Tri-Star TAC 17X, Operation & Maintenance Manual

Page 1: ...Page 1 TAC 17X OPERATION MAINTENANCE MANUAL TRI STAR TECHNOLOGIES 2201 ROSECRANS AVE EL SEGUNDO CA 90245 WWW TRI STAR TECHNOLOGIES COM October 2018 Rev 2 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: ...t 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 17X 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 substance...

Page 5: ...Page 5 Figure 1 1 TAC 17X 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 17X SPECIFICATIONS TAC 17X most shouldered and shoulder less contacts W...

Page 9: ...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 may be discarded However if reshipment to another loca...

Page 10: ...Page 10 Primary air input at rear of TAC Figure 2 1 Pneumatic Hook Ups ...

Page 11: ...e 2 2 below AC Input AC On Off Figure 2 2 AC Hook Ups Each contact requires its own unique tool set The shouldered tool set includes transfer tip track assembly and escapement spacer 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 Escapement Spacer Track Assembly Figure 2 3 Shouldered Tool Set Track Assembly Figure 2 4 Shouldered less Tool Set ...

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: ...llowed and 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 switch is on and sleeve valve is closed Step 1 Select the desired feeder bowl on off switch from HMI display Step 2 Observe that th...

Page 18: ...t is present let the funnel close and proceed to Step 5 If no contact is present repeat Step 3 Step 5 Obtain a 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 ...

Page 19: ...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 removed from the transfer tip Step 9 Visually inspect the crimp as required See Figure 3 3 St...

Page 20: ...s Reset button Observe shuttle mechanism movement to the left If required the drop tube can now be exchanged Step 2 Depress Bowl 2 switch to turn off bowl Then depress Bowl 1 switch to turn on Bowl 1 Adjust bowl amplitude if required Step 3 Depress Shoulderr less switch to load first contact SWITCHING BOWLS ...

Page 21: ...g this Theory of Operation Air pressure is supplied to the TAC via the primary input and sleeve valve The primary air supply is used to control release of shoulder less contacts at shoulder less shuttle mechanism 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 intern...

Page 22: ...enoid at V 1 With V 1 activated 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 a...

Page 23: ...r less Contact Shuttle mechanism is activated moving contact from staging area to 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...

Page 24: ...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 25: ...Page 25 Figure 6 1 TAC 17X Pneumatic Control Panel ...

Page 26: ...Page 26 Figure 6 2 TAC 17X Components Right View ...

Page 27: ...Page 27 PLC Controller Switching Power Supply HMI Display Figure 6 3 TAC 17X Components Left View Stepping Motor Controller ...

Page 28: ...urce in conjunction with periodic filter inspection will prevent pneumatic components from jamming clogging or otherwise malfunctioning The feed of shouldered contacts onto and into the track assembly is the result of the feeder bowl vibrations and the setting of several air pressure controls The TAC base plate must be level and solid Feeder bowl vibrations transport contacts to the top of the bow...

Page 29: ... 6 5 6 6 LODGED CONTACT SHOULDER LESS CONTACT TRACK FEED Figure 6 5 TAC 17X Shoulder less Bowl Contacts enter 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 r...

Page 30: ...p 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 between the transfer tip and drop tube If alignment appears off consult the factory or your local area service representative for further i...

Page 31: ...osing system malfunctions the TAC system has sensor status display in the HMI control panel To view sensor statuses press Sensor switch from main display SENSOR STATUS Below is view of Sensor Status Panel Click Main to return to Main Screen ...

Page 32: ...Page 32 Sensor switch status are indicated by color intensity of indicator light Dark color indicates sensor is Not Active ...

Page 33: ...e indicator will be light blue Activated sensor light blue indicates cam arm assembly is closed extended and has not retracted Limit Switch Sensor indicates when the limit switch is engaged transfer arm in up position If transfer arm is in full up position indicator light should be light blue Slide Sensor Switch Sensor indicates when the Transfer Tip slide is fully depressed wire has pushed contac...

Page 34: ...een indicates a shoulder less transfer tip is loaded dark green indicates a shouldered transfer tip is loaded Bowl On Off switch indicates when Shoulder less feeder bowl has been turned off via the bowl on off sensor This sensor monitors the feed tube from the shoulder less bowl Once feed tube is full the bowl is shut down thus preventing any contact jamming If bowl switch is light green bowl will...

Page 35: ...and or contact drop position follow below instructions In order to gain access to shuttle adjustment screen you must first login by depressing Login button Default Login User name usr0 Password 1234 Once you enter login information press Setup button to move to Shuttle adjustment page SHUTTLE ADJUSTMENT ...

Page 36: ...Page 36 Shuttle Adjustment Enter appropriate distances in 1mm increments in either of the two adjustment boxes When adjustments are complete press Main to return to Home Screen ...

Page 37: ...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 38: ...Page 38 ...

Page 39: ...Page 39 Carefully Remove Hose Clamp ...

Page 40: ...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 41: ...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 42: ...Page 42 ...

Page 43: ...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 17X for production use and establish a periodic verification schedule ...

Page 44: ...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 45: ...1 12 13 14 S1 Slide sensor com no S2 Limit Switch com no S4 G Stop com no S6 Transfer Tip com no S5 On Off Sensor com no Transfer Arm Cyl Slide Cyl Crimp Cyl CN1F CN1M _ 24VDC POWER SUPPLY 7 8 9 10 11 12 17 13 14 15 7 8 10 11 12 13 14 15 0 1 L N G 110VAC CP1L EM30DTDT D CRIMPER _ Com 1CH 00 01 02 03 04 05 00 01 02 03 101CH Com 0 23 24 16 19 20 18 21 22 21 22 0 1 17 16 19 20 18 4 3 V1 0 5V V2 0 5V ...

Page 46: ...3 4 5 6 out sens Prox Sen Motor For the Slide Motor Driver A A B B _ VDC Red Blue Yellow White Transfer trip Detector Sensor _ sig TOUCH SCREEN _ BOWL CONTROLLER BOWL CONTROLLER Com Step Dir _ _ V1 V2 Prox sensor L N L N 2 2k 2 2k 1 0 1 9 1 9 21 22 1 1 9 1 9 1 9 23 1 5 V1 4 3 1 0 1 0 1 0 1 0 V2 17 1 9 Home Switch 24 1 4 Sensor Amplifier 09 07 2018 K1 K1 K2 K2 18 16 1 9 1 9 ...

Page 47: ...Page 47 Figure 7 3 TAC 17X Pneumatic Diagram ...

Page 48: ...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 ...