Upload
lenga
View
223
Download
3
Embed Size (px)
Citation preview
Hand Crimp ToolUser ManualUser Manual
North AmericaPower & Signal GroupWorld Headquarters6675 Parkland BlvdSolon, OH 44139USAPhone: 1-800-722-5273 440-836-6600Fax: 440-836-6122E-mail: [email protected] [email protected]
South AmericaPower & Signal Group, an Arrow CompanyRua José Gomes Falcão, 111Attn: Roberto Cutrupi, Sales Manager South America01139-010 - Barra Funda - São Paulo - S.P. - Brasil - BRPhone: 55 11 3613 9371Email: [email protected]
AsiaPower & Signal Group11F, BM Intercontinental Business Center100 Yu Tong RoadShanghai 200070ChinaPhone: +86 21 22152000Fax: +86 21 22152435E-mail: [email protected]
Europe, the Middle East & AfricaPower & Signal Group GmbHBalcke-Duerr-Allee 240882 RatingenGermanyPhone: +49 2102/1677-0 +49 800 10 10 772Fax: +49 (0)2102/1677-160E-mail: [email protected] [email protected]
Table of Contents
General hand crimp tool (HCT) information •Introduction •FunctionofHCTratchet •Scopeofusage •Responsibilitiesofuser •NoteregardingHCTmanualdimensions
HCTPowerAssistDevicesToolTypes •ToolType1:Blade&BoxTerminals •ToolType2:Pin&SleeveTerminals
AssemblyandRemovalofHCTDieSets •Dieselection •Dieinsertion •Dieremoval •Crimpverification •CrimpHeightAdjustment
CrimpToolReferenceDataSheetCrimpingInstructions •TerminalLoading •TerminalCrimping •CrimpHeightMeasurement
VisualCrimpQualityRecommendations •Goodcrimp •Crimpdimensionsnotintolerance •Lowcore •Insulationundercorewing •Twistedordistortedterminalsorcableseals •ExcessiveTab •Allstrandsnotcapturedbycorewings •Terminalstraightness •Cutormissingstrands
HCTMaintenance&CleaningHCTVisualInspectionWireStripperInstructionsHCTSupport
2
General Hand Crimp Tool (HCT) information
Introduction Power&SignalGroup’sHCTshavebeendesignedtooptimizecrimpqualityforlowvolume,repair,or prototypeusage.InNorthAmericaandAsia,theHCTsmaybeorderedasindividualdiesets.In Europe,theMiddleEast&Africa,theHCTsmaybeorderedpre-assembledorasindividual compo nentstocrimpmultipleDelphiConnectionSystemterminalstovariouscablesizes.TheHCT issoldinoneoftwodesigns,bothensuringoptimumcrimpquality.Type2crimpspinandsleeve terminalswhileType1crimpsbladeandboxterminals.
Function of HCT ratchet ThePowerSignalGroupHCTratchethasdetents.Therearesixaudible“clicks”fromopeningto closing.Thecrimptoolisdesignedtocompletethefullcycleofdetentsinordertoassureaquality crimp.
IfitisnecessarytoopentheHCTpriortofullclosure,pressthehandlestogetherslightly.Turnthe emergencyunlockingreleaseclockwise(directionofthearrow)andopenthehandles simultaneously. NOTE:Iftheemergencyreleaseisutilized,thecrimpedterminalisnottobeused.
Scope of usage Power&SignalGroupHandCrimpTools(HCT)havebeendevelopedforoptimalcrimpingin: •Lowvolumeproduction •Repair •FieldService •Prototyping TheHCTshouldnotbeusedforotherpurposes.RepetitiveStressInjury(RSI)canresultfroma prolongeduseofmanuallypoweredhandcrimptools.Power&SignalGrouphandcrimptoolsare intendedforoccasionalandlowvolumeapplicationsonly.PleasecallPower&SignalGroupfor availabilityofpowerapplicatordiesandequipmentforhigh-volumeapplications.
