TE AMP 3K series Customer'S Manual Download

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TOOLING ASSISTANCE CENTER 1-800-722-1111

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Customer Manual

409-32034

16 SEP 16 Rev D

SAFETY PRECAUTIONS

READ THIS FIRST! ............................................................. 2

INTRODUCTION .................................................................................................................. 3

DESCRIPTION ..................................................................................................................... 4

2.1.

Functional Description ................................................................................................. 5

2.2.

Electrical Description ................................................................................................... 6

2.3.

Machine Guard (Figure 7) ........................................................................................... 8

RECEIVING INSPECTION AND INSTALLATION ............................................................... 9

3.1.

Receiving Inspection ................................................................................................... 9

3.2.

Installation ................................................................................................................... 9

3.3.

Considerations Affecting Placement of Bench Machines .......................................... 10

OPERATION ...................................................................................................................... 11

4.1.

Machine Operation .................................................................................................... 11

4.2.

Crimp Quality Monitor II (CQM II) .............................................................................. 11

4.3.

Applicator Installation ................................................................................................ 14

4.4.

Setup ......................................................................................................................... 14

4.5.

Mode Selection and Operation .................................................................................. 15

4.6.

Crimp Height Adjustment .......................................................................................... 17

4.7.

End-Feed/Side-Feed Applicator Conversion ............................................................. 17

MACHINE FAULT CODES ................................................................................................ 17

PREVENTIVE MAINTENANCE ......................................................................................... 18

6.1.

Cleaning .................................................................................................................... 18

6.2.

Lubrication ................................................................................................................. 18

ADJUSTMENTS ................................................................................................................. 19

7.1.

Measuring the Shut Height ........................................................................................ 19

7.2.

Shut-Height Adjustment ............................................................................................ 20

7.3.

Crimp Height Adjustment Using Precision Adjustment Mechanism .......................... 21

7.4.

Guard Insert Adjustment ........................................................................................... 22

MACHINE OPTIONS AND INSTALLATION ...................................................................... 24

8.1.

Installation of Work Light Assembly Kit ..................................................................... 24

8.2.

Installation of the Work Light Assembly Kit ............................................................... 26

8.3.

Installation of Batch Counter Kit 1424267-1 .............................................................. 27

8.4.

Installation of Air Feed Kit 1424266-1 ....................................................................... 28

TROUBLESHOOTING ....................................................................................................... 31

10.

RoHS INFORMATION ........................................................................................................ 31

11.

REVISION SUMMARY ....................................................................................................... 31

AMP 3K* Terminating Machine 1725950-[ ] and
AMP 5K* Terminating Machine 1725900-[ ]

TIONS

Summary of Contents for AMP 3K series

Page 1: ...t of Bench Machines 10 4 OPERATION 11 4 1 Machine Operation 11 4 2 Crimp Quality Monitor II CQM II 11 4 3 Applicator Installation 14 4 4 Setup 14 4 5 Mode Selection and Operation 15 4 6 Crimp Height Adjustment 17 4 7 End Feed Side Feed Applicator Conversion 17 5 MACHINE FAULT CODES 17 6 PREVENTIVE MAINTENANCE 18 6 1 Cleaning 18 6 2 Lubrication 18 7 ADJUSTMENTS 19 7 1 Measuring the Shut Height 19 7...

Page 2: ...elry that may catch in moving parts of the equipment Never alter modify or misuse the equipment TOOLING ASSISTANCE CENTER CALL TOLL FREE 1 800 722 1111 CONTINENTAL UNITED STATES AND PUERTO RICO ONLY The Tooling Assistance Center offers a means of providing technical assistance when required In addition Field Service Specialists are available to provide assistance in the adjustment or repair of the...

Page 3: ... 1725900 0 5000 41 25 No Amp 135 79 0 025 Yes Yes Air Feed Overside Guards 4 1725900 2 5000 41 25 Yes Amp 135 79 0 025 Yes Yes 4 1725900 3 5000 30 Yes Amp 135 79 0 025 Yes Yes 5 1725900 0 5000 30 No Universal Jam 119 50 0 025 Yes Yes 5 1725900 1 5000 30 Yes Universal Jam 119 50 0 025 Yes Yes Figure 1 1 INTRODUCTION This manual contains information on operation preventive maintenance and adjustment...

Page 4: ...packaged with each applicator The applicator instruction sheets provide information on applicator installation care and adjustment When reading this manual pay particular attention to DANGER CAUTION and NOTE statements DANGER Denotes an imminent hazard that may result in moderate or severe injury CAUTION Denotes a condition that may result in product or equipment damage NOTE Highlights special or ...

