Accu-Drive Applicator User Manual
Contents
1. This warranty does not cover defects resulting from e Improper use Improper handling Improper adjustments Use of electrical power sources outside of specified voltage or frequency ranges Use of electrical power supplies that were not provided by CrimpTronix Use of improper lubricants Lack of timely and proper preventive maintenance Electrical power surges Use in presses that do not have the industry standard shut height of 135 8mm 5 346 No other warranties are expressed or implied including any implied warranties of merchantability or fitness for a particular purpose CrimpTronix is not liable under any circumstances for any direct or consequential damages howsoever incurred even if notified of the possibility of such damages PAGE 41 CRIMP RONIX the future of wire termination is here gt Appendix H Contact Information CONTACT INFORMATION CrimpTronix 5223 A Hwy 96 West Youngsville NC 27596 Phone 919 570 9303 Email sales crimptronix com Web CrimpTronix com PAGE 42 the future of wire termination is here gt Notes PAGE 432. the future of wire termination is here gt Section 5 Control Module continued Accu Drive includes a series of configuration and troubleshooting screens To access these screens do the following e Turn Accu Drive off e Press and hold the knob e While keeping the knob pressed turn Accu Drive on These screens are shown below Total Feed Count Maximum Position Offset Ram Position Software Revision erminal Sensor Status 5V Supply 15V Supply Additional information on the configuration troubleshooting screens are provided in section 8 PAGE 8 CRIMP RONIX the future of wire termination is here gt Section 5 Control Module continued The control module is tethered to the Accu Drive applicator using Ethernet connectors and an Ethernet cable Please note that neither the control module nor the applicator support the Ethernet standard and neither connector is an Ethernet port The control module applicator interface supports data communications unique to this product DO NOT CONNECT THE APPLICATOR OR CONTROL MODULE TO AN ETHERNET PORT To connect the control module to the Accu Drive applicator simply connect the right angle end of the supplied Ethernet cable to the connector on the bottom of the control module Plug the straight end of the cable to the con nector on the side of the electronics enclosure of the applicator Once the Accu Drive applicator has been set up for a production run the con
3. To display or change speed do the following Scroll through menu selections to display the Speed screen The current speed setting is displayed To change the speed setting press the knob to access the second row of the screen The arrow indicates that the sec ond row is selected Turn the knob clockwise to increase the setting Turn it counterclockwise to decrease the setting Press the knob to enter the new setting Note that the arrow has disappeared You can now use the knob to access other screens PAGE 14 CRIMP RONIX the future of wire termination is here gt Section 7 5 Delay In operation the Accu Drive applicator initiates a feed cycle by sensing the upward motion of the ram after a terminal has been crimped In some cases problems occur if a feeding cycle begins immediately after the upward motion of the ram is sensed additional time may be needed by an operator or a machine to clear a just crimped wire from the anvil The delay setting is used to create a delay between the time the ram rises and the time feeding actually begins The range of delay settings is from 0 to 5 0 seconds in steps of 0 1 second To display or change delay do the following Scroll through menu selections to display the Delay screen The current delay setting 1s displayed To change the delay setting press the knob to access the second row of the screen The arrow indicates that the sec ond row is selected T
4. position pull back on the release and rotate it either clockwise or counter clockwise to latch it in position Then slide the lower tooling into place into Accu Drive Rotate the release again either clockwise or counterclockwise to secure the assembly in place MAKE CERTAIN THAT THE LOWER TOOLING IS FULLY INSERTED AND THAT THE RELEASE IS FULLY SEATED TO SECURE THE LOWER TOOLING IN PLACE e IMPORTANT Manually slide the ram up and down to verify that tooling meshes correctly Or if installed in a press manually cycle the press or run the press in slow mode If any interferences are observed then do the following Verify that the lower tooling is the correct mate to the upper tooling Verify that the upper and lower tooling are installed correctly Make certain that the release has the lower tooling properly secured To avoid damage to the tooling do not operate Accu Drive until matching tooling 1s installed correctly PAGE 28 CRIMP RONIX the future of wire termination is here gt Section 15 Install Terminals The specific steps to install terminals into the stock guide of the lower tooling depends upon the design of the lower tooling which in turn depends upon the terminal For example un insulated open barrel terminals must be aligned with a rail that typically fits between the insulation and crimp portions of the terminal For mylar tape the slots in the tape must be secured in a hold down mechanism A generic procedure
