TE AMP 3K series Guida di riferimento

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*Trademark

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.

TOOLING ASSISTANCE CENTER

1-800-722-1111

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com.

Customer Manual

409-32034

16 SEP 16 Rev D

SAFETY PRECAUTIONS

READ THIS FIRST!

.............................................................2

1. INTRODUCTION ..................................................................................................................3

2. DESCRIPTION .....................................................................................................................4

2.1. Functional Description.................................................................................................5

2.2. Electrical Description...................................................................................................6

2.3. Machine Guard (Figure 7) ...........................................................................................8

3. RECEIVING INSPECTION AND INSTALLATION ...............................................................9

3.1. Receiving Inspection ...................................................................................................9

3.2. Installation ...................................................................................................................9

3.3. Considerations Affecting Placement of Bench Machines..........................................10

4. OPERATION ......................................................................................................................11

4.1. Machine Operation ....................................................................................................11

4.2. Crimp Quality Monitor II (CQM II)..............................................................................11

4.3. Applicator Installation ................................................................................................14

4.4. Setup.........................................................................................................................14

4.5. Mode Selection and Operation..................................................................................15

4.6. Crimp Height Adjustment ..........................................................................................17

4.7. End-Feed/Side-Feed Applicator Conversion.............................................................17

5. MACHINE FAULT CODES ................................................................................................17

6. PREVENTIVE MAINTENANCE .........................................................................................18

6.1. Cleaning ....................................................................................................................18

6.2. Lubrication.................................................................................................................18

7. ADJUSTMENTS.................................................................................................................19

7.1. Measuring the Shut Height........................................................................................19

7.2. Shut-Height Adjustment ............................................................................................20

7.3. Crimp Height Adjustment Using Precision Adjustment Mechanism ..........................21

7.4. Guard Insert Adjustment ...........................................................................................22

8. MACHINE OPTIONS AND INSTALLATION......................................................................24

8.1. Installation of Work Light Assembly Kit .....................................................................24

8.2. Installation of the Work Light Assembly Kit ...............................................................26

8.3. Installation of Batch Counter Kit 1424267-1..............................................................27

8.4. Installation of Air Feed Kit 1424266-1 .......................................................................28

9. TROUBLESHOOTING .......................................................................................................31

10. RoHS INFORMATION........................................................................................................31

11. REVISION SUMMARY .......................................................................................................31

AMP 3K* Terminating Machine 1725950-[ ] and

AMP 5K* Terminating Machine 1725900-[ ]

ORIGINAL INSTRUCTIONS

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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. Do not operate equipment in a gaseous or

hazardous environment.

Carefully observe the following safety precautions before and during operation of the equipment:

Always wear approved eye protection while operating

equipment.

Always wear appropriate ear protection while using

equipment.

Moving parts can crush and cut. Always keep guard(s)

in place during normal operation.

Electrical shock hazard.

Always turn off the main power switch and disconnect

the electrical cord from the power source when

performing repair or maintenance on the equipment.

Never insert hands into installed equipment.

Never wear loose clothing or jewelry that may catch in

moving parts of the equipment.

Never alter, modify, or misuse the equipment.

TOOLING ASSISTANCE CENTER

CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)

The Tooling Assistance Center offers a means of providing technical assistance when required.

In addition, Field Service Specialists are available to provide assistance in the adjustment or repair of the

application equipment when problems arise which your maintenance personnel are unable to correct.

INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER

When calling the Tooling Assistance Center regarding service to equipment, it is suggested that a person

familiar with the device be present with a copy of the manual (and drawings) to receive instructions. Many

difficulties can be avoided in this manner.

