MEP-6TOperations Manual

(Manual Electrical Press – 6 Ton)

Rev B 1/99

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

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About This Manual.............................................5SAFETY.................................................................5

Lock Out/ Tag Out..............................................5Safety Covers / Guards........................................6Laser Sensor........................................................6Emergency Machine Off (EMO) / ESTOP...........7Two-Hand Start Switches....................................7Light Curtains.....................................................7Light Curtain Override Key Switch.....................7Pneumatic System...............................................8Caster Wheels.....................................................8Seismic Restraints...............................................8Frame Construction and Weight Distribution.......8

INSTALLATION....................................................9Uncrating............................................................9Initial Assembly..................................................9Facilities Labeling.............................................10Electric Supply Circuit......................................10Pneumatic Supply..............................................10

PRESS OVERVIEW.............................................11Purpose.............................................................11Capabilities.......................................................11Options..............................................................12Machine Specific Configuration........................14Layout...............................................................14

OPERATION........................................................15Getting Started..................................................15Powering Up.....................................................15Operator Interface.............................................16Logging On.......................................................16User Access.......................................................17Selecting The Board..........................................18Running The Board...........................................18Run Screen Buttons...........................................19On Screen PCB Rendering................................22Start Pressing....................................................22First Article Signoff..........................................23Interrupting the Pressing Cycle..........................23Changing the Pressing Sequence.......................23Error Conditions Related to the Board, Connector, Tools, and Programs..........................................23Runtime Help Screen:.......................................24

PRESSING TOOLS..............................................25SUPPORT FIXTURES (Platens/ Backup Fixtures)25PROGRAMMING & DATA ENTRY...................25

The Tool Editor.................................................26Purpose..........................................................26Entries...........................................................26

The Connector Editor........................................28Purpose..........................................................28Entries...........................................................28

The Profile Editor..............................................30Purpose..........................................................30Explanation...................................................30Entries...........................................................31Examples.......................................................34

The Press Data Editor........................................36

Purpose..........................................................36Entries...........................................................36

SPC OPTION........................................................39Overview...........................................................39Process Data......................................................40

CPK (Process Capability)..............................40X-Bar (Process Average)...............................40Std Dev. (Standard Deviation).......................40UCL (Upper Control Limit)...........................40LCL (Lower Control Limit)...........................40VCL (Variability Control Limit)....................40

Point Data.........................................................40Options..............................................................41

Range Bars....................................................41Control Limits...............................................41Spec. Limits..................................................41Grid...............................................................41Shaded...........................................................41Thick Lines...................................................41Print..............................................................41

MAINTENANCE FUNCTIONS (UTILITIES)......42Machine Logs....................................................42

Error Log.......................................................42User Log.......................................................43

Joystick.............................................................44Analog Inputs................................................44Points:...........................................................45Control..........................................................45Calibration....................................................46Tools.............................................................46Machine Zero................................................46

Input / Output Screen........................................47Servo Terminal..................................................48Servo Parameters...............................................49Setup Parameters...............................................51

Machine Operation........................................51Load Cells.....................................................51Save..............................................................52Cancel...........................................................52

Utilization.........................................................53PREVENTATIVE MAINTENANCE....................54

Accessing the Press Head..................................54Cleaning............................................................54Inspection..........................................................54Lubricating........................................................54

Z Axis Rods..................................................54Z Axis Screw.................................................54

Torquing Critical Bolts......................................54Clean Water Trap In Air System.......................55Load Cell Calibration........................................56

Calibration Procedure for Initial Setup of MEP-6T:................................................................56Zero and Balance TMO Procedures...............58Balance Load Cells Procedure:......................59Calibrate load cell Procedure.........................60

APPENDIX A - SPARE PARTS LIST..................62

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APPENDIX B – FEATURES & SPECIFICATONS:.............................................................................63APPENDIX C – MAJOR COMPONENT LAYOUT / DESCRIPTION:.................................64

APPENDIX D - ELECTRICAL / MECHANICAL SCHEMATICS 71

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INTRODUCTION

About This ManualThis manual contains the installation, safety, operation, and maintenance procedures for the 6 ton Manual Electric Press (MEP-6T).

SAFETYThe MEP-6T is designed to comply with the latest safety standards required by OSHA, NFPA-79, CSA, and CE. It has been evaluated by a third party Inspection Agent for SEMI-S2 compliance.

Lock Out/ Tag Out

The main power disconnect switch is provided in the rear panel of the machine and is clearly marked. When it is in the “ON” position, it is mechanically interlocked to prevent the access door from being opened. In addition to the mechanical interlock, the door is equipped with a keyed lock.

! Eye Protection

Eye protection should be worn at all times when operating or servicing this machine. In the event a connector is crushed during the pressing operation, pieces of the connector could become airborne. Please note: the laser sensor does not require eye protection use.

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CE Required

CE Required

Safety Covers / Guards

All safety guards must be in place before operating the press. This includes all sheet metal and Lexan panels around the machine.

Laser Sensor

The press is equipped with a Class II laser sensor model FSL manufactured by Keyence. It emits a visible red laser beam at 670nm, and 3 mw maximum power. The FDA registration number for the laser is 922328-00. The laser beam is not directly viewable during normal operation due to the mounting position. No special eye protection is required.

No eye protection required under normal operating condition. Reflected laser may be dangerous.

CAUTION: Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure.

The FSL laser device is equipped with an interlock that prevents laser emission if the fiber beam delivery cable is disconnected.

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CE Required

CE Required

Laser Warning label location

Eye protection label location

Safety Cover and Guard labels

Lockout label

Electrical hazard labels (MEP-6T viewed from rear)

(MEP-6T viewed from front)

Note: The above photos illustrate typical locations for the safety labels on the MEP-6T. Safety cover and guard labels are also located on both side covers and on the rear panel.

Emergency Machine Off (EMO) / ESTOP

The Emergency Machine Off / Emergency Stop switches are mounted at the left and right corners of the table at the front of the press. They are clearly marked. When pressed, the switch latches in the pressed state and must be twisted to release. The EMO circuit is a hardware (dry contact) based latching circuit that does not reset when the EMO switch is released.

All voltage that is above 24VDC and external to the control cabinet (with the exception of the computer monitor) is removed when the EMO is pressed.

The EMO circuit is energized by an output from the computer when all safety conditions are met. The conditions which must be met are: (please refer to the schematic, 197E0900, “Power & Control” sheet)

1) Acroloop Servo Controller Watchdog Signal True - signal is false if the controller detects a problem

2) Acroloop Servo Controller PLC Output – the servo controller has an internal program that monitors servo operation and drops the EMO circuit if a problem is detected

3) Motor Overload Relay – This is heater based motor overload detection device that monitors the motor current draw and trips if the motor pulls too much current for too long a time. It automatically resets after a cooling period of approximately 2 minutes.

Two-Hand Start SwitchesThe Two-Hand Start Switches are the primary operator safety devices. They are located below the table on the right and left sides of the keyboard drawer. Zero force is required for actuation due to the optical switch design.

Each switch is wired to separate input, allowing the computer to monitor them for both actuation and release. Before a cycle can be initiated both switches must be clear, then actuated within ½ second of each other. If either switch is released during a cycle all motion is immediately halted.

During normal operation, messages displayed on the screen can be acknowledged and cleared by touching either of the buttons.

Light CurtainsThe light curtain is a secondary operator safety device. When the curtain is blocked, a relay in the Light Curtain Control box is de-energized (please refer to the schematic, 197E0900, “Power & Control” sheet, relay CR7). A normally open contact from this relay drops the latched safety circuit. This safety circuit disables the motor amplifier and removes power from the motor. The motor can only be re-energized after the light curtain is cleared and the computer resets the safety circuit. If there is a failure in the computer, such as a lockup, the safety circuit cannot be re-energized. See Light Curtain Override Key Switch section below for important light curtain operational information.

Light Curtain Override Key SwitchThe key switch is used to inhibit normal light curtain operation (please refer to the schematic, 197E0900, “Power & Control” sheet). This allows the head to be moved while the light curtain is blocked when in maintenance mode only. Normal operation is prohibited when the key is in the “BYPASS” position.

In addition to the security of the key bypass and software prohibiting normal operation while in bypass mode, all maintenance functions are protected by password.

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Pneumatic SystemThe pneumatic system is provided strictly for the air bearing that floats the head for side to side adjustment. There are no special precautions required when for pneumatic system considerations.

Caster WheelsThe machine is mounted on four swivel casters. The rear two casters are lockable. Two people are required when moving the machine as it is heavy.

Seismic RestraintsProtection from unwanted motion during an earthquake can be achieved by bolting the frame to the floor. This can be done in many ways, two of which are described here.

1) Drill holes through the lower frame tube on the right and left sides of the machine. Secure Eye-Bolts to the holes. Anchor similar Eye-Bolts into the floor below the machine. Secure the machine to the floor using chain or cable.

2) Fabricate steel angle plates to bolt to the lower frame tube at the left and right sides of the machine. Anchor the angle plates to the floor.

A seismic restraint kit is available from ASG on request.

Frame Construction and Weight Distribution The frame is constructed of tubular steel welded together as shown below.

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INSTALLATIONThis section describes the installation steps and requirements.

UncratingThe press, computer, monitor, leveling feet, and other removed parts are shipped on one pallet and is shrink-wrapped for protection. Remove the shrink-wrap and unpack the monitor, computer and other shipped parts. Remove Press from pallet by unbolting holddown bolts on four legs and lifting up several inches with a forklift (using 2x4 wood between underside of Top Horizontal Frame Plates, P/N 209A0210 and fork lift blades).

Initial Assembly

1. Using the four supplied bolts (3/16” – 16 X ¾” socket head screws and 3/8” flat washers per wheel), install the four Caster wheels to bottom of Press with two steerable wheels on front of Press.

