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Tri-Star PORTA TAC E Series Operation And Maintenance Manual

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OPERATION
AND
MAINTENANCE MANUAL
PORTA TAC
SERIES E
MAGAZINE FEED CRIMPER
TRI-STAR TECHNOLOLGIES
2201 ROSECRANS AVE. EL SEGUNDO, CA 90245
U.S.A.
www.tri-star-technologies.com
tel.310-536-0444
fax. 310-536-9322
SERIAL NUMBER:____________________
VERSION 1.4
1

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  • Page 1 OPERATION MAINTENANCE MANUAL PORTA TAC SERIES E MAGAZINE FEED CRIMPER TRI-STAR TECHNOLOLGIES 2201 ROSECRANS AVE. EL SEGUNDO, CA 90245 U.S.A. www.tri-star-technologies.com tel.310-536-0444 fax. 310-536-9322 SERIAL NUMBER:____________________ VERSION 1.4...
  • Page 2 NOTICE This is an OPERATION and MAINTENANCE MANUAL. Its purpose is to assist users in the initial set-up, verification and operation of the PORTA-TAC Crimper. It is not intended to be used as the guide to per form major: adjustments or to effect major repairs. Consult the factory if adjustments or repairs other than those described herein are necessary.
  • Page 3 INDEX SECTION I. INTRODUCTION Paragraph DESCRIPTION OPERATION OPERATOR TECHNIQUE PORTA-TAC CRIMPER SPECIFICATIONS SECTION II. THEORY OF OPERATION Paragraph INTRODUCTION PNEUMATIC SUPPLY INITIAL TURN-ON/RESET NORMAL OPERATION SECTION III INITIAL SET-UP Paragraph 3 –1 INTRODUCTION UNPACKING DROP TUBE AND TRANDFER TIP PNEUMATIC HOOK-UP 3-4.5 ELECTRICAL HOOK-UP INITIAL CHECK-OUT FUNCTIONAL CHECK-OUT...
  • Page 4 SECTION V OPERATING PROCEDURES Paragraph INTRODUCTION NORMAL OPERATION OPERATOR TECHNIQUE SECTION VI MAINTENANCE AND TROUBLESHOOTING Paragraph IN T RODUCTION PREVENTIVE MAINTENANCE LODGED CONTACT TRANSFER TIP TRIGGER INDENTERS-REPLACEMENT INDENTERS.-ADJUSTMENT PNEUMATIC/ELECTRIC TROUBLESHOOTING SECTION VII. PARTS LIST 7-1 PARTS LIST...

  • Page 5: Table Of Contents

    LI ST OF FIGURES PAGE TITLE PORTA-TAC CRIMPER, FRONT VIEW PORTA-TAC CRIMPER, WITH MAGAZINE PORTA-TAC CRIMPER, SIDE VIEW WIRE INSERTION PORTA-TAC PNEUMATICS CRIMP CYLINDER ARBOR, OPEN CRIMP CYLINDER ARBOR, CLOSED CRIMP INSPECTION POINTS IMPROPER CRIMPS "T" DIMENSION CHECK POINT CRIMPS PANEL COMPONENTS CABINET COMPONENTS (TRANSFER MECHANISM) 41 INDENTER SYSTEM REPLACEMENT...
  • Page 6 SECTION I INTRODUCTION DESCRIPTION The Tri-Star Technologies Portable Automatic Contact Crimper, hereina£ter referred to as PORTA-TAC, is a device which automatically crimps loose electrical contacts that have been pre-loaded into a magazine. Both shouldered and shoulderless type contacts may be re-loaded manually or automatically using other Tri-Star equipments.

  • Page 7: Porta-Tac Crimper, Front View

    FIGURE 1-1. PORTA-TAC CRIMPER, FRONT VIEW...

  • Page 8: Porta-Tac Crimper, With Magazine

    FIGURE 1-2. PORTA-TAC CRIMPER, WITH MAGAZINE...

