WAND* SINGULATION SYSTEMS Machine (Press)

Transcription

1 WAND* SINGULATION SYSTEMS Machine (Press) Customer Manual 28 JUL 03 Rev D SAFETY PRECAUTIONS READ THIS FIRST! INTRODUCTION DESCRIPTION General Description Machine Specifications RECEIVING/INSPECTION/INSTALLATION Receiving/Inspection Installation SCREENS Main Operating Screen Options Screen Input/Output Table Screen Sensors Screen LOADING/UNLOADING THE DIE PACKAGES Loading the Die Package Unloading the Die Package OPERATION Operating Procedure Emergency Stop PREVENTIVE MAINTENANCE Cleaning Monthly Inspection Lubrication Hydraulic Oil Leakage/Depressurizing the System Refilling and Venting HyperCyl HPT Series Tandem Hydraulic Cylinders TROUBLESHOOTING CE PRESS VARIATIONS REVISION SUMMARY Tyco Electronics Corporation, Harrisburg, PA. All International Rights Reserved. WAND SINGULATION SYSTEMS and Tyco are trademarks. *Trademark Other Products Logos, and Company names Used are the Property of their Respective Owners. 1 of 34 LOC B

2 SAFETY PRECAUTIONS AVOID INJURY Safeguards are designed into this application equipment to protect operators and maintenance personnel from most hazards during equipment operation. However, certain safety precautions must be taken by the operator and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application equipment must be operated in a dry, dust free environment. Do not operate equipment in a gaseous or hazardous environment. Carefully observe the following safety precautions before and during operation of the equipment: ALWAYS wear appropriate ear protection. ALWAYS wear approved eye protection when operating powered equipment. ALWAYS keep guard(s) in place during normal operation. ALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock. ALWAYS turn off the main power switch and disconnect electrical cord from the power source when performing maintenance on the equipment. NEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment. NEVER insert hands into installed application equipment. NEVER alter, modify, or misuse the application equipment. WAND SINGULATION SYSTEMS Customer Service Center CALL The Customer Service Center offers a means of providing technical assistance when required. INFORMATION REQUIRED WHEN CONTACTING THE CUSTOMER SERVICE CENTER When calling the Customer Service Center regarding service to equipment, it is suggested that a person familiar with the device be present with a copy of the manual (and drawings) to receive instructions. Many difficulties can be avoided in this manner. When calling the Customer Service Center, be ready with the following information: 1. Customer name 2. Customer address 3. Person to contact (name, title, telephone number, and extension) 4. Person calling 5. Equipment number (and serial number if applicable) 6. Product part number (and serial number if applicable) 7. Urgency of request 8. Nature of problem 9. Description of inoperative component(s) 10. Additional information/comments that may be helpful 2 of 34 Rev D

3 WAND SINGULATION SYSTEMS Press Safety Light Curtain Operator Control Panel MAIN START Pushbutton EMERGENCY STOP Pushbutton Die Package Palm Buttons Access Door Release Buttons Figure 1 1. INTRODUCTION This manual describes the machine (press) portion of the WAND SINGULATION SYSTEMS. The WAND SINGULATION SYSTEM cuts (punches) a number of printed circuit boards from printed circuit board panels. The die package performs the actual singulation. The press causes the die to singulate the printed circuit board panels. For maintenance and sharpening procedures of the WAND SINGULATION SYSTEMS die assemblies, refer to Instruction Sheet When reading this manual, pay particular attention to, CAUTION, statements. Denotes an imminent hazard which may result in moderate or severe injury. CAUTION Denotes a condition which may result in product or equipment damage. Highlights special or important information. Dimensions in this manual are in metric units [with U.S. customary units in brackets]. Refer to Section 10 for revision information. Rev D 3 of 34

4 2. DESCRIPTION 2.1. General Description Specific WAND SINGULATION SYSTEMS die assemblies punch specific size printed circuit boards. For information about die package maintenance and sharpening, refer to Instruction Sheet The upper die is driven by the ram assembly. When the ram extends, the upper die punches (singulates) the printed circuit board panel. The operator interface with the WAND SINGULATION SYSTEMS machine is the operator control panel. See Figure 1. The control panel consists of a red EMERGENCY STOP Button, a MACHINE START button, and a touch screen. In addition, two palm buttons are located on the front of the press for initiating a press cycle. The press will cycle only once each time the palm buttons are touched. Holding the touch pad has no effect. Both palm buttons must be touched at the same time to start a press cycle. The press contains a safety light curtain in front of the die package. If the field of the safety light curtain is interrupted by any object while the die assembly is moving to or from the singulation chamber, the press will stop. The press cycle will resume when the interference has been cleared Machine Specifications Figure 2 contains the machine specifications for the WAND SINGULATION SYSTEMS machine. MACHINE DIMENSIONS Width mm [36 in.] Length mm [67 in.] Height mm [84 in.] (CE Version 2286 mm [90 in.]) Table Height mm [38.5in.] Weight kg [2800 lbs.] FACILITY SPECIFICATIONS Voltage 120 Vac (CE Version 220 Vac) Frequency 60 Hertz, Single Phase (CE Version 50/60 Hertz, Single Phase) Current 7 Amp (CE Version 3.0 Amp) Air 85 psi (5.86 bars) Temperature 41 to 104ºF (5 to 40ºC) Relative Humidity 20 to 90% (non condensing) Normal Noise Level Less than 85dba CONTROL SPECIFICATIONS PLC Controlled Capacitive Palm Buttons 10.4 In. Touch screen Password Protection STI Light Curtain PANEL SPECIFICATIONS Panel Size 50.8 mm [2 in.] less in width and mm [4 in.] less in depth than the die package being used. Maximum Board Thickness mm [.125 in.] Maximum Component Height Top 63.5 mm [2.5 in.] Maximum Component Height Bottom 25.4 mm [1.0 in.] Component Free Zone 1.52 mm [.060 in.] from the edge at tab location Figure 2 4 of 34 Rev D

