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PRODUCT INFORMATION 1-800-522-6752

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409-32048

18 MAY 17 REV A

SAFETY PRECAUTIONS

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AVOID INJURY

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READ THIS FIRST! ...................................... 2

INTRODUCTION .................................................................................................................. 5

1.1.About This Manual ......................................................................................................... 5

1.2.Press Overview .............................................................................................................. 5

1.3.Production Details .......................................................................................................... 6

1.4.General Specifications ................................................................................................... 6

1.5.Capabilities ..................................................................................................................... 6

1.6.Layout ............................................................................................................................ 8

SAFETY ................................................................................................................................ 8

2.1.Equipment Lockout ........................................................................................................ 8

2.2.Emergency Machine Off (EMO) / ESTOP ...................................................................... 9

INSTALLATION ................................................................................................................... 9

3.1.Shipping ......................................................................................................................... 9

3.2.Uncrating ........................................................................................................................ 9

3.3.Initial Assembly .............................................................................................................. 9

3.4.Facilities Labeling ......................................................................................................... 10

3.5.Electric Supply Circuit .................................................................................................. 10

OPERATION ...................................................................................................................... 10

4.1.Operator Interface ........................................................................................................ 10

4.2.Logging On ................................................................................................................... 10

4.3.Selecting the Board ...................................................................................................... 11

4.4.Running the Board ....................................................................................................... 11

4.5.On Screen PCB Rendering .......................................................................................... 12

4.6.Interrupting the Pressing Cycle .................................................................................... 12

4.7.Changing the Pressing Sequence ................................................................................ 12

4.8.Error Conditions ........................................................................................................... 13

4.9.Runtime Help Screen ................................................................................................... 13

PROGRAMMING AND DATA ENTRY ............................................................................... 14

5.1.The Tool Data Base Editor ........................................................................................... 14

5.2.Profile Editor ................................................................................................................. 15

5.3.The Connector Editor ................................................................................................... 21

5.4.The Press Sequence Editor ......................................................................................... 24

SPC Option ........................................................................................................................ 27

6.1.Overview ...................................................................................................................... 28

6.2.Process Data ................................................................................................................ 28

Continued

CAP-6T and CAPI-6T
Automatic Electric Press
6-Ton Operations Manual

TIONS

Содержание CAPI-6T

Страница 1: ... 1 5 Capabilities 6 1 6 Layout 8 2 SAFETY 8 2 1 Equipment Lockout 8 2 2 Emergency Machine Off EMO ESTOP 9 3 INSTALLATION 9 3 1 Shipping 9 3 2 Uncrating 9 3 3 Initial Assembly 9 3 4 Facilities Labeling 10 3 5 Electric Supply Circuit 10 4 OPERATION 10 4 1 Operator Interface 10 4 2 Logging On 10 4 3 Selecting the Board 11 4 4 Running the Board 11 4 5 On Screen PCB Rendering 12 4 6 Interrupting the Pr...

Страница 2: ...enance 40 9 CONVEYOR EXTENSION AUTOLOAD OPTION 41 9 1 Installation 42 9 2 Operation 43 10 PREVENTATIVE MAINTENANCE PM 44 10 1 Cleaning 44 10 2 Inspection 44 10 3 Air Supply Filter 44 10 4 Lubricating 44 11 CALIBRATION PROCEDURES 44 11 1 Purpose 44 11 2 Automatic Load Cell Calibration Optional 44 11 3 Machine Zero 45 12 PREVENTATIVE MAINTENANCE PM SCHEDULE 45 13 SEQUENCE OF OPERATION 46 13 1 CAP 6T...

Страница 3: ...guards are in place and secure to equipment Do not operate the equipment without guards in place Always disconnect air supply and then exhaust system air pressure before performing maintenance or repair on the equipment Always disconnect the air and lockout the tool when not in use or when head or tool holder is detached Use caution when working with this equipment Never insert hands into installe...

