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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.
Crimp Quality Monitor 2031940-2 (For Use
with AMPLIVAR* Product Terminator IIIA
Assembly 679453-[ ] and 679457-[ ])
SAFETY PRECAUTIONS
READ THIS FIRST !
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1.1.
1.2.
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1.3.
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2.1.
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2.2.
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2.3.
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3.1.
3.2.
4.1.
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4.2.
4.3.
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4.4.
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4.5.
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4.6.
4.7.
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4.8.
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4.9.
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5.1.
5.2.
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5.3.
5.4.
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TOOLING ASSISTANCE CENTER 1-800-722-1111
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This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
Customer Manual
409-10092
08 SEP 08 Rev A
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LOC B
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Summary of Contents for Tyco Electronics 2031940–2
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Page 1: Table Of Contents
For latest revision and Regional Customer Service, All International Rights Reserved visit our website at TE logo and Tyco Electronics are trademarks. www.tycoelectronics.com LOC B *Trademark. Other products, logos, and company names used are the property of their respective owners. - Page 2 05. Equipment number (and serial number if applicable) 06. Product part number (and serial number if applicable) 07. Urgency of request 08. Nature of problem 09. Description of inoperative component(s) 10. Additional information/comments that may be helpful 2 of 86 Rev A Tyco Electronics Corporation...
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Page 3: Introduction
The sensors are built into the AMPLIVAR Product Terminator (APT) IIIA. The Crimp Quality Monitor notifies the operator with visual cues when faulty crimps occur. See Figure 1 for front and back panel views of the CQM. of 86 Tyco Electronics Corporation... -
Page 4: The Manual
However, damage may occur during shipment. Remove the outer bands from the box and carefully remove the CQM from the box. Inspect the CQM for damage. If damage is evident, file a claim against the carrier and notify Tyco Electronics immediately. Save the shipping carton/box and the entire documentation package shipped with the CQM. -
Page 5: Installation
0.009 inches.The operator’s name is Jordo. To complete the job, 4000 good motors must be made in batches of 25. 1. From the Main Menu screen, touch the “Job Setup” button to enter the Job Setup screen and establish the job settings. of 86 Tyco Electronics Corporation... - Page 6 If the values are incorrect or have not been entered, touch the order number (0–5) buttons to display the screens to enter the position sensor values. 6 of 86 Rev A Tyco Electronics Corporation...
- Page 7 The Batch/Job Complete screen will be displayed each time the batch count reaches 25 and when the job count equals 4000. Touch the button on this screen to continue production. Rev A 7 of 86 Tyco Electronics Corporation...
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Page 8: Crimp Analysis Results
The green light and the red light are turned on. See NOTE 3 (below) The operator must visually inspect the crimp. If it satisfies the inspection criteria, the operator should touch the “Accept as Good” button on the Inspect Crimp screen. See NOTE 1 (below). 8 of 86 Rev A Tyco Electronics Corporation... - Page 9 The red and green crimp status lights are connected by a cable to the I/O port on the back of the CQM. The lights should be located in a position that allows ease of observation while the machine is operating. Rev A 9 of 86 Tyco Electronics Corporation...
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Page 10: Crimp Quality Monitor Menus And Screens
If a system password has been created, the password must be entered on the Enter Password screen (see Paragraph 4.11) before the Diagnostics Menu screen is displayed. Touch the button to display the Power Down screen. Refer to Paragraph 4.9. 10 of 86 Rev A Tyco Electronics Corporation... -
Page 11: Production
Touch the “Batch Count/Size” button or the ”Job Count/Size button” to display the Counts screen. See Paragraph 4.1,A. Touch the “Reset Kit” button to display the Reset Kit screen. See Paragraph 4.1,A. Touch the “CQM” button to display the Production/CQM screen. See Paragraph 4.1,B. Rev A 11 of 86 Tyco Electronics Corporation... - Page 12 This screen displays parts in the kit currently selected for the job. Touch a part name to highlight it. Touch the button to display the highlighted part on the Part Viewer screen. Touch the button to return to the Production screen. of 86 Tyco Electronics Corporation...
