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© 2010 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names might be trademarks of their respective owners.
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AMP-O-LECTRIC* Model "G"
Terminating Machines 354500-[ ]
SAFETY PRECAUTIONS
A.
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1. Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2. Electrical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3. Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. RECEIVING/INSPECTION, AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1. Receiving/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3. Considerations Affecting Placement of the Machine . . . . . . . . . . . . . . . . . . . . . . . . 10
4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1. Applicator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2. Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3. Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4. Crimp Height Adjustment Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5. End-Feed/Side-Feed Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.2. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1. Measuring the Shut Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2. Shut-Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3. Crimp Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4. Guard Insert Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.5. Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.6. Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8. RoHS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9. REVISION SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TOOLING ASSISTANCE CENTER 1-800-722-1111
READ THIS FIRST !
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
Customer Manual
409-5842
03 DEC 10 Rev L
1 of 34
LOC B
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Summary of Contents for Tyco AMP-O-LECTRIC G
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Page 1: Table Of Contents
9. REVISION SUMMARY ..........34 1 of 34 © 2010 Tyco Electronics Corporation, Berwyn, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. - Page 2 409-5842 DANGER SAFETY PRECAUTIONS AVOID INJURY Safeguards are designed into this application equipment to protect operators and maintenance personnel from most hazards during equipment operation. However, certain safety precautions must be taken by the operator and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application equipment must be operated in a dry, dust-free environment.
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Page 3: Introduction
409-5842 PART AMP-O-LECTRIC Model “G” NUMBER Terminating Machine 354500-[ ] 1 5/8 In. Stroke Figure 1 1. INTRODUCTION This manual contains information on operation, preventive maintenance, and adjustments of the AMP-O-LECTRIC Model “G” Terminating Machines shown in Figure 1. Descriptions in this manual pertain to the controls and adjustments on the “G”... -
Page 4: Description
409-5842 When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements. DANGER Denotes an imminent hazard which may result in moderate or severe injury. CAUTION Denotes a condition which may result in product or equipment damage. NOTE Highlights special or important information. -
Page 5: Available Option
409-5842 The following options are available for the AMP-O-LECTRIC Model “G” Terminating Machine: AVAILABLE OPTION PART NUMBER PURPOSE Air Feed Assembly 354578-1 The optional air feed assembly is required to run air-feed applicators. Guard Inserts (Figure 22) Guard inserts are used for certain strip-fed and tape-fed product. Lubricator Bowl Assembly 354550-3 The lubricator bowl assembly is required to pre-lubricate strip-fed... -
Page 6: Function Buttons
409-5842 16-Character Total Cycle Display Counter Batch Counter Mode Icons Lights Function Buttons FUNCTION BUTTONS Allows the controller to provide power to the motor. POWER Selects the current mode of operation by stepping through the four choices indicated. MODE Manually activates the optional air feed valve. Press once to turn “on,” press again to turn “off.”... -
Page 7: Guards
409-5842 There are four CPC connectors located on the electrical control box. See Figure 5. The interface connection to the Crimp Quality Monitor Machine, connector J1, is located on the left side of the machine just below the top cover. The remaining three are located along the right side of the machine just below the top cover. Starting at the front of the machine are connections for;... - Page 8 409-5842 Guard Shroud Light Bulb Safety Interlock Figure 6 In addition, the machines contain safety interlocks at the guard insert that prevent full-cycle and split-cycle production operation if the guard insert is removed. See Figure 7. Optional Air Feed Assembly Safety Interlock Guards...