When calling the Tooling Assistance Center, be ready with the following information:

1. Customer name

2. Customer address

3. Person to contact (name, title, telephone number, and extension)

4. Person calling

5. Equipment number (and serial number if applicable)

6. Product part number (and serial number if applicable)

7. Urgency of request

8. Nature of problem

9. Description of inoperative component(s)

10. Additional information/comments that may be helpful

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PART

NUMBER

CAPACITY

(lbs)

STROKE

LENGTH

(mm)

CQM II

APPLICATOR

BASE

SHUT HEIGHT

(mm)

WORK

LIGHT

BATCH

COUNTER

SPECIAL

1725950-2

3000

41.25

Amp

135.79 ±0.025

Yes

---

1725950-3

3000

Amp

135.79 ±0.025

Yes

---

4-1725950-2

3000

41.25

Yes

Amp

135.79 ±0.025

Yes

---

4-1725950-3

3000

Yes

Amp

135.79 ±0.025

Yes

---

5-1725950-0

3000

Universal (Jam)

119.50 ±0.025

Yes

---

5-1725950-1

3000

Yes

Universal (Jam)

119.50 ±0.025

Yes

---

1725900-2

5000

41.25

Amp

135.79 ±0.025

Yes

---

1725900-3

5000

Amp

135.79 ±0.025

Yes

---

1-1725900-0

5000

Quick (Jam)

119.50 ±0.025

Yes

---

3-1725900-0

5000

41.25

Amp

135.79 ±0.025

Yes

Air

Feed/Overside

Guards

4-1725900-2

5000

41.25

Yes

Amp

135.79 ±0.025

Yes

---

4-1725900-3

5000

Yes

Amp

135.79 ±0.025

Yes

---

5-1725900-0

5000

Universal (Jam)

119.50 ±0.025

Yes

---

5-1725900-1

5000

Yes

Universal (Jam)

119.50 ±0.025

Yes

---

Figure 1

1. INTRODUCTION

This manual contains information on operation, preventive maintenance, and adjustments of the AMP 3K and

AMP 5K Terminating Machines 1725950-[ ] and 1725900-[ ] respectively. See Figure 1.

Both series machines (AMP 3K and AMP 5K) are equipped with precision crimp height adjustments and a

guard interlock.

Descriptions in this manual pertain to the controls and adjustments on the AMP 3K and AMP 5K machines

only.

When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.

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The specifications and requirements for the AMP 3K and AMP 5K Terminating Machines are as listed below:

Deflection

0.13 mm [.0046 in.] Maximum per 4,448 Newtons [1,000 lb] Crimp Force

Noise (Model 3k Series):

Less than 76 dBa Typical at operator position with standard mechanical feed applicator

Noise (Model 5k Series):

Less than 80 dBa Typical at operator position with standard mechanical feed applicator

Weight

68.86 Kilograms [143 lb]

Height

510 mm [20 in.] without reel supports

Electrical

100-240 Vac, 50/60 Hz, Single-Phase Current

Air

620-760 kPa [90-100 psi], 2.83 liters/sec (6 scfm) When required for use with air-feed applicators

Physical Environment:

Temperature: 4.4° to 40° C [40° to 104° F]

Relative Humidity: Less than 95% (non-condensing)

Transportation and Storage: Store in a clean, dry environment after coating all surfaces lightly with a rust

preventing oil.

Various TE applicators can be used in the AMP 3K and 5K terminating machines. Applicator instructions sheets

are packaged with each applicator. The applicator instruction sheets provide information on applicator

installation, care, and adjustment.

When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements

DANGER

Denotes an imminent hazard that may result in moderate or severe injury.

CAUTION

Denotes a condition that may result in product or equipment damage.

NOTE

Highlights special or important information.

NOTE

Dimensions in this customer manual are in metric units [with U.S. customary units in brackets]. Figures are not drawn to scale.

2. DESCRIPTION

The AMP 3K and AMP 5K Terminating Machines were designed to be used as stand-alone semi-automatic

bench units. They are assembled with metric hardware.

These machines accept a wide variety of miniature (mini) quick-change applicators (including the TE Ocean

Applicator), thus providing a great selection of terminals for many applications.

Older TE applicators use different feed cams depending on the machine stroke. Refer to Figure 2 for

changeover cams required to run 1 1/8-in. stroke cams (for AMP-O-LECTRIC* Model "K" terminating

machines) and 1 5/8-in. stroke cams (for Model "T" and Model "G" Terminating machines) in the machines.