2. Install customer supplied 4-conductor power cord (220VAC 3 20 Amp) thru 90 deg. Sealtite connector feedthru to Master Power Switch in back of MEP-6T. Note: The press can use either 220 or 208 VAC, but the transformer behind the panel in the lower front must be tapped appropriately. This transformer is used to generate 120 VAC for the computer and other devices.

3. Install customer supplied Industrial Air line to ‘Quik Disconnect’ input on lower back side of Press. Verify that shop air input has a minimum of 80 P.S.I. to MEP-6T Air Regulator.

4. Reattach Monitor Stand using the Pivot Bolt (P/N 91259A724) and extension arm (P/N 197A0612) to attach to the installed mount block (P/N 197A0610).

5. Reinstall Barcode Reader and Touch Pad on Monitor Stand.

6. Install Touch Screen Monitor on Stand using 2 lockdown brackets (supplied) on monitor base. Reattach 110Vac power cord, video cord and touch screen control cable to monitor back.

7. Remove Press Head lockdown brackets, if installed.

8. Bring Computer to backside of Press and open up computer chassis. Install P.C. Card cage, complete with both Acroloop cards into the computer chassis. Reinstall computer power cord and Monitor video cable to backside of computer. Set down computer into a vertical position and snugged into lower positioning blocks located on Electrical chassis floor. Reinstall upper locating bracket (upper computer support).

9. Power up Press by turning on Master Power Switch. Verify that computer comes ‘up’. If proper supervisor data (specific customer assignments) is installed in computer database, Press should be fully operational. Log on. initially, using “Aaron Arnold” with password “1”. Note: Adminisrator (Customer / Owner) should have changed this initial logon name from Aaron Arnold to ‘Administrator’ with appropriate password.

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Facilities LabelingThe electrical and pneumatic requirements are given on the label on the left side of the machine

Electric Supply CircuitElectrical supply circuit must be 220 VAC or 208 VAC, 3 phase, 4 wire service. It must be protected by a breaker rated for at least 10,000 IAC. Important Note: The press is shipped with an internal step down transformer taped for 220VAC. If your service is 208 VAC, the transformer must be re-tapped. The transformer is located behind the front kick panel. The instructions are attached to the transformer cover. Check the 110VAC circuit for proper voltage before operating the press.

Pneumatic SupplyThe pneumatic supply must be connected to the port provided at the lower left corner of the press. Any pressure above 80 PSI is acceptable. Compressed air is used only for the head positioning air bearing. Air consumption is minimal.

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PRESS OVERVIEWThis section introduces the MEP-6T, Manual Electric Press. A brief review of the purpose, capabilities, options, and layout is given.

PurposeThe MEP-6T all electric servo press was designed for two primary purposes. First, to satisfy the increasing need for controlled quality pressing of connectors on today’s complex circuit boards. As the density of connectors increases they become more fragile. At the same time circuit boards have become more complex, susceptible to damage, and costly. This trend will undoubtedly continue and accelerate as interconnect PCB’s continue move from simple passive elements to more complex devices with surface mount devices, and devices buried in the inner layers. In recent years, backpanel assembly shops have had to dramatically increase their process sophistication. It has become obvious that the old methods of “slamming” the connectors into the board are no longer acceptable. The MEP-6T, being an electric servo driven press, precisely controls the force and speed of each pressing cycle. In addition to control, quality feedback in the form of SPC (Statistical Process Control) analysis, display, and reports is available for the first time. Valuable data can now be captured and analyzed to improve the entire interconnect process.

The second purpose is to improve the efficiency of the pressing process. The manual techniques traditionally used for pressing connectors have been very labor intensive, unsafe, and ergonomically unacceptable. The result is that the throughput and quality have been operator dependant, which inevitably produces variable results. The electric servo press improves throughput while yielding more consistent computer controlled results with quality data feedback.

Thus, the dual purpose of this press meets the needs of the assembly shop and the end customer simultaneously.

CapabilitiesThe MEP-6T delivers a controlled force of up to 6 tons (12,000 lbs) through a 10” long x 1-1/2 wide “flat rock” head. The Z axis travel is 5”, and the “up” position can be programmed for any desired clearance above the tool before pressing. This improves efficiency by limiting the stroke travel per cycle. It can also be very convenient to use the press head as a tool support for unstable tool/connector situations.

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Overall Height 70”

Overall Depth36”

Overall width including printer

50”Overall width

38”

The pressing process can be controlled in one of five ways.

1) FIXED FORCE - A connector can be pressed to a set force such as 1000 pounds. This is the common technique used by hydraulic and pneumatic presses. It is the least sophisticated method available, and is the most likely to damage the PCB or connector.

2) FIXED FORCE PER PIN - A connector can be pressed to a set force per pin, such as 30 pounds per pin. This is slightly better than the first method because it recognizes that the force applied should be proportional to the number of pins being pressed. It cannot, however, compensate for normal variations in required force per pin for different connectors, in different positions, in different boards.

3) 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 the pins into the board. No excess force is pressed into the connector plastic or the board. This sophisticated technique is made possible by the control available using an electric servo press head and a rigid press structure. In order for press to height to be accurate, the board thickness must be precisely known. This can be done using the thickness measurement probe and sequence provided.

4) (PARS) – PERCENT ABOVE RANGE SAMPLE – A connector can be pressed with force that is proportional to the actual resisting force detected during the pressing cycle. We call this Percent Above Range Sample or PARS. In this technique, the connector’s resisting force while pressing is sampled and averaged over a distance range before seating to the board surface. The final force percent added assures complete seating of the connector. This is the most widely used technique because it limits the stress to the assembly, but does not require great accuracy for board thickness measurement.

5) FORCE GRADIENT – Monitors the rate of change of force to distance. This method is used for robust connectors that need to be seated against the board surface. Generally, the force vs distance plot will make a steep upturn as the connector contacts the board surface. The connector stops moving so the force rises quickly. A minimum angle is specified for the upturn which corresponds to how solidly the connector is pressed against the board.

The PCB size limit is 24” X 36”. The structure opening width is 30”, and press head can be manually move from side to side to access the edges of wide boards.

The program for pressing is a simple table of connector types and positions. Each pressing cycle, called a profile, is precisely defined by the user to control force, speed, and distance as the connector is pressed. This highly flexible technique allows a virtually unlimited variety of pressing options to satisfy the needs of present and future connectors. Data describing the connectors, tools, PCB, and pressing profile are stored in databases that can be modified either on or off line.

Many useful features and utilities are provided for maintenance. This includes on screen display of all machine inputs, and access to force all outputs.

Options

Touch screen SVGA monitor

The touch screen monitor provides a very convenient operator interface. It allows the operator to quickly respond to messages without diverting their attention from the screen.

Board Thickness Measurement

Board thickness measurement facilitates the press to height technique by measuring the actual thickness of the PCB before the pressing cycle starts. If the board thickness is not measured, the program uses a nominal thickness in height calculations.

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SPC (Statistical Process Control)

The SPC option provides real time data on the pressing force on each connector. Charts can be viewed live on screen, or recalled later for review. The supporting raw data is available for local or network access. Configurable reports are also available. The charts and data can be shared with the end user to increase their confidence in the quality of the pressing process.

Bar Code Reader

The bar code reader option allows PCB serial numbers to be quickly entered for tracking purposes. Stored data and printed reports include the scanned serial number.

Pressing tools can also identified by bar code for efficient and accurate control. A setup check box allows tool identification to be turned on and off.

Laser pointer

The laser pointer is an aid to correctly positioning the PCB under the press head. Proper positioning can be achieved by providing a target on the top of the pressing tool, which the operator aligns with the laser spot.

The active laser pointer / sensor provides the same visual feedback, but also uses an integral sensor to confirm the presence of a tool via a reflective target on the top of the tool. The pressing cycle is inhibited if no tool is detected by the laser. This provides an added level of safety and quality.

Light curtain - CE certified

The light curtain is mounted across the front access area of the press. If it is obstructed, the pressing process is inhibited. A bypass key allows access to maintenance personnel when needed. This safety device is a secondary backup to the two-hand anti-tie-down switches that are standard.

Digital color camera

One of the methods of programming a PCB uses a digital photograph. The image is used to guide the operator through the desired pressing sequence. The digital camera is used to acquire these images.

Color printer

SPC charts, reports, and screen captures can be printed out on the color printer. A printer shelf, which can be mounted on either side of the press, is provided with this option.

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Machine Specific Configuration

The configuration of the machine can be viewed by double clicking the left mouse button on the main screen. The machine attributes are given as shown here. The status of the available options available is also shown.

Layout

The press is a freestanding steel famed machine mounted on four swivel wheels. The pressing forces are contained within an “H frame structure” constructed of 1” thick steel plates. The width between the vertical support plates is 30”.

The press head assembly is mounted on the top of the structure. It can be manually adjusted to any point between the left and right vertical supports.

The electrical components are located in locked and electrically interlocked cabinet in the rear of the machine. The computer is also in the rear cabinet. The light curtain control DC power supplies are behind the panel in the front below the table. The panel must be removed to access this area.

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OPERATION

Getting StartedThis startup procedure assumes all necessary information has been entered in the Tool Database, Connector Database, Profile Database, and Press Data File. See the programming section for details in entering data in these files.

Powering Up

! CAUTION: THE REAR DOOR MUST BE FULLY CLOSED AND LOCKED BEFORE TURNING POWER ON. BE SURE ALL SAFETY COVERS ARE IN PLACE, AND PERSONNEL ARE CLEAR OF THE MACHINE BEFORE STARTING THE MACHINE.

The main power disconnect is mounted in the panel at the rear of the machine. Turning the switch to the “OFF” position disconnects all three phases of the incoming power. It can be locked out for safety and security proposes. Turn it to the “ON” position to start the machine.

