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TE AMP 3K series Customer's Manual

Manual is about: Terminating Machine

Summary of AMP 3K series

  • Page 1

    1 of 31 © 2016 te connectivity family of companies all rights reserved *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 d...

  • Page 2

    409-32034 rev d 2 of 31 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 avo...

  • Page 3

    409-32034 rev d 3 of 31 part number capacity (lbs) stroke length (mm) cqm ii applicator base shut height (mm) work light batch counter special 1725950-2 3000 41.25 no amp 135.79 ±0.025 yes yes --- 1725950-3 3000 30 no amp 135.79 ±0.025 yes yes --- 4-1725950-2 3000 41.25 yes amp 135.79 ±0.025 yes yes...

  • Page 4

    409-32034 rev d 4 of 31 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 mechani...

  • Page 5

    409-32034 rev d 5 of 31 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 mod...

  • Page 6

    409-32034 rev d 6 of 31 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 pl...

  • Page 7

    409-32034 rev d 7 of 31 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 electron...

  • Page 8

    409-32034 rev d 8 of 31 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 ...

  • Page 9

    409-32034 rev d 9 of 31 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 dama...

  • Page 10

    409-32034 rev d 10 of 31 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...

  • Page 11

    409-32034 rev d 11 of 31 figure 8 scrap removal a suggested method of scrap removal: place a tray on the right side of the machine, under the cast slot in the frame, to capture the scrap chips. 4. Operation 4.1. Machine operation the machine is operated by the footswitch, the jog button, and the spe...

  • Page 12

    409-32034 rev d 12 of 31 cycling the machine when the footswitch is pressed to cycle the machine, the machine looks at the monitor’s output relays, relay 1 and relay 2. The indicator light, ds2, on the machine’s cpu/motor controller board indicates the status of relay 2. The light will be turned on ...

  • Page 13

    409-32034 rev d 13 of 31 figure 9 yellow indicator jog button speed control knob speed control icon green indicator machine ready icon fault icon jog button icon optional batch counter guard open icon guard disabled icon the green and yellow indicators on top of the control panel indicate the machin...

  • Page 14

    409-32034 rev d 14 of 31 4.3. Applicator installation note these instructions apply to machines that have an amp style base plate with the quick release feature. Machines with the universal style base plate, do not have a quick release feature and require a hex wrench to install an applicator. Machi...

  • Page 15

    409-32034 rev d 15 of 31 note machine should be able to jog through the terminal and wire at maximum jog speed. 3. Inspect the crimped terminal to verify that the terminal is being positioned properly within the applicator. 4. Correct for any positioning errors according to the applicator instructio...

  • Page 16

    409-32034 rev d 16 of 31 adjusting the jogging speed using the speed control knob the default speed of the machine, when jogging, is set to a minimum value which is not defined by the initial position of the speed control knob. Adjusting the speed upward enables jogging at speeds greater than the de...

  • Page 17

    409-32034 rev d 17 of 31 4.6. Crimp height adjustment refer to paragraph 7.3. For procedures to adjust the crimp height using the machine precision adjustment feature. 4.7. End-feed/side-feed applicator conversion when changing from an end-feed applicator to a side-feed applicator (or from a side-fe...

  • Page 18

    409-32034 rev d 18 of 31 6. Preventive maintenance preventive maintenance will keep the machine in good working order and ensure maximum reliability and service from all of its components. Danger to avoid personal injury, electrical and pneumatic power must be disconnected at the source prior to mai...

  • Page 19

    409-32034 rev d 19 of 31 figure 11 7. Adjustments the following adjustments are necessary to maintain the machine in operating condition, and to set up the machine after replacing parts. Danger to avoid personal injury, always disconnect electrical and air supplies before performing adjustments. 7.1...

  • Page 20

    409-32034 rev d 20 of 31 figure 12 7.2. 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 machine, contact your local field service representative, or call the tooling...

  • Page 21

    409-32034 rev d 21 of 31 b. Re-install the ram post adaptor. Insert both screws in the ram post adaptor and place the shims over the screws and onto the adaptor post. C. Re-install the socket head cap screws into the ram assembly to secure the ram post adaptor. Re- tighten the screws. 3. Repeat step...

  • Page 22

    409-32034 rev d 22 of 31 figure 13 7.4. Guard insert adjustment a guard insert is supplied with the machine. Some applications may require a special insert. See figure 14 for available guard inserts. The guard contains two slots into which the inserts can be placed: the rear slot places the insert c...

  • Page 23

    409-32034 rev d 23 of 31 guard insert dimension part number description a b 354529-2 standard (away from the applicator) 7.80 [.307] 6.35 [.250] 1-679532-0 standard (close to the applicator) - shipped with the machine 6.22 [.245] 5.08 [.200] 679994-2 near tape 6.35 [.250] 6.35 [.250] 679995-2 away f...

  • Page 24

    409-32034 rev d 24 of 31 8. Machine options and installation the following machine options are available for the amp 3k and amp 5k machines: part number description purpose 1424264-1 work light kit (64111 osram/sylvania) provides lighting to the work area 1424266-1 air feed valve kit with 40-mm [15/...

  • Page 25

    409-32034 rev d 25 of 31 figure 16 8. Attach the light (as shown in figure 16, detail a) to the top of the user interface enclosure using the socket screws provided. 9. If equipped with batch counter kit 1424267-1, insert the batch counter kit into the appropriate knockout opening until it snaps int...

  • Page 26

    409-32034 rev d 26 of 31 11. Install the user interface assembly into the frame and secure using the two socket head screws. Caution be sure the interface assembly wiring harness is not pinched or kinked. 12. Close the clear guard on the machine. 13. Connect the machine to the power source and turn ...

  • Page 27

    409-32034 rev d 27 of 31 figure 18 8.3. Installation of batch counter kit 1424267-1 danger to avoid personal injury, be sure to turn "off" the machine, and disconnect it from the power source. 1. Open the clear guard on the machine to gain access to the two socket head screws securing the user inter...

  • Page 28

    409-32034 rev d 28 of 31 9. Install the user interface assembly into the frame and secure using the two socket head screws. Caution be sure the interface assembly wiring harness is not pinched or kinked. 10. Close the clear guard on the machine. 11. Connect the machine to the power source and turn t...

  • Page 29

    409-32034 rev d 29 of 31 2. Remove the control panel from the machine and pivot it in order to view the control board. 3. Insert the small end of the air feed cable assembly (see customer drawing 1424266) into the j7 socket. See figure 20. 4. Install the control panel into the machine with the air f...

  • Page 30

    409-32034 rev d 30 of 31 figure 21 9. Connect the air lines to the applicable ports. 10. Turn the air "on" by moving the slide valve toward the filter. Note the air can be turned "off "by moving the slide valve away from the filter. Figure 22 11. Lock the air in the "off" position. Turn the air "off...

  • Page 31

    409-32034 rev d 31 of 31 figure 23 9. Troubleshooting contact the tooling assistance center at 1-800-722-1111. 10. Rohs information information on the presence and location of any substances subject to rohs (restriction on hazardous substances) can be found at the following website: http://www.Tycoe...