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TE Connectivity AMP 3K/40 CE 2161600-1 Original Instructions Manual

Terminators with stripping module
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© 2012 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
AMP 3K/40 CE Terminators (with Stripping Module)
2161600-[ ] and AMP 5K/40 CE Terminators (with
Stripping Module ) 2161700-[ ] 
SAFETY PRECAUTIONS
A.
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1. Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2. Electrical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3. Machine Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4. Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. RECEIVING INSPECTION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1. Receiving Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2. Installation of Terminator and Stripping Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3. Considerations Affecting Placement of the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1. Host Module Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2. Applicator Setup and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3. Stripping Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2. Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3. Terminator Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6. DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7. MECHANICAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.1. Strip Blade Closure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.2. Strip Length Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.3. Wire Brush Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.4. Gripper Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.5. Tonk Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.6. Strip Cam Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.7. Start Sensor Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8. ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9. PARTS REPLACEMENT AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11. DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12. ROHS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
13. REVISION SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TOOLING ASSISTANCE CENTER 
1-800-722-1111
READ THIS FIRST !
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com
Customer Manual
409-32021
08 FEB 12 Rev A
1 of 29
LOC B

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Summary of Contents for TE Connectivity AMP 3K/40 CE 2161600-1

  • Page 1: Table Of Contents

    All Rights Reserved 1-800-722-1111 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOC B TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
  • Page 2 409-32021 DANGER STOP SAFETY PRECAUTIONS AVOID INJURY Safeguards are designed into this application equipment to protect operators and maintenance personnel from most hazards during equipment operation. However, certain safety precautions must be taken by the operator and repair personnel to avoid personal injury, as well as damage to the equipment.

  • Page 3: Introduction

    409-32021 Terminator Control Panel Reel Support Bracket Terminal Strip Guide Optional CQM II DAQ Module Host Module Gripper Pressure Regulator Stripping Module Main Guard Work Light TERMINATOR TE PART NUMBER AMP 3K/40 CE Terminator with Stripping Module 2161600-1 AMP 3K/40 CE Terminator with Stripping Module and CQM II 2161600-2 AMP 5K/40 CE Terminator with Stripping Module 2161700-1...
  • Page 4 409-32021 When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements.  Denotes an imminent hazard which may result in moderate or severe injury. DANGER   STOP   Denotes a condition which may result in product or equipment damage. CAUTION ...

  • Page 5: Description

    409-32021 2. DESCRIPTION The Stripping Module is a pneumatically driven, microprocessor controlled, in-line stripping module designed to be used to provide wire stripping capability to the AMP 3K/40 CE terminator and AMP 5K/40 CE terminator Machines. The stripping modules accept a wide range of wire insulation types. It is assembled with metric hardware.
  • Page 6 409-32021 Precision Adjust Tonk Block T-Handle Location Stripping Subassembly Gripper  Subassembly Transfer Subassembly Figure 3 (Cont’d) Rev A 6 of 29...

  • Page 7: Electrical Description

    409-32021 Strip Cylinder Strip Cam Main Block Start Sensor Assembly Outer Strip Blade Figure 3 (End) 2.2. Electrical Description The stripping module components consist of the host module, electrically controlled pneumatic valves, and various switches and sensors. The host module operates on +24VDC power which is supplied by the terminator. The terminator main power switch applies power to the terminator and to the host module.

  • Page 8: Description Of Operation

    409-32021 2.4. Description of Operation The strip and crimp cycle of operation is as follows: 1. The cycle may be started automatically (with "Wire Sensor" selected as the starting means), or with the foot switch. In automatic operation ("Wire Sensor" selected as the starting means), the operator places a wire through the grip jaws and strip blades to depress the wire sensor, which automatically starts the cycle.

  • Page 9: Receiving Inspection And Installation

    409-32021 3. RECEIVING INSPECTION AND INSTALLATION 3.1. Receiving Inspection The Stripping Module is thoroughly inspected during and after assembly. A final series of inspections is made to insure the proper machine functioning before packaging and shipping. To protect against damage that may have occurred during shipment, remove the machine from the packaging and carefully inspect the machine for damage.
  • Page 10 409-32021 a. Press the tools icon at the top of the screen. Tools Icon b. Scroll down and touch the System Settings icon. System Settings Icon  c. Select the terminator marked “AMP 3K/5K CE” from the host machine pull-down menu. Appropriate Pull-Down Menu Terminator...
  • Page 11 409-32021 Pull-Down Menu Stripper Module  Installed This completes configuration of the host module for the AMP 3K/40 CE terminator or AMP 5K/40 CE terminator stripping module. After configuring the host module, proceed as follows: 1. Remove the applicator. 2. Manually return the terminator ram to the top of its travel (TDC). 3.

  • Page 12: Considerations Affecting Placement Of The Machine

    409-32021 Reset Button  This screen will only be displayed for a few seconds if the user does not press one of the buttons shown. NOTE A green check will indicate that the stripping module has been reset. Green Check Indicates Stripping Module Has Been Reset.
  • Page 13 409-32021 Mounting Hole Mounting Hole Figure 5 Figure 7illustrates: A. Bench The bench to be used should be of sturdy construction, preferably with rubber mounts to minimize noise. A height of 762.0mm to 812.8mm [30 in. to 32 in.] is the most suitable for operator comfort and convenience. This height allows the operator to rest both feet on the floor, thereby providing for the shifting of weight and leg position.