5 Figure 3 contains system features, as well as available optional features. SYSTEM FEATURES Air/Oil power pack PLC control Structural tube frame OPTIONAL FEATURES Electronically controlled storage elevators (stores up to four die packages) Storage racks and Die Cart SCARA robotics for in line processing Completely guarded work area Anti repeat, anti tie down palm buttons Automatic Tool Shuttle Average Cycle Time of 12 Seconds (Does not include printed circuit board loading/unloading time) Figure 3 3. RECEIVING/INSPECTION/INSTALLATION 3.1. Receiving/Inspection WAND SINGULATION SYSTEMS presses are thoroughly inspected during and after assembly. A final series of inspections is made to insure the proper functioning before packaging and shipping. However, damage may occur during shipment. Remove the press from the crate and carefully inspect the WAND SINGULATION SYSTEMS press for damage. If damage is evident, file a claim against the carrier and notify Tyco Electronics immediately Installation 1. Remove the lower front and rear guards to gain access to the four bolts that secure the machine to the shipping pallet. The bolts are located at each corner. Remove the jam nuts and washers from the bolts. 2. Locate the following items (in a box attached to the skid under the front of the press): a. Box containing four leveling bolts and four floor pads. b. Box containing a hydraulic fluid fill can/pump. c. Documentation package. 3. Use a fork lift truck to lift the press from the shipping pallet and place the press. The machine is top heavy. When it is being lifted or moved by a forklift truck, it should be strapped to the mast of the forklift truck to prevent it from tipping over. 4. Do NOT place the press next to any ignition sources. Refer to Documentation Package No for fluid flammability and fire fighting measures (Material Safety Data Sheet for Mobil VELOCITE lubricant). 5. Thread each of the leveling bolts down through the frame until they extend below the frame approximately 12.7 mm [.5 in.]. Hold a floor pad against the bottom of each bolt to ensure that it does not touch the frame. 6. Move the machine into place and set it down on the floor pads. 7. Level the machine. a. Place a level on the die package. b. Adjust the leveling bolts until the die package ways are level. Secure with the accompanying nuts. It is important to level the die package ways and not the WAND SINGULATION SYSTEMS Press. Check to determine if the die package ways are level by placing a die package on the ways. If the die package does not move when untouched, the ways are level. Rev D 5 of 34

6 Leveling Bolt Machine Frame Locking Nut Machine Pad Figure 4 The die package way must NEVER be leveled so that the die package rolls toward the operator. However, it is acceptable for the die package way to to be leveled so that the die package rolls toward the press. This will assure that the die package when unsecured or unattended does NOT accidently roll out of the machine onto the operator. 8. Connect the machine to the required air and electrical power. Reference the Specification table in Figure SCREENS This section of the manual will explain the primary display screens that are available to use or view. Located beside the display screen are the MAIN START pushbutton and the EMERGENCY STOP pushbutton. EMERGENCY STOP Pushbutton (Switch) Pressing the mushroom shaped EMERGENCY STOP Pushbutton (Switch) will de energize the Main Operating screen and stop the machine cycle. Twisting the mushroom shaped EMERGENCY STOP Pushbutton (Switch) clockwise will automatically return the spring loaded switch to the out position. The MAIN START pushbutton can then be depressed. MAIN START Pushbutton Pressing the MAIN START pushbutton will energize the electronic control circuits and display the Main Operating screen. 6 of 34 Rev D

7 4.1. Main Operating Screen Figure 5 The first screen displayed after the MAIN START pushbutton is pressed is the main operating screen. See Figure 5. Buttons and displays located on the Main Operating screen include the following: MACHINE START Button Pressing the MACHINE START display button will energize the input/ output circuits and the pneumatic system. The machine will enter it s previous mode (the mode prior to the time the MACHINE STOP button or the EMERGENCY STOP pushbutton were pushed). MACHINE STOP Button Pressing the MACHINE STOP display button will stop the machine cycle and de energize the input/output circuits and the pneumatic system. AUTO/SETUP Button Pressing the AUTO/SETUP display box (button) will select either the AUTO mode or the SETUP mode. (The mode toggles between AUTO and SETUP each time the display box is pressed.) The mode that is currently selected is displayed just below this box. AUTO ON Display This display box lights when the machine is in the AUTO mode. SETUP Display This display box lights when the machine is in the SETUP mode. MACHINE ON Display This display box lights when the MACHINE START button is pressed. MACHINE OFF Display This display box lights when the MACHINE STOP button is pressed. LOW CLAMP PRESSURE Display This display box lights when the pressure in the clamps retract system is below the minimum required for proper clamping. It is normal for this box to be lit in the SETUP mode when the clamps are open (extended). TOP DIE IN Display This display box lights when the top part of the die package is properly loaded into the working area of the machine and the top die in sensor is made ( on ). This box should remain lit while in the AUTO mode. BOTTOM DIE IN Display This display box lights when the bottom part of the die package is properly loaded into the working area of the machine and the bottom die in sensor is made ( on ). This box will not be lit when the bottom part of the die package is in the load/unload position while loading and unloading printed circuit boards. Rev D 7 of 34