Page 5: ...nes provide the force required to crimp terminals in the applicator A terminal is attached to the wire by placing the wire in the crimp area and pressing the footswitch The machine consists of four functional areas 1 The motor group includes a dc motor which drives a crankshaft The motor is activated each cycle and rotates the crankshaft one full revolution A 6 mm hex key placed in the recess loca...

Page 6: ...ecision Crimp Height Adjustment Mechanism 2 2 Electrical Description The 1725950 and 1725900 machine electrical components consist of the operator control panel the motor and the CPU motor controller package The machine operates on 100 240 Vac 50 60 Hz single phase current with ground The machine will automatically detect the supply voltage and adjust the controller accordingly The operator contro...

Page 7: ...tem The CPU motor controller is located behind the back cover of the machine It is a modular unit that contains all of the electronics necessary to operate the machine See Figure 6 Machine Ready Icon Green Indicator Guard Open Icon Yellow Indicator Jog Button Speed Control Knob Speed Control Icon Fault Icon Batch Counter Optional Guard Disable Icon Jog Button Icon ...

Page 8: ... the work area The guard swings open to allow easy access for applicator installation and setup A safety interlock on the guard prevents the machine from cycling if the guard door is open during production operation Reel Support Hole DC Motor Power Receptacle Back Cover CPU Motor Controller Behind Back Cover Terminal Strip Guide Power Switch Circuit Breaker ...

Page 9: ...lation Remove all mounting bolts securing the machine to the shipping pallet Install lift ring see Figure 7 on top of the machine NOTE Lift ring M1220 eye bolt is customer supplied NOTE Install the lift ring carefully A 19 05 mm 75 in thread length engagement is required for the lift ring to support the machine Attach a suitable hoist to the lift ring lift the machine and place it in the selected ...

Page 10: ...applied not more than 152 4 to 203 2 mm 6 to 8 in minimum 50 8 mm 2 in from the front edge This location will eliminate unnecessary operator motion and help to avoid back strain and fatigue Orientation of the machine should be such that the target area is facing the front of the bench and is parallel to the front edge access to the back of the machine MUST also be provided DANGER Machines should b...

Page 11: ...ashes a pause two green flashes a pause and one green flash would indicate version 3 2 1 Refer to Customer Manual 409 10100 for detailed instructions regarding the use of the CQM II This manual is included in the machine s documentation package Machine Power Up During power up the machine looks to see if the monitor s interface cable is connected Specifically it looks to see if the jumper from J10...

Page 12: ...ts stop flashing Bad Crimp Fault After the Machine Cycles After the machine has been cycled the machine looks at the monitor s output relays Relay 1 and Relay 2 If the Relay 1 is pulsed and Relay 2 remains closed the machine will be ready for the next crimp cycle If the Relay 1 is not pulsed and Relay 2 is open the monitor has detected a BAD crimp and both the green and yellow light will be flashe...

Page 13: ...dicator light stops flashing Some machines faults require AC power to be cycled using the rocker switch on the back panel Leave the machine powered off for approximately ten seconds before reapplying power When the yellow indicator is on and not flashing the guard is disabled and the machine will only operate with the Jog button When the yellow indicator is flashing by itself the guard interlock s...

Page 14: ...l K terminating machine loosen the quick release T handle slide down the applicator base clamp and remove the rear stop located on the left side of the base plate Install the rear stop PN 354561 1 supplied with the air feed kit at the alternate mounting position on the base plate See Figure 4 4 Set the crimp height and insulation crimp discs so that the letters and numbers on the applicator pad al...

Page 15: ...ull cycle release the jog button Before continuing verify that there is not an interference problem in the crimping area To complete the cycle either press the footswitch or jog at a faster speed The jog speed can be temporarily increased by following the Adjusting the Jogging Speed Using the Speed Control Knob procedure described below If the Jog button is held down for longer than five seconds a...

Page 16: ...n The guard disable indicator will flash at a rate of two flashes per second indicating that the guard has been disabled Pressing the Jog button causes the crankshaft to be rotated at a default reduced speed in the forward direction until the Jog button is released or the crankshaft completes the machine cycle If the Jog button is released in mid cycle the crankshaft will stop turning Press the Jo...

Page 17: ...tch not closed Close the guard to close the guard switch 4 Top Dead Center TDC switch fault machine motion not detected The switch was not unmade within the allotted time 175 ms 5 Top Dead Center TDC switch fault complete machine cycle not detected The switch was not made within the allotted time The allotted time for the Run mode is 1 5 seconds The allotted time for Jog mode is six seconds 6 Moto...

Page 18: ...r lubrication to ensure reliable service and long life The preferred greases are Chevron Ultra Duty EP NLGI 2 Chevron Ulti Plex EP NLGI 2 and Caltex Ultra Duty EP NLGI 2 NOTE Contact TE Engineering for 2nd choice alternates CAUTION It is important to only use Lithium based grease with extreme pressure EP additives NOTE For operation in temperatures below 10 C 50 F it will be necessary to use a No ...

