TE Connectivity OCEAN 2.0 User manual

Instruction Sheet

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*Trademark

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.

PRODUCT INFORMATION

1-800-522-6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com.

408-35042

08 APR 19 Rev C

1. INTRODUCTION

The OCEAN 2.0 side-feed applicators are available with either a mechanical terminal feeder or a pneumatic

terminal feeder assembly. Each style of applicator accepts side-feed strip terminals and applies pre-stripped

wires.

NOTE

Dimensions in this instruction sheet are in metric units [with U.S. customary units in brackets]. Figures are not drawn to scale.

NOTE

This instruction sheet, the exploded-view drawing with the associated parts list packaged with the applicator, along with the

applicable customer manual provide all the information required to operate and maintain the applicator and machine.

Following is a list of the terminating machine customer manuals that apply:

409-5128 Basic AMP-O-LECTRIC* Machine

409-5207 or 409-5289 Model “T” Terminating Unit

409-5842 Model “G” Machine

409-10047 AMP 3K* Machines 1725950-[ ] and AMP 5K* Machines 1725900-[ ]

409-10099 AMP 3K/40* Machines 2119683-[ ] and AMP 5K/40* Machines 2119684-[ ]

NOTE

Refer to Instruction Sheet 408-350051for translations of the Safety Warnings specified herein.

2. DESCRIPTION

Overview

1. Main components of the mechanical and air feed applicators are identified in Figures 1 and 2,

respectively.

Figure 1

1Future Release

OCEAN 2.0 Side-Feed Applicators

Mechanical Feed Applicator

Base Plate

Side-Feed Strip-Form

Terminals

Rear Strip Guide Plate

Mechanical Terminal

Feeder Assembly

Mounting Screw (2 Places)

Feed Pawl

Ram Assembly

Applicator Housing

Front Strip Guide Plate

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Figure 2

2. Each applicator is individually designed for specific terminals. The wire crimp height and insulation

crimp height can be adjusted to accommodate different wire sizes and insulation ranges. The

applicator is also designed to accept modular-feed packages.

Figure 3

Air Feed Applicator

Air Supply

Connection

Retract Speed Control

Forward Speed Control

Feed Arm

Feed Pawl

Pneumatic Terminal

Feeder Assembly

Mechanical Terminal

Feeder Assembly

Mounting Screw (2 Places)

Ram Assembly

Applicator

Housing

Pneumatic Terminal

Feeder Assembly

Front Strip Guide Plate

Rear Strip Guide Plate

Base Plate

Vertical Etched Line

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Rev C

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3. The OCEAN applicator can be used in various machines; provided the machine has the proper stroke

length and all the necessary equipment.

There are two basic applicator design styles; Atlantic and Pacific, to meet the many terminator and

leadmaker configurations worldwide (see Figure 4).

Figure 4

NOTE

The Pacific applicator will work only when used with a machine having a ram that falls within the dimensional envelope shown

in Figure 5.

Figure 5

Atlantic

Machine Ram for

Ram Post Adapter

Basic Applicator Design Styles

Pacific

Machine Ram for

Ram Post Adapter

Wire Crimp Disc

Ram Clamp

Ram Post

Insulation

Crimp Dial

Insulation Crimper

Front Shear Depressor

Crimper Bolt

Front Shear Depressor

Wire Crimper

Insulation Crimper

Note:

Dimensions are in millimeters with inches in brackets.

Pacific Applicator Requirements

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4. Though the Atlantic and Pacific applicator ram and base plate interfaces are different, most of the

OCEAN 2.0 features and adjustments are the same.

The terminal strip must be fed into the applicator with the wire barrels facing out; between the Front

(outer) and Rear (inner) Strip Guides. The terminal strip passes the Stock Drag, and the lead terminal

is positioned 1) over the Anvil for pre-feed applicators, or 2) one terminal length from the Anvil for

post-feed applicators. The Feed Pawl will feed one terminal during each cycle of the machine. The

Ram Post (also referred to as the Ram Mounting Post) will engage the Post Adapter of the machine

ram, and the machine ram will actuate the applicator.

