Tyco Electronics AMP 3K Reference guide

409-10083
Customer Manual
AMP 3K and AMP 5K Terminating Machines
1 of 38
L C B
E 2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. ther products, logos, and company names used are the property of their respective owners.
T LING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
14 APR 08 Rev E
with the SL Starlite Crimp Quality Monitor
EAD THIS FI ST ! 2..........................
SAFETY PRECAUTIONS
1. INT ODUCTION 3....................................................
2. DESC IPTION 5......................................................
2.1. Functional Description 5.............................................
2.2. Electrical Description 7..............................................
2.3. Machine Guard 9..................................................
3. ECEIVING INSPECTION AND INSTALLATION 10............................
3.1. Receiving Inspection 10.............................................
3.2. Installation 10....................................................
3.3. Considerations Affecting Machine Placement 11...........................
4. OPE ATION 12......................................................
4.1. Machine peration 12..............................................
4.2. SL Starlite peration 12.............................................
4.3. Applicator Installation 13............................................
4.4. Setup 16........................................................
4.5. Mode Selection and peration 16......................................
4.6. Crimp Height Adjustment 18..........................................
4.7. End-Feed to Side-Feed / Side-Feed to End-Feed Conversion 18..............
5. MACHINE FAULT CODES 19............................................
6. P EVENTIVE MAINTENANCE 20........................................
6.1. Cleaning 20.....................................................
6.2. Lubrication 20....................................................
7. ADJUSTMENTS 21....................................................
7.1. Measuring the Shut Height 21........................................
7.2. Shut-Height Adjustment 22..........................................
7.3. Crimp Height Adjustment Using Preciaon Adjustment Mechanism (If Equipped) 23...
7.4. Guard Insert Adjustment 24..........................................
8. MACHINE OPTIONS AND INSTALLATION 26................................
8.1. Installation of Work Light Assembly Kit 1424264-1 26.......................
8.2. Installation of Work Light Assembly Kit 1424264-1 (Inside the Guard) 28..........
8.3. Installation of Batch Counter Kit 1424267-1 33............................
8.4. Installation of Air Feed Kit 1424266-1 35.................................
8.5. Installation of Precision Adjustment Kit 1424208-1 38.......................
9. T OUBLESHOOTING 38...............................................
10. EVISION SUMMA Y 38..............................................

409-10083
AMP 3K and AMP 5K Terminating Machines with the SL Star ite CQM
Rev E2 of 38 Tyco Electronics Corporation
SAFETY PRECAUTIONS AVOID INJURY
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:
D ALWAYS wear appropriate ear protection.
D ALWAYS wear approved eye protection when operating powered equipment.
D ALWAYS keep guard(s) in place during normal operation.
D ALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock.
D ALWAYS turn off the main power switch and disconnect electrical cord from the power source when
performing maintenance on the equipment.
D NEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment.
D NEVER insert hands into installed application equipment.
D NEVER alter, modify, or misuse the application equipment.
TOOLING ASSISTANCE CENTER
CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Tooling Assistance 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 TOOLING ASSISTANCE CENTER
When calling the Tooling Assistance 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 Tooling Assistance Center, be ready with the following information:
01. Customer name
02. Customer address
03. Person to contact (name, title, telephone number, and extension)
04. Person calling
05. Equipment number (and serial number if applicable)
06. Product part number (and serial number if applicable)
07. Urgency of request
08. Nature of problem
09. Description of inoperative component(s)
10. Additional information/comments that may be helpful
DANGER