Страница 4: ...n calling the Support 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 Support Center be ready with the following information 1 Customer name 2 Customer address 3 Person to contact name title telephone number and exte...

Страница 5: ...e and at the same time circuit boards have increased complexity susceptibility to damage and cost This trend will undoubtedly continue and accelerate as interconnect PCB s move from simple passive elements to more complex devices with components buried in the inner layers In a similar way it has become obvious that the old methods of slamming the connectors into the board are no longer acceptable ...

Страница 6: ...phere Ambient Operating Temperature range 5 to 40 C 41 to 104 F Altitude Up to 1000 m 3300 ft above sea level Relative Humidity range 20 to 95 non condensing Transportation and Storage 25 to 55 C 13 to 131 F and up to 65 C 149 F for short periods not exceeding 4 hours Suitable means shall be provided to prevent damage from excessive moisture vibration stress and mechanical shock during shipment El...

Страница 7: ... method is the ability to dynamically adjust the force that is applied to match what is actually needed thus reducing the stress on the PCB and connector No matter what percentage above the average is defined the maximum force applied is limited by the pre defined maximum force per pin The gentlest pressing technique is press to height This method yields the absolute minimum stress to the board an...

Страница 8: ...s are stored in the tool rack directly behind the fixture support table assembly The tool holder is a static assembly for holding the tools A Tool ID system is incorporated in the tool rack to manage the presence and position of each tool The press head will pick and place from the tool rack automatically as required 2 SAFETY The CAP is designed to comply with the latest safety standards The opera...

Страница 9: ...ly 1 Remove X and Y Axis shipping straps 2 Level procedure Verify that the Press is sitting flat on all six supports Use a Bubble gage set in both the X and Y Axis position and located on the Horizontal center plate bottom tool fixture support Adjust the feet as appropriately to level bubble gage in both X and Y Axis 3 Install customer supplied 4 conductor power cord 230VAC 1Ø 25 Amp thru bottom p...

Страница 10: ...ade by either touching the screen with a finger or by pointing and left clicking with the trackball Alpha numeric entries can be entered by the keyboard or by touching the screen buttons provided Note that any moisture on the face of the touch screen will prevent normal operation until it is removed See Figure 6 Figure 6 4 2 Logging On When the boot process is complete the startup screen is displa...

Страница 11: ... on the input data on the left a blank graph for the pressing force and distance data on the right and a series of buttons along the bottom If an error message regarding missing data is displayed you must return to the editors to correct the problem The rendering will be shown with the next connector to be pressed highlighted in blue This will be connector 1 unless the board being run was aborted ...

Страница 12: ...ill restart the process where it left off Exit Used to return to the main screen as displayed on startup This is usually done at the completion of a press run From the main screen a new PCB can be selected or the operator can log off Logging off when leaving the machine unattended will prevent unauthorized access 4 5 On Screen PCB Rendering The PCB rendering drawn on the screen shows the connector...

Страница 13: ...connector was tilted and the tool corrected the lean when it touched it Use caution when retrying because if there is a bent pin the retry may bend it over further and press it flat to the connector bottom Missing Connector This error is generated by the Profile program It will be obvious if a connector is missing If the connector is not missing there is an error in the Profile program which must ...

Страница 14: ...ation and PCB information Once the information has been stored it is available for use by current and future operations Access to the editors is normally restricted to levels higher than operator 5 1 The Tool Data Base Editor Purpose The tool data base editor is used to view and modify the tool data base which is an Access Data Base file The tool data base contains all the necessary information ab...

Страница 15: ...r Enter the number from the keyboard Tool Width This is used for drawing the PCB assembly rendering on the screen and for collision avoidance with obstructions Enter the width of the tool at the widest points Maximum tool width is 25 4 mm 1 00 in centered on tool bar Tool Length This is used for drawing the PCB assembly rendering on the screen and for collision avoidance with obstructions Enter th...