The Wire Crimp Disc is located just below the ram post interface, which is designed with a spring-

loaded adjustment mechanism for precise crimp height adjustment in increments of 0.01 mm [.0004

in.]; with a total adjustment range of 1.45 mm [0.057 in.]. By rotating the Wire Crimp Disc, the ram

interface raises and lowers relative to the applicator housing. The indicator notch of the ram points to

the numbers on the outer diameter of the Wire Crimp Disc, indicating a relative crimp height.

The Wire Crimper is held in a pre-set position by the Ram and the Crimper Bolt. The Insulation

Crimper and the Front Shear Depressor are also held by the Crimper Bolt. The Insulation Crimper is

free to move up and down so the insulation crimp height can be adjusted via the Insulation Crimp Dial

by pulling the spring-loaded dial outward slightly and rotating to a different number.

The applicator mounting surface is the base plate. The Anvil, Front Shear Holder, Terminal Support,

Strip Guide Plate, and applicator housing are mounted on the base plate. The Stock Drag, and Front

and Rear Strip Guides are mounted on the Strip Guide Plate.

Terminals with dual-carrier strips

When terminals with dual-carrier strips are to be processed, an additional Shear Depressor, Rear

Shear Holder, and Rear Floating Shear are required. The Rear Shear Depressor will push the Rear

Floating Shear down to cut the terminal from the rear carrier strip and the Terminal Hold-Down will

keep the terminal from raising during the crimping and shearing process. The Rear Floating Shear

and Rear Shear Holder are mounted on the base plate.

Figure 6

Rear Shear Holder

Rear Floating Shear

Rear Shear Insert

Front Shear Holder

Front Shear Insert

Front Floating Shear

408-35042

Rev C

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5. Lubrication

Some terminal strips require the use of a terminal lubricant. Wick-type lubricators apply lubricant to the

terminal strip as it feeds into the applicator. Terminal lubricants reduce tooling wear and help reduce

damage to the plating on some terminals.

OCEAN applicator, Side-Feed Lubricator Assembly PN 2119955-1 is available.

For rear-carrier style terminals, Lubricator Assembly PN 2119955-5 is available.

CAUTION

Depending on the final use of the crimped terminal, terminal lubrication is not always recommended. To determine if your

applications warrant the use of a terminal lubricator, contact your Field Representative.

NOTE

If your application warrants the use of a terminal lubricator, the recommended lubricant is Stoner Mechanical Lubricant E807

available from Stoner, Inc. Call 1-800-227-5538 or visit www.stonersolutions.com.

Applicator with Mechanical Feed System

With a Mechanical Feed applicator, the terminals are fed by the action of the Feed Cam and a series of rods

and levers, which move the Feed Pawl. Two feed cams are available (Pre-Feed and Post Feed) and can be

mounted in two different mounting holes depending on machine stroke length and feed type (see Figure 7).

The Post-Feed feed cam advances the lead terminal over the Anvil on the downward stroke of the ram

assembly; leaving the Anvil clear when the machine is at rest.

The Pre-Feed feed cam advances the lead terminal over the Anvil on the upward stroke of the ram assembly;

leaving a terminal over the Anvil when the machine is at rest.

NOTE

When not in use, the spare Feed Cam can be mounted to the applicator housing in the spare feed cam storage location (see

Figure 8).

NOTE

Pacific applicators can only be used with 30-mm stroke machines and, therefore, only have the 30-mm feed cam mounting

positions on the applicator ram.

Figure 7

Mounting Feed Cam (Atlantic Applicator w/Mechanical Feed shown)

40-mm [15/8-in.] Stroke Machine

30-mm [11/8-in.] Stroke Machine

Pre-

Feed

Pre-

Feed

Post-

Feed

Post-

Feed

Mounting

Screw

(typ)

Mounting

Screw

(typ)

Mounting

Screw

(typ)

Mounting

Screw

(typ)

408-35042

Rev C

6 of 26

Figure 8

Applicator with Air Feed System

NOTE

The air supply connection (shown in Figure 2) must be connected to an air supply line providing continuous pressure of 5.00 to

6.00 bars [72 to 87 psi] at the applicator.

NOTE

NO oil lubrication of air for the OCEAN Air Feed module is required after receiving and use within a production environment.

The ram continues downward, completes the crimping action, and starts back up. As it approaches the fully

raised position, the push rod drops off the high portion of the ram mounted cam, shifting the air feed valve. The

extend side of the cylinder is then filled, moving the feed pawl and terminal strip over the anvil for the next

cycle. The exhaust control valves control the speed of the feed stroke and retract stroke.

