Tri-Star TAC-7AE, Operation & Maintenance Manual

Page 1: ...TAC 7X MANUAL TAC 7X Vibratory Feed Automatic Crimper Tri Star Technologies 2201 Rosecrans Ave El Segundo CA 90245 ph 310 536 0444 fax 310 536 9322 OPERATION MAINTENANCE MANUAL www tri star technologies com July 2017 Rev 1 0 ...

Page 2: ...st users in the initial set up verification and operation 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 ...

Page 3: ...WARNING This machine must be supplied with a clean dry oil free air supply Absence of such will void warranty ...

Page 4: ...f Contents Section Title 1 Introduction 2 InitialSet up 3 Crimp Verification 4 Operating Procedures 5 Theory of Operation 6 Maintenance Troubleshooting 7 Parts List Electrical Pneumatic Diagrams TAC 7X MANUAL ...

Page 5: ...ept 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 7X 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 substanc...

Page 6: ...Figure 1 1 TAC 7X Front View ...

Page 7: ...r 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 it slightly and the cycle repeats F...

Page 8: ... Figure 1 2 Wire Insertion Through Funnel ...

Page 9: ...was probably 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 exceeding 2000 crimps per hour have been attained 4 TAC 7X Specifications TAC 7X mostshoulderedcontacts W...

Page 10: ...ival of the device The bottom base piece of the container holds the TAC the other pieces of the shipping container consists of the top and four sides which are secured to the bottom base by mounting straps To Uncrate Unpack the TAC Step 1 Carefully cut all mounting straps surrounding the ship ping container Step 2 Carefully lift the top and sides of the container until all sides are clear of the T...

Page 11: ... packing mate rial be retained INITIAL INSTALLATION AND SETUP Perform the following steps to hook up the pneumatic input Step 1 Referring to Figure 2 1 obtain a 1 4 in male air fitting not supplied with the TAC that is compatible with the air supply and sleeve valve on top of the controller cabinet The sleeve valve is used to turn the air and controller ON and OFF The air supply must be approx 80 ...

Page 12: ...Figure2 1 Pneumatic Hook Up ...

Page 13: ... the air gauge to ensure a pressure of about 80 PSI at G 1 Step 3 Turn ON the FEEDER BOWL ON OFF switch Step 4 While gently touching the feeder bowl with your right hand slowly rotate the FEEDER BOWL SPEED CONTROL Step 5 Note that the feeder bowl vibrates more rapidly when the SPEED control is rotated clockwise and vibrates less rapidly when the SPEED control is rotated counterclockwise Step 6 Clo...

Page 14: ... Fiqure 2 4 Track Drop Tube Escapement ESCAPEMENT SYSTEM _ _ _ BR ASSEMBL I TRA ...

Page 15: ...e following steps to ascertain that the functional operation of the TAC is satisfactory Step 1 Load the feeder bowl with approximately 1000 2000 contacts Step 2 Set the feeder bowl power on off switch to on Step 3 Observe the feeder bowl and set the variable vibration control to a setting which feeds contacts around the bowl at a rate of approximately 1 inch second Step 4 Observe that after a whil...

Page 16: ...nt in the transfer tip in the ready to crimp position If no contact is present release the funnel depress the First Part Switch see Figure 6 1 and repeat Step 8 Step 14 Open the sleeve valve Step 15 Swing the transfer arm to the almost vertical position and remove the contact from the transfer tip manually Step 16 Repeat Steps 6 through 16 until satisfied that contact transfer operates satisfactor...

Page 17: ...to verify acceptable crimps The Initial Crimp Verification should be performed immediately 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 detail...

Page 18: ... ARBOR COVER PLA TE REMOVED Figure 3 1 Crimp Cylinder Arbor Open ...

Page 19: ...20 7 01 Step 7 Using only hand pressure extend the arbor as far to the left 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 determine the G dimension Step 9 Record the GO NO GO dimensions Conta ct Gaug Setting Wire Gauge Go No 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...

