Tyco Electronics AMP 3K Customer'S Manual Download Page 36 | Manualshive

Page: 36 / 38

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409-10083

AMP

3K

and
AMP

5K

Terminating

Machineswith

the
SL

Starlite

CQM

Rev
E

36

of

38

Tyco
Electronics

Corporation

Figure 28

Footswitch Assembly

Worklight Assembly

Rear Panel

Mounting Bolts

Air Feed Cable

Assembly

Detail of Footswitch

Entering Notch in Frame

Diode

Manual

Override

DoubleActing

Air Cylinder

Spring Return

Air Cylinder

Connection

Bolt Securing

Sheet Metal

Guard

Manual

Water

Drain

Valve

Lockout

Auxilliary Air

Connectiion

J10

J2

SLE Starlite

CQM Interface Cable

SLE Starlite CQM Interface Cable

Plugs Into J2 and J10

Plugs Into J7

J7

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Summary of Contents for AMP 3K

Page 1: ... 10 3 2 Installation 10 3 3 Considerations Affecting Machine Placement 11 4 OPERATION 12 4 1 Machine Operation 12 4 2 SL Starlite Operation 12 4 3 Applicator Installation 13 4 4 Setup 16 4 5 Mode Selection and Operation 16 4 6 Crimp Height Adjustment 18 4 7 End Feed to Side Feed Side Feed to End Feed Conversion 18 5 MACHINE FAULT CODES 19 6 PREVENTIVE MAINTENANCE 20 6 1 Cleaning 20 6 2 Lubrication...

Page 2: ...h in moving parts of the application equipment D NEVER insert hands into installed application equipment D NEVER alter modify or misuse the application 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 ...

Page 3: ...MP 3K and AMP 5K machines only The various applicators that can be used in the machines are covered in applicator instruction sheets packaged with each applicator Applicator instruction sheets provide information on applicator installation care and adjustment The specifications and requirements for the AMP 3K and AMP 5K Terminating Machines are as listed below Deflection 0 13mm 0046in Maximumper4 ...

Page 4: ...s 1 1725900 8 22 2 5000 30 AMP Univ Yes No No 1 1725900 9 22 2 5000 41 28 AMP No Yes Yes 2 1725900 0 22 2 5000 41 28 AMP Yes Yes Yes 2 1725900 1 22 2 5000 30 JAM Quick Yes No No 2 1725900 2 22 2 5000 30 JAM Quick Yes No Yes 2 1725900 3 22 2 5000 30 AMP Yes No Yes 2 1725900 4 22 2 5000 30 AMP Yes No No 2 1725900 5 22 2 5000 41 28 JAM Quick Yes No No Machines containing an asterisk are restricted to...

Page 5: ...hines Post Feed Ċ 690501 3 Heavy Duty Industrial HD I Applicator Pre Feed Post Feed Refer to the HD I Applicator customer drawing for part numbers Figure 3 2 1 Functional Description A Machine Functional Areas These machines 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 foot switch During th...

Page 6: ...uality Monitor consists of four functional parts refer to Figure 5 1 The monitor receives signals from the trigger sensor and the frame sensor during a crimp cycle decides if the crimp was good or bad and passes the appropriate signals to the machine 2 The trigger sensor tells the monitor when the beginning of the crimp cycle occurs 3 The frame sensor is a piezo electric strain sensor As the crimp...

Page 7: ...e current with ground The operator control panel Figure 6 is mounted on the left side of the machine frame The control panel consists of two indicator lights one jog button and one speed control knob with icons depicting each function See Paragraph 4 1 for control panel operation A main power switch circuit breaker Figure 7 is located on the back of the machine This switch connects ac power to the...

Page 8: ...e SL Starlite CQM Rev E 8 of 38 Tyco Electronics Corporation Figure 6 Guard Open Icon Green Indicator Yellow Indicator Jog Button Speed Control Knob Fault Icon Guard Disabled Icon Machine Ready Icon Speed Control Icon Jog Button Icon Batch Counter Kit 3K 40 ...

Page 9: ...A guard is installed to provide protection for the operator while maintaining proper visibility of 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 Machines 18 22 24 and 25 do not include the safety interlock feature To avoid personal...

Page 10: ...inst damage that may have occurred during shipment remove the machine from the crate Paragraph 3 2 and carefully inspect the machine for damage If damage is evident file a claim against the carrier and notify Tyco Electronics immediately 3 2 Installation Remove all mounting bolts securing the machine to the shipping pallet Install lift ring see Figure 8 on top of the machine Lift ring M12 20 eye b...