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ORIGINAL APPLICATOR

FEED TYPE

CHANGEOVER CAMS FOR THE MACHINES

1 5/8-in. [41.25 mm]

Stroke Machines

1 1/8-in. [30 mm]

Stroke Machines

1 1/8-in. Stroke Applicator for

Model “K" Terminating Machine

Pre-Feed

690602-6

---

Post-Feed

690501-4

---

1 5/8-in. Stroke Applicator for

Model “T" and Model “G"

Terminating Machines

Pre-Feed

---

690602-5

Post-Feed

---

690501-3

Heavy-Duty Industrial (HD-I)

Applicator

Pre-Feed/Post-Feed

Refer to the HD-I Applicator customer drawing for part numbers.

Figure 2

2.1. Functional Description

These machines provide the force required to crimp terminals in the applicator. A terminal is attached to the

wire by placing the wire in the crimp area and pressing the footswitch. The machine consists of four functional

areas:

1. The motor group includes a dc motor which drives a crankshaft. The motor is activated each cycle

and rotates the crankshaft one full revolution. A 6 mm hex key placed in the recess located on the end

of the motor, can be used to cycle the motor manually. See Figure 3.

2. The crankshaft-ram group converts the motor’s rotational motion into the up-and-down action of the

ram for driving the applicator during the crimping cycle.

Figure 3

Crankshaft

DC Motor

Hex Key

Location for

Manual

Cycling

Power Cord

Receptacle

409-32034

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Figure 4

3. The base plate provides the mounting surface on which the applicator is installed. The quick-release

latching feature on machines with the AMP style base plate permits fast, easy installation and removal

of the applicator. Machines with the Universal style base plate do not include the quick-release

latching feature. See Figure 4.

4. The crimp height adjustment group uses an eccentric located in the ram linkage, along with

detented stops in the mechanism to adjust the crimp height. Indexing the mechanism in either

direction will change the crimp height in increments of approximately 0.013 mm [.0005 In.] per step.

Refer to Figure 4 for the Precision Crimp Height Adjustment Mechanism.

2.2. Electrical Description

The 1725950-[ ] and 1725900-[ ] machine electrical components consist of the operator control panel, the

motor, and the CPU/motor controller package. The machine operates on 100/240 Vac, 50/60 Hz, single-phase

current with ground. The machine will automatically detect the supply voltage and adjust the controller

accordingly.

The operator control panel (Figure 5) is mounted on the left side of the machine frame. The control panel

consists of two indicator lights, one jog button, and one speed control knob, with icons depicting each function.

See Figure 9 for control panel operation.

Precision Crimp Height

Adjustment Mechanism

Mounting Hole

AMP Style Applicator

Base Plate

Quick-Release

T-Handle

Universal Style

Applicator Base Plate

Base Plate for JAM

Style Applicators

Alternate Rear Stop

Mounting Position

Swing Handle

409-32034

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Figure 5

A main power switch/circuit breaker (Figure 6) is located on the back of the machine. This switch connects ac

power to the control system. The CPU/motor controller is located behind the back cover of the machine. It is a

modular unit that contains all of the electronics necessary to operate the machine. See Figure 6.

Machine

Ready Icon

Green

Indicator

Guard Open

Icon

Yellow

Indicator

Jog

Button

Speed

Control

Knob

Speed

Control

Icon

Fault Icon

Batch

Counter

(Optional)

Guard

Disable

Icon

Jog

Button

Icon

409-32034

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Figure 6

2.3. Machine Guard (Figure 7)

A guard is installed to provide protection for the operator while maintaining proper visibility of the work area.

The guard swings open to allow easy access for applicator installation and setup. A safety interlock on the

guard prevents the machine from cycling if the guard door is open during production operation.

