TE Connectivity AMP 5K/30 Reference guide

Customer Manual
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PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
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visit our website at www.te.com.
409-35013
11 NOV 19 Rev A
SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!......................................2
1. INTRODUCTION ..................................................................................................................3
2. DESCRIPTION .....................................................................................................................5
2.1.Functional Description....................................................................................................5
3. RECEIVING INSPECTION AND INSTALLATION ...............................................................6
3.1.Receiving Inspection and Installation.............................................................................6
3.2.Initial CQM Setup ...........................................................................................................6
3.3.Configuring the CQM for use with DCCM ......................................................................6
4. OPERATION ........................................................................................................................6
4.1.Machine Cycle with a Good Crimp as Determined by the CQM: ...................................6
4.2.Machine Cycle with a Defective Crimp as Determined by the CQM: .............................7
5. ADJUSTMENTS...................................................................................................................7
5.1.DCCM Adjustment .........................................................................................................7
5.2.Guard Insert Adjustment ................................................................................................8
6. TROUBLESHOOTING .........................................................................................................8
7. DISPOSAL ...........................................................................................................................8
8. REPLACEMENT AND REPAIR ...........................................................................................8
9. RoHS INFORMATION..........................................................................................................8
10. REVISION SUMMARY .........................................................................................................8
AMP 5K/30, AMP 5K/40 and G II CE Terminating
Machines with Defective Crimp Cut Module
(PN 2362229-[ ])
ORIGINAL INSTRUCTIONS

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SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!
Safeguards are designed into this application equipment to protect operators and maintenance personnel from
most hazards during equipment operation. However, certain safety precautions must be taken by the operator
and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application
equipment must be operated in a dry, dust-free environment. Do not operate equipment in a gaseous or
hazardous environment.
Carefully observe the following safety precautions before and during operation of the equipment:
Always wear approved eye protection while operating
equipment.
Always wear appropriate ear protection while using
equipment.
Moving parts can crush and cut. Always keep guard(s)
in place during normal operation.
Electrical shock hazard.
Always turn off the main power switch and disconnect
the electrical cord from the power source when
performing repair or maintenance on the equipment.
Never insert hands into installed equipment.
Never wear loose clothing or jewelry that may catch in
moving parts of the equipment.
Never alter, modify, or misuse the equipment.
SUPPORT CENTER
CALL TOLL FREE 1-800-522-6752 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Support Center offers a means of providing technical assistance when required. In addition, Field Service
Specialists are available to provide assistance in the adjustment or repair of the application equipment when
problems arise which your maintenance personnel are unable to correct.
INFORMATION REQUIRED WHEN CONTACTING THE SUPPORT CENTER
When calling the Support Center regarding service to equipment, it is suggested that a person familiar with the
device be present with a copy of the manual (and drawings) to receive instructions. Many difficulties can be
avoided in this manner.
When calling the Support Center, be ready with the following information:
1. Customer name
2. Customer address
3. Person to contact (name, title, telephone number, and extension)
4. Person calling
5. Equipment number (and serial number if applicable)
6. Product part number (and serial number if applicable)
7. Urgency of request
8. Nature of problem
9. Description of inoperative component(s)
10. Additional information/comments that may be helpful

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Terminator
Part Number
Description
Stroke
Customer Manual
Standard Machine
CQM
2362229-1
AMP 5K Atlantic DCCM Terminator
40mm
409-10204
409-10100
2362229-2
AMP 5K Pacific DCCM Terminator
30mm
2362229-3
G II Atlantic DCCM Terminator
40mm
409-32035
Figure 1
1. INTRODUCTION
This manual contains supplemental information on the operation and adjustments of the AMP 5K/40, 5K/30, and
GII (PN 2362229-[ ]) CE Terminating Machines with a Defective Crimp Cut Module (DCCM) installed (see
Figure 1).
The specifications and requirements for the CE Terminating Machines with a DCCM installed that differ from the
specifications and requirements of the standard machine are as listed
below:
Weight: 77.6 Kilograms [171.1 lb] (2362229-1, 2362229-2)
107.2 Kilograms [236.3 lb] (2362229-3)
Air: 80 - 100 psi supplied to DCCM
NOTE
Information in this manual highlights the specific differences of machineswith aDCCM installed when compared with those that do not
have aDCCM installed and does not provide complete information on the operation and maintenance of the overall terminating
machine. For information on the operation and preventative maintenance of 5K or GII machines refer to the applicable 409 Series
Customer Manual shown in the table in Figure 1.

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When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements and the
additional icons that follow.
DANGER
Denotes an imminent hazard which may result in moderate or severe injury.
CAUTION
Denotes a condition which may result in product or equipment damage.
NOTE
Highlights special or important information.
Always wear approved eye protection while operating the equipment.
Always wear approved hearing protection while operating the equipment.
Use caution working with this equipment.
Main electric ON/OFF switch.
Do NOT operate the equipment if the guard is removed.
Lift point for the equipment.
Read and understand the entire manual before using the equipment.
Moving parts can crush and cut. Do not operate the equipment without guards in place.

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2. DESCRIPTION
The AMP 5K/40, 5K/30, and GII CE Terminating Machines with a DCCM installed were designed to be used as
stand-alone semi- automatic bench units that cut the wire when there is a defective crimp; thereby severing a
questionable crimp before it can be withdrawn from the machine.
They are assembled with metric hardware.
NOTE
Measurements are in metric units [followed by U.S. customary units in brackets] unless otherwise indicated. Some commercial
items may contain non-metric hardware.
2.1. Functional Description
These machines are equipped with an automatic wire chopper that works in conjunction with the Crimp Quality
Monitor [CQM] to immediately remove terminations that do not meet the requirements for a good crimp as set
in the CQM. These machines have two important differences from the standard machines that are described
below:
1. The Defective Crimp Cut Module is a pneumatically operated chopping blade that is mounted to the
front of the terminator’s base plate. The DCCM cutting blade is actuated when the pneumatic solenoid
connected to DCCM receives a signal from the CQM. The DCCM is hinged and can pivot away from
the machine baseplate to provide more access when installing, adjusting or inspecting an applicator.
Figure 2 Detail A shows the DCCM Unit, Figure 2 Detail B shows the DCCM solenoid that is attached
to the left side of the machine and identifies the air supply hose.
Figure 2
2. The Guard and Guard Insert on machines equipped with a DCCM are designed specifically for use
on these terminators. The guard insert is adjustable to bring the opening in line with the DCCM
window. The main guard is interlocked to the control system of the machine preventing the machine
from operating with the main guard open.
DANGER
Do not operate the machine without the guards or guard insert installed. Operating the machine without all guards in place
could result in serious injury of the operator.
Detail A
Detail B
Cut Window
Hinge Pin
Air Supply Line
[80-100 PSI]

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3. RECEIVING INSPECTION AND INSTALLATION
3.1. Receiving Inspection and Installation
Inspect and install machine in accordance with the applicable 409 Series Customer Manual (see Figure 1).
Air, regulated to 80-100 psi, must be supplied to the DCCM solenoid through port identified in Figure 2 Detail B.
3.2. Initial CQM Setup
Follow these steps when the machine is being set up for the first time to ensure that the CQM is properly
configured to operate with the DCCM.
1. Turn the machine and CQM on.
2. On the CQM screen, select the Use DCCM radio button.
3. Proceed with normal CQM setup as described in Section 4 of Customer Manual 409-10100.
NOTE
The DCCM will not operate during the learning process of the CQM. Once the learning process is complete, the DCCM will
operate when the CQM detects a non-conforming crimp.
3.3. Configuring the CQM for use with DCCM
NOTE
The following steps only need to be performed if the Use CQM option is not seen on the CQM screen when the machine is
turned on.
1. In the CQM Control Panel screen select System Setting and then select DCCM Installed pick.
2. Turn the machine and CQM off and wait approximately 10 seconds.
3. Turn the machine and CQM on.
4. On the CQM screen, select the Use DCCM radio button.
5. Proceed with normal CQM setup as described in Section 4 of Customer Manual 409-10100.
4. OPERATION
NOTE
For complete instructions on the operation of the bench terminator and applicator installation and setup, reference the
applicable 409 Series Customer Manual (see Figure 1).
NOTE
For complete instructions on the setup and operation of the CQM, refer to Customer Manual 409-10100.
4.1. Machine Cycle with a Good Crimp as Determined by the CQM:
1. Place the stripped wire through the opening in the guard insert, through the DCCM cutting window and
against the wire stop of the applicator.
2. Press the foot switch.
The terminator cycles to apply a terminal to the wire.
The CQM analyzes the crimp and determines that it is good.
3. Remove the terminated wire from the machine.

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4.2. Machine Cycle with a Defective Crimp as Determined by the CQM:
CAUTION
When the DCCM severs a bad crimp, the operator must open the guard and remove the severed terminal. Failure to remove
the severed terminal could interfere with proper application of future crimps.
1. Place the stripped wire through the opening in the guard insert, through the DCCM cutting window and
against the wire stop of the applicator.
2. Press the foot switch.
The terminator cycles to apply a terminal to the wire.
The CQM analyzes the crimp and determines that it does not conform to the learned requirements.
3. The CQM activates the DCCM which severs the defective terminal from the wire.
4. Open the guard and remove the severed terminal from the crimping area.
5. Close the guard and clear air via the CQM screen.
5. ADJUSTMENTS
Both the insert in the machine guard and the DCCM module are adjustable to properly align the windows in the
guard and the DCCM with the applicator crimping area. Proper alignment will ensure that the wire is in the
correct place when the machine is cycled.
DANGER
To avoid personal injury, ALWAYS disconnect electrical and air supplies before performing adjustments.
5.1. DCCM Adjustment
The DCCM should be adjusted before adjusting the guard insert. To adjust the position of the DCCM proceed
as follows:
NOTE
The applicator to be used in the machine must be installed in the machine prior to adjusting the DCCM or the machine guards.
Install the applicator in the machine according to the instructions packaged with the applicator.
Horizontal Adjustment
1. Install the applicator in the machine according to the instructions packaged with the applicator.
2. Observe the position of the DCCM cut window relative to the height of the applicator anvil.
The bottom of the window should be in line with, or just below, the top of the anvil and centered right
to left with respect to the anvil.
3. Pivot the DCCM unit away from the applicator by means of the unit’s detent hinge.
4. Loosen the screws holding the DCCM mounting bracket to the applicator base plate until the bracket
can move right to left.
5. Adjust the mounting bracket position until the DCCM cut window, when the DCCM is rotated back into
the operating position, is centered relative to the applicator anvil.
6. Tighten the DCCM mounting bracket screws securely.
Vertical Adjustment
1. With the DCCM unit in the normal operating position, loosen the screws holding the DCCM to the
DCCM mounting bracket.
2. Adjust the vertical position of the DCCM unit until the bottom of the cut window is in line with or just
below the top of the applicator anvil.
3. Tighten the DCCM unit screws securely.
4. Double-check the vertical and horizontal position of the DCCM cut window.
If adjustments are still required, repeat necessary steps above

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5.2. Guard Insert Adjustment
The DCCM guard insert is adjustable to align the guard insert window with the DCCM cut window and the
applicator crimp area. To adjust the guard insert proceed as follows:
1. Open the main guard door and loosen the three screws that secure the guard insert.
2. Close the main guard door.
3. Align the vertical slot in the guard insert with the center of the DCCM cut window.
If the DCCM unit was aligned correctly as described in Section 6.1 then centering the window of the
guard insert with the cut window of the DCCM unit should center the guard with the crimping area of
the applicator.
4. Hold the guard in the correct position and open the main guard door.
5. Tighten the two inside screws securing the guard insert, then tighten the outside screw.
6. Close the main guard door and double check the guard insert slot alignment. If adjustments are still
required repeat necessary steps above.
6. TROUBLESHOOTING
Contact the Support Center at 1-800-522-6752.
7. DISPOSAL
Contact TE Connectivity (TE) for disposal.
8. REPLACEMENT AND REPAIR
There are no customer-replaceable parts. Call 1-800-522-6752 for customer repair service.
9. RoHS INFORMATION
Information on the presence and location of any substances subject to Restriction on Hazardous Substances
(RoHS) can be found at the following website:
http://www.tycoelectronics.com/customersupport/rohssupportcenter/
Click on “Find Compliance Status" and enter equipment part number.
10. REVISION SUMMARY
This is the initial release.