MAY 10 Rev A

Transcription

1 TERMASHIELD* Ferrule Crmpng Des for Tools and MAY 10 PROPER USE GUIDELINES Cumulatve Trauma Dsorders can result from the prolonged use of manually powered hand tools. Hand tools are ntended for occasonal use and low volume applcatons. A wde selecton of powered applcaton equpment for extended-use, producton operatons s avalable. 1. INTRODUCTION Ths nstructon sheet s ntended to provde you wth nstructons on product applcaton and a mantenance and for: TERMASHIELD Ferrule Crmpng Des (Used n Tools and (Mod. 2): Tools Crmpng Des TERMASHIELD ferrules on sngle and multple conductor shelded wres wth a prmary conductor nsulaton range of.033" to.270", Basc nstructons on the use of these tools, des, de nserton and removal, etc., are provded n Secton 2, 'For further nstructons relatve to the pneumatc tool and hand tool, refer to the nstructons packaged wth these tools. Secton 3 contans a Mantenance and Inspecton Procedure whch wll enable you to establsh and mantan a de certfcaton program. These nstructons may be used for des not lsted n Fgure 1 but accompaned by ths 408 seres document. For unlsted des, strp wre and crmp n the same manner as for dentcal sze des. 2. INSTRUCTIONS 2.1. Selecton Data for Des, Ferrules, and Insulatng Caps A. Sngle Conductor Shelded Wre To determne whch des, ferrule and nsulatng cap to use wth sngle conductor shelded wre, refer to - Fgure The package numbers shown n Fgure 1 are suppled wth equal quanttes of ferrules and nsulatng caps, but nclude only znc plated ferrules. 1. Determne the outsde (nsulaton) dameter of the prmary conductor. 2. Locate ths dmenson n the approprate prmary conductor nsulaton range n column 2 of Fgure 1. Opposte the nsulaton range you wll fnd the catalog numbers of the crmpng de. ferrule and nsulatng cap to use. Crmpng des, ferrules and nsulatng caps are color coded. For example: Use des color coded green to crmp a green fermle. Place a green nsulatng cap on the green ferrule after ferrule s crmped. B. Multple Conductor Shelded Wre To determne whch des, ferrule and nsulatng cap to use wth shelded wre havng two or more conductors, use the followng formula: Multply the outsde (nsulaton) dameter of one prmary conductor by the factor, see Fgure 2, lsted opposte the total number of conductors n the wre. For example: 1. If you had a 3-conductor shelded wre, you would frst fnd the outsde (nsulaton) dameter of one conductor. In ths case, we wll use an outer dameter of.082 nches. 2. Opposte the number 3 (the number of prmary conductors n the wre) n column one of Fgure 2, you wll fnd a multplyng factor of Multply the outer dameter of the one conductor (.082 nches) by ths factor (2.17). The result s.177. Ths fgure (.177) s the prmary conductor nsulaton range of the three-conductor shelded wre. 4. Next, refer to column 2 of Fgure 1. Opposte the nsulaton range of.145 to.184, you wll fnd the numbers of the crmpng de, ferrule and nsulatng cap to use De Inserton Hand Tool No Des are coated wth ol to prevent rust and corroson. Wpe ths ol from des, partcularly from crmpng area. 1. (To open tool handles, close handles untl CERTI-CRIMP* tool ratchet releases. See Fgure 3. Note that once ratchet s engaged, handles cannot be opened untl they are fully closed Tyco Electroncs Corporaton, Berwyn, PA TOOLING ASSISTANCE CENTER All Rghts Reserved PRODUCT INFORMATION TE logo and Tyco Electroncs are trademarks *Trademark. Other products, logos, and company names mght be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at 1 of 8

2 Tool Prmary Conductor Insulaton Range (Inches) Crmpng De Number Znc-Plated w/inspctn Hole Ferrule Number Tn-Plated w/out Inspctn Hole Tn-Plated w/ Inspctn Hole Insulaton Cap De, Ferrule and Cap Color Code.033 Max GREEN VIOLET and WHITE BROWN ORANGE GREEN VIOLET WHITE BROWN ~ ORANGE GREEN 2. Each set of des conssts of a male de and a female de. See Fgure Pull female de holdng pn out of tool. Close handles untl male de holdng screw s vsble. See Fgure Turn de holdng screw slot n a vertcal poston. See Fgure Insert male de nto head of tool wth the color coded groove facng operator. Do not attempt to nsert des nto the tool whle holdng des together. Des are nserted nto the tool separately. 6. Insert female de nto bead of tool. Both color coded grooves should now be facng operator. 7. Turn male de holdng screw slot 1/4 sum to left or rght. 8. Open the handles slghtly and push the female de down so that the hole n the female de lnes Fgure 1 up wth the hole n the nsert. Insert the female de holdng pn. See Fgure 5. Conductors n Wre Multply Factor Conductors n Wre Multply Factor Fgure 2 2 of 8

