Alpha 488 S

Alpha 488 S


  • Alpha 488 S Wire crimping machine - Wire twister

    Alpha 488 S Wire crimping machine - Wire twister

  • Alpha 488 S Wire crimping machine - Wire twister

    Alpha 488 S Wire crimping machine - Wire twister

  • Alpha 488 S Wire crimping machine - Wire twister

    Alpha 488 S Wire crimping machine - Wire twister - Open ends

  • Alpha 488 S Wire crimping machine - Wire twister

    Alpha 488 S Wire crimping machine - Wire twister

Alpha 488 S – Economical processing of twisted pairs

  • Automatic highly efficient production of twisted pairs
  • Flexibility of 6 Stations and possibilities for special wire-end processing
  • Gentle wire handling guarantees undamaged products
  • Well proven and innovative quality monitoring systems for OEM-approved quality and precision
  • Full process control and strict separation of good and bad lead sets
  • Networking possibilities for more transparency along the value creation chain
  • The processing set short open ends enables production of UTP wires, for example for Ethernet applications with very short open wire ends
  • Minimal footprint and little maintenance required thanks to compact, robust and durable machine design
  • Swiss technology and twisting competences for 15 years

Alpha 488 S produces fully automatically Twisted-Pairs out of two single bulk wires completely cut-to-length and terminated, with all quality controls included. The modular composition of the system provides superb flexibility. Four processing stations at the wire beginning and two at the wire end offer extensive processing possibilities.


Highest flexibility

The machine layout accommodates up to six processing modules. Wires with cross sections ranging from 2 × 0.22 mm² (AWG 24), optionally from 2 × 1.3 mm² (AWG 26), to 2 × 2.5 mm² (AWG 14), (processing set short open ends up to 2 × 1.0 mm²) can be processed in the highest quality.
Alpha488S is available in the versions of four, seven and ten meters.
In combination with the Komax crimping modules mci 722 or mci 712 and the Komax seals module mci 765 C as well as with the quick-change systems and the integrated quality monitoring systems Alpha 488 S ensures maximum process reliability and extremely short changeover times.
With the processing set short open ends UTP (unshielded twisted pair) wires with very short open wire ends can be produced, as required, for example, for Ethernet applications.

Outstanding user-friendliness

The system is characterized by a remarkable user-friendliness. Accessibility to all stations is optimal due to a large swivel radius and an upwards opening protection cover.
In addition, long and fold-up wing-doors allow the operator an excellent and quick access to the upper wire deposit tray as well as to the twisting area.
A pivoting operator console allows an improved machine operation, since the wire deposit tray is freely accessible at all times.
The touch screen which combines visual output and data input in the same spot, also contributes to a more efficient operation of the machine. It is included in the standard configuration.
The graphical user interface is based on the well-proven TopWin and allows the easiest control of the Alpha 488 S.
The compact design of the wire feed-in unit provides central and fast access to daily used guiding parts and tools.

Alpha 488 S Module

Maximal ease of maintenance

Thanks to a sophisticated, highly innovative, wireless electrical transmission system - ICS (Inductive Communication System) in combination with an autonomous air-pressure storage system allows the suppression of the drag chain at the wire-puller
carriage. The highly simplified guiding concept for the linear carriages, the compact deposit cells and some automated adjustments greatly simplify the installation and maintenance of the system.
A single control cabinet and the simplified hardware architecture further facilitate the maintenance work.


The twisting head with AC servo-drive is the heart of Alpha 488 S and delivers the required dynamics. The integrated Twist Force Analyzer (TFA) monitors the forces during twisting and regulates the subsequent adjustment movements of the twisting head.That ensures a steady and ultra-precise twisting.
The linear wire-puller with integrated Delta Length Analyzer (DLA) ensures that wires are drawn-in gently and with great accuracy of length. The high output of the system results from the parallel processing of two wires and the division of the overall processing cycle into three perfectly synchronized main processes.
A further central element of the Alpha 488 S is the transfer bridge with motorized axes. It allows wires to be handled gentler and more precise than ever while enabling the automation of some adjustment procedures.


The optional interface WPCS (Wire Processing Communication Stand-ard) allows Komax machines to be networked under TopWin. With this open interface, the machine is easy to integrate into existing production sequences.

TopNet is a clearly arranged mana-gement software with functions for the centralized creation and management of parts, articles and jobs that help you to optimize your production operations.

