new products, you can resort

ﬁg 3.07 Cable selection for a new product

EN – 14 SW TopTouch Kappa – Version 2.0

3.4 Recurring controls

OK Conﬁrms and saves the entered values.

Aborts the wizard (without saving the values).

Forward Moves you to the next window in the wizard.