IDEAL ACAM User manual

Automatic Connector Application
Machine (ACAM)
Trouble Shooting Guide
1330 E Lincoln Hwy, DeKalb, IL 60115 U.S.A.
Ajax, Ontario L1S 2E1 CANADA
Warrington, Cheshire WA5 5TN ENGLAND
Technical Assistance: 1-877-201-9003
7:00 am - 3:30 pm CST M-F
www.idealindustries.com
LA2418-1 P-664 8/04 Printed in U.S.A.

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ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide
This is the ACAM Troubleshooting Guide. When used in conjunction with IDEAL
ACAM Set-up and Instruction Manual, it offers a comprehensive maintenance and
repair system. Refer to the ACAM Instruction Manual for detailed explanations of
"Solutions" listed in the ACAM Trouble Shooting Guide.
Through the ACAM Troubleshooting Guide, you will see "Reference" listed. Refer to
the inside back page for detailed address and phone number information for IDEAL
Technical Services / Engineering Applications Service, Customer Service, Quality
Hotline and your OEM Sales Specialists.
Quick Guide
I. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pages 1 to 4
Connector won't tighten completely
Connector won't tighten at all
Finished connection doesn't have twists
Stripped wire twists off
Stripped wire is exposed
ACAM won't turn on
Electronic board will not function
Hand tool stops before completing connection
Connector is backward
Connector falls out of hand tool
Connector is jammed
II. Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pages 4 to 7
Connector jammed in bowl
Connectors spilling out of bowl
Bowl will not stop vibrating
Vibration of bowl is inconsistent
Wire connector does not reach hand tool
III. Wire Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pages 7 and 8
Connector has no spring
Connector separates from spring
IV. Reference Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
Connector won't tighten completely
V. Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back cover page
Automatic Connector Application Machine
Optional Accessories
General Trouble Shooting Guide
Situation
If the wire connector won't tighten completely...
Possible Cause: Solution:
Torque adjustment too low. Check torque range (high vs. low)
and adjust torque level upward by
increments of 5 until connector
tightens correctly.
Gun is out of adjustment Adjust hand tool. Check to see if
finger receiving washer is correctly
positioned as hand tool is adjusted.
Incorrect strip length of wires Check with IDEAL for recommended
strip length. (Reference #1.
Situation:
If the wire connector won't tighten at all...
Possible Cause: Solution:
Hand tool is out of adjustment Adjust hand tool.
Disassembled, damaged or Repair or replace as needed.
broken drive shaft Check set-screws making drive shaft
connections.
Using wrong connector for machine Check machine number to connector
used. Reference #1.
Incorrect strip length of wires or Check with IDEAL for recommended
incorrect connector for strip length wire and wire connector
combinations for your specific wire size, insulation
and combinations. Reference #1.
Hand tool friction is set too low Increase hand tool friction setting on
keypad up to a maximum of 250.

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ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide
Situation:
If the finished connection doesn't have 1 to 3 wire twists below
connector skirt...
Possible Cause: Solution:
Torque set too low Increase torque setting.
Wire strip length may be too short Increase the strip to the
recommended length. Reference #1.
Operator technique Receive training on operation of
ACAM. REference #4.
Improper connector model for wire Check with IDEAL to see if wire
combination combination is listed for the
specific connector. Reference #1.
Hand tool not properly adjusted Adjust hand tool.
Situation:
If the stripped length of wire twists off when the wire connector is
applied...
Possible cause: Solution:
Torque may be set too high Decrease your torque setting.
Possible wrong connector for Check with your IDEAL OEM Sales
application Specialist or IDEAL Application
Engineering Service for correct
connector for application. Reference
#1 or #4.
Strip length of wires may be too Increase strip length so that no wire
short is exposed below the bottom of the
connector. Reference #1.
Using extremely "soft" wire Some lots of wire are soft and do
not allow for a connection to be
made. Consider alternate wires.
Hand tool may be out of adjustment Adjust hand tool.
Situation:
If the stripped wire is exposed below the bottom of the wire
connector skirt...
Possible Cause: Solution:
Wire strip lengths may be too long Shorten strip to recommended
lengths. Reference #1.
Wire strip lengths may be too long Use a longer skirted connector.
Reference #1.
Operator technique may be incorrect Receive training on operation of
ACAM. Reference #4.
May have the incorrect connector Reference #1.
for the application
Connector is not fully seated on Adjust torque level.
combinations
Several strands of a stranded wire Pre-twist stranded combinations.
have turned back within the
connection
Situation:
If the ACAM AM will not turn on or electronic module won't
function...
Possible cause: Solution:
Fuse at power cord may be blown Replace fuse.
CPU Module may have received a Replace CPU Module. Always protect
surge, spike or static energy your ACAM with surge protected
outlets or strips or a power
conditioner.
Power not getting to ACAM Check power source for correct
voltage.
Bad connections between Check connections.
electronic module

