SDE Electrc Bench Termnator 1490076-2 Customer Manual 409-10052 31 JAN 12 customer manual SAFETY A. PRECAUTIONS READ THIS FIRST!............................ 2 1. INTRODUCTION........................................................ 3 2. DESCRIPTION.......................................................... 4 3. RECEIVING INSPECTION AND INSTALLATION............................... 5 3.1. Recevng Inspecton.................................................. 5 3.2. Installaton.......................................................... 6 4. OPERATION........................................................... 6 4.1. Installaton and Removal of SDE Tool Head 1763663-2....................... 6 4.2. Installaton of Crmpng Des............................................ 8 4.3. Termnator Power Supply.............................................. 9 4.4. Producton Operaton................................................. 9 5. CRIMP HEIGHT ADJUSTMENT............................................ 10 6. TROUBLESHOOTING.................................................... 11 7. MAINTENANCE AND INSPECTION......................................... 11 7.1. Cleanng........................................................... 12 7.2. Vsual Inspecton..................................................... 12 7.3. Lubrcaton......................................................... 12 7.4. Parts Lst........................................................... 12 8. REPLACEMENT AND REPAIR............................................. 12 9. CIRCUIT DIAGRAM...................................................... 13 10. RoHS INFORMATION................................................... 13 11. REVISION SUMMARY................................................... 13 ORIGINAL INSTRUCTIONS 2012 Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company All Rghts Reserved *Trademark TOOLING ASSISTANCE CENTER 1-800-722-1111 Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.te.com TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of ther respectve owners. 1 of 14 LOC B
DANGER SAFETY PRECAUTIONS AVOID INJURY Safeguards are desgned nto ths applcaton equpment to protect operators and mantenance personnel from most hazards durng equpment operaton. However, certan safety precautons must be taken by the operator and repar personnel to avod personal njury, as well as damage to the equpment. For best results, applcaton equpment must be operated n a dry, dust-free envronment. Do not operate equpment n a gaseous or hazardous envronment. Carefully observe the followng safety precautons before and durng operaton of the equpment: ALWAYS wear approprate ear protecton. ALWAYS wear approved eye protecton when operatng powered equpment. ALWAYS keep guard(s) n place durng normal operaton. ALWAYS nsert power plug nto a properly grounded receptacle to avod electrcal shock. ALWAYS turn off the man power swtch and dsconnect electrcal cord from the power source when performng mantenance on the equpment. NEVER wear loose clothng or jewelry that may catch n movng parts of the applcaton equpment. NEVER nsert hands nto nstalled applcaton equpment. NEVER alter, modfy, or msuse the applcaton equpment. TOOLING ASSISTANCE CENTER CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY) The Toolng Assstance Center offers a means of provdng techncal assstance when requred. In addton, Feld Servce Specalsts are avalable to provde assstance n the adjustment or repar of the applcaton equpment when problems arse whch your mantenance personnel are unable to correct. INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER When callng the Toolng Assstance Center regardng servce to equpment, t s suggested that a person famlar wth the devce be present wth a copy of the manual (and drawngs) to receve nstructons. Many dffcultes can be avoded n ths manner. When callng the Toolng Assstance Center, be ready wth the followng nformaton: 1. Customer name 2. Customer address 3. Person to contact (name, ttle, telephone number, and extenson) 4. Person callng 5. Equpment number (and seral number f applcable) 6. Product part number (and seral number f applcable) 7. Urgency of request 8. Nature of problem 9. Descrpton of noperatve component(s) 10. Addtonal nformaton/comments that may be helpful 2 of 14
