Sentinel SPA-100 User Manual

®

SENTINEL

CONNECTOR SYSTEMS

SPA-100 MODULAR PLUG

APPLICATOR

Sentinel Connector Systems

1953 Stanton Street

York, Pa. 17404

Ph. 717-843-4240

SENTINEL

CONNECTOR

SYSTEMS

SPA-100

MACHINE

MANUAL

INTRODUCTION

Your SPA-100 machine comes to you fully equipped and set up to terminate
the style of plug you have requested.

The SPA-100 will accommodate those small connector configurations such
as 4 position, 4 contacts (4x4); 6 position, 2 contacts (2x6); 6 position, 4 contacts
(4x6); and 6 position, 6 contacts (6x6). -Consult factory-

When set-up to do so, this machine will accommodate both small and large
connectors alike, easy changeover from one to the other.

It is also electrically powered and does not require high-pressure airlines. It
is are portable enough to be moved around easily and their straightforward design
allows setup people to make changes in minutes.

All machines have full test capability with the cable tests performed as part
of the termination procedure.

1

SPECIFICATIONS FOR SPA-100 MODEL CRIMPING

MACHINES

Crimping machine portion

1. Usable connectors…………………Recommended Sentinel Connectors
8x8, Cat 5 &Cat 6
(4x4, 2x6, 4x6, 6x6 Consult factory)

2. Function ………………………….. Crimping modular connectors onto cable

3. Power Source ……………………. AC 115v, 60Hz, 5Amp

4. Driving System …………………… Single phase induction motor with gear head

Power consumption …………… 90w
Rated current ………………….. 0.75A
Starting current ……………….. 1.9A
Gear head reduction ratio …… 30:1
Power………………………………1/10 H.P.

5. Mechanical power ……………….. Punch pressure 130Kg

Punch stroke 16mm

6. Operation speed …………………. Machine cycle time …… 1.5 sec. (1.1 sec. of

Crimping + 0.5 sec. of electrical check under
10 ft. cable)

7. Emergency release function ……Reversing motor by “Rev” switch

8. Fuse ………………………………… 5 A

9. Size ……………………………….. 5.5” (w) x 10 5/8 (h) x 13 1/8 (d)

10. Weight ……………………………. 40.4lbs

2

I. Set-up

A) Refer to page 6 for a pictorial view while following instructions.
B) Plug press into the wall outlet 110 volts.
C) Plug cable tester into 110 volts outlet.
D) Attach cables (supplied) to press and cable tester as labeled.
E) Select proper combination of switches on press.

1) “Auto/Hand” (on press)

2) “Double/Single” (on press)

3) With a “known good cable” set-up a signature (on tester).

II. Ready to run

With the signature cable, insert into the nest(s). When the plug reaches
proper depth, a micro switch in rear of nest actuates a single rotation of the
press. When a single plug is required, only the left nest can be utilized.

CAUTION: When using both nests, make sure the selector switch is on
double!

After ram on press has returned to top position, maintain the position of the
plugs in the nest to insure an accurate reading on the tester. The plugs in
the nests will actuate a micro switch to cycle machine, (if plug is removed
and reinserted it will cycle again). When the ram is at it top position the test
wires are making contact with the gold pins in the plugs, this will allow the
tester to check continuity, shorts and correct polarity of plugs to wire. This
test will remain active as long as plugs remain in the nests. Once the plug
moves away from the micro switch in rear of nest, the machine resets itself
to begin a new termination.

III. Adjustments

A) Nests

Both nests are in a fixed position and cannot be adjusted. However,
They can be removed and replaced with other nests allowing termination
of various Sentinel Connector Systems connectors.

1) The nests are equipped with two ball vilers that seat the connector
into the nest securely. At times it may be necessary to remove these
and replace them with new, when doing this please be sure not to
over tighten as to damage the connector.

MANUAL FOR SPA-100 PRESS

3

B) Punch holder assembly

The punches can also be adjusted as a unit or individually.
To move punches as a unit, loosen the two cap screws in the front of the

head (item #65, page 18), move the head up or down using the screw on
top (item #64 page13) for adjusting, and retighten screws when proper
position is located.

C) Punches

1) In order to make individual adjustments of the punches, there are
small slotted screws on the top (item #60 page 17) of punch holder
assembly. To make an adjustment first loosen screw (item #69 page

17) in front and the set screw on the side of punch holder assembly
(item #61 page17). Make the desired adjustments (NOTE: one
complete turn of #60 screw is equivalent to .020 or 5mm). When the
movement is made, push tooling up while lightly snugging the set
screws on the side (item #61); then tighten the screws in front (item
#69).

2) Any adjustment left to right can be made if necessary by loosening the
screws at (item#66) adjustment required can be made by adjusting the
proper tool unit in direction desired. (see step 3 for a detailed
description of how to make alignment.

