Tyco electronics 1338600 series Reference guide

409-10016

Customer Manual

Entry Level Terminator

of 34

L C B

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

21 AUG 08 Rev H

(ELT) Machine 1338600-[ ]

EAD THIS FI ST !

2..........................

SAFETY PRECAUTIONS

1. INT ODUCTION

3....................................................

2. DESC IPTION

4......................................................

2.1. Functional Description 5.............................................

2.2. Electrical Description 6..............................................

2.3. Machine Guard 9..................................................

3. ECEIVING INSPECTION AND INSTALLATION

9.............................

3.1. Receiving Inspection 9..............................................

3.2. Installation 9.....................................................

3.3. Considerations Affecting the Placement of Bench Machines 10.................

4. OPE ATION

11......................................................

4.1. Control Panel peration 11..........................................

4.2. Applicator Installation 11............................................

4.3. Setup 14........................................................

4.4. Mode Selection and peration 14......................................

4.5. Crimp Height Adjustment 16..........................................

4.6. End-Feed/Side-Feed Applicator Conversion 16...........................

5. P EVENTIVE MAINTENANCE

17........................................

5.1. Cleaning 17.....................................................

5.2. Lubrication 17....................................................

6. ADJUSTMENTS

18....................................................

6.1. Measuring the Shut Height 18........................................

6.2. Shut-Height Adjustment 18..........................................

6.3. Crimp Height Adjustment Using Precision Adjustment Mechanism (If Equipped) 19..

6.4. Guard Insert Adjustment 21..........................................

7. MACHINE OPTIONS AND INSTALLATION

23................................

7.1. Installation of Work Light Assembly Kit 1424264-1 23.......................

7.2. Installation of Work Light Assembly Kit 1424264-1 (Inside the Guard) 25..........

7.3. Installation of Batch Counter Kit 1424267-1 29............................

7.4. Installation of Air Feed Kit 1424266-1 32.................................

7.5 Installation of Precision Adjustment Kit 1424208-1 34.......................

8. T OUBLESHOOTING

34...............................................

9. EVISION SUMMA Y

34...............................................

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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:

ALWAYS wear appropriate ear protection.

ALWAYS wear approved eye protection when operating powered equipment.

ALWAYS keep guard(s) in place during normal operation.

ALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock.

ALWAYS turn off the main power switch and disconnect electrical cord from the power source when

performing maintenance on the equipment.

NEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment.

NEVER insert hands into installed application equipment.

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

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PART NUMBER DESCRIPTION SUPSD BY

1338600-1 ELT Machine with 40-mm [15/8-in.] Stroke 1725950-1

1338600-2 ELT Machine with 40-mm [15/8-in.] Stroke, Tool-less Precision Crimp Adjust 1725950-2

1338600-3 ELT Machine with 30-mm [11/8-in.] Stroke, Tool-less Precision Crimp Adjust

[

1725950-3

1338600-4 ELT Machine with 30-mm [11/8-in.] Stroke, Tool-less Precision Crimp Adjust, No Safety Interlock

[

1725950-4

1338600-5 ELT Machine with 40-mm [15/8-in.] Stroke, CE ersion 1725950-5

1338600-6 ELT Machine with 40-mm [15/8-in.] Stroke, CE ersion, Tool-less Precision Crimp Adjust 1725950-6

1338600-7 ELT Machine with 40-mm [15/8-in.] Stroke, Tool-less Precision Crimp Adjust, Crimp Quality Monitor

(CQM) Sensors 1725950-7

1338600-8 ELT Machine with 30-mm [11/8-in.] Stroke, Tool-less Precision Crimp Adjust, CQM Sensors 1725950-8

1338600-9 ELT Machine with 40-mm [15/8-in.] Stroke, Tool-less Precision Crimp Adjust, CQM Sensors, CE Filter 1725950-9

[

This machine is restricted to the Asia/Pacific market. Base plate on the machine does not contain quick-release feature.

Figure 1

1. INTRODUCTION

This manual contains information on operation, preventive maintenance, and adjustments of the Entry Level

Terminator (ELT) Machine 1338600–[ ]. See Figure 1. Descriptions in this manual pertain to the controls and

adjustments on the ELT machine

only

The various applicators that can be used in the ELT machine are covered in applicator instruction sheets

packaged with each applicator. Applicator instruction sheets provide information on applicator installation, care,

and adjustment.

Figure 2 contains specifications and requirements for the ELT machine.

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Capa ity:

13,345 Newtons [3,000 lb] Maximum Crimp Force

Defle tion:

0.13 mm [.0046 in.] Maximum per 4,448 Newtons [1,000 lb] Crimp Force

Noise:

Less than 76 dBa Typical at operator position with standard mechanical feed applicator

Weight:

68.86 Kilograms [143 lb]

Height:

510 mm [20 in.] without reel supports

Ele tri al:

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

Figure 2

Physi al Environment:

Temperature: 4.4

-40

C [40

-104

Altitude: Not Applicable

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.

When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.

Denote an imminent hazard which may re ult in moderate or evere injury.

Denote a condition which may re ult in product or equipment damage.