5. OF 135 80MM 5 3467 INSTALLATION IN CRIMP PRESSES WITH OTHER THAN STANDARD SHUT HEIGHTS CAN CAUSE SEVERE TOOL BREAKAGE IT IS RECOMMENDED THAT SHUT HEIGHT BE VERIFIED BEFORE INSTALLLING ACCU DRIVE IN A PRESS CRIMPTRONIX WILL NOT BE LIABLE FOR ANY DAMAGES AS A RESULT OF INSTALLATION IN A CRIMP PRESS WITH NONSTANDARD OR IMPROPERLY SET SHUT HEIGHT Do not attempt to alter disassemble or adjust any part of this equipment that is not expressly described in this manual Avoid using or storing Accu Drive crimp packs power supplies power cords or cables in the following places e Places subject to temperatures above 104 degrees Fahrenheit or below 32 degrees Fahrenheit e Places that are humid or wet e Places that are excessively dusty Do not cut damage alter or place items on the power cords Use only specified AC power sources PAGE 2 CRIMP RONIX the future of wire termination is here gt Section 2 Safety Precautions continued e Ensure that the Accu Drive power cords and any extension cords that may be used are routed to avoid interference with equipment and personnel Keep power cords well away from damp or wet areas e Do not allow liquids or foreign objects to enter Accu Drive e Do not use Accu Drive in any press that does not have a compatible means to secure it to the press e Do the following before making any mechanical adjustments on Accu Drive removing or installing crimp packs performing maintenance or
6. gt Section 8 Configuration Troubleshooting Screens Configuration troubleshooting screens are accessible when Accu Drive is turned on while the knob on the control module is being pressed Turn Accu Drive off press and hold the control knob and while keeping the knob pressed turn Accu Drive on These screens are used occasionally to change configuration or troubleshoot prob lems PAGE 18 CRIMP RONIX the future of wire termination is here gt Section 8 1 Total Feed Count Accu Drive maintains a count of the total number of feeding cycles This counter is not resettable You can use this counter to support a preventive maintenance program based on usage PAGE 19 CRIMP RONIX the future of wire termination is here gt Section 8 2 Diagnostic Screens Five diagnostic screens are available to facilitate troubleshooting if needed The screens are e Terminal Sensor The terminal sensor is an optical sensor mounted on the lower tooling of the crimp pack This screen indicates if the light beam in the optical sensor is blocked or not blocked Use this screen to determine if the terminal sensor and interconnecting cables are functioning properly e Ram Position This screen indicates if the ram is up or down Use this screen to determine if the ram sensor and interconnecting cables are functioning properly e Supply Voltages Accu Drive operates from both a 5 volt supply and 12 volt supply The status of each power
7. it counterclockwise to decrease the setting Press the knob to enter the new setting Note that the arrow has disappeared You can now use the knob to access other screens PAGE 21 CRIMP RONIX the future of wire termination is here Section 9 Crimp Pack Identification Crimp packs consist of two separate tooling modules upper tooling module and lower tooling module When a crimp pack is installed in Accu Drive it is imperative that the lower tooling is the correct mate to the upper tooling Otherwise the tooling will very likely be damaged when Accu Drive is put into operation To verify that the upper and lower tooling are mates compare the numbers as shown below and make certain that the numbers match After installing the tooling cycle the ram manually or operate the press in slow mode to verify that that the tools mate properly If the press is cycled at full speed with mismatched tooling the tooling will be damaged The pictures below show the location of the identification numbers for a representative sample of the upper and lower tooling Tooling designs vary depending upon the specific terminal and may not appear exactly as pictured Location of upper tooling identification number Location of lower tooling identification number PAGE 22 CRIMP RONIX the future of wire termination is here gt Section 10 Wire Stop Adjustment When Accu Drive is used in a bench top press the wire stop must be adju
8. the ram can easily fall out When carrying or transporting Accu Drive remove the ram or take precautions to prevent it from falling out PAGE 3 CRIMP RONIX the future of wire termination is here gt Section 3 Features and Benefits Accu Drive s patented feeding system and quick change crimp packs provide the following features and benefits e Crimp packs substantially reduce tooling costs e Accu Drive works in industry standard presses and fully automatic wire processing equipment e Installing crimp packs to accommodate a different terminal can be done in less than one minute e Accu Drive does not have to be removed from the press to install or remove crimp packs e Loading terminals is easy because the lower tooling has very little drag and there are no feed pawls to interfere with the loading process e All of Accu Drive s features and capabilities are integrated into the product no data buttons or data interfaces to other equipment is required e Terminals are precisely positioned over the anvil In most cases no positioning adjustments are required If an operator chooses to modify terminal position a position offset range of up to 050 in 001 steps can be achieved electronically via a control module e The speed at which terminals are fed is controlled electronically The operator can select speeds from 5 inch second to 5 inches second in steps of 0 1 inch second e A delay can be set electronicall