3) Try this when lining up connector to punch. Remove the two punches
on the side needing adjustment(left or right). Leave the contact punch
installed, being held by set screw on the side of the unit. Now place a
pre-inserted connector into the nest and jog the ram down just above
the connector. With a small magnifying glass you will be able to see
which way the tools need to move in relationship to the connector.
You will now be able to make this adjustment. Loosen the proper
bolts that move this unit and adjust. Retighten the bolts and return
ram to its top position. Replace the punches and retighten them.

4) Strip the jacket cord, trim the conductor to length, place a connector
on both ends of cord and insert the plugs into the nest.

5) When a cycle is made the test fingers will remain on the conncetor and
test for shorts, continuity and miswires. If the product is ok and
meets the desired signature, the tester will display a “good reading”.

6) If there is a short or other problem, a tone will be heard and “error”
will be displayed on the screen. Test fingers will stay down, touching
the contacts, until at least one of the plugs has been removed from the
nest, deactivating the micro switch.

7) If for some reason the ram does not return to its original position after
crimping, turn the switch (labeled rev) on to return the ram manually.
When ram is at the top, turn rev switch off before.

4

TERMINATION INSTRUCTIONS

These instructions are intended for use with the SPA-100 in conjunction
with Sentinel Connectors modular plugs.
This product comes to you in single assemblies with contacts pre-inserted.
Please refer to product manual for details on determining which of Sentinel’s plugs
will work the best for your application. Any further help may be obtained by
contacting Sentinel direct and obtaining the proper guides.
Once you have determined which combination is best suited, strip the cable
back far enough to allow the individual conductors to be inserted into the plug
while also maintaining the outer jacket positioned under the jacket lock on the
plug. Position the conductors, as desired, and insert them into the plug, making
sure the conductors, as desired, and insert them into the plug, making sure the
conductors are securely positioned against the front of the plastic, to ensure the
contacts penetrate properly.
After preparing cables with connectors, you are ready for termination. If only
one plug is required to be terminated, switch machine to single. If both are
desired, switch the button to double. This will allow you to properly align both
connectors before the ram cycles down. After the ram completes the cycle,
(keeping the plugs positioned in the nests) the test leads will come down, testing
for continuity, shorts and opens. If the tested cable is defective, the tester will
indicate exactly what the defect is. For further instructions on the tester, refer to
the tester manual provided.
Once the cable is completed, a contact height check is necessary to maintain
compliance with FCC, which is .237 +/- .005 from the bottom of the plug base (not
including the tab) to the top of the contacts. This is roughly .023 from the top of
the plug to the contacts at a nominal tolerance.
The tooling can be replaced relatively simply and quickly for short down
time. Each tool can be adjusted individually or as a unit depending on what the
need is.
The machine can be adjusted manually by removing motor guard to obtain
access. Then turn the power off and rotate the fan in the direction desired (the
ram will go up or down depending on the direction fan is turned clockwise or
counter clockwise). Rotate the motor until ram comes down to a plug inserted into
the nest for any adjustment necessary (the contacts in the plug should align with
the contacts that do the driving). After making the adjustment, continue rotating
the motor either way until the ram reaches the top and makes contact with the
micro switch.

7

RECEIVING INSPECTION

This machine has been thoroughly inspected before leaving our facility. This
provides the assurance that the machine produces good termination and
Is ready to use. However, the following points should be reviewed to verify that no
problems have occurred during shipment.

1. Carefully uncrate the machine and place it on a sturdy bench and
examine it against the report sent with machine.

2. Inspect the entire machine for evidence of damage that may have
occurred during transit. If in fact the machine shows signs of damage,
contact Sentinel Connector Systems, Inc. immediately.

3. Check all components to be certain they are secure. Don’t operate
machine until all loose tooling has been tightened down safely.

4. Please maintain the crate the machine has been delivered. In the event
the machine has need of repairs or lease if terminated the machine must
be sent back in its original crate. This is to maintain proper protection of
the machine from any shipping damage. Your help in this manner is
greatly appreciated.

5.

8

SPA-100 SPARE TOOLING

Suggested Spare tooling for the SPA-100 machine is as follows:

A. One each machine – 901306 micro switch
B. Two each machine - 902300 micro switch
C. One pair of contact punches on most used product

8-position 901053 contact driver

TROUBLE SHOOTING TIPS

Motor will not run Check the relays in rear of machine. They may have

come loose during shipment.

Ram cycling continuously Check the micro switch at the top of machine for
up and down or drifting proper placement and/or not working. Check break

pac relay to ensure it is working properly. (see
adjustment notes below)

No cycle on auto Micro switch in nest may be faulty, or may be

pushed too far. There maybe lint build-up. Check
both nests.

Testing displaying error; Tooling may be out of adjustment, causing
product looks fine plastic skiving of the ribs which insulates the

test probes from the contacts.