- Page 13 Touch the “Add to Batch and Job Count” button to display the Add to Batch and Job Count screen. See Paragraph 4.1, D. Touch the button to save any changes and return to the Production screen. Touch the button to return to the Production screen. of 86 Tyco Electronics Corporation...
- Page 14 Touch the “Yes” button to reset the kit and return to the previous screen. The incomplete kit count for the job and the current batch will be incremented by one. Touch the “No” button to return to the previous screen without resetting the kit. of 86 Tyco Electronics Corporation...
- Page 15 Touch the “Sample” button display the Control Limit screen. See Paragraph 4.1,K. Touch the “Reset Kit” button to display the Reset Kit screen. See Paragraph 4.1,E. Touch the button to return to the Production screen. of 86 Tyco Electronics Corporation...
- Page 16 Force vs Position graph. Refer to Paragraph 4.1,H. Touch the button to display the Crimp Height Graph screen.. Touch the button to return to the Production/CQM screen or Manual Operation screen. of 86 Tyco Electronics Corporation...
- Page 17 The screens display the force and/or position sensor data collected during the last crimp. Touch the button to display the Force vs Position graph. Touch the button to display the Force vs Time graph. Touch the button to display the Position vs Time graph. of 86 Tyco Electronics Corporation...
- Page 18 The mean value and standard deviation for the work index are recalculated after every good crimp by including the crimp’s work index in the history. Touch the button to return to the Production/CQM screen or Manual Operation screen. of 86 Tyco Electronics Corporation...
- Page 19 The mean value and standard deviation for the peak force are recalculated after every good crimp by including the crimp’s peak force in the history. Touch the button to return to the Production/CQM screen or Manual Operation screen. of 86 Tyco Electronics Corporation...
- Page 20 CQM. The new control limit tolerance is equal to three times the standard deviation of the sample crimp heights. Touch the button to return to the Production/CQM screen or Manual Operation screen. of 86 Tyco Electronics Corporation...
- Page 21 If returning to the Production or Production/CQM screen the CQM will advance to the next part in the kit sequence. The work index and peak force values that were calculated are added to the collection of values that will be used to establish the ranges for good crimps. of 86 Tyco Electronics Corporation...
- Page 22 The inspect crimp count for the job and the current batch will be incremented by one. Touch the “Clear Limits” button to clear the existing limits and reset the learning process for good work index and peak force values. of 86 Tyco Electronics Corporation...
- Page 23 The “Repeat Crimp,” “Next Part,” and “Reset Kit” buttons are shown on the screen when the crimp occurs while the Production or Production/CQM screens are displayed. button is shown when the crimp occurs while the Manual Operation screen is displayed. of 86 Tyco Electronics Corporation...
- Page 24 The control limit for the sample is equal to the control limit for the part divided by the square root of the sample size. The control count and sample size are process control settings. Refer to the Process Control screen, in Paragraph 4.6,A. of 86 Tyco Electronics Corporation...
- Page 25 Touch the “Reset Kit” button to return to the Production or Production/CQM screen and reset to the first part in the kit. The incomplete kit count will be incremented by one. of 86 Tyco Electronics Corporation...
- Page 26 The Batch/Job Complete screen is displayed when the batch count is equal to the batch size, or the job count is equal to the job size. Touch the button to return to the Production screen or Production/CQM screen. of 86 Tyco Electronics Corporation...
- Page 27 Touch the “Sample” button to display the Control Limit screen. See Paragraph 4.1, K. Touch the “Select Part” button to display the Select Part To Run screen. See Paragraph 4.1, S. Touch the button to return to the Production screen. of 86 Tyco Electronics Corporation...
- Page 28 Touch the name of the part to be selected as the current part. The name touched will be highlighted. Touch the button to select the highlighted part as the current part and return to the Manual Operation screen. Touch the button to return to the Manual Operation screen. of 86 Tyco Electronics Corporation...
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Page 29: Crimp Height Calibration
Touch the “Calibrate Kit” button to display the Calibrate Kit screen. See Paragraph 4.2, A. Touch the “Calibrate Part” button to display the Calibrate Part screen to calibrate the highlighted part. See Paragraph 4.2, E. Touch the button to return to the Main Menu screen. Rev A 29 of 86 Tyco Electronics Corporation... - Page 30 Force vs Position screen. Refer to Paragraph 4.1,D. Touch the button to save any changes made to the offset or calibration status and return to the Crimp Height Calibration screen. Touch the button to return to the Crimp Height Calibration screen. of 86 Tyco Electronics Corporation...
- Page 31 S If calibrating a part, the Enter Hand Measured Crimp Height screen (Paragraph 4.2,F) is displayed. Touch the “NO” button to reject the crimp for calibration and return to the Calibrate Kit or Calibrate Part screen. of 86 Tyco Electronics Corporation...
- Page 32 If the CQM determines that the data cannot be used for crimp height calibration, the Invalid Crimp Detected screen is displayed. Touch the button to return to the Calibrate Kit or Calibrate Part screen. of 86 Tyco Electronics Corporation...
- Page 33 Touch the “Enter” button to complete the entry. The Calibrate Kit screen is displayed after the crimp height is entered for the last part in the kit. Touch the button to discard any changes and return to the Calibrate Kit screen. of 86 Tyco Electronics Corporation...
- Page 34 Touch the button to save any changes made to the adjust motor offset or calibration status and return to the Crimp Height Calibration screen. Touch the to to return to the Crimp Height Calibration screen. of 86 Tyco Electronics Corporation...
- Page 35 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Calibrate Part screen. Touch the button to return to the Calibrate Part screen. of 86 Tyco Electronics Corporation...
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Page 36: Job Setup
Touch the “Batch Size” button to display the Enter Batch Size screen. Refer to Paragraph 4.3, G. Touch the button to save any changes and return to the Main Menu screen. Touch the button to return to the Main Menu screen. 36 of 86 Rev A Tyco Electronics Corporation... - Page 37 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Job Setup screen. Touch the button to return to the Job Setup screen. of 86 Tyco Electronics Corporation...
- Page 38 Enter New Operator Name screen. Refer to Paragraph 4.3,C. Touch the button to display the Delete Operator screen. Refer to Paragraph 4.3,D. Touch the button to return to the Job Setup screen. of 86 Tyco Electronics Corporation...
- Page 39 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters Touch the “Enter” button to complete the entry and return to the Operators screen. Touch the button to return to the Operators screen. of 86 Tyco Electronics Corporation...
- Page 40 Operators screen will result in the Delete Operator screen. “Yes” Touch the button to delete the operator name and return to the Operators screen. ”No” Touch the button to abort the deletion and return to the Operators screen. of 86 Tyco Electronics Corporation...
- Page 41 Delete Kit screen in order to delete the highlighted kit. The kit currently selected for the job cannot be deleted. Refer to Paragraph 4.4,E. Touch the button to return to the Job Setup screen. of 86 Tyco Electronics Corporation...
- Page 42 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Job Setup screen. Touch the button to return to the Job Setup screen. of 86 Tyco Electronics Corporation...
- Page 43 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Job Setup screen. Touch the button to return to the Job Setup screen. of 86 Tyco Electronics Corporation...
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Page 44: Kits
Delete Kit screen to delete the highlighted kit. The kit currently selected for the job cannot be deleted. Refer to Paragraph 4.4,E. Touch the button to return to the Main Menu screen. 44 of 86 Rev A Tyco Electronics Corporation... - Page 45 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and display the Kit Editor screen. Refer to Paragraph 4.4,B. Touch the to return to the Kits screen. of 86 Tyco Electronics Corporation...
- Page 46 Touch the button to remove the highlighted part from the kit. Touch the button to save any changes and return to the Kits screen. Touch the button to return to the Kits screen. of 86 Tyco Electronics Corporation...
- Page 47 Delete Part screen in order to delete the highlighted part. The part currently selected for the job cannot be deleted. Refer to Paragraph 4.5,J. Touch the button to return to the Kit Editor screen. of 86 Tyco Electronics Corporation...