9. wire termination is here gt Section 17 Set Up Accu Drive to Run a New Terminal This section describes how to set up Accu Drive to run a new terminal FOLLOW ALL SAFETY PRECAUTIONS OUTLINED IN SECTION 2 BE CERTAIN TO HEED THE FOLLOWING NEVER NEVER NEVER CAUTION USE THE CRIMPTRONIX ACCU DRIVE APPLICATOR IN A PRESS OR WIRE PROCESSING MACHINE WITHOUT GUARDS OR SAFETY DEVICES THAT ARE INTENDED TO PREVENT HANDS FROM REMAINING IN THE DIE SPACE THIS APPLICATOR IS SUPPLIED WITH NO GUARDS AND IS INTENDED TO BE USED WITH THE GUARDS SUPPLIED BY THE PRESS AND OR THE WIRE PROCESSING MANUFACTURER OPERATE SERVICE INSTALL OR ADJUST THIS ACCU DRIVE APPLICATOR WITHOUT PROPER INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL AND ALL APPLICABLE PRESS AND OR WIRE PROCESSING MACHINE MANUALS INSTALL OR SERVICE THIS ACCU DRIVE APPLICATOR WHILE CONNECTED TO ANY ELECTRICAL POWER SOURCE DISCONNECT POWER BY UNPLUGGING ACCU DRIVE FROM ITS POWER SOURCE CRIMPTRONIX ACCU DRIVE APPLICATORS ARE DESIGNED TO OPERATE IN PRESSES WITH STANDARD SHUT HEIGHTS OF 135 80MM 5 346 INSTALLATION IN CRIMP PRESSES WITH OTHER THAN STANDARD SHUT HEIGHTS CAN CAUSE SEVERE TOOL BREAKAGE IT IS RECOMMENDED THAT SHUT HEIGHT BE VERIFIED BEFORE INSTALLLING ACCU DRIVE IN A PRESS CRIMPTRONIX WILL NOT BE LIABLE FOR ANY DAMAGES AS A RESULT OF INSTALLATION IN A CRIMP PRESS WITH NONSTANDARD OR IMPROPERLY SET SHUT HEIGHT In the
10. 1 second increments 0 5 in sec to 5 0 in sec in steps of 0 1 in sec 050 to 050 in 001 steps 1 0 mm 039 0127 mm 0005 90V to 240V AC 50 60 Hz single phase 30 watts Length 222 5 mm 8 76 Height 146 4 mm 5 76 Depth 125 7 mm 4 95 4 88 kg 10 75 pounds 40 to 104 degrees Fahrenheit 10 to 90 relative humidity non condensing PAGE 34 CRIMP RONIX the future of wire termination is here gt Appendix A Bill of Materials Accu Drive Base Applicator 140 1 BPE OF F3OS ev O001 00 Jojoalddy espg BAUG NDOY XIU dwu IHJ KUOLLA O NSA pen JVS 108 Og CCS amp SSES IS QO E z l y u6oW N ap amp LOZ LOC 40ji4e5OWOW 4 VELVE CS 4D j43SejWOW zZz 9 1VO6cL6 JOPODIGdy 8sog aa n22w xiuo4jduuu 0001 00 D a E E juawysnipy 2018 9201 102 uj RON z CVE uo goo 9 OLveses Cm5 y WYEES ue eoo tslveLi0 ueS wowow z OSlY00Pt6 d vtF GCZL INOW 3 90 njg OSS VW A WW FE 40j4950WOW Ir Ha Ce MOD A SOWOW L OcOVS 60r 6 App zZ EOLVEETLS WER E EE soloDIddy xiu duuu A QUUSSS Y aunso 2u3 jo4juo uoy Sau xiuo4duu 1007 007 quuessy aunso pu3 290p u sasn 8Au n22 y xiuo4j Guu ZOOF 00C OOLFMHIA 10j5npuoonus ADUSIA auy duuu Apjquuassy juauujsnipw YBIs uongonsu PUD
11. A control module allows the operator to set feeding parameters electronically As a result of this superior terminal feeding system crimp packs are readily accessible and easy to swap set up is quick and easy and compared to industry standard applicators it all comes at reduced costs and downtime PAGE 1 CRIMP RONIX the future of wire termination is here gt Section 2 Safety Precautions Accu Drive is designed to provide millions of wire crimps reliably and safely Please read and follow all of the warnings and precautions listed below to avoid personal injury and equipment damage NEVER NEVER NEVER USE THE CRIMPTRONIX ACCU DRIVE APPLICATOR IN A PRESS OR WIRE PROCESSING MACHINE WITHOUT GUARDS OR SAFETY DEVICES THAT ARE INTENDED TO PREVENT HANDS FROM REMAINING IN THE DIE SPACE THIS APPLICATOR IS SUPPLIED WITH NO GUARDS AND IS INTENDED TO BE USED WITH THE GUARDS SUPPLIED BY THE PRESS AND OR THE WIRE PROCESSING MANUFACTURER OPERATE SERVICE INSTALL OR ADJUST THIS ACCU DRIVE APPLICATOR WITHOUT PROPER INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL AND ALL APPLICABLE PRESS AND OR WIRE PROCESSING MACHINE MANUALS INSTALL OR SERVICE THIS ACCU DRIVE APPLICATOR WHILE CONNECTED TO ANY ELECTRICAL POWER SOURCE DISCONNECT POWER BY UNPLUGGING ACCU DRIVE FROM ITS POWER SOURCE CAUTION CRIMPTRONIX ACCU DRIVE APPLICATORS ARE DESIGNED TO OPERATE IN PRESSES WITH STANDARD SHUT HEIGHTS
12. CrimPiRonin the future of wire termination is here Accu Drive Applicator User Manual Rev 1 Ta E mg H DEE l Rn the future of wire termination is here CrimPTRonin Accu Drive User Manual Table of Contents Section Page 1 Introduction l 2 Safety Precautions 2 3 Features and Benefits 4 4 Overview of the Terminal Feeding Process 5 5 Control module 6 6 Power Supply and Power Switch 10 7 Operational Screens 11 7 Welcome Screen 11 7 2 Home Screen Ready to Feed 12 7 3 Position Offset 13 7 4 Speed 14 7 5 Delay 15 7 6 Batch Count 16 7 7 Illumination 17 8 Configuration Troubleshooting Screens 18 8 1 Total Feed Count 19 8 2 Diagnostic Screens 20 8 3 Maximum Position Offset 21 9 Crimp Pack Identification 22 10 Wire Stop Adjustment 29 11 Bellmouth Adjustment 24 12 Crimp Height Adjustment 25 13 Remove a Crimp Pack 26 14 Install a Crimp Pack 28 15 Install Terminals 29 16 Remove Terminals 30 17 Set Up Accu Drive to Run a New Terminal 31 CRIMP RONIX the future of wire termination is here gt Accu Drive User Manual Table of Contents Section Page 18 Maintenance 33 19 Specifications 34 A Bill of Material for Accu Drive Base App 45 B Bill of Material for Feed Drive Assembly 36 C Bill of Material for Release Stud Assembly 37 D Bill of Material Crimp and Ins Height Adj 38 E Bill of Material Idler Roller Assembly 39 F Accessories 40 G Warranty 4 H Contact Information 42 CRIMPIRONIK the future o
13. HERWISE SPECINED mae eb p DO NOT SCALE DRAWING REVISION O See H 125 Xxx wcs tne Vet CrimpTronix Inc MAME SAIT DAN m DAWN Goong eo APVO MEG QA IB Idler Roller Assembly 201 4000 i SCALET S SHEET OF I PAGE 39 CRIMP RONIX the future of wire termination is here gt Appendix F Accessories ACCESSORIES To install or operate the Accu Drive applicator in selected presses some modifications to the press may be necessary CrimpTronix offers the following accessories to facilitate these modifications K oe 711 712 5 Screw Reduced Head Dia 5MM Soc FSBB5 10 Komax MCI 711 712 icin Hd Cap Press TYCO Press Applicator Clamp 201 5002 TE K Press PAGE 40 CRIMP RONIX the future of wire termination is here gt Appendix G Warranty WARRANTY CRIMPTRONIX INC CrimpTronix Inc warrants that products delivered shall be free of defects in material workmanship and fabrication for a period of ninety 90 days from the date of delivery Defective material covered by this warranty will be repaired refurbished or replaced at the sole discretion of CrimpTronix The cost of shipping suspect material to CrimpTronix shall be borne by the customer The cost of shipping repaired refurbished or replaced material to the customer shall be borne by CrimpTronix Exclusions Components designated by CrimpTronix as perishable tooling are not covered by this warranty This warranty is not transferrable