Page 11: ...tate work flow 3 the operator uses a swivel chair with padded seat and back rest which are independently adjustable and 4 the foot switch on machines so equipped is placed on a rubber mat to maintain its movability while preventing it from sliding unintentionally Figure 9 illustrates proper machine location and operator position and the following A Bench The bench to be used should be of sturdy co...

Page 12: ...on the right side of the machine under the cast slot in the frame to capture the scrap chips Applied Product Supply Figure 9 Materials LocationsĊPlan View Machine Location and Operator Position 4 OPERATION 4 1 Machine Operation The machine is operated by the foot switch the jog button and the speed control knob The jog button and the speed control knob are located on the control panel Control pane...

Page 13: ... will flash together three times Monitor Not Ready Fault If the GOOD crimp output is not OFF open the green and yellow light will flash together six times Good Crimp Signal Fault Both of these faults can be cleared by holding the footswitch until the lights stop flashing or by cycling power on the machine C Bad Crimp Fault After the Machine Cycles After the machine has been cycled the machine look...

Page 14: ...de down the applicator base clamp and remove the rear stop located on the left side of the base plate Install the rear stop part number 354561 1 supplied with the air feed kit at the alternate mounting position on the base plate See Figure 5 4 Set the crimp height and insulation crimp discs so that the letters and numbers on the applicator pad align with the front pad on the ram post adapter 5 If ...

Page 15: ... indicator is flashing but the green indicator is not the guard is disabled and the machine will only operate with the Jog button An SL Starlite monitor fault has been detected when both indicators green and yellow are flashing See Figure 11 To reset the machine power down the machine clear the problem area and then power up the machine or hold down the footswitch until the indicators stops flashi...

Page 16: ... guards in the open or closed position A Full Cycle Mode Depressing the footswitch with the guard closed causes the crankshaft to be rotated at a speed defined by the speed control knob through a complete revolution This completes one full machine cycle B Jog Mode Figure 10 Pressing the Jog button causes the crankshaft to be rotated at a default reduced speed in the forward direction until the Jog...

Page 17: ...gging the machine with the guards open This mode allows maintenance and setup personnel to slowly rotate the crankshaft with the guard door open To activate this mode turn off power and open the guard door Turn the power back on and immediately after the machine ready and guard disable indicators flash on press and hold the Jog button The guard disable indicator will flash at a rate of two flashes...

Page 18: ...the precision adjustment feature the crimp height must be adjusted at the applicator Refer to the instructions provided with the applicator to perform this adjustment Refer to Paragraph 6 3 for procedures to adjust the crimp height using the machine precision adjustment feature 4 7 End Feed to Side Feed Side Feed to End Feed Conversion When changing from an end feed applicator to a side feed appli...

Page 19: ...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 Motor control circuit fault A bad transistor PWM IGBT was detected The C...

Page 20: ...h a clean soft cloth DO NOT USE ANY SOLVENT TO CLEAN THE GUARDS Solvent could damage the guards 6 2 Lubrication The moving parts of the machine require regular lubrication to ensure reliable service and long life Use only Chevron Ultra EP NLGI No 2 Pennzoil Pennlith Ultra EP NLGI No 2 or Conoco Syncon EP Heavy Duty Grease For operation in temperatures below 10_C 50_F it will be necessary to use a ...

Page 21: ...d the top surface of the machine base plate as shown in Figure 13 Shut Height Gage 679655 see the table in Figure 13 is recommended for measuring shut height refer to 408 8535 for instructions on use of the gage 1 Turn off the machine using the power switch on the back panel 2 If installed adjust the manual precision adjustment lever to the 0 setting 3 Remove the access cover Figure 7 on the end o...

Page 22: ...ance Center at 1 800 722 1111 to schedule a visit from a Field Service Specialist NEVER attempt to adjust the shut height without FIRST trying an applicator that is known to produce terminations of the correct crimp height If this applicator produces correct terminations the trouble is in the original applicator and the shut height MUST NOT BE CHANGED If it is determined that the shut height must ...

Page 23: ...justment Using Precision Adjustment Mechanism If Equipped The precision adjustment mechanism is available on most machines with the exception of 15 and 19 machines as well as Field Retrofit Kit 1424208 1 for Machines 15 and 19 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 l...

Page 24: ...t A guard insert is supplied with the machine Some applications may require a special insert See Figure 15 for available guard inserts The guard contains two slots into which the inserts can be placed 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 ...

