Panduit CA9 Operation Manual
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Panduit CA9 Operation Manual

Panduit CA9 Operation Manual

Applicator for use in automatic wire processing machines and bench presses
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PA23998A01
CA9 APPLICATOR
Rev. 09 12-2023
FOR USE IN AUTOMATIC WIRE PROCESSING MACHINES
AND BENCH PRESSES
OPERATION MANUAL
© Panduit Corp. 2011
FEEDS AND CRIMPS Reel Smart™ CONTINUOUSLY MOLDED
TERMINALS, DISCONNECTS AND SPLICES IN AUTOMATIC
WIRE PROCESSING MACHINES AND BENCH PRESSES
RETAIN THIS MANUAL FOR FUTURE REFERENCE
Website: www.panduit.com
Email: cs@panduit.com
Panduit Corp. • USA Technical Support
Tel: 888-506-5400, ext. 3255 • Fax: 630-759-7532
EU Website:
www.panduit.com/emea
Panduit Europe • EMEA Service Center
:
Almelo, Netherlands
EU Email
Tel: +31 546 580 452 • Fax: +31 546 580 441
emeatoolservicecenter
@panduit.com

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  • Page 1 TERMINALS, DISCONNECTS AND SPLICES IN AUTOMATIC WIRE PROCESSING MACHINES AND BENCH PRESSES RETAIN THIS MANUAL FOR FUTURE REFERENCE Website: www.panduit.com Email: cs@panduit.com Panduit Corp. • USA Technical Support Tel: 888-506-5400, ext. 3255 • Fax: 630-759-7532 EU Website: www.panduit.com/emea Panduit Europe • EMEA Service Center...

  • Page 2: Table Of Contents

    KOMAX 40T WIRE PROCESSING MACHINE WITH MECAL PE7 PRESS ....... 17 MEGOMAT ASM 3001A & PRIMO WIRE PROCESSING MACHINES ........18 Panduit CP-862 BENCH PRESS ....................19 Panduit CP-871 BENCH PRESS ....................20 SCHLEUNIGER CRIMPCENTER 12 WIRE PROCESSING MACHINE WITH ACP 01 PRESS . 21 SCHLEUNIGER UniCrimp 208 ....................

  • Page 3: Introduction

    The CA9 Applicator can feed and crimp the complete line of Reel Smartϑ Continuously Molded Terminals, Disconnects and Splices offered by Panduit. Changes from one part to another can be made by changing product reels and die inserts. Die inserts can be changed without removing the applicator from the press. The specific wire processing machine should be set up exactly as indicated in the manufacturer’s press manual.
  • Page 4 CA9 APPLICATOR...
  • Page 5 Always disconnect the power when changing the die inserts or making any adjustments. Panduit Corp. recommends the CA9 be used with all installed safety features. Customer assumes all liability for injury that could result from improper use of this applicator and responsibility for all necessary training to ensure safe operation of this applicator.

  • Page 6: Wire Processing Machine / Press Compatibility By Manufacturer

    Alpha 411 w/Mecal PE7 or P107 Press (WPM) KOMAX Alpha 433 w/Mecal PE7 or P107 Press (WPM) 40T w/Mecal PE7 Press (WPM) 40T w/Panduit CP-861 Press (WPM) bt711 Bench Press only ASM 3001A / APE 300 Press (WPM) MEGOMAT Contact (WPM) Primo w/MP-3.0 Press (WPM)

  • Page 7: Applicator Installation

    The AMP CLS III G, CLS IV, & CLS IV Plus are fully automated wire processing machines. These units are fitted with the AMP G Press. The following are the general requirements for the operation of the CA9 Applicator in this machine.

  • Page 8: Amp Cls Ii & Cls Iii Wire Processing Machines And T Bench Press

    Verify that the terminating unit ram lock mechanism is in the “unlocked" position and that the applicator base clamp is in the “DOWN” position. The CA9 Applicator utilizes the press's standard shut height (5.348" or 135,8 mm). Therefore, no shut height changes are required for setup of the applicator.

  • Page 9: Artos Cs-600 Wire Processing Machine With Amp G Press

    Bench Press. Always refer to the Applicator Setup and Operation sections on Pages 25 - 31 in this manual for further information. NOTE: The AMP T press must be equipped with a Quick Change type base plate for the CA9 Applicator to be installed.
  • Page 10 Verify that the terminating unit ram lock mechanism is in the “UNLOCKED” position and the applicator base clamp is in the “DOWN” position. The CA9 Applicator utilizes the press’s standard shut height (5.348” or 135.8 mm). Therefore, no shut height changes are required for setup of the applicator.