1. INTRODUCTION (Fgure 1) Fgure 1 These nstructons contan operaton and setup procedures for the SDE Electrc Bench Termnator 1490076-2. Ths termnator has been manufactured n accordance wth DIN EN ISO 9001. When readng ths manual, pay partcular attenton to DANGER, CAUTION,, and SAFETY statements. DANGER Denotes an mmnent hazard whch may result n moderate or severe njury. CAUTION Denotes a condton whch may result n product or equpment damage.! Hghlghts specal or mportant nformaton. Dmensons n ths manual are n metrc unts [wth U.S. customary unts n brackets]. Fgures and llustratons are for reference only and are not drawn to scale. Read and understand these nstructons completely before attemptng to operate the termnator. Always wear approprate eye3 protecton. 3 of 14
DANGER Ths unt should only be operated by traned personnel. 2. DESCRIPTION Ths termnator s equpped wth a holder for tool heads, allowng a quck nstallaton and removal of the varous tool heads. The termnator s actvated by means of a foot pedal whch must be operated durng the entre work cycle to meet all CE-safety requrements. A further safety component s a safety lock on the foot pedal. The ergonomc desgn of the foot pedal cover supports the foot of the operator. The sturdy workmanshp of the unt s desgned for long lastng performance. Specfcatons for SDE Electrc Bench Termnator 1490076-2 are contaned n Fgure 2. Dmensons: Weght: Power Requrements: Power Consumpton: Nose (Max) Vbraton (Max) SPECIFICATIONS 390 mm X 260 mm X 200 mm [15.5 n. X 10 n. X 8 n.] 13 kg [ 29 lbs] 220 Vac / 240 Vac, 50/60 Hz -- 110 Vac / 120 Vac, 60 Hz.7 KVA Max. <70 dba <2..5 m/s² Fgure 2 Identfcaton of tems on SDE Electrc Bench Termnator 1490076-2 can be found n Fgure 3. Ram Tool Head Holder Rotary Swtch for Varo-Adjustment Locatng Pns for Fastenng of Tool Head ON-OFF Swtch Counter Sgnal Lamp Joggng Swtch for Varo-Operaton Double-Throw Swtch for Reverse Operaton Fgure 3 An dentfcaton of the front panel controls can be seen n Fgure 4. 4 of 14
Counter 180 Joggng Swtch Poston Standard Operaton" (Press One Tme for a Full Cycle) ON/OFF Swtch Sgnal Lamp 180 Joggng Swtch Poston Varo- Operaton" (Adjustment by Knob on Left Sde of Termnator) Press 2 Tmes for a Full Cycle Double Throw Swtch (Retracts Ram to Lowest Poston) Fgure 4 An dentfcaton of the rear mounted controls can be seen n Fgure 5. Man Power Receptacle Voltage Selector Fuses Socket for Foot Pedal Fgure 5 3. RECEIVING/INSPECTION AND INSTALLATION 3.1. Recevng/Inspecton The SDE Electrc Bench Termnator 1490076-2 s thoroughly nspected durng and after assembly. Pror to packagng and shppng, a fnal seres of tests and nspectons s made to ensure proper functonng of the termnator. The followng nspecton should be performed as a safeguard aganst potental problems generated n transt. The components of the termnator are packaged so that they can be removed from the packagng and mmedately nstalled, as descrbed n Paragraph 3.2. 1. In a well-lghted area, carefully uncrate the termnator and nspect each component as t s removed from the crate. 5 of 14
2. Thoroughly nspect each component for evdence of damage that may have occurred n transt. If any of the components are damaged, fle a clam aganst the carrer and notfy TE mmedately. 3. Inspect all electrcal lnes for evdence of damage. It s mportant that ths manual and other documents (such as drawngs and parts lsts), as well as any enclosed product samples, reman wth the termnator for the beneft of personnel responsble for nstallaton, operaton, and mantenance. 3.2. Installaton Place the SDE Electrc Bench Termnator 1490076-2 on a well lghted desktop. If the head and des are nstalled, plug the electrcal cord nto the electrcal outlet (refer to Fgure 2 for power requrements, and Paragraph 4.4,A for nstructons on pluggng the cord nto the outlet). If requred, secure the termnator to the bench. 