854449-3

Instruction Sheet 408-- 9515 Ribbon Cable Notcher 854449- [ ] 30 DEC 09 Rev C Air Control Valve Retaining Ring (2 Places) Upper Die Plate Subassembly To Air Supply Cable Stop Plate Pressure Plate Pressure Plate Dowel Post (2 Places) Die Cable Support Plate Upper Tooling Guard Scrap Chute CABLE CONNECTOR NOTCH (mm [in.]) RIBBON CABLE C NOTCHER CENTERLINE (mm [in.]) SIZE (AWG) TYPE SIZE (Number of Positions) WIDTH OF WEB REMOVED 854449--1 2.54 [.100] 24--22 AMPMODU*, MT, MTE 2--28 1.27 [.050] 854449--2 2.54 [.100] 28--26 AMPMODU, MT, MTE, MTA 2--28 1.42 [.056] 854449--3 3.96 [.156] 24--18 MTA 2--24 1.80 [.071] 854449--4 2.54 [.100] 28--22 MTA 2--28 1.07 [.042] LENGTH End Feed Through 10.92 [.43] 20 32 [[.80] 20.32 80] Figure 1 1. INTRODUCTION Ribbon Cable Notcher 854449--[ ] is used to separate individual wires of ribbon cable for application onto the connectors listed Figure 1. NOTE i Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures are not drawn to scale. NOTE The ribbon cable notcher is designed to be used with any one of the following power units: — Manual Arbor Frame Assembly 58024--1 (408--6923) NOTE i — Pneumatic Applicator Frame Assembly 91112--2 (408--7763) — 2700--lb Pneumatic Power Unit 312522--1 (409--5843) with Adapter Kit 854468--2 (408--9687) — AMP--O--LECTRIC* Model “K” Terminating Machine 2--565435--2 or 565435--5 (409--5128) with Adapter Kit 854468--1 (408--9687) This frame assembly is not recommended for use on connectors with more than 14 positions. i Machine 565435--5 is no longer available for new applications, but can still be used for existing applications. For operation and adjustment of the power units, refer to the instruction sheet (408--series) or customer manual (409--series) included with the power unit. Reasons for reissue of this instruction sheet are provided in Section 8, REVISION SUMMARY. TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2009 Tyco Electronics Corporation, Harrisburg, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 All International Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 5 LOC B 408- 9515 Ribbon Cable Notcher 854449- [ ] 1.1. European Regulatory Information A technical file document, as required by the Supply of Machinery (Safety) Regulations 1992, has been prepared for Ribbon Cable Notcher 854449--[ ] for use with Pneumatic Applicator Frame Assembly 91112--2 and 2700--lb Pneumatic Power Unit 312522--1. These components are CE approved only when used in conjunction with each other, and are not approved separately. Refer to Product Drawing 356767 for Declaration of Conformity. 1.2. Noise Level The noise level generated by the combination of the ribbon cable notcher and the following power units are: The scrap chute and air control valve is used for scrap removal. The cable stop plate positions the cable for end notching. 3. PRESSURE PLATE ADJUSTMENT Due to dimensional variations in ribbon cable, it might be necessary to adjust the height of the pressure plate. Four brass laminated shims (0.051 [.002] per lamination) have been provided to adjust the height of the pressure plate. The ribbon cable should fit snugly under the pressure plate with a slight drag and no side--to--side movement. If adjustment to the pressure plate is required, refer to Figure 2, and proceed as follows: 1. Remove the guard. Remove the retaining rings and upper die plate subassembly. POWER UNIT NOISE LEVEL RANGE (dB) Pneumatic Applicator Frame Assembly 91112--2 82--88 2. Carefully remove the upper tooling and compression springs. 2700--lb Pneumatic Power Unit 312522--1 86--90 3. Remove the pressure plate and curved spring washers. 4. Peel and place shims under the curved spring washers as necessary. Both curved spring washers must have an equal amount of shims. Noise levels generated by periodic depression of the air control valve are in the range of 104 to 106 dB. 5. Re--assemble the notcher, making sure that the compression springs are properly seated in the counterbores. 