Thomas & Betts TBM5 Instructions Manual

TBM5, TBM5-S and TBM5-SV
Compression Tool Instructions
Read and understand all of the instructions
and safety information in this manual before
operating or servicing this tool.
Table of Contents
1.0 Operating Instructions . . . . . . . . . . . . . . . . . . . 2
1.1 Tool Description . . . . .
1.2 Applications . . . . . . .
1.3 Choosing the Die Nest . .
1.4 Removing and Installing Die
1.5 Preparing the Conductor .
1.6 Making a Compression . .
2.0
3.0
.
.
.
.
.
.
Installation Test Procedure.
2.1 Installation Test Procedure . .
2.2 Tensile Test Procedure . . .
Calibration Verification. . .
3.1 Visual Inspection . . . . . .
3.2 Handle Spread Check . . . .
3.3 Gaging Procedure . . . . .
3.4 Gaging Table . . . . . . .
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TA00084 G Page 1 of 6
1.0
OPERATING INSTRUCTIONS
WARNING
SHURE STAKE® SAFETY RELEASE
WARNING
Keep fingers clear of die nests whenever handles are brought together.
The TBM5-S compression tool is equipped with the Shure Stake® full
stroke compelling mechanism. If it becomes necessary to release the
Shure Stake® Mechanism before completion of the crimp cycle, disengage ratchet as follows. Slightly squeeze handles, and push the dowel
pin, releasing the locking mechanism allowing the handles to open.
1.1
1.2
TOOL DESCRIPTION
APPLICATIONS
®
TOOL HEAD
SHURE STAKE
MECHANISM
(TBM5-S and
TBM5-SV ONLY)
HANDLES
LOCKSCREW
DIE
SLOT
DOWEL PIN
ADJUSTING
SCREW
RAM
GRIPS
DIES
(FULL SET INCLUDED)
SHURE STAKE® MECHANISM IS DESIGNED
TO PROVIDE COMPLETE CLOSURE.
CHOOSING THE DIE NEST
1.4
REMOVING & INSTALLING DIE
REMOVING DIE
Match color on connector to the color on the die.
Reference chart below.
NOTE: A crimping nest with more than one
color band may be used to crimp Color-Keyed®
connectors matching any of the nest color bands.
Open handles of tool until fully extended. Pull
die out from under the die retaining spring thus
removing it from the tool.
INSTALLING OR CHANGING DIE
NEST
EQUIV. HEX
DIE CODE NO.
Red
21
Blue
24
Grey
29
33
Green
37
ORNG
Brown
BLK
13454
DIE GROOVE
COLOR
GREEN
DIE CAT. NO.
PINK
13457
13458
42
45
Orange
50
Purple
54
COLOR CODE
DIE LOCATOR PIN
DIE RETAINING
SPRING
ORNG
13456
Pink
Black
BLK
13455
Hold tool with die retaining spring facing you and
open handles of tool until they are fully extended.
Hold the die with the desired crimping nest and
color code in the lower right corner. Insert the die
under the die retaining spring in the tool head. The
die retaining spring will hold the die by pressure on
the die locator pin.
GREEN
1.3
1. This tool is suitable for installing Color-Keyed
lugs and splices, #8 to 250 MCM copper and #10
to 4/0 aluminum.
2. This tool is also suitable for installing C-Taps from
catalog number 54705 to 54750.
3. Check label and connector for UL and/or CSA
monogram and letters AL or AL9CU. Connectors
marked AL are listed for use on aluminum
conductors only. Connectors marked AL9CU
are listed for aluminum and copper conductors.
Use only a listed Thomas & Betts connector with
this tool. Any other combination may result in
a connection which does not meet established
standards.
PINK
Yellow
62
Gold
45
Tan
50
Olive
54
Ruby
60
White-66
66
DIE
CAUTION
Use only a listed (UL and/or CSA) Thomas & Betts connector with this tool.
Any other combination may result in a connection which does not meet established standards.
TA00084 G Page 2 of 6
1.5
PREPARING THE CONDUCTOR
AL
U
M
SHIE A
LD
1. Strip insulation properly without cutting or nicking the conductor
strands. Refer to the instruction sheet supplied with the connectors
regarding strip length.
