VIRGINIA PANEL CORPORATION TRIPADDLE CONTACTS AND MODULES USER’S MANUAL: SECTION 2 TRIPADDLE SIGNAL ITA CONTACT ASSEMBLY PART # 610 110 108 / 610 110 146 / 610 110 169 TOOLS REQUIRED Crimp Tool, Part # 910 101 103 Locator, Part # 910 104 107 CRIMP TOOL SETUP 1. Set up Crimp Tool, Part # 910 101 103 (Figure A), by loosening the latch locking screw (counter-clockwise, until turning stops). Remove any previously used locator. 2. Insert the open end of Locator, Part # 910 104 107 (Figure B), into the crimp tool locator retainer. RETAINING LATCH ASSEMBLY AND LOCKING SCREW LOCATOR RETAINER MICROCRIMP ADJUSTING KNOB 3. Slide the retaining latch toward the locator until the locator is securely locked into place. Tighten the latch locking screw. CRIMP TOOL ADJUSTMENT AND WIRE PREPARATION 1. Adjust the crimp tool setting by pulling the microcrimp adjusting knob and turning it at the same time (clockwise increases, counter-clockwise decreases setting) until the desired setting is achieved on the microcrimp indicator (Table 1). Verify with pin gauge. For more information about gauge pins, visit vpc.com/gaugepins. See calibration instructions for Part # 910 101 103 for pin gauge verification instructions. Determine the strip length according to wire gauge (Table 1). NOTE: if the wire insulation diameter is greater than 0.07 [1.78], the strip length should be 0.250 [6.35]. 2. MICROCRIMP INDICATOR Figure A. Crimp Tool, Part # 910 101 103. Figure B. Locator Part # 910 104 107. 3. Strip wire. Continued on next page... Table 1. CONTACT CRIMP TOOL LOCATOR DIE STRIP LENGTH WIRE GAUGE (IN [MM]) 0.200 [5.08] 610110108/ 610110146 610110169 910101103 910101103 910104107 910104107 CRIMP SETTING (IN [MM]) MAX MIN 20 0.037 [0.94] 0.033 [0.84] 22 0.033 [0.84] 0.029 [0.74] PULLOUT FORCE EXTRACTION (LBS [N]) TOOL 10 [44.5] 24 0.029 [0.74] 0.025 [0.64] 0.250 [6.35] 2-24* 0.041 [1.04] 0.037 [0.94] 0.200 [5.08] 26 0.024 [0.61] 0.021 [0.53] 0.250 [6.35] 2-26* 0.036 [0.91] 0.033 [0.84] 3-26* 0.041 [1.04] 0.037 [0.94] 4* [17.8]* 0.200 [5.08] 26 0.028 [0.71] 0.026 [0.66] 4 [17.8] 28 0.024 [0.61] 0.023 [0.58] 0.250 [6.35] 2-28* 0.028 [0.71] 0.026 [0.66] 0.200 [5.08] 30 0.022 [0.56] 0.020 [0.51] 0.250 [6.35] 2-30* 0.026 [0.66] 0.025 [0.63] 8* [35.6]* 910110102 2* [8.9]* 1.0* [4.4]* *Pullout force is for individual wires 2-1 For more information visit vpc.com 8/29/12 VIRGINIA PANEL CORPORATION TRIPADDLE CONTACTS AND MODULES USER’S MANUAL: SECTION 2 TRIPADDLE SIGNAL ITA CONTACT ASSEMBLY PART # 610 110 108 / 610 110 146 / 610 110 169 CONTACT SETUP AND CRIMPING 1. Insert the contact into the crimp tool. 2. Insert stripped wire fully into the contact and squeeze the crimp tool handle until a positive stop is reached. The tool will release and return into a fully “open” position. Remove crimped contact and wire. OBSERVE PRECISION RATCHET ACTION BY OPENING AND CLOSING THE CRIMP TOOL FULLY SEVERAL TIMES. NOTE THAT THE TOOL CANNOT BE OPENED WITHOUT COMPLETING A CYCLE. NEVER ATTEMPT TO DISASSEMBLE THE TOOL. NEVER TIGHTEN OR LOOSEN STOP NUTS ON THE BACK OF THE TOOL. CRIMP INDENTIONS ACCEPTABLE CRIMP CRITERIA 1. Follow the instructions for tool setup to ensure the tool is ready for use. 2. Crimp the contact onto the respective wire according to the contact assembly instructions. Ensure that the crimp minimum is measured with an approved gauge pin. 3. The crimp must be between the inspection hole and the end of the contact to be acceptable. The crimp creates two distinctive indentions on four sides of the contact creating a square appearance. This is an acceptable result (Figure C). 4. Inspect the crimp to ensure none of the indentions are connected to the inspection hole (Figure D). If the indentions make contact with, or are above the inspection hole, the crimp is unacceptable. 5. Inspect the crimp to ensure none of the indentions are connected to the end of the contact. If the indentions make contact with the end of the contact, the crimp is unacceptable. 2-2 Figure C. Correct location of the crimp divots. INSPECTION HOLE Figure D. The crimp region is between the inspection hole and the end. For more information visit vpc.com 8/29/12