  • Page 11: Artos Cs-600 Wire Processing Machine With Tu-10 Press

    Wire Processing Machine Accessories Required For the CA9 Applicator to work in the CS-600, the machine must be equipped with the air feed kit provided by Artos. The air fitting used to control the applicator is typically mounted on the back of the press. The applicator performs best when the wire processing machine runs with the press in the split cycle mode.

  • Page 12: Artos Mtx Series 5 Wire Processing Machine With Tu-10 Press

    Wire Processing Machine Accessories Required For the CA9 Applicator to work in the MTX, the machine must be equipped with the air feed kit provided by Artos. The air fitting used to control the applicator is typically mounted on the back of the press. The applicator performs best when the wire processing machine runs with the press in the split cycle mode.

  • Page 13: Gamma Meccanica T20P-110V Bench Press

    The T20P-110V Bench Press is an electric bench press for semi-automatic termination of terminals and disconnects onto 22-10 gauge wire. The following are general requirements for the use of the CA9 Applicator in this press. Wire Processing Machine Accessories Required Since this is not a wire processing machine, no wire processing machine accessories are required.

  • Page 14: Kodera Series C451/C450 & C551/C550 Wire Processing Machines

    Wire Processing Machine Accessories Required For the CA9 Applicator to work in a Kodera Wire Processing Machine, the machine must be equipped with the AFA Air Feed Kit, a One Touch Base Plate (Part #23), and the Software (ROM) for the Panduit CA9 Applicator (specify your Kodera machine when ordering).

  • Page 15: Komax Gamma 311 Wire Processing Machine With Mecal K300 Press

    Wire Processing Machine Accessories Required For the CA9 Applicator to work in the 311, the machine must be equipped with the Air Feed Kit provided by Komax. The kit consists of a solenoid valve, timing controls and activation controls. The solenoid valve is typically mounted to the press and the activation controls are typically mounted on the main control panel of the 311.
  • Page 16 Turn “OFF” the power to the terminating unit before installing the applicator. Insert the applicator from the left and slide it to the right until the keyway of the CA9 Applicator’s base plate contacts the stop clamp on the press base plate. While moving the applicator to the right, pull “UP” on the applicator ram and insert its shank collar into the slot of the press ram collar.

  • Page 17: Komax Alpha 411 Wire Processing Machine With Mecal Pe7 Or P107 Press

    Wire Processing Machine Accessories Required For the CA9 Applicator to work in the 411, the machine must be equipped with the Air Feed Kit provided by Komax. The kit consists of a solenoid valve, timing controls and activation controls. The solenoid valve is typically mounted to the press and the activation controls are software driven.
  • Page 18 Turn “OFF” the power to the terminating unit before installing the applicator. Insert the applicator from the left and slide it to the right until the keyway of the CA9 Applicator’s base plate contacts the stop clamp on the press base plate. While moving the applicator to the right, pull “UP” on the applicator ram and insert its shank collar into the slot of the press ram collar.

  • Page 19: Komax 40T Wire Processing Machine With Mecal Pe7 Press

    Wire Processing Machine Accessories Required For the CA9 Applicator to work in the 40T, the machine must be equipped with the Air Feed Kit provided by Komax. The kit consists of a solenoid valve, timing controls and activation controls. The solenoid valve is typically mounted to the press and the activation controls are software driven.

  • Page 20: Megomat Asm 3001A & Primo Wire Processing Machines

    The Megomat ASM3001A and Primo are fully automated wire processing machines. The Megomat ASM3001A is typically fitted with the Megomat APE300 terminating press, and the Primo is typically fitted with the Megomat MP- 3.0 terminating press. The following are the general requirements for the use of the CA9 Applicator in these machines.

  • Page 21: Panduit Cp-862 Bench Press

    The CP-862 Bench Press is an electric bench press for semi-automatic termination of terminals and disconnects onto 22-10 gauge wire. The following are the general requirements for the use of the CA9 Applicator in this press. Wire Processing Machine Accessories Required Since this is not a wire processing machine, no wire processing machine accessories are required.

