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E
2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
AMP 3K and AMP 5K Terminating Machines
with the SL Starlite Crimp Quality Monitor
SAFETY PRECAUTIONS
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2.1.
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2.2.
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2.3.
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3.1.
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3.2.
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3.3.
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4.1.
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4.2.
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4.3.
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4.4.
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4.5.
4.6.
4.7.
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6.
6.1.
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6.2.
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7.1.
7.2.
7.3.
7.4.
8.1.
8.2.
8.3.
8.4.
8.5.
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TOOLING ASSISTANCE CENTER 1-800-722-1111
READ THIS FIRST !
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This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
Customer Manual
409-10083
14 APR 08 Rev E
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Table of Contents
Related Manuals for Tyco Electronics AMP 3K
Summary of Contents for Tyco Electronics AMP 3K
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Page 1: Table Of Contents
Customer Manual AMP 3K and AMP 5K Terminating Machines 409-10083 with the SL Starlite Crimp Quality Monitor 14 APR 08 Rev E SAFETY PRECAUTIONS READ THIS FIRST ! ...... - Page 2 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 DANGER 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.
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Page 3: Introduction
SL Starlite monitor. Quick references/descriptions to these machines can be found in Figure 2. Both series machines (AMP 3K and AMP 5K) contain separate machines to produce a 30mm stroke or a 41.28mm stroke. - Page 4 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 MACHINE STROKE PART APPLICATOR PRECISION GUARD CAPACITY LENGTH NUMBER TYPE ADJUST VERSION INTERLOCK kN [LB]) (MM) 1-1725950-5 13.3 [3000] 41.28 1-1725950-6 13.3 [3000] 41.28 1-1725950-7 13.3 [3000]...
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Page 5: Description
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 2. DESCRIPTION The AMP 3K/40 and AMP 5K/40 Terminating Machines were designed to be used as stand–alone semi–automatic bench units. The SL Starlite Crimp Quality Monitor provides 100% inspection of the crimping process. - Page 6 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 DC Motor Crankshaft Motor Access Cover Figure 4 4. The crimp height adjustment group uses an eccentric located in the ram linkage, along with the detents in the mechanism, to adjust the crimp height. See Figure 5. Indexing the mechanism in either direction will change the crimp height in increments of approximately 0.013mm [.0005 in.] per step.
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Page 7: Electrical Description
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Ram Post Adapter Precision Crimp SL Starlite Monittor Height Adjustment Mechanism Trigger Sensor Frame Sensor Base Plate for Machines -17 and -18 Quick-Release Base Plate for Machines -15, -16,... - Page 8 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Guard Open Yellow Speed Control Speed Control Jog Button Icon Indicator Knob Icon Green Indicator Machine Ready Icon 3K/40 Fault Icon Batch Counter Guard Disabled Jog Button...
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Page 9: Machine Guard
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Reel Support Hole DC Motor Motor Access Cover Terminal Strip Guide Back Cover CPU/Motor Controller (Behind Back Cover) Power Switch/Circuit Breaker Figure 7 2.3. Machine Guard (Figure 8) A guard is installed to provide protection for the operator while maintaining proper visibility of the work area. -
Page 10: Receiving Inspection And Installation
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Hole for Customer Supplied Lift Ring Machine Shown with Optional Guard Precision Crimp Height Adjustment Mechanism Shown with Safety Interlock (Not on Machines -18, -22, -24 and -25) -
Page 11: Considerations Affecting Machine Placement
The machine will automatically detect the supply voltage and adjust the controller accordingly. NOTE Machines exported to Europe will be installed by Tyco Electronics service specialistss. These specialistss will verify NOTE that the electrical and pneumatic connections are correct. Both pneumatic and electrical connections must be installed in a way that provides a lockable isolation switch for hard-wired or direct piped machines. -
Page 12: Operation
4.2. SL Starlite Monitor Operation The AMP 3K / AMP 5K machine must have software version 3.2.1 or later to interface with the monitor. The software version can be checked by pressing and holding the foot switch when the green and yellow lights start to blink while the terminator is powering up. -
Page 13: Applicator Installation
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 c. Trigger/Trg. Edge = H –> L d. Sorting Output/Mode = Standard e. Sorting Output/Learn as = Good f. Sorting Output/Duration = 100ms A. Machine Power Up During power up, the machine looks to see if the monitor’s interface cable is connected. - Page 14 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Install the proper applicator in the quick–change mounting base as follows: CAUTION If the machine is equipped with a precision adjustment feature, make sure that the precision adjustment lever has been returned to the 0"...
- Page 15 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Guard Yellow Speed Control Open Icon Indicator Button Knob 3K/40 Green Indicator Machine Ready Icon Fault Icon Speed Control Icon Optional Batch Counter Guard Disabled Icon Jog Button Icon The green and yellow indicators on the top of the control panel indicate the machine status.
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Page 16: Setup
4.5. Mode Selection and Operation The three basic modes of operation for the AMP 3K and AMP 5K machines are: Full–Cycle, Jog, and Jog (With Guards Disabled). However, if during the machine cycle while crimping a terminal and wire, the motor stalls;... - Page 17 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Adjusting the Speed Control Knob The default speed of the machine, when jogging, is set to a minimum value which is not defined by the initial position of the speed control knob. Adjusting the speed upward enables jogging at speeds greater than the default in case greater speeds are required to complete a cycle.
