TriStar TAC-10X Manual

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TAC
10X
OPERATION &
MAINTENANCE
MANUAL
TRI-STAR TECHNOLOGIES!
2201 ROSECRANS AVE
EL SEGUNDO, CA 90245!
!
WWW.TRI-STAR-TECHNOLOGIES.COM
September 2018
Rev. 1.0
AUTOMATIC CONTACT CRIMPER

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N O T I C E
This is an OPERATION and MAINTENANCE
MANUAL. Its purpose is to assist users in the initial
set-up, verification and operation of the Vibratory Feed
Crimper. It is not intended to be used as the guide to
perform major adjustments or to effect major repairs.
Consult the factory if adjustments or repairs other than
those described herein are necessary.
WARNING!
This machine must be supplied with a clean, dry, oil-
free air supply. Absence of such will void warranty.

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TABLE OF CONTENTS
Section Title
1. Introduction
2. Initial Set-up
3. Crimp Verification
4. Operating Procedures
5. Theory of Operation
6. Maintenance and Troubleshooting
7. Parts List, Electrical/Pneumatic
Diagrams "

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INTRODUCTION
Section 1
The Tri-Star Technologies TAC Series of Vibratory Feed Bowl Crimpers are
devices which automatically crimp loose electrical contacts to electrical
conductors. This operation manual is for the TAC-10X model. Figure 1-1 is a
photograph of a TAC-10X as viewed from the front (operator) side. This
photograph gives a view of the cabinet housing, the feeder-bowl, the
escapement system, and the crimping system.
TAC-10X requires no lubrication or preventive maintenance except to
periodically change the air filter or drain it. Crimp acceptability should be
verified in accordance with the user's normal practices.
lndenters used in the TAC-10X are qualified to the M22520 specification and
are of the highest quality, to ensure a substantial quantity of acceptable
terminations.
Reasonable care must be exercised, however, to prevent any foreign matter,
particularly hard substances, from being crimped. lndenters might be damaged
if subjected to crimping anything other than the contact specifically intended.
Under normal operating conditions, however, the control system precludes the
TAC from crimping anything other than the specific contact for which the
equipment is tooled.

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Figure 1-1: TAC-10X, Front View

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OPERATION
All functions of the TAC are initiated, terminated, controlled and operated both pneumatically
and electrically. After the TAC has been set up properly, only two functions are operator-
adjustable: The amplitude of the feeder-bowl vibrations and, if a feature of this particular
TAC, the selected "G" dimension. All other functions are machine controlled.
Interlocks are provided in the Control System to prevent any out-of sequence event from
occurring. System design is such that if the indenter does not crimp completely, the device
will not permit that particular contact from exiting the crimper without performing a reset. If a
contact does not seat properly in the transfer tip the equipment will disengage. If the wrong
transfer tip is installed, the system will produce error message. All events occur
automatically, except the insertion and extraction of the conductor, which is operator
performed.
The crimp cycle initiation occurs when a properly stripped conductor is inserted into the
contact to be crimped, and depressed. Depressing the contact with the conductor inserted
triggers the TAC; when the crimp is completed the operator withdraws the conductor with
the contact now attached; the TAC re-cycles and places another contact in proper position;
the operator inserts another properly stripped wire into the contact, depresses it slightly, and
the cycle repeats.
Figure 1-2 shows the funnel through which the operator inserts the conductor into the
contact. In most cases the arbor cover plate is chemically treated a dull black color in order
that operators may more easily recognize a flayed or skewed conductor strand prior to
insertion.
TAC's equipped with funnels eliminate eye-hand coordination fatigue as the operator need
not visually affirm each conductor strand is inserted into the contact. The funnel design
assures all conductor strands, even if not twisted together, will enter the contact so long as
they are not bent back when inserted into the funnel. TAC's eliminate all eye-hand-foot
coordination fatigue and timing techniques, as there are no foot-switches.

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Figure 1-2: Wire Insertion Through Funnel

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OPERATOR !
TECHNIQUE
Crimp location on the contact, and depth of crimp, are entirely TAC dependent. The
operator only need select (if applicable) the proper "G" dimension setting and initiate
the crimp cycle by inserting the conductor into the contact and depressing it by
applying slight pressure. A conductor whose strands are not visible through the contact
inspection hole (if applicable) was probably not stripped to proper length.
Operators usually get the "feel" of the machine within 15 minutes of use. Noise
generated by the device is minimal; operators have been observed to develop a
rhythm of insertion and withdrawal based on the unique sounds generated by the
device. Crimp rates of 1800 crimps per hour have been attained.
TAC-10X !
SPECIFICATIONS
TAC-10X most shouldered and
shoulder-less contacts
Weight 70 lbs
Air approx. 10 CFM @ 85 PSI
Input Air Connections 3/8" ID
Electric 115 VAC, 60 cycle, 5 AMP
Europe 220 VAC, 50 cycle, 5 AMP
Dimensions 17” wide x 21” deep x 21” height!
Contact Feed Rate approx. 1800+/hr

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INTRODUCTION
Although all TAC's are ruggedly constructed, adequate precautions must be observed
and all instructions followed to prevent damage to the device during the Initial Set-up
Lift and transport the TAC using only the baseplate Do not lift, pull shove or jostle the
feeder bowl, the crimp cylinder or any component mounted on the baseplate.
Damage will result!!
Read this entire section before proceeding. The time required to have this TAC ready
for CrimpVerification {Section 3) is less than one hour.
The shipping container in which the TAC is transported is a three piece design
constructed to ensure safe arrival of the device.
The bottom base piece of the container holds the TAC; the other pieces of the
shipping container consists of the top and four sides, which are secured to the bottom
base by mounting straps.
To Uncrate/Unpack the TAC:
Step 1. Carefully cut all mounting straps surrounding the ship- ping container.
Step 2. Carefully lift the top and sides of the container until all sides are clear of
the TAC.
Step 3. Inspect for damage.
If damage due to shipping is observed, do not continue. Contact the factory and the
shipping carrier.
Step 4. Carefully raise the TAC using only the baseplate for lifting,
then set the machine on a smooth level working surface
Step 5. The shipping container may be discarded. However, if reshipment to
another location is possible, it is recommended that the container,
fasteners and packing material be retained.
INITIAL INSTALLATION AND SETUP
Perform the following to hook-up the pneumatic input:
Referring to Figure 2-1. Attach appropriate female connector to male connector
located at sleeve valve on right side of TAC. The air supply must be approx. 85 PSI
minimum - 125 PSI maximum through a 3/8- in. hose or conduit. Air must be clean,
dry and oil-free.
The sleeve valve is used to turn the controller ON and OFF and all pneumatic valves
and sensors.
DO NOT CLOSE (Turn On) THE SLEEVE VALVE AT THIS TIME.
INITIAL SET-UP
CAUTION!
UN-CRATING/!
UNPACKING
PNEUMATIC !
HOOK-UP
Section 2

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Figure 2-1: Pneumatic Hook-Ups
Air Off
Air On