IDEAL 30-946, 30-947 TECHNICAL MANUAL
Pre-Insulated Crimp Application Machine (PCAM™)
Instruction Manual and Parts List
30-94 6, 3 0-947
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Warning and
Safety
Instructions
Please read, understand and follow the warnings and instructions in this manual and
on the machine. Failure to do so can result in serious personal injury.
■ Do not operate machine when any component is missing or damaged.
■ Do not perform any maintenance on the machine unless the electrical and air
supply to the machine are disconnected.
■ Do not operate machine without wearing proper eye protection.
■ Do not operate machine in a damp or wet location.
■ Do not operate if liquid is spilled on or in machine.
■ Do not operate machine on an ungrounded electrical system.
■ Do not alter, modify or misuse the machine.
■ Do not operate machine unless all instructions are read and understood.
■ Do not operate machine in a gaseous or hazardous environment.
Technical
Data
Description
Specifications
Total Cycle Time 4 Seconds
Electrical Supply 120 VAC 60 Hz
Compressed Air Supply 80-90 PSI Regulated & Dry
Dimensions 15” Deep x 13-5/8” Wide x 9-7/8” High
Shipping Weight 59 lbs.
For technical assistance with this machine, call:
1-877-201-9003
OEM Tech Support
Table of Contents
Part I General Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. PCAM™ Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. PCAM™ Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
D. PCAM™ Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Part II Equipment Set-up Instructions . . . . . . . . . . . . . . . . . . . . . . . . 6
A. Unpacking PCAM™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Hand Gun Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. Console Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
D. Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E. Mounting Hopper Unit to Console Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F. Installing and Adjusting Hopper Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
G. Attaching Tool Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
H. Assembling Bench Mounting Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
I. Loading Hopper Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
J. Checking Hopper Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
K. Adjusting Hand Gun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Part II I Operational Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Feed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Part IV Maintenance Service Program . . . . . . . . . . . . . . . . . . . . . . 10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Part V Service and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 10
Proper Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Part VI Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18
A. Hand Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
B. Console Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
C. Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
D. Hopper Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
E. Bench Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Part VII PCAM Setup and Diagnostic Program . . . . . . . . . . . . . . . . . 19
Appendix A Service and Troubleshooting . . . . . . . . . . . . . . . . . . . . . 20-21
Appendix B1 Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Appendix B2 Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Appendix C Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Addendum Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Addendum Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
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Part I General Coverage
A. Introduction
The Pre-Insulated Crimp Machine (PCAM™) is especially designed to quickly and firmly apply IDEAL PreInsulated Crimp Connectors to a wide range of conductor types and sizes.
PCAM™ is a computer-controlled machine that insures integrity and consistency for each electrical connection.
PCAM™ is the only computer-controlled machine that applies "pig-tail" type crimp connectors, with precision,
faster than manual assembly operators.
B. PCAM™ Models
Model 30-946
30-947
C. PCAM™ Components
Each PCAM™ model consists of the following components:
■ Console Unit
■ Hand Gun Assembly
■ Tool Balancer
The Console Unit contains the main control components, including the:
■ Electronics Modules
■ Pneumatic Components
■ Connector Feed Bowl
The Hand Gun Assembly applies the connector to the stripped conductor ends. It is
a lightweight hand-held unit that is controlled from the console unit. It contains the:
■ Hand Gun
■ Feed Hose
■ Pneumatic 1/4" Feed Tubes
The Tool Balancer is an adjustable counter balance for the Hand Gun. It allows the
Hand Gun to hang vertically weight free and locates the Hand Gun at a desired
height position.
D. PCAM™ Accessories
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1. Bench Mount and Foot Switch (30-930)
The Bench Mount and Foot Switch are used together. The Foot Switch can be used in place of hand gun
trigger. The Bench Mount holds and positions the Hand Gun. It is used for applications where the work can
be brought to the Hand Gun – usually small components that can be hand held.
2. Hopper Unit (30-951)
The Hopper Unit holds the wire connectors and feeds them to the feed bowl. This system is controlled by a
proximity sensor, which constantly monitors and maintains the correct level of connectors in the feed bowl
at all times.
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Part II Equipment Set-up Instructions
A. Unpacking PCAM™
Caution: Do Not use feeder bowl to lift console from carton.
Note: See assembly drawing on page 13 for item numbers.
Remove the following contents from carton:
■ Instruction Manual ■ 90º swivel air hose fitting (item #22)
■ Green ground wire (item #27) ■ 1/2" clear feed air hose (item #21)
■ 1/4" O.D. red air line tubing (item #14) (2) ■ Hand Gun (item #15)
■ Protective Sleeve (item #26) (2) ■ Tool Balancer (1161.033)
■ Power Cord (item #32)
■ Console Unit (30-947). Remove packing prior to lifting out unit.
■ Hose Assembly (item #13)
B. Hand Gun Assembly
■ Unwind switch cable from hand gun body
■ Screw black feed hose (item #13) into threaded fitting on back of hand gun body. Push both 1/4" O.D. red
air lines (item #14) into quick release air fittings on the hand gun adjacent to the black feed hose (item #13)
until they are fully seated. Notice dimple adjacent to quick release air fitting on back of the hand gun body.
■ Loosen screw adjacent to black feed hose (item #13) two to three turns. Slide spade terminal connector from
hand gun ground wire (item #27) under loosened screw. Tighten screw.