- Page 48 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Kits screen. Touch the to return to the Kits screen. of 86 Tyco Electronics Corporation...
- Page 49 Touch the “Yes” button to delete the kit name and return to the Kits screen. Only the kit name is deleted. The part names used in the kit are not deleted. Touch the “No” button to abort the deletion and return to the Kits screen of 86 Tyco Electronics Corporation...
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Page 50: Parts
Delete Part screen to delete the highlighted part. Parts currently used in a kit cannot be deleted. Refer to Paragraph 4.5,I. Touch the button to return to the Main Menu screen. 50 of 86 Rev A Tyco Electronics Corporation... - Page 51 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and display the Part Editor screen. Refer to Paragraph 4.5,B. Touch the to return to the Parts screen. of 86 Tyco Electronics Corporation...
- Page 52 APT IIIA Machine, is cycled during the machine cycle when the part is the “current part.” Touch the button to save any changes and return to the Parts screen. Touch the button to return to the Parts screen. of 86 Tyco Electronics Corporation...
- Page 53 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Part Editor screen. Touch the button to return to Part Editor screen. of 86 Tyco Electronics Corporation...
- Page 54 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Part Editor screen. Touch the button to return to Part Editor screen. of 86 Tyco Electronics Corporation...
- Page 55 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Part Editor screen. Touch the button to return to Part Editor screen. of 86 Tyco Electronics Corporation...
- Page 56 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Part Editor screen. Touch the button to return to Part Editor screen. of 86 Tyco Electronics Corporation...
- Page 57 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Part Editor screen. Touch the button to return to Part Editor screen. of 86 Tyco Electronics Corporation...
- Page 58 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Part Editor screen. Touch the button to return to Part Editor screen. of 86 Tyco Electronics Corporation...
- Page 59 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Parts screen. Touch the to return to the Parts screen. of 86 Tyco Electronics Corporation...
- Page 60 Parts screen will result in the Delete Part screen. Touch the “Yes” button to delete the part name and return to the Parts screen. Touch the “No” button to abort the deletion and return to the Parts screen of 86 Tyco Electronics Corporation...
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Page 61: System Settings Menu
Touch the “Software Setup” button to display the Software Setup screen. Refer to Paragraph 4.6, N. Touch the button or the button to change the Screen Saver delay time. Touch the button to return to the Main Menu screen. Rev A 61 of 86 Tyco Electronics Corporation... - Page 62 Touch the “Defaults” button to set the sample size to “1,” the learn count to “5,” and the control count to “3.” Touch the button to save any changes and return to the System Settings Menu screen. Touch the button to return to the System Settings Menu screen. of 86 Tyco Electronics Corporation...
- Page 63 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Process Control screen. Touch the button to return to the Process Control screen. of 86 Tyco Electronics Corporation...
- Page 64 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Process Control screen. Touch the button to return to the Process Control screen. of 86 Tyco Electronics Corporation...
- Page 65 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Process Control screen. Touch the button to return to the Process Control screen. of 86 Tyco Electronics Corporation...
- Page 66 Touching the “Language / Units” button on the System Settings Menu screen will result in the Language / Units screen. The language selection specifies what language is used for the screens. The units selection specifies what units are used when displaying crimp heights and related values. of 86 Tyco Electronics Corporation...
- Page 67 Touch the current units selection to display a list of unit choices. Touch the desired units from the list. Touch the button to save any changes and return to the System Settings Menu screen. Touch the button to return to the System Settings Menu screen. Rev A 67 of 86 Tyco Electronics Corporation...
- Page 68 A/D calibration procedure and follow the instructions to complete the procedure. Touch the button to save any changes made and return to the System Settings Menu screen. Touch the button to return to the System Settings Menu screen. of 86 Tyco Electronics Corporation...
- Page 69 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Position Sensor screen. Touch the button to return to the Position Sensor screen. of 86 Tyco Electronics Corporation...
- Page 70 Touch the “Back” button to delete the last character entered, the character preceding the cursor, or the highlighted characters. Touch the “Enter” button to complete the entry and return to the Position Sensor screen. Touch the button to return to the Position Sensor screen. of 86 Tyco Electronics Corporation...