4. OPERATION DANGER To avod personal njury, be sure that the unt s unplugged whle the head or des are not nstalled. 4.1. Installaton and Removal of SDE Tool Head 1673663-2 A. Installaton Before mountng the SDE tool head, always make sure that the gude ram of the termnator s n the lowest poston. (Refer to Fgure 6.) Gude Ram Fgure 6 DANGER To avod personal njury, be sure the SDE Electrc Bench Termnator s dsconnected from the power source pror to the nstallaton or removal of the tool head. 1. Be sure that the termnator has been swtched off and unplugged. 2. Be sure that the SDE tool head s mounted wth openng for the des n the front, to facltate de nstallaton and removal. 3. Mount the head from the back and lock wth the safety pns. (Refer to Fgures 7 and 8.) 4. Refer to Paragraph 4.2, to remove and nstall the crmpng des. B. Removal DANGER To avod personal njury, be sure the SDE Electrc Bench Termnator s dsconnected from the power source pror to the nstallaton or removal of the tool head. 6 of 14
Control Lever Tool Head Fgure 7 1. Be sure the termnator has been "swtched off and unplugged". 2. Remove the locatng pns from the tool holder. 3. Remove and/or replace the tool head. 4. When removng the tool head, make sure that the gude ram of the termnator s n the lowest poston. 5. If nstallng or removng crmpng des, refer to Paragraph 4.2. Fgure 8 7 of 14
4.2. Installaton of Crmpng Des DANGER To avod personal njury, be sure the SDE Electrc Bench Termnator s dsconnected from the power source pror to the nstallaton or removal of the crmpng des. CAUTION These nstructons are specfc to the use of TE SDE crmpng des. BE SURE to use only TE crmpng des.! A. Installaton of Shouldered Des 1. Remove the two de retanng screws from the tool head. Be sure to keep the de retanng screws. They WILL be requred to nstall shouldered des. 2. Depress the control lever to open the tool head and place the upper de n the upper jaw of the tool head so that the largest ndenter s facng nward. 3. Insert the de retanng screw through the upper jaw and through the de. Tghten the screw just enough to hold the de n place. Do NOT tghten the screw completely at ths tme. 4. Place the lower de n the movng jaw of the tool head so that the largest anvl s facng nward. 5. Insert the de retanng screw through the lower jaw and through the de. Tghten the screw just enough to hold the de n place. Do NOT tghten the screw completely at ths tme. 6. Release the control lever to close the tool head, makng sure the anvls and ndenters algn properly. Hold the tool head closed to keep the des n place, and then tghten both retanng screws. 7. To dsassemble, open the tool head, remove the two de retanng screws, and slde the des out of the tool head. B. Installaton of Pnned Des 1. Remove the two de retanng screws from the tool head. Be sure to keep the de retanng screws. Although they wll not be requred to nstall pnned des, you may need them for future use. 2. Depress the control lever to open the head and nstall the anvl de nto the movng jaw of the tool head. The de assembly should be orented so that the chamfers are postoned toward the front of the head assembly, and the de markngs are facng outward. 3. Insert two de retanng pns and the short de retanng screw nto the movng jaw and through the anvl de. Tghten the screw just enough to hold the de n place. Do NOT completely tghten the screw at ths tme. 4. Install the crmper de nto the upper crmpng upper crmpng jaw of the tool head. The de should be orented so that the chamfers are postoned toward the front of the head assembly and the de markngs are facng outward. 5. Insert two de retanng pns and the long de retanng screw nto the upper jaw and through the the crmper de. Tghten the screw just enough to hold the de n place. 6. Check the de algnment by releasng the control lever to close the tool head, makng sure the anvl and ndenter algn properly. When the des are properly algned, fully tghten the the de retanng screws. 7. Install the locator assembly onto the long retanng screw and secure t wth the approprate hex nut. 8. To remove the des from the tool head, open the tool head, remove the de retanng pns and screws, and slde the des out of the tool head. 8 of 14