2. For aluminum conductor, smear a thin layer of joint compound onto
the conductor and brush it in with a wire brush or emery cloth.
1.6
MAKING A COMPRESSION
1. Insert prepared conductor into connector.
2. Locate connector in die grooves of tool, so the die is between the color code marks for copper and on the color
code marks for aluminium, see graphics below.
3. Some connectors require more than one compression. Refer to the instruction sheet supplied with the connectors
regarding the number of compressions required. If more than one compression is indicated, the first compression
should be in the indicated area nearest to the tongue of a terminal and nearest the center of a splice, and then
working progressively toward the end of the barrel.
4. Close handles of tool completely for each compression.
STEP 1
TYPICAL COPPER
INSTALLATION
CABLE
DIE
DIE
STEP 2
TYPICAL ALUMINUM
INSTALLATION
CABLE
DIE
DIE
STEP 3
TA00084 G Page 3 of 6
2.0 INSTALLATION TEST PROCEDURE (TBM5S & TBM5SV ONLY)
WARNING
®
SHURE STAKE SAFETY RELEASE The TBM5-S compression tool is equipped with the Shure Stake® full stroke compelling mechanism. If
it becomes necessary to release the Shure Stake® Mechanism before completion of the crimp cycle, disengage ratchet as follows. Slightly squeeze
handles, and push the dowel pin, releasing the locking mechanism allowing the handles to open.
2.1
INSTALLATION TEST PROCEDURE
Using a tool that has passed the calibration requirements
install a minimum of six (6) terminals for each die nest on the
appropriate wire for which a performance check is required.
In order to obtain valid and consistent results, perform
installation procedure as follows:
COLORED-KEYED® CONNECTORS
1. Strip conductor approximately 1/4” longer than the connector
barrel. (Strip length for test purposes only. For actual installation,
refer to the instruction sheet supplied with the connectors).
5. Locate connector in die grooves of tool, so that die is
between the color code marks for copper and on the color
code marks for aluminium, see graphics below.
6. Some connectors require more than one compression.
Refer to the instruction sheet supplied with the connectors
regarding the number of compressions required. If more
than one compression is indicated, the first compression
should be in the indicated area nearest to the tongue of a
terminal and nearest the center of a splice, and then working
progressively toward the end of the barrel.
7. Squeeze handles fully closed until SHURE STAKE®
mechanism releases.
CAUTION
Care should be taken to strip the insulation of the conductor
without cutting or nicking the conductor strands, as this
condition will result in premature pull-test failures.
2. For aluminum conductors, smear a thin layer of joint compound
onto the cable and brush it in with a wire brush or emery cloth.
TYPICAL COPPER
INSTALLATION
TYPICAL ALUMINUM
INSTALLATION
INTERCHANGEABLE
NEST
COLOR CODE
BANDS
CONNECTOR
INTERCHANGEABLE
NEST
COLOR CODE
BANDS
CONNECTOR
3. Insert stripped conductor into connector barrel until it
bottoms out.
4. Choose an installing die with the same color marking as the
connector.
CABLE
2.2
FIXED
NEST
FIXED
NEST
CABLE
TENSILE TEST PROCEDURE
1. Install test sample in a tension-testing machine or a suitable pulltest fixture.
NOTE: The pull is to be exerted gradually. An abrupt pull is not a
proper test method.
2. Subject each sample to an axial pull which is to be increased until
failure of the connection occurs, (see graphics below).
3. The pull force required to separate a terminal from its associated
wire shall be no less than the minimum pullout (see table on the
right).
NOTE: On “C” tap and wire joints, only the smallest wire in each
combination is to be tested for pullout.
EXAMPLES OF TENSILE TESTING MACHINES
1. Ametek Testing Equipment Systems, E. Moline, IL 61244.
Mechanical Force Gage Model No. D-150M, Testing Stand Model
No. CTM.
2. John Chatillion & Sons, Kew Gardens, N.Y., N.Y. 11415. Gage Model
No. DPPH-100 or DPPH-200, Testing Stand Model No. HTC.
