Page 1
OPERATING INSTRUCTION MANUAL
QUICK-KON™ AUTOMATED CRIMPING SYSTEM
for Catalog Number: TNB170-ELECDIE
IMPORTANT: Read and understand all of the instructions and safety
information in this manual before operating or servicing this tool.
TABLE OF CONTENTS
1.0 GENERAL CHARACTERISTICS ...................... Page
1.1 Description..............................................................2
1.2 Warning...................................................................2
1.3 Tool Includes...........................................................2
2.0 INSTALLING ELECTRIC DIE ........................... Page
2.1 Installation...............................................................2
3.0 TOOL PACK...................................................... Page
3.1 Tool Pack Features .................................................3
3.2 Table I......................................................................3
3.3 Catalog Number Location.......................................3
3.4 Installing Ram Tool..................................................3
3.5 Installing Stock Guide.............................................4
3.6 Alignment of Tool Packs .........................................4
3.7 Un-Installing Tool Packs .........................................4
4.0 TERMINALS & DISCONNECTS....................... Page
4.1 Overview.................................................................5
4.2 Inserting Carrier Strip..............................................5
4.3 Removing of Carrier Strip .......................................5
5.0 CRIMPING ........................................................ Page
5.1 Determine Proper Crimp Settings...........................6
6.0 SETTING ADJUSTMENTS............................... Page
6.1 Feed Control ...........................................................6
6.2 Run Mode ...............................................................6
6.3 Speed Mode Calibration.........................................7
6.4 Position Mode Calibration ......................................7
6.5 Delay Mode Calibration ..........................................7
7.0 STOCK GUIDE ................................................. Page
7.1 Wire Stop Adjustments...........................................8
7.2 Terminal Sensor Adjustment...................................8
8.0 INDICATORS .................................................... Page
8.1 Power Supply .........................................................9
8.2 Ram Sensor............................................................9
8.3 Status LED’s ...........................................................9
9.0 SPECIFICATIONS............................................. Page
9.1 Cleaning.................................................................10
9.2 Inspection ..............................................................10
9.3 Lubrication.............................................................10
10.0 MAINTENANCE.............................................. Page
10.1 Table IV................................................................11
11.0 OPTIONS.........................................................Page
11.1 TNB197 - FUNNEL KIT ASSEMBLY....................12
11.2 Table V..................................................................13
TA04864 E Page 1 of 13© 2016 Thomas & Betts. All Rights Reserved.
Page 2
1.0
GENERAL CHARACTERISTICS
1.1
The QUICK-KON™ Automated Crimping System is a left-to-right side feed applicator which installs in most
industry standard presses, which is comprised of the Electric Die, the Stock Guide Assembly and the Ram Tool.
As a result, one unit can be used to crimp a large variety of terminals - simply through the purchase of additional
tool packs.
Unlike traditional applicators, which use mechanical designs to feed terminals, the Thomas & Betts® Electric Die
uses a patented feeding method that electronically performs feeding operations pre-termination. The stepper
motor driven pinch rollers engage the carrier strip and push the terminals into place for crimping. Microprocessor
based electronics, in conjunction with sensors, initiate a feeding cycle on the upward motion of the ram and
control the stepper motor to precisely position the next terminal to be crimped. A feed controller allows the
operator to set feeding parameters electronically. As a result of this superior terminal feeding system, tool packs
are readily accessible and easy to swap…set-up is quick and easy.
1.2
1. BEFORE USING THE TOOL, CAREFULLY READ
INSTRUCTIONS IN THIS MANUAL.
2. ALWAYS DISCONNECT POWER AND DE-ENERGIZE UNIT
WHILE PERFORMING MAINTENANCE OR TOOLING
CHANGES.
3. WHEN OPERATING THE TOOL NEVER PLACE HANDS OR
OTHER BODY PARTS BETWEEN THE CRIMPING DIES.
4. WEAR EYE PROTECTION WHEN OPERATING OR
PERFORMING MAINTENANCE.
5. WEAR FOOT PROTECTION WHEN MOVING OR
OPERATING THE UNIT.
6. CAUTION IS REQUIRED WHEN MOVING OR LIFTING THE
ELECTRIC DIE ASSEMBLY.
