IDEAL ACAM Manuel utilisateur

Automatic Connector Application

Machine (ACAM)

Trouble Shooting Guide

1330 E Lincoln Hwy, DeKalb, IL 60115 U.S.A.

Ajax, Ontario L1S 2E1 CANADA

Warrington, Cheshire WA5 5TN ENGLAND

Technical Assistance: 1-877-201-9003

7:00 am - 3:30 pm CST M-F

www.idealindustries.com

LA2418-1 P-664 8/04 Printed in U.S.A.

ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide

This is the ACAM Troubleshooting Guide. When used in conjunction with IDEAL

ACAM Set-up and Instruction Manual, it offers a comprehensive maintenance and

repair system. Refer to the ACAM Instruction Manual for detailed explanations of

"Solutions" listed in the ACAM Trouble Shooting Guide.

Through the ACAM Troubleshooting Guide, you will see "Reference" listed. Refer to

the inside back page for detailed address and phone number information for IDEAL

Technical Services / Engineering Applications Service, Customer Service, Quality

Hotline and your OEM Sales Specialists.

Quick Guide

I. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pages 1 to 4

Connector won't tighten completely

Connector won't tighten at all

Finished connection doesn't have twists

Stripped wire twists off

Stripped wire is exposed

ACAM won't turn on

Electronic board will not function

Hand tool stops before completing connection

Connector is backward

Connector falls out of hand tool

Connector is jammed

II. Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pages 4 to 7

Connector jammed in bowl

Connectors spilling out of bowl

Bowl will not stop vibrating

Vibration of bowl is inconsistent

Wire connector does not reach hand tool

III. Wire Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pages 7 and 8

Connector has no spring

Connector separates from spring

IV. Reference Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9

Connector won't tighten completely

V. Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back cover page

Automatic Connector Application Machine

Optional Accessories

General Trouble Shooting Guide

Situation

If the wire connector won't tighten completely...

Possible Cause: Solution:

Torque adjustment too low. Check torque range (high vs. low)

and adjust torque level upward by

increments of 5 until connector

tightens correctly.

Gun is out of adjustment Adjust hand tool. Check to see if

finger receiving washer is correctly

positioned as hand tool is adjusted.

Incorrect strip length of wires Check with IDEAL for recommended

strip length. (Reference #1.

Situation:

If the wire connector won't tighten at all...

Possible Cause: Solution:

Hand tool is out of adjustment Adjust hand tool.

Disassembled, damaged or Repair or replace as needed.

broken drive shaft Check set-screws making drive shaft

connections.

Using wrong connector for machine Check machine number to connector

used. Reference #1.

Incorrect strip length of wires or Check with IDEAL for recommended

incorrect connector for strip length wire and wire connector

combinations for your specific wire size, insulation

and combinations. Reference #1.

Hand tool friction is set too low Increase hand tool friction setting on

keypad up to a maximum of 250.

ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide

Situation:

If the finished connection doesn't have 1 to 3 wire twists below

connector skirt...

Possible Cause: Solution:

Torque set too low Increase torque setting.

Wire strip length may be too short Increase the strip to the

recommended length. Reference #1.

Operator technique Receive training on operation of

ACAM. REference #4.

Improper connector model for wire Check with IDEAL to see if wire

combination combination is listed for the

specific connector. Reference #1.

Hand tool not properly adjusted Adjust hand tool.

Situation:

If the stripped length of wire twists off when the wire connector is

applied...

Possible cause: Solution:

Torque may be set too high Decrease your torque setting.

Possible wrong connector for Check with your IDEAL OEM Sales

application Specialist or IDEAL Application

Engineering Service for correct

connector for application. Reference

#1 or #4.

Strip length of wires may be too Increase strip length so that no wire

short is exposed below the bottom of the

connector. Reference #1.

Using extremely "soft" wire Some lots of wire are soft and do

not allow for a connection to be

made. Consider alternate wires.

Hand tool may be out of adjustment Adjust hand tool.

Situation:

If the stripped wire is exposed below the bottom of the wire

connector skirt...