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ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide
Hand Tool Trouble Shooting Guide
Situation:
If the hand tool stops before completing the wire connection...
Possible cause: Solution:
Drive cable is building up excessive Check cable at machine and hand
resistance tool connection, adjust torque level
and grease drive cable.
Torque level set too low Check torque range (high vs. low)
and adjust torque level upward.
Hand tool adjustment is set too tight Adjust hand tool barrel assembly
clockwise.
Connector jammed in the hand tool Unjam hand tool by removing the
connector.
Hand tool friction set too low Increase hand tool friction setting on
keypad up to a maximum of 250.
Situation:
If the wire connector is backward in hand tool or shaft...
Possible cause: Solution:
Vibration is set too high Lower vibration adjustment(s) - fine
tune vibration adjustment on side of
ACAM and/or course adjustment
directly under ACAM motor center
base plate.
Debris in ejector is tripping Remove debris from ejector.
connector
Trip screw in alignment ramp is Lower screw on alignment ramp
too high that trips the connectors.
Alignment ramp misaligned Realign alignment ramp.
Situation:
If the wire connector falls out of hand tool...
Possible cause: Solution:
Retaining spring is worn out or Replace U-shaped retainer spring.
missing
Front barrel is adjusted too tight Loosen barrel adjustment.
Situation:
If the wire connector is jammed in hand tool...
Possible cause: Solution:
Connector is in the hand tool Squeeze front retaining spring on
backward hand tool to release connector.
Hand tool is dirty Preventive maintenance - clean hand
tool
Connector that fell on the floor and Be careful not to place debris or
was stepped on was placed back deformed connectors into
into hopper or bowl machine.
Flash on the connector Use only the family of IDEAL
Wire-Nut® Wire Connector products.
Reference #3 and #4.
Hand tool is improperly adjusted Adjust hand tool.

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ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide
Feed System Trouble Shooting Guide
Situation:
If the wire connector is jammed in bowl...
Possible cause: Solution:
Feed tube is out of alignment Align feed tube or barrel.
Something in system is physically Check for connector caught in bowl
impairing connector movement track, connector or debris blocking
alignment ramp or feed tube.
Telescoping connectors have formed Break up the jam and adjust vibration
a bridge across the bowl as needed.
Bowl may - in some instances - Lightly sand the interior of the bowl.
form rough edges causing the
connectors to hang up in the bowl
Situation:
If the wire connectors are spilling out of the bowl...
Possible cause: Solution:
Operator has placed too many Reduce quantity of connectors in
connectors directly into bowl bowl.
Hopper is feeding too many Check height of Capacitive Proximity
connectors into bowl sensor and adjust proximity switch.
Capacitive Proximity sensor should
have approximately 3-6 threads
exposed on top of upper nut. Adjust
sensitivity screw on proximity level
sensor as outlined in manual.
Hopper gate may be open Check hopper operation, especially
hopper gate area. See if solenoid
cycles in the test mode. Also, check
vibrator module. Replace solenoid or
vibrator module if needed.
Connector is jammed at entrance to Align feed tube with alignment ramp.
feed tube
Situation:
If the bowl will not stop vibrating...
Possible cause: Solution:
Faulty hopper, solenoid, vibrator Replace components as needed. Turn
module or connector adapter ACAM off, then on to reset,.
Level sensor incorrectly set, Correctly set proximity level sensor.
incorrectly positioned or faulty Replace as needed.
Level sensor may be dirty Clean as needed.
ACAM may be in test mode Push Clear button several times. Turn
ACAM off, then on.
Connector may be hung up in Locate and remove jammed
system connector.
Situation:
If the vibration of feeder bowl is inconsistent...
Possible cause: Solution:
Course vibration adjustment nut Tighten the course vibration nut
under ACAM may be loose under the CAM motor centerbase
plate.
Fuse in the switch is turned to the Turn fuse to 110V position.
220V position causing the machine
to vibrate at 1/2 speed
Erratic voltage in the line to the Use a voltage power conditioner.
ACAM Reference #4.

