Tri-Star TAC-10X, Operation & Maintenance Manual

Page 1: ...Page 1 TAC 10X OPERATION MAINTENANCE MANUAL TRI STAR TECHNOLOGIES 2201 ROSECRANS AVE EL SEGUNDO CA 90245 WWW TRI STAR TECHNOLOGIES COM September 2018 Rev 1 0 AUTOMATIC CONTACT CRIMPER ...

Page 2: ...ation of the Vibratory Feed Crimper It is not intended to be used as the guide to perform major adjustments or to effect major repairs Consult the factory if adjustments or repairs other than those described herein are necessary WARNING This machine must be supplied with a clean dry oil free air supply Absence of such will void warranty ...

Page 3: ... TABLE OF CONTENTS Section Title 1 Introduction 2 Initial Set up 3 Crimp Verification 4 Operating Procedures 5 Theory of Operation 6 Maintenance and Troubleshooting 7 Parts List Electrical Pneumatic Diagrams ...

Page 4: ... to periodically change the air filter or drain it Crimp acceptability should be verified in accordance with the user s normal practices lndenters used in the TAC 10X are qualified to the M22520 specification and are of the highest quality to ensure a substantial quantity of acceptable terminations Reasonable care must be exercised however to prevent any foreign matter particularly hard substances...

Page 5: ...Page 5 Figure 1 1 TAC 10X Front View ...

Page 6: ... when a properly stripped conductor is inserted into the contact to be crimped and depressed Depressing the contact with the conductor inserted triggers the TAC when the crimp is completed the operator withdraws the conductor with the contact now attached the TAC re cycles and places another contact in proper position the operator inserts another properly stripped wire into the contact depresses i...

Page 7: ...Page 7 Figure 1 2 Wire Insertion Through Funnel ...

Page 8: ...not stripped to proper length Operators usually get the feel of the machine within 15 minutes of use Noise generated by the device is minimal operators have been observed to develop a rhythm of insertion and withdrawal based on the unique sounds generated by the device Crimp rates of 1800 crimps per hour have been attained TAC 10X SPECIFICATIONS TAC 10X most shouldered and shoulder less contacts W...

Page 9: ...g the ship ping container Step 2 Carefully lift the top and sides of the container until all sides are clear of the TAC Step 3 Inspect for damage If damage due to shipping is observed do not continue Contact the factory and the shipping carrier Step 4 Carefully raise the TAC using only the baseplate for lifting then set the machine on a smooth level working surface Step 5 The shipping container ma...

Page 10: ...Page 10 Figure 2 1 Pneumatic Hook Ups Air Off Air On ...

Page 11: ...source European 220 VAC 5O Hz 5A Refer to Figure 2 2 below AC Input Figure 2 2 AC Hook Ups Each contact requires its own unique tool set The shoulder less tool set includes track and shuttle mechanism These exactly machined parts are already installed and configured per your requirements TOOL SETS ...

Page 12: ...Page 12 Figure 2 3 Shoulder less Track Assembly Track Assembly Figure 2 4 Shoulder less Track Assembly ...

Page 13: ...y after the TAC has been set up Section 2 Although the procedure is the same as all other verification tests it affords the user an opportunity to record data before the machine has been used extensively Read and understand Section 4 Operating Procedures before performing the verification This paragraph details the procedure to verify TAC s with a fixed G dimension and with an operator selectable ...

Page 14: ... Go 22 1 26 016 021 22 2 24 019 024 22 3 22 022 027 20 4 24 025 030 20 5 22 029 034 20 6 20 033 038 16 1or 4 20 029 034 16 2 or 5 18 033 038 16 3 or 6 16 037 042 TABLE 3 1 GO NO GO DIMENSIONS M22520 7 01 Step 7 Using only hand pressure extend the arbor as far to the right as it will go Refer to Figure 3 2 Step 8 Using GO and NO GO gauges open the funnel and insert gauges into the indenters to dete...

Page 15: ...tor into the funnel until it bottoms out Step 18 When the conductor bottoms out the crimp cycle will initiate Step 19 When the crimping cycle is complete the funnel will open at this time remove the conductor When the funnel opens remove the conductor smoothly by simply pulling it towards yourself Step 20 Inspect the crimp per required specifications Step 21 Below figures are samples of inspection...

Page 16: ...Page 16 Crimp Inspection Points Improper Crimps Figure 3 3 Crimped Samples ...

Page 17: ...d then only when authorized This section assumes the TAC has been set up properly and that Crimp Verification has been performed Sections 2 and 3 Read this section completely before operating the TAC Perform the following steps to operate the TAC Make sure AC is on and sleeve valve is closed Air On Step 1 Set the feeder bowl power on off switch to on Step 2 Observe that the feeder bowl is vibratin...

Page 18: ... properly stripped conductor Select the proper G dimension setting See Table 4 1 TABLE 4 1 EXTERNAL G SELECTIONS SETTING WIRE SIZE For 22 gauge contacts 1 26 AWG 2 24 AWG 3 22 AWG For 20 gauge contacts 4 24 AWG 5 22 AWG 6 20 AWG G Selector Contacts loading in feed tube are controlled by Feed Tube Sensor If feed tube is full the sensor detects and shuts off feeder bowl As feeder tube empties sensor...

Page 19: ...trigger Step 8 When the trigger is fully activated the crimp cycle is initiated When the crimp cycle is complete the funnel will open Smoothly pull the conductor out immediately after the funnel opens NOTE Do not attempt to remove the conductor until the funnel opens A built in safety feature precludes the transfer mechanism from returning to the vertical position until the crimped contact is remo...