Possible Cause: Solution:

Wire strip lengths may be too long Shorten strip to recommended

lengths. Reference #1.

Wire strip lengths may be too long Use a longer skirted connector.

Reference #1.

Operator technique may be incorrect Receive training on operation of

ACAM. Reference #4.

May have the incorrect connector Reference #1.

for the application

Connector is not fully seated on Adjust torque level.

combinations

Several strands of a stranded wire Pre-twist stranded combinations.

have turned back within the

connection

Situation:

If the ACAM AM will not turn on or electronic module won't

function...

Possible cause: Solution:

Fuse at power cord may be blown Replace fuse.

CPU Module may have received a Replace CPU Module. Always protect

surge, spike or static energy your ACAM with surge protected

outlets or strips or a power

conditioner.

Power not getting to ACAM Check power source for correct

voltage.

Bad connections between Check connections.

electronic module

ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide

Hand Tool Trouble Shooting Guide

Situation:

If the hand tool stops before completing the wire connection...

Possible cause: Solution:

Drive cable is building up excessive Check cable at machine and hand

resistance tool connection, adjust torque level

and grease drive cable.

Torque level set too low Check torque range (high vs. low)

and adjust torque level upward.

Hand tool adjustment is set too tight Adjust hand tool barrel assembly

clockwise.

Connector jammed in the hand tool Unjam hand tool by removing the

connector.

Hand tool friction set too low Increase hand tool friction setting on

keypad up to a maximum of 250.

Situation:

If the wire connector is backward in hand tool or shaft...

Possible cause: Solution:

Vibration is set too high Lower vibration adjustment(s) - fine

tune vibration adjustment on side of

ACAM and/or course adjustment

directly under ACAM motor center

base plate.

Debris in ejector is tripping Remove debris from ejector.

connector

Trip screw in alignment ramp is Lower screw on alignment ramp

too high that trips the connectors.

Alignment ramp misaligned Realign alignment ramp.

Situation:

If the wire connector falls out of hand tool...

Possible cause: Solution:

Retaining spring is worn out or Replace U-shaped retainer spring.

missing

Front barrel is adjusted too tight Loosen barrel adjustment.

Situation:

If the wire connector is jammed in hand tool...

Possible cause: Solution:

Connector is in the hand tool Squeeze front retaining spring on

backward hand tool to release connector.

Hand tool is dirty Preventive maintenance - clean hand

tool

Connector that fell on the floor and Be careful not to place debris or

was stepped on was placed back deformed connectors into

into hopper or bowl machine.

Flash on the connector Use only the family of IDEAL

Wire-Nut® Wire Connector products.

Reference #3 and #4.

Hand tool is improperly adjusted Adjust hand tool.

ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide

Feed System Trouble Shooting Guide

Situation:

If the wire connector is jammed in bowl...

Possible cause: Solution:

Feed tube is out of alignment Align feed tube or barrel.

Something in system is physically Check for connector caught in bowl

impairing connector movement track, connector or debris blocking

alignment ramp or feed tube.

Telescoping connectors have formed Break up the jam and adjust vibration

a bridge across the bowl as needed.

Bowl may - in some instances - Lightly sand the interior of the bowl.

form rough edges causing the

connectors to hang up in the bowl

Situation:

If the wire connectors are spilling out of the bowl...

Possible cause: Solution:

Operator has placed too many Reduce quantity of connectors in

connectors directly into bowl bowl.

Hopper is feeding too many Check height of Capacitive Proximity

connectors into bowl sensor and adjust proximity switch.

Capacitive Proximity sensor should

have approximately 3-6 threads

exposed on top of upper nut. Adjust

sensitivity screw on proximity level

sensor as outlined in manual.

Hopper gate may be open Check hopper operation, especially

hopper gate area. See if solenoid

cycles in the test mode. Also, check

vibrator module. Replace solenoid or

vibrator module if needed.

Connector is jammed at entrance to Align feed tube with alignment ramp.

feed tube

Situation:

If the bowl will not stop vibrating...

Possible cause: Solution:

Faulty hopper, solenoid, vibrator Replace components as needed. Turn

module or connector adapter ACAM off, then on to reset,.

