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
!

409-10083
AMP 3K and AMP 5K Term nat ng Mach nes w th the SL Starl te CQM
Rev E11 of 38
Tyco Electronics Corporation
Attach the terminal strip guide included with the machine with the two thumbscrews supplied. Mount the guide
on the left guard for side–feed applicators. Mount the guide on the right guard for end–feed applicators.
Connect the power cords to the machine and to the SL Starlite monitor, and then connect the power cords to a
suitable electrical supply.
The machine will automatically detect the supply voltage and adjust the controller accordingly.
Machines exported to Europe will be installed by Tyco Electronics service specialistss. These specialistss will verify
that the electrical and pneumatic connections are correct. Both pneumatic and electrical connections must be installed
in a way that provides a lockable isolation switch for hard-wired or direct piped machines. This is necessary to
interrupt power to the machine for setup or maintenance.
3.3. Cons derat ons Affect ng Placement of Bench Mach nes
The location of the machine in relation to the operator’s position is extremely important in terms of both safety
and maximum efficiency. Studies have repeatedly shown that operator fatigue will be reduced, and greater
efficiency achieved, if:
1. the bench is of appropriate height, preferably with sound–deadening rubber mounts;
2. the machine is properly located on the bench with ample work areas on both sides to facilitate work
flow;
3. the operator uses a swivel chair with padded seat and back rest which are independently adjustable;
and
4. the foot switch, on machines so equipped, is placed on a rubber mat to maintain its movability, while
preventing it from sliding unintentionally.
Figure 9 illustrates proper machine location and operator position and the following:
A. Bench
The bench to be used should be of sturdy construction, preferably with rubber mounts to minimize noise. A
height of 762 to 812.8 mm [30 to 32 in.] is the most suitable for operator comfort and convenience. This
height allows the operator to rest both feet on the floor, thereby providing for the shifting of weight and leg
position.
B. Mach ne Locat on on Bench
The machine should be located near the front of the bench with the “target area” (tooling area where the
product is applied) not more than 152.4 to 203.2 mm [6 to 8 in.] from the front edge. This location will
eliminate unnecessary operator motion and help to avoid back strain and fatigue.
Orientation of the machine should be such that the “target area” is facing the front of the bench and is
parallel to the front edge (access to the back of the machine MUST also be provided).
Machines have provisions for being bolted to the bench.
C. Operator's Cha r
The operator’s chair should swivel, and should have independent seat height and back rest adjustments.
The seat and back rest should be padded, and the back rest should be large enough to provide support
both above and below the waist line.
In use, the chair should be far enough under the bench so that the operator’s back is straight and is
supported by the back rest.
NOTE
i
NOTE
i
NOTE
i

409-10083
AMP 3K and AMP 5K Terminatin Machines with the SL Starlite CQM
Rev E12 of 38 Tyco Electronics Corporation
D. Foot Switch
When the operator is correctly positioned in front of a machine equipped with a foot switch, the foot should
rest on the switch comfortably. The foot switch should be movable, so that its location can be readily
changed when the operator shifts position to minimize fatigue. Placing the switch on a rubber mat keeps it
movable while preventing unintentional sliding.
The preferred foot switch location varies to some extent among operators. Some operators prefer the
switch located so that their foot rests on the switch when their feet are in the natural sitting position (calf of
leg perpendicular to the foot). Others prefer the leg to be slightly in front of the natural position. The
important thing to remember is that the foot should be at approximately 90 _ (right angle) to the calf when
resting on the switch. Those operators who prefer the foot switch slightly in front of the natural position
may require a wedge–shaped block placed under it.
E. Scrap Removal
A suggested method of scrap removal: place a tray on the right side of the machine, under the cast slot in
the frame, to capture the scrap chips.
Applied
Product
Supply
Figure 9
Materials LocationsĊPlan ViewMachine Location and Operator Position
4. OPERATION
4.1. Machine Operation
The machine is operated by the foot switch, the jog button, and the speed control knob. The jog button and the
speed control knob are located on the control panel. Control panel features are described in Figure 10.
4.2. SL Starlite Monitor Operation
The AMP 3K / AMP 5K machine must have software version 3.2.1 or later to interface with the monitor. The
software version can be checked by pressing and holding the foot switch when the green and yellow lights start
to blink while the terminator is powering up.
The yellow light will flash three times, and then the green light will flash the software version. For example,
three yellow flashes followed by three green flashes, a pause, two green flashes, a pause, and one green
flash would indicate version 3.2.1.
Refer to the operating instructions manual for detailed instructions regarding the use of the SL Starlite monitor.
This manual is included in the machine’s documentation package.
In order for the SL Starlite crimp quality monitor to properly interface with the machine, the following monitor
settings are required:
a. Trigger/Trg. Mode = Prox
b. Trigger/Trg. Input = Standard

409-10083
AMP 3K an AMP 5K Terminating Machines with the SL Starlite CQM
Rev E 13 of 38
Tyco Electronics Corporation
c. Trigger/Trg. Edge = H –> L
d. Sorting Output/Mode = Standard
e. Sorting Output/Learn as = Good
f. Sorting Output/Duration = 100ms
A. Machine Power Up
During power up, the machine looks to see if the monitor’s interface cable is connected. Specifically, it
looks to see if the jumper from J10–3 to J10–4 is installed on the CPU/Motor Controller Board.
If the jumper is seen, the green and yellow lights will alternately flash a couple of times on power up. If the
jumper is not detected, the green and yellow lights flash together a couple of times.
After seeing the jumper, the machine looks to see if the monitor is ready to accept a crimp by looking at
the monitor’s STOP output relay. The STOP relay is a normally open relay that is closed when the monitor
is ready for a crimp.
If the STOP relay is not closed when the machine is powered up, it will flash both lights seven times
(Monitor Not Detected Fault).
This fault can be cleared by holding down the footswitch until the lights stop flashing or by cycling power
on the machine.
B. Cycling the Machine
When the footswitch is pressed to cycle the machine, the machine looks at the SL Starlite’s STOP output
and the GOOD crimp output. The indicator light, DS2, on the machine’s CPU/Motor Controller Board
indicates the status of the STOP output. The light will be turned on when the STOP output is closed.
If the STOP output is not closed, the green and yellow lights will flash together three times (Monitor Not
Ready Fault). If the GOOD crimp output is not OFF (open) the green and yellow light will flash together six
times (Good Crimp Signal Fault).
Both of these faults can be cleared by holding the footswitch until the lights stop flashing or by cycling
power on the machine.
C. Ba Crimp Fault (After the Machine Cycles)
After the machine has been cycled, the machine looks at the monitor’s GOOD crimp output and at the
STOP relay output. If the GOOD crimp output is pulsed and the STOP relay output remains closed, the
machine will be ready for the next crimp cycle.
If the GOOD crimp is not pulsed and the STOP relay is open, the monitor has detected a BAD crimp and
both the green and yellow light will be flashed four times (Bad Crimp Fault).
The fault can be cleared by holding the footswitch until the lights stop flashing, or by cycling power on the
machine.
D. Crimp Analysis Fault (After the Machine Cycles)
If the GOOD crimp pulse is not detected and the STOP relay output remains closed (after the machine
has cycled), the green and yellow light will be flashed five times (Crimp Analysis Fault). This fault could be
the result of a faulty trigger sensor.
The fault can be cleared by holding the foolswitch until the lights stop flashing, or by cycling power on the
machine.
4.3. Applicator Installation
These instructi ns apply t Machines -15, -16, -19, -20, -23, and -24. Since machines -17 and -18 d not c ntain
a quick-release feature, they d n t c ntain a quick-change m unting base plate. The appr priate additi nal
baseplate t ling will be required n machines -17 and -18. The -21, -22, and -25 machines use a swing handle t
release applicat rs. Installati n is in the reverse rder f rem val.
NOTE
i

409-10083
AMP 3K and AMP 5K Terminating Mac ines wit t e SL Starlite CQM
Rev E14 of 38 Tyco Electronics Corporation
Install the proper applicator in the quick–change mounting base as follows:
If the machine is equipped with a precision adjustment feature, make sure that the precision adjustment lever has
been returned to the 0" position before installing the applicator. Be sure that the applicator has the proper feed cam
prior to installation.