  • Page 22: Panduit Cp-871 Bench Press

    The CP-871 Press is an electric bench press for semi-automatic termination of terminals and disconnects onto 22-10 gauge wire. The following are the general requirements for the use of the CA9 Applicator in this press. Wire Processing Machine Accessories Required Since this is not a wire processing machine, no wire processing machine accessories are required.

  • Page 23: Schleuniger Crimpcenter 12 Wire Processing Machine With Acp 01 Press

    Turn “OFF” the power to the terminating unit before installing the applicator. Insert the applicator from the left and slide it to the right until the keyway of the CA9 Applicator base plate contacts the stop clamp on the press base plate. While moving the applicator to the right, pull “UP” on the applicator ram and insert its shank collar into the slot of the press ram collar.
  • Page 24 The CrimpCenter 12 is equipped with 4mm metric hose fittings to control the air feed of pneumatic applicators. The standard air fitting on the CA9 Applicator is ¼”. Therefore, a hose adapter assembly (Panduit Part Number KHCA9), provided by Panduit, must be used to operate the CA9 Applicator in this equipment. This is accomplished as follows: Remove the ¼”...

  • Page 25: Schleuniger Unicrimp 208

    “red transparent square” over a picture of the press when the safety shield is ”open”. If the safety shield can not close with the CA9 inside the press, you can remove the triangle piece of the safety glass. This can be found on the side of the safety glass.

  • Page 26: Shinmaywa Trd111 Or Tr111 Wire Processing Machine

    Wire Processing Machine Accessories Required For the CA9 Applicator to work in the TRD111, the machine must be equipped with proper Quick Change press base plate. The standard base plate, used with all makes of mini-die applicators, should be used with the CA9 Applicator.

  • Page 27: Applicator Setup

    Turn “OFF” the power to the terminating unit before installing the applicator. Insert the applicator from the right side and slide it left until the keyways of the CA9 Applicator’s base plate contact the stop clamps on the press base plate. While moving the applicator to the right, pull “UP” on the applicator ram and insert its shank collar into the slot on the press ram collar.
  • Page 28 (wire feed arm shifts right after termination to clear crimp area), the stripper plate may have to be raised slightly or removed completely to run certain types of male disconnects. Proceed to Crimp Shut Height Tolerance Test on Page 29. CA9 APPLICATOR: PA23998A01_09 Page: 26 of 32 12-2023...

  • Page 29: Die Insert Changeover

    CA9 APPLICATOR DIE INSERT CHANGEOVER To change die inserts, remove upper inserts, stripper plate, and then lower inserts. Refer to Die Insert Installation section on Page 25, beginning with Step 1. CA9 APPLICATOR: PA23998A01_09 Page: 27 of 32 12-2023...

  • Page 30: Reel Smart™ System Reference Table

    16-14 DNG-FB .188 (4.78) / TA13722A01 CD9-17B YELLOW 12-10 CD9-18B YELLOW 12-10 DNF-FIMB ** Modified lower die for barrel insulated disconnects. Available as a complete die set, or just lower die assembly. CA9 APPLICATOR: PA23998A01_09 Page: 28 of 31 12-2023...

  • Page 31: Crimp Shut Height Tolerance Test

    Follow the procedure for Installation of Reel Arm Assembly in the appropriate press manual and follow the instructions below to correctly load your desired disconnects, terminals, or butt splices into the CA9 Applicator. Verify that the press is turned “OFF”.
  • Page 32 Install the safety shield provided for your particular wire processing machine or stand alone press. CA9 APPLICATOR: PA23998A01_09 Page: 30 of 31 12-2023...

  • Page 33: Operation

    Follow the operation procedure (below) to terminate the terminals, disconnects, or butt splices correctly. If terminations are not acceptable, see Troubleshooting section on Pages 31 -33. SAFETY CHECKLIST For CA9 Applicator 1. Is the crimp area free of foreign matter? 2. Is a part positioned between the die inserts? 3.

  • Page 34: Troubleshooting Checklist

    (See Figure 1 inset on control set screw counterclockwise, until Page 4). the proper feed is achieved. D. Air pressure to CA9 Applicator is D. Adjust air pressure to 80 – 90 PSI. above 90 PSI. Parts are not being positioned A.
  • Page 35 F. Position the manual precision adjustment F. Improper press adjustment. lever on the terminating unit at the 00mm (0.00 in) position before installing CA9 Applicator. G. Air hose is connected to the wrong G. Connect the air hose to the normally port of the press air valve.

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