3 2.3. De Inserton Pneumatc Tool No Mod.2 Des are coated wth ol to prevent rust and corroson. Wpe ths ol from des, partcularly from Crmpng area. Pneumatc tool No , Model 2 s equpped wth a pneumatc de take-up lever. See Fgure 3. Ths take-up lever s used to hold the ferrule n a proper poston pror to crmpng. 1. Each set of des conssts of a male de and a female de. See Fgure 4. Fgure 3 2. Connect ar supply. (85 to 100 P.S.!.) 3. Pull female de holdng pn out of tool. Depress take-up lever untl male de holdng screw s vsble, See Fgure 4. Wth take-up lever depressed, turn de holdng screw slot n a vertcal poston. See Fgure 4, 5. Insert male de nto head of tool wth the color coded groove facng operator. Do not attempt to nsert des nto the tool whle holdng the des together. Des are nserted nto the tool separately. 6. Insert female de nto head of tool. Both color coded groves should now be facng operator. Fgure 4 7. Turn male de holdng screw slot 1/4 turn to left or rght. (horzontal poston) See Fgure Release take-up lever, then push female de down so that hole n female de lnes up wth hole 3 of 8

4 n tool. Insert female de holdng pn. See Fgure Push de set up wth a small screwdrver or drft pn just enough to permt female de to be pulled out of tool. 5. Remove male de and nsert de holdng pn back nto tool Wre Strppng And Crmpng Procedures A. Wre Strppng 1. Strp shelded wre as shown n Fgure 7. Fgure De Removal Hand Tool No Remove female de holdng pn. 2. Close handles untl male de holdng screw s vsble. See Fgure Turn male de holdng screw slot n a vertcal poston. See Fgure Push de set up wth a small screwdrver or drft pn just enough to permt female de to be pulled out of tool. 5. Remove male de and nsert de holdng pn back nto tool. Fgure 7 2. Strp ground wre to dmensons gven n Fgure 8. Ferrule Number Recommended Ground No. of Wres Max. Ins Da Strp Length One # thru Two # One # One # One # Two # One # 18 1/4 Inch Mn. Fgure De Removal Pneumatc Tool No Mod thru One # 20 Two # 20 One # 22 No Lmt on Insul Dameter 7/16 Inch Mn 1. Remove female de holdng pn. Two # Depress take-up lever untl male de holdng screw s vsble. See Fgure Wth take-up lever depressed, turn male de holdng screw slot n a vertcal poston. See Fgure 6. B. Crmpng Procedures Fgure 8 1. Place ferrule on shelded wre as shown n Fgure 9. Flare the brad so that t wll pass over and around support sleeve of ferrule. 4 of 8

5 Fgure 9 2. Insert ground wre nto ferrule. See Fgure 10. On sx smaller ferrules (Part No and through ) slde the ground wre nsulaton under ferrule skrt approxmately /16 nch. On fve larger ferrules (Part No through DO NOT slde the ground wre nsulaton under ferrule skrt. Pneumatc Tool a.place ferrule, wth shelded wre and ground wre attached, n lower crmp area of des. Push ferrule all the way nto tool. See Fgure 1 b.hold ground wre and shelded wre n poston and depress take-up lever to hold ferrule n place. c.smultaneously release take-up lever and depress trgger to complete crmp. Release trgger and remove crmped ferrule. Fgure 11 C. Ferrule Insulatng Caps 1. Place nsulatng cap on ferrule as shown n Fgure Insulatng caps are color coded for easy matchng wth ferrule. To select correct nsulatng cap, refer to Fgure 1. Fgure 10 Hand Tool a.open tool handles all the way. b.place ferrule wth shelded wre and ground wre attached n lower crmp area of des. Push ferrule all the way nto tool. See Fgure 11. c.hold ground wre and shelded wre n poston and close handles untl CERTI-CRIMP tool ratchet releases. Open handles and remove crmped ferrule.pneumatc Tool Fgure 12 5 of 8