Страница 16: ...e This percent added assures complete seating of the connector This is the most widely used technique because it limits the stress to the assembly and does not require accurate board thickness measurement PRESS TO HEIGHT A connector can be pressed to within a programmed distance short of seating on the board surface This is the gentlest process possible because it exerts only enough force to press...

Страница 17: ...hese are user defined error messages If the height is reached and the action is an error The pressing process is immediately halted and the error message is displayed on the screen The operator must acknowledge the error message to continue Force This defines the force which will trigger the force action It is used to detect force errors and to define cycle completion based on the force generated ...

Страница 18: ...e is calculated by multiplying the number of pins in the particular connector being pressed by the maximum allowable force per pin Both the number of pins and the maximum force per pin are entries in the connector database This can be used to prevent excessive force from being generated during the pressing process User F Pin Pins This variable is provided for the flexibility of defining a force ev...

Страница 19: ...surface of the connector when PARS force readings are started A typical number is between 0 030 0 020 in Distance This is the distance over which force readings are averaged for PARS use A typical number is 0 010 0 015 in The shorter the distance the fewer the number of points averaged Look at the screen plot after the connector is pressed PARS information is overlaid on the graph to be sure the a...

Страница 20: ... connector but the process will actually be complete as soon as the force reaches the PARS force plus 25 The height given simply provides a destination that is not intended to be reached because the force condition will be satisfied first If the destination is reached before the PARS force is reached then there is most likely an error in the parameters used to calculate the distance relationship b...

Страница 21: ...tion example different connector manufacturer Giving multiple connectors the same code will initiate a prompt asking operator to identify connector type prior to press setup Number of Pins Enter the TOTAL number of pins per connector If more than 1 connector is to be pressed at a time enter the full pin count for all connectors to be pressed as a group The number of pins on a connector is used to ...

Страница 22: ...face of the connector that contacts the PCB It is used to calculate the position the head must achieve to seat the connector to the proper height Unseated Top Defined as the distance from the surface of the connector that contacts the tool to the surface of the PCB typically measured with the connector preloaded into the PCB Overall Height Defined as the distance from the top surface of the connec...

Страница 23: ...analyzed for a seven point trend A seven point trend is seven consecutive points with increasing values with decreasing values above the mean below the mean The objective is to identify trends that indicate a change in the process is occurring If one of these trends is found it will be highlighted in red on the SPC chart Flag Control Limit Violation When this box is checked the SPC button within t...

Страница 24: ...a description of the board to be pressed Board Clearance This is the safe distance that the tool is above the board that the head will allow when moving between connectors Be sure to allow enough clearance for the tallest component on the board NOTE The distance is actually dynamic in that the press will provide the same clearance between the board and pressing tool regardless of tool length The t...

Страница 25: ... substitution codes that are defined in the connector database Each associated connector must be individually entered into the database but will be linked by the common substitution code First Article Signoff This feature stops the pressing cycle after the first board is complete An approval is required from a person other than the operator of the machine Load Unload Time per Board s This Administ...

Страница 26: ... the head rotation as follows The head is at zero degrees when longer protrusion of the tool bar containing the ID device is toward the left side of the machine Positive 90 degrees is a turn counter clockwise as viewed from the top Thus the tool load unload angle is 270 degrees Connector The connector to be pressed is selected from the connector database by using the drop down menu All connectors ...

Страница 27: ...e For example all boards are measured before starting pressing connectors The first tool is then selected from the tool rack and all connectors of that type are pressed on all active boards before the next tool is selected Mouse clicking the small square on the board rendering that designates the board zero reference will deselect that board The background switches from green to clear when a board...

Страница 28: ... PCB is plotted on the R Range chart The R chart becomes an S Standard Deviation chart when the subgroups size is greater than 5 connectors The S chart plots the standard deviation of all connectors of the same type on a specific PCB 6 2 Process Data This area Figure 29 shows data that is calculated for the process It is a measure of the health of the process for a number of PCBs Figure 29 CPK Pro...