WARNING
DESCRIPTION
1.3
ELECTRIC DIE
QUICK-KON™ AUTOMATED
CRIMPING SYSTEM INCLUDES
POWER SUPPLY
M5 HEX WRENCH
4 5 61 2 3
2.0
2.1
1. The QUICK-KON™ Automated Crimping System is designed be used with Thomas & Betts Press Assembly
(TNB010-press). Refer to the Press Assembly manual for proper installation.
INSTALLING AUTOMATED CRIMPING SYSTEM
INSTALLATION
TA04864 E Page 2 of 13
Page 3
3.0
TOOL PACK
3.1
IMPORTANT:
RAM TOOL
Ram Fastener
3.2
STA-KON
TOOL PACK
CAT. NO.
TNB177D01 RA-NYLON RA-VINYL 22 18
TNB177D02 RB-NYLON RB-VINYL 16 14
TNB177D03 RC-NYLON RC-VINYL 12 10
TOOL PACK
CAT. NO.
TNB177T01 RA-NYLON 22 16
TNB177T02 RB-NYLON RB-VINYL 18 14
TNB177T03
TNB177T04 RA-VINYL 22 16
TNB177T05 A-NON INSULATED 22 16
The
QUICK-KON™ Automated Crimping System is to be used in conjunction with the Thomas
& Betts Tool Packs, purchased separately.
TABLE I
®
TOOL PACK CAT NO's
DISCONNECT REEL
TERMINAL REEL
RC-NYLON RC-VINYL 12 10
RBC-NYLON RBC-VINYL 16 12
WIRE RANGE
WIRE RANGE
Tool Pack Features
STOCK GUIDE
Terminal Position
Sensor
Sensor
Adjustment Screw
3.3
IMPORTANT: Before using
Ram Tool and Stock
(AWG)
(AWG)
Guide, the Cat. No. on the
parts must match.
Wire Stop
CAT. NO. LOCATION
Cat. No.
Locations
3.4
1. Push Actuator up until it stops and remains in the
up position.
2. Install Ram Tool into Electric Die as shown and
tighten Ram Fastener with supplied Hex Wrench.
Install
(Partial View)
INSTALLING RAM TOOL
Ram ToolElectric Die
3.
Ensure that the top of the Ram Tool is ush below
the Act.
Nut
Ram
Tool
Side View of
the Ram Tool
ush below
the Act
Tighten
Ram Fastener
Dial
Act
(
until it
stops)
TA04864 E Page 3 of 13
Push up
Page 4
3.5
1. Disengage the Idler Release on the Automated
Crimping System.
2. Slide Stock Guide assembly into place and
rotate Locking Pin on Stock Guide to secure
onto the Automated Crimping System.
INSTALLING STOCK GUIDE
STOCK GUIDE
Locking Pin
Location
Rotate
Disengaged
Engaged
Idler Release Switch
Slide Stock Guide
into Electric Die
3.6
1. Verify that the Ram Tool and the Stock Guide Jaws
are aligned vertically.
CAUTION: Failure to
properly align Jaws will
result in damage to the
tool upon operation.
2. See section 4 for
operation.
Front View of
Ram Tool and Stock Guide
3.7
1. Turn Power OFF to Electric Die and Press Assembly.
2. Remove Stock Guide by disengaging Idler Release Switch (Step 3.5). Disengage Locking Pin by pulling out
Locking Pin and rotating into Locked position.
3. Remove Ram Tool by unscrewing Ram Fastener and pulling Ram Tool out.
ALIGNMENT OF TOOL PACKS
Ram Tool Jaws
Stock Guide Jaws
Not Aligned
Side View
UN-INSTALLING TOOL PACKS
Aligned
Side View
Pull Locking Pin
out to disengage.
Pull Out
Ram Fastener
unscrew with
the supplied
Hex Wrench
Pull Ram
Tool out.
Slide Stock Guide Out Ram Tool
TA04864 E Page 4 of 13
Page 5
Pull
Carrier
Strip
out
Insert
Carrier
Strip
Automated
Crimping System
4.0
TERMINALS & DISCONNECTS
4.1
Thomas & Betts® Terminals & Disconnects are available on Mylar tape rolls in quantity of 1,000 pieces. These left
hand feed reels are designed to work with the Automated Crimping System. See TABLE I in Step 3.2 for Terminal
& Disconnect Tool-Pack catalog numbers.