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Main Power Switch

Operator InterfaceAll selections on the computer monitor can be made by either touching the screen with a finger (if the touch screen option is included) or by pointing and left clicking with the mouse. Alphanumeric entries can be entered by the keyboard or by touching the screen buttons provided. Note that a drop of moisture on the face of the touch screen will prevent normal operation until it is removed.

Logging OnWhen the boot process is complete, the startup screen is displayed. The only option available on startup is

the “OPERATOR” icon. Touch the icon with your finger or left click with the mouse pointer.

Select your name from the list displayed (if your name does not appear on the list, you must see the system ADMINISRATOR to add it). Enter your password and press “OK”.

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User Access

User access is controlled by 4 levels of passwords. To enter a new user, an individual with an administrator level must log in and press the “User Access” button pictured above. The new user access will be limited to not exceed the level of the individual presently logged in. Fill in the first and last names, the password, and the options to access. The Notes entry may be used for any purpose.

The “Temp Disqualify” selection allows a user name to stay in the computer but not be usable. It can be re-enabled at a later time.

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Selecting The Board

Press the “SELECT BOARD” button on the lower left area of the screen. Now select the board from the list presented. Use the up and down arrow keys as needed to change pages.

Running The Board

Double click the “RUN” icon to start the pressing process.

The first screen displayed will depend on which options have been turned on in the Press Data Editor for the current board. The requested information can be entered at this time, or press “Cancel” to enter it later. See the “Start Pressing” section below for details on information requested before running a board.

The run screen will display showing a rendering of the PCB based 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 a missing data is displayed you must return to the editors to correct the problem. See the “Programming” section below for details on information in the databases.

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Run Screen ButtonsDepending on the access level of the person logged in, only some of the buttons may be available. The purposes of the buttons from left to right are as follows.

“Z Up” - Used to raise the Z axis after a normal cycle is interrupted. An interruption can be caused automatically by an error condition or manually by releasing the START buttons.

“Go To” - Used for random access to any connector on the PCB. Using the mouse pointer, left click on the desired connector. The selected connector will be highlighted. Now press the “GO TO” button to select this connector to be pressed next. No machine movement will occur. The sequence will continue from this point.

“Tools” - Used to access the tool information. Pressing this button will display a list of all the tools in the current job. In User Mode, the next tool to be used can be picked form this list. See the Press Data Editor section below for further explanation of modes of operation. This button may not be available to all user access levels.

“Run Screen” – Restores the normal run screen view after selection of one of the other available views such as SPC.

“SPC” - Gives access to the SPC data screen. If SPC is not available, this button will be low lighted (grayed out). If any SPC parameter goes out of control, the icon will flash with two red horizontal bars. See SPC section for details on display and use of this feature.

“Offset” - Used to change the pressing height or graph alignment. The offset window allows a stored offset to be changed for all connectors on the PCB, or only the current connector type. A check box selects between these options. Offset is particularly useful in compensating for the many variables encountered when pressing to height. The offset shown when this button is pressed corresponds the next connector to be pressed in the current sequence. When changing an offset, verify the name of the connector in the upper right of the screen to avoid unexpected results.

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The Graph Offset changes the alignment of the displayed data to the graph X-axis. This is useful to correct

the display to align the upturn in the plot that occurs when the connector touches the board surface, with 0.000”.

This button may not be available for all users access levels.

“Profile Editor” - Used to enter a new pressing profile, or to modify the current profile at run time. See the Editors section for details on usage. This button is not available for all user access levels.

“New Board” - Used to reset the sequence pointer to the first connector. The result is the same as touching connector # 1 and pressing the “Go To” button. A prompt will be given to verify a return to the first connector is desired.

“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.

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“Performance” – The performance button is in the upper right corner of the screen. Pressing this button

displays process performance parameters. The Throughput parameters are self explanatory. The Profile Timing / Errors section shows the number of seconds taken to press the last connector of each type. It also shows the number of profile errors, types 1 through 5, that have occurred. The force monitor section shows the average force over a distance range (this is the SPC distance range if available). It also shows the maximum force and the height where it was measured.

“Diagnostics” – Pressing function key “F2” toggles diagnostics. The current state is shown at the bottom of the screen. With diagnostics on, detailed information relating to the pressing process is shown in light gray on the screen. The profile speed and transition points are shown, and the termination of each profile step is shown as “F” for force or “H” for height. This data can be useful in understanding the profile path taken while pressing. It also shows the update time for the force and height readings in milliseconds.

“Runtime Help” – “F1” displays runtime help. It gives a brief description of function keys available while in the run screen.

“Data Collection” – Collects raw data and assigns the file a .PDC extension. The file is written to SPC path (C:\MEP\SPC). This option is only effective if Diagnostics mode is active. To start Data Collection, press “F3”.

“Print Force vs Distance Graph” – Press “F4” to print the displayed Force vs Distance Graph.

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On Screen PCB Rendering The PCB rendering drawn on the screen shows the connector locations relative to each other and the board edges. The board thickness measurement point is shown as a circle with an “M” inside. The rendering is a good check for gross errors when running a new program for the first time.

It will be obvious for example if a connector is off the board, or if there is an interference.

The rendering is shown with the first connector to be pressed highlighted in blue. This will be either the board thickness measurement (if the option is enabled) or the first connector in the sequence.

It also shows the pressing sequence by number and gives the connector name. To read the detailed information, zoom in by double clicking the rendering using the left mouse button. You can step through the three zoom levels by continuing to double click. Panning around the PCB is done by touching or pointing and left clicking, then dragging in the direction to pan.

Start Pressing

The pressing process is started by pressing the two-hand buttons simultaneously. If further information is required before running the board it will be requested at this time. There are four entries that will be requested if the options have been selected in the Press Data Editor. Keep in mind that a combination of any, all, or none of these will be prompted depending on the program being run. The information can be typed from the keyboard, entered via the touch screen, or bar code scanned.

Connector Substitution – This feature allows for interchangeable connectors, typically from different manufacturers, to be selected at runtime. If any connector on the currently selected board has an alternate and this feature has been checked in the Press Data File editor (see the Connector and Press Data Editors for programming of this feature), you will be prompted to make a selection. Pressing “enter” will select the default connector type.

PCB Verify – This feature requires verification of the “type” or “model” of the board being run. Ideally, the board will be bar coded with this information, but typing it in will also work.

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Serial Number – This feature requests the serial number for each board. Bar coding is the most convenient

method to use. For data options refer to the Press Data Editor below.

Tool ID – This feature requires the tool identification to be verified before pressing proceeds. It is a quality confirmation that reduces the possibility of a mismatch between what the press expects and what the operator is doing. The ID can be typed or scanned in.

First Article SignoffIf this feature is activated, the press will stop after the first board is completed, and will not continue until signoff has been completed. Signoff is controlled by options set in the Press Data File. See the Press Data Editor below for details.

Interrupting the Pressing CycleReleasing the two hand start switches will cause the press to stop immediately. Once the cycle is stopped, pressing the buttons again will resume normal sequence where it left off. This makes it possible to slowly “jog” the tool into the connector to closely observe the process. The “Z Up” on screen button can be pressed at any time to bring the head up.

Changing the Pressing SequenceThe next connector to be pressed can be changed after a cycle has been interrupted. Using the mouse pointer or a finger on the touch screen, highlight the connector to be pressed next, then press the “Go To” button at the bottom of the screen. The sequence will start from the new point, and will automatically step to the next connector according in the program.

Error Conditions Related to the Board, Connector, Tools, and ProgramsSome of the common error conditions encountered during pressing are detailed below. Other error machine related conditions are listed in the “Error Messages” section of this manual. The error conditions generated by the Profile program are user defined so the wording may vary. In addition, new error messages not covered here may be introduced in the future.

Premature Contact - This error is generated by the Profile program and is likely to be the most common error condition that is encountered during normal operation. It occurs when the press head makes contact with the tool before it should. The contact force and position thresholds are defined in the Profile for the connector. Here are some of the possible causes:

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The connector is tilted so it is sitting too highThe pressing tool is raised by a bent pin in the connector The connector below the head is not the one expected by the program (the PCB is in the wrong position)There is an error in the Press Profile program (*.prs) where the approach height is too low and causes the head to hit the tool before expectedAn incorrect board or backup thickness is called out in the Press Data File (*.pdf)An incorrect tool height is called out in the tool databaseThe connector has a bent pin that is preventing it from entering the board

When this condition is encountered, the press head will rise to the board clearance position and display a message. Careful inspection will usually reveal the problem. If the error is generated the first time a new program is run, expect a position an error in one of the data files. In some cases it is OK to use the “Retry” option in case the 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. Press “Stop/Eject” to bring the board out to replace the connector. If the connector is not missing there is an error in the Profile program that must be corrected by the programmer.

Excess Force - This error is generated by the Profile program. It is displayed when the force required to seat the connector exceeds the programmed limit. There may be a problem with the connector or PCB causing too much resistance before the connector reaches its seated height. The fixture could be too thick causing the connector to contact the PCB higher than expected. There may be a problem with the force or height definitions in the Profile program.

Insufficient Force - This error is generated by the Profile program. It can be caused by a loose pin to hole interference. It can also be caused by the platen being too thin, connector thickness problems, or Profile program errors. The programmer should be consulted to correct the problem.

Runtime Help Screen:This is the screen that can be brought up by pressing the F1 Key while in the 'Runtime mode' to assist in

Diagnostics of Profile performance. Also, this screen will indicate to you how to start the Data Collection mode that creates a file defining 'point by point' performance within the press profile and logs this file to the SPC Directory within the Press computer harddrive.

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PRESSING TOOLSThis section defines general requirements for connector pressing tools that will be used in the manual press. In most cases, insertion tools used in other manual pressing operations can be used in the electric press. The guidelines below must be followed in order to ensure optimum performance.