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Page 9: Receiving/Inspection, And Installation
However, damage may occur during shipment. Remove the machine from the crate, as described in Paragraph 3.2, and carefully inspect the machine for damage. If damage is evident, file a claim against the carrier and notify Tyco Electronics immediately. 3.2. Installation DANGER The AMP-O-LECTRIC Model “G”... -
Page 10: Considerations Affecting Placement Of The Machine
The machine will automatically detect the supply voltage and adjust the controller accordingly. NOTE Models exported to Europe will be installed by Tyco Electronics Service Representatives. These engineers will verify that the electrical and pneumatic connections are correct. Both pneumatic and electrical connections must be installed in a way that provides a lockable isolation switch for hard-wired or direct piped machines. -
Page 11: Operation
409-5842 readily changed when the operator shifts position to minimize fatigue. Placing the switch on a rubber mat keeps it movable while preventing unintentional sliding. The preferred foot switch location varies to some extent among operators. Some operators prefer the switch located so that their foot rests on the switch when their feet are in the natural sitting position (calf of leg perpendicular to the foot). - Page 12 409-5842 Thumbscrew for Ram Lock Mechanism Base Plate of Optional Lubricator Terminating Bowl Assembly Machine Applicator Base Clamp Removable Rear Stop (Ref) T-Handle Alternate Mounting Position for Removable Stop Applicator Base Plate Figure 11 2. Lower the applicator ram lock mechanism by loosening the thumbscrew at the front of the ram assembly.
- Page 13 409-5842 Thumbscrew for Ram Lock Mechanism Applicator Ram Ram Post Adaptor Applicator Front Pad of Ram Post Adaptor Base Plate of Terminating Machine Rear Stop(s) Typical T-Handle Applicator Applicator Base Clamp Figure 12 7. If the applicator is an air-feed type, connect the airlines to the valves located on the right side of the machine.
- Page 14 409-5842 Feed Finger Retract Forward Feed w/Flow Control Constant Air Valve Assembly 354579-1 Feed Finger Retract Forward Feed Constant Air w/Flow Control Valve Assembly 354579-3 Figure 13 Rev L 14 of 34 Downloaded from Elcodis.com electronic components distributor...
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Page 15: Setup
409-5842 Latch Handle T-Handle Figure 14 4.2. Setup Install a miniature applicator and terminals according to Paragraph 4.1, Applicator Installation. 1. Turn on the main power using the switch located on the left side of the machine. 2. Place the machine in Jog Forward mode, and carefully cycle the machine through a complete crimp cycle. - Page 16 409-5842 16-Character Total Display Cycle Counter Batch Counter Mode Icons Lights Function Buttons Full Cycle When the foot switch is depressed in this mode, the crankshaft will rotate at full speed through a full revolution. Split Cycle When the foot switch is depressed in this mode, the machine moves the ram down at full speed only far enough for the terminal to be held in the tooling.
- Page 17 409-5842 Jog Mode This mode allows maintenance and setup personnel to slowly jog the machine (forward or in reverse) with (Guards Open) the guard doors open. To activate this mode, first place the machine in either the “Jog Forward” or “Jog Reverse”...
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Page 18: Crimp Height Adjustment Feature
(See Figure 16) The moving parts of the machine require regular lubrication to ensure reliable service and long life. Use only good grade lubricants. Contact Tyco Electronics Engineering for recommended brands NOTE For operation in temperatures below 10°C [50°F], it will be necessary to use a No. 1 grease. -
Page 19: Adjustments
409-5842 Lubrication Point(s) Lubrication Point(s) Figure 16 Using a grease gun, apply grease every 250,000 cycles to the fittings at the following locations: • The left side of the ram assembly; • The right side of the ram assembly; • The left side of the frame just behind the ram assembly;... - Page 20 409-5842 1. Adjust the manual precision adjustment lever to .051 mm [.002 in.] below the “0” setting. See Figure 20. 2. Remove the rear guard. 3. Follow the procedure described in instruction sheet 408-8535. 4. Reset the manual precision adjustment lever to “0” position. Refer to Figure 20. 135.8 ±...