Though all air feeds are pre-feed type, the feed cam position can be changed for use in different stroke

machines: 40-mm [15/8-in.] stroke or 30-mm [11/8-in.] stroke (refer to Figures 7 and 9).

Note that the air feed requires a different cam than the mechanical pre-feed or post-feed.

Figure 9

Air Feed Cam

Installed

Pre-Feed

Mounting Screw

Air Feed Cam

Installed

Pre-Feed

Mounting Feed Cam (Atlantic Applicator w/Pneumatic Feed shown)

40-mm [15/8-in.] Stroke Machine 30-mm [11/8-in.] Stroke Machine

Spare Feed Cam Storage Location

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3. APPLICATOR INSTALLATION AND REMOVAL

DANGER

To avoid personal injury, make sure the power and air source to the machine is turned OFF and power cord/air supply are

disconnected before installing or removing the applicator.

NOTE

Always remove the Ram Transportation Collar after installing the applicator on a machine and be sure to install the Ram

Transportation Collar back onto the applicator ram just prior to removing the applicator from the machine.

NOTE

With the applicator in the machine, never attempt to cycle machine under power without terminals properly loaded, as

described in Section 4; otherwise, the tooling may be damaged.

DANGER

To avoid personal injury, the applicator should be used only in an appropriate terminating machine. The pressurized air supply

should only be connected after the applicator is properly installed in the terminating machine.

AMP-O-LECTRIC Machine and Model “K” Machine (with Mini-Applicator Conversion)

A. Installation

This machine must be equipped with Machine Conversion Kit PN 690675-2 to adapt it for use with the

OCEAN 2.0 applicators. The kit includes applicator Instruction Sheet 408-8022, which explains how an

applicator with mechanical feed is installed and removed from the machine.

B. Removal

1. Turn off, and disconnect, the power to the machine.

2. Unload the applicator as described in Section 4.

3. Remove the Hold-Down Bracket and Movable Stop, then slide the applicator away from the stop on

the base mount until the Ram Post is clear of the machine ram.

Model “T” Terminating Unit

NOTE

For the Atlantic Applicator only.

A. Installation

1. Turn off and disconnect the power to the machine.

2. Push in the Release Bar on the quick-change base plate. The Locking Latch will pivot downward.

3. Place the applicator on the quick-change base plate, then slide it back until two notches engage the

stops at the back of the plate. At the same time, guide the Ram Post into the Ram Post Adapter.

4. Flip the Locking Latch up to secure the applicator in place.

B. Removal

1. Disconnect the power cord.

2. Cut the terminal strip one or two terminals from the end of the applicator.

3. Push in the release bar on the quick-change base plate. The Locking Latch will pivot downward.

4. Slide the applicator forward until it is clear of the Ram Post Adapter.

408-35042

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Other Terminating Machines

For installation and removal procedures for the basic AMP-O-LECTRIC machine, Model “G” machine, AMP 3K

and AMP 5K machines, and AMP 3K/40 and AMP 5K/40 machines, refer to the appropriate 409 Series

Customer Manual specified in Section 1.

For installation and removal procedures for terminating machines not listed, refer to the customer

documentation supplied with the machine.

NOTE

Adjustment of the Stripper may be required when moving the applicator between bench and leadmaker applications.

4. APPLICATOR LOADING AND UNLOADING

Terminal Strip Loading

NOTE

Before loading the terminal strip in applicator, make sure the installed applicator is the right one for the terminal to be applied.

Compare the terminal part number on the reel with the numbers listed on the applicator print.

1. Turn off and disconnect the power to the machine.

2. Make sure the ram assembly is all the way up. If necessary, hand-cycle the machine to raise the Ram.

Refer to the applicable 409 Series Customer Manual.

3. Remove the applicator guard assembly.

4. Raise the Stock Drag by turning the Drag Release Lever upward. Remove a length of the terminal

strip left in the applicator by grasping the terminals at the strip guide entry, raising the Feed Pawl, and

pulling the strip straight out of the applicator (see Figure 10).

5. With the reel of terminals installed on the Reel Support, feed the terminal strip into the applicator

between the Strip Guides.