- Page 71 Touch the “Restore Parts/Kits” button to display the Restore Settings/Database screen. Refer to Paragraph 4.6, K. Touch the “Upgrade Firmware” button to display the Select a Firmware File screen. Refer to Paragraph 4.6, L. Touch the button to return to the System Settings Menu screen. of 86 Tyco Electronics Corporation...
- Page 72 Touch the button on the message screen to return to the USB screen. Touch the button to return to the USB screen. of 86 Tyco Electronics Corporation...
- Page 73 Touch the various option buttons to set the restore option. Touch the “Restore Selected Database” button to complete the restore operation. Touch the button to return to the USB screen. of 86 Tyco Electronics Corporation...
- Page 74 This screen allows the user to download the latest version of the CQM software from a USB drive to the CQM. Touch the file name to select it. Then touch the “Open” button to begin the firmware upgrade. Touch the “Cancel” button to abort the upgrade and return to the USB screen. of 86 Tyco Electronics Corporation...
- Page 75 Touch the “Enter” button to complete the entry the second time the new password is entered and return to the System Settings Menu screen. Touch the button to return to the System Settings Menu screen. of 86 Tyco Electronics Corporation...
- Page 76 APTCQM for proper operation. Touch the current software setup selection to display the drop down list of choices. Touch the button to save the selection. Touch the button to return to the System Setting Menu screen. of 86 Tyco Electronics Corporation...
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Page 77: Statistics
The Statistics screen is used to view current job and batch statistics. Touch the button to send the statistics to a printer connected to one of the monitor’s USB ports. Touch the button to return to the Main Menu screen. Rev A 77 of 86 Tyco Electronics Corporation... -
Page 78: Diagnostics Menu
Touch the button to return to the Main Menu screen. Diagnostic Menu Main Menu NOTE The Crimp Quality Monitor's outputs are turned off" when the screen is closed and the screen is displayed. 78 of 86 Rev A Tyco Electronics Corporation... - Page 79 Touching the “Sensors” button on the Diagnostics Menu screen will result in the Sensors screen. Touch the button to display the CQM Sensors –– Help screen. Touch the button to return to the Diagnostics Menu screen. of 86 Tyco Electronics Corporation...
- Page 80 During the homing procedure the monitor checks for proper motor, encoder, and home switch operation. Touch the button to display the Adjust Motor –– Help screen. Touch the button to return to the Diagnostics Menu screen. of 86 Tyco Electronics Corporation...
- Page 81 “on.” Touch buttons 1 through 6 to toggle the corresponding output “off” and “on.” Touch the button to display the CQM I/O –– HELP screen. Touch the button to return to the Diagnostics Menu screen. of 86 Tyco Electronics Corporation...
- Page 82 Touching the “Printer” button on the Diagnostics Menu screen will result in the Printer Test screen. Touch the “Test” button to send data to the printer connected to the USB port. Touch the button to return to the Diagnostics Menu screen. of 86 Tyco Electronics Corporation...
- Page 83 RAM battery on the CQM Analog –Input/Output board is bad and should be replaced with a new 3032 3V coin cell battery. Touch the button to return to the Diagnostics Menu screen. of 86 Tyco Electronics Corporation...
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Page 84: Power Down
This screens display the version of CQM software being run and additional details regarding that particular version. When contacting the customer hotline regarding a CQM issue, provide the software version. Touch the button to return to the Main Menu screen. 84 of 86 Rev A Tyco Electronics Corporation... -
Page 85: Enter Passsword Screen
Touch the entry field to position the cursor or highlight characters. Touch the Q/A button to select the optional button configuration. Touch the “Clear” button to delete all the characters that have been entered. Rev A 85 of 86 Tyco Electronics Corporation... -
Page 86: Crimp Quality Monitor Maintenance
3. Make sure that the cooling vents on the back and side panels are not blocked. 5.4. Evaluation and Repair Crimp Quality Monitors can be returned to Tyco Electronics for evaluation and repair. Call the Tyco Electronics Tooling Assistance Center at 1–800–722–1111 for instructions.
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