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- Page 1 OPERATION & MAINTENANCE MANUAL UTOMATIC ONTACT RIMPER TRI-STAR TECHNOLOGIES 2201 ROSECRANS AVE EL SEGUNDO, CA 90245 WWW.TRI-STAR-TECHNOLOGIES.COM September 2018 Page 1 Rev. 1.0...
- Page 2 N O T I C E This is an OPERATION and MAINTENANCE MANUAL. Its purpose is to assist users in the initial set-up, verification and operation of the Vibratory Feed Crimper. It is not intended to be used as the guide to perform major adjustments or to effect major repairs.
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Page 3: Table Of Contents
ABLE OF ONTENTS Section Title Introduction Initial Set-up Crimp Verification Operating Procedures Theory of Operation Maintenance and Troubleshooting Parts List, Electrical/Pneumatic Diagrams Page 3... - Page 4 The Tri-Star Technologies TAC Series of Vibratory Feed Bowl Crimpers are devices which automatically crimp loose electrical contacts to electrical conductors. This operation manual is for the TAC-10X model. Figure 1-1 is a photograph of a TAC-10X as viewed from the front (operator) side. This photograph gives a view of the cabinet housing, the feeder-bowl, the escapement system, and the crimping system.
- Page 5 Figure 1-1: TAC-10X, Front View Page 5...
- Page 6 OPERATION All functions of the TAC are initiated, terminated, controlled and operated both pneumatically and electrically. After the TAC has been set up properly, only two functions are operator- adjustable: The amplitude of the feeder-bowl vibrations and, if a feature of this particular TAC, the selected "G"...
- Page 7 Figure 1-2: Wire Insertion Through Funnel Page 7...
- Page 8 Crimp rates of 1800 crimps per hour have been attained. TAC-10X TAC-10X most shouldered and...
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Page 9: Introduction
NITIAL Section 2 Although all TAC's are ruggedly constructed, adequate precautions must be observed NTRODUCTION and all instructions followed to prevent damage to the device during the Initial Set-up Lift and transport the TAC using only the baseplate Do not lift, pull shove or jostle the AUTION feeder bowl, the crimp cylinder or any component mounted on the baseplate. - Page 10 Page 10 Figure 2-1: Pneumatic Hook-Ups...
- Page 11 Connect the TAC power cord to a grounded 115 VAC, 60 Hz, 5A power source. LECTRICAL (European 220 VAC, 5O Hz, 5A). Refer to Figure 2-2 below NSTALLATION AC Input Figure 2-2: AC Hook-Ups Each contact requires its own unique tool set. The shoulder-less tool set includes track and shuttle mechanism.
- Page 12 Figure 2-3: Shoulder-less Track Assembly Track Assembly Figure 2-4 Shoulder-less Track Assembly Page 12...
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Page 13: Crimp Verification
RIMP VERIFICATION Section 3 Initial and periodic crimp verifications must be made in order to be certain a given TAC NTRODUCTION is crimping properly. Once a TAC is set-up and crimp verification accomplished, the device will normally complete hundreds of thousands of acceptable crimps before indenter adjustment or replacement is necessary. - Page 14 Step 5. Remove the crimp cylinder arbor cover plate and the funnel cover plate. Step 6. Refer to Table 3-1. If the TAC has a operator-adjustable "G" dimension control, perform Steps 6 through 9 for the fixed "G" dimension. TABLE 3-1. GO NO-GO DIMENSIONS M22520/7-01 Contact ...
- Page 15 After all specimens have been produced, set the power on off switch to off and open the sleeve valve. Step 24. If crimps meet all established parameters, certify the TAC-10X for production use and establish a periodic verification schedule. ...
- Page 16 Crimp Inspection Points Improper Crimps Figure 3-3: Crimped Samples Page 16...
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Page 17: Operating Procedures
PERATING ROCEDURES Section 4 The TAC series crimpers are simple to operate. No previous experience with crimpers NTRODUCTION of any kind is required; however, operators need to exercise reasonable care when operating the TAC and should be familiar with acceptable crimp criteria. No adjustments to the equipment should be made unless specific procedures in this manual are followed, and then only when authorized. - Page 18 Contacts loading in feed tube are controlled by Feed Tube Sensor. If feed tube is full, the sensor detects, and shuts off feeder bowl. As feeder tube empties, sensor detects and feeder bowl is turned back on. Step 3. Depress First Part switch to load first contact Step 4.
- Page 19 Step 6. Carefully and smoothly insert a conductor into the funnel, being careful all conductor strands enter the funnel. NOTE Conductor strands do not have to be twisted together, but they do have to enter the funnel parallel to one another. Step 7.