Responsibilities of user Theoperation,maintenanceandserviceofthePower&SignalGroupHCTrequiresadegreeof practiceandskill.EachpersonwhoisworkingwiththeHCTmustbefamiliarwiththetool’soperation andfollowthemanual’sinstruction.Therefore,theinstructionsheetmustbeconstantlywithinreach oftheHCT.Inaddition,anyotherinstructionsresultingfromcurrentnationalregulationsintermsof healthandsafetyshouldbemaintainedwiththetool’sinstructionsheet.Theusershallnotmakeany revisionstotheHCTwithouttheconsentofthemanufacturerorsupplier.BeforeusingtheHCT,the operatorshouldconductavisualinspectionofthetooltoverifythatitisnotdamaged,maladjusted, orotherwisemalfunctioning.Power&SignalGroupdeclinestoacceptanyliabilityfordamagesthat occurduetoinappropriateuseoftheHCTordisregardfortheguidelinessetforthinthetool’s insructionsheet.TheuseroftheHCTisresponsibleforthequalityofthecrimp.
Note Regarding HCT manual dimensions DimensionsprovidedinthisHCTUsageManualareinmillimeters(mm).Figuresandillustrationsare notdrawntoscale.
HCT Power Assist Devices Power&SignalGroupcanalsorecommendor,inlimitedinstances,supplyPneumaticorMechanicalAssistdevicesfor usewithstandardPSGHandCrimpTools.Formoreinformation,pleasecontactthetechnicalsupportgroupforyour region.
3
Tool Types
4
Type 1: Box & Blade Terminal
Type 2: Pin & Sleeve Terminals
Type 3: Pin & Sleeve Terminals
WireStop
WireStop
WireStop
ChamferUpperDie
LowerDie
Stationaryjaws
M4X25mmAllenScrew
M4X11mmAllenScrew
M4X11mmAllenScrew
M4X16mmAllenScrew
M4X16mmAllenScrew
M4X18mmAllenScrew
DieRetaingScrews
M4LockNut
M4RegularNut
Locator
Locator
Assemblescrewswithoutfullytightening.Tightenscrewsafterclosinghandlestofullyseattheupperandlowerdie.
Turnsmallknobtoopenandcloseholdterminal.
DonotovertightenthewirestopM4nut.Makecertainthatthewirestopspringloadedblademovesfreely.
-PresstoOpen-Insertcontact-ReleasetocloseonContact-Opentoreleasecontact
-Aligntobottomdie-Snap
Emergencyrelease
For All Tool Types: Placeendofstrippedwireagainstthewirestop.
Assembly and Removal of HCT Die SetsIfyouhavepurchasedapre-assembledHCTbeginwiththecrimpverificationinstructions.
Die selection •SelecttheappropriatediefortheterminalpartandgaugesizeasdefinedintheCrimpToolReference DataSheet.
Die insertion •Assembletheupperandlowerdieinsertstogetherwiththeterminallocatorandwirestop. •Besurethatthebevelingsidepointstotheleft. •Thepropernutandallenscrewsareprovidedwitheachtoolkit.
Die Removal •Openthetoolhandles. •LoosenandremovethetwodieretainingscrewsbymeansofanAllenwrench •Slidethediesoutofthetooljaws.
Crimp verification Inordertoensurepropercrimpingandtocontrolthewearingofthetoolanddie,crimpverificationmustbedoneafter everydiesetchangeandregularlythereafter. StepOne Measurethecrimpheightandwidthwithacaliper.
StepTwo ComparethecaliperresultstothespecifiedtolerancerangefoundintheCrimpHeightReferenceDataSheetincluded witheachdieset.
Ifthecrimpheightisoutofthespecifiedtolerancerange,theHCTneedstobeadjusted.