Width – May be any width that adequately supports the pressing forceHeight – There is 6” clearance from table to the full up pressing head. The tool, backup fixture, connector, and board must be less than this measurement. The tool must be tall enough to avoid hitting any tall components on the board.Length - Up to 10” (to stay within the capture of the flat rock head), single or multiple tool combinationLaser Centering Option – An optional laser targeting spot can be used to align the tool below the center of the pressing head.. The active laser pointer requires a reflective dot to be provided in a ½” diameter recess on the top of the tool at the centroid. When the tool is properly positioned below the head, a signal is sent to the computer. The green light in the front panel above the table lights when the tool is detected.

SUPPORT FIXTURES (Platens/ Backup Fixtures)The support fixture, sometimes called a platen, must be a reasonably hard material. The flatness should be held to a maximum deviation of .005” for best results. Most fixtures in use on other presses are adequate, but flatness is often poor. Pressing to height will be a problem if the fixture is not flat.

PROGRAMMING & DATA ENTRYThe press is a highly versatile tool due to simple yet flexible programmability. Four databases are used to guide the press through specific sequences of operations. The variables stored include pressing tool physical information, pressing profile information, connector physical information, and PCB/ backup fixture information. Once the information has been stored, it is available for use by current and future programs.

Access to the editors is restricted to those who have been trained and have the check box for our editor checked in ‘User Access’.

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The Tool Editor

PurposeThe tool editor is used to view and modify the Microsoft Access Database information. It contains all the necessary information about the mechanical pressing tools that are used during the pressing process. The editor can be accessed either from the icon at the bottom of the screen, or from the supplied off line editor running on a desktop PC. The following fields are maintained in the database and are saved immediately as they are changed so there is no save operation on exiting.

Entries“Tool Type” - This is a name you choose up to 20 characters long, spaces allowed, that will be used to refer to this tool in the future. To enter a new tool type, click on “Edit” in the upper left of the screen, then select “Add New Tool”. Alternatively, you can select “Copy Tool” to copy the currently viewed tool. You must enter a new name. Selecting “Delete Tool” will delete the currently viewed tool entry.

“Bar Code” - This is the unique number that is used to identify the tool. It can be engraved and/or bar coded the tool. It is convenient to use a bar code reader to confirm the tool type at run time.

Note: No two tools should ever have the same number except for interchangeable duplicates. In this case, only one entry is made in the database.

“Enable Active Laser Target” – Select this checkbox if you are using the laser tool presence verification option. See Pressing Tools section above for further explanation of this option.

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“Dimensions”

Tool Clearance – This is the desired height of the pressing head above a tool that has been placed in/on the connector. It is desirable to keep this to a minimum so the head can support the tool before pressing. It also aids in detection of bent pins since the tool will not slide easily under the head if tool and connector are not both seated properly.

Tool Height – The tool height information is needed in order to confirm the pressed height of the connector. Enter the height of the tool from the top surface to the plane that presses on the connector as shown in the graphic.

Tool Width – This entry is used to draw a rendering of the connector width in the PCB drawing on the screen.

Tool Length – This entry is used to draw a rendering of the connector length in the PCB drawing on the screen

“Comments” - Enter any comments desired such as a short description of the tool application.

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The Connector Editor

PurposeThe Connector Editor is used to enter and store physical data for the connectors. It is an Access Data Base file. All changes are saved immediately so there is no save operation on exiting.

Entries“Connector Type” - This is a name you choose up to 20 characters long, spaces allowed, that will be used to refer to this connector in the future. To enter a new tool type, click on “Edit” in the upper left of the screen, then select “Add New Connector”. Alternatively, you can select “Copy Connector” to copy the currently viewed connector. You must enter a new name. Selecting “Delete Connector” will delete the currently viewed connector entry.

“Tool” - This is the type or name of the tool to be used for pressing the connector. It is picked from the tool data base entries using the drop down menu. The tool must be entered in the tool database before the connector data can be completed.

“Number of Pins” - This is the number of pins in the connector. It is used to calculate force when using max or min force per pin in the profile. It is also used to calculate and graph the force per pin on the run time screen.

“Profile” - This is the name of the profile file to be used for the connector. It is picked from the profile data base entries using the drop down menu. The profile must be completed before the connector database can be generated.

“Dimensions” -

Base Thickness - This is the thickness of the connector between the inside (mating section) bottom and the outside bottom as shown. It is used to calculate the head travel to seat the connector to the proper height.

Unseated Top – This is the measurement of the distance of the top surface of the connector to the top surface of the PCB.

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Height – This is the measurement of distance from the top of the connector to the seating surface of the connector. Subtracting ‘Unseated Top’ from ‘Height’ will give actual amount of distance left to press connector to seated condition.

Seated Height - This is the desired distance between the board surface and the bottom of the connector after pressing. It is usually zero, but may be set above the board surface for press to height applications

“Graph Scale” – These entries control the graphing scale for the pressing process. The first is the vertical full scale in pounds per pin, and the second is the horizontal scale in distance from the bottom of the connector to the board surface.

“Force” -

Min Force / Pin - This is the minimum acceptable force per pin. It is referenced in the pressing profile.

Max Force / Pin - This is the maximum acceptable force per pin. It is referenced in the pressing profile.

User Force / Pin - This is a user defined force per pin. It is referenced in the pressing profile.

Other Force:

“PARS” – A connector can be pressed with force that is proportional to the actual resisting force detected during the pressing cycle. This profile is controlled by the start and finish connector height and amount of % of force applied over what is detected at end of cycle.

“Force Gradient” - Monitors the rate of change of force to distance. Generally, the force vs distance plot will make a steep upturn as the connector contacts the board surface.. A minimum angle is specified for the upturn which corresponds to how solidly the connector is pressed against the board. Enter the gradient angle at which you want to complete the press cycle.

“Comments” - This is a field for useful comments.

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The Profile Editor

PurposeThe pressing Profile is information that is used to control the pressing process speed, force, and height. It is the heart of the control sequence, and allows the user to define exactly how a connector is pressed into the PCB. The editor provides up to 20 steps, numbered at the left of the screen, to be entered for a given profile. Profiles are stored as ASCII files with a user-specified name. The .prf extent is automatically added. They can be viewed in any text editor.

ExplanationThe insertion process starts at row 1, and proceeds from there. Each row has two “events”. “Height Above the Board” and “Force”. As the press head travels down, the program continuously monitors these events and acts on whichever occurs first. Each event has an “action”, which either continues the pressing process at another step or generates an error. These events and actions are used to:

1. detect and announce unexpected contact2. detect unacceptably high or low force generated during pressing3. detect a missing connector condition4. press to/verify the proper seated height5. repress a connector that has already be partially pressed

There are four basic methods of pressing, and each requires a unique profile.

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FIXED FORCE PER PIN - A connector can be pressed with a force proportional to the number of pins, such as 30 pounds per pin. This is slightly better than the first method because it recognizes that the force applied should be proportional to the number of pins being pressed. It cannot compensate for normal variations in required force per pin for different connectors, in different positions, in different boards.

PERCENT ABOVE RANGE SAMPLE (PARS) – A connector can be pressed with force that is proportional to the actual resisting force detected during the pressing cycle. This is called Percent Above Range Sample or PARS. In this technique, the connector’s resisting force while pressing is sampled and averaged over a distance Range before seating to the board surface. The final force exerted on the connector is limited to a user-programmed Percent Above the Sample force. 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 the pins into the board. No excess force is pressed into the connector plastic or the board. This sophisticated technique is made possible by the control available using an electric servo press head and a rigid press structure. In order for press to height to be accurate, the board thickness must be precisely known. This can be done using the thickness measurement probe and sequence provided.

FORCE GRADIENT - Monitors the rate of change of force to distance. This method is used for robust connectors that need to be seated against the board surface. Generally, the force vs distance plot will make a steep upturn as the connector contacts the board surface. The connector stops moving so the force rises quickly. A minimum angle is specified for the upturn which corresponds to how solidly the connector is pressed against the board. See “Press Profile” for more detail.

The “standard” profile for each of the techniques above is provided with the press. They use variables whose values come from the Connector and Tool databases rather than discrete numbers. Since each connector requires the same basic steps, one profile with variables can be used for many different connectors.

The standard profiles are named “standard_force”, “standard_pars”, and “standard height”. The sample above is the “standard_pars” profile.

Entries“Height” - This defines the next destination of the pressing surface of the tool in inches above the board. The press head will drive to this height at a speed that is linearly “ramped” from the height and speed of the previous step.

The initial height (before step 1) is defined in the “Board Clearance” section of the “Press Data File”.

The available variables are shown here. Alternatively, a numeric height can be entered.

Height Action” - This defines the action to be taken when the height at this step is reached

Actions are selected from the drop down menu. The available actions are:

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Next Step - This directs the process to the next step belowGo To - This directs the process to continue at any step below. The step number is entered from the keyboardComplete - This signals that the pressing process is complete. The head will stop immediately and rise to the next tool clearance height.Error 1 - 5 - These 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 for both

to detect force errors and define cycle completion based on the force generated. There are four variable choices provided on the drop down menu. Alternatively, an actual force in pounds can be entered from the keyboard.

PARS-FPPL xx% (dynamic press cycle termination based on actual forces generated during the pressing process) Pressing the PARS Help button will produce the picture below.

PARS-FPPL is defined as “Percent Above Range Sample - Force Per Pin Limited”. This force condition uses a special algorithm that calculates the average force generated while pressing the connector into the PCB. The “Start” and “Distance” boxes in the middle of the screen define the bounds for the average. Thus, rather than pressing to a specific force, the actual force required is dynamically calculated for each cycle and termination is based on this force. The “xx%” is an excess force, as a percentage of the calculated average, which is added to the average to ensure the connector is fully seated.