8 PRESS COUNTER Display This display box indicates the number of press cycles after the press counter was last reset. Press the PRESS FOR OPTIONS box to access the screen to reset the counter. DIE COUNTER Display This display box indicates the number of press cycles after the die counter was last reset. Press the PRESS FOR OPTIONS box to access the screen to reset the counter. The counter is normally reset when the die package is changed. TIME BOX Display This display box indicates the current time. Press the PRESS FOR OPTIONS box to access the screen to set the clock. PRESS FOR OPTIONS Button Pressing the PRESS FOR OPTIONS display box (button) will display the screen shown in Figure 6, and facilitate the options listed in the next section Options Screen Buttons and functions of the Options screen include the following: PRESS FOR MAINTENANCE SCREEN Button Pressing this button will display screens that indicate the names and location of important components of the press. PRESS FOR DIE COMPONENT DRAWINGS Button Pressing this button will display the screen that indicates the location and name of die package components. PRESS FOR I/O TABLE SCREEN Button Pressing this button will display the screen that indicates the input and output numbers, their names, and their current status (ON or OFF). Refer to Paragraph 4.3 in this manual and the I/O screen for more information. GO TO PANEL PRESS FOR MAINTENANCE SCREEN GO TO PANEL PRESS TO RETURN TO MAIN SCREEN GO TO PANEL PRESS FOR I/0 TABLE SCREEN GO TO PANEL GO TO PANEL GO TO PANEL PRESS FOR TROUBLESHOOTING SCREENS PRESS FOR SENSORS SCREEN PRESS FOR MACHINE HISTORY GO TO PANEL PRESS TO SET CLOCK GO TO PANEL ENTER PASSWORD TO RESET COUNTER GO TO PANEL PRESS FOR DIE COMPONENT DRAWINGS GO TO PANEL PRESS FOR PREVENTIVE MAINTENANCE SCREEN Figure 6 8 of 34 Rev D

9 PRESS FOR SENSORS SCREEN Button Pressing this button will display the screen that indicates the location, input number, and status of the input sensors. Refer to the Paragraph 4.4 in this manual for more information. PRESS FOR TROUBLESHOOTING SCREENS Button Pressing this button displays the machine troubleshooting screens. A similar troubleshooting table can be seen in Section 8, TROUBLESHOOTING. PRESS TO SET CLOCK Button Pressing this button displays a screen which facilitates the setting of the clock. PRESS FOR MACHINE HISTORY Button Pressing this button displays the screen that indicates the total number of machine cycles. This number cannot be reset. ENTER PASSWORD TO RESET COUNTER Button Pressing this box (button) will display the screen used to reset the press or die counter value (displayed on the main operating screen) to zero. PRESS TO RETURN TO THE MAIN SCREEN Button Pressing this box (button) will return the operator to the Main Operating screen (Figure 5) Input/Output Table Screen The screen in Figure 7 shows the input and output circuit numbers, the description of the input/output, and the current status of the circuit (ON or OFF). Inputs are activated by sensors and switches, palm buttons, and light curtain signals. Outputs are activated to energize pneumatic solenoid valves to move cylinders during the machine cycle. Pressing the PRESS TO RETURN TO MAIN SCREEN box (button) will return the operator to the main operating screen (Figure 5). Pressing the PRESS FOR OPTIONS SENSORS SCREEN box (button) will display the screen that shows the location of the input sensors and their status I/O TABLE GO TO PANEL PRESS TO RETURN TO MAIN SCREEN GO TO PANEL PRESS FOR OPTIONS SENSORS SCREEN I:0/0 CLAMP PRESSURE SWITCH ON/OFF O:0/0 RAM DOWN S.V. ON/OFF I:0/1 LEFT PALM BUTTON ON/OFF O:0/1 RAM UP ON/OFF I:0/2 TOP DIE IN ON/OFF O:0/2 RELEASE DIE CLAMPS S.V. ON/OFF I:0/4 SETUP POSITION PROX. ON/OFF O:0/4 SPACERS AND FENCE S.V. ON/OFF I:0/5 RIGHT PALM BUTTON ON/OFF O:0/5 FEED IN S.V. ON/OFF I:0/7 DIE OUT REED SWITCH ON/OFF O:0/6 FEED OUT S.V. ON/OFF I:0/8 BOTTOM DIE IN PROX. ON/OFF O:0/7 ENGAGE DIE CLAMPS S.V. ON/OFF I:0/9 RAM UP PROX. ON/OFF O:0/7 POWER STROKE S.V. ON/OFF I:0/10 LIGHT CURTAIN OUTPUT ON/OFF I:0/11 LIGHT CURTAIN STATUS ON/OFF I:0/12 POWER STROKE PRESS. SW. ON/OFF Figure 7 Rev D 9 of 34

10 A. Explanation of Inputs Refer to Figure 7 to view the I/O table. CLAMP PRESSURE SWITCH LEFT PALM BUTTON TOP DIE IN SETUP POSITION PROX RIGHT PALM BUTTON DIE OUT REED SWITCH BOTTOM DIE IN PROX RAM UP PROX LIGHT CURTAIN OUTPUT LIGHT CURTAIN STATUS POWER STROKE PRESS. SW It is ON and sends a signal to the PLC when the minimum air pressure required for proper clamping is present and when the clamps are closed. It is normal for this input to be ON during the AUTO mode. It is OFF in the SETUP mode when the clamps are open. It is ON and sends a signal to the PLC when the palm button is touched. A proximity sensor that is ON and sends a signal to the PLC when the upper half of the die package is properly loaded into the working area of the press. A proximity sensor that is ON and sends a signal to the PLC when the ram extends to position the upper half of the press down against the setup blocks. The clamps are open and the machine is in the SETUP mode ready to load the upper part of the die package into the press. It is ON and sends a signal to the PLC when the palm button is touched. It is ON and sends a signal to the PLC when the bottom half of the die package is at the Load /Unload position. A proximity sensor that is ON and sends a signal to the PLC when the bottom half of the die package is properly loaded into the working area of the press. A proximity sensor that is ON and sends a signal to the PLC when the ram is retracted to position the upper half of the press at its UP position. These are signals to the PLC and are ON indicating proper operation of the light curtain and that it is clear, not interrupted. It is OFF until the ram extends the upper part of the press down to the proper position to begin singulating (cutting) the printed circuit board. Then it sends a signal to the PLC to apply hydraulic pressure to the ram. 10 of 34 Rev D