14. btain information to facilitate troubleshooting and maintenance The control module contains one LCD display and one knob The display has two rows of characters with 16 characters per row Using the control module is easy Rotate the knob to access menu selections screens and change data press the knob to initiate actions and enter data Just rotate and press it s that simple n 7 PAGE 6 CRIMP RONIX the future of wire termination is here gt Section 5 Control Module continued The user interface presents screens that are displayed in the LCD display and navigated using the knob Navigating through the menu is very easy The menu items can be thought of as a forming a circle A clockwise rotation of the knob moves you in a clockwise direction around the circle a counter clockwise rotation moves you in a counter clockwise direction Simply rotate the knob in the direction you want to move through screens When Accu Drive is first turned on a welcome screen is displayed for approximately three seconds followed by the first of a series of operational screens The operational screens are used to set up and manage production runs which are needed in the day to day usage of the applicator The operational screens are Welcome Screen Home Ready to Feed Illumination Position Offset Batch Count Speed Delay Additional information on the operational screens are provided in section 7 PAGE 7 CRIMP RONIX
15. control module to select the HOME screen Ready to Feed Manually initiate a feed cycle to place a terminal over the anvil Depending on how terminals were installed it may be necessary to initiate more than one feed cycle e Observe the left to right position of the terminal over the anvil Modify the position of the terminal if necessary using the control module Refer to section 7 3 e Turn the press on Crimp a terminal to a properly prepared wire If possible operate the press manually or run the press in slow mode to avoid tooling damage Inspect the crimp Make adjustments to crimp heights feed position or bellmouth as may be necessary e If Accu Drive is being used in a bench top press make adjustments to the wire stop if necessary See section 10 e Start production PAGE 32 CRIMP RONIX the future of wire termination is here gt Section 18 Maintenance To provide optimum performance and minimum down time it is recommended that Accu Drive and crimp packs be cleaned inspected and lubricated every 8 hours of operation The recommended lubricants are NLGI 2 Grade Lithium Complex EP grease or equivalent DO NOT USE SOLVENTS TO CLEAN ACCU DRIVE OR CRIMP PACKS DO NOT IMMERSE ACCU DRIVE OR CRIMP PACKS IN SOLVENTS OR CLEANING AGENTS Cleaning Accu Drive e Remove the ram Do not remove the crimp dial from the ram e Remove the crimp pack e Using clean cloth remove grease and any other debris from the ram and asse
16. dwup 000Z L10Z espg old 8101 10c woy GuisnoH 0Z01 10Z GI Ld Vd E t amp BISA l NI M t E j o rj dc ON Wall PAGE 35 CRIMP RONIX the future of wire termination is here gt Appendix B Bill of Materials Feed Drive Assembly O JAIN LJ KA A Y Ti O MAX SCOOSR 6 mm x 5 mm Imported 5 DESC 201 1013 Plate Wear 6 7 DESCRIPTION Stepper Drive Motor Coupling Zero Max REESE UNG ESS OTHERWISE SPECIHED freee DIVERSIONS ARE IM MELLIVETERS SURFACE FINI 125 TOLERANCES UNEAR XIa ej 010 ANGULAR 500g MAME SIGNAPURE Otan toong oxo APPNO MFG QA DER AND SHEAR SHARP XXX Dam leis SCALET S DO HOTSCALE DRAWING REVISION O CrimpTronix Inc Feed Drive Assembly 201 1000 EET ot 1 A3 PAGE 36 CRIMP RONIX the future of wire termination is here gt Appendix C Bill of Materials Stock Release Stud Assembly A ITEM NO PART NUMBER DESCRIPTION 201 1025 Stud Stock Assembly Release EN Screw Set McMaster 60765K312 Knob McMaster Carr hea UNLESS OTHERWISE SPECIRED Fito DIMENSIONS ARE IM MELLIVETERS MAME SIGNAPUKE Otan tong oro APPVO MFG ROUEN ale UMBER 4 hrpt DESIR AND SHEAR SHARP wcs Dat l 1645 See Tabie mE OWG NO SCALED DO HOT SCALE DRAWING REVISION O CrimpTronix inc 201 1002 SHEET OF Stock Release Stud Assembly A3 PAGE 37 CRIMP RONIX the future of wire termination is here
17. e electronics enclosure The switch is illuminated when Accu Drive is on At all times follow safety precautions listed in section 2 When Accu Drive is turned on after being turned off or after a loss of AC power it will restore all feeding parameters to the state that existed prior to being turned off or loss of power If a feeding cycle is in progress when Accu Drive is turned off or it loses AC power the feed cycle is terminated it will not complete that feeding cycle when it is turned on again PAGE 10 CRIMP RONIX the future of wire termination is here gt Section 7 Operational Screens Operational screens are accessible when Accu Drive is turned on normally that is when the control knob is not pressed when the applicator is being turned on Operational screens are used in the day to day usage of the appli cator to set up and monitor production runs Section 7 provides details on the usage of the operational screens Section 7 1 Welcome Screen The welcome screen is the first screen displayed each time Accu Drive is turned on It is displayed for approxi mately three seconds and is followed by the home screen PAGE 11 CRIMP RONIX the future of wire termination is here gt Section 7 2 Home Screen Ready to Feed The home screen Ready to Feed screen should be selected whenever you want to manually initiate a terminal feeding cycle that is when you want to feed the next terminal into position wi