4.2
Inserting:
1. WARNING: Turn Power off to Automated Crimping System and Press Assembly.
2. Verify that the installed Tool Pack is appropriate for the selected Terminal or Disconnect Reel (see section 3.2).
3. Place selected Terminal or Disconnect Reel onto Terminal Reel Support Arm which is connected to the Press
Assembly (see instruction manual supplied with Press Assembly).
4. On Press Assembly, position ram at top of stroke (see instruction manual supplied with Press Assembly).
5. Raise the Idler Release Switch in the disengaged position (see Step 3.5).
6. Slide Terminal or Disconnect Carrier Strip from the Reel into the Automated Crimping System.
7. When Carrier Strip is in place, lower the Idler
Carrier Strip.
8. See section 5 for crimping.
INSERTING CARRIER STRIP
OVERVIEW
Release
Switch (see Step 3.5) to engage Idler Roller onto the
Idler Release Switch
(shown disengaged)
Carrier Strip
BACK END OF AUTOMATED CRIMPING SYSTEM
4.3
Removal:
1. WARNING: Turn Power off to Automated Crimping System and Press Assembly.
2. Raise Idler Roller by disengaging the Idler Release Switch (see Step 3.5).
3. Pull Carrier Strip out of the Stock Guide.
REMOVING OF CARRIER STRIP
(Make sure Idler Release Switch
is lowered to engage Idler Roller)
Idler Release Switch
(shown disengaged)
Idler Roller
BACK END OF AUTOMATED CRIMPING SYSTEM
TA04864 E Page 5 of 13
Page 6
5.0
CRIMPING
5.1
IMPORTANT: Recommended crimp height settings, specic to terminal or disconnect tooling, are provided
with tool packs. Before crimping with recommended settings, calibrate per instructions below.
Crimp Setting:
1. Set Conductor Dial and Insulator Dial to “0”.
2. If applicable, close saftey guards. Restore power.
3. Crimp terminal/disconnect or 1/4” diameter solder.
4. Measure the crimp height and compare values to layout provided with the appropriate Tool Pack.
5. Record Settings for future use.
DETERMINE PROPER CRIMP SETTINGS
CRIMP ADJUSTMENT DIAL
CONDUCTOR DIAL
The higher the value is
set, the tighter the crimp
42
42
048
048
6
6
12
12
will be.
INSULATION DIAL
The higher the value is
set, the tighter the crimp
will be.
DIAL INDICATOR
6.0
6.1
1. The Automated Crimping System has (4) adjustable
‘MODES’.
2. Select desired mode with ‘MODE’ button on feed
control screen display.
3. Mode values are adjusted via the ‘UP/FEED’ &
‘DOWN’ buttons.
4. Pressing the ‘UP/FEED’ & ‘DOWN’ buttons
simultaneously will display the total number of feed cycles completed.
6.2
1. Terminals/disconnects will automatically feed when Run Mode is selected.
2. Run Mode will also be auto initiated by movement of the ram.
3. Run mode will run with the speed, delay, and position values that have been programmed. If no adjustments
have been made, run mode will function with default values.
SETTING ADJUSTMENTS
FEED CONTROL
MODE
LOCK
DELAY
SPEED
RUN MODE
UP/FEED
COUNT
DOWN
RUN
POSITION
TA04864 E Page 6 of 13
Page 7
6.3
SPEED MODE CALIBRATION
IMPORTANT: The feed cycle is the advancing
movement of the carrier strip. This cycle is initiated after
crimping in order to feed a new terminal/disconnect into
alignment with crimp tooling.
1. Set and adjust the Speed of the carrier strip during the
feed cycle.
2. There are 9 Speeds available as dened in Table II.
6.4
POSITION MODE CALIBRATION
Position Mode Calibration:
1. Left-to-right adjustments of the terminal/disconnect
relative to the tooling.
2. Each value represents 0.001” of shift to the right or the left.
Speed
Selection
1 6.35 0.25
2 12.70 0.50
3 19.05 0.75
4 25.40 1.00
5 31.75 1.25
6 38.10 1.50
7 50.80 2.00
8 63.50 2.50
9 76.20 3.00
CENTERED
TABLE II
Approximate Speed
(mm / second)
C
L
Left Limit: -50
Default Setting: 0
Right Limit: +50
Approximate Speed
(inches / second)
6.5
DELAY MODE CALIBRATION
1. Set and adjust the Delay that occurs between the
triggering of the feed cycle and the start of the feed cycle
(Feed cycle is triggered by movement of ram or by
pressing ‘FEED’ button on display).
