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AMP DT05000_408-4050_Instruction Sheet

TOOLING ASSISTANCE CENTER 1-800-722-1111PRODUCT INFORMATION 1-800-522-6752This controlled document is subject to change.For latest revision and Regional Customer Service, 1 of 6

Crimp Quality Monitor (CQM)

Adapters 122990-[ ] and 1424265-1

408-4050

03 MAR 11 Rev E

Figure 1

1. INTRODUCTION

These instructions cover Crimp Quality Monitor (CQM) Adapter 122990-[ ], which is used with

AMP-O-LECTRIC Model "G" Terminating Machines 354500-[ ] and 1213127-[ ], and CQM Adapter 1424265-1, which is used with the AMP 3K Terminating Machines 1725950-[ ] and AMP 5K

Terminating Machines 1725900-[ ].These adapters are used in conjunction with Crimp Quality Monitor 2031940-1.All dimensions are in millimeters [with inches in brackets]. Illustrations are for identification only and are not drawn to scale.

For additional information regarding operation, setup, and adjustment of the AMP 3K/5K Terminating

Machines, refer to Customer Manual 409-10047. For additional information on the Crimp Quality Monitor, refer to Customer Manual 409-10091.

Reasons for reissue are provided in Section 9, REVISION SUMMARY .

2. DESCRIPTION

The CQM Adapter consists of two sensor assemblies, mounting hardware, and a cable. These items allow the Crimp Quality Monitor to monitor the crimping process without the use of special applicators.

Crimp Quality Monitor (Ref)

CQM Adapter

Ram Assembly

AMP-O-LECTRIC* Model “G” Terminating Machine (Ref)

NOTE: Refer to Drawing 1320431 for CQM Adapter Hookup to the AMP 3K/AMP 5K Terminating Machines

NOTE

O R I G I N A L I N S T R U C T I O N S

3. INSTALLATION

3.1. Mounting the Base Plate Sensor (Figure 2)

To avoid personal injury, disconnect all power to the

terminating machine and to the Crimp Quality

Monitor before performing the following operations.

1. Remove the existing base plate assembly from

the terminating machine.

2. Remove all components from the existing base

plate assembly, and install them in the same

locations on the base plate sensor assembly

supplied with the CQM Adapter.

3. Clean the mounting surface, then install the new

base plate sensor assembly on the terminating

machine.

4. Check the alignment of the base plate with the

terminating machine ram.

5. Make alignment corrections, if necessary.

6. Check the shut height.

7. If shut height corrections are necessary, use the

supplied shims.

To check the shut height or if shut height

corrections are necessary, refer to the appropriate

machine manual.

If installing a new ram (see Paragraph 3.2), check

the shut height after installing the new ram.

Figure 23.2. Replacing the Ram and Gib

Early Model "G" Terminating Machines do not have the mounting features needed for the CQM Adapter. These machines will have to have the ram and a gib replaced (included in PN 1-122990-0). For those units that have the proper mounting features, skip to Paragraph 3.3, Installing Position Sensor Kit.

To avoid personal injury, disconnect all power to the

Model "G" Terminating Machine and to the Crimp

Quality Monitor before performing the following

operations.

If your Model "G" Terminating Machine is not an

auto-adjust unit, skip to Step 4.

1. Remove the terminating machine top cover.

2. Disconnect the auto-adjust subassembly.

3. Remove the auto-adjust subassembly.

4. Remove the gibs.

5. Remove the ram.

6. Remove the components from the old ram

assembly and install them in the same locations on the new ram.

7. Install the new ram assembly into the terminating

unit.

8. Replace the left-side (when facing terminating

unit) gib with the new gib and re-install the existing right-side gib.

If your Model "G" Terminating Machine is not an

auto-adjust unit, skip to Step 12.

9. Install the auto-adjust subassembly (check the

shaft alignment).

10. Re-connect the auto-adjust subassembly.

11. Replace the top cover.

12. Check the shut height.

13. If shut height corrections are necessary, use the

supplied shims.

To check the shut height or if shut height

corrections are necessary, refer to the appropriate

machine customer manual.

3.3. Installing Position Sensor Kit (Figure 3)

To avoid personal injury, disconnect all power to the

terminating machine and to the Crimp Quality

Monitor before performing the following operations.

DANGER

STOP

NOTE

Base Plate Sensor Assembly Model “G” Terminating

Machine (Ref)DANGER

STOP

NOTE i

NOTE i DANGER

STOP

Figure 3

1. Position the terminating machine's ram at bottom-dead-center.

2. Remove the position sensor from the sensor bracket. Install the fixture onto the sensor bracket by using the two screws from the sensor. See Figure 4.

Figure 4

3. Loosely fasten the sensor bracket to the left side

gib, making sure that the fixture is in the magnet

cavity of the ram.