Reel Support Hole

DC Motor

Power

Receptacle

Back Cover

CPU/Motor Controller

(Behind Back Cover)

Terminal

Strip Guide

Power

Switch/Circuit

Breaker

409-32034

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Figure 7

3. RECEIVING INSPECTION AND INSTALLATION

3.1. Receiving Inspection

These machines are thoroughly inspected during and after assembly. A final series of inspections is made to

insure the proper machine functioning before packaging and shipping.

To protect against damage that may have occurred during shipment, remove the machine from the crate

(Paragraph 3.2.) and carefully inspect the machine for damage. If damage is evident, file a claim against the

carrier and notify TE immediately.

3.2. Installation

Remove all mounting bolts securing the machine to the shipping pallet. Install lift ring (see Figure 7) on top of

the machine.

NOTE

Lift ring (M1220 eye bolt) is customer supplied.

NOTE

Install the lift ring carefully. A 19.05-mm [.75-in.] thread length engagement is required for the lift ring to support the machine.

Attach a suitable hoist to the lift ring, lift the machine, and place it in the selected operating location.

Insert the reel support post into the appropriate hole on top of the machine (Figure 6) until the roll pin engages

a groove in the machine frame.

Hole for Customer

Supplied Lift Ring

Precision Crimp Height

Adjustment Mechanism

Safety Interlock

Machine

Guard

Quick Release T-Handle

with AMP Style Base Plate

409-32034

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Attach the terminal strip guide included with the machine with the two thumbscrews supplied. Mount the guide

on the left guard for side-feed applicators. Mount the guide on the right guard for end-feed applicators.

Connect the power cord to a suitable electrical supply.

NOTE

The machine will automatically detect the supply voltage and adjust the controller accordingly.

3.3. Considerations Affecting Placement of Bench Machines

The location of the machine in relation to the operator's position is extremely important in terms of both safety

and maximum efficiency. Studies have repeatedly shown that operator fatigue will be reduced, and greater

efficiency achieved, if:

1. The bench is of appropriate height, preferably with sound-deadening rubber mounts.

2. The machine is properly located on the bench with ample work areas on both sides to facilitate work

flow.

3. The operator uses a swivel chair with padded seat and back rest which are independently adjustable;

and

4. The footswitch, on machines so equipped, is placed on a rubber mat to maintain its movability, while

preventing it from sliding unintentionally.

Figure 8 illustrates proper machine location and operator position and the following:

Bench

The bench to be used should be of sturdy construction, preferably with rubber mounts to minimize noise. A height of 762 to 812.8

mm [30 to 32 in.] is the most suitable for operator comfort and convenience. This height allows the operator to rest both feet on

the floor, thereby providing for the shifting of weight and leg position.

Machine Mounting and Location on Bench

The machine should be located near the front of the bench with the “target area" (tooling area where the product is applied) not

more than 152.4 to 203.2 mm [6 to 8 in.] -- minimum 50.8 mm [2 in.] from the front edge. This location will eliminate unnecessary

operator motion and help to avoid back strain and fatigue.

Orientation of the machine should be such that the “target area" is facing the front of the bench and is parallel to the front edge

(access to the back of the machine MUST also be provided).

DANGER

Machines should be securely bolted to the bench using the machine mounting hole(s) shown in Figure 4. Hardware is

customer supplied. Machines should not extend beyond the front of the bench.

Operator's Chair

The operator's chair should swivel, and should have independent seat height and back rest adjustments. The seat and back rest

should be padded, and the back rest should be large enough to provide support both above and below the waist line.

In use, the chair should be far enough under the bench so that the operator's back is straight and is supported by the back rest.

Footswitch

When the operator is correctly positioned in front of a machine equipped with a footswitch, the foot should rest on the switch

comfortably. The footswitch should be movable, so that its location can be 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 footswitch 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). Others prefer the

leg to be slightly in front of the natural position. The important thing to remember is that the foot should be at approximately 90°

(right angle) to the calf when resting on the switch. Those operators who prefer the footswitch slightly in front of the natural

position may require a wedge-shaped block placed under it.

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