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Tri-Star TAC 17X Operation & Maintenance Manual

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OPERATION &
MAINTENANCE
MANUAL
TRI-STAR TECHNOLOGIES
2201 ROSECRANS AVE
EL SEGUNDO, CA 90245



WWW.TRI-STAR-TECHNOLOGIES.COM


TAC
17X
A
C
UTOMATIC
ONTACT
October 2018
Rev. 2.0
C
RIMPER
Page 1

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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 October 2018 Page 1 Rev. 2.0...
  • 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.

  • 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 NTRODUCTION Section 1 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-17X model. Figure 1-1 is a photograph of a TAC-17X as viewed from the front (operator) side. This photograph gives a view of the cabinet housing, the feeder-bowls, the escapement systems, and the crimping system.
  • Page 5 Figure 1-1: TAC-17X, 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 location on the contact, and depth of crimp, are entirely TAC dependent. The PERATOR operator only need select (if applicable) the proper "G" dimension setting and initiate TECHNIQUE the crimp cycle by inserting the conductor into the contact and depressing it by applying slight pressure.

  • 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 Primary air input at rear of TAC 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 AC On/Off Figure 2-2: AC Hook-Ups Each contact requires its own unique tool set. The shouldered tool set includes transfer tip, track assembly and escapement spacer.
  • Page 12 Escapement Spacer Track Assembly Figure 2-3: Shouldered Tool Set Track Assembly Figure 2-4 Shouldered-less Tool Set Page 12...

  • 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 Step 9. Record the GO NO-GO dimensions. Step 10. Verify that these dimensions comply with specifications. Step 11. Install the crimp cylinder arbor cover plate removed in Step 4 and 5. Step 12. Connect the air supply to the sleeve valve. Step 13.
  • Page 16 Crimp Inspection Points Improper Crimps Figure 3-3: Crimped Samples Page 16...

  • 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 Step 3. Depress Shoulder-less or Shouldered switch to load first contact Step 4. Open the funnel and observe if a contact is present. If contact is present, let the funnel close and proceed to Step 5. If no contact is present, repeat Step 3 Step 5.
  • 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.
  • Page 20 
 In this scenario, we will be switching from Bowl 1 (shouldered) to Bowl 2 (shoulder- WITCHING less) BOWLS Step 1. Depress Reset button. Observe shuttle mechanism movement to the left. If required, the drop tube can now be exchanged. Step 2.

  • Page 21: 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. Additionally, an HMI display has been incorporated to provide easier and a more intuitive interface to the TAC.
  • Page 22 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 23 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 24 & 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 25 Figure 6-1: TAC 17X Pneumatic Control Panel Page 25...
  • Page 26 Figure 6-2: TAC 17X Components (Right View) Page 26...
  • Page 27 PLC Controller Switching Power Supply Stepping Motor Controller HMI Display Figure 6-3: TAC 17X Components (Left View) Page 27...
  • Page 28 "bouncing" and not setting against the escapement system firmly. Figure 6-4: TAC 17X Shouldered Bowl Contacts will not feed from the track assembly through the drop tube to the transfer tip ESCAPEMENT unless the escapement system is aligned and secured properly.
  • Page 29 90 degrees counter-clockwise and drop. This is because the wire barrel end is lighter than hooded end. If contact enters hooded end first, the opposite action will occur. Part will rotate 90 degrees clockwise and drop. Figure 6-6: TAC 17X Shoulder-less Track Assembly Page 29...
  • Page 30 If aforementioned contact orientation is not occurring, slight adjustments to feeder bowl amplitude via the HMI panel may be required. Jamming or mis-feeding can also occur from damaged (bent) contacts. If this occurs, turn off feeder bowl via HMI panel, and clear damaged contact(s).
  • Page 31 To better help facilitate diagnosing system malfunctions, the TAC system has sensor ENSOR status display in the HMI control panel. To view sensor statuses, press Sensor switch STATUS from main display. Below is view of Sensor Status Panel Click Main to return to Main Screen. Page 31...
  • Page 32 Sensor switch status are indicated by color intensity of indicator light. Dark color indicates sensor is Not Active Page 32...
  • Page 33 Transfer Tip Sensor switch status indicates if contact is properly nested in transfer tip. If no contact is present, indicator will be dark blue. If contact is present, indicator will be light blue. Air Sensor Switch indicates if system air is on (light blue) or off (dark blue) G-Stop Sensor switch status indicates if G-Stop sensor switch is...
  • Page 34 Home Sensor switch status indicates when Shoulder-less shuttle is in Home position (far left position). If in Home position, indicator will be light green. Transfer Tip Sensor switch indicates which type transfer tip is loaded. Light green indicates a shoulder-less transfer tip is loaded, dark green indicates a shouldered transfer tip is loaded.
  • Page 35 Shuttle Adjustment: In the unlikely event that you may need to adjust HUTTLE shuttle position for home and/or contact drop position, follow below DJUSTMENT instructions. In order to gain access to shuttle adjustment screen, you must first login by depressing “Login” button. Default Login:
...
  • Page 36 Shuttle Adjustment: Enter appropriate distances in 1mm increments in either of the two adjustment boxes. When adjustments are complete, press Main to return to Home Screen Page 36...
  • Page 37 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 38 Page 38...
  • Page 39 Hose Clamp Carefully Remove Page 39...
  • Page 40 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 41 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 42 Page 42...
  • Page 43 Step 21. Crimp the conductor. Step 22. Inspect the crimp per required specifications. Step 23. Repeat Steps 19 through 22 for each conductor wire gauge to obtain the necessary specimens; inspect per established procedure. Step 24. After all specimens have been produced, set the power on-off switch to off and open the sleeve valve.

  • Page 44: 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 45 (2.1) (2.1) V1( 0-5V) (2.1) (2.1) V2( 0-5V) (2.1) (2.1) 101CH (2.1) (2.1) (2.1) (2.1) NEXT PAGE DIAGRAM VERSION DATE DRAWN BY Gustavo Morejon 09/07/2018 PAGE CRIMPER MACHINE TYPE : TOTAL PAGES Figure 7-1: TAC 17X Electrical Diagram Page 45...
  • Page 46 (1.0) Prox Sen. (1.0) BOWL CONTROLLER (1.0) Sensor Amplifier sens. (1.9) (1.0) BOWL CONTROLLER (1.9) NEXT PAGE DIAGRAM VERSION DATE DRAWN BY Gustavo Morejon 09/07/2018 PAGE CRIMPER MACHINE TYPE : TOTAL PAGES Figure 7-2: TAC 17X Electrical Diagram Page 46...
  • Page 47 Figure 7-3: TAC 17X Pneumatic Diagram Page 47...
  • Page 48 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...