Page 25: ...e guard door Secure the insert to the door with two screws placed through the large square holes in the left guard door and into the threaded holes in the top of the insert Do not tighten the screws 2 Move the insert horizontally and vertically as needed to align the slot with the crimp area of applicator 3 Tighten the screws B Guard Insert 354529 2 and Guard Insert 679995 2 1 Slide the insert int...

Page 26: ...following machine options are available only for Machines 17 and 18 JAM Applicator Mounting Kit 1424268 1 JST Applicator Mounting Kit 1424269 1 8 1 Installation of Work Light Assembly Kit 1424264 1 To avoid personal injury be 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 i...

Page 27: ...unter Kit Option User Interface Assembly As Viewed from the Bottom PC Board J1 Connector J3 Connector 5 Remove the three work light kit knockout holes Figure 16 Detail A from the top of the user interface assembly When removing the knockouts be careful to not damage the pc board inside the assembly 6 Insert connector end of lighting kit wire into the center knock out hole 7 Plug the lighting kit c...

Page 28: ...ness to the J1 connector on the pc board in the interface assembly 11 Install the user interface assembly into the frame and secure using the two socket head screws Be 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 Work Light Assembly Kit 1424264 1 Ins...

Page 29: ...th the SL Starlite CQM Rev E 29 of 38 Tyco Electronics Corporation Figure 18 1 Align the marks on the head of the work light as shown in Figure 18 This allows the top of the work light to be disassembled 2 Remove the cap as shown in Figure 19 Figure 19 ...

Page 30: ...iver begin prying the retaining clip out of the light assembly See Figure 20 4 Finish removing the retaining clip from the light assembly and remove the light assembly from the goose neck Refer to Figure 21 Figure 21 5 Thread the goose neck through the hole in the cover Refer to Figure 22 6 Install the light assembly to the end of the goose neck ...

Page 31: ...f 38 Tyco Electronics Corporation Figure 22 7 Install the retaining clip in the light assembly Refer to Figure 23 Figure 23 8 Replace the cap on the light assembly and align the marks as shown in Figure 24 Turn the cap clockwise as viewed from the top to tighten the work light assembly ...

Page 32: ...and AMP 5K Terminating Machines with the SL Starlite CQM Rev E 32 of 38 Tyco Electronics Corporation Figure 24 After closing the guard door the finished work light assembly should appear as shown in Figure 25 Figure 25 ...

Page 33: ...terface assembly b Remove and replace the board with Operator Interface Board Assembly 1490444 1 c Re assemble hex nuts to secure the board assembly in the user interface assembly d Re assemble the small push button e Position and tighten the locking screw of the larger dial button on the shaft of the switch so that when the dial is rotated fully counterclockwise the indicator on the dial is align...

Page 34: ...emoved from Machine Knockout for Batch Counter Kit Batch Counter Kit Option Detail A Detail B PC Board J2 Connector on PC Board User Interface Assembly As Viewed from the Bottom Red Reset Button Batch Counter Kit Option Figure 27 When the Dial is Turned Fully Counterclockwise the Indicator on the Dial Should Align with the Indicator on the Control Panel ...

Page 35: ...ft sheet metal guard See Figure 28 6 Install Air Feed Bracket 1338977 1 to the frame see Figure 29 using the two bolts securing the sheet metal guard Figure 28 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 in Figure 30 Then remove the back left baseplate clamp b For Air Feed...

Page 36: ...el Mounting Bolts Air Feed Cable Assembly Detail of Footswitch Entering Notch in Frame Diode Manual Override Double Acting Air Cylinder Spring Return Air Cylinder Connection Bolt Securing Sheet Metal Guard Manual Water Drain Valve Lockout Auxilliary Air Connectiion J10 J2 SLE Starlite CQM Interface Cable SLE Starlite CQM Interface Cable Plugs Into J2 and J10 Plugs Into J7 J7 ...

Page 37: ...Electronics Corporation Air Feed Bracket 1338977 1 Large End of Air Feed Cable Assembly 1424287 1 Four Way Solenoid Valve Slide Valve Filter Figure 29 Figure 30 Socket Head Cap Screw Rear Stop Standard Machine Base Plate Figure 31 Socket Head Cap Screw Air Feed Clamp Universal Machine Base Plate ...

Page 38: ...ram that retains the eccentric pin 4 Pull the non eccentric pin and replace with Eccentric Pin 354510 1 5 Drive two slotted spring pins PN 21920 5 into ram housing and attach indexing plate with two socket head cap screws PN 992285 1 6 Assemble Adjust Lever 1320363 1 and install onto eccentric pin Apply a thread locking substance to the threads and tighten the setscrew 7 Install the grease fitting...

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