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ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide
Situation:
If the wire connector does not make it to the hand tool...
Possible cause: Solution:
A connector may be jammed in Unjam the connector.
some location
A connector may not be able to Straighten tube. Check stand height
fall down the end tube and raise as needed.
There is a kink in the feed spring Repair or replace as needed.
assembly
Wire Connector Trouble Shooting Guide
Situation:
If the wire connector has no spring in it...
Possible cause: Solution:
Using an All-Plastic wire connector There is a type of wire connector that
has no spring. It is correct to use on
specific applications. Contact your
IDEAL OEM Sales Specialist if
alternative types of wire connectors
are needed. Reference #4.
Check original manufacturer of Only IDEAL wire connectors are
wire connector designed to work with IDEAL
ACAMs. If your connector is
supposed to have a spring in it and
doesn't, remove the connectors.
Reference #3. ACAMs are leased to
facilitate the efficient application of
IDEAL wire connectors only.
Situation:
If the wire connector shell separates from spring during assembly...
Possible cause: Solution:
Inferior competitive connectors Use only IDEAL wire connectors in
used in place of IDEAL the ACAM. REference #4.
Torque setting too high Lower torque setting.
Incorrect wire combination for Consult your OEM connector guide
connector for the correct combination for each
connector or contact your IDEAL
OEM Sales Specialist or contact
IDEAL Technical Service.
Reference #4.
Any other situation Reference #3
Notes:

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References
For additional information, contact:
Reference #1 -- Technical Service/Engineering Application Service
Ph: 800.338.4495 Ph: 815.895.5181
Fax:[phone] Fax:[phone]
For assistance with ACAM leases, troubleshooting, replacement parts and
part drawings. To get assistance on which connector to use, recommended
strip lengths and UL/CSA-approved wire combinations.
Reference #2 -- Customer Service
Ph: 800.435.0705 Ph: 815.895.5181
Fax:[phone] Fax:[phone]
To place or expedite an order, check shipping dates, receive proof of
delivery, or to order replacement parts.
Reference #3 -- Quality Hotline
Ph: 800.435.0705, ext. 100 Ph: 815.895.5185, ext. 100
To report any problem related to the product, packaging, delivery, or
service.
Reference #4 -- OEM Sales Specialists
Ph: 800.435.0705 Ph: 815.895.5181
To receive ACAM demonstrations, field service, operator training, product
samples, and pricing information.
Reference #5 -- Tech Support Hotline
Ph: 877-201-9003
IDEAL INDUSTRIES, INC.
Becker Place
Sycamore, IL 60178-2499
www.idealindustries.com
Ordering Information
Automatic Connector Application Machine
Connector Model No. ACAM Cat.No
71B® Gray 30-971
72B® Blue 30-972
73B® Orange 30-973
74B® Yellow 30-974
76B® Red
341® Tan Twister®
342® Gray Twister®
High Temperature Model
71B® Black 30-971
72B® Black 30-972
73B® Black 30-973
59B® Black
Optional Accessories
Description Cat.No.
Adjustable Mounting Stand 2-9053
Bench Mount and Foot Switch 30-984
Auxiliary Hopper 30-951
ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide