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ORIGINAL INSTRUCTIONS
409-32022
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 approved eye protection while operating
equipment.
Always wear appropriate ear protection while using
equipment.
Moving parts can crush and cut. Always keep guard(s)
in place during normal operation.
Electrical shock hazard.
Always turn off the main power switch and disconnect
the electrical cord from the power source when
performing repair or maintenance on the equipment.
Never insert hands into installed equipment.
Never wear loose clothing or jewelry that may catch in
moving parts of the equipment.
Never alter, modify, or misuse the 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:
1. Customer name
2. Customer address
3. Person to contact (name, title, telephone number, and extension)
4. Person calling
5. Equipment number (and serial number if applicable)
6. Product part number (and serial number if applicable)
7. Urgency of request
8. Nature of problem
9. Description of inoperative component(s)
10. Additional information/comments that may be helpful
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409-32022
Valve Stack Assembly
(Under Cover)
Ram Group
Air Input Group
Operator
Control Panel
Feed Plate Group
Crimp Tooling Group
AMPLIVAR PRODUCT TERMINATOR
Type
Model
APT-5E (Economy)
APT-5A (Automatic)
Splice
APT-5E HF
(Economy High Force)
APT-5A HF
(Automatic High Force)
APT-5E DC (Economy)
Direct Connect
APT-5A DC (Automatic)
APT-5E Infinite Splice
Infinite Splice
APT-5A Infinite Splice
Note:
Refer to
409-10100
for information for the CQM II.
Crimp Quality Monitor (CQM) II
(Ref, Refer to Table)
Part Number
2161900-[ ]
2161800-[ ]
2217700-[ ]
2217600-[ ]
2161950-[ ]
2261850-[ ]
2326145-[ ]
2326135-[ ]
Description
Has precision manual crimp height adjustment.
Used with CQM II and has automatic crimp height adjustment and
automatic sequencing.
Has precision manual crimp height adjustment with high force
capacity.
Used with CQM II and has automatic crimp height adjustment and
automatic sequencing with high force capacity.
Has precision manual crimp height adjustment.
Used with CQM II and has automatic crimp height adjustment and
automatic sequencing.
Equipped with Infinite Splice feature and has precision manual
crimp height adjustment
Equipped with Infinite Splice feature and CQM II and has
automatic crimp height adjustment and automatic sequencing
Figure 1
1. INTRODUCTION
This manual provides information concerning the setup, operation, and maintenance of the AMPLIVAR product
terminator shown in Figure 1. Terminator variations are given in Figure 1. These terminators apply AMPLIVAR
pigtail splices and AMPLIVAR cluster receptacles to pre-stripped wires and unstripped magnet wire.
NOTE
Dimensions in this manual are in metric units [with U.S. customary equivalents in brackets] unless otherwise indicated.
Serrations in the splices cut through the magnet wire insulation to make electrical contact. This eliminates a
time-consuming stripping operation. Splices are applied with uniformly high mechanical strength and electrical
conductivity at high-volume production pin rates.
Each AMPLIVAR product terminator weighs approximately 71 kg [156 lbs] and requires a power source of
100 to 240 Vac, 50/60 Hz 3 A, single phase, depending on the model of the terminator. Compressed air at a
minimum pressure of 620.5 to 689.5 kPa [90 to 100 psi] for standard (E, A, and DC) terminators and 760 to
830 kPa [110 to 120 psi] for high force (HF) terminators is required for proper operation.
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409-32022
Optional wire stuffer assembly 2161635-1 can be used with this terminator to eliminate the need to change
AMPLIVAR splices if the combined circular mil area (CMA) of the wires to be crimped is less than the specified
minimum of the splice used.
Note:
This device is used when the customer CMA is less than the minimum
published CMA for the AMPLIVAR product being terminated. The wire stuffer provides additional magnet wire
CMA to the terminated CMA to meet the specified CMA range for a given AMPLIVAR product.
NOTE
An air amplifier may be required if the available compressed air supply does not meet the minimum requirements. Refer to
Paragraph 2.1 D.
NOTE
The Infinite Splice assembly cannot be used at the same time as the wire stuffer assembly. The user must choose one
assembly per application.
When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.
DANGER
Denotes an imminent hazard that may result in moderate or severe injury.
CAUTION
Denotes a condition that may result in product or equipment damage.
NOTE
Highlights special or important information.
For information beyond the scope of this manual, contact the Tooling Assistance Center at the number at the
bottom of page 1.
NOTE
Dimensions in this customer manual are in metric units [with U.S. customary units in brackets]. Figures are not drawn to scale.
2. DESCRIPTION
AMPLIVAR product terminators automatically feed terminals into position in the crimping area, crimp the
terminals to magnet wire, and trim the scrap wire from the terminals. Unlike many standard bench-type
crimping machines, the primary crimping motions on the terminator occurs in the horizontal plane, and not
vertically, as in many other TE automatic machines.
The crimp tooling is nearly flush with the right-hand surface of the terminator, allowing the operator to hold the
wire close to the tooling for splicing very short leads.
During production operation, the operator places magnet wire and lead wire in the barrel of the terminal in the
"target area" of the terminator, then depresses the foot switch. The terminator automatically shears the terminal
from its strip, crimps the terminal onto the wire, shears off the excess wire, and advances the next terminal into
the crimping position. The terminator electrical circuit prevents double-tripping; that is, the foot switch cannot be
actuated when a cycle is in progress. The amount of time the foot switch is depressed is not critical.
The large number of wire combinations that can be joined with the splices requires some tooling changes,
although design features minimize the number of changes required. Refer to drawing 216175 for tooling
combinations. Only two different feed plates are required to terminate the entire range of splices. Two or three
wires may be joined in one splice and combinations of magnet wire and lead wire (stranded, solid, or fused
stranded) can be used.
NOTE
Magnet wire should always be placed on the bottom of the terminal wire barrel so that the serrations pierce the magnet wire
varnish for an acceptable termination.
NOTE
CMA is the cross-sectional circular area of a magnet wire. For example, when terminating two .040-in. diameter magnet wires,
each wire would have a CMA of 40 mils squared or 1600 CMA per wire for a total CMA of 3200. CMA for stranded wire is the
diameter of a single strand in mils squared times the number of strands.
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2.1. Major Groups
The four major terminator groups, or subassemblies, are: 1) the feed plate group, 2) the crimp tooling group,
3) the ram group, and 4) the air input and valve stack assembly. Refer to Figure 1.
Feed Plate Group
For Splice Terminators
Two feed plates are available to accommodate the full range of terminals. Each feed plate contains a
groove that guides the terminal strip to the "target area." The feed finger, driven by the air feed
cylinder, advances the terminal strip. Each cycle of the terminator advances the strip one position. The
terminal strip drag prevents the strip from being pulled back as the feed finger retracts to pick up the
next feed point in the strip. The hold down secures and controls the terminal strip through the feed
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