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Page 20: Theory Of Operation
HEORY OF OPERATION Section 5 The TAC Crimper has been extensively redesigned. The redesign results in additional NTRODUCTION logic functions being added to prevent possible malfunctions, while at the same time reducing the overall number of components. All logic, control and operating functions of the TAC Crimper are performed pneumatically, electrically or both. - Page 21 Reset occurs any time the operator-controlled sleeve valve is initially closed, or NITIAL opened and then closed. / TURN RESET Upon closing the sleeve valve, air pressure is supplied to the TAC as defined below. When the sleeve value is closed, the TAC cycles to insure that all cylinders are in the proper position: -Crimp Cylinder is retracted: V-1 OFF -Transfer Arm is extended (forward): V-2 OFF...
- Page 22 When the Transfer Arm reaches the vertical position, a limit switch (LS- is engaged and the following events occur: -Limit Switch sensor (S-2) is turned on -High pressure is supplied to Slide Cylinder, allowing it to stay in the full extended position.
- Page 23 & AINTENANCE TROUBLESHOOTING Section 6 The primary purpose of the Maintenance and Troubleshooting section of this manual is NTRODUCTION to permit the user to perform required preventive maintenance, perform minor adjustments and to correct minor malfunctions caused by incorrect/unacceptable contacts. Detailed instructions for adjusting and changing indenters are also given.
- Page 24 Figure 6-1: TAC 10X Pneumatic Control Panel Page 24...
- Page 25 Figure 6-2: TAC 10X Components (Right View) Page 25...
- Page 26 PLC Controller Switching Power Supply Figure 6-3: TAC 10X Components (Left View) Page 26...
- Page 27 Contacts in the shoulder-less bowl are fed in a horizontal position. See figure 6-5 & 6-6 - HOULDER LESS ONTACT TRACK FEED Figure 6-5: TAC 10X Shoulder-less Bowl Contacts enter the shoulder-less track, either wire barrel or hooded end first. If they enter wire barrel first, they will rotate 90 degrees counter-clockwise and drop.
- Page 28 If aforementioned contact orientation is not occurring, slight adjustments to feeder bowl amplitude may be required. Jamming or mis-feeding can also occur from damaged (bent) contacts. If this occurs, turn off feeder bowl, and clear damaged contact(s). The feeder tube sensor monitors contacts in feeder tube. When feeder tube is full, EEDER sensor detects and shuts off feeder bowl.
- Page 29 lndenters are adjustable and replaceable. The procedure described herein is for the NDENTER physical replacement of the indenters. The adjustment procedure for both new and REPLACEMENT already installed indenters is given in paragraph 6-9. ·- Upon completion of the installation and adjustment of new indenters, perform a crimp verification (Section 3).
- Page 30 Page 30...
- Page 31 Hose Clamp Carefully Remove Page 31...
- Page 32 Step 16. Rotate the indenter plate, insert the cam arm into the arbor shaft and set the plate onto the housing. NOTE: The arbor shaft can be rotated slightly to facilitate cam arm insertion. Step 17. Proceed to Paragraph 6-9, Step 4. The adjustment of indenters should be performed whenever existing indenters are NDENTER slightly worn and "G"...
- Page 33 Step 5. Using only hand pressure, extend the arbor as far to the left as it will Step 6. Using appropriate GO NO-GO gauges, open the funnel and insert gauges into the indenters to determine the "G" dimensions. to correspond to the largest wire size. NOTE: Be sure to use gauges corresponding to proper wire gauge and contact gauge.
- Page 34 Page 34...
- Page 35 After all specimens have been produced, set the power on-off switch to off and open the sleeve valve. Step 25. If crimps meet all established parameters, certify the TAC-10X for production use, and establish a periodic verification schedule. Page 35...
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Page 36: Parts List, Electrical/Pneumatic
ARTS LECTRICAL NEUMATIC IAGRAMS Section 7 ESIGNATION ESCRIPTION UMBER TAC-F-4200-15 N-1 Slide Sensor Switch Limit Sensor Switch TAC-F-4200-60 First Part Sensor Switch TAC-F-4200-60 G-stop Sensor Switch TAC-F-4200-15 Air ON/OFF Sensor Switch TACF-4200-60 Transfer Tip Sensor Switch TAC-F-4200-X30 Crimp Cylinder Valve TAC-A-110-4EI Transfer Arm Valve TAC-A-110-4EI... - Page 37 Transfer Tip G-Stop CN1F CN1M First Part 24VDC POWER SUPPLY 0VDC 24VDC Limit Switch Slide sensor On/Off Sensor 100CH Transfer Arm Cyl 110VAC Prox Sen. Slide Cyl sens. Crimp Cyl NEXT PAGE DRAWN BY DIAGRAM VERSION DATE Gustavo Morejon PAGE CRIMPER MACHINE TYPE : TOTAL PAGES...
- Page 38 Figure 7-3: TAC 10X Pneumatic Diagram Page 38...
- Page 39 OR MORE INFORMATION www.tri-star-technologies.com ph: 310.536.0444 fax: 310.526.9322 TRI-STAR TECHNOLOGIES 2201 ROSECRANS AVE EL SEGUNDO, CA 90245 WWW.TRI-STAR-TECHNOLOGIES.COM...
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