2. There are 9 Delays available as dened in Table III.
TABLE III
Delay
Selection
0 0
1 0.2
2 0.4
3 0.6
4 0.8
5 1
6 1.5
7 2
8 3
9 5
Approximate Delay
ADJUST LEFT / RIGHT
(seconds)
TA04864 E Page 7 of 13
Page 8
7.0
STOCK GUIDE
7.1
1. Bench Top Presses: Wire stop will allow user to insert the wire into the terminal/disconnect at correct depth (See
terminal/disconnect documentation for depth value).
2. Automated Presses: Wire stop will aid in the removal of the terminal/disconnect from ram tooling.
3. Adjustment: Height / Depth: Adjust to desired position with screws in locations shown.
7.2
Overview:
1. Sensor locates the position of the terminal/disconnect in relation to the
tooling.
2. Default position setting of ‘0’.
3. The terminal/disconnect is to be centered over the anvil for proper
crimp.
4. Adjust as needed to align center terminal/disconnect with tooling.
WIRE STOP ADJUSTMENTS
Wire Stop
Height
Adjustment
Screw
BACK END OF STOCK GUIDE
TERMINAL SENSOR ADJUSTMENT
Terminal Sensor
Depth
Adjustment
Screw
Adjustment:
1. Set position to ‘0’ (see section 6, step 6.4).
2. Loosen terminal sensor lock screws.
3. Adjust sensor left/right to move terminal/disconnect position left/right.
4. Tighten screw.
5. Visually conrm center of terminal/disconnect is in line with tooling.
Adjust Left / Right
Terminal Censor
Screw
FRONT OF STOCK GUIDE
C
L
Centered
Anvil
TA04864 E Page 8 of 13
Page 9
8.0
INDICATORS
POWER SUPPLY
8.1
8.1
1. The Power Supply indicator lights up green when
1. The Power Supply indicator lights up green when
power is on.
power is on.
Green Indicator.
Green Indicator.
8.3
Overview:
There are four LEDs on
1. TS: Toggles on-off as terminals pass the terminal sensor.
2. RS: Toggles on-off as the Ram moves up and down.
3. 5V: 5 Volt Supply.
4. 15V: Volt Supply
POWER SUPPLY
STATUS LED’s
Automated Crimping System that provide the status of supply, voltages, and sensors
8.2
1. The LEDs toggle on-off when the ram moves up and
down.
Automated
Crimping System
LED’s
RAM SENSOR
Ram Sensor
Location
Example of Ram Sensor
.
4. 15V
3. 5V
LEDs light up Green
2. RS
1. TS
Top View of
Automated Crimping System
TA04864 E Page 9 of 13
Page 10
9.0
MAINTENANCE
IMPORTANT: The
wear/damage and lubricated every (8) hours of operation.
IMPORTANT: For parts or service, contact the tool service center at (800) 284 - TOOL (8665).
WARNING: TURN OFF POWER.
9.1
IMPORTANT: DO NOT use solvents when
cleaning the
Tool Packs
Recommended Cleaning Aid: Clean cloth or equivalent
material.
1. Remove the Ram from the
System
2. Remove the Crimp Dial from the Ram.
3. Remove the tool pack from the
System
Assembly.
Assembly.
Automated Crimping System
CLEANING
Automated Crimping System
Automated Crimping
Automated Crimping
and tool packs should be cleaned, inspected for visible signs of
LUBRICATION
and
9.3
Recommended lubricant: NLGI #2 Grade Lithium
Complex EP grease or equivalent.
1. Apply light coating of lubricant to each corner of the
Ram.
2. Apply a light coating of lubricant to each corner of the
Ram Guide.
3. Remove any excess lubricant and re-insert Ram into
Assembly.
9.2
IMPORTANT: Portions of the tooling that make
contact during the crimping process are more
prone to visual signs of wear.
1. Remove the Tool Packs from the
Crimping System
2. Clean Tool Packs, refer to step 9.1 above.
3. Inspect Stock Guide Assembly and Ram Tooling for
visible signs of wear/damage.
4. Replace any worn/damaged parts.
INSPECTION
Automated
Assembly.
TA04864 E Page 10 of 13
Page 11
10.0
SPECIFICATIONS
10.1
Tool Pack
Automatic Crimping
System
Tooling Type Quick change Tool Pack.
Terminal Feed
Mechanism
Crimp Heights
(Both Conductor and
Insulator)
TABLE IV
Left-to-right side feed Tool Pack.
Stand-alone operation (no need for host controller)
Fits in most industry-standard presses with a shut height of 135.8 mm
Electronic / stepper motor
Delay - 10 selections, ranging from: 0 to 5 seconds
Speed - 9 selections, ranging from
• 6.35 to 76.2 (mm/sec)
• 0.25 to 3.0 (in/sec)
Position Offset from:
• ±12.7 mm in ±0.024 mm increments
• ±0.50” in ±0.01 increments
Range: 1.0 mm (0.039”) Max Adjustment.
Resolution: 0.015 mm (0.005”) Min. Adjustment.
Power Requirements Single Phase AC, 90 to 240 V @ 50-60 Hz
Temperature:
• 4 to 40 degrees Celsius
Environmental
• 40 to 104 degrees Fahrenheit
Humidity (non-condensing):
• 10% to 90% relative humidity
TA04864 E Page 11 of 13
Page 12
11.0
OPTIONS
11.1
OPTIONAL:
RIGHT WIRE GUIDE KIT.
( WIRE GUIDE SLOTS )
TNB197 - FUNNEL KIT ASSEMBLY
3. AIR LINES
2. FUNNEL KIT
ASSEMBLY
( GUIDE PINS )
1. WIRE GUIDE
ASSEMBLY
( LOCATE FUNNEL KIT )
ASSEMBLY:
1. Place wire guide assembly and secure.
2. Locate funnel kit onto the tool pack and align pins with wire guide slots.
3. Connect air lines.
( LEFT - WIRE GUIDE KIT IS SHOWN )
REFER TO:
TNBDOC16-11 FOR WIRE GUIDE KIT - LEFT
TNBDOC16-12 FOR WIRE GUIDE KIT - RIGHT
MATING AIR CONNECTION QUICK
*
COUPLER - USE BF63 FOR M4 TUBE
OR BF64 FOR M6 TUBE
WIRE GUIDE: FOR SIZING SEE
TABLE V ON PAGE 13.
TA04864 E Page 12 of 13
Page 13
11.2
TABLE V
WIRE GUIDE KIT (LEFT/RIGHT HAND) SELECTION GUIDE
TNBDOC16-11
LEFT HAND ASSEMBLY (30 DEG LEAD-IN)
Wire Guide Kit
TNB189-018
TNB189-022
TNB189-025
TNB189-031
TNB189-039
TNB189-050
TNB189-062
REF. AWG
22
20
18
16
14
12
10
TNBDOC16-12
RIGHT HAND ASSEMBLY (30 DEG LEAD-IN)
Wire Guide Kit REF. AWG Conductor Dia Wire Dia
TNB190-018
TNB190-022
TNB190-025
TNB190-031
TNB190-039
TNB190-050
TNB190-062
22
20
18
16
14
12
10
Conductor Dia Wire Dia
0.028 - .034
0.035 - .040
0.041 - 0.048
0.049 - 0.064
0.065 - 0.073
0.074 - 0.095
0.096 - 0.120
0.028 - .034
0.035 - .040
0.041 - 0.048
0.049 - 0.064
0.065 - 0.073
0.074 - 0.095
0.096 - 0.120
0.028 - .034
0.035 - .042
0.043 - 0.048
0.049 - 0.060
0.069 - 0.076
0.089 - 0.098
0.109 - 0.122
0.028 - .034
0.035 - .042
0.043 - 0.048
0.049 - 0.060
0.069 - 0.076
0.089 - 0.098
0.109 - 0.122
IN ORDER TO OBTAIN WARRANTY SERVICE YOU MUST REGISTER YOUR PRODUCT BY LOGGING IN ON
www.tnb.com/toolregistration. FAILURE TO REGISTER YOUR PRODUCT VOIDS ALL WARRANTIES.
Thomas & Betts Corporation
Thomas & Betts Corporation
Memphis, Tennessee
Memphis, Tennessee
www.tnb.com
© 2016 Thomas & Betts Corporation. All Rights Reserved. TA04864 E Page 13 of 13
www.tnb.com
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