Page 19: ...for measuring the shut height refer to 408 8535 for instructions on use of the gage 1 If installed adjust the manual precision adjustment lever to the 0 crimp setting 2 Turn off the machine and disconnect the power cord plugged into the receptacle mounted to the motor end plate Figure 6 3 Insert a 6 mm hex wrench into the end of the motor until it completely engages the recess in the end of the mo...

Page 20: ...y ALWAYS turn off the machine and disconnect the power supply to the machine before making any adjustments If applicator is an air feed type DISCONNECT air lines to valve located on the right side of the machine 1 Check shut height as described in Paragraph 7 1 2 If the shut height is incorrect refer to Figure 13 and proceed as follows a Remove the two socket head cap screws which secure the ram p...

Page 21: ...Precision Adjustment Mechanism DANGER To avoid damaging the applicator ALWAYS return the precision adjustment lever to the 0 position when finished using the applicator 1 Adjust the manual precision adjustment lever to 0 by pulling the lever away from the pivot pin Lock the lever in place by releasing it 2 Install the applicator into the machine as described in Paragraph 4 3 3 Cycle the machine to...

Page 22: ...ced the rear slot places the insert close to the applicator the front slot places the insert farther away from the applicator The type of insert used determines which slot is to be used An insert placed into the wrong slot cannot be secured in place NOTE Some special inserts are designed to mount in the standard insert slot These inserts have the threaded holes at the top corners and should be ins...

Page 23: ...e holes in the left guard door and into the threaded holes in the top of the insert Do not tighten the screws 1 Move the insert horizontally and vertically as needed to align the slot with the crimp area of applicator 2 Tighten the screws Guard Insert 354529 2 and Guard Insert 679995 2 1 Slide the insert into the front slot of the guard door Secure the insert to the door with two screws placed thr...

Page 24: ...e sure to turn off the machines and disconnect them from the power source 1 Open the clear guard on the machine to gain access to the two socket head screws securing the user interface to the frame 2 Remove the two socket head cap screws securing the user interface to the frame Carefully lift the user interface assembly to clear the sheet metal guard CAUTION Use caution when removing the interface...

Page 25: ...ng until it snaps into place The red reset button should be on the right hand side 10 Re attach the connector from the machine wiring harness to the J1 connector on the pc board in the interface assembly Socket Screws Provided with Work Light Kit Work Light Kit Optional Batch Counter Kit Optional Work Light Kit Knockout Holes User Interface Assembly Removed from Machine Red Reset Button PC Board J...

Page 26: ... sure the interface assembly wiring harness is not pinched or kinked 12 Close the clear guard on the machine 13 Connect the machine to the power source and turn the machine on 8 2 Installation of the Work Light Assembly Kit The work light can be located outside or inside the 3 front cover as shown in Figure17 and Figure 18 Figure 17 ...

Page 27: ...o the interface is not damaged 3 Disconnect the wiring harness connector from the pc board inside the user interface assembly 4 Remove the batch counter kit knockout from the front of the user interface assembly CAUTION Do not damage the pc board inside the interface assembly when removing knockout 5 Insert the connector end of the batch counter wire through the knockout opening 6 Plug the batch c...

Page 28: ...personal injury be sure to turn off the machines and disconnect them from the power source NOTE Some applications require the installation of an Oversized Guard Kit 1976900 1 These applications are primarily ones that use two inch stroke air feed cylinders 1 Remove the four bolts securing the rear controller panel to the frame Refer to Figure 20 User Interface Assembly Removed from Machine Knockou...

Page 29: ...using the two bolts securing the sheet metal guard 7 Prepare the baseplate assembly as follows a For Air Feed Kit 1424266 1 standard machine base plate install the socket head screw and rear stop to the baseplate as shown Then remove the back left baseplate clamp b For Air Feed Kit 1424266 2 universal machine base plate install the socket head cap screw and Air Feed Clamp 1338963 1 Then remove the...

Page 30: ...he air can be turned off by moving the slide valve away from the filter Figure 22 11 Lock the air in the off position Turn the air off and clamp the valve lockout in position as shown Four Way Solenoid Valve Air Feed Bracket Slide Valve Filter Large End of Air Feed Cable Assembly 1424287 1 AMP Style Applicator Base Plate Rear Stop Socket Head Cap Screw ...

Page 31: ...nter equipment part number 11 REVISION SUMMARY Revisions to this customer manual include Updated to most current TE logo header footers Changed para 4 7 Note from Lubricator Bowl Assembly PN 354550 1 to 3 and added When using an Ocean Side Feed or End Feed applicator the lubricator assembly part numbers are 2119955 1 and 2119955 2 respectively Created Figure 15 paragraph 8 and renumbered all Figur...

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