For example: The “Start” height is entered as .010”, and the “Distance” as 0.005”. PARS-FPPL force is invoked in the ‘Force (lbs)’column, row 4, and 25% is entered. As the connector is pressed, the force readings taken from .010” to .005” above the board are averaged. The head continues to press until the force generated is 25% higher than this average.

Min F/Pin * #Pins

This force is calculated by multiplying the number of pins in the particular connector being pressed by the minimum required force per pin. Both the number of pins and the minimum force per pin are entries in the connector data base. This can be used to assure at least a minimum force is generated during the pressing process.

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Max F/Pin * #Pins

This force 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 data base. 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 event variable other than Max and Min force per pin. Its use is up to the programmer’s discretion. For example, while pressing to force it may be useful to terminate on “User F/Pin * #Pins” rather than “Max F/Pin * #Pins”. The variable “Max F/Pin * #Pins” would still be used to generate an error if the allowable force is exceeded.

Other Force

“ Force Action” - This defines the action to be taken when the force at this step is reached. Actions are selected from the drop down menu. The force actions are the same as the height actions

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Next Step - This directs the process to the next step belowGo To - This directs the process to continue at any step below. The step number is entered from the keyboardComplete - This signals that the pressing process is complete. The head will stop immediately and rise to the next tool clearance height.Error 1 - 5 - These 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.

“Speed (in/sec)” - This is the speed target for the current step in the process. The speed starts at

“Run Speed” as entered in the “Servo Parameters” editor, and changes (“ramps”) linearly down to the speed given in step 1. When step 1 is reached, the speed ramps to the speed given in the next step processed. This will generally be step 2, but not if a “Go To” was programmed as an action.

Typical speeds range from 2”/ second during approach, down to .05”/ second when pressing. Some experimenting may be required to optimize the process. Some connectors are more fragile than others and may require slow speeds, while others can be pressed quickly.

“Comments” - This entry is for your use as information and reminders. Typically each step has a purpose such as “rapid to clearance above connector” or “slow down to enter connector and engage pins”, etc..

“Start” - This is the distance in inches between the board surface and the bottom (seating surface) of the

connector when PARS force readings are started. A typical number is 0.010”.

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“Distance” - This is the distance over which force readings are averaged for PARS use. A typical number is 0.005”. 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 average is being taken over the correct range.

“PARS Help” - A text and graphic help screen is provided for PARS when this button is pressed.

“Action Errors” - Up to five errors can be defined here. They are used in the “Action” columns above. Typical errors are “Premature Contact”, or “Excessive Force”, or “Missing Connector”.

Saving The File - Press “File”, “Save” or “Save As”, then “Exit”. If you press “Exit” before saving, you will be warned and given the opportunity to save or quit without saving.

ExamplesExample # 1– Pressing with PARS

The screen capture example above is a typical PARS press profile. The comments at the right end of each line indicate the action that line will perform. In general, PARS pressing is the preferred method because it limits excess pressing force but still presses the connector to the board surface. Fragile connectors that cannot accept any excess force must be pressed to height as described in the example below.

1) Move the head from the tool clearance height (as given in the Tool Database) down to .03” above the unseated top of tool. The speed will ramp linearly from the press “Run Speed” to .3 inches per second. When the height is reached, the sequence will continue on the next step. If more than 50 pounds is detected before the height is reached, terminate and display error #1, typically “Premature contact detected”.

2) Continue to move down to until the connector is .03” above its seated height. The speed is reduced to .15”/second. This line tests to see if a connector is actually detected. If it is, as indicated by detecting at least the minimum force per pin, the process continues on the next line. If not, the process continues on line 5.

3) Press until the connector is within .01” of the desired seated height. When this position is reached, the connector will be within a generally accepted tolerance of seated height. The .01” can be adjusted as needed for specific circumstances. If the force exceeds the maximum force per pin before the height is reached, an error message is displayed.

4) The destination of this step will theoretically overpress the 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 between connector, tool, and board surface. If this occurs, review the tool height, the connector base thickness, the backup fixture thickness, and the board thickness

5) This “GO TO” step tests to see if there is a connector below the head. If the normal seated height is reached without generating at least 100 pounds of force, it is determined that the connector is missing. If the force is reached, the process continues on the next line.

6) This line verifies the connector is pressed to within generally accepted height tolerance, and the maximum force per pin is not exceeded.

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7) This line gives a destination below the nominal seated height, and terminates on the maximum force per pin * # of pins. This variable here could also be “user force per pin” rather then maximum.

A typical resulting screen plot is shown below. The PARS average force is given as 14.8 pounds per pin, or a total of 7,548 pounds total. With 10% added to ensure seating, the force becomes 16.4 pounds per pin. Note the average is taken between the vertical ‘PARS Sample’ lines.

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The Press Data Editor

PurposeThe Press Data Editor is used to enter and store the data about the board including board physical characteristics and connector locations. All connectors to be used on the board being programmed must be defined in the connector database before the press data file can be generated.

The file is ASCII format with a .prs extent. It may be convenient to open an existing file and do a “Save As” to a new name in some cases.

Entries“Revision” - This is the revision level of the board to be pressed, or alternatively the revision of the Press Data program. It is used as reference in this file only.

“Board Thickness” - This is the nominal board thickness which is used to calculate the connector pressed height. If the board thickness measurement option is selected, the measured thickness will be used instead.

“Platen Thickness” - This is the thickness of the “platen” or “fixture” that supports the board on the top tool press. It must be accurately measured in order for press to height to be accurate.

“Use Tool ID” – If this feature is checked a tool identification will be required on first entering the run screen, and each time a tool change is encountered. The tool ID is the alphanumeric identification given in the tool database. The ID can be entered manually, or by a bar code mounted on the tool.

“Description” - This is a description of the board to be pressed.

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“No. of Char. Req’d for Serial Number” – The serial number of the board, if entered, is stored with the raw pressing data in a file on the computer hard drive. If the connectors are pressed sequentially, the force for each connector will be stored with the serial number and XY coordinates.

This feature has three types of entry. A zero means no prompt serial number will be given. A positive number means exactly that number of characters is required for a valid serial number, and a negative number means at least that number of characters is required. Bar code scanning is the preferred method of data entry.

“No. of Char. To Clear Between Boards” – This feature is used in conjunction with the serial number entry above. In the case of sequential serial numbers, the program will clear this number of characters from the end of the previous serial number. This is generally used when manual serial number entry is used.

“Verify Text” – This feature is intended to verify that the correct board type is used with its press data editor. If text is entered in this cell, board identification (type, name, model, etc,) will be required on first entering the run screen, and each time a new board is started. Any text or number can be used, but ideally a bar code label will be available. The text can also be entered manually. To enter the name, type “%V” followed by the string of characters.

“First Article Signoff” – This feature stops the pressing process after the first board is complete. An approval is required from a different person than is operating the machine. The authorization level is established by selecting one of the four dots below first article message text.

“Prompt for Connector Substitution” – This check box enables substitution connectors to be selected at run time. For example, manufacturer “A” may be the prime source for a given connector, but “B” is also approved as interchangeable on this board. If this box is checked, the operator will be offered a selection of possible alternates for the connector at run time. Their selection will drive the tool and profile selected for pressing that connector. Thus, it is possible to press an alternate connector that requires a different tool and different profile than the primary connector. The alternates are associated with each other by “substitution codes” that are defined in the connector database. The associated connectors are individually entered into the database, but they are “linked” by a common substitution code. See the connector editor for details on entering connector substitution codes.

“Image Mode” – The user mode is defined as operator driven pressing sequence. In other words, the connectors are pressed in any order the operator chooses. There are three options in the user mode.

Digital Picture – This option uses a bitmap picture from a digital camera or scan of a photograph to show the board being pressed.

Data Image – This option creates an image from the X, Y, angle, and connector data and displays it.

None – This option does not display an image on the screen. It has the advantage of the simplest to program, but a press data file is still necessary to supply the operational information described above.

“Pressing Order” – The sequential mode provides a specific pressing sequence which must be followed. There are two options in the sequential mode.

Sequential – The pressing sequence is established by picking connectors from the database and placing them on the digital picture in the desired order.

Non-sequential – The pressing sequence follows the order of the data in the X, Y, angle, and connector table below.

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PRESS SEQUENCE

“Measure Board Thickness” - The check box calls for board thickness to be measured on each board. The X & Y entries provide the location on the board for the thickness to be measured. Only one point on the board is measured.

“Board thickness by Lot” - The check box calls for measuring board thickness only once for the current manufacturer's board type within the present production run. A "Lot" is defined as a number of identical PCBs used in a current production run.

“Board Edge to Reference Hole” - This entry is used by the program to properly locate and display the connectors on the board. It is the nominal distance from edge of the board, in the X & Y directions, to the board’s datum. The datum is the point on the board from which the X & Y locations (entered as explained below) for the connectors are defined. In other words, it is the (0,0) for the array of connectors. The datum can be any convenient point, and is usually either a tooling hole or the board edge.

Remember that the X direction is always defined as left to right with the board in normal orientation in the press.

“Reference Hole Board Frame Coordinate” - This is the distance from the datum (0,0) of the board which locates the connectors (as explained immediately above) to the datum hole in the board. The datum hole mates with a pin in the fixture (platen) which locates the board on the fixture. It is generally one of the board’s tooling holes, but could be any hole chosen to physically locate the board.

“Board Width” - This is the dimension of the board in the X axis direction (left to right) as normally positioned in the machine. It may or may not be the smaller board dimension.

“Board Length” - This is the dimension of the board in the Y axis direction (front to back) as normally positioned in the machine. It may or may not be the larger board dimension.