Crimp Height Adjustment •Removesetscrew. •Rotatingtheadjustmentwheelcounterclockwiseincreasesthecrimpforceanddecreasesthecrimpheight. •Rotatingtheadjustmentwheelclockwisedecreasesthecrimpforceandincreasesthecrimpheight. •Reinsertsetscrew
5
Crimp Tool Reference Data Sheet Power&SignalGroupsuppliesspecificrequiredinformationwitheachshipmentofitspre-assembledhandcrimptools andwithindividualdieinserts.Informationincludesterminalpartnumber,cabletype,striplength,andotherinformation relevanttoobtainingaqualitycrimpedterminal.Additionalvalidationdataisavailableuponrequest.
Crimping Instructions Theproperinserts,terminallocatorandwirestopshouldalwaysbeusedfortheintendedterminalandwiregaugesize (SeeCrimpToolReferenceDataSheet). •Referencetoolnumber,terminalnameandwiregaugesizesontoolparts. •Referenceterminalpartnumbersandcablegaugesizesfromauthorizedwiringprintsorotherdocuments. •UsethespecificcablestriplengthfromtheCrimpToolReferenceDataSheet.
Terminal Loading InsertloosepieceterminalintoholderopeningasshowninFigure1.Type2(Pin&SleeveTerminal)locatorsmustbe openedwithknurledwheelandclosedtoorientterminalsoastocaptureterminalwings.Usecorrectcablesealif required(Figure2).
Figure 1 Figure 2
Makesureterminalisfullyinsertedsowingsareoverthecrimpanvils.Ifwingsdonotcatchproperly, slightlybendinwardtoclearupperplate.Partiallycloseratchethandlestocaptureterminal.(Use wrenchtoturnsquarenutclockwisetoreleasehandlesifterminalisnotcapturedproperly.) PositionstrippedwireendagainstwirestopinbottomofcrimpwingsforType2orinupperdiefor Type1.Makesurethespringloadedwirestopreturnsaftereachcrimp.(Ifwirestopdoesnotreturn, thelockingnutistootightorthestopneedstobelubricated.)Ifacablesealisused,makesurethe sealispositionedsothattheinsulationwingscapturetheseal.Makesurenostrandsarecutorare missinginthestrippingprocess.
Terminal Crimping Completetheratchetingclosureofhandlesuntiltheyspringopen.Removecrimpedleadscarefully. InspectcrimpedleadaccordingtotheVisualCrimpQualityRecommendationstoeliminatenonconformances: Measureallcrimpdimensionswithcalibratedmeasuringequipment.Comparetocrimpdimensionssuppliedwiththe toolinsertsforspecificcablesizeandterminalpartnumber.
Ifcrimpsaretoohigh,removesetscrewandturnserratedwheelcounterclockwise(+)untilpropercrimpheightis achieved.(Reinsertscrewbeforetryingagain.)Ifcorecrimpheightistootight,followthesameprocedureexceptturnina clockwisedirection.
6
Crimp Height Measurements Inordertoinsurepropercrimpquality,thecrimpheightmustbemeasuredandreadjustedifitdoesnotmeettheCore CrimpHeight(CCH)requirementsasshownintheCrimpToolReferenceDataSheetforthespecifiedterminalandcable size.TheCCHshouldbemeasuredwithapprovedcalipers.
Visual Crimp Quality Recommendations
Good Crimp: Correctcrimptoolapplicationwillminimizeoreliminate non-conformingcrimps.Improperlycrimpedterminals mayfailelectrically.Practiceonsamplesuntilgoodquality crimpsareconsistentlymade.Crimpedterminalsmust alwaysbe100%visuallyinspectedaftercrimpingprocess byfollowingthenon-conformancelistingsbelow.
Crimp dimensions not in tolerance: Wronginserttooling,crimpadjustmentnotright,inserts notseated,wronginsertjaw,wrongcableorterminal (Seedatasheetwithtooling.)
Low core:
Corenotshowinginfrontofterminalcorewingsdueto shortstrip,notusingwirestoporincorrectplacement.
Insulation under core wing:
Nostrip,shortstrip,wirestopnotused,incorrectplacement (mayalsoresultinhighcore).