Highlight pecial or important information.

Reasons for reissue are in Section 9, REVISION SUMMARY.

2. DESCRIPTION

The ELT machine was designed to be used as a stand–alone semi–automatic bench unit. It is assembled with

metric hardware.

Mea urement are in metric unit [followed by U.S. cu tomary unit in bracket ]. Some commercial item may

contain non-metric hardware.

The ELT machine 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 ELT machine.

Some heavy-duty mini applicator require pecial cam that are not li ted in Figure 3. Refer to the applicator log

hipped with the applicator for additional information.

DANGER

CAUTION

NOTE

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Quick–Disconnect Coupling 23238–1 is required to run air–feed applicators.

End–feed and side–feed miniature applicators are easily installed and removed without repositioning the

applicator mounting plate on the machine. An optional precision adjustment feature is available for the machine

to provide quick and accurate crimp height adjustments.

Refer to Section 7, MACHINE OPTIONS for more ELT machine options.

ORIGINAL APPLICATOR

FEED TYPE

CHANGEOVER CAMS FOR ELT MACHINE

ORIGINAL APPLICATOR

FEED TYPE

1338600-1, -2, -5, and -6 1338600-3, -4

-in. Stroke A

licator for Pre-Feed 690602-6 Ċ

/8pp

Model K" Terminating Machine Post-Feed 690501-4 Ċ

/8-in. Stroke Applicator for

Model



and Model



Terminating

Pre-Feed Ċ 690602-5

l T"

l G" T

erm

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

The ELT machine provides 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. 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.

Figure 4

DC Motor

Crankshaft

Motor Access Cover

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2. The

crankshaft–ram group

covers 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 –1, –2, –5, and –6 permits fast, easy installation and removal of the

applicator. Note that Machines –3 and –4, restricted to Asia/Pacific market, do not include the

quick–release latching feature. See Figure 5.

4. An

optional crimp height adjustment group

uses an eccentric located in the ram linkage, along

with detented stops in the mechanism to adjust the crimp height. Indexing the mechanism in either

direction will change the crimp height in increments of approximately 0.013 mm [.0005 in.] per step.

Figure 5

Base Plate f r Machines

-1, -2, -5, and -6

Quick-Release

T-Handle

Shown with Optional

Precision Crimp Height

Adjustment Mechanism

Base Plate f r Machines

-3 and -4

Alternate Rear St p

M unting P siti n

2.2. Electrical Description

The ELT 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 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.

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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 package contain high voltage which can remain even after power ha been removed.

Contact the Tooling A i tance Center at 1-800-722-1111 for precautionary mea ure to follow if internal acce to

the CPU/motor controller i required.

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

DANGER

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Figure 7

DC Motor

Back Cover

CPU/Motor Controller

(Behind Back Cover)

Motor Access

Cover

Reel Su ort Hole

Power Switch/Circuit

Breaker

Terminal

Stri Guide

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2.3. Machine Guar

(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.

Machine -4 does not include the safety interloc feature. To avoid personal injury, remember that the power is not

automatically shut off when the guard doors are opened.

Figure 8

Machine

Guard

Shown with Safety Interloc

(Not on Machine -4)

Hole for Customer

Supplied Lift Ring

Quic -Release T-Handle

for Machines -1, -2, -5,

and -6

Shown with Optional

Precision Crimp Height

Adjustment Mechanism

3. RECEIVING INSPECTION AND INSTALLATION

3.1. Receiving Inspection

ELT 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.

Lift ring (M12



20 eye bolt) is customer supplied.

DANGER

NOTE

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Install the lift ring

carefully

. A 19.05-mm [.75-in.] thread length engagement is required for the lift ring to su ort 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.

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 cord to a suitable electrical supply.

The machine will automatically detect the su ly voltage and adjust the controller accordingly.

Machines ex orted to Euro e will be installed by Tyco Electronics service engineers. These engineers will verify that

the electrical and neumatic connections are correct. Both neumatic and electrical connections must be installed in a

way that rovides a lockable isolation switch for hard-wired or direct i ed machines. This is necessary to interru t

ower to the machine for setu or maintenance.

3.3. Considerations Affecting Placement of Benc Mac ines

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. Benc

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. Mac ine Location on Benc

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 rovisions for being bolted to the bench.

C. Operator's C air

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.

CAUTION

NOTE

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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.

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 R moval

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. Control Pan l Op ration

The basic control panel operation is as described in Figure 10. The control panel will be used to set up and

operate the machine (see Paragraphs 4.3 and 4.4).

4.2. Applicator Installation

These instructions apply to Machines -1, -2, -5, and -6. Since Machines -3 and -4 do

not

contain a quick-release

eature, they do not contain a quick-change mounting base plate. The appropriate additional baseplate tooling will be

required on Machines -3 and -4.

Install the proper applicator in the quick–change mounting base as follows:

I the machine is equipped with a precision adjustment eature, make sure that the precision adjustment lever has

been returned to the 0" position be ore installing the applicator. Be sure that the applicator has the proper eed cam

prior to installation.