“X,Y” - These entries define the position of the connector relative to the board’s coordinate system datum. Each coordinate pair defines the location of the geometric center of the area that the pressing tool engages. This is generally the centroid of the connector, but in some cases it is not.

“Angle” - This defines the angle of the connector relative to the board mounted on the machine. Select the appropriate angle from the drop down menu. Angles are defined with zero degrees to the right. The positive 90 degree position is ¼ turn counter clockwise as viewed from the top. The connector “pointer” for angles is the polarized end if defined.

“Connector” - The connector to be pressed is selected from the connector database by using the drop down menu. All connectors to be used on the board must be defined in the connector database before the press data file can be generated. The pressing sequence follows the order of the connectors entered here, so thought should be given to optimize the movements. Connectors of one type should be pressed before proceeding to the next to minimize tool changes.

“Comments” - User defined comment for future reference and reminder.

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SPC OPTIONThe SPC option is a software package of data collection, analyses, display, and printing.

OverviewRaw data for the average force in pounds per pin for each connector pressed is maintained in a file with the same name as the connector, with a .RAW extension. SPC information is calculated from the raw data and displayed on command.

Please refer to the “Connector Database” section above for SPC related parameters that are entered for each connector type.

To view data for a connector, select the connector name from the drop down list in the upper left corner of the SPC screen. All data on the SPC screen is for the specific connector type selected. The force data for a connector is stored in the same file regardless of the specific PCB type (part number, model, etc.) it is pressed into. In other words, the SPC data for a specific connector pressed into PCB type ABC is stored in the same file as the data for connectors pressed into PCB type XYZ.

The raw data is stored on the hard drive indefinitely. It includes the PCB model, serial number (if used), date, time, operator, the SPC force reading point, the maximum force read, and the maximum force reading point. The header at the top of the raw data file explains the data format in detail.

An average force reading for each connector of a given type on a PCB is calculated and plotted as one point on the X-bar chart. In other words, each point on the chart is the average of all connectors of the same type on a specific PCB.

The difference between the highest and lowest force readings for the same connector type on a specific 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.

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Process Data

This area shows data that is calculated for the process. It is a measure of the “health” of the process for a number of PCBs.

CPK (Process Capability)This quality measure is often used to evaluate the capability of the process being monitored. A number between 1 and 1.5 is generally considered to indicate a process is “in control”. The CPK is higher for a tighter and more centered distribution, and conversely lower for a broad or poorly centered distribution. A distribution is “centered” when the average of the measured data is near the target value for that data. A distribution is “tight” when all measured values are close to each other.

X-Bar (Process Average)This is the average of all the points on the X-bar chart. Each point on the chart is the average of a connector type on a specific PCB.

Std Dev. (Standard Deviation)This is the standard deviation (InterQuartile Range method ) of the plotted X-bar points.

UCL (Upper Control Limit)If the plotted X-bar point exceeds this value, the process is considered out-of-control.

LCL (Lower Control Limit)If the plotted X-bar point is less than this value, the process is considered out-of-control.

VCL (Variability Control Limit)If the plotted variability point (R or S ) exceeds this value, the process is considered out of control.

Point Data

This area displays the data for a specific point. To view the data for any point on the chart, point to it and click the left mouse button.

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Options

Range BarsThe 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 has a short horizontal line at the maximum and minimum readings for the averaged data. Checking this box enables range displaying.

Control LimitsChecking this box enables the displaying of control limits on the charts.

Spec. LimitsChecking this box enables the displaying of specification limits (max and min force) on the charts.

GridThis check box enables grid line display on the graphs.

ShadedThis adds shading between the spec limits and control limits.

Thick LinesThis thickens the plotted lines.

PrintPress this button to print the charts on a printer. The printer driver must be installed using the standard windows method.

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MAINTENANCE FUNCTIONS (UTILITIES)The press software provides operational parameters and utilities as described below.

Machine Logs

Error LogThe error log is automatically appended with every error message that is displayed during any machine function. This includes time and date stamp, operator, description , and duration of error condition. Cold startup is also captured. By reviewing the log, machine operation can be evaluated on a detailed level. Data covering Selected Dates can be viewed, or All can be chosen. Also see the Machine Utilization section for related data.

The error log can be purged by selecting the data period that you would like to save, then pressing Update Error Log. For example, to delete all but the last 60 days of data, select “60 Days”, then press Update Error Log.

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User LogThe user log is automatically appended every time there is a log in or out event. Data covering Selected Dates can be viewed, or All can be chosen.

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.

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Joystick

The Joystick is used primarily for setup and maintenance purposes. Tabs at the top of the screen access utilities. The right third of the screen is used to drive the servo axis.

Analog Inputs The load cells provide a proportional analog signal of 0 to 10 volts over the full force range.

This screen shows the voltage and force numbers for each cell and the sum of the cells, as well as a bar graph display. A small amount of “noise” (less than 1% of full scale) in the reading is normal. The balance between the individual load cell readings should generally be within 10% of each other.

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Points: The points tab provides a robotic type of point saving capability. To add a new point , move

to the desired position then press “New Point”. Enter the name of the point and press “Save”. The new point will be entered into the grid below.

Selecting any saved point from the grid will load the name and coordinates into the upper section of the screen. Pressing “Move” will cause a move to the saved position. Pressing “Delete” will delete the point.

To change the coordinates of an existing point, move to the desired position, select the point to change, press “Set Current”, then “Save”. The point’s coordinates will be changed.

Control The “Control” tab is used to control the servo axis speed, turn it on or off, or set the maximum joystick

force limit. Both speed and force are at a default value on first entry into the joystick.

Enable / Disable Servo

To turn the servo axis off, press the “Disable” button. The indicator turns red. Press “Enable” and the servo turns on and the indicator turns green. If the axis is off for any reason when entering this tab, the indicator will be red already.

Speed

To change the joystick speed, drag the speed arrow to the right or left with the mouse. The current speed is shown in the window below the speed slider.

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Force Limit

The maximum press force while in the joystick is limited as a machine protection. The default limit is 25 pounds, but it can be changed by dragging the slider. Attempting to press forces higher than the limit will result in an error message.

CalibrationThis tab is reserved for future implementation of an automatic load cell calibration procedure. Please refer to the calibration procedure in the Maintenance section for the manual calibration procedure.

ToolsThis tab is reserved for future tool related utilites.

Machine ZeroThe Z axis zero is defined as the position where the head pressing surface is in contact with the table and loaded to 300 pounds. The load is applied to be sure all clearance is eliminated from the various head components such as the ball screw and the head to structure air gap.

Since the head cannot actually travel all the way to this point, a 2” spacer block must be placed between the head and the table to set the zero. A tool is supplied with the press for this purpose. This same tool is also used for PCB thickness measurement.

To set or verify the Zaxis zero position, place the space block on the table below the head. The head should be positioned at the center of the machine. Go to the Control tab and reduce the speed to minimum. Also, set the maximum joystick force to 350 – 500 lbs. Go to the Analog tab to get ready to read the load. Very carefully jog the head down until it almost touches the spacer. At this point, change to incremental mode and move only in increments of .001"” Apply load until 300 pounds is achieved.

WARNING! – Due to the machine’s high rigidity the force can build very quickly, resulting in significant force overshoot if the Z axis is moving faster the minimum. Always reduce the speed when approaching an object such as the thickness probe tool. Use incremental mode @ 0.005” or 0.001” when pressing in the joystick.

When the load reaches 300 pounds +/- 50, read the Z axis position. It should read 2.000” (assuming the spacer block is exactly 2” tall) +/- 0.002”. If there is an error, click on the machine zero tab and enter the known height of the spacer block ( or thickness probe ). Then click the “Set Z” button to correct the machine’s position. This will permanently modify the Z axis position. Although not required, it is a good idea to rehome and confirm the zero position.

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Input / Output Screen

Inputs

The Input/Output screen is provided for diagnostic purposes. All machine inputs are shown on the top half of the screen. A red indicator signals an “on” condition for the given input. This screen is convenient for checking sensor signals.

Outputs

The digital outputs are shown on the bottom half of the screen. Pressing a button will turn on the corresponding output. A red button indicates the output is currently in the “on” state.

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Servo Terminal

The Servo terminal is used to communicate with the servo controller card that resides in the PC. Various information and data related to the servo card is displayed on the right half of the screen. Buttons below the terminal window are provided for convenience. All parameters on this screen are continuously updated.

Servo Terminal Window

The servo terminal window is used to send low level commands to the servo controller. This feature will normally be used only in conjunction with an ASG service technician advisor.

Warning: Be cautious when entering commands in this window since unexpected results, including a major machine “crash” could result.

Buttons Below Terminal Window

Two help buttons below the window provide information on available commands. The “Erase Text” button clears the screen. The servo can be turned on and off using two buttons below the window. The servo axis can be homed by pressing the “Home” button.

ESTOP Indicator

The ESTOP indicator shows the status of the ESTOP circuit. If the circuit is energized (servo power is on), the indicator will be red.

Position Data Windows

Windows on the right half of the screen show the position in inches and encoder counts, as well as position error in encoder counts. The servo control command voltage is also shown.

Servo Status Indicators

The indicators show the status of several servo control signals.

ADC Input

The force on each load cell is shown in these windows. A one or two percent dithering is normal.

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Servo Parameters

The Servo Parameters screen is used to input and display the servo related constants. These parameters should only be changed by a qualified technician. Consultation with ASG is recommended before changing these parameters.

Encoder Counts / in (PPU) – This is the conversion from encoder counts to inches. It is set at the factory and should never have to be changed.

Proportional Gain – This control component provides the primary correcting voltage to the amplifier during movement. The correcting voltage is proportional to the error between the actual and desired position, and the gain modifies the correcting voltage.

Derivative Gain – This control component is a function of the rate of change (derivative) of position error.

Integral Gain – This control component is used only during the final position stage of a move. The correcting voltage is a function of the position error integrated over time.