Level sensor incorrectly set, Correctly set proximity level sensor.

incorrectly positioned or faulty Replace as needed.

Level sensor may be dirty Clean as needed.

ACAM may be in test mode Push Clear button several times. Turn

ACAM off, then on.

Connector may be hung up in Locate and remove jammed

system connector.

Situation:

If the vibration of feeder bowl is inconsistent...

Possible cause: Solution:

Course vibration adjustment nut Tighten the course vibration nut

under ACAM may be loose under the CAM motor centerbase

plate.

Fuse in the switch is turned to the Turn fuse to 110V position.

220V position causing the machine

to vibrate at 1/2 speed

Erratic voltage in the line to the Use a voltage power conditioner.

ACAM Reference #4.

10 11

ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide

Situation:

If the wire connector does not make it to the hand tool...

Possible cause: Solution:

A connector may be jammed in Unjam the connector.

some location

A connector may not be able to Straighten tube. Check stand height

fall down the end tube and raise as needed.

There is a kink in the feed spring Repair or replace as needed.

assembly

Wire Connector Trouble Shooting Guide

Situation:

If the wire connector has no spring in it...

Possible cause: Solution:

Using an All-Plastic wire connector There is a type of wire connector that

has no spring. It is correct to use on

specific applications. Contact your

IDEAL OEM Sales Specialist if

alternative types of wire connectors

are needed. Reference #4.

Check original manufacturer of Only IDEAL wire connectors are

wire connector designed to work with IDEAL

ACAMs. If your connector is

supposed to have a spring in it and

doesn't, remove the connectors.

Reference #3. ACAMs are leased to

facilitate the efficient application of

IDEAL wire connectors only.

Situation:

If the wire connector shell separates from spring during assembly...

Possible cause: Solution:

Inferior competitive connectors Use only IDEAL wire connectors in

used in place of IDEAL the ACAM. REference #4.

Torque setting too high Lower torque setting.

Incorrect wire combination for Consult your OEM connector guide

connector for the correct combination for each

connector or contact your IDEAL

OEM Sales Specialist or contact

IDEAL Technical Service.

Reference #4.

Any other situation Reference #3

Notes:

12 13

References

For additional information, contact:

Reference #1 -- Technical Service/Engineering Application Service

Ph: 800.338.4495 Ph: 815.895.5181

Fax:815.895.9470 Fax:800.533.4483

For assistance with ACAM leases, troubleshooting, replacement parts and

part drawings. To get assistance on which connector to use, recommended

strip lengths and UL/CSA-approved wire combinations.

Reference #2 -- Customer Service

Ph: 800.435.0705 Ph: 815.895.5181

Fax:815.895.9470 Fax:800.533.4483

To place or expedite an order, check shipping dates, receive proof of

delivery, or to order replacement parts.

Reference #3 -- Quality Hotline

Ph: 800.435.0705, ext. 100 Ph: 815.895.5185, ext. 100

To report any problem related to the product, packaging, delivery, or

service.

Reference #4 -- OEM Sales Specialists

Ph: 800.435.0705 Ph: 815.895.5181

To receive ACAM demonstrations, field service, operator training, product

samples, and pricing information.

Reference #5 -- Tech Support Hotline

Ph: 877-201-9003

IDEAL INDUSTRIES, INC.

Becker Place

Sycamore, IL 60178-2499

www.idealindustries.com

Ordering Information

Automatic Connector Application Machine

Connector Model No. ACAM Cat.No

71B® Gray 30-971

72B® Blue 30-972

73B® Orange 30-973

74B® Yellow 30-974

76B® Red

341® Tan Twister®

342® Gray Twister®

High Temperature Model

71B® Black 30-971

72B® Black 30-972

73B® Black 30-973

59B® Black

Optional Accessories

Description Cat.No.

Adjustable Mounting Stand 2-9053

Bench Mount and Foot Switch 30-984

Auxiliary Hopper 30-951

ACAM Trouble Shooting Guide ACAM Trouble Shooting Guide

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