  • Page 9: Porta-Tac Crimper, Side View

    FIGURE 1-3. PORTA-TAC CRIMPER, SIDE VIEW...
  • Page 10 OPERATION All functions of the PORTA-TAC are initiated, terminated, controlled and operated both pneumatically and electrically. After the PORTA-TAC has been set up properly, only one function is operator-adjustable: the selected "G" dimension. All other functions are machine controlled. Interlocks are provided in the logic to prevent any out-of- sequence event from occurring.
  • Page 12 OPERATOR TECHNIQUE Crimp location on the contact and depth of crimp are entirely PORTA-TAC dependent. The operator only need select (if applicable) the proper "G" dimension setting and initiate the crimp cycle by inserting the conductor into the contact and depressing it by applying slight pressure.
  • Page 13 INTRODUCTION The PORTA-TAC Crimper has been extensively redesigned. The re-design results in additional 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 PORTA-TAC Crimper are performed pneumatically, electrically or both.
  • Page 14 Pneumatic Supply (cont) The system air supply is filtered at F-l and overall system air pressure is regulated by Regulator R-l. (FOR LOCATION OF COMPONENTS, REFER TO FIGURES 6-l & 6- 2, in the Maintenance section). The air pressure at R-l should be approximately 60 PSIG, and may be monitored with Pressure Gauge G-l.
  • Page 15 NORMAL OPERATION This discussion originally assumes a contact is in the Transfer Tip after Initial Turn- When a properly stripped conductor is inserted into the wire funnel and subsequently into the contact, it eventually bottoms out in the contact. Continued pressure depresses the trigger mechanism until Nl Slide Sensor closes, which blocks the air bleed existing at the Nl Sensor.
  • Page 16 Normal Operation (cont). When the Transfer Arm reaches the vertical position, a limit switch (LS-l) 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 fully extended position -V-3 is deactivated closing funnels -Index Cylinder (IC-l) is activated, advancing the magazine belt one...
  • Page 18 INTRODUCTION Although all PORTA-TACs are ruggedly constructed, adequate precautions must be observed and all instructions followed to prevent damage to the device during the initial Set-up. CAUTION Lift and transport the PORTA-TAC using only the handles. Do not lift, pull shove or jostle the crimp cylinder, the switches, power pack or any component mounted on the mainframe.
  • Page 19 Unpacking (cant) Step 3. Carefully remove the PORTA-TAC and its power pack from the container, using only the handles for lifting, and set the machine on a smooth level work surface. Step 4. Discard the shipping container, being certain all components have been removed.
  • Page 20 PNEUMATIC HOOK-UP Perform the following steps to hook-up the pneumatic input: Step I. Refer to Figure 1-3. Step 2. Obtain a 1/4" male air fitting (not supplied with the PORTA-TAC) that will fit into the sleeve valve located on the right side of the device, and will mate with the air supply.
  • Page 21 CAUTION If any observation is not as specified, refer to Maintenance and Troubleshooting (Section VI) before proceeding with subsequent steps. WARNING KEEP HANDS CLEAR OF THE TRANSFER MECHANISM DURING OPERATION WHEN CLOSING THE SLEEVE VALVE. Step 1. Close the sleeve valve. NOTE The PORTA-TAC will reset and cycle when the sleeve valve is closed and...
  • Page 22 3-6 FUNCTIONAL CHECK-OUT ( Cont.) Perform the following steps to ascertain that the functional operation of the PORTA-TAC is satisfactory: NOTE If any observation is not as specified, refer to Maintenance and Troubleshooting (Section VI) before proceeding with subsequent steps Step 1.
  • Page 23 3-6 FUNNEL REPLACEMENT If it is necessary to change the funnel due to a different contact gauge, perform the following steps: Step 1. Open the sleeve valve. Step 2. Remove the two screws securing the funnel cover plate. Step 3. Remove the funnel cover plate. Step 4.
  • Page 24 SECTION IV CRIMP VERIFICATION 4-1 INTRODUCTION Initial and periodic crimp verifications must be made in order to be certain a given PORTA-TAC is crimping properly. Once a PORTA-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 25 INITIAL CRIMP VERIFICATION (cont) Step 4. Remove the crimp cylinder arbor cover plate and the funnel cover plate and the funnel cover plate. Refer to Table 4-1. If the PORTA-TAC has an operator adjustable “G” Step 5. dimension control, perform Steps 6 through 9 for each of the six settings (1, 2, 3, etc.) If the setting is not adjustable, perform Steps 6 through 9 for the fixed “G”...

  • Page 26: Crimp Cylinder Arbor, Open

    FIGURE 4-1. CRIMP CYLINDER ARBOR, OPEN (ARBOR COVER PLATE REMOVED)

  • Page 27: Crimp Cylinder Arbor, Closed

    FIGURE 4-1. CRIMP CYLINDER ARBOR, CLOSED (ARBOR COVER PLATE REMOVED)
  • Page 28 INITIAL CRIMP VERIFICATION (cont). Step 9. Verify that these dimensions comply with specifications. Step 10. Install the crimp cylinder arbor Cover plate and the funnel cover plate. Step 11. Connect the air supply to the sleeve valve mum of 85 PSIG). Step 12.
  • Page 29 Step 20. Continue inserting the conductor. As the conductor strands bottom out in the contact, the contact will depressed and, in turn, activate the slide sensor. Step 21. When the crimping cycle is complete, the funnel will open; at this time, remove the conductor. NOTE When the funnel opens, remove the conductor smoothly by simply pulling it towards yourself.