4. Using the long screw, fasten the fixture to the ram

cavity. Tighten screw. This positions the sensor

bracket relative to the magnet in the ram.

5. Tighten the sensor bracket mounting screws.

Remove the fixture and fasten it to the gib as shown in Figure 3. Fasten the sensor magnet with the

chamfered edges down in the ram cavity. (You may hand cycle the ram up to install the sensor magnet.)

6. Install the transducer assembly to the sensor

bracket with the position sensor oriented on the

lower half and toward the ram.

7. When the system is completely assembled, the

sensor will have to be adjusted. Refer to Section 5, ADJUSTMENT.

3.4. Cable Connections

1. The supplied cable has a 15-position

subminiature "D" connector which mates to the

connector labeled on back of the Crimp

Quality Monitor.

2. The cable splits into two sections. The four-

position connector goes to the base plate and the

three-position connector goes to the position

sensor.

3. The four-position connector can attach to the

base plate in either of two orientations (either 0 or

180 degrees); either orientation will work correctly.

4. The three-position connector has a mark to

indicate position 1 on the connector. Align this mark

with the corresponding mark on the position

sensor's connector and attach the connectors.

5. The sensor cover provides a strain relief for the

cable that connects to the position sensor. A cable

clamp mounts to the cover with a socket head

screw and hex nut. Slide the cable clamp onto the

cable and loosely mount the clamp to the cover.

Position the cover in its proper location and adjust

the cable to provide ample strain relief. Tighten the

cable clamp hardware.

6. Attach the cover to the sensor bracket with the

two screws provided.

4. OPERATION

Refer to Customer Manual 409-10091 for Crimp

Quality Monitor operating instructions. The six position

sensor numbers located on the sensor cover must be

entered on the CQM SYSTEM SETTINGS/POSITION

SENSOR screen.

Sensor Cover

Sensor Mount Bracket Magnet

Assembly

Connect

to CQM

Gib

Fixture Transducer

Assembly

Sensor Mount Bracket Fixture

Sensor Mount Bracket Mounting Holes

5. ADJUSTMENT

To avoid personal injury, be very careful of moving

mechanisms when making adjustments while the

terminating machine is "on."

Set precision adjust to tightest setting (-9).

This adjustment should be made only by qualified

personnel under the guidance of Tyco Electronics.

1. Jog the machine ram down until the ram is in the

bottom-dead-center position.

2. Check the Crimp Quality Monitor SENSORS

DIAGNOSTICS screen for a height reading of 900 to 1100. If the monitor screen does not indicate 900 to 1100, adjust as follows:

a.Remove the two screws securing the sensor

cover.

b.Loosen the two screws securing the sensor.

c.Watching the monitor diagnostics sensor

screen, move the sensor "up" to decrease the

position sensor reading; "down" to increase the

position sensor reading until the position

sensor reading is between 900 and 1100.

d.Tighten the screws securing the sensor.

e.Replace the cover and secure it with the two

screws removed earlier.

3. Return the machine ram to the top-dead-center

position.

4. Re-adjust precision adjust to .00 mm [.000 in.]. 6. INSPECTION/MAINTENANCE

6.1. Daily Inspection/Maintenance

It is recommended that each operator be made aware of and responsible for the following daily maintenance steps.

1. Check the position sensor reading (Crimp Quality

Monitor SENSORS DIAGNOSTICS menu) to be

sure that the position sensor reading is in the proper range. Adjust, if necessary according to Section 5, ADJUSTMENT.

2. Inspect all wiring for any damaged cables or

unmated connectors.

3. Clean all crimping areas in accordance with the

instructions for the Heavy Duty Miniature Applicator.

4. Ensure that the applicator that is mounted in the

terminating machine is held securely by both the base plate and the applicator ram lock.

6.2. Periodic Inspection/Maintenance

Regular inspection should be performed by Quality Control personnel. A record of scheduled inspections should remain with the CQM system and/or be supplied to supervisory personnel responsible for the system. Though recommendations call for at least one inspection a month, the inspection frequency should be based on the amount of use, working conditions, operator training and skill, and established company standards. These inspections should be performed in the following sequence.

1. Make sure all screws, cables, and connectors are

in place.

2. Check all parts for wear. Remove and replace

worn components.

3. Inspect the crimp area for flattened, cracked,

worn, or broken areas. If damage is evident, the

tooling must be repaired before returning it to

service. Refer to the terminating machine and

applicator instructions.

7. REPAIR/REPLACEMENT

Do not remove or perform any maintenance on

components not explicitly called for in this

instruction sheet. Damage could be done to the

entire Crimp Quality Monitor system.

7.1. Troubleshooting/Repair of Sensor Wiring

The Crimp Quality Monitor requires continuous electrical flow through the force and position sensors on the terminating machine in order to acquire the necessary data points to analyze a crimp. If the electrical path is broken by a damaged connector or wire, the monitor will not be able to analyze the data in order to calibrate or report the crimp status.