18. f wire termination is here gt Accu Drive Applicator User Manual Section 1 Introduction Accu Drive is a left to right side feed applicator which installs in industry standard presses Those tooling elements that are unique to the terminal packaged as an upper tooling module and a lower tooling module are designed and manufactured to be removed installed easily and quickly Tooling for one terminal can easily be swapped with another The swappable tooling for a given terminal is referred to as a Crimp Pack As a result one Accu Drive applicator can be used to crimp a large variety of terminals simply through the purchase of additional crimp packs Significant reductions in tooling costs can be achieved because a complete applicator does not have to be purchased for each terminal Unlike traditional applicators which use mechanical designs to feed terminals pre termination Accu Drive uses a patented feeding method that electronically performs feeding operations downstream from crimping operations that is feeding occurs post termination Accu Drive employs pinch rollers which engage the intact carrier strip after the terminal has been crimped to the wire and removed from the carrier strip The pinch rollers are driven by a stepper motor Microprocessor based electronics in conjunction with sensors initiates a feeding cycle on the upward motion of the ram and controls the stepper motor to precisely position the next terminal to be crimped
19. gt Appendix D Bill of Materials Crimp and Insulation Height Adjustment Assembly 6 PART NUMBER 01 200 evis Mount Crimper Insulation Height Adi usiment DO ight Adi leet Hand and insulation Height ion g insulation Height e insulation Height Adjustment Right Hand Gum dai ators PAESE Pin Dowel 201 2011 Latch Index Index Latches nma 4A Ooo O Ooo OE St DESCRIPTION QTY pring Compression Compression Spring Lee Spring 2 OIM 95263A576 McMaster Car Screw UM FSS OTHERWISE SPECIRED freee IN MELUMETERS SURFACE FINI 125 TOLERANCES UNEAR XXX ef 040 ANGULAR S Deg MAME SIGNAPUKE Otan tong oxo APPVO MG Qa OESR AND SHEAR SHARP XXX Dat l 1645 mE DO HOT SCALE DRAWING REVISION O CrimpTronix Inc Crimp and Insulation Height OWG MO SCALET S Adjustment Assembly 201 2000 SHEET OF A3 PAGE 38 CRIMP RONIX the future of wire termination is here gt Appendix E Bill of Materials Idler Roller Assembly 6 7 PART NUMBER DESCRIPTION QTY ue ita em 2 D Roller pO E pou aid ee 4 201 1008 Plate Side TL s poe L 7 p0278A376 McMaster Carr Shoulder Screw 1 SCH f pg Ir 9 pe3l GER McMaster Carr Retaining Ring 2 s aiiis me Sena Carsten Note The idler roller part UMBB5 20 is designated as perishable tooling and is therefore not covered by the CrimpTronix warranty DRESS OT
20. is provided below Contact CrimpTronix if you have questions about loading terminals in the lower tooling e Raise or remove the ram e Rotate the idler roller release to raise the idler roller above the drive roller e Slide the terminals carrier strip into the left side of the lower tooling assembly across the anvil drive roller and idler roller Secure the terminals carrier strip in accordance with the specific design of the crimp pack e Loosen the idler roller position thumbscrew e Slide the idler roller to position it above the carrier strip such that it has no interference with terminals that may pass through without getting terminated e Tighten the idler roller thumbscrew to secure the idler roller in position e Rotate the idler roller release to lower the idler roller against the carrier strip e Ifthe ram had been removed re install the ram Idler Roller Release Idler Roller Drive Roller Idler Roller Position Thumbscrew PAGE 29 CRIMP RONIX the future of wire termination is here gt Section 16 Remove Terminals To remove terminals from Accu Drive do the following Pictures of the items referenced below can be found in section 15 e Raise or remove the ram e Rotate the idler roller release to raise the idler roller above the drive roller e Release any hold down mechanism if applicable e Slide the terminals carrier strip out of the lower tooling assembly PAGE 30 CRIMP RONIX the future of
21. isplayed To change the offset press the knob to access the second row of the screen The arrow indicates that the second row 1s selected Turn the knob clockwise to increase the setting Turn it counterclockwise to decrease the setting After position offset has been changed the next press of the knob initiates a feeding cycle This allows the operator to make position changes and quickly check if the new position is acceptable Once a final position has been deter mined the first press of the knob that occurs with no changes made will enter the new value A feeding cycle is not initiated Note that the arrow has disap peared You can now use the knob to access other screens PAGE 13 CRIMP RONIX the future of wire termination is here gt Section 7 4 Speed The speed at which terminals are advanced toward the anvil during a feeding cycle can be set using the control module Speed settings range from 0 5 inch second to 5 0 inches second in steps of 0 1 inch second Because the terminal is carefully accelerated to the selected speed at the beginning of the feeding cycle and carefully decelerated as it approaches the anvil terminal positioning is accurate and precise even at high feeding speeds Feeding is graceful and smooth with few mis feeds particularly with mylar tape And because terminal feeding is not mechanically linked to the ram high press speeds can be used to maximize throughput without causing feeding problems