Integral Delay – The Integral Gain is turned on after the servo profiler reaches its destination. It is turned on after this delay time in seconds.

Acceleration – This is the acceleration for all moves except during the pressing cycle. See Press Parameters for Down Stroke.

Deceleration – This is the deceleration for all moves except during the pressing cycle. See Press Parameters for Down Stroke.

Minimum Speed – This is the minimum speed that can be selected in the joystick.

Maximum Speed – This is the maximum speed that can be selected in the joystick.

Run Speed – This is the default speed used during the process. The Z axis speed used during pressing is controlled by the profile.

Homing Speed – This is the speed used during the homing sequence.

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Marker to Limit Distance – This is the physical distance the axis travels when moving from the marker pulse on the encoder to the limit switch. It is used as verification that the homing sequence did not miss an index pulse on the encoder. If the distance measured during homing does not match this number within a few thousandths of an inch, an error is generated. The accuracy of the homing sequence is not dependent on this number. This number will only have to be changed if the relationship between the encoder, which is mounted on the motor, and the head is changed. This will happen if the motor is disconnected from the screw.

Marker to Zero Offset – This is the distance travel from the home pulse marker to the defined axis zero position. It is the machine zero calibration point, and is set up at the factory. The zero position for the Z axis is defined as the pressing flat rock surface in contact with the table surface. This position cannot actually be reached by the axis. This number will only have to be changed if the relationship between the encoder, which is mounted on the motor, and the head is changed. This will happen if the motor is disconnected from the screw.

Minimum Coordinate – This is the soft limit in the negative direction of travel. It is set up at the factory to be a safe distance from the limit switch and the hard stop. This number will only have to be changed if the relationship between the encoder, which is mounted on the motor, and the head is changed. This will happen if the motor is disconnected from the screw.

Maximum Coordinate – This is the soft limit in the positive direction of travel. It is set up at the factory to be a safe distance from the limit switch and the hard stop. This number will only have to be changed if the relationship between the encoder, which is mounted on the motor, and the head is changed. This will happen if the motor is disconnected from the screw.

Excess Error Limit – This is the maximum allowable error between the actual and desired position during movement.

In Position Band –When the desired position plus or minus this distance (in inches) is reached, the In Position Flag is set. When In Position is detected, the Integral Gain component is enabled.

Homing Torque Limit – This is the maximum torque (voltage) that the controller is allowed to issue during the homing sequence. It is a machine protection feature that limits the runaway speed in case an encoder signal is lost during homing.

Stall Detect Time – This is the allowed time in seconds (during an attempted move) that an axis can be stationary before a stall condition is flagged. The axis is automatically disabled if a stall is detected.

Press Parameters

Down Stroke Acceleration & Deceleration – The machine default acceleration and deceleration are changed to these values during the press down stroke. This allows more control flexibility during the pressing cycle.

Retract Speed and Acceleration - The machine default speed and acceleration are changed to these values during the press retract stroke. This allows more control flexibility during the pressing cycle.

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Setup Parameters

The Setup Parameters screen is used for miscellaneous parameter settings as described below.

Machine OperationThreshold in SPC range for repress consideration

If the SPC force for a connector is less than this value, the connector is considered to have been repressed (the connector has been partially repressed before). Repressed connectors are not used for SPC analysis as they would “pollute” the data from their low forces in the SPC range.

Time Waiting For Two Hand Start

This is the time allowed before the machine utilization tracking changes from “Run” to “Idle”. If the next cycle is initiated within this time, the utilization tracking remains in “Run” mode. The mode is changed from “Idle” to “Run” as soon as the next cycle is started by pressing the two-hand buttons.

Number of Press Cycles

This is a non-resetable cumulative cycle counter. Each time a production pressing cycle is completed, this counter is incremented.

Load CellsThe load cells measure the pressing force as each connector is seated. The force reading for each load cell will be graphed if the check box is selected. Otherwise, only the total (sum) force is graphed.

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Dynamic load cell zeroing is a feature that automatically eliminates any offset (difference from zero reading) detected when no force is being applied. If checked, the offset updates before each pressing cycle.

Multiple readings from the load cells can be averaged before evaluating and graphing. This reduces the “noise” that is present in typical analog signals. A setting of one will provide the fastest update, but could cause a false reading if a noise spike is read as a real force. The larger this number is, the slower the response will be. A setting of two is recommended.

The load cell readings are calibrated by entering gain and offset numbers for each rod load cell. The gain converts the voltage from the load cell amplifier to pounds. The gain can only be set using an independent, calibrated, load cell. Refer to the calibration section below for details. Offset is the load read when no force is actually being applied to the head. Once calibrated, small deviations from zero can occur due to mechanical or electrical changes. To set the offset, first enter “zero” in the offset window. Go to the joystick and read the voltage shown for the rod you are working on. Enter the negative of this number in the appropriate window. Recheck the joystick to be sure the force reading close to zero. Some dithering is normal.

SavePressing this button will save the changes and exit the screen.

CancelPressing this button will cancel the changes and exit the screen.

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Utilization

Machine utilization is tracked in four categories; Error, Idle, Run, and Off. The data can be displayed on the screen as shown above, or printed in color or black and white. A check box in the lower right of the screen allows the graph to show off time along with the other categories.

The period to display or print can be selected using the controls at the right side of the screen. To update the graph for a new period, press the “Update Graph” button.

Printing charts is selected from the panel in the upper right of the screen. The standard printer setup dialog is provided. The daily chart shows breakdown on an hourly basis, while the cumulative chart shows the distributions as a pie chart.

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PREVENTATIVE MAINTENANCEThe press has been designed to minimize maintenance as much as possible. The following preventive maintenance procedures should be done on the intervals given below. An annual inspection, adjustment, and calibration service is offered by ASG.

Accessing the Press HeadTo gain access to the press head for inspection or service, the upper sheet metal panels must be removed using the following procedure.

1) Remove the nine screws that secure the top cover to the front and back panels and set the cover aside.

2) Remove the four screws in the front panel and four screws in the back panel.

3) Lift out the front and back panels. Set them off to the side; reinstall in same order after completion of press head service.

CleaningAll surfaces should be kept clean and free of dust buildup. Wipe down all exposed flat surfaces with a soft rag. If allowed use light air pressure to blow the press head and structure areas from the top down.

InspectionVisually inspect the press head area. The top sheet metal housing should be removed once per year to allow a thorough inspection. See procedure above for top housing removal.

LubricatingLight machine oil or 30W non detergent motor oil should be used in the following areas of the machine:

Z Axis RodsWith the Z axis in the down position, put a small amount of oil on the rods above each of the linear guide bushings. Wipe with a rag to coat the entire circumference of the shaft and leave only a thin film of oil.

Z Axis ScrewWith the Z axis in the down position, put a small amount of oil on the screw and wipe down with a rag. There should only be a thin coating of oil remaining.

Torquing Critical BoltsNote: This procedure requires the top sheet metal housing to be removed. See the procedure above for details.

The critical bolts on the pressing head should be checked for proper torque. There are six high-grade 3/8-24 socket head cap screws mounting the top and bottom 1” thick steel plates. These screws should be tightened to 70 lb-ft.

On press serial numbers 1-4, the Z-axis bearing housing is mounted top of the 1” steel plate (on subsequent presses the separate bearing housing has been eliminated). The block is secured with four 5/8 socket head cap screws. The bearings are secured by a steel plate with four 3/8 socket head cap screws. These screws should be tightened to 70 lb-ft.

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Clean Water Trap In Air SystemThe air-inlet filter/ regulator set is in the rear cabinet. The power disconnect must be turned off to enter the cabinet.

Check and drain water trap as needed. Replace air filter according to the schedule below.

PM Schedule

ITEM DAILY WEEKLY 3 MONTH YEARLY

BLOW MACHINE OFF *WIPE MACHINE DOWN *INSPECT WIRES AND HOSES *OIL AS INDICATED ABOVE *DRAIN WATER TRAP *REPLACE AIR FILTER *TORQUE HEAD BOLTS *CALIBRATE Z-AXIS LOAD CELLS *INSPECT BALL SCREW *

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Load Cell Calibration

Calibration Procedure for Initial Setup of MEP-6T:

! CAUTION - This procedure requires access to 24VDC and exposed pinch points. It must be carried out carefully by a trained technician.

Care must be taken to avoid personal or equipment damage. Proper safety equipment (ie. safety glasses) should be worn at all times.

Pressing more than 10,000# force can only be done for a few seconds at a time to avoid tripping the thermal overload circuit breaker, or entering and automatic amplifier power fold back. If the thermal overload trips you must wait a few minutes for it to reset automatically.

When applying force by moving the press head down, be very cautious not to overload or impact the press head on the calibration load cell.

Purpose:To perform initial (or as designated) Calibration of MEP-6T Press force accuracy from Zero to Full Span and to document actual vs. acceptable measured points of Force along the Press’s range of pressure.

Equipment Required:

15K – 20K lb Calibrated Load Cell (National Bureau of Standards traceable)Digital Readout for Calibrated Load CellMultimeter (Digital & Calibration Traceable)Computer Workstation & Appropriate Calculation Spreadsheet programPrinter & AGS Calibration Record3/4” Deep socket3/8” Allen wrench

Procedure:

1. Turn MEP-6T on and observe safe process of bootup to ‘Ready for Operation’ 2. Loosen Jam nuts and Load screws on top of each (2) of the Load Cells located in the Press Head.

3. Using Calibrated Digital VOM, perform Zero and Balance procedure on both TMO’s located on side of Press head. See “Zero & Balance TMO Procedure.”