TopConvert can be used to convert already existing job and article lists to WPCS format. This data can then be directly processed by fully automatic crimping machines.

Processing modules

The Alpha 488 S can be customized with various modules to meet specific customer needs:

  • Crimp module mci 712 (with CFA/CFA+)
  • Crimp module mci 722 (with programmed crimp heights and CFA/CFA+)
  • Seal module mci 765 C (with seal position monitoring SPM)
  • other processes on request

Processing sets

  • short lengths
  • open ends standard
  • short open ends
  • long and unequal length open ends
  • small-gage wires
  • halogen-free insulation


There are a number of different accessories available with which you can adapt the Komax Alpha 488 S to your own specific needs and expand its capabilities as desired.

Preliminary wire processing

  • Ink jet marker
  • Hot stamp marker
  • Wire feed systems

Crimping module accessories

  • Paper winder
  • Carrier strip chopper
  • Valve set for pneumatically operated advance
  • Pressure regulation set
  • Monitoring of length-wise and cross-wise transport of terminals

Process monitoring

  • Twist force analyzer (TFA)
  • Delta length analyzer (DLA)
  • Crimp force analyzer (CFA/CFA+)
  • Seal position analyzer (SPM)
  • Splice detection
  • Quality assurance Komax 331, 341, 371, Generic Barcodescanner

Deposit systems

  • Deposit cells 4m, 7m or 10m

Further accessories

  • Tower light
  • Wire measurement band
  • Magnifying glass
  • Keypad
  • Uninterruptible power supply (USV)


Komax offer to you an optimal support by individual Service offers.

  • After-Sales Service
  • Production Assistance
  • Certified Training Courses
  • Feasibility Test
Length range 700mm–4000mm (27.6in–157.5in)
700mm–7000mm (27.6in–275.6in)
700mm–10000mm (27.6in–393.7in)
Optional from 150mm (5.9in)
Final length of twisted pairs
Length accuracy ±(0.3% +1.5mm(0.06in.)
Stripping lengths Side 1: 0.1mm - 18mm (0.004in. - 0.7in.)
Side 2: 0.1mm - 35mm (0.004in. - 1.4in.)
Wire cross sections* 2 × 0.22 mm² – 2 × 1.0 mm² (AWG 24-AWG 17)
with processing set for short open ends
2 × 0.22 mm² – 2 × 2.5 mm² (AWG 24 – AWG 14) 
with processing set for standard open ends 
Optional with feasibility test from 0.13 mm² (AWG 26) on
Open wire ends**
(Data without end processing)
15 – 99 mm (0.6 – 3.9 in.) with processing set for short open ends
30 – 99 mm (1.2 – 3.9 in.) with processing set for standard open ends 
30 – 125 mm (1.2 – 4.9 in.) with processing set for long and unequal length open ends on side 1
Pitch length  5mm - 80mm (0.2in. - 3.2in.) programmable
accuracy: ±10%, max. 5mm  
Wire draw-in speed  max. 5m/s (16.4ft/s) 
Noise level <75dB (no crimping module)
Electrical connection 3×208–480V/50–60Hz; 10kVA
Compressed air connection 5 – 8 bar (73 – 116 psi)
Recommended operating pressure*** 6 ±0.5 bar (87 ±7.25 psi)
Weight incl. two crimping modules and two seal loading modules
Alpha 488 S / 4m: approx. 2800kg (7502lb.)
Alpha 488 S / 7m: approx. 3400kg (9109lb.)
Alpha 488 S / 10m: approx. 4000kg (10717lb.)

* Extremely hard and tough wires may not be able to be processed even if they are within the above cross section range. If you are in doubt about your wires, we are happy to process your samples.

** Producible parameters depend on pitch, outer diameter and end processing. Producibility can be checked with the software producibility check or with a feasibility test.

*** The correct functioning of peripheral devices may be restricted outside the recommended operating pressure. Also heed the technical data for the peripheral devices. The maximum admissible operating pressure depends on the ambient temperature: 6.5 bar up to 40 °C / 6 bar from 40 °C onward


Alpha 488 S Layout

Cutting Cutting
Cutting pulled strands Cut pulled strands
Full stripping Full strip both sides
Half stripping Half strip both sides
Twisted pair / Different, short open wire ends processing Twisted pair Alpha 488
Crimping Crimping cc
Hot stamp marking Hot stamp marking with strip
Inkjet marking Inkjet
Split cycle for closed barrels Split cycle both sides
Seal insertion Sealing both sides