22. k It consists of two pieces 1 Lower tooling This includes the terminal sensor lower tooling anvil and other tooling 2 Upper tooling This includes all tooling located in the ram All of the pieces of the upper tooling are clipped together to form a single unit To remove a crimp pack from Accu Drive do the following e Pull back on the lower tooling release and rotate it either clockwise or counter clockwise to latch it in position Then pull the lower tooling toward you to slide it out of Accu Drive Release Lower tooling Assembly PAGE 26 CRIMP RONIX the future of wire termination is here gt Section 13 Remove a Crimp Pack continued e Remove the upper tooling retaining bolt followed by removal of the upper tooling Upper Tooling Retaining Bolt Upper Tooling PAGE 27 CRIMP RONIX the future of wire termination is here gt Section 14 Install a Crimp Pack To install a crimp pack in Accu Drive follow the steps listed below Refer to section 13 for pictures of all items referenced e Verify that that the lower and upper tooling to be installed are the correct mates to each other Section 9 describes how this is determined e Ifa crimp pack is currently installed in Accu Drive remove it Refer to section 13 e Locate the upper tooling in the ram and secure it in place by installing and tightening the retaining bolt e Ifthe lower tooling release is not already in the release
23. making repairs e Turn Accu Drive off e Disconnect power from Accu Drive e If Accu Drive is in a press turn off or remove power from the press e When installing crimp packs ensure that the identification number on the lower tooling matches the identification number on the upper tooling before crimping terminals e Accu Drive dispenses the intact carrier strip after the crimping process is complete and terminals have been removed from the carrier strip Make certain that the carrier strip is routed such that e The strip cannot contact AC power cords e The strip cannot contact AC power outlets e The strip cannot enter equipment or tooling e Operators avoid being cut by sharp edges that may be present on the edge of the strip e During high volume production the carrier strip is cut periodically to prevent excessive amounts of the carrier strip from accumulating e Use only specified lubricants e The pinch rollers used by Accu Drive to feed terminals can operate anytime Accu Drive is connected to AC power and turned on Accu Drive does not have to be installed in a press to operate the rollers Keep hands fingers and clothing clear of the rollers at all times e Stop operating Accu Drive and remove power from it immediately if it emits smoke a strange smell or otherwise behaves abnormally e Unlike traditional applicators which use a mechanical linkage to the ram to feed terminals the ram in Accu Drive moves freely As a result
24. mbly e Lubricate per the instructions below Accu Drive Lubrication e With ram removed apply light coating of grease to each corner of the ram e Apply a light coating of grease to each corner of the ram guide e Re insert ram remove any excess grease or oil Crimp Pack Cleaning and Inspection e Remove the crimp pack from Accu Drive e Using clean cloth remove grease oil and any other debris from the crimp pack e Inspect the lower and upper tooling assemblies with special attention to items that touch the terminal such as the tooling punch anvil die sections cutter and cutter retainer Replace any worn or damaged parts e Nothing on the crimp pack requires lubrication PAGE 33 CRIMP RONIX the future of wire termination is here gt Section 19 Specifications Applicator Type Compatibility with presses Tooling Terminal Feed Mechanism Delay Speed Position Offset Crimp Heights Conductor and Insulation Range Resolution Power Requirements Dimensions Mass Environmental Left to right side feed applicator Stand alone operation no need for host controller Fits in most industry standard presses with shut height of 135 8 mm 5 35 Compatible with 41 28 mm 1 625 stroke and 28 58 mm 1 125 stroke Modifications to guards may be necessary Custom clamps available from CrimpTronix may be necessary Quick change crimp pack Electronic stepper motor 0 to 5 seconds in 0
25. ng cycle e Ifa delay has been set by the user no action is taken until the specified delay expires e After the delay if any the stepper motor is actuated to begin feeding terminals Feeding occurs at a speed selected by the operator Feeding continues until the terminal sensor which is an optical sensor located on the lower tooling senses the presence of a terminal or a hole in the carrier strip If a terminal or hole is never sensed the motor will dispense three inches of the carrier strip and stop e Immediately after the terminal sensor has sensed a terminal the stepper motor continues to advance terminals a pre determined distance This distance is modified increased or decreased based upon a position offset specified by the operator e The feeding cycle ends Accu Drive awaits the upward motion of the ram to begin another feeding cycle The next section describes how the operator uses the control module to display and change information to control the feeding process perform diagnostics and facilitate maintenance and production runs PAGE 5 CRIMP RONIN the future of wire termination is here fg Section 5 Control Module A control module is provided with each Accu Drive applicator Unlike traditional mechanical applicators that rely exclusively on mechanical adjustments you can use the control module to e ectronically configure many of the set up parameters for a production run initiate actions to simplify set up and o