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Page 21: Shut-Height Adjustment
The shut height is pre-set at the factory and should not require further adjustment unless it is necessary to replace parts. Before you make any changes to the terminating machine, contact your local Tyco Electronics Field Service Representative, or call the Tooling Assistance Center at 1-800-722-1111. -
Page 22: Crimp Height Adjustment
409-5842 Lubrication Point/ Lubrication Eccentric Pin Point Adjustment Lever Reading (“+” above .00 mm [.000 in.] setting) Read Half Step Read Full Step .064 mm + .051 mm + [.0025 in.] [.002 in.] Manual Precision Adjustment Lever PRECISION ADJUST Positioned on .00 mm [.000 in.] Dial Indicator... - Page 23 409-5842 2. Install the applicator into the terminating machine as described in Paragraph 4.1. 3. Cycle the terminating machine to crimp three sample terminations. Check the crimp height of the samples. If the crimp heights are not correct, adjust the crimp height according to Step 4. 4.
- Page 24 409-5842 Optional Air Feed Assembly Lubrication Lubrication Point Points Indicator Plate Counterclockwise Increases Crimp Height (“+” above 0.00 mm [.000 in.] setting) Clockwise Decreases Crimp Height (“-” below 0.00 mm [.000 in.] setting) Figure 21 Rev L 24 of 34 Downloaded from Elcodis.com electronic components distributor...
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Page 25: Guard Insert Adjustment
409-5842 6.4. Guard Insert Adjustment A guard insert is supplied with the machine. Some applications may require a special insert which is included with the applicator. See Figure for standard and tape guard inserts. The left guard contains two slots into which the inserts can be placed: the rear slot places the insert close to the applicator;... -
Page 26: Drive Belt Tension Adjustment
409-5842 NOTE The reflective surface must be located at the bottom of the insert facing the operator, with two large square holes at the bottom. 2. Move the insert horizontally and vertically as needed to align the slot with the crimp area of the applicator. -
Page 27: Light Bulb Replacement
409-5842 6.6. Light Bulb Replacement The work light in the machine uses a No. 464 wedge base 28 volt bulb (993130-2) or a No 655 wedge base 28 volt bulb (993130-3), available from your local supplier. See Figure 24 and replace the bulb as follows: 1. -
Page 28: Troubleshooting
EEPROM ERROR The controller detected a problem with its Contact a Tyco Electronics Field Service memory. Representative to replace memory. FOOT SW INPUT ON While powering up, the terminating machine Check the foot switch for proper operation. - Page 29 (see System Schematic), or the 24 Vdc used to operate the fan is not present. Call the Tooling Assistance Center at 1-800-722- 1111 or contact a Tyco Electronics Field Service Representative for assistance. Rev L 29 of 34 Downloaded from Elcodis.com...
- Page 30 Try to reset the error by pressing the ERR RESET button (on the operator keypad). Contact a Tyco Electronics Field Service Representative, or call the Tooling Assistance Center at 1-800-722-1111 for further troubleshooting procedures if the problem has not been solved after checking the following areas.
- Page 31 409-5842 PROBLEM POSSIBLE CAUSE REMEDY SW 1 NOT UNMADE This message indicates that the terminating machine ram did not move off of top-dead-center after a cycle was initiated with the foot switch. Fuse blown on capacitor board Remove the top plastic cover of the machine. DANGER: The control box contains high residual voltage after disconnection from the power source.
- Page 32 409-5842 PROBLEM POSSIBLE CAUSE REMEDY SW 1 NOT UNMADE (Continued) Broken motor shaft The motor shaft can break at the bearing behind the face plate inside the motor body. The motor armature will then turn, but the shaft does not, resulting in this error.
- Page 33 Remove the ribbon cable connections, re-seat them, and see if the problem is corrected. If problems persist, call the Tooling Assistance Center at 1-800-722-1111 or contact a Tyco Electronics Field Service Representative for further troubleshooting procedures. Rev L...
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Page 34: Rohs Information
.03 and .4 Vdc. With a vane in the gap, the voltage should be 15 Vdc. If problems persist, call the Tooling Assistance Center at 1-800-722-1111 or contact a Tyco Electronics Field Service Representative for further troubleshooting procedures.
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