Page 20: ...ied to the TAC via the input at the sleeve valve The operator controlled Sleeve Valve SV supplies air to all valves air cylinders air sensors and air activated switches Electrical power is suppled to the TAC control system via an internally mounted transformer Transformer and feeder bowl power is supplied from standard 120V outlet European model 220V Transformer power is switched on via switch S 5...

Page 21: ...vated air pressure is supplied to the extend portion of the Crimp Cylinder CR 1 initiating the crimp cycle Note This event is precluded from happening if no part exists in the transfer tip The mechanics of the Crimp Cylinder are such that unless the cylinder moves closes enough to block the air bleed at the Crimp Head Forward sensor G Sensor and allow air pressure to be applied to S 4 the system w...

Page 22: ...e drop tube If the contact exits the Drop Tube and seats properly in the Transfer Tip adequate vacuum will exist to switch on the Transfer Tip Sensor S 6 Supply for Vacuum Sensor switch is provided by Vacuum Generator VG 1 If a contact does not seat properly in the Transfer Tip the cycle will terminate until reset With S 6 turned on again V 2 is turned off allowing the Transfer Arm to return to th...

Page 23: ...en draining The vacuum filter RFV 1 can easily be located in line between the transfer tip holder and the TAC Control Unit If the vacuum filter becomes clogged decreased performance with part detection at the transfer tip will be observed When this situation occurs replacement of the vacuum filter is suggested Please note the vacuum filter orientation when removing as the replacement filter must b...

Page 24: ...Page 24 Figure 6 1 TAC 10X Pneumatic Control Panel ...

Page 25: ...Page 25 Figure 6 2 TAC 10X Components Right View ...

Page 26: ...Page 26 PLC Controller Switching Power Supply Figure 6 3 TAC 10X Components Left View ...

Page 27: ...nter the shoulder less track either wire barrel or hooded end first If they enter wire barrel first they will rotate 90 degrees counter clockwise and drop This is because the wire barrel end is lighter than hooded end If contact enters hooded end first the opposite action will occur Part will rotate 90 degrees clockwise and drop Figure 6 6 TAC 10X Shoulder less Track Assembly ...

Page 28: ...from the transfer tip Close the sleeve valve to reset the system Please note the TAC system has a sensor that detects if proper transfer tip is being used based on which feeder bowl is selected via the HMI control panel If wrong tip is inserted system will not operate and error message will appear on HMI display See error message details described later in this section Step 2 Verify the alignment ...

Page 29: ...d Figure 6 5 Step 8 Remove the four screws securing the indenter plate Step 9 Carefully lift the indenter plate up from the housing such that the cam arm disengages smoothly from the arbor shaft It may be necessary to manually move the arbor shaft to the left Step 10 Carefully turn the indenter plate over exposing the indenter cam CAUTION DO NOT PINCH THE AIR LINE Step 11 Refer to Figure 6 5 Step ...

Page 30: ...Page 30 ...

Page 31: ...Page 31 Carefully Remove Hose Clamp ...

Page 32: ...stalled Paragraph 6 8 Perform the following steps to adjust indenters Step 1 Open the sleeve valve Step 2 Disconnect the air supply from the sleeve valve Step 3 Remove the crimp cylinder arbor cover plate and the funnel cover plate Step 4 Refer to Table 6 1 If the TAC Crimper has an operator adjustable G dimension control set the control to setting 6 the largest wire gauge If the setting is not ad...

Page 33: ...tafford clamp collar being careful not to change the adjustable stop position Step 13 Repeat steps 5 and 6 NOTE Operator adjustable G dimension TAC s should be adjusted at setting 6 If desired after adjustment has been completed GO NO GO verification may be performed for the remaining settings Step 14 Install the crimp cylinder arbor cover plate and the funnel cover plate removed in Step 3 Step 15...

Page 34: ...Page 34 ...

Page 35: ...h conductor wire gauge to obtain the necessary specimens inspect per established procedure Step 24 After all specimens have been produced set the power on off switch to off and open the sleeve valve Step 25 If crimps meet all established parameters certify the TAC 10X for production use and establish a periodic verification schedule ...

Page 36: ...inder N 1 Slide Cylinder Valve TAC A 110 4EI R 1 SystemAir Regulator TAC 601 3009 2 R 2 N 1 Slide Cylinder Regulator TAC R 900 30 R 3 N 1 Slide Sensor Regulator TAC R 900 10 R 4 G stop Sensor Regulator TAC R 900 10 VG 1 Vacuum Generator TAC ME 03 G 1 Gauge R 1 TAC 206804 G 2 Gauge R 2 TAC 206804 FP 1 FirstPartSwitch TAC SV 3 M5 LS 1 Limit Switch TAC 41P FC 1 Funnel Cylinder 2 TAC SM3 2 SC 1 N 1Sli...

Page 37: ... 05 06 07 0CH 100CH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 out sens 1 2 3 4 5 6 7 8 9 10 11 12 13 14 S1 Slide sensor com no S2 Limit Switch com no S3 com no First Part S4 G Stop com no S6 Transfer Tip com no S5 On Off Sensor com no Transfer Arm Cyl Slide Cyl Crimp Cyl Prox Sen CN1F CN1M _ 24VDC 0VDC 24VDC POWER SUPPLY 7 8 9 10 11 12 17 13 14 15 7 8 9 10 11 12 13 14 15 0 1 L N G 110VAC CP1L L...

Page 38: ...Page 38 Figure 7 3 TAC 10X Pneumatic Diagram ...

Page 39: ...TRI STAR TECHNOLOGIES 2201 ROSECRANS AVE EL SEGUNDO CA 90245 WWW TRI STAR TECHNOLOGIES COM FOR MORE INFORMATION www tri star technologies com ph 310 536 0444 fax 310 526 9322 ...