409-10083
AMP 3K nd AMP 5K Termin ting M chines with the SL St rlite CQM
Rev E 3 of 38
Tyco Electronics Corporation
Figure 1
AMP 3K 1725950-15
through 172950-24
AMP 5K 1725900-15
through 1725900-25
1. INTRODUCTION
This manual contains information on operation, preventive maintenance, and adjustments of the AMP 3K and
AMP 5K Terminating Machines 1725950–15 through –24 and 1725900 – 15 through –25 respectively. Each
machine has an SL Starlite Crimp Quality Monitor system installed on the machine. See Figure 1. An operation
manual is included in the machine’s documentation package for the SL Starlite monitor. Quick
references/descriptions to these machines can be found in Figure 2.
Both series machines (AMP 3K and AMP 5K) contain separate machines to produce a 30mm stroke or a
41.28mm stroke.
Descriptions in this manual pertain to the controls and adjustments on the AMP 3K and AMP 5K machines
only .
The various applicators that can be used in the machines are covered in applicator instruction sheets
packaged with each applicator. Applicator instruction sheets provide information on applicator installation, care,
and adjustment.
The specifications and requirements for the AMP 3K and AMP 5K Terminating Machines are as listed below:
– Deflection: 0.13mm [.0046 in.] Maximum per 4,448 Newtons [1,000 lb] Crimp Force
– Noise (Model 3K Series): Less than 76 dBa Typical at operator position with standard mechanical feed applicator
- Noise (Model 5K Series): Less than 80 dBa Typical at operator position with standard mechanical feed applicator
– Weight: 68 Kilograms [150 lbs]
– Height: 610mm [24 in.] without reel supports
– Electric l: (machine and arlite monitor) 100-240 Vac, 50/60 Hz, ingle-Phase Current
– Air: 620-760 kPa [90-100 psi], 2.83 liters/sec (6 scfm) When required for use with air-feed applicators
– Physic l Environment: Temperature: 4.4 ° -40 ° C [40 ° -104 ° F]
Relative Humidity: Less than 95% (non-condensing)
Transportation and torage: tore in a clean, dry environment after coating all surfaces lightly
with a rust preventing oil.

409-10083
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM
Rev E4 of 38 Ty o Ele troni s Corporation
PART
NUMBER
MACHINE
CAPACITY
kN [LB])
STROKE
LENGTH
(MM)
APPLICATOR
TYPE PRECISION ADJUST CE ERSION GUARD INTERLOCK
1-1725950-5 13.3 [3000] 41.28 AMP No No Yes
1-1725950-6 13.3 [3000] 41.28 AMP Yes No Yes
1-1725950-7 13.3 [3000] 30 AMP (Univ) Yes No Yes
1-1725950-8* 13.3 [3000] 30 AMP (Univ) Yes No No*
1-1725950-9 13.3 [3000] 41.28 AMP No Yes Yes
2-1725950-0 13.3 [3000] 41.28 AMP Yes Yes Yes
2-1725950-1 13.3 [3000] 30 JAM (Qui k) Yes No Yes
2-1725950-2* 13.3 [3000] 30 JAM (Qui k) Yes No No*
2-1725950-3 13.3 [3000] 30 AMP Yes No Yes
2-1725950-4* 13.3 [3000] 30 AMP Yes No No*
1-1725900-5 22.2 [5000] 41.28 AMP No No Yes
1-1725900-6 22.2 [5000] 41.28 AMP Yes No Yes
1-1725900-7 22.2 [5000] 30 AMP (Univ) Yes No Yes
1-1725900-8* 22.2 [5000] 30 AMP (Univ) Yes No No*
1-1725900-9 22.2 [5000] 41.28 AMP No Yes Yes
2-1725900-0 22.2 [5000] 41.28 AMP Yes Yes Yes
2-1725900-1 22.2 [5000] 30 JAM (Qui k) Yes No No*
2-1725900-2* 22.2 [5000] 30 JAM (Qui k) Yes No Yes
2-1725900-3 22.2 [5000] 30 AMP Yes No Yes
2-1725900-4* 22.2 [5000] 30 AMP Yes No No*
2-1725900-5 22.2 [5000] 41.28 JAM (Qui k) Yes No No*
* Machi es co tai i g a asterisk are restricted to the Asia/Pacific market..
JAM applicators are ma ufactured by ToyoJamCo., Ltd.
Quick-cha ge JAM baseplates do ot require tools to cha ge the applicator.
U iversal baseplates require a hex wre ch to cha ge the applicator.
U iversal baseplates ca be co figured to use AMP/JAM/JST applicators.
Figure 2
When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.
De otes a immi e t hazard which may result i moderate or severe i jury.
De otes a co ditio which may result i product or equipme t damage.
Highlights special or importa t i formatio .
DANGER
CAUTION
!
NOTE
i

409-10083
AMP 3K and AMP 5K erminating Machines with the SL Starlite CQM
Rev E 5 of 38
Tyco Electronics Corporation
2. DESCRIP ION
The AMP 3K/40 and AMP 5K/40 Terminating Machines were designed to be used as stand–alone
semi–automatic bench units. The SL Starlite Crimp Quality Monitor provides 100% inspection of the crimping
process.
They are assembled with metric hardware. Although, some commercial items may contain non–metric
hardware.
Measurements are in metric units [followed by U.S. customary units in brackets] unless otherwise indicated.
These machines accepts a wide variety of miniature (mini) quick–change applicators, with minor adjustments,
thus providing a great selection of terminals for many applications. Figure 3 lists changeover cams required to
run 11/8–in. stroke cams (for AMP–O–LECTRIC* Model “K” terminating machines) and 15/8–in. stroke cams
(for Model “T” and Model “G” Terminating machines) in the machines.
CHANGEOVER CAMS FOR HE MACHINES
ORIGINAL APPLICA OR FEED YPE 1-1725950-5, -16, -19, -20
and
1-1725900-5, -16, -19, -20
1-1725950-7, -18, -23, -24
and
1-1725900-7, -18, -23, -24
1
1
/
8
-in. Stroke A
pp
licator for Pre-Feed 690602-6 Ċ
/8pp
Model K" Terminating Machine Post-Feed 690501-4 Ċ
1
5
/8-in. Stroke Applicator for
Model

T
"
and Model

G
"
Terminating
Pre-Feed Ċ 690602-5
M
o
d
e
l T"
an
dM
o
d
e
l G" T
erm
i
na
ti
ng
Machines Post-Feed Ċ 690501-3
Heavy-Duty Industrial (HD-I)
Applicator Pre-Feed/Post-Feed Refer to the HD-I Applicator customer drawing for part num ers.
Figure 3
2.1. Functional Description
A. Machine Functional Areas
These machines provide the force required to crimp terminals in the applicator. A terminal is attached to
the wire by placing the wire in the crimp area and pressing the foot switch. During the crimping process,
data is collected from the frame sensor by the SL Starlite monitor and evaluated. If the crimp is
determined to be “Good,” the operator can continue with the next crimp. If the crimp is determined to
“Bad,” the machine can not be cycled until the Bad Crimp error has been cleared on the monitor.
The machine consists of four functional areas:
1. The motor group includes a dc motor which drives a crankshaft. The motor is activated each cycle
and rotates the crankshaft one full revolution. A motor access cover, located on the end of the motor,
covers a hex key which allows the motor to be cycled manually. See Figure 4.
2. The crankshaft–ram group converts the motor rotational force to the up–and–down action of the
ram for driving the applicator during the crimping cycle.
3. The
base plate provides the mounting surface on which the applicator is installed. The quick–release
latching feature on Machines –15, –16, and –19, through –24 permit fast, easy installation and removal
of the applicator. Note that Machines –17 and –18 do not include the quick–release latching feature.
See Figure 5.
NO E
i

409-10083
AMP 3K and AMP 5K Ter inating Machines with the SL Starlite CQM
Rev E6 of 38 Tyco Electronics Corporation
Figure 4
DC Motor
Crankshaft
Motor Access Cover
4. The crimp height adjustment group uses an eccentric located in the ram linkage, along with the
detents in the mechanism, to adjust the crimp height. See Figure 5. Indexing the mechanism in either
direction will change the crimp height in increments of approximately 0.013mm [.0005 in.] per step.
B. SL Starlite Functional Areas
The SL Starlite Crimp Quality Monitor consists of four functional parts (refer to Figure 5):
1. The monitor receives signals from the trigger sensor and the frame sensor during a crimp cycle,
decides if the crimp was good or bad, and passes the appropriate signals to the machine.
2. The trigger sensor tells the monitor when the beginning of the crimp cycle occurs.
3. The frame sensor is a piezo electric strain sensor. As the crimp occurs, it senses the longitudinal
change in the frame of the machine and converts it to a voltage that is seen by the monitor.
4. The interface cable connects the monitor to the control circuitry of the machine. The monitor tells the
machine when a bad crimp occurs and when it is ready to analyze the next crimp.