NOTE

Make sure the terminal strip enters the Strip Guides with the terminal open-side up and the wire barrel end toward the Stock

drag.

6. Raise the Feed Pawl and continue to feed the terminal strip until the lead terminal is over the Anvil

and the Feed Pawl engages the hole in the carrier strip.

Figure 10

Stock Drag

Drag Release Lever

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7. If terminals are post-feed, lift the Feed Pawl and pull the strip back one terminal length (the lead

terminal will then be moved over the Anvil on the downward stroke of the ram assembly).

8. Turn the Drag Release Lever downward to lower the Stock Drag.

9. Make sure the tip of the Feed Pawl is in the feed hole in the carrier strip.

NOTE

Some carrier strips have additional holes which are not used for feed purposes.

10. Hand-cycle the machine several times to make sure the applicator is properly adjusted as described in

Section 5.

11. Re-install the applicator guard assembly.

Terminal Strip Unloading

1. Cut the terminal strip one or two terminals from the end of the applicator.

NOTE

The applicator should never be unloaded unnecessarily. A section of terminal strip should always be left in the unit. Since it is

not necessary to remove the strip section for cleaning, lubrication, or repair, it should only be removed as a part of the loading

procedure.

2. If terminals are post-feed, turn the Drag Release Lever upward to raise the Stock Drag, lift the Feed

Pawl, and move the lead terminal over the Anvil.

5. ADJUSTMENTS

Wire Crimp

A. Crimp Height

1. The wire crimp is adjustable by rotating the Wire Crimp Disc from 0 (largest crimp height) to 14.5

(smallest crimp height) in increments of .01 mm [.0004 in.].

2. Select a crimp height reference setting number from 0 (largest crimp height) to 14.5 (smallest crimp

height) from the applicator print for the wire size to be used.

3. Turn the Wire Crimp Disc to line up with the specified crimp height reference setting number with the

indicator notch/cut out on the front of the Ram (see Figure 11).

4. Turn the Wire Crimp Disc clockwise to decrease the crimp height and turn the Wire Crimp Disc

counterclockwise to increase the crimp height. Each increment represents a change in crimp height of

0.01 mm [.0004 in.].

Figure 11

Wire Crimp Disc

Indicator Notch/Cut Out

Insulation Crimp Dial

408-35042

Rev C

10 of 26

5. Make the insulation crimp adjustment described in Paragraph 5.2, then make several test cycles and

inspect the terminations closely. Look for rough or sharp edges around the crimped barrels (flash),

deformed crimps, bent terminals, or other defects caused by worn or broken tooling. If necessary,

replace tooling as described in Section 6.

—If the terminations appear normal, measure the crimp height of each termination as described in Instruction Sheet 408-

7424, packaged with the applicator. The crimp height must agree with the measurement specified on the applicator print

for the wire size being used. Record crimp height dimensions for reference.

—If the crimp height is incorrect, remove the applicator, and install one that is known to produce terminations of correct

crimp height. Make several test cycles and repeat the inspection. If the crimp height is incorrect for this applicator, the

problem is the machine shut height, and corrective information can be found in the applicable 409 Series Customer

Manual. If the crimp height is correct, the problem is in the original applicator, and refer to Paragraph 6.7; Adjustable

Crimp Height Repair, for corrective measures.

6. During extensive operation, periodically inspect the terminals as described in Step 4 to make sure the

applicator is producing correct terminations.

B. Wire Crimp Adjust Lock Position

1. The wire crimp height adjusts can be locked in position by changing the Detent Pin orientation (see

Figure 12).

Verify the setup dimension (distance from Crimper Seating Feature on the Ram) to the top of the

Crimp Height Adjust Head (see Figure 13).

NOTE

This distance is also provided on the Applicator Print.

Hold down the spring-loaded Detent Pin and turn the Adjust Head out of the Ram until the Detent

Pin can be removed.

DANGER

The spring-loaded pin can injure if released unexpectedly.

Invert the pin so the locking end will contact the Detent Plate and re-install the pin and spring.

While holding the pin down, turn the Adjust Head until the proper set-up dimension is reached.

Verify the crimp height as shown in Paragraph 5.1.A.

CAUTION

When changing crimp height while in the locked orientation, the spring-loaded Detent Pin must be depressed to rotate the

number ring, or damage will occur.

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