26. om you This increases the bellmouth on the rear of the terminal and diminishes it on the front of the terminal e WARNING EXCESSIVE BELLMOUTH ADJUSTMENT CAN RESULT IN INTERFERENCES BETWEEN THE UPPER AND LOWER TOOLING TO AVOID DAMAGING THE TOOLING MOVE THE RAM MANUALLY AFTER EACH ADJUSTMENT TO VERIFY THAT NO INTERFERENCES EXIST e Tighten the bellmouth lock nut Bellmouth Lock Nut Bellmouth Adjustment Screw PAGE 24 CRIMP RONIX the future of wire termination is here gt Section 12 Crimp Height Adjustment Accu Drive is designed for use in a press having a shut height of 135 8 mm 5 35 The conductor crimp height adjustment range is 1 0 mm 039 The insulation crimp height adjustment range is also 1 0 mm 039 For the conductor and insulation crimp the resolution is 0127 mm 0005 To adjust crimp height do the following e Refer to crimp specifications provided by the terminal manufacturer e Adjust the conductor dial and insulation dial to 0 e Crimp a terminal and measure inspect the conductor and insulation crimp Increase the dial settings until acceptable crimps are obtained e Higher numerical settings equate to tighter crimps E lt 4 Conductor Crimp Insulation Crimp Dial Indicator PAGE 25 CRIMP RONIX the future of wire termination is here gt Section 13 Remove a Crimp Pack All of the tooling required to crimp a specific terminal is referred to as a Crimp Pac
27. sted to assist the operator in placing the wire over the terminal to the correct depth When used in fully automated wire processing equipment the wire stop aids in the removal of the terminal from the upper tooling One adjustment is available to position the height of the wire stop A second adjustment is available to control the front to back position The pictures below show the location of the wire stop and how it 1s adjusted for a representative sample of lower tooling Lower tooling designs vary depending upon the specific terminal and may not appear exactly as pictured Wire Stop Height Adjustment Depth Adjustment PAGE 23 CRIMP RONIX the future of wire termination is here Section 11 Bellmouth Adjustment Bellmouth is adjusted at the factory During normal usage bellmouth should not have to be adjusted for the life of the crimp pack If adjustment becomes necessary use the procedure below The pictures below show a representative sample of lower tooling These designs vary depending upon the specific terminal and may not appear exactly as pictured e With the lower tooling properly installed in Accu Drive loosen the bellmouth lock nut e Adjust the bellmouth adjustment screw clockwise to move the lower tooling toward you This increases the bellmouth on the front of the terminal and diminishes it on the rear of the terminal e Adjust the bellmouth adjustment screw counter clockwise to move the lower tooling away fr
28. steps below it is assumed that the Accu Drive applicator is installed in a press and has a crimp pack and terminal already installed The crimp pack terminal already installed is referred to as the old crimp pack and terminal The crimp pack terminal to be installed is referred to as the new crimp pack and terminal For some steps sections are referenced which provide additional information about that step Using the Ethernet cable supplied connect the control module to Accu Drive if not already connected Remove the old terminal refer to Section 16 Remove the old crimp pack refer to Section 13 Install the new crimp pack refer to Section 14 Install the new terminal refer to Section 15 PAGE 31 CRIMP RONIX the future of wire termination is here gt Section 17 Set Up Accu Drive to Run a New Terminal continued e Verify that the lower tooling assembly is the correct mate to the upper tooling installed in the ram Verify that the crimp pack was installed correctly Refer to sections 9 and 14 e Apply power to Accu Drive and turn Accu Drive on Refer to Section 6 e Set the conductor crimp and insulation crimp dials on the ram to 0 e Ifnecessary use the control module to select the DELAY screen and set the delay to an appropriate value Refer to section 7 5 e f necessary use the control module to select the SPEED screen and set the speed to an appropriate value Refer to section 7 4 e Use the
29. supply can be displayed e Software Revision A fifth screen not illustrated provides the software revision number of the software installed in the applicator PAGE 20 CRIMP RONIX the future of wire termination is here gt Section 8 3 Maximum Position Offset Section 7 3 describes how the control module can be used to change the position of the terminal over the anvil The range of adjustment for position offset has a maximum value of 050 However using the maximum position offset screen this range can modified to any value from 0 up to the maximum of 050 For example if the value set in maximum position offset screen is 019 the position offset screen would limit the operator to a position offset range of 019 This feature is provided to prevent operators from selecting position offsets that are large enough to damage tooling A maximum position offset of 0 can be selected This eliminates the ability to change position offset Note that whenever the maximum position offset is changed the current position offset is reset to 0 To adjust maximum position offset do the following Scroll through menu selections to display the Max Position Offset screen The current maximum position offset is displayed To change the maximum offset press the knob to access the second row of the screen The arrow indicates that the sec ond row is selected Turn the knob clockwise to increase the setting Turn
30. thout having to move the ram To initiate a feeding cycle manually simply press the knob A feeding cycle will begin immediately even if a delay has been set refer to section 7 5 The home screen is accessed in three different ways 1 The home screen can be accessed through normal screen selection rotating the knob 2 At any time an upward motion of the ram is sensed Accu Drive will automatically revert to the home screen and initiate a feeding cycle For this case if a delay 1s set feeding will not begin until the delay has expired The screen will display the amount of delay time remaining until it has expired The screen will display feeding while the feeding cycle is in progress 3 The home screen can be accessed from any other screen by pressing the knob on the control module for more than one second PAGE 12 CRIMP RONIX the future of wire termination is here gt Section 7 3 Position Offset The Accu Drive applicator and crimp packs are designed to feed terminals accurately In most cases no positioning adjustments are needed However if adjustments are needed for example to accommodate worn tooling the control module can be used to make an adjustment in steps of 001 The adjustment range is user selectable up to a maximum of 050 Refer to section 8 3 To adjust position offset do the following Scroll through menu selections to display the Position Offset screen The current offset is d
31. trol module can be disconnected and securely stowed to prevent unauthorized changes to the set up The applicator will be responsive to upward motions of the ram to trigger feeding cycles and will do so based upon the most recently entered set up The control module can be unconnected or re connected to the applicator at any time even 1f the applicator is powered up The control module has a magnetic backing Attach the module to any convenient magnetic surface that best facilitates access to the module Set up information is stored in a non volatile memory and is therefore retained when the Accu Drive applicator is turned off or loses power The last set up is restored each time Accu Drive is turned on The sections to follow describe how to navigate the user interface menu structure display information modify set up parameters and initiate actions to simplify set up tasks PAGE 9 CRIMP RONIX the future of wire termination is here gt Section 6 Power Supply and Power Switch To connect electrical power to Accu Drive and turn it on do the following Plug the power supply into an AC outlet 120V 60 hertz Power consumption does not exceed 30 watts A green led on the power supply is lit when AC power is present Plug the barrel connector on the power supply into the power input connector located on the side panel of the Accu Drive electronics enclosure Turn Accu Drive on using the power switch located on top of th
32. urn the knob clockwise to increase the setting Turn it counterclockwise to decrease the setting Press the knob to enter the new setting Note that the arrow has disappeared You can now use the knob to access other screens PAGE 15 CRIMP RONIX the future of wire termination is here gt Section 7 6 Batch Count The Accu Drive applicator provides a counter that can tally the number of feed cycles that occur You can use the batch counter to keep track of completed product during a production run This counter is resettable It can count up to 99 999 feed cycles To display or reset the batch count do the following Scroll through menu selections to display the Batch Count screen The current value of the counter is displayed Simply press the knob to reset the count Rotate the knob to ac cess other screens PAGE 16 CRIMP RONIX the future of wire termination is here gt Section 7 7 Illumination The Accu Drive applicator brightly illuminates the crimping zone to facilitate terminal positioning and troubleshooting crimping problems If desired illumination can be turned off To turn illumination on or off do the following Scroll through menu selections to display the Illumination screen The current setting of the led is displayed Press the knob to toggle the state of the led Rotate the knob to access other screens PAGE 17 CRIMP RONIX the future of wire termination is here
33. y to provide a delay between the time a feed cycle is initiated by the upward movement of the ram and the time at which feeding actually begins Delays provide time to allow a just crimped wire to clear the anvil before the next feeding cycle begins Delay times can be set from 0 seconds to 5 seconds in 0 1 second increments e Crimp force analysis available on selected automatic wire processing equipment is much more accurate and consistent because of the absence of a mechanical feeding mechanism e To optimize access to the control module it has a magnetic backing which allows it to be docked at a location convenient to the operator It can also be disconnected from the applicator By disconnecting and stowing the control module in a secure location a supervisor can prevent unauthorized operators from modifying feeding parameters e The crimping zone is brightly illuminated using an led Illumination can be turned off if desired e Because of the superior feeding system fewer mis feeds occur This substantially increases the life of the perishable tooling PAGE 4 CRIMP RONIX the future of wire termination is here gt Section 4 Overview of the Terminal Feeding Process To get the most out of any product it is always beneficial to have a basic understanding of how the product works Accu Drive executes the following sequence during each feeding cycle The press moves the ram upward This triggers a ram sensor to initiate a feedi
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