The following error messages could indicate a

broken electrical path:

? "NOT ENOUGH VALID POINTS" (Calibrate

Mode)

? "INVALID CRIMP" (Run Mode)

To check the sensor wiring, proceed as follows:

1. Select DIAGNOSTICS from the Crimp Quality

Monitor main menu.

2. Select 2-SENSORS from the DIAGNOSTICS

menu.

3. Using the terminating machine's Jog Mode, crimp

a terminal without wire, and observe the FORCE

and POSITION readings.

DANGER

STOP

NOTE

CAUTION

NOTE

Terminals may get stuck in the tooling when

crimped without wire. A stuck terminal must be

cleared from the tooling to avoid tooling breakage

during successive crimps.

a.The force reading should start at a value

between 0 and 300, gradually increase to a

value less than 4095 at bottom-dead-center

and then gradually return to approximately the

same starting value.

b.The position reading should start at a value

between 2000 and 3000, increase to a

maximum less than 4095, then decrease to

minimum between 900 and 1800 at bottom-

dead-center.

The position sensor value should not go below 900

during this cycle. If necessary refer to Section 5,

ADJUSTMENT for position sensor adjustment.

4. If the sensor values indicate a problem, test the

cable between the Crimp Quality Monitor and the sensors (Sensor Cable PN 122955-1) with an

ohmmeter for continuity, or replace the sensor cable and repeat Steps 1, 2, and 3.

5. If the sensor cable fails the continuity test,

replace it. If the cable passes, but the force sensor readings were incorrect, see Paragraph 7.3, Force Sensor Replacement. If the cable passes, but the position sensor readings were incorrect, see

Paragraph 7.4, Position Sensor Replacement.

7.2. Force Sensor Removal

To avoid personal injury, disconnect all power to the

terminating machine and to the Crimp Quality

Monitor before removing the force sensor.

1. Disconnect the sensor cable at the force sensor.

The connector is a locking-style connector and

must be removed by pulling on the connector

housing. Pulling on the wires will not release the

connector and will cause damage to the wires.

2. Remove the base plate's mounting screws and

then the base plate.

7.3. Force Sensor Replacement

To avoid personal injury, make sure that power to

the terminating machine and Crimp Quality Monitor

is disconnected before replacing the force sensor.

1. Remove all components from base plate

assembly, and install them in the same location on new base plate sensor assembly.

2. Clean mounting surface, then mount new base

plate sensor assembly on terminating machine.

3. Check alignment of the base plate with the

terminating machine's ram.

4. Make alignment corrections, if necessary.

5. Connect the cable to the sensor.

7.4. Position Sensor Removal

To avoid personal injury, disconnect all power to the

terminating machine and to the Crimp Quality

Monitor before removing the position sensor.

1. Remove the sensor cover and disconnect the

position sensor assembly.

2. Disassemble the cable clamp from the sensor

cable.

3. Disassemble the sensor mount bracket and

fixture from the gib.

4. Remove the magnet assembly from the

terminating machine's ram.

7.5. Position Sensor Replacement

To avoid personal injury, disconnect all power to the

terminating machine and to the Crimp Quality

Monitor before replacing the position sensor.

The position sensor kit contains a position sensor,

magnet assembly, fixture, and a cover with

configuration numbers. These kit parts must be

replaced as a set. DO NOT mix the new parts with

any of the removed parts.

1. With the machine power disconnected, position

the terminating machine's ram at bottom-dead-

center.

2. Loosely attach sensor mount bracket to gib with

supplied hardware.

3. Mount the fixture to the terminating machine ram

and to the sensor mount bracket. The fixture is used to establish the critical distance between the sensor and magnets.

4. Tighten the sensor mount bracket screws.

5. .Remove the fixture and store it on the gib as

shown in Figure 3.

6. Mount the magnet assembly to the terminating

machine ram.

7. Attach the position sensor assembly to the

sensor mount bracket.

8. Attach cable clamp to the cable and the cover.

CAUTION

NOTE i

DANGER

STOP

CAUTION

DANGER

STOP DANGER

STOP

DANGER

STOP

NOTE i

9. Connect the cable to the sensor. Observe the connector orientation marks.

10. Reconnect the power to the machine and turn the machine on.

11. Adjust the sensor according to Section 5, ADJUSTMENT.

12. Attach cover to gib.

13. Enter the position sensor numbers.8. PARTS REPLACEMENT

Refer to the assembly drawings shipped with the CQM Adapter for replacement part numbers. No spare parts are recommended for this assembly. Order parts through your Tyco Electronics representative, or call 1-800-526-5142, or send a facsimile of your purchase order to 1-717-986-7605, or write to:

CUSTOMER SERVICE (038-035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

9. REVISION SUMMARY

Since the previous revision of this instruction sheet, the TE logo has been applied.