WIRE
TERMINAL
TERMINAL
TERMINAL
FORCE
FORCE
TYPICAL COPPER TEST SAMPLE
MIN. PULL-OUT (lbs.*)
CABLE
SIZE
COPPER
ALUMINUM
12
70
35
10
80
40
8
90
45
6
100
50
4
140
70
2
180
90
1
200
100
1/0
250
125
2/0
300
150
3/0
350
175
4/0
450
225
250
500
250
300
550
275
350
600
300
*Conforms to UL and CSA requirements
WIRE
TERMINAL
FORCE
FORCE
TYPICAL ALUMINUM TEST SAMPLE
TA00084 G Page 4 of 6
3.0
CALIBRATION VERIFICATION
NOTE: Calibration verification of the tool should be performed whenever damage or suspected damage has occurred or as
often as operating conditions warrant.
3.1
VISUAL INSPECTION
3.2
1. Tool must be free of cracks, sharp edges and
other obvious imperfections that may affect
performance of the tool. Nest area must be free
of burrs, dents or scratches.
3.3
HANDLE SPREAD CHECK
To ensure the tool will produce a reliable
compression, the tool must be properly adjusted.
CHECKING TOOL ADJUSTMENT
1. Insert die in place.
2. Lay tool on a flat surface. Open handle A and
allow it to close under its own weight. The ram
should be touching the die.
3. Measure distance between handle grips. In
a properly adjusted tool, the distance should
be between 11” and 14”. If it is less than 11”
or more than 14”, the tool needs adjustment.
(See graphic below).
GAGING PROCEDURE
NOTE: Wipe dies before gaging.
1. Squeeze handles until jaws are fully closed.
2. Select gage pin which can be inserted into nest
with minimal hand pressure. See graphic below.
3. Gage pin should fall between the limits shown on
tables in section 3.4.
ADJUSTING TOOL
1. Loosen lockscrew.
2. To increase distance between handles, turn
adjusting screw clockwise.
3. To decrease distance between handles, turn
adjusting screw counterclockwise.
4. Tighten lock screw.
5. Recheck handle distance. Adjust again, if
necessary.
GAGE PIN
RAM JUST
TOUCHING DIE
ADJUSTING SCREW
HANDLE A
LOCK SCREW
DIE
MEASURE
HERE
3.4
GAGING TABLE
DIE
COLOR
DIE
CAT. NO.
GAGING
MIN. - MAX.
RED
BLUE
GRAY
BROWN
13454
.165-.181
.181-.201
.230-.251
.260-.281
GREEN
PINK
BLACK
ORANGE
13455
.313-.335
.351-.371
.383-.406
.429-.454
PURPLE
YELLOW
13456
.480-.503
.529-.562
GOLD
TAN
OLIVE
RUBY
13457
.383-.406
.429-.454
.480-.503
.533-.553
WHITE
13458
.580-.604
RETAINING SCREW
FLAT SURFACE OR
TABLE TOP
TA00084 G Page 5 of 6
WARRANTY: Thomas & Betts sells this product with the understanding that the user will perform all necessary tests to
determine the suitability of this product for the user’s intended application. Thomas & Betts warrants that this product
will be free from defects in materials and workmanship for the period stated on the enclosed warranty card. Upon prompt
notification of any warranted defect, Thomas & Betts will, at its option, repair or replace the defective product or refund
the purchase price. Proof of purchase is required. Misuse or unauthorized modification of the product voids all warranties.
Limitations and Exclusions: THE ABOVE WARRANTY IS THE SOLE WARRANTY CONCERNING THIS PRODUCT, AND IS IN
LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE SPECIFICALLY DISCLAIMED. LIABILITY FOR
BREACH OF THE ABOVE WARRANTY IS LIMITED TO COST OF REPAIR OR REPLACEMENT OF THE PRODUCT, AND UNDER NO
CIRCUMSTANCES WILL THOMAS & BETTS BE LIABLE FOR ANY INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES.
FOR PARTS OR SERVICE,
CONTACT THOMAS & BETTS TOOL SERVICE CENTER AT 1-800-284-TOOL (8665)
Thomas & Betts Corporation
Memphis, Tennessee
www.tnb.com
© 2009 Thomas & Betts Corporation.
All Rights Reserved.
TA00084 G Page 6 of 6