11 B. Explanation of Outputs Refer to Figure 7 to view the I/O table. RAM DOWN S.V. RAM UP S.V. RELEASE DIE CLAMPS S.V. SPACERS AND FENCE S.V. FEED IN S.V. FEED OUT S.V. ENGAGE DIE CLAMPS S.V. POWER STROKE S.V. The PLC sends a signal to the solenoid valve of the ram cylinder to move down. The PLC sends a signal to the solenoid valve of the ram cylinder to move Up. The PLC sends a signal to the solenoid valve of the clamp to release the upper die half. The PLC sends a signal to the solenoid valve of the spacers (setup blocks) to retract and the fence (if so equipped) to extend in the AUTO mode. The PLC sends a signal to the solenoid valve of the auto feed cylinder to move the bottom half of the die package into the working area of the machine or out to the Load/Unload area. The PLC sends a signal to the solenoid valve of the clamp cylinders to engage (clamp) the upper half of the die package. The PLC sends a signal to the power stroke solenoid valve to apply hydraulic pressure to the ram Sensors Screen This screen (Figure 8) shows the physical area of the machine where the input sensors are located. Match the sensor input number in the I/O table screen for the description of each sensor. GO TO PANEL PRESS TO RETURN TO MAIN SCREEN SENSORS GO TO PANEL PRESS FOR OPTIONS SENSORS SCREEN I:O/8 I:O/2 I:O/8 ON ON ON I:0/9 ON I:0/4 ON I:0/7 ON Figure 8 Rev D 11 of 34

12 5. LOADING/UNLOADING THE DIE PACKAGE To avoid personal injury, be sure to follow all local safety practices, including the use of steel toed shoes when transferring die packages to and from the machine. In addition, if any hydraulic oil is detected, press Emergency Stop Button(s) and notify your maintenance department Loading the Die Package Steps 6 and 11 are NOT required for CE version presses, since the door has been remove on these presses. To avoid personal injury, be sure power to the machine is turned off and disconnected. 1. Open the door of the storage rack and position a die transfer cart in front of the die package. The table level of the die cart should be level with the desired die package. Refer to the instructions packaged with the die cart. 2. Set the floor brake on the transfer cart. 3. Roll the die package onto the cart. 4. Release the floor brake on the transfer cart. To avoid personal injury, be sure the die assembly is secured to the cart to prevent accidental roll and movement of the die assembly. 5. Position the transfer cart close to the press. 6. Open the front access door of the WAND SINGULATION SYSTEMS press and swing the door down as far as possible. 7. With the cart in front of the press access door, adjust the height of the die to facilitate easy loading into the press. 8. Set the floor brake on the transfer cart. 9. Roll the die package into the press and secure it to the feed mechanism with the two shoulder bolts provided. On CE version presses, BE SURE to press and hold the palm buttons until the die package has completely shuttled into the press before releasing the palm buttons. 10. Release the brake on the transfer cart and remove the cart. 11. Close the front access door. To avoid personal injury, keep clear of the press when turning on the main power. Machine assemblies may move when the power is turned on. 12. Turn on the main power switch. The main power switch is located at the rear of the press on the electrical panel. To turn on the main power switch, rotate the switch clockwise. To avoid personal injury, keep clear of the press when turning on the main air power. Machine assemblies may move when the main air is turned on. 13. Turn on air and check the pressure. To turn on the air, push up the air shut off valve located on the inlet of the air filter/regulator at the rear of the press. Verify that the pressure is set at 5.86 bars [85 psi]. 12 of 34 Rev D

13 Air Shut Off Valve Pressure Gage Figure Press the green MAIN START button on the operator control panel. The screen on the control panel will light. Be sure all guards are closed and the safety light curtain is undisturbed. 15. Touch the MACHINE START button on the operator control panel screen. See Figure 10. The MACHINE ON box will light and press assemblies may move. Rev D 13 of 34

14 Figure Touch the AUTO/SETUP box on the operator control panel screen until the screen reads, SETUP SELECTED. 17. Simultaneously touch both palm buttons located on each side of the front of the press to load the die package into the WAND SINGULATION SYSTEMS press. The die package will enter the singulation chamber. The upper half of the package will be clamped into the press. The ram will retract and the lower half of the package will return to the position for loading the printed circuit board panel. Refer to Paragraph 5.1 for complete die package loading instructions. The machine will cycle only once each time the palm buttons are touched. Holding the touch has no effect. Both palm buttons must be touched at the same time to start a machine cycle. 18. After the dies are loaded, touch the AUTO/SETUP box on the control panel screen until the screen reads, AUTO SELECTED. The AUTO ON box will light Unloading the Die Package To avoid personal injury, exercise caution around the press when the press is powered up. 1. Touch the AUTO SETUP box on the operator interface screen until the screen reads, SETUP SELECTED. The SETUP box will light. 14 of 34 Rev D