409-10083
AMP 3K and AMP 5K Terminating Mac ines wit t e SL Starlite CQM
Rev E 7 of 38
Tyco Electronics Corporation
Figure 5
Base Plate for Machines -15, -16,
-19, -20, -23,, and -24
Base Plate for Machines
-17 and -18
Tri er Sensor
Frame
Sensor
Ram Post Adapter
Precision Crimp
Hei ht Adjustment
Mechanism
SL Starlite Monittor
Alternate Rear Stop
Mountin Position
Quick-Release
T-Handle
2.2. Electrical Description
The 1725950–[ ] and 1725900–[ ] machine electrical components consist of the operator control panel, the
motor, and the CPU/motor controller package. The machine operates on 100/240 Vac, 50/60 Hz, single–phase
current with ground. The machine will automatically detect the supply voltage and adjust the controller
accordingly.
The components of the crimp quality monitoring system consist of the SL Starlite monitor, a trigger sensor with
cable, a frame sensor with cable, and a machine interface cable. The monitor operates on 100–240 Vac, 50/60
Hz, single–phase current with ground.
The operator control panel (Figure 6) is mounted on the left side of the machine frame. The control panel
consists of two indicator lights, one jog button, and one speed control knob, with icons depicting each function.
See Paragraph 4.1 for control panel operation.
A main power switch/circuit breaker (Figure 7) is located on the back of the machine. This switch connects ac
power to the control system. The CPU/motor controller is located behind the back cover of the machine. It is a
modular unit that contains all of the electronics necessary to operate the machine. See Figure 7.
The CPU/motor controller assembly contains a high voltage which remains for a short period of time even after power
has been removed. Disconnect the electrical power source from the machine and wait several minutes before
removing the screws to access the the CPU/motor controller assembly.
The SL Starlite monitor has its own power cord and switch for connecting ac power to the monitor. The switch
is located on the bottom panel of the monitor. Refer to the SL Starlite operating instructions manual included
with the machine’s documentation package.
DANGER

409-10083
AMP 3K and AMP 5K Termina ing Machines wi h he SL S arli e CQM
Rev E8 of 38 Tyco Elect onics Co po ation
Figure 6
Gua d Open
Icon
G een
Indicato
Yellow
Indicato Jog Button Speed Cont ol Knob
Fault
Icon
Gua d Disabled
Icon
Machine Ready
Icon
Speed Cont ol
Icon
Jog Button
Icon
Batch Counte
Kit
3K/40

409-10083
AMP 3K and AMP 5K Term nat ng Mach nes w th the SL Starl te CQM
Rev E 9 of 38
Tyco Electro ics Corporatio
Figure 7
DC Motor
Back Cover
CPU/Motor Co troller
(Behi d Back Cover)
Motor Access
Cover
Reel Support Hole
Power Switch/Circuit
Breaker
Termi al
Strip Guide
2.3. Mach ne Guard (Figure 8)
A guard is installed to provide protection for the operator while maintaining proper visibility of the work area.
The guard swings open to allow easy access for applicator installation and setup. A safety interlock on the
guard prevents the machine from cycling if the guard door is open during production operation.
Machines -18, -22, -24, and -25 do not include the safety interlock feature. To a oid personal injury, remember that
the power is not automatically shut off when the guard doors are opened.
DANGER

409-10083
AMP 3K an AMP 5K Terminating Machines with the SL Starlite CQM
Rev E10 of 38 Tyco E ectronics Corporation
Figure 8
Machine
Guard
Shown with Sa ety Interlock
(Not on Machines -18, -22,
-24 and -25)
Ho e for Customer
Supp ied Lift Ring
Quick-Re ease T-Hand e for
Machines -15, -16, -19, -20,
-23, and -24
Shown with Optional
Precision Crimp Height
Adjustment Mechanism
3. RECEIVING INSPECTION AND INSTALLATION
3.1. Receiving Inspection
These machines are thoroughly inspected during and after assembly. A final series of inspections is made to
insure the proper machine functioning before packaging and shipping.
To protect against damage that may have occurred during shipment, remove the machine from the crate
(Paragraph 3.2) and carefully inspect the machine for damage. If damage is evident, file a claim against the
carrier and notify Tyco Electronics immediately.
3.2. Installation
Remove all mounting bolts securing the machine to the shipping pallet. Install lift ring (see Figure 8) on top of
the machine.
Li t ring (M12  20 eye bolt) is customer supplied.
Install the li t ring carefully . A 19.05-mm [.75-in.] thread length engagement is required or the li t ring to support the
machine.
Attach a suitable hoist to the lift ring, lift the machine, and place it in the selected operating location.
Insert the reel support post into the appropriate hole on top of the machine (Figure 7) until the roll pin engages
a groove in the machine frame.
NOTE
i
CAUTION
!