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Page 18: Crimp Height Adjustment
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 The machine will exit the Jog (With Guards Disabled) Mode whenever the guards are closed or the power is turned “off.” D. Manual Cycling 1. Turn off the machine using the power switch on the back panel. -
Page 19: Machine Fault Codes
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 5. MACHINE FAULT CODES Figure 11 contains a list of fault codes commonly seen on the AMP 3K / AMP 5K Terminating Machines with SL Starlite CQM. INDICATOR LIGHTS... -
Page 20: Preventive Maintenance
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 6. PREVENTIVE MAINTENANCE Preventive maintenance will keep the machine in good working order and ensure maximum reliability and service from all of its components. DANGER To avoid personal injury, electrical and pneumatic power must be DISCONNECTED at the source prior to maintenance. -
Page 21: Adjustments
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Shown with Optional Precision Crimp Height Adjustment Mechanism Lubrication Points Lubrication Points Figure 12 7. ADJUSTMENTS The following adjustments are necessary to maintain the machine in operating condition, and to set up the machine after replacing parts. -
Page 22: Shut-Height Adjustment
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Shown with Optional Precision Crimp Height Adjustment Mechanism Shut Height Dimension (See the Table Below) SHUT HEIGHT GAGE MACHINE PART NUMBERS SHUT HEIGHT DIMENSIONS APPLICATOR TYPE PART NUMBER (1725950-[ ] and 1725900-[ ]) 135.79mm +/- 0.025mm... -
Page 23: Crimp Height Adjustment Using Preciaon Adjustment Mechanism (If Equipped)
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 If additional shims are required, they can be ordered using the numbers 1338618-1 (for 41.25mm stroke machines) or NOTE 1424680-1 (for 30mm stroke machines). b. Re–install the ram post adaptor. Insert both screws in the ram post adaptor and place the shims over the screws and onto the adaptor post. -
Page 24: Guard Insert Adjustment
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Adjustment Lever Reading (+" above 0.00 mm [.000 in.] setting) Read Full Step Read Half Step Read Full Step 0.051 mm 0.064 mm .051mm [.002 in.] [.0025 in.] [.002 in.]... - Page 25 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Tape Guard Insert Standard Guard Insert B" A" GUARD INSERT DIMENSION PART NUMBER DESCRIPTION 354529-2 Standard (Away from the Applicator) 7.80 [.307] 6.35 [.250] Standard (Close to the Applicator) 1-679532-0 6.22 [.245]...
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Page 26: Machine Options And Installation
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 218. MACHINE OPTIONS AND INSTALLATION The following machine options are available for the AMP 3K and AMP 5K machines: PART NUMBER DESCRIPTION PURPOSE 1424264-1 Work Light Kit (64111 Osram/Sylvania) - Page 27 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Detail A Socket Screws Provided with Work Light Kit Work Light Kit Work Light Kit (Option) Knockout Holes User Interface Assembly (Removed from Machine) Batch Counter Kit...
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Page 28: Installation Of Work Light Assembly Kit 1424264-1 (Inside The Guard)
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 8. Attach the light (as shown in Figure 16, Detail A) to the top of the user interface enclosure using the socket screws provided. 9. If equipped with Batch Counter Kit 1424267–1, insert the batch counter kit into the appropriate knockout opening until it snaps into place. - Page 29 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 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.
- Page 30 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Figure 20 3. Using a screwdriver, 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.”...
- Page 31 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 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 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Figure 24 After closing the guard door, the finished work light assembly should appear as shown in Figure 25. Figure 25 32 of 38 Rev E Tyco Electronics Corporation...
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Page 33: Installation Of Batch Counter Kit 1424267-1
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 8.3. Installation of Batch Counter Kit 1424267-1 DANGER To avoid personal injury, be sure to turn off" the machine, and disconnect it 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. - Page 34 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Detail A User Interface Assembly (Removed from Machine) Batch Counter Kit (Option) Knockout for Batch Red Reset Counter Kit Button Detail B Batch Counter Kit (Option) PC Board...
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Page 35: Installation Of Air Feed Kit 1424266-1
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 8.4. Installation of Air Feed Kit 1424266-1 DANGER To avoid personal injury, be sure to turn off" the machines, and disconnect them from the power source. 1. Remove the four bolts securing the rear controller panel to the frame. Refer to Figure 28. - Page 36 Worklight Assembly Auxilliary Air Connectiion Diode Valve Manual Lockout Override Manual Double Acting Detail of Footswitch Water Air Cylinder Entering Notch in Frame Drain Spring Return Air Cylinder Connection Bolt Securing SLE Starlite CQM Interface Cable Sheet Metal Plugs Into J2 and J10 Guard SLE Starlite CQM Interface Cable...
- Page 37 AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM 409-10083 Large End of Air Feed Cable Assembly 1424287-1 Four-Way Slide Valve Solenoid Valve Air Feed Bracket 1338977-1 Filter Figure 29 Standard Machine Base Plate Rear Stop Socket Head...
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Page 38: Installation Of Precision Adjustment Kit 1424208-1
8. Adjust the shut height and crimp height as described in Paragraphs 7.2 and 7.3. 9. TROUBLESHOOTING Contact the Tooling Assistance Center at 1–800–722–1111. 10. REVISION SUMMARY Since the previous release of this manual, the hyphens in AMP 3K and AMP 5K were removed. 38 of 38 Rev E Tyco Electronics Corporation...
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