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Load Screw & Jam Nut

Load Screw & Jam Nut

Figure 1

4. Balance Load Cells. See “Balance Load Cell Procedure.”5. Calibrate Load Cells. See “Calibrate Load Cell Procedure.”

Capture Screens for TMO Balance Procedure

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Load Cell Amplifiers Figure 2

Gain Pot

Balance Pot

Terminal #3

Terminal #4White Set Button

Screen 1

Zero and Balance TMO ProceduresEquipment needed:

Calibrated Digital Volt meterSmall screw driverZero Amplifiers

Note: Ref. Figure 2 for component layout of TMO Boards.1) Remove the upper sheet metal panels. 2) Move the press head to the upper limit and to the right side. 3) Remove the cover over the load cell amplifiers. The cover is mounted on the left side of the press head.4) Loosen the two bolts and jam nuts at the load cell housings above the Z axis rods. Back the jam nuts off and

turn each screw until it just touches the load cell. Without applying any load to the screws, turn the jam nuts until they just touch the load cell housings.

5) Using a volt meter check the output of the load cell amplifier at screw terminals 3 & 4 on the left side. Using the “BAL” Pot at the lower right, adjust the voltage to 0.00 +/- .01 Volts DC.

6) Press the white button at the lower right and hold while adjusting the “GAIN” Pot until the output voltage is 3.50 +/- .01 Volts.

7) Readjust the zero volts as needed, and recheck the gain voltage.8) Repeat for both amplifiers

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Screen 2

Balance Load Cells Procedure:1) Place the press head in the middle position.2) Position the calibrated load cell below the press head.

3) From the Joystick, select the “Analog Inputs” tab to view the load cell input. Verify that Forces for Rod #1 and Rod #2 are at zero. Ref. Screen 1

4) Select the “Setup Parameters” button at the bottom of the screen. Ref. Screen 2. Press the ‘Zero Load Cells’ Button

5) Temporarily, change the ‘number of force readings to average’ number from 2 to 20.6) Press “Save”.7) Go back to the “Setup Parameters” screen and note gains for Rod #1 and Rod #2.8) Adjust the software Gain & Offset, as per the MEP & AEP Transducer Calibration Spreadsheet (Figure 4),

by inputting numbers from step 7 into spreadsheet location E7 & E8.9) Go to the “Control” tab of the Joystick and enable force of 10000#.10) Slowly lower the Z axis until it is in light contact, then use the increment mode on the joystick at 0.001” or

0.005” per move until 2000# is read on the digital display of the external load cell.11) Balance the two load cells by adjusting the screws above them until each cell reads the same load. Keep the

total load at about 2000# by adjusting the screws tighter or looser as needed. 12) Raise the head until it clears the calibration load cell. If the load indication on the computer screen does not

return to zero, the screw(s) must be backed off until all force is removed, and the balancing process must be repeated.

13) Continue to balance the cells until they are within 50# to 100# of each other at 2000# total, and completely unloaded when the head is raised.

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Calibrated Load Cell Figure 3

Calibrate load cell Procedure1) Make sure the Load Cell screws snug up to the Load Cells and lock down the Jam nuts.2) Lower the Z-axis until a load of about 5000#, “Actual Load”, is indicated on the calibration load cell Digital

readout.3) Note the Total Force, “Indicated Load”, given in the Joystick Analog Inputs tab.4) Note the “Rod Force #1”and “Rod Force #2”, given in the Joystick Analog Inputs tab 5) Note the Gain Values indicated in the Setup Parameters screen for Rod #1 and Rod #2 6) Using the spreadsheet tool: MEP & AEP Transducer Calibration file, input the values copied in steps 1, 3 & 47) Reduce the load to less than 2000# by raising the Z axis8) Go to the Setup Parameters tab and input the gain for both load cells according to the MEP & AEP

Transducer Calibration file: “New Gain Values”9) Remove the load and be sure the indication returns to zero.10) Reapply the load, check, and repeat as necessary.Check the calibration at loads from 1,000# , 2000#, 4000#

and 8000 #. Do not maintain high force for more than a few seconds. The indicated and actual should track within 200#. Each load cell should carry about the same load throughout the test, but some variation is normal and acceptable.

11) Fill out Calibration Certificate (example shown on next page) as appropriate and as per figures generated at bottom of Calibration Spreadsheet.

MEP & AEP Transducer Calibration Spreadsheet file

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Figure 4

EXAMPLE

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APPENDIX A - SPARE PARTS LISTThis is a comprehensive list of spare parts that may be required during the life of the press. Any combination or quantity of the parts listed below may be purchased from ASG. Delivery ranges from two to eight weeks depending on the part ordered. Please contact ASG for the latest list and prices.

MEP-6T RECOMMENDED SPARE PARTS

Item Qty Req.

ASG Part # Manf. Part # Description

1 1 10110139 LBO-10K LOAD CELL - 10,000 LBS.2 1 10110140 TMO-1 LOAD CELL AMPLIFIER3 1 10110038 FS-L71 PHOTOELECTRIC SENSOR. LASER FIBER

AMPLIFIER4 1 10110037 FS-L41 PHOTOELECTRIC SENSOR, LASER FIBER5 1 10110381 SLS-24-024 24VDC POWER SUPPLY6 1 10110029 SLD-12-3015-05 5 & 12 VDC POWER SUPPLY7 1 10110072 OETL-NF30 40 AMP 3 POLE DISCONNECT SWITCH8 1 10110064 S273-K16 16 AMP 3 POLE CIRCUIT BREAKER9 1 10110065 S273-K10 10 AMP 3 POLE CIRCUIT BREAKER10 1 10110066 S272-K4 4 AMP 2 POLE CIRCUIT BREAKER11 1 10110067 S272-K8 8 AMP 2 POLE CIRCUIT BREAKER12 1 10110068 KC622-Y 24 VDC OPER. CONTROL RELAY 20P 2 CL13 1 10110069 T25DU14 10-14 AMP THERMAL OVERLOAD RELAY14 1 10110070 AB25125A THERMAL OVERLOAD RELAY MOUNTING KIT15 1 10110059 CBF-PMT4R-01 RED MUSHROOM E-STOP16 2 10110219 CBK-B24 PILOT LIGHT BULBS17 1 10110100 OTBVN6QD BANNER OPTO-TOUCH SWITCH18 1 10110043 AAE-D204-M DPDT RELAY 8 PIN OCTAL RELAY19 1 10110045 AAE-D304-M 3PDT 11 PIN RELAY20 2 10110133 EE-SX670 PHOTOMICROSENSOR21 2 10110136 EE-1006 CONNECTOR CABLE22 1 10110147 DTR 90-015-H-348 15:1 PLANETARY GEARHEAD (RIGHT ANGLE)23 1 10110021 H-348-H-0802 SERVO MOTOR24 1 10110022 SE10000-1H348H SERVO AMPLIFIER25 1 10110023 PA0800 SERVO MOTOR POWER SUPPLY26 1 10110138 L BK 222800 MOTION CONTROLLER CARD27 1 10110053 15975T12 REFLECTIVE TAPE28 2 10110390 FNYBU24 SELF-LUBRICATED LINEAR BEARING 1 1/2w ID29 1 10110149 6006 SINGLE ROW RADIAL BALL BEARING30 1 10110151 6A30-C 1” x 20MM SINGLE FLEX COUPLINGS CLAMP & KEYED31 1 10110142 CCFE-5/8-SB CAMROL BEARINGS ECCENTRIC32 1 10110143 CCF-5/8-SB CAMROL BEARINGS CONCENTRIC33 2 10110148 16054 UPPER & LOWER BEARING SEALS34 2 10110150 7206WSU SINGLE ROW ANGLE BEARING35 1 10110626 7824253 Z-AXIS BALL SCREW & NUT36 1 10110538 PS-P2E-B EXTENDED PUSH BUTTON37 1 10110085 MAV—3 MINIMATIC 3-WAY POPPET VALVE38 1 10110025 NVZA2141-1-O1T AIR PILOT PNEUMATIC VALVE

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APPENDIX B – FEATURES & SPECIFICATONS:

Features ~ Pentium PC computer with Windows software

SPC calculation, display, log & print -- Option Touch screen monitor - Option On-line setup drawings and photographs Operator log in & out Error log with date, time, & operator information saved to

disk Maintenance & setup software utilities Graphic display of board in process Force-Vs-distance on screen graphs Software controlled pressing profile with error detection

and user defined messages Electric servo pressing (Z axis) Support table with brass surface for static grounding High rigidity - 2 large Z axis guide rods with linear

bearings Press to force PCB thickness measurement and press to height Missing connector detection No oil, no air in oil problems Clean & Quiet Energy efficient

Specifications ~ Force-6 tons Force sensitivity - 15 lbs Z axis travel = 5” Z axis speed = 2” in/sec Power: 220 VAC, 3 Phase, 15 A Dimensions: 56” Wide X 36” Deep X 70” High Weight: Approximately 1500 lbs.

Options ~OptionSPO PackageBoard Thickness MeasurementTouch Screen Monitor

Updates ~Call (561)848-6746 for information on how to obtain the latest version of MEP-6T Software.

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APPENDIX C – MAJOR COMPONENT LAYOUT / DESCRIPTION:

MEP-6T HARDWARE

Main Frame Assembly:

1. MEP-6T Main Frame (structure). The Main frame, also referred to as the structure, is the center or heart of the MEP-6T. All accuracy’s and precessions are originated from this main frame (structure). It consists of a Tubular Frame, Tabletop, Side Posts (2 ea.), Top Side Plates (2 ea.), and

Bottom Side Plates (2 ea.). 4 Casters utilized for ease of machine mobility.

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MEP-6TFrame Assy.

Top Side Plate

Table Top

Bottom Side Plate

Press Frame

Side Post

MEP-6T HARDWARE

Floating Head Assembly:

1. MEP-6T Floating Head Assembly. Utilizes a floating air bearing technique to float the Head Assembