TE Connectivity Crimp Quality Monitor II User manual

Crimp Quality Monitor II
Part number 2359600-1
Customer Manual
412-10100
22 SEP 2022 Rev D
Original instructions

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General information
The information provided is intended solely for product description purposes. Users must carry out their
own assessments and tests. Our products are subject to natural wear and aging processes.
All rights are retained by TE Connectivity (TE) in case of applications for protective rights. We reserve
all rights of disposal, such as copying and transfer rights.
The front cover shows a sample configuration. The supplied product may vary from what is shown.
This operating manual is only intended for internal use by the user of the crimping machine for FFC
and F crimping (referred to herein as "FFC-FFC-CM") and their personnel.
The relevant supplementary operating manual contains descriptions, technical drawings, specifications
and instructions, no part of which may be reproduced, circulated, disclosed, or used for the purpose of
competition without permission.
Should third parties endeavor to gain access to this operating manual, the same fairness is expected
from you as you would expect from your customers in such cases.
All rights reserved, including the granting of patents or other registrations. Subject to technical
changes.
© Copyright 2022 TE Connectivity Ltd. family of companies. All rights reserved.
TE Connectivity, TE Connectivity (logo), and TE (logo) are trademarks. Other logos and product or
company names may be trademarks of their respective owners.
PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For the latest revision and Regional Customer Service, visit our website at www.te.com.

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Contents
1Introduction..................................................................................................................................................... 7
2Description ................................................................................................................................................... 10
2.1 Screen description ............................................................................................................................... 10
2.2 Menu Bar ............................................................................................................................................. 10
2.3 Control Panel Screen .......................................................................................................................... 11
2.4 Help ..................................................................................................................................................... 12
2.5 Screen Information .............................................................................................................................. 12
2.6 Graphing Information........................................................................................................................... 12
2.7 Task Bar .............................................................................................................................................. 13
2.8 Definitions ............................................................................................................................................ 13
2.8.1 Headroom (and how it affects crimps)............................................................................................. 13
2.8.2 Crimp Height.................................................................................................................................... 13
2.8.3 Work index....................................................................................................................................... 14
2.8.4 Peak force........................................................................................................................................ 14
2.8.5 Point-to-point (P2P) analysis ........................................................................................................... 14
2.8.6 Fast Fourier transform (FFT) analysis ............................................................................................. 14
2.8.7 Force Only Mode ............................................................................................................................. 14
3Receiving, inspection, and installation ......................................................................................................... 15
3.1 Receiving and inspecting..................................................................................................................... 15
3.2 Installation............................................................................................................................................ 15
3.3 System settings ................................................................................................................................... 16
3.4 CQM settings ....................................................................................................................................... 16
3.4.1 Setup Tab ........................................................................................................................................ 17
3.4.2 Position Sensor Tab ........................................................................................................................ 18
3.4.3 Force Sensor Tab ............................................................................................................................ 19
3.4.4 Sensor Calibration Tab .................................................................................................................... 19
3.4.5 Learn Tab ........................................................................................................................................ 20
3.4.6 Control Limit Tab ............................................................................................................................. 21
3.4.7Graphing Tab................................................................................................................................... 21
4Production run setup .................................................................................................................................... 22
4.1 Options ................................................................................................................................................ 22
4.2 Work Order .......................................................................................................................................... 22
4.3 Order Size............................................................................................................................................ 23
4.4 Part ...................................................................................................................................................... 23
4.5 Analysis Methods................................................................................................................................. 24
4.6 Crimp Height........................................................................................................................................ 25
4.7 Peak Force (PF) and Work Index (WI) Sensitivity............................................................................... 26

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4.8Point to Point (P2P) / FFT Sensitivity .................................................................................................. 27
4.9 Sample................................................................................................................................................. 28
4.10 Calibrate .............................................................................................................................................. 29
4.11 Learn.................................................................................................................................................... 30
5Production .................................................................................................................................................... 32
5.1 Basic Screen........................................................................................................................................ 33
5.2 Status................................................................................................................................................... 34
5.3 Crimp Height........................................................................................................................................ 35
5.4 Work Index........................................................................................................................................... 36
5.5 Peak Force .......................................................................................................................................... 37
5.6 P2P ...................................................................................................................................................... 38
5.7 FFT ...................................................................................................................................................... 39
6Control panel ................................................................................................................................................ 40
6.1 Language icon ..................................................................................................................................... 40
6.2 Login/Logout ........................................................................................................................................ 40
6.3 Users ................................................................................................................................................... 41
6.3.1 Add New User.................................................................................................................................. 41
6.3.2 Change Password ........................................................................................................................... 41
6.3.3 Delete .............................................................................................................................................. 41
6.3.4 Permission Settings ......................................................................................................................... 42
6.4 Locale Settings .................................................................................................................................... 44
6.4.1 Date/Time Settings .......................................................................................................................... 45
6.4.2 Reports ............................................................................................................................................ 46
6.4.3 Report Setup.................................................................................................................................... 53
6.4.4 Curve History Graph ........................................................................................................................ 53
6.4.5 Network............................................................................................................................................ 54
6.4.6 Display Settings ............................................................................................................................... 56
6.4.7 Calibrate Touchscreen..................................................................................................................... 57
6.4.8 Maintenance .................................................................................................................................... 58
6.4.9 Diagnostics ...................................................................................................................................... 62
6.4.10 Error Log Viewer.......................................................................................................................... 66
6.4.11 Demo ........................................................................................................................................... 67
6.4.12 Printer Icon .................................................................................................................................. 67
7Troubleshooting............................................................................................................................................ 69
7.1 Additional information for specific sensors .......................................................................................... 70
7.1.1 Linear Encoder ................................................................................................................................ 70
7.1.2Analog Height Sensor...................................................................................................................... 70
7.1.3 Base Plate Strain Gage (Force Sensor) .......................................................................................... 71

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7.1.4 Piezo Sensor (Force Sensor) .......................................................................................................... 71
7.1.5 Trigger Sensor (on non-TE terminators).......................................................................................... 71
8Maintenance................................................................................................................................................. 72
8.1 Touch screen cleaning ........................................................................................................................ 72
8.2 Daily maintenance ............................................................................................................................... 72
8.3 Special handling precautions for systems with the linear encoder installed ....................................... 72
8.4 Quality control maintenance ................................................................................................................ 73
9Evaluation and repair ................................................................................................................................... 73
10 Revision summary ................................................................................................................................... 73

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SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!
NOTE
Keep all decals clean and legible. Replace them when
necessary.
DANGER
Inspect the tool and jaws/dies before each use.
Replace any worn or damaged parts. A damaged or
improperly assembled tool can break and strike nearby
personnel.
Failure to observe this warning could result in severe
injury or death.
DANGER
ELECTRIC SHOCK HAZARD
This tool is not insulated. When using this unit near
energized electrical lines, use proper personal
protective equipment.
Failure to observe this warning could result in severe
injury or death.
DANGER
Denotes an imminent hazard that can result in
moderate or severe injury.
SKIN INJECTION HAZARD
Do not use hands to check for oil leaks. Highly
pressurized oil punctures the skin, causing serious
injury, gangrene, or death. If injured, seek immediate
medical help to remove the oil.
CAUTION
Do not place the tool in a vise. The crimping tool is
designed for hand-held operation.
Protect the crimping tool from rain and moisture. Water
damages the crimping tool and battery.
Failure to observe these precautions can result in injury
or property damage.
DANGER
FIRE HAZARD
Do not use solvents or flammable liquids to clean the
crimping tool. Solvents or flammable liquids could
ignite and cause serious injury or property damage.
Failure to heed these warnings could result in severe
injury from harmful fumes or burns from flying debris.
CAUTION
Do not perform any service or maintenance other than
as described in this manual. Injury or damage to the
tool can result.
Failure to observe these precautions can result in injury
or property damage.
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 turn off the main power switch and disconnect
the electrical cord from the power source when
performing repair or maintenance on the equipment.
Always wear appropriate ear protection while using
equipment.
Never alter, modify, or misuse the equipment.
Moving parts can crush and cut. Always keep guards
in place during normal operation.
Do not operate equipment if the guards are removed.
Electrical shock hazard.
Read and understand this entire document before
using equipment.
Always turn off the main power switch and disconnect
the electrical cord from the power source when
performing repair or maintenance on the equipment.

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1 Introduction
Crimp Quality Monitor II (CQM II, Figure 1) provides immediate inspection of the crimp height and the work
curve of a crimp by analysis of data provided by force and position sensors. The sensors can be built into
special CQM II applicators or installed into the terminating machine. The CQM II uses visual cues to notify the
operator when faulty crimps occur.
Figure 1: Crimp Quality Monitor II
CAUTION
Do not use any metal object as a stylus on the touch screen.
NOTE
The CQM II is a process monitor. It is influenced by many variables, including changes in wire, terminal, applicator terminal
condition, operator, and environment. Changes in any of these variables can affect the process, which must be re-learned.

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The CQM II was designed for many machines, but when it is installed on an AMP-O-LECTRIC™ Model G
Terminating Machine (Figure 2) equipped with the crimp height adjustment motor, the CQM II automatically
adjusts the crimp height to keep the process at nominal.
The CQM’s operation, functions, screens, and touchscreen inputs are detailed in this document. Refer to
customer manuals and instructions shipped with the application equipment for machine information.
Figure 2: AMP 3K/5K Terminating Machine
1
AMP 3K/5K Terminating Machine
2
CQM II

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The specifications for the CQM II are listed in Table 1, Table 2, and Table 3.
Table 1: Electrical
Operating voltage (DC power supply)
100-240 VAC, 50/60 Hz, 1.5 amps (max.)
Host and DAQ (data acquisition) operating voltage
24 VDC
Table 2: Ambient operating environment
Temperature
5-40° C [40-104° F]
Relative humidity
< 95% non-condensing
Table 3: Sensors
Force strain gage
Wheatstone bridge force sensor
Force piezo
ICP low impedance quartz force sensor
Displacement
Analog hall effect sensor
Linear quadrature encoder (5Vdc, 2 micron)
Inputs/outputs: Four programmable outputs for machine interface.
NOTE
Use the AC power cord that is appropriate with your country’s power system (typically included with the system). Ensure that
the cord is plugged into a circuit that has over-current protection of no greater than 15-20 amps (country dependent).
To best use the machine and manual, complete the following steps.
1. Open the package.
2. Inspect the contents.
3. Install the machine (using drawings and 408 instructions).
4. Configure the machine as described in section 3.3.
5. Set up the machine for production operation.

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2 Description
2.1 Screen description
Many of the screens are designed to walk the operator through the crimping process with a series of arrows
and headings.
2.2 Menu Bar
Icons on the menu bar (Figure 3) are used to access the home screen (Work Order Screen), Help, Control
Panel, Back Arrow (to go to the previous screen), and a menu collapse arrow. The menu collapses
automatically if the screen is not touched for five seconds.
Figure 3: Menu bar
1
Back arrow
5
To Control Panel
2
Home screen
6
Time and date
3
Help
7
Menu collapse arrow
4
Screen name [screen number]
A series of icons guides you through the use of this monitor. Table 4 lists the buttons and icons you will need to
use, including the edit icon, the delete icon, and the radio buttons.
Table 4: Buttons and icons
Button
or icon
Description
Back arrow
Menu collapse arrow
Edit icon
Delete icon
Radio button (selected)
Radio button (deselected)