Страница 29: ...o press the charted connector type Brd Rev Revision of board file 6 4 Options See Figure 31 for the following options Figure 31 Range Bars The range for the data whose average forms a point on the X bar chart can be displayed on the X bar chart It is represented as a vertical line through the plotted point with a short horizontal line at the maximum and minimum readings for the averaged data Check...

Страница 30: ...Width Up to 25 4 mm 1 00 in including any mounting features Height 56 8mm 0 5 mm 2 236 020 in including mounting plate tool bar Length Up to 203 mm 8 in single or multiple tool combination Tool Bar The tools will be mounted on a Tool Bar Each plate is encoded with a unique code which provides a specific tool ID Zero is not allowed Number 1 is reserved for the calibration thickness tool Mounting Th...

Страница 31: ...ring pressing Height minimum 6 mm 236 in maximum 50 8 mm 2 00 in Flatness and parallelism of top and bottom surfaces should have a maximum run out of 0 13 mm 005 in Length Up to 914 4 mm 36 in Width Up to 762 mm 30 in Mounting The fixture must precisely locate and orient the PCB relative to the Origin 0 0 position dowel in the fixture support plate Any two of the dowel holes provided in the machin...

Страница 32: ...B over the fixture plate lowers it onto self centering pins and then clamps the board in place At the completion of pressing the board is automatically unloaded from the machine by the conveyor system Figure 34 PCB Support Fixture Specifications CAUTION Consideration must be given to any portion of the fixture that is close to the conveyor side rail to ensure that the fixture height and the Press ...

Страница 33: ...down to the fixture This prevents the PCB from being lifted when an insertion tool is retracted from a pressed connector Also the clamp holds the PCB flat to the fixture The height of the clamp bar is adjusted so it provides a small clearance of 1 mm 03 in when the clamp bar is in the up position and the PCB is being conveyed PCB thickness range is 1 5 to 6 mm 06 to 236 in Alternate mounting of cl...

Страница 34: ...TOLOAD OPTION FOR THE CAPI 6T NOTE The following portion of this manual may not apply to your machine configuration The Autoload option used with an adjustable width conveyor will allow either in line or stand alone operation and increases the throughput capabilities of the CAPI 6T over the CAP 6T PCBs are loaded and secured automatically Once a press sequence has completed the Autoload conveyor u...

Страница 35: ...stream connector and the SMEMA connector on the right is always the downstream connector Logically operating the machine in Reverse Production mode flips the upstream and downstream directions this requires the SMEMA cables be routed from the opposite sides of the CAPI 6T to the adjacent inline machines If the press is located at the beginning or end of a PCB line then a Conveyor Extension 2018690...

Страница 36: ... throughput If the CAPI 6T is the last machine in the line manually remove the PCB from the exit Conveyor Extension when prompted Reverse Shuttle Mode Place the desired PCB on the Conveyor Extension when prompted The Conveyor Extension must be previously installed and aligned to the exit side of the CAPI 6T The cover for the infeed conveyor opening must also be previously installed The infeed conv...

Страница 37: ...ns allow for manual raising and lowering of the main Autoload conveyor rails When both SAV Solenoid Air Valve buttons are off both ports of the lift air cylinders are closed to maintain position The state of the four 4 conveyor lift air cylinder sensors is indicated by the related input displays The Clamp PCB button lowers and raises the two main conveyor clamping bars that lock the PCB into posit...

Страница 38: ...tes a PCB is staged and ready for transfer to the main conveyor 4 The input and output devices are usually other SMEMA compliant PCB processing equipment or conveyor buffers The press can also be used in a stand alone configuration where the PCB s are loaded and unloaded at the output of the main conveyor Reverse Shuttle Mode The Input device Board Available display indicates if a PCB is available...