Applicators from AMP-O-LECT IC Model K" terminating machine and Model T" terminating machine can be used in
these machines by using a special replacement cam. efer to Figure 3.
1. Loosen the quick–release T–handle (see Figure 5) and slide the applicator base clamp down.
2. Place the applicator on the quick–change base plate, then slide it back until the two notches in the
applicator base engage the stops at the back of the quick–change base plate. At the same time, guide
the ram post into the ram post adapter.
3. Slide the applicator base clamp UP and re–tighten the quick–release T–handle to secure the
applicator in place.
When using Applicator 567200-2 (originally intended for use with AMP-O-LECT IC Model K" terminating machine),
loosen the quick-release T-handle, slide down the applicator base clamp, and remove the rear stop located on the left
side of the base plate. Install the rear stop (part number 354561-1), supplied with the air feed kit, at the alternate
mounting position on the base plate. See Figure 5.
4. Set the crimp height and insulation crimp discs so that the letters and numbers on the applicator pad
align with the front pad on the ram post adapter.
5. If the applicator is an air–feed type, connect the airlines to the valves located on the back of the
machine.
Quick Disconnect Coupling 23238-1 is required to run air-feed applicators.
6. Adjust the reel support for side–feed or end–feed product, depending on the applicator being used.
7. Mount the terminal strip guide on the left sheet metal guard for side–feed product, or on the right
sheet metal guard for end–feed product, depending on the applicator being used.
8. Mount the terminal reel on the reel support. Thread the terminal strip through the guard and into the
applicator according to the instruction sheet included with the applicator. If necessary, adjust the
lubricator bowl.
9. Align the product reel to the applicator by adjusting the reel flanges.
10. Close the guard.
The guard door must be closed in order to operate the machine, unless you are in the Jog (With Guards Disabled)
Mode. See Paragraph 4.4,C.
Opening the guard door will not disable Machine-18, -22, -24, and -25.
CAUTION
!
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409-10083
AMP 3K and AMP 5K Termina ing Machines wi h he SL S arli e CQM
Rev E 15 of 38
Tyco Electronics Corporation
Figure 10
Guard
pen Icon
Green Indicator
Yellow
Indicator Jog Button Speed Control Knob
Fault Icon
Guard Disabled Icon
Machine Ready Icon
Speed Control Icon
Jog Button Icon
The green and yellow indicators on the top of the control panel indicate the machine status.
When the green indicator is on" and is not flashing, the machine is ready for operation.
When the green indicator is flashing by itself, a machine fault has been detected. When the green and
yellow indicators are flashing together, an SL Starlite monitor fault has been detected. See Figure 11.
To reset the machine, "power down" the machine, clear the problem area, and then "power up" the
machine; or hold down the footswitch until the indicators stops flashing.
When the yellow indicator is on and is not flashing, the guard is open and the machine will not run. (Note
that this will not occurr on the -18, -22, -24, and -25 machines.
When the yellow indicator is flashing but the green indicator is not, the guard is disabled and the machine will
only operate with the Jog button. An SL Starlite monitor fault has been detected when both indicators, green
and yellow, are flashing. See Figure 11. To reset the machine, "power down" the machine, clear the problem
area, and then "power up" the machine; or hold down the footswitch until the indicators stops flashing.
The Jog button icon indicates intermittent operation at a slower speed when using the Jog button.
The Jog button allows the operator to cycle through various stages of the machine cycle.
The Speed Control Knob determines the machine speed (active in both normal operation and Jog operation)
Speed increases as the knob is turned CLOCKWISE .
Speed Ranges:
From 100% to 60% with the foot pedal
From 60% to 25% with the Jog button
ptional Batch
Counter
3K/40
The speed control knob also adjusts the air feed timing. Normally, the air feed timing is set at 280 ms. When
the speed control is set at less than 50% of its maximum setting (pointing straight down or counterclockwise
from pointing straight down), the air feed timing changes to 440 ms. This is done to accommodate applicators
that have longer than normal air cylinders.

409-10083
AMP 3K nd AMP 5K Termin ting M chines with the SL St rlite CQM
Rev E16 of 38 Tyco Electronics Corporation
4.4. Setup
1. Install a miniature applicator and terminals according to Paragraph 4.3.
2. Turn on power to the SL Starlite monitor. Put the monitor in the Quality Assurance Check mode. This
mode allows crimps to occur with out being analyzed. Turn on the main power to the machine using the
switch located on the machine’s back panel.
3. Jog the machine (as described in Paragraph 4.5, B) through a complete crimp cycle.
The machine sh uld be able t j g thr ugh the terminal and wire at maximum j g speed.
4. Inspect the crimped terminal to verify that the terminal is being positioned properly within the
applicator.
5. Correct for any positioning errors according to the applicator instruction sheet, and repeat Steps 3
and 4 until a terminal is properly positioned.
6. Place a prepared wire in the crimp area and press the foot switch to cycle the machine.
7. Inspect the completed crimp and make adjustments as necessary.
8. Repeat Steps 6 and 7 until a proper crimp has been made.
4.5. Mode Selection nd Oper tion
The three basic modes of operation for the AMP 3K and AMP 5K machines are: Full–Cycle, Jog, and Jog
(With Guards Disabled). However, if during the machine cycle while crimping a terminal and wire, the motor
stalls; it may be necessary to manually cycle the machine. When the machine detects a system fault, it goes
into the fault mode and flashes the indicator lights to indicate the fault detected.
T av id pers nnal injury, excercise cauti n when j gging r perating the -18, -22, -24, and -25 machines. These
machines will j g/cycle with the guards in the pen or cl sed p siti n.
A. Full-Cycle Mode
Depressing the footswitch (with the guard closed) causes the crankshaft to be rotated (at a speed defined
by the speed control knob), through a complete revolution. This completes one full machine cycle.
B. Jog Mode ( (Figure 10))
Pressing the Jog button causes the crankshaft to be rotated at a default–reduced speed in the forward
direction until the Jog button is released or the crankshaft completes the cycle. If the Jog button is
released in mid–cycle and pressed again, the crankshaft will continue to rotate in the forward direction at
the default reduced speed. If the machine does not complete the cycle, either adjust the speed control
knob (as described below), or complete the cycle using the footswitch (at a speed determined by the
speed control knob) after the Jog button has been pressed and released.
Holding the Jog button down for more than five seconds will cause the machine to “err.” To clear the error,
“power down” the machine, clear the problem area, and then “power up” the machine again. An alternate
method of clearing the error is to hold down the foot pedal until the green status indicator stops flashing. If
the motor is stalled, it may be necessary to manually cycle the machine to the home position. Refer to
Paragraph 4.4,D for the proper manual cycling procedure.
While in the J g m de, attempting t c mplete a crimp cycle with terminals and wire in the applicat r may cause the
m t r t stall. Alth ugh the machine can terminate s me smaller terminals and wire, it may be necessary t turn  ff"
the machine and manually cycle the machine t the h me p siti n. Refer t Paragraph 4.4,D.
T av id pers nal injury, exercise cauti n when j gging r perating the -18, -22, -24, and -25 machines. These
machines will j g/cycle with the guards in the pen r cl sed p siti n.
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CAUTION
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409-10083
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM
Rev E 17 of 38
Tyco Electronics Corporation
Adjusting the Speed Control Knob
The default speed of the machine, when jogging, is set to a minimum value which is not defined by the
initial position of the speed control knob. Adjusting the speed upward enables jogging at speeds greater
than the default in case greater speeds are required to complete a cycle.
To cause the machine to run at a jog speed other than the default speed, perfom the following:
1. Rotate the speed control knob completely counterclockwise.
2. Rotate the speed control knob to the desired speed.
3. Within three seconds, press the jog button. The machine will run at the speed set by the speed
control knob.
4. If the jog button is released and pressed again within three seconds, the machine will run at the set
speed. If the jog button is pressed after three seconds the machine will run at the default speed.
5. If the jog button is released, the speed control knob is adjusted to a different position, and the jog
button is pressed within three seconds, the machine will jog at the newly adjusted speed.
6. If the jog button is not pressed for three seconds, repeat Steps 1, 2, and 3 to set the jog speed to a
setting other than the default jog speed.
The ram may drift downward if the Jog button is re eased in mid-stroke.
C. Jog ( ith Guards Disabled) Mode (Figure 10)
Since the -18, -22, -24, and -25 machines do not emp oy safety inter ock switches in the guard doors, this section
does not app y to them.
The foot peda wi NOT initiate cyc ing in this mode.
To avoid persona injury, be very carefu of moving mechanisms when jogging the machine with the guards open.
This mode allows maintenance and setup personnel to slowly rotate the crankshaft with the guard door
open. To activate this mode, turn “off” power, and open the guard door. Turn the power back “on” and,
immediately after the machine ready and guard disable indicators flash “on”, press and hold the Jog
button. The guard disable indicator will flash at a rate of two flashes per second, indicating that the guard
has been disabled. Pressing the Jog button will rotate the crankshaft at a reduced rate until the Jog button
is released or the crankshaft completes one cycle.
Pressing the Jog button causes the crankshaft to be rotated at a default–reduced speed in the forward
direction until the Jog button is released or the crankshaft completes the cycle. If the Jog button is
released in mid–cycle and then pressed again, the crankshaft will continue to rotate in the forward
direction at the default reduced speed. If the machine does not complete the cycle, see “Adjusting the
Speed Control Knob,” above.
Holding the Jog button down for more than five seconds will cause the machine to “err.” To clear the error,
“power down” the machine, clear the problem area, and then “power up” the machine again. An alternate
method of clearing the error is to hold down the foot pedal until the green status indicator stops flashing. If
the motor is stalled, it may be necessary to manually cycle the machine to the home position. Refer to
Paragraph 4.4,D for the proper manual cycling procedure.
Whi e in the Jog mode, attempting to comp ete a crimp cyc e with termina s and wire in the app icator may cause the
motor to sta . A though the machine can terminate some sma er termina s and wire, it may be necessary to turn off"
the machine and manua y cyc e the machine to the home position. Refer to Paragraph 4.4,D.
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CAUTION
!

409-10083
AMP 3K and AMP 5K Terminating Ma hines with the SL Starlite CQM
Rev E18 of 38 Tyco Electronics Corporation
The machine will exit the Jog (With Guards Disabled) Mode whenever the guards are closed or the power
is turned “off.”
D. Manual Cy ling
1. Turn off the machine using the power switch on the back panel.
2. Remove the access cover on the end of the motor (Figure 7).
3. Insert a 6mm wrench into the hex key on the back of the motor.
4. Turn the wrench to rotate the motor and crankshaft.
5. Remove the wrench.
6. Replace the access cover.
To avoid personal inj ry, always t rn off power to the machine when man ally cycling. Be s re to remove the hex
wrench and replace the access cover before t rning on power to the machine.
4.6. Crimp Height Adjustment
On machines that do not include the precision adjustment feature, the crimp height must be adjusted at the
applicator. Refer to the instructions provided with the applicator to perform this adjustment. Refer to Paragraph
6.3 for procedures to adjust the crimp height using the machine precision adjustment feature.
4.7. End-Feed to Side-Feed / Side-Feed to End-Feed Conversion
When changing from an end–feed applicator to a side–feed applicator (or from a side–feed applicator to an
end–feed applicator), the reel support assembly must be moved to the opposite side of the machine. With the
terminal reel removed, lift and rotate the reel support bar to the opposite side of the machine. Mount the
terminal reel on the reel support and load the terminal strip into the applicator. Remove the metal terminal
lead–in and thumbscrews and move to the opposite side of the machine. Move the machine lubricator bowl to
the opposite side of the machine as required.
L bricator Bowl Assembly 354550-1 is an optional accessory.
DANGER
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409-10083
AMP 3K nd AMP 5K Termin ting M chines with the SL St rlite CQM
Rev E 19 of 38
Tyco Electronics Corporation
5. MACHINE FAULT CODES
Figure 11 contains a list of fault codes commonly seen on the AMP 3K / AMP 5K Terminating Machines with
SL Starlite CQM.