2. DESCRIPTION The ribbon cable notcher consists of a cable support plate, pressure plate, upper tooling, die scrap chute, air control valve, upper die plate subassembly, and cable stop plate. See Figure 1. 4. INSTALLATION AND REMOVAL (Manual Arbor Frame and Pneumatic Applicator Frame) The cable support plate provides initial alignment of the ribbon cable in the notcher. The pressure plate aids in positioning the cable during the notching process. The upper tooling and die notches the cable. Refer to the instructions included with the corresponding adapter kit for installation and removal of the notcher for the pneumatic power unit and the terminating machine. Compression Springs Pressure Plate Adjustment Retaining Rings Pressure Plate Pressure Plate Curved Spring Washer (2 Places) Shim(s) Upper Tooling Figure 2 2 of 5 Tyco Electronics Corporation Rev C 408- 9515 Ribbon Cable Notcher 854449- [ ] Orientation of Ribbon Cable Notcher for End Notching Manual Arbor Frame (Ref) Cable Support Plate Only Orientation of Ribbon Cable Notcher for Feed- Through Notching Cable Support Plate Figure 3 4.1. Installation 2. Place the cable on the cable support plate, and align the cable with the flutes of the plate. 1. Raise the ram to the top of its stroke. 2. Remove the four socket head cap screws from the underside of the notcher. 3. Place the notcher on the base of the frame, oriented according to type of notching. Refer to Figure 3. Install the four socket head cap screws onto the notcher from the underside of the frame. 3. Slightly press down on the cable (to keep the cable aligned with the flutes in the plate), and slide the cable into the notcher until it butts against the cable stop plate. Refer to Figure 4. Slightly Press Down on Cable 4. Set the ram height on the frame: 69.8 [2.75] for end notching or 65.8 [2.59] for feed--through notching. For procedure, follow the instructions included with the frame. 4.2. Removal 1. Remove the four socket head screws from the underside of the notcher. 2. Slide the notcher out from the base of the frame. Flutes in Cable Support Plate 5. OPERATION CAUTION ! To avoid personal injury, make sure that the guard is in place when operating the notcher. ! 6. Refer to Figure 5, and inspect the cable according to the specifications listed in Figure 1. Make sure that the ram height is set at 69.8 [2.75]. 5.2. Feed- Through Notching 1. Loosen the two socket head screws securing the cable stop plate, and locate the cable stop plate against the dowel posts. Tighten the screws. Rev C 4. Cycle the power unit. 5. Remove notched end of cable by pulling the cable straight back and out of the notcher. 5.1. End Notching CAUTION Figure 4 CAUTION ! Tyco Electronics Corporation Make sure that the ram height is set at 65.8 [2.59]. 3 of 5 408- 9515 Ribbon Cable Notcher 854449- [ ] End Notch Feed- Through Notch Width of Web Removed Width of Web Removed Notch Length Notch Length Figure 5 CAUTION ! Make sure that the notcher is oriented in the power unit as shown in Figure 3. 1. Remove the two socket head screws securing the cable stop plate, and remove and store the cable stop plate. CAUTION ! DO NOT bend or otherwise damage the cable stop plate during removal. 2. Place the cable on the cable support plate, and align the cable with the flutes of the plate. 3. Slightly press down on the cable (to keep the cable aligned with the flutes in the plate), and slide the cable into the notcher until desired length. Refer to Figure 4. 4. Cycle the power unit. 2. Periodically depress the air control valve button to remove scraps. Depress the button for a maximum of two seconds. 6. MAINTENANCE AND INSPECTION 6.1. Daily Maintenance It is recommended that each operator be responsible for the following four steps of daily maintenance: 1. Remove dust, moisture, and outer contaminants with a clean, soft brush or a soft, lint--free cloth; or clean the notcher with compressed air. DANGER Compressed air used for cleaning must be reduced to less than 206.8 kPa [30 psi]. Effective chip guarding and personal protective equipment (including eye protection) must be used. 2. Make sure that the upper tooling is in place and secure. 