6 3. MAINTENANCE/INSPECTION PROCEDURE Tyco Electroncs recommends that a mantenancenspecton program be performed perodcally. Ths s necessary to assure that contnued use of the des wll result n the same dependable and unform termnatons for whch the des were desgned. We recommend an ntal frequency of nspecton of once a month. Ths frequency may be adjusted to sut your requrements through experence. The frequency of an nspecton s dependent upon: The care, amount of use, and handlng of the des. The type and sze of the products crmped. The degree of operator skll. The presence of abnormal amounts of dust and drt.; and Your own establshed standards. Wth proper mantenance and nspecton, these des wll gve years -of satsfactory servce. All Tyco Electroncs des are thoroughly nspected before beng shpped from the factory, however, snce there s a possblty of de damage n shpment, t s recommended that new des be nspected n accordance wth Secton 3 when receved n your plant Cleanng Do not allow deposts of drt, grease and foregn matter to accumulate n the de closure area and on the bottomng surfaces of the des. These deposts may prevent the des from bottomng fully and may also cause excessve wear n the de closure surfaces, thereby affectng the qualty of the crmp. The des should be wped clean frequently wth a clean cloth Vsual Inspecton Vsually nspect the de closure surfaces for broken or chpped condtons. Although des may gage wthn permssble lmts, worn or damaged de closure surfaces are objectonable and can affect the qualty of the crmp. Examples of possble damaged de surfaces are shown n Fgure De Closure Inspecton Every Tyco Electroncs de set s nspected and tested for proper de closure before beng shpped from the factory. An nspecton should, however, be performed perodcally to measure the de closure. Fgure 13 The de closure nspecton s accomplshed usng GO NO-GO plug gages. Tyco Electroncs nether manufactures nor sells plug gages, however, a suggested plug gage desgn and the GO NO-GO dmensons of the plug gage members are lsted n Fgure 14. The followng procedure s recommended for measurng the de closures. Refer to for orderng nformaton and for nformaton concernng the GO NO-GO gages. 1. Remove traces of ol or drt from de crmpng area and plug gage members. 2. Insert des n tool. 3. When usng hand tool, close handles of tool untl des bottom. Do not apply addtonal pressure to tool handles. 4. When usng pneumatc tool, reduce ar supply pressure to a range between p.s.. Depress trgger to bottom des. 5. Wth crmpng des bottomed, check the de closure usng the proper plug gage. Hold gage n straght algnment wth the de closure and carefully try to nsert wthout forcng, the GO member, and then the NO-GO member. See Fgure14. The GO member must pass completely through the de closure. 6 of 8

7 De Set De Set De Closure Dmensons A Gage Member Dmensons B GO NO-GO GO NO-GO C Max R Max Plug gag.e dmensons apply when des are bottomed, but not under pressure. Materal -- Tool Steel 6. The NO-GO member may enter partally, but must not pass completely through the de closure. 7. If the de closures meet the GO NO-GO gage condtons, the des may be consdered dmensonally correct. If you fnd that the de closures do not conform wth the GO NO-GO gage condtons, contact your local Tyco Electroncs feld servce representatve CERTI-CRIMP Tool Ratchet Inspecton The CERTI-Crmp tool ratchet feature on Tyco Electroncs hand tools should be checked to make certan that the ratchet does not release prematurely allowng des to open before they have fully bottomed. To check ratchet feature: Fgure Make a test crmp usng ferrule, shelded wre and ground wre as outlned n Paragraph 2.6,B. When ths crmp s made, close handles untl the ratchet s free, however, DO NOT RELAX PRESSURE ON TOOL HANDLES. 2. If a.001 or smaller shm can be nserted between the bottomng surfaces of the des. or f there s no openng whatever, the ratchet s consdered satsfactory. 3. If the clearance between the bottomng surfaces of the des s greater than.001, the des are consdered as not bottomng. Contact your local Tyco Electroncs feld servce representatve. 7 of 8

8 3.5. Replacement Parts It may be advantageous to stock replacement des to prevent loss of producton tme. Fgure 16 lsts the replacement de nserts that can be purchased from Tyco Electroncs Corporaton. Fgure 15 For customer spares, refer to: CUSTOMER SERVICE ( ) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA REVISION SUMMARY Appled the TE logo Changed values n Fgure 14 Item Descrpton De Set Numbers Male De Female De Item Descrpton De Set Numbers Male De Female De Fgure 16 8 of 8