  • Page 30: Crimp Inspection Points

    4-3. FIGURE CRIMP INSPECTION POINTS...
  • Page 31 FIGURE 4-4. IMPROPER CRIMPS...
  • Page 33 SECTION V OPEATING PROCEDURES INTRODUCTION The PORTA-TAC Crimper is simple to operate. No previous experience with crimpers of any kind is required; however, operators need to exercise reasonable care when operating the PORTA-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 34 5-2 NORMAL OPERATION (CONT.) Step 4. Set the LAST PART Switch to the QFF position (up).. Step 5. Close the sleeve valve. Step 6. Open the funnel and observe if a contact is present. NOTE No contact should be present in the transfer tip. Step 7.
  • Page 35 5-2 NORMAL OPERATION (CONT.) Step 11. Continue inserting the conductor; as the conductor strands bottom out in the contact, the contact will be depressed and, in turn, depress the trigger. Step 12. When the trigger is fully depressed, the crimp cycle is initiated. When the crimp cycle is complete, the funnel will open.
  • Page 36 5-3. OPERATOR TECHNIQUE (CONT.) The only precautions an operator need observe are: Do not insert a conductor so fast as force conductor strands to spring back out the contact. Remove the crimped conductor only when the crimp cycle is complete. {funnel open) Be certain the magazine is filled on with the proper type contacts.
  • Page 37 CONDUCTOR STARNDS PROPER INDENTS VISIBLE ACCEPTABLE CRIMP BIRDCAGE UNACCEPTABLE CRIMP FIGURE 5-1. CRIMPS...
  • Page 38 SECTION VI MAINTENANCE AND TROUBLESHOOTING INTRODUCTION The primary purpose of the Maintenance and Troubleshooting section user to perform required preventive maintenance, perform minor adjust malfunctions caused by incorrect/unacceptable contacts. Detailed instructions for adjusting and changing indenters are also given. In the event it is necessary to replace an item for which there is no specific disassembly instructions, use extreme care and/or consult the factory £or assistance.
  • Page 39 PREVENTIVE MAINTENANCE (CONT.) Step G Repeat step F several times. Step H Turn off air supply. Step I Replace transfer tip in the tip holder. Step J. Replace control unit cover plate. Step K Plug power pack to wall outlet. Step L Turn on air supply.

  • Page 40: Panel Components

    FIGURE 6-1. PANEL COMPONENTS...
  • Page 41 FIGURE 6-2. CABINET COMPONENTS (TRANSFER MECHANISM)
  • Page 42 TRANSFER TIP (CONT.) Step1 Inspect the transfer tip to see if a contact is present but does not appear seated. If a contact is visible, open the sleeve valve. Remove the contact from the transfer tip. Close the sleeve valve. Verify the transfer tip is "the one designated for the contact being used.
  • Page 43 6-5 TRIGGER (Slide Sensor) Inserting a conductor into a contact and depressing it forces the trigger down onto a slide sensor, initiating the crimp cycle. If depressing the conductor into a contact does not initiate the crimp cycle, perform the following checks: -With air turned off, inspect the trigger assembly to be sure no foreign objects have lodged themselves in any of the moving parts.

  • Page 44: Indenter System Replacement

    FIGURE 6-3. INDENTER SYSTEM REPLACEMENT...

  • Page 46: Indenter Replacement

    FIGURE 6-5. INDENTER REPLACEMENT...
  • Page 47 Upon completion o£ the installation and adjustment of new indenters, perform crimp verification (Section IV). Perform the following-steps to replace indenters: Step 1. Open the sleeve valve. Step 2. Disconnect the air supply from the sleeve valve Step 3. Remove the four button head socket cap screws securing the crimp cylinder arbor cover plate.
  • Page 48 Step 14. Manually move the indenter arm and observe that indenters move' and spring back freely. Step 15. 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 16.
  • Page 49 Step 5. Using only hand pressure, extend the arbor as far to the right as it will go. Step 6. Using appropriate GO NO-GO gauges, open the funnel and insert gauges into the indenters to determine the "G" dimensions. NOTE Be sure to use gauges corresponding to proper wire gauge and contact gauge.
  • Page 51 Step 18. Close the sleeve valve. Step 19. Open the funnel and observe if a contact is present No contact should be present in the transfer tip. Step 20. Momentarily depress the INITIAL PART pushbutton switch. Step 21. Open the funnel and observe that a contact is present Let the funnel close. NOTE The funnel should be closed during normal operation when inserting a...
  • Page 52 PNEMATIC/ELECTRIC The ppneumatic and electric system is described in Section II manual. If a pneumatic or electric malfunction occurs, refer to Section II to determine the probable cause. Use standard troubleshooting techniques and normal standards of workmanship when locating and replacing defective components. 6-9 TROUBLESHOOTING CHART The following is a list of malfunctions that may occur during operation.

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