INDICATOR LIGHTS
(Number of Consecutive
Green Fl shes)
INDICATOR LIGHTS
(Number of Consecutive
Yellow Fl shes) MACHINE FAULT
2 --
Guard switch opened while motor was running. Do not open the guard
while the motor is running. Note that this fault is not applicable to all
machines. Refer to Figure 2 to see which machines have or do not have a
guard switch. If the error occurs on a machine without a guard switch,
check to be sure the jumper J4 on the CPU/Motor Control Board assembly
is properly installed.
3 --
Guard switch not closed. Close the guard to close the guard switch. Note
that this fault is not applicable to all machines. Refer to Figure 2 to see
which machines have or do not have a guard switch. If the error occurs on
a machine without a guard switch, check to be sure the jumper J4 on the
CPU/Motor Control Board assembly is properly installed.
4 -- Top Dead Center (TDC) switch fault; machine motion not detected. The
switch was not unmade within the allotted time, 175 ms.
5 -- Top Dead Center (TDC) switch fault: complete machine cycle not detected. The switch was not made within the allotted time. The allotted time for the
Run mode is 1.5 seconds. The allotted time for Jog mode is six seconds.
6 -- Motor control circuit fault. A bad transistor (PWM IGBT) was detected. The
CPU/Motor Control Board assembly must be replaced.
7 -- Jog Push Button Fault. During power up, the jog button pressed input was
detected.
8 -- Footswitch fault. During power up, the footswitch pressed input was
detected.
9 -- Jog button detection circuit fault; DC bus relay turned on during power up.
The CPU/Motor Control Board assembly must be replaced
10 -- Jog enable input circuit fault was detected. The CPU/Motor Control Board
assembly must be replaced.
11 -- Not applicable to this machine.
12 -- J9 Input fault; Input on during power up. Note that this fault in not applicable to this machine. If it occurs, the CPU/Motor Control Board
assembly must be replaced.
3 3 Crimp uality Monitor Not Ready Fault (Refer to Paragraph 4.2,B.)
4 4 Bad Crimp Fault (Refer to Paragraph 4.2,C.)
5 5 Crimp Analysis Fault (Refer to Paragraph 4.2,D.)
6 6 Good Crimp Signal Fault (Refer to Paragraph 4.2,B.)
7 7 Monitor Not Detected (Refer to paragraph 4.2,A.)
Figure 11

409-10083
AMP 3K and AMP 5K Terminating Machines with the SL Starlite CQM
Rev E20 of 38 Tyco Electronics Corporation
6. PREVENTIVE MAINTENANCE
Preventive maintenance will keep the machine in good working order and ensure maximum reliability and
service from all of its components.
To void person l injury, electric l nd pneum tic power must be DISCONNECTED t the source prior to
m inten nce.
6.1. Cleaning
Clean any debris from the applicator area daily.
Compressed ir used for cle ning must be reduced to less th n 207 kP [30 psi] nd effective chip gu rding nd
person l protective equipment (including eye protection) must be used.
If an air–feed assembly is installed, check and replace the air filter element if necessary.
Wipe off the guards with a clean soft cloth.
DO NOT USE ANY SOLVENT TO CLEAN THE GUARDS. Solvent could d m ge the gu rds.
6.2. Lu rication
The moving parts of the machine require regular lubrication to ensure reliable service and long life. Use only
Chevron Ultra EP NLGI No. 2, Pennzoil Pennlith Ultra EP NLGI No. 2, or Conoco Syncon EP Heavy Duty
Grease.
For oper tion in temper tures below 10 _ C [50 _ F], it will be necess ry to use No. 1 gre se.
Using a grease gun, apply grease every 250,000 cycles to the fittings at the following locations and as shown
in Figure 12:
S the left side of the ram assembly;
S the right side of the ram assembly;
S the left side of the frame just behind the ram assembly at two places; and
Give one pump of gre se while the r m is ne r the top of its stroke nd one pump of gre se while the r m is ne r the
bottom of its stroke for best distribution of gre se round the be ring.
S the crimp height adjuster pivot pin.
DANGER
DANGER
CAUTION
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