If test leads don’t have enough bend on the
front, they may not snap down between the ribs
to make continuity with the contacts in the plug.

22

MAINTENANCE FOR SPA-100

1. Use a soft brush to lightly remove any debris that may build up on machine.
Always keep the nest cavity clean.

2. Grease machine at the top, once a month or every 500 hours of service.
With the machine off, take a cloth underneath the ram and remove excess
grease. This should be done from time to time between greasings to assure
that grease does not come in contact with product.

3. When replacing tooling, store unused tooling in plastic or wax paper after
being lightly sprayed with light oil. When replacing tooling lightly brush off
tooling working surfaces and wipe oil clean from tooling. Do not oil the
gibbs, as this will break down the grease that has been placed in them from
the factory.

4. A maintenance program should be established for service on a regular basis.
The amount of usage will determine whether this should be performed daily,
weekly or monthly.

5. Take extra care that no chemicals remain in the nest portion of the machine
when resuming production. This will prevent any possible chemical
reaction.

6. Contact a service representative for any further information.

WARNING! When maintenance is being performed, please make sure

power is off!

23

Ram adjusting procedure:

If the ram is cycling erratically or drifting down where it is difficult to insert a
plug into the nest, follow these instructions.

When the ram drops down to low after the plugs have been tested and then
removed from the nest, the micro switch is a bit out of adjustment.

• Loosen the nut (item #72) and turn the screw counter clockwise about
1/8th of a turn, then tighten the nut.
If this doesn’t eliminate the problem repeat the process.

(this could also be done if the ram runs up and down without

stoping.) but turn screw clockwise.

If the ram reaches the top and doesn’t come down properly to it’s initial
starting point an adjustment the opposite direction is necessary
(counterclockdwise).

24

SPA-100 SPARE PARTS – ELECTRICAL ITEMS

ITEM # PART # DESCRIPTION

1 901306 Micro Switch SS-SGL
2 902300 Micro Switch (Radio Shack)
3 902301 Brothers Gear Motor
4 902302 Mitubishi Controller
5 902303 Terminal Block
6 902304 Capacitor
7 902305 Break Rectifier
8 902306 Reverse Switch

9 902307 Power Switch
10 901370 Rocker Switch (DS-308)
11 901371 Fuse Holder
12 901372 Midget fuse
13 901373 Power Cord
14 902308 Power Cord Grommet
15 901375 20 Pin Header-Right Angle
16 902309 Test Wires
17 902310 Test Blocks
18 902311 Test Block Assembly
19 902312 Relay
20 902313 Socket

SPA-100 SPARE TERMINATING PUNCHES

ITEM # PART # DESCRIPTION

26 901053 CD-8 (8 Position Contact Driver)

27 901057 CB-8/10 (8 & 10 Position Conductor

Bar Punch)

28 901059 LC-8/10 (8 & 10 Position Latch Crimp

Punch)

25

SPA-100 SPARE NESTS, ACCESSORIES & HARDWARE

ITEM # PART # DESCRIPTION

51 901112 8/10 Position Nest – Left Hand
52 901113 8/10 Position Nest – Right Hand
53 901114
54 901115

55 901116
56 901117
57 901125 Ball Vilers for Plug Nests

58 902100 Ground Screws for Plug Nests
59 902101 Springs on Testers
60 902102 Punch Adjusting Screw & Nut
61 902103 Set Screws for Punches
62 902104 Bearing Tester
63 901348 Bearing Motor
64 902105 Adjustment Screw & Nut
65 902106 Vertical Adjustment Screw
66 902107 Horizontal Adjustment Screw
67 902108 Test Block Screw & Nuts
68 902109 Test Block Slide Pin
69 902110 #10-32 SHCS
70 902111 Dowel Pin for Spring

26

SPA-100 MACHINE COMPONENTS

ITEM # PART # DESCRIPTION

101 902325 Machine Base
102 902326 Upright Tool Slide
103 902327 Base Cover
104 902328 Front Panel
105 902329 Rear Panel
106 902330 Bottom Mounting Plate
107 902331 Spacer Block
108 902332 Nest Holder
109 902333 Left Plug Stop
110 902334 Right Plug Stop
111 902334 Guide Rail
112 902335 Slide Block
113 901353 Guide Block
114 901318 Brass Ram Bushing
115 902336 Eccentric Shaft
116 902337 Key
117 902338 Slide Stop
118 902339 Adjustment Block
119 902340 Punch Holder RH
120 902341 Punch Holder LH
121 902342 Pivot Bracket
122 902343 Tester Pivot Plate
123 902344 Micro Switch Bracket
124 902345 Guard Spacer

125 902346 Guard Spacer
126 902347 Main Machine Guard
127 902349 Cam Plate
128 902350 Main Machine Spacer for Guard

129 902351 Stop Plate

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