Twisted or distorted terminals or cable seals:
Terminalnotpositionedcorrectlyintool.
7
Excessive Tab
Maydamagesealorcausesealtonotsealproperly. Terminalsnotcutoffstripproperly.
All strands not captured by core wings: Maycausealoosecrimpandelectricalormechanical non-conformance.Mayneedtoinspectstrandspriorto crimping.
Terminal straightness:
Excessivelybentterminalsmaycauseterminalsnotto seat,pushmatingterminaloutofcavity,ornotbeableto seatTerminalPositionLock.Maybecausedbylocating terminalincorrectlyintool.
Cut or missing strands: Incorrectstrippingofcable.Maycausealoosecrimpand electricalormechanicalnon-conformance.
HCT Maintenance and Cleaning ResponsiblepersonnelandoperatorsofthePower&SignalGroupHCTshouldmaintainthetoolwitheachuse. •Useaclean,lint-freeclothtoremovedust,moisture,anddebrisfromthetool.Donotuseabrasivecleanerson thetool,whichcouldresultindamage. •Makesurethatallscrewsandotherremovablepartsaresecureandinplace. •Allpivotpoints,bearingsurfaces,joints,andothermovementpointsshouldberegularlyoiled. •Whenthetoolisnotinuse,itshandlesshouldbeclosedtopreventforeignobjectsfrombeinglodgedinthe nichesandrecessesofthetool. •Storethetoolinacleananddryarea.
8
HCT Visual Inspection •QualitycontrolpersonnelshouldregularlycheckupontheHCTtoensurethatcrimpqualityisoptimal. •Inspectionsonthetoolshouldbemaderegularlyandlogged. •Thefrequencyofuse,workingenvironment,companystandards,andoperatortraining,strength,and proficiencyaresomefactorstotakeintoconsiderationwheninspectingthetool. •Whenvisuallyinspectingthetool,greaseshouldberemovedbyusingacommercialdegreaserthatwillnot negativelyaffectthetool. •Afterthetoolhasbeendegreased,makesurethattherangeofmotiononthetoolisquickandcleanwhenyou openandclosethetool. •Inspectthatthewirestop,holders,jaws,andothermovingpartsareinplace. •Makesurethattheunitisnotmissinganyscrewsandthattheemergencyreleaseisoperational. •Ifthereisanydamagespotted,makesureitisnotedandproperlycaredfor.Ifthetoolisstillinuseable conditions,thenlubricatethetoolandreturntoservice.Donotuseexcessiveamountsofoil. •Ifanyadjustmentsorreplacementsneedtobemade,pleasecontactthePower&SignalGroupservicenumber foryourregion.
Wire Stripper Instructions ObtaintheproperstriplengthfromtheCrimpToolReferenceDataSheet,whichislistedforeachcablegaugesizeofthe specifiedterminalpartnumber.(WireStrippersarenotincludedwithallHCTs) •Adjusttheredwirestoponthestrippertotheproperstriplength. •Inspectthestrippedleadscarefullyforcuts,scrapes,missingstrandsordeformedinsulationinthestriparea. •Readjustwirestripperifnecessary. •Acompletevisualinspectionisrecommendedpriortocrimping.
Imperialscale(inches)(forwiregauge32-7)
Metricscale(mm)(forwiregauge0.03-10)
9
HCT Technical Support Forassistance,pleasecontact: Power&SignalGroupNA 4670RichmondRoad,Suite120 Cleveland,OH44128USA EngineeringTechLine:(800)610-4837or(216)378-6600ext.5422 Sales:(800)722-5273or(216)[email protected] Power&SignalGroupEMEA Itterpark9-11 40724HildenGermany EngineeringTechLine:+492103250510 Sales:[email protected]
Power&SignalGroupAsia 6/FBuilding1 3000LongDongAvenue Pudong,Shanghai201023China Sales:[email protected]
Notes:
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
10