Страница 39: ...if necessary Note When machine power is down the conveyor controllers switch the LED s to low power to extend LED life When power is restored Machine Enable active the LED power is set to the requested state indicated by the checkbox 8 5 Setup Autoload Width To manually adjust the Autoload conveyor width perform the following steps Refer to Figure 41 1 Open the right front door on the CAPI 6T base...

Страница 40: ...l purpose oil on the bearing guide rails Check all air lines for crushing crimping during motion of the clamps hard stops and or main conveyor rails Check for any binding in the up down motion of the clamps in out motion of the hard stops and up down motion of the main conveyor rails If necessary loosen the mount attachment screw to the actuators check for smooth fixture motion and retighten as ne...

Страница 41: ...ines to provide sufficient input staging length for longer boards to be processed in line The extension is a simple edge guide belt conveyor mechanically connected to the CAPI 6T main or infeed conveyor rails and belt motor The CAPI 6T conveyor input or exit sensors are moved to the end of the extension rails The extension has no electrical controls or components Guarding on the extension prevents...

Страница 42: ...afts on the ends of the machine conveyor rails 6 Position the Conveyor Extension against the end of the machine conveyor rails Make sure the conveyor extension rail alignment pins are engaged in the slots in the end of the machine conveyor rails 7 Use a long straight edge to align the Conveyor Extension rails to the rails on the machine conveyor 8 Connect the Conveyor Extension to the side panel o...

Страница 43: ...veyor the Conveyor Extension operates as an integral part of the machine conveyor Once properly installed no additional actions are required to operate the CAPI 6T with extension s Conveyor Extension Detail Conveyor Extension Drive Coupling Drive Coupling Fiber Sensor Belt Tensioner ...

Страница 44: ... bearings should only be performed by trained maintenance personnel and is normally only required every two to three years Be particularly careful not to over pack the Z axis bearing housing as it can push the grease seal out of the top of the housing The Z axis ball screw nut should be lubricated every three to six months depending on use The Z axis ball screw nut has a M6 threaded port on the un...

Страница 45: ...200 lbs to the table top On the Machine Zero tab set both Z and ZL positions at 56 79 2 236 if English units are displayed and then press Set Z and Set ZL buttons X Y axis Zero The X Y axis zero is defined as the center of the press head positioned directly above the front left dowel hole on the fixture mounting plate table top This dowel hole represents the machine origin 0 0 To set check the zer...

Страница 46: ...th the option to either retry if appropriate or cancel The operator may interrupt the press cycle by clicking the on screen Stop button or pressing the green Start Pause push button The press cycle will stop after the current connector is completed Pressing the green Start Pause button during execution of a connector press profile will immediately halt the press head If the press cycle was interru...

Страница 47: ...n or pressing the green Start Pause push button Any error conditions must be corrected first 10 When the operation is complete the PCB will be unclamped raised above the fixture and conveyed out of the press area onto the Conveyor Extension The operator will then be prompted to remove the completed assembly from the Conveyor Extension Once the PCB is removed the operator must acknowledge this by p...

Страница 48: ... in or out event Data covering Selected Dates can be viewed or All can be chosen See Figure 50 The user log can be purged by selecting the data period that you would like to save then pressing Update User Log For example to delete all but the last 60 days of data select 60 Days then press Update User Log Figure 50 ...

Страница 49: ...d when the main press program is initiated from the Windows desktop The only action available is the Operator button which will initiate the Operator Access Screen on the next page The Status Bar located at the bottom of the screen indicates no operator is currently logged into this machine Figure 51 Initial AEP Screen The Status Bar located at the bottom of the screen indicates no operator is cur...

Страница 50: ... by the Page Up or Page Down buttons or the Alphabetical Tabs located on the top of the screen The Log Off button refers to logging off the current operator and going back to the Initial AEP Screen If an operator is currently logged onto the machine the Status Bar at the bottom will indicate the name of the current operator If there is no current operator the Log Off button will be Grayed out The ...