15 2. Simultaneously touch the two palm buttons. The lower half of the die package will go into the press and the ram will extend. The clamping cylinders will then release the upper half of the package. The entire die package will return to the loading position. Then the ram will retract. 3. Open the access door of the press and position the die transfer cart in front of the die package. The table level of the die cart should be level with the desired die package. There is no access door on CE version presses. Instead, there is a latch that must be moved to the left to release the die package. 4. Set the floor brake on the transfer cart. 5. Remove the shoulder bolts securing the die package to the feed mechanism and roll the die package from the press onto the transfer cart. To avoid personal injury, be sure the die assembly is secured to the cart to prevent accidental roll and movement of the die assembly. 6. Release the floor brake on the transfer cart. 7. Roll the transfer cart and die package to the storage rack. 8. Transfer the die assembly to the storage rack. 6. OPERATION 6.1. Operating Procedure The following explanation assumes the press is connected to the proper power and air supplies. 1. Be sure the die package is loaded as described in Paragraph Place a printed circuit board panel in position on the lower assembly of the die package. See Figure 11. Pilot pins on the lower assembly were designed to restrict the positioning of the printed circuit board panel, allowing only one orientation. Printed Circuit Board Panel Figure Simultaneously touch both palm buttons. The lower assembly of the die package will feed into the singulation chamber. The ram will extend, causing the upper assembly to punch (singulate) printed circuit boards from the printed circuit board Rev D 15 of 34

16 panel. The ram will then retract and stop in the up position. The lower assembly will return to position for loading another printed circuit board panel panel. CAUTION If the field of the safety light curtain is interrupted by any object while the die assembly is moving to or from the singulation chamber, the press will stop. The press cycle will resume when the interference has been cleared. 4. If the die package is equipped with a carrier tray, remove the tray containing the singulated circuit boards and panel scrap. Otherwise, the circuit boards and panel scrap must be individually removed. See Figure 12. After the board is singulated, BE SURE to remove all the singulated printed circuit boards. Leaving printed circuit boards in the upper die assembly could jam or damage the die package. 5. Repeat Step 2 through Step 4 until all printed circuit board panels are singulated. Singulated Printed Circuit Boards Figure If the same die package is used for eight hours of operation, inspect the singulated printed circuit boards and scrap for sharpness of the cut. At the end of each eight hour shift, it is recommended that the upper part of the die package be repositioned by entering the SETUP mode and cycling the machine to return the entire die package to the loading position. Cycle the machine again to reload the die package before beginning the next eight hour shift. If the air supply is removed with the upper part of the die package clamped in the machine, DO NOT cycle the machine in the AUTO mode. Enter the SETUP mode and bring the die package out to the loading position. Reload the die package to reposition the upper part of the die package in the machine clamps then enter the AUTO mode and run the machine. 7. Unload the die package as described in Paragraph Emergency Stop A red EMERGENCY STOP button is located on the operator control panel. If this button is pressed, all machine activity will stop. If the ram is extended or extending, it will return to the fully retracted position. The screen of the operator console will go blank after ten minutes of inactivity. Touch anywhere on the screen to wake up (refresh) the display. 16 of 34 Rev D

17 7. PREVENTIVE MAINTENANCE It is important that a preventive maintenance program be performed at regular intervals to ensure efficient, dependable performance of the press. The preventive maintenance program consists of cleaning, visual inspection, and lubrication. Refer to Instruction Sheet supplied with the die packages for die maintenance procedures Cleaning To avoid personal injury, turn off the main power switch and disconnect the press from the electrical supply and air supply. A. Daily 1. Turn off and disconnect electrical power and air supply. 2. Drain any accumulated water from the filter/regulator bowl located on the side of the press. 3. Remove any foreign objects that may have accumulated on the working surfaces. 4. Vacuum all exposed areas of working surfaces. 5. Restore power and air sources to the press. 6. Verify the air pressure is set to 5.86 bars [85 psi] and adjust if required. 7. Turn on the press and verify proper operation. To avoid personal injury, exercise caution when working with the brake. If the brake is not operating properly due to wear, broken springs or other malfunctions, be SURE the press is repaired before resuming production. 8. Check the brake mechanism for proper operation. a. Place both hands on the palm buttons. The shuttle should begin to move. b. Remove one or both hands. The shuttle should stop immediately. B. Monthly Since guards to covered areas must be removed for monthly maintenance, monthly maintenance must be performed ONLY by a trained technician. 1. Clean the bezels of the light curtain with a mild detergent, glass cleaner, or isopropyl alcohol. Use a clean, soft, lint free cloth or wipe. 2. Remove the side guards to permit access to the top of the press and under the scrap chute. Vacuum any debris and dirt from these areas. 3. Install the removed guards. 4. Vacuum the area around the die feed cylinder. 5. Wipe the entire press with a clean rag to remove dust produced by the singulation of printed circuit boards. Although dust is minimal, maintenance personal should exercise caution when cleaning. Excessive dust is known to cause irritation to the eyes, nose, throat, and lungs. Prolonged inhalation can cause lung disease. It is recommended that the appropriate Material Safety Data Sheets be obtained from the printed circuit board manufacturer Monthly Inspection To avoid personal injury, disconnect the press from the electrical supply for the inspection procedures. The inspection procedure should be performed by a trained technician. The air remains supplied to the machine and the valves must be manually shifted. CAUTION Equipment damage COULD occur if this procedure is performed by an untrained technician. Rev D 17 of 34