Page 20: ... ARBOR COVER PLAT E REMOVED Figure 3 2 Crimp Cylinder Arbor Closed ...

Page 21: ... in the ready to crimp position Step 16 Using a conductor of proper material and gauge strip it to the proper strip length If applicable set the operator adjustable G dimension control to the proper setting Step 17 While being careful that all conductor strands enter the funnel without bending back insert the conductor into the funnel until it bottoms out Step 18 When the conductor bottoms out the...

Page 22: ...en produced set the power on off switch to off and open the sleeve valve Step 24 If crimps meet all established parameters certify the TAC 7X for production use and establish a periodic verification schedule 3 Periodic Crimp Verification Perform Periodic Crimp Verification in the same manner as the Initial Crimp Verification Users may desire to prepare an equipment data sheet upon which G and T an...

Page 23: ... Crimp Inspection Points Improper Crimps ...

Page 24: ...ification has been performed Sections 2 and 3 Read this section completely before operating the TAC Perform the following steps to operate the TAC Step 1 Set the feeder bowl power on off switch to on CAUTION KEEP HANDS CLEAR OF THE TRANSFER MECHANISM DURING OPERATION AND WHEN CLOSING THE SLEEVE VALVE NOTE IMPORTANT NEVER TURN ON SLEEVE VALVE WITH A CONTACT LOADED INTHE TRANSFER TIP IF LOADED TURN ...

Page 25: ...ain a properly stripped conductor or coil of properly stripped conductors Select the proper G dimension setting if applicable See Table 4 1 TABLE 4 1 EXTERNAL G SELECTIONS SETTING WIRE SIZE For 22 gauge contacts 1 26 gauge 2 24 gauge 3 22 gauge For 20 gauge contacts 4 24 gauge 5 22 gauge 6 20 gauge Step 8 Carefully and smoothly insert a conductor into the funnel being careful all conductor strands...

Page 26: ... 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 11 Visually inspect the crimp as required See Figure 3 3 Step 12 Repeat Steps 7 through 12 until all crimps are made Select the proper...

Page 27: ...g funnel opening contact ready to crimp etc The only precautions an operator need observe are 1 Do not insert a conductor so fast as to force conductor strands to spring back out of the contact 2 Remove the crimped conductor only when the crimp cycle is complete 3 Remove the crimped conductor immediately after the funnel opens 4 Be certain the feeder bowl is filled only with the proper type contac...

Page 28: ...nt has properly occurred subsequent events will not occur This design in conjunction with high tolerance machined components reduces significantly the possibility of initiating crimps on incorrect contacts or proceeding to crimp additional contacts if proper crimp tolerances are not being achieved If the crimped contact conductor is not removed after the crimping cycle is complete the TAC will pau...

Page 29: ...uired Indiscriminate changes to regulator or switch settings should not be made A clean air supply is imperative to proper system operation Filter F 1 should be drained or changed as required 3 Initial Turn On Reset Reset occurs any time the operator controlled sleeve valve is initially closed or opened and then closed Upon closing the sleeve valve air pressure is supplied to the TAC When the slee...

Page 30: ...s 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 will terminate its cycle until reset The purpose of this feature is to insure the Crimp Cylinder has advanced to correspond to the G dimension set Supply for G Sensor Air Bleed is provided by R 4 If the...

Page 31: ...ctivated closing funnels Escapement Cylinder EC 1 is activated allowing a contact to be advanced from the track assembly to the 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...

Page 32: ...ccumulated moisture on the bottom the moisture should be drained by placing a cup or other container under F1 opening the sleeve valve opening the F1 drain and draining the filter Do not allow the moisture to spray drip or enter the cabinet when 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 clogg...

Page 33: ...Figure 6 1 TAC 7X Components ...

Page 34: ...Figure 6 2 Control Box Components Figure 6 2 TAC 7X Components Right View ...

Page 35: ...PLC Controller Switching Power Supply Vibratory Feed Controller Figure 6 3 TAC 7X Components Left View ...

Page 36: ... 6 3 Feeder bowl vibrations transport contacts to the top of the bowl where the combination of vibrations and air pressure from the tube controlled by BR 1 permits contacts to orient themselves vertically in the track Air pressure controlled by BR 2 forces the contacts towards the escapement system Air pressure controlled by BR 3 forces contacts not oriented vertically to return to the feeder bowl...

Page 37: ...Figure 6 3 Contact Track Feed Air Adjustments ...

Page 38: ...the escapement system to its operating position that both sections be firmly set in place and secured with the black locking handle If a contact lodges itself in the drop tube always remove it by inserting a thin object from the bottom of the drop tube and pushing the contact out the top Refer to Figure4 1 Use only a smooth non metallic object The transfer tip is equipped with a vacuum sensing sys...

Page 39: ...k should be heard from the switch each time it is activated NOTE Should the work environment be too noisy for an effective audible check an electrical meter may be used instead Top tab is common bottom tab is normally open position Step 4 If switch S 6 fails the above test consult factory for adjustment instructions No adjustments should be attempted prior to factory instructions 7 Trigger Slide S...

Page 40: ...S 1 is switching on and off An audible click should be heard from switch each time it is activated NOTE 8 lndenters Replacement Should the work environment be too noisy for an effective audible check an electrical meter may be used instead Top tab is common middle tab is normally open position Step 8 lf switch S 1fails the above test consult factory for adjustment instructions No adjustments shoul...

Page 41: ... the funnel cover plate Step 7 Refer to Figure 6 4 and 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...

Page 42: ... Figure 6 4 Indenter Plate Removal ...

Page 43: ...HOSE CLAMP CAREFULL Y REMOVE Figure 6 5 Indenter Replacement ...

Page 44: ... indenter plate insert the cam arm into the arbor shaft and set the plate onto the housing The arbor shaft can be rotated slightly to facilitate cam arm insertion Step 17 Proceed to Paragraph 6 9 Step 4 The adjustment of indenters should be performed whenever existing indenters are slightly worn and G dimension is out of tolerance when Crimp Verification Section 3 dictate adjustment is necessary a...

Page 45: ...argest wire size TABLE 6 1 GO NO GO DIMENSIONS Step 5 Using only hand pressure extend the arbor as far to the left as it will go Step 6 Using appropriate GO NO GO gauges open the funnel and insert gauges into the indenters to determine the G dimensions Conta ct Gaug Setting Wire Gauge Go No 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 ...

Page 46: ...ps 5 through 10 until the G dimension is within acceptable parameters Step 12 Hand tighten the Stafford clamp collar being careful not to change the adjustable stop posi tion Step 13 Repeat steps 5 and 6 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 Insta...

Page 47: ...Figure 6 6 Indenter Adjustment ...

Page 48: ...he funnel without bending back insert the conductor into the funnel until it bottoms out Step 21 Crimp the conductor Step 22 Inspect the crimp per required specifications Step 23 Repeat Steps 19 through 22 for each 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 s...

Page 49: ...ng and replacing defective components The following is a list of malfunctions that may occur during operation Following the malfunction specified are probable causes of that mal function Refer to applicable handbook sections for correction MALFUNCTION CAUSE 1 No contacts in track assembly 2 No contact in transfer tip a Feeder bowl off b Feeder bowl amplitude too high c Feeder bowl amplitude too lo...

Page 50: ...nnel Cylinder N 1 Slide TAC A 110 4EI Cylinder Valve 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 Limtt Switch TAC 41P FC 1 Funnel Cylinder 2 TAC SM3 2 SC ...

Page 51: ...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 L20DT D CRIMPER TAC 7X Electrical Dia...

Page 52: ...TAC 7X Pneumatic Diagram ...