Applicators rom AMP-O-LECTRIC Model K" terminating machine and Model T" terminating machine can be used in

the ELT machine by using a special replacement cam. Re er to Figure 3.

NOTE

CAUTION

NOTE

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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 (PN 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-4.

NOTE

DANGER

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Figure 10

Guard

Open 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 indicator on the top of the control panel indicates the machine status.

hen the green indicator is on" and is

not

flashing, the machine is ready for operation.

hen the green indicator is flashing, a machine fault has been detected. (To reset the machine,

power down" the machine, clear the problem area, and then power up" the machine. Or hold down

the foot pedal until the green indicator stops flashing.

The yellow indicator on the top of the control panel indicates the guard status.

(Note that this indicator is not active on Machine -4).

hen the yellow indicator is on and is

not

flashing, the guard is open and the machine will not run.

hen the yellow indicator is flashing, the guard is disabled and the machine will only operate with the Jog

button.

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

Optional Batch

Counter

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4.3. Setup

Install a miniature applicator and terminals according to Paragraph 4.1.

1. Turn on the main power using the switch located on the back of the machine.

2. Jog the machine (as described in Paragraph 4.3, B) through a complete crimp cycle.

Machi e should be able to jog through the termi al a d wire at maximum jog speed to determi e crimp capacity.

3. Inspect the crimped terminal to verify that the terminal is being positioned properly within the

applicator.

4. Correct for any positioning errors according to the applicator instruction sheet, and repeat Steps 2

and 3 until a terminal is properly positioned.

5. Place a prepared wire in the crimp area and press the foot switch.

6. Inspect the completed crimp and make adjustments as necessary.

4.4. Mo e Selection an Operation

The three basic modes of operation for the ELT machine include: Full–Cycle, Jog, and Jog (With Guards

Disabled).

A. Full-Cycle Mo e

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 Mo e

(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 the

CAUTION and DANGER statements below for the proper manual cycling procedure.

While i the Jog mode, attempti g to complete a crimp cycle with termi als a d wire i the applicator may cause the

motor to stall. Although the machi e ca termi ate some smaller termi als a d wire, it may be ecessary to tur off"

the machi e a d ma ually cycle the machi e to the home positio . Ma ually cycle the machi e by removi g the

access cover o the e d of the motor (Figure 7), e gagi g the hex key with a 6-mm hex wre ch, a d rotati g the key

to ma ually rotate the motor.

To avoid perso al i jury, be sure to remove the hex wre ch before operati g the machi e u der power. Be sure to

replace the access cover.

To avoid perso al i jury, exercise cautio whe joggi g or operati g Machi e -4. These machi es will jog/cycle with

the guards i the ope or closed positio .

Adjusting the Speed Control Knob

The default speed of the crankshaft in the Jog Mode is set to a minimum initial value which is

not

defined

by the initial position of the speed control knob. Adjusting the speed upwards enables jogging at speeds

NOTE

CAUTION

DANGER

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greater than the default in case greater speeds are required to complete a cycle. To cause the crankshaft

to rotate at other than the initial default speed, the speed control knob must be rotated completely

counterclockwise

, then rotated back clockwise to the desired speed setting. If the Jog button is depressed

within three seconds of setting the speed control knob, the crankshaft will rotate at the speed defined by

the position of the speed control knob. The new speed setting will remain active for a maximum of three

seconds after the Jog button is released, or until the crankshaft completes the cycle. If the cycle is not

complete and the Jog button is again pressed within three seconds from its release, the crankshaft will

rotate at the speed defined by the position of the speed control knob. Failure to push the Jog button within

the three seconds of its release will cause the crankshaft jog speed to revert back to the initial minimum

default value. After the Jog button is released, the speed control knob can be rotated in either direction to

increase or reduce the crankshaft jog speed, but Jog button must be activated again within three seconds

of the release or the speed will revert back to minimum default speed. The speed control knob can be

reset as many times as desired.

The ram may drift downward if the Jog button is released in mid-stroke.

C. Jog (With Guards Disabled) Mode

(Figure 10)

Since Machine -4 does not employ safety interlock switches in the guard doors, this section does not apply to

Machine -4.

The foot pedal will NOT initiate cycling in this mode.

To a oid personal injury, be ery careful of mo ing 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,” below.

Holding the Jog button for more than five seconds and not completing the cycle may cause the machine to

“err.” To clear the error, “power down” the machine, clear the problem area, and then “power up” the

machine. Another method of clearing an 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. See the CAUTION and DANGER statements above for manual cycling.

Adjusting the Speed Control Knob

The default speed of the crankshaft in the Jog Mode is set to a minimum initial value which is

not

defined

by the initial position of the speed control knob. Adjusting the speed upwards enables jogging at speeds

greater than the default in case greater speeds are required to complete a cycle. To cause the crankshaft

to rotate at other than the initial default speed, the speed control knob must be rotated completely

counterclockwise

, then rotated back clockwise to the desired speed setting. If the Jog button is depressed

within three seconds of setting the speed control knob, the crankshaft will rotate at the speed defined by

NOTE

DANGER

409-10016

ELT Machine 1338600-[

R v

H16

of 34 Tyco El ctronics Corporation