18 1. Turn off power to the press and disconnect from the electrical power source. Allow the air to remain on to permit manual activation of the valves. 2. Remove the guards and covers, as necessary, to inspect the covered pneumatic connections. Check for leakage at pneumatic fittings using the manual override buttons on the valves for the ram, clamps, setup blocks, and auto feed. Ensure the valves are placed in both positions when checking for leaks. If any leaks are found, remove air to the hose, reseat the hose in the fitting and tighten the fitting if necessary. If the leak still exists, trim the end of the hose, reseat the hose and recheck. 3. Check hydraulic lines and fittings for evidence of leakage. If leakage is found, repair as necessary or call the Customer Service Center for assistance. 4. Disconnect the air supply from the press. 5. Perform the lubrication procedure, as described in Paragraph Lubrication A. Monthly Lubrication To avoid personal injury, turn off the main power switch and disconnect the press from the electrical supply and air supply. The lubrication procedure should be done only by a trained technician. CAUTION Equipment damage COULD occur if this procedure is performed by an untrained technician. Silicon spray is the desired lubricant (versus light machine oil) because dust and debris do not accumulate as rapidly. However, light machine oil may be used if silicone is not available. CAUTION DO NOT USE GREASE. Grease will become a fiber glass filled, abrasive paste which will cause premature wear. 1. Turn off power and air to the press and disconnect from the power sources. 2. Remove covers and guards to access the press die assembly. 3. Wipe the existing oil and dirt from the four guide pins and bearings of the press die assembly. 4. Lubricate the guide pins and bearings sparingly with silicon spray. Use a cloth behind the guide pins to minimize over spray. 5. Install covers and guards. 6. Restore power and air sources to the press. 7. Turn on the press and verify proper operation. B. Recommended Hydraulic Lubricants The manufacturers of the hydraulic cylinders specify that the following oils be used when topping off the oil levels: HyperCyl Spindle Oil and Tox Pressotechnik Hydraulic Oil. Types of HyperCyl Spindle Oil include: Chevron Hydraulic Oil AW ISO 32 Exxon Mobil Spinesstic 22 Exxon Mobil Velocite Oil No. 10 Imperial Oil Nuto A 22 Shell Tellus Plus 22 The primary type of Tox Pressotechnik Hydraulic Oil is: OEST Hydraulic Oil H LP 32L 18 of 34 Rev D

19 Pressure Release Pushbutton Clamps Check Valve Pressure Release Pushbutton Ram Check Valve Figure Hydraulic Oil Leakage / Depressurizing the System (Figure 13) CAUTION Do NOT continue to operate the machine when it is leaking hydraulic fluid. If there is evidence of hydraulic oil leakage, depressurize the system as follows: 1. If the leak is not severe, use the SETUP mode to unload the die package. 2. Disconnect the air and electrical power supplies to the machine. To avoid personal injury, be sure to block up the ram before releasing pressure. The ram MAY move down when the press is depressurized. 3. Remove any pressure remaining in the press by depressing the pushbutton on the ram check valve and the clamps check valve. Refer to Figure 13. Rev D 19 of 34

20 This step is not required on CE version presses. The air piloted check valve on these presses is replaced with a mechanical rod locker. 4. When all the pressure is removed, it is safe to inspect the machine for the source of leakage. Refer to the Material Safety Data Sheet (MSDS) supplied with the machine for proper handling and disposal of contaminated materials. 5. If assistance is required to identify or repair the leak, contact the WAND SINGULATION SYSTEMS Customer Service Center at Refilling and Venting HyperCyl HPT Series Tandem Hydraulic Cylinders By re filling and venting in one procedure, overfilling of the cylinder is prevented. All HyperCyl hydraulic cylinders are pre filled and tested at the factory. The internal oil reservoir contains sufficient excess oil, (30%) that, with normal operation will operate for many trouble free cycles. All units are supplied with a reservoir fill coupling that is protected by a black rubber dust cap. Cylinders are also equipped with a low oil level indicator pin, which will extend outward to energize the low level switch. This activates an input signal to the PLC and the machine stops indicating a low oil level alarm. To refill the cylinder use only the HyperCyl Fill Unit (pump can) shipped with the machine. Fill with an ISO 32 Hydraulic Oil (refer to Paragraph 7.3,B. 20 of 34 Rev D

21 Rear View HyperCyl Cylinder Black Rubber Dust Cover (Over the Cylinder Fill Coupling) Low Oil Level Indicator Pin Low Oil Level Switch Figure 14 Proceed as follows: 1. Make sure the cylinder rod is fully retracted. 2. Block the ram in the up position. Rev D 21 of 34

22 3. Turn off the air supply to the machine. Push down the air shut off valve located on the inlet of the air filter/regulator at the rear of the press. Verify that the pressure falls to zero. See Figure Remove trapped air remaining in the machine by depressing the pushbutton on the ram check valve and the clamps check valve. See Figure 13. Failure to remove trapped air could result in the eruption of oil when the vent port plug is removed. This step is not required on CE version presses. The air piloted check valve on these presses is replaced with a mechanical rod locker. 5. Make sure the fill unit contains a sufficient quantity of oil. While holding the fill unit coupling over a collection pan to collect expelled oil, depress the inner ring of the fill unit coupling and depress the fill unit handle until all air has been vented from the fill unit tubing. Release (close) the coupling. 6. Remove the black rubber dust cover from the cylinder fill coupling. See Figure 14. Connect the fill unit coupling to the cylinder fill coupling. 7. Remove the vent port plug and position a collection pan to collect expelled oil. Refer to Figure 15. Front View Vent Port Plug Figure of 34 Rev D

23 8. Repeatedly depress the fill unit handle until oil is expelled from the vent port hole with no air bubbles seen in the oil. 9. Install the vent port plug. Remove the fill unit coupling from the cylinder. 10. Install the black rubber dust cover onto the cylinder fill coupling. 11. Push in on the low oil level indicator pin until it is flush with the surface of the cylinder. Rev D 23 of 34