Страница 51: ... Figure 53 Operator Password The Password Entry Screen allows the operator selected on the previous page to enter his her individual Password Enter Password by using the screen buttons cursor or touch then press the OK button ...

Страница 52: ...cess to Press functions as authorized by the designated machine administrator In most cases a standard operator will only have access to the Run button Technicians could be allowed at Supervisor discretion the ability to access the Joystick screen for manual operation and various Setup and Editor screens ...

Страница 53: ...needs to add another operator or modify an existing operator this Main Menu option allows that individual to be entered into the database of qualified people The individual inputting new user information is limited by their level of access and can only extend that level or below to the new user ...

Страница 54: ...epending on Administrative discretion The Administrator or Superman symbol allows access to all screens and editors Note the level of access is limited by the level of the operator currently logged on Temporarily Disqualify allows a user with equal or above access level authority to remove an operator s access pending further decision Figure 56 ...

Страница 55: ... predetermined velocity or Incremented a specific distance by clicking on the center Joystick button The tool holder can rotate 360 degrees in 90 degree increments and this is accomplished by selecting the appropriate Tool Rotation When the Press tools come in contact with the item to be pressed the active graphic load bars on the left side of the screen indicate the real time contact pressures be...

Страница 56: ...ring you to the correct coordinates The safety feature is the Move button you activate the desired position but the Press Head will not move until the Move button is depressed New preprogrammed buttons are created by depressing the New Point button and then clicking on the Set Current button for where you are at the present moment or typing in the X Y Z coordinates that you desire Assign a name to...

Страница 57: ...l the maximum programmed speed in the X Y Z Axis that the Joystick can give you in Jog mode or programmed motion can generate Maximum Joystick generated force is controlled by the bottom slider In Run mode the maximum speed and force are controlled by the software and the settings in the Servo Parameter screen Each Axis can be deactivated by the Enable Disable boxes ...

Страница 58: ...govern which tool by slot number the loading mechanism will go to load replace the press tool It can be programmed by check box to auto search for a specific tool as listed in the Tool Type Box if you desire when loading a tool It will also auto search for an empty slot if you desire and check the box to unload a tool when done with the appropriate task Tool ID s are also programmed using this scr...

Страница 59: ...k Machine Zero Joystick Functions Right side of the screen remain the same This screen is used to set up the actual Machine Zero 0 0 of the coordinate system used by the motion control system This should only be performed by qualified personnel ...

Страница 60: ...the right side of the screen are the same as before The left side controls are used for automatic calibration of the load cells using the ACAL unit load cell standard This calibration is performed initially at the factory It is recommended to perform annual calibration ...

Страница 61: ...tputs used by the machine The status of the inputs can be viewed and the Outputs can be manually activated This screen is very useful in troubleshooting sensor adjustment shot pin functioning and fixture table action Several Tabs are available within this Screen Head System shown above Safety Autoload optional ...

Страница 62: ...all the axes X Y Z The right side of the screen indicates Real Time tracking of the Servo outputs for all axes as active readouts in their associated boxes and indication through simulated lamps of any tracking errors and hard soft limits reached by the Servos This section is useful for watching encoder operation in action Figure 64 ...

Страница 63: ...nufacturer to set the parameters required to operate the servo system safely These values should only be accessed by qualified personnel under the instruction of the manufacturer Damage can occur to the machine or personnel nearby These numbers control the action of each servo axis Figure 65 ...

Страница 64: ...E 038 035 TE CONNECTIVITY CORPORATION PO BOX 3608 HARRISBURG PA 17105 3608 Call 1 800 522 6752 for customer repair service 17 REVISION SUMMARY Initial release Shutdown Screen Utilize this screen to shut down the AEP by double clicking on the picture of the press then selecting Shutdown System Once the system has completed the shutdown process and has saved all critical files it is safe to power do...

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