  • Page 14: Operation

    409-32021 Figure 7 C. Operator's Chair The operator's chair should swivel, and should have independent seat height and back rest adjustments. The seat and back rest should be padded, and the back rest should be large enough to provide support both above and below the waist line.
  • Page 15 409-32021 DEFINITION ACTION Mode Selection: Allows the user to select the strip option or strip and crimp option Allows the user to select whether the wire sensor or footswitch is used to Enable Via: cycle the system. Allows the user to increase or decrease the duration that the air blast is Air Blast Duration: applied.

  • Page 16: Applicator Setup And Installation

    409-32021 To operate the machine in step mode the radio button "Single Step Mode" must be selected. Once in single step mode each touch of the step button will perform a single step until the cycle has been completed. See Figure 10. Step Button (For Operating in Single Step Mode Icon Step Mode)
  • Page 17 409-32021 C. Applicator Installation/Removal It may be necessary to install the applicator from either the left side or the right side of the gripper mechanism, depending on the applicator and type of product being run. Instructions for installing the applicator from the left side and the right side are listed below.

  • Page 18: Stripping Module Removal

    409-32021 4.3. Stripping Module Removal The stripping module may need to be removed when changing applicators (refer to Paragraph 4.2,C for applicator installation procedures). To avoid personal injury, be sure to disconnect power to the module and the terminator before installing or removing the DANGER stripping module.

  • Page 19: Terminator Preventive Maintenance

    409-32021 Use a grease gun to apply grease to the transfer assembly through the grease fitting at least every million cycles. It is necessary to remove the Tooling-In Position Switch to gain access to the grease fitting. NOTE 5.3. Terminator Preventive Maintenance For preventive maintenance procedures for the terminator, refer to customer manual 409-10204.
  • Page 20 409-32021 Diagnostics Figure 12 3. Touch the tab marked “AMP 3K/5K CE diagnostics tab”. See Figure 13 Figure 13 The Stripping Module I/O can be viewed and changed (outputs). The user should be completely familiar with all stripping module mechanisms before attempting to change any CAUTION outputs, otherwise diagnostics mode is not recommended and the user should instead go to “Single Step”...

  • Page 21: Mechanical Adjustments

    409-32021 Stripping Module I/O Consists of the Following: Grip/Strip output Transfer output Air Blast output Pullback switch input Tonk Switch input Tooling in place input, Side Transfer input Footswitch input Wire Sensor input Guard Interlock input 7. MECHANICAL ADJUSTMENTS Most of the mechanical adjustments are made with adjustment screws containing (NYLON) locks. A 3mm wrench is required to make most adjustments.

  • Page 22: Strip Length Adjustment

    409-32021 7.2. Strip Length Adjustment (Figure 14) The wire strip length may vary between applicators and various terminals. This adjustment is made with the adjustment screw located at the front of the stripping module. Turn the adjustment screw clockwise to increase the strip length or counterclockwise to decrease the strip length. 7.3.
  • Page 23 409-32021 Strip Cam Speed Strip Cylinder Flow Control Strip Cam Pull-Back Switch Strip Blade Drive Block Hole for Hex Wrench Strip Depth  Adjustment Block Start Sensor Block Strip Depth Adjustment Screw Start Sensor Assembly Main Block Outer Strip Blade Strip Length Adjusting Screw Inner Strip Blade...
  • Page 24 409-32021 Upper Jaw Jaw Drive Block Lower Jaw Scrap Deflector Jaw Height Adjustment Screw Left Gib Right Gib Tonk Switch Gripper Mounting Block Grip Air Cylinder Rear Stops Tooling-In-Position Switch Grease Fitting Side Transfer Applicator Latch Block Transfer Air Cylinder Figure 15 Rev A 24 of 29...

  • Page 25: Tonk Adjustment

    409-32021 B. Gripper Pressure Adjustment The gripper pressure adjustment may be necessary to prevent damage to the wire insulation. To see the pressure level on the gage, enter the step mode while in strip and crimp mode or strip only mode. Perform the first step by pressing the step button.

  • Page 26: Electrical Assembly

    409-32021 25mm [.010 In.] Figure 16 8. ELECTRICAL ASSEMBLY Refer to the electrical assembly drawings shipped with the machine. 9. PARTS REPLACEMENT AND REPAIR 9.1. Strip Blade Replacement (Figure 17) To avoid personal injury, be sure to disconnect power to the stripping module and terminator before replacing strip blades. DANGER STOP 1.
  • Page 27 409-32021 Scrap Cover Retaining Screw Strip Air Cylinder Scrap Cover Hole for 3mm Hex Wrench Blade Adjustment Block Start Sensor Block Start Sensor Screw Securing Inner Strip Blade Inner Strip Blade Outer Strip Screws Securing Blade Outer Strip Blades Guard Stop Plate Figure 17 Rev A...
  • Page 28 409-32021 1424638-1 Must Touch 1428188-2 5.59 [.22] 4.78 [.188} 10.16 [.400] 1428188-2 Must Touch 1424635-1 Figure 18 6. Adjust the start sensor arm so that the lever is 4.78 [.188] from the back of cutting surface of the outer strip cam.

  • Page 29: Troubleshooting

    10. TROUBLESHOOTING Contact the Tooling Assistance Center at 1-800-722-1111. 11. DISPOSAL Contact TE Connectivity for disposal. 12. ROHS INFORMATION Information on the presence and location of any substances subject to RoHS (Restriction on Hazardous Substances) can be found at the following website: http://www.tycoelectronics.com/customersupport/rohssupportcenter/...

This manual is also suitable for:

Amp 5k/40 ce 2161700-1Amp 5k/40 ce 2161700-2Amp 3k/40 ce 2161600-2

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