408-4050 Datasheet, PDF (5/6 Pages) Tyco Electronics – Crimp Quality Monitor

408-4050
CAUTION
!
Terminals may get stuck in the tooling when
crimped without wire. A stuck terminal must be
cleared from the tooling to avoid tooling breakage
during successive crimps.
a. The force reading should start at a value
between 0 and 300, gradually increase to a
value less than 4095 at bottom-dead-center
and then gradually return to approximately the
same starting value.
b. The position reading should start at a value
between 2000 and 3000, increase to a
maximum less than 4095, then decrease to
minimum between 900 and 1800 at bottom-
dead-center.
NOTE
i
The position sensor value should not go below 900
during this cycle. If necessary refer to Section 5,
ADJUSTMENT for position sensor adjustment.
4. If the sensor values indicate a problem, test the
cable between the Crimp Quality Monitor and the
sensors (Sensor Cable PN 122955-1) with an
ohmmeter for continuity, or replace the sensor cable
and repeat Steps 1, 2, and 3.
5. If the sensor cable fails the continuity test,
replace it. If the cable passes, but the force sensor
readings were incorrect, see Paragraph 7.3, Force
Sensor Replacement. If the cable passes, but the
position sensor readings were incorrect, see
Paragraph 7.4, Position Sensor Replacement.
7.2. Force Sensor Removal
DANGER
To avoid personal injury, disconnect all power to the
terminating machine and to the Crimp Quality
STOP Monitor before removing the force sensor.
1. Disconnect the sensor cable at the force sensor.
CAUTION
!
The connector is a locking-style connector and
must be removed by pulling on the connector
housing. Pulling on the wires will not release the
connector and will cause damage to the wires.
2. Remove the base plate's mounting screws and
then the base plate.
7.3. Force Sensor Replacement
DANGER
To avoid personal injury, make sure that power to
the terminating machine and Crimp Quality Monitor
STOP is disconnected before replacing the force sensor.
1. Remove all components from base plate
assembly, and install them in the same location on
new base plate sensor assembly.
2. Clean mounting surface, then mount new base
plate sensor assembly on terminating machine.
3. Check alignment of the base plate with the
terminating machine's ram.
4. Make alignment corrections, if necessary.
5. Connect the cable to the sensor.
7.4. Position Sensor Removal
DANGER
To avoid personal injury, disconnect all power to the
terminating machine and to the Crimp Quality
STOP Monitor before removing the position sensor.
1. Remove the sensor cover and disconnect the
position sensor assembly.
2. Disassemble the cable clamp from the sensor
cable.
3. Disassemble the sensor mount bracket and
fixture from the gib.
4. Remove the magnet assembly from the
terminating machine's ram.
7.5. Position Sensor Replacement
DANGER
To avoid personal injury, disconnect all power to the
terminating machine and to the Crimp Quality
STOP Monitor before replacing the position sensor.
NOTE
i
The position sensor kit contains a position sensor,
magnet assembly, fixture, and a cover with
configuration numbers. These kit parts must be
replaced as a set. DO NOT mix the new parts with
any of the removed parts.
1. With the machine power disconnected, position
the terminating machine's ram at bottom-dead-
center.
2. Loosely attach sensor mount bracket to gib with
supplied hardware.
3. Mount the fixture to the terminating machine ram
and to the sensor mount bracket. The fixture is used
to establish the critical distance between the sensor
and magnets.
4. Tighten the sensor mount bracket screws.
5. .Remove the fixture and store it on the gib as
shown in Figure 3.
6. Mount the magnet assembly to the terminating
machine ram.
7. Attach the position sensor assembly to the
sensor mount bracket.
8. Attach cable clamp to the cable and the cover.
Rev E
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