4.3. Termnator Power Supply 409-10052 The termnator can be operated wth 220/240 Vac or 110/120 Vac. The voltage selector s located at the rear sde of the termnator. The termnator s set by the manufacturer at 220/240 Vac. 4.4. Operaton DANGER To avod personal njury, keep fngers clear of the crmp des when operatng the tool. Never place anythng n the crmpng des but termnals and splces. A. Normal Producton Operaton Ths procedure assumes that the tool head and des have been nstalled. 1) Connect the provded power cord nto the receptacle at the rear of the termnator, and then nto the power outlet. 2) Move the ON/OFF button to Poston No." ". The green sgnal lamp should lght when the ON/OFF swtch s n Poston No. " ". If the sgnal lamp does not lght, check the fuses at the rear of the termnator. These fuses can be checked after rotatng and removng the the back fuse holders. 3) Connect the foot pedal to the foot pedal socket at the rear of the termnator. Lock the pedal n place by turnng the connector clockwse. The foot pedal s equpped wth a safety lock, whch prevents operaton of the termnator when the foot pedal has been completely floored due to excessve pressure appled to the foot pedal. Ths safety lock can be released by turnng the knob on the foot pedal back to ts orgnal poston. Now the termnator s ready for operaton agan. The des are normally closed, for safety reasons. The des are opened (retracted) wth the control lever at the front of the tool head n order to nsert the connector to be crmped. 4) After the connector s properly postoned n the crmp des, release the control lever to allow the des to sprng shut, holdng the connector n poston. 5) Insert the strpped wre, then apply moderate pressure to the foot pedal to cycle the termnator. The foot pedal must be held down constantly to ensure a complete workng cycle. 6) Open the des by depressng the control lever, and remove the completed crmp. B. Varo-Operaton (Fgure 9) The termnator can be operated also n "double step" mode. When the termnator has been swtched to Varooperaton, t can be operated wth two separate and dstnct steps: Frst step for holdng the nserted contact, second step for crmpng and movng back nto the fnal poston. The Varo-poston can be adjusted to the respectve contact materal (1 = mn; 6 = max.) by means of the knob for Varo-adjustment (refer to Fgure 3). C. Reverse Rocker Swtch If t s necessary to retract the des wthout completng the crmpng cycle, depress and hold the reverse rocker swtch to return the gude ram of the tool head to the lowest poston. 9 of 14
Fgure 9 5. CRIMP HEIGHT ADJUSTMENT Crmp heght adjustment s requred only f the crmp heght lsted n the TE de specfcaton s not acheved. Adjust the crmp heght wth a flat-bladed screwdrver. There are four dfferent crmp heghts. Refer to Fgure 10. Although TE normally recommends Poston No. 2 (adjustment of the manufacturer), Postons No. 3 and No. 4 ncrease the travel of the tool head, whch decreases the crmp heght. Poston No. 1 decreases the the travel of the head, whch ncreases the crmp heght. Crmp Heght Adjustment (One Step Equals 0.1mm [.004 In.]) Fgure 10 10 of 14
6. TROUBLESHOOTING Refer to the table n Fgure 11 for troubleshootng nformaton. PROBLEM ACTION Check correct poston of connectng cable Sgnal lamp doesn't lght ON/OFF swtch n Poston? "? Inspect fuses Power supply o.k.? Sgnal lamp lghts up? Termnator cannot be operated Foot pedal correctly connected? Foot pedal locked n? Release the safety lock by turnng knob. Termnator performs only a half cycle 1805 Joggng swtch n Varo" poston. Swtch t to Standard." Tool head cannot be nstalled n holder Termnator not n fnal poston Tool head not n fnal poston! Tool head ram doesn't engage correctly n termnator ram 180 Joggng-swtch n Varo" poston! Swtch to Standard"and try agan Move the devce to start poston by means of the double throw swtch Move crmp anvl to lowest poston (see the nstructon sheet of the approprate tool head) Refer to Paragraph 4.1, Installaton/ Removal of the Tool Head Move the termnator stepwse back by means of the double throw swtch Tool head doesn't open Clean and lubrcate tool head n the crmp area and nspect for damages CAUTION: Never use a damaged tool! Tool head cannot be removed Tool head s under preload Move back stepwse by means of the double-throw swtch untl tool head can be removed. Fgure 11 7. MAINTENANCE AND INSPECTION DANGER To avod personal njury, ALWAYS dsconnect the SDE Electrc Bench Termnator from the power supply before performng any mantenance or nspecton. TE recommends that a mantenance and nspecton program be performed perodcally to ensure dependable and unform termnatons. The SDE Electrc Bench Termnator should be nspected monthly. Frequency of nspecton should be adjusted to sut your requrements through experence. Frequency of nspecton depends on: The care, amount of use, and handlng of the termnator. The type and sze of the product crmped. The degree of operator skll. The presence of abnormal amounts of dust or drt, and Your own establshed standards. It s recommended that all movng parts (partcularly the movable drvng parts) of the tool be lubrcated after every 40 hours of use. Lubrcaton not only keeps the toolng operatng effcently, t protects the toolng from humdty. 11 of 14
For de closure nspectons and plug gage dmensons, as well as nspectons of the crmp areas, and crmpng de mantenance, refer to the approprate de assembly nstructon sheet. 7.1. Cleanng Remove dust, mosture, and other contamnants wth a clean soft brush, or a soft, lnt-free cloth after every 40 hours of use or as needed. Do NOT use objects or cleanng materals that could damage toolng. Re-lubrcate the sldng surfaces of the head assembly as descrbed n Paragraph 7.3 before placng the head back nto servce. 7.2. Vsual Inspecton 1. Inspect the tool head assembly for mssng heads or screws before each use of the tool. Check all movable drve parts and tool head surfaces for wear. 2. Inspect the crmp areas n the de assembly for flattened, chpped, or broken areas after every eght hours of use. Although the des may gage wthn permssble lmts, worn or damaged de closure surfaces may affect the qualty of the crmp. 7.3. Lubrcaton Lubrcate all movable drvng parts wth a hgh qualty grease. TE recommends the use of MOLYCOTE paste (whch s a commercally avalable lubrcant).lubrcate accordng to the followng schedule: Lubrcate the head assembly used n daly producton on a daly bass Lubrcate the head assembly (used occasonally) n daly producton on a weekly bass Lubrcate the head assembly used weekly on a monthly bass Wpe the excess grease from the head assembly, partcularly n the de closure areas. The grease transferred from the de closure de closure area onto certan termnatons may affect the electrcal characterstcs of a termnaton. 7.4. Parts Lst Fgure 12 contans a basc parts lst for the SDE Electrc Bench Termnator. 8. REPLACEMENT AND REPAIR Basc replacement parts are lsted n Paragraph 7.4. Parts SHOULD be replaced by TE to ensure qualty and relablty of the head assembly and termnator. Order replacement parts through your TE servce representatve, or send a facsmle of your purchase order to 1-717-986-7605, or wrte to: CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 For customer repar servce, call 1-800-526-5136. 12 of 14
3 2 1 9. CIRCUIT DIAGRAM ITEM TE PART NUMBER DESCRIPTION 1 1673677-1 SDE Electrc Bench Termnator 2 1673663-2 Head, SDE Electrc Bench Termnator 3 1673664-1 Foot Pedal Fgure 13 contans the termnator crcut dagram. 10. RoHS INFORMATION Fgure 12 Informaton on the presence and locaton of any substances subject to RoHS (Restrcton on Hazardous Substances) can be found at the followng webste: http://www.tycoelectroncs.com/customersupport/rohssupportcenter/ Clck on "Fnd Complance Status" and enter equpment part number. 11. REVISION SUMMARY Snce ths document was revsed, the current company logo was appled. 13 of 14
Fgure 13 14 of 14