C. Console Unit Assembly
■ Screw black feed hose (item #13) into threaded adapter (item #12) on top front left of console unit.
■ Locate two quick release air fittings on the console adjacent to the black feed hose (item #13). Locate
dimple adjacent top quick release fitting. Push other end of 1/4" O.D. red air line (item #14) adjacent to the
dimple in hand gun into top quick release air fitting on console unit until it is fully seated.
■ Push second 1/4" red air line (item #14) into bottom quick release fitting adjacent to the black feed hose on
the console unit until it is fully seated.
■ Insert RJ-11 modular plug from hand gun switch into socket adjacent to the black hose on the console unit.
■ Loosen top screw of RJ-11 socket on console two to three turns. Slide spade terminal connector from hand
gun ground wire (item #27) under loosened screw. Tighten screw.
■ Install protective sleeves (item #26) by fastening hook, and loop material over red air lines, black feed tube,
ground wire, and switch cable.
D. Supply Assembly
Caution: A minimum 80 PSI clean dry compressed air is essential for the proper function of the PCAM™
machine. Failure to provide proper air supply will result in PCAM™ machine failure.
■ Apply a non-tape pipe thread sealant such as "Loctite®" #565 to threads of 90º swivel fitting (item #22).
Tighten 90º swivel fitting into brass bulkhead fitting on rear right side of console unit.
■ Insert 1/2" air hose (item #21) into the 90º swivel fitting above until it is fully seated.
■ With air supply shut off, connect 1/2" air hose above to clean dry regulated air supply.
■ Insert 120 VAC line cord socket (item #32) into on/off switch socket on right side of console unit.
■ With PCAM™ power switch in "off" position, plug power line cord into a 120 VAC supply.
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E. Mounting Hopper Unit to Console Unit
■ Mount hopper arm with rubber bumpers to right rear corner of Console Unit
using four 10-24 screws provided.
■ Slide arm attached to hopper over left rear Hopper mount post.
■ Secure with 10-24 x 1/2" screw.
■ The PCAM can be operated without the Hopper in place. To disable proximity sensor, access the display
board by removing the red bezel located at the front of the console. Rotate switch SW3 to the #5 position
and press button SW1 until the display reads "HOP OFF." This indicates that the automatic feed from the
hopper is turned off. Turn switch SW3 to the #0 position, resume normal operation without Hopper.
Note: See Part VII (page 19) for switch position description.
F. Installing and Adjusting Hopper Level Sensor
■ Fill bottom of feed bowl with connectors to about one inch depth.
■ Adjust sensor nuts to allow sensor to protrude through bracket about two
inches.
■ Plug proximity sensor into Hopper sensor connector located on left side of
Console Unit.
■ Plug Hopper power cord into outlet on back of Console Unit.
■ Turn power "ON." Switch located on right side of console.
■ If sensor light is on, turn adjustment screw counterclockwise until light just
goes off.
■ With sensor light off, turn adjustment screw clockwise until light just comes
on.
The level sensor is now adjusted. Slight adjustments can be made to the
connector level by turning adjusting screw counterclockwise to increase the level
and clockwise to decrease the level.
G. Attach Tool Balancer
■ A counter balance is supplied with each unit to locate hand tool to desired
height position. Swivel hook on counter balance can be attached to mounting
eye on hand tool.
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H. Assembling Bench Mounting Stand (optional).
■ Place Hand Gun in Bench Mount Stand.
■ Secure by tightening clamp collar screw.
■ Position Hand Gun and Bench Mount Stand in convenient working location
on bench.
■ Fasten Mounting Stand to bench securely.
■ Insert male plug from Foot Switch Control into Foot Switch INPUT jack on
rear left side of Console Unit.
I. Loading Hopper Unit
■ Fill Hopper.
■ IMPORTANT – Use only IDEAL Pre-Insulated Crimp Connectors in PCAM™.
Do not mix different size connectors in PCAM™.
J. Check Hopper Solenoid Adjustment
■ Gate should clear the connector entry path with the solenoid plunger
completely seated in the solenoid coil. Gate should not touch bottom of
Hopper Chute when in the open position.
Note: Improper solenoid adjustment will result in premature solenoid
failure.
■ To correct solenoid position, loosen mounting screws, slide solenoid
forward or back as required, retighten screws and double check adjustment.
K. Adjusting Hand Gun Sensor
■ The Hand Gun sensor is set at the factory. Due to changing Hand Gun housing, the sensor may need to be
adjusted to match the new housing.
■ Remove the six screws holding the red bezel to the front of the console.
Note: See Part VII (page 19) for switch position description.
■ Rotate switch “SW3” to the #6 position. The display will show "ADJ TOOL" (adjust tool). Hand Gun will
release the connector.
■ Push the connector back into the Hand Gun about 3-4".
■ The Hand Gun sensor adjustment can be reached with a small slotted screwdriver through a small hole
located on the front panel adjacent to the red air hoses.
■ Rotate the potentiometer counterclockwise until the warning beeper stops. Rotate the potentiometer
clockwise until the warning beeper has a consistent beep.
■ Rotate switch “SW1” to the #0 position. The PCAM will blow and the Hand Gun will clamp onto the
connector.
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