5. Advance the cable to the location of the next notch. 3. Lubricate the upper tooling dowel pins and pressure plate dowel posts daily with an extreme pressure (EP) lithium grease or equivalent. DO NOT lubricate excessively. 6. Remove the cable by pulling the cable either straight front or back and out of the notcher. NOTE 7. Refer to Figure 5, and inspect the cable according to the specifications listed in Figure 1. 4. When not in use, store the notcher in a clean, dry area. 5.3. Scrap Removal The frequency of scrap removal will depend on the number of notches. DANGER Compressed air used for scrap removal must be reduced to less than 206.8 kPa [30 psi]. Effective chip guarding and personal protective equipment (including eye protection) must be used. 1. Connect the air control valve to a suitable air supply. 4 of 5 i For location of components, refer to the drawing included with the notcher. 6.2. Periodic Inspection Regular inspection should be performed by quality--control personnel. A record of scheduled inspections should remain with the notcher or be supplied to personnel responsible for notcher. Though recommendations call for at least one inspection a month, the frequency should be based on amount of use, working conditions, operator training and skill, and established company policies. Tyco Electronics Corporation Rev C 408- 9515 Ribbon Cable Notcher 854449- [ ] 6.3. Visual Inspection 1. Remove all lubrication and accumulated film by immersing the dies in a suitable commercial degreaser that will not damage the dies. 2. Make certain all components are in place. 3. Check all surfaces for wear. Replace worn parts. 4. Inspect the upper tooling and dies for flattened, chipped, or broken areas. 7. REPLACEMENT AND REPAIR NOTE i For location of parts and replacement component part numbers, refer to the drawing included with the notcher. 4. Remove the pressure plate and the four compression springs. 5. Locate the cable stop plate against the pressure plate dowel posts. Secure the cable stop plate with the two socket head cap screws. 6. Place new upper tooling onto the upper die plate subassembly, and insert, but do not tighten, the socket head cap screws. Slide the upper die plate subassembly onto the pressure plate dowel pins. NOTE Replacement parts are listed in Figure 6. Parts other than those listed should be replaced by Tyco Electronics to ensure quality and reliability. Order replacement parts through your representative, or call 1--800--526--5142, or send a facsimile of your purchase order to 717--986--7605, or write to: CUSTOMER SERVICE (038--035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105--3608 DESCRIPTION i Make sure that the upper tooling is properly oriented. 7. Gently lower the upper die plate subassembly until the upper tooling is fully engaged in the die. Tighten the two socket head cap screws that secure the upper tooling. Remove the upper die plate subassembly. 8. Re--install the pressure plate, compression springs, and upper die plate subassembly. REPLACEMENT PARTS PART NUMBER 3. Remove the two socket head screws securing the upper tooling to the upper die plate subassembly. Remove the retaining ring, upper die plate subassembly, and upper tooling. Note orientation of upper tooling. NOTE QTY PER NOTCHER i Make sure that the compression springs are properly seated in their counterbores. 854438--1 PLATE, Pressure, 2.54 [.100] 1 854443--1 PLATE, Pressure, 3.96 [.156] 1 7.2. Repair SPRING, Compression 4 SUBASSEMBLY, Upper Die Plate 1 For customer repair service, contact a representative at 1--800--526--5136. 23846--7 854435--1 Figure 6 8. REVISION SUMMARY 7.1. Upper Tooling Replacement Revisions to this instruction sheet include: S Updated instruction sheet to corporate 1. Disconnect power from the power unit. 2. Remove the notcher from the power unit. Rev C requirements Tyco Electronics Corporation 5 of 5