24 8. TROUBLESHOOTING These pages can be viewed on the machine display screen. On the main display screen, touch the PRESS FOR OPTIONS box, then touch the PRESS FOR TROUBLESHOOTING SCREENS box. PROBLEM Machine will not turn on Machine is on but the die will not enter the working area Die enters the press but does not set up Top die clamps but ram does not retract Top die clamps and ram retracts but the lower die does not return to the load area Lower die will not enter the working area POSSIBLE SOLUTION Plug in the machine power cord. Turn the main circuit breaker to the on position. Make sure all of the guards are on. Make sure the guard interlocks circuit is completed. Make sure the light curtains are clear. Adjust the air pressure to between 5.52 and 6.21 bars [80 and 90 psi]. Clear the working area of debris. Make sure the die package out sensor is on. See the I/O table screen. Make sure the ram up proximity sensor is on. See the I/O table screen. Make sure the palm buttons are being touched simultaneously. Make sure the palm button inputs are on. See the I/O table screen. Make sure the light curtains are clear. Adjust the air pressure to between 5.52 and 6.21 bars [80 and 90 psi]. Make sure the top die in sensor is on. See the I/O table screen. Make sure the bottom die in sensor is on. See the I/O table screen. Make sure the set up sensor is on. See the I/O table screen. Adjust the air pressure to between 5.52 and 6.21 bars [80 and 90 psi]. Make sure the top die in sensor is on. See the I/O table screen. Make sure the clamps pressure switch is on. See the I/O table screen. Make sure the light curtains are clear. Adjust the air pressure to between 5.52 and 6.21 bars [80 and 90 psi]. Make sure the top die in sensor is on. See the I/O table screen. Make sure the ram up sensor is on. See the I/O table screen. Make sure the light curtains are clear. Adjust the air pressure to between 5.52 and 6.21 bars [80 and 90 psi]. Make sure the palm buttons are being touched simultaneously. Make sure the palm button inputs are on. See the I/O table screen. Make sure the top die in sensor is on. See the I/O table screen. Make sure the ram up sensor is on. See the I/O table screen. Make sure the die package out sensor is on. See the I/O table screen. Figure of 34 Rev D

25 PROBLEM Lower die enters the working area but the ram does not extend Ram extends and retracts, but the boards are not separated (singulated) Ram extends and separates the boards but does not retract to the ram up position Boards are separated and the ram returns but the lower die doesn t return to the loading position. Die slams against the stops when it enters the working area, or when it returns to the loading position. POSSIBLE SOLUTION Make sure the light curtains are clear. See the I/O table screen. Adjust the air pressure to between 5.52 and 6.21 bars [80 and 90 psi]. Make sure the ram up sensor is on. See the I/O table screen. Make sure the top die in sensor is on. See the I/O table screen. Make sure the bottom die in sensor is on. See the I/O table screen. Make sure the clamps pressure switch is on. See the I/O table screen. Make sure the light curtains are clear. See the I/O table screen. Make sure the top die in sensor is on throughout the machine s cycle. See the I/O table screen. Make sure the bottom die in sensor is on throughout the ram s cycle. See the I/O table screen. Check for proper operation of the power stroke pressure switch. See the I/O table screen. Adjust the air pressure between 5.52 and 6.21 bars [80 and 90 psi]. Make sure the ram cylinder is not overfilled with hydraulic oil. Make sure the light curtains are clear.. See the I/O table screen. Adjust the air pressure to between 5.52 and 6.21 bars [80 and 90 psi]. Make sure that the ram up sensor is on. See the I/O table screen. Clear debris from work area of the machine. Adjust the feed regulator and flow controls located on the feed cylinder solenoid valve. Adjust the hydraulic cushions. 9. CE PRESS VARIATIONS Figure 17 This section of the manual deals with variations and modifications made to the machine for CE purposes. These variations apply to WAND SINGULATION SYSTEMS Press See Figure 18. Refer to Drawing Number , in the documentation package, for the Declaration of Conformity. WAND SINGULATION SYSTEMS Press is virtually the same press as described (in ) with the following exceptions: A main air dump valve was added to the EMERGENCY STOP (E stop) circuit, The front door was replaced with a die package latch, A telescoping guard was added (see Figure 18), The two Palm (hand touch) buttons and pneumatic system were updated, The Main Operating Screen (Figure 19) is slightly different, An automatic brake was added to the auto load cylinder, The ram check valve was replaced with a mechanical rod locker, A software initialization routine was added, and A password protected output toggle screen was added Description of Operation A. Power Up and Initialization Like the standard WAND SINGULATION SYSTEMS Presses, the power up initialization process begins after air and electric power to the press are supplied. However, only the the MAIN START button needs to be pressed. At this point the press will initialize to the load position. Rev D 25 of 34

26 WAND SINGULATION SYSTEMS Press Operator Control Panel Safety Light Curtain Telescoping Auto Load Guard Hex T Wrench Main Start Button Emergency Stop Button Die Package Latch Palm Buttons Oil Fill Unit Figure of 34 Rev D

27 Figure 19 If there is NO tooling in the press, it will open and close to the setup position the machine is then ready to have a die package loaded. If tooling IS properly loaded in the press, the press will open and shuttle the lower die package out to the load position. The WAND SINGULATION SYSTEMS Press is then ready to resume production. If the tooling is not located properly in the press, an alarm window will appear on the display and the initialization routine will not complete. Intervention from trained maintenance personnel is then required. B. Palm Buttons and Light Curtain If at any time during the press cycle, the light curtain beam is broken, the press will reverse its motion and automatically return the die package to the load position. The palm buttons must be held until the die package has completely traveled into the press. Once the die package is fully inserted, the press will complete a singulation or a load/unload cycle and automatically return the die package to the load position. When the die package is loaded in the press, the palm buttons must be released or an alarm will appear on the display and the die package will not automatically return to the load position. If an operator removes his/her hands from the palm buttons while the die package is in transit into the press, the die package will stop. The operator must place his/her hands back on the palm buttons to complete the loading of the die package. Otherwise, the light curtain beam can be momentarily broken to automatically return the die package to the load position Specifications If the die package is very close to the end of it s travel, the auto load cylinder may not have enough force to completely push the die package into the press. It is recommended that the light curtain beam be momentarily broken to automatically retract the die package to the load position. The load procedure can then be repeated. Machine specifications for CE version presses are reflected in Figure 2. Rev D 27 of 34

28 9.3. Options Screen The standard options screen was replaced with an options screen which contains a toggle to outputs screen. See Figure 20. See Paragraph 4.2 and Figure 6 for a description of other buttons on the Option Screen. PRESS FOR TOGGLE OUTPUTS SCREEN Button Pressing this button will display the screen that allows properly trained maintenance personnel to toggle the PLC outputs on or off to make machine adjustments or recover from situations where tooling is loaded improperly. This screen is password protected and does not work in normal run or setup mode. This screen works only when the machine fails to properly initialize. Refer to Paragraph 9.5 for information concerning the TOGGLE OUTPUTS Screen. Figure 20 (Refer to Figure 6) 9.4. Input/Output Table (Figure 21) The Input/Output states can also be determined by observing the state of the LEDs on the PLC. 28 of 34 Rev D

29 I/O TABLE Figure 21 Rev D 29 of 34

30 A. Explanation of Inputs Inputs for the CE machine include the following: LEFT AND RIGHT PALM BUTTONS LOW AIR PRESSURE PALM BUTTONS ON LOW OIL PRESSURE TOP DIE IN CLAMPS These directly control the Auto Load Solenoid (L5) through a safety relay. They no longer run to the PLC, so they are no longer listed. This monitors the main air pressure and displays an error message if there is insufficient air pressure. The PLC monitors the state of the safety relay for the palm buttons. This indicates that the air/oil cylinder does not have enough oil. An alarm window will appear on the display. The switch must be manually re set after oil is added. (Normally Closed) S16 indicates if there is upper tooling in the die clamps. If Input 2 (S5) is on and Input 14 (S16) is off, then the upper tooling is properly loaded. If Input 2 is off and Input 14 is on, then there is no upper tooling loaded. If Inputs 2 and 14 are BOTH off, then the upper tooling is installed but mislocated. Refer to Figure 7 and Paragraph 4.3 (A and B) for additional I/O information. B. Explanation of Outputs FEED IN RAM UP (HIGH PRESSURE) Is no longer PLC controlled, so it is no longer listed. This valve used to be a two position spring return. Since it is now a three position double solenoid valve, output 9 (L9) was added. Refer to Figure 7 and Paragraph 4.3 (A and B) for additional I/O information Toggle Outputs Screen (Figure 22) This screen is password protected and does not work in the normal run or setup mode. It only works when the machine fails to properly initialize. ONLY trained personnel should use this mode. To avoid personal injury, exercise caution. Unguarded motion could occur. To enter this screen after receiving an error alarm during machine initialization, first clear the alarm and press the Options button on the main screen. You must do this within a few seconds to avoid the alarm from being displayed again. From the options screen, select Press for Toggle Outputs Screen. Once in this screen, select Enter Password to Enable Outputs. Type the password and select Enter and Done. The outputs will now show as enabled. PRESS FOR TOGGLE OUTPUTS SCREEN See Drawing Number in the documentation package for the password. 30 of 34 Rev D

31 Figure 22 You can toggle to and from this screen at any time by selecting Press for I/O Table Screen without resuming the press initialization. If you leave this screen, the press initialization routine will resume and may cause motion. To avoid personal injury, be sure all guards are in place and all personnel are clear before exiting this screen. Rev D 31 of 34

32 A description of the output toggle buttons can be found below: The ram is physically locked in position until RAM UP or RAM DOWN is selected. RAM DOWN VALVE O:0/0 RAM UP VALVE O:0/1 RAM DOWN AND UP RELEASE DIE CLAMPS VALVE O:0/2 DIE CLAMPS CLOSE VALVE O:0/7 SPACER BLOCKS RETRACT VALVE O:0/4 AUTO LOAD VALVE O:0/6 Turns on/off outputs 0 and 9 (L1) and (L9) and sends the ram down when on. The power stroke is NOT engaged. Turns on/off outputs 1 and 9 (L2) and (L9) and sends the ram up when on. Turns on/off outputs 0, 1, and 9 (L1, L2, and L9) and may allow the ram to float (down) with the rod locker disengaged when on. Turns on/off output 2 (L3) and opens the clamps when on. Turns on/off output 7 (L7) and closes the clamps when on. Turns on/off output 4 (L4) and retracts the spacer (setup) blocks when on. Turns on/off output 6 (L6) to shuttle the auto load cylinder to the load position when on Preventive Maintenance for CE Version Presses Follow the procedures outlined in Section 7 with following additions. To avoid personal injury, turn off the main power switch and disconnect the press from the electrical and air supply. Always use the scotch (stop block) ( Figure 23) to prevent unintended motion. Be aware that residual air pressure will exist in the die clamp circuit until the manual relief button (Figure 24) on the check valve is pressed. Scotch Block Figure 23 Shown in Storage Location with Securing Screw 32 of 34 Rev D

33 Die Package Clamps Check Valve Manual Relief Button Figure 24 IMPORTANT When air pressure is removed, the ram is held in place with a mechanical rod locker. The rod locker can resist up to 4 tons [3628 kg] of force, so in order to release someone accidentally trapped in the press, the rod locker will have to be unlocked. To unlock the rod locker, a minimum 60psi [4.1 bar] air pressure must be applied to the rod locker port (see figure below). To access the rod locker port, it is necessary to remove the machine covers (top, side, and front). When the rod locker is released, the middle die plate can move freely up or down. Since the plate weighs approximately 600 lbs [272 kg] it is strongly advised that jacks be put in place before unlocking the rod locker to prevent unintended motion. Refer to Figure 25. Rev D 33 of 34

34 Rod Locker Rod Lock Release Port Figure REVISION SUMMARY Per EC : Added CE version main operating screen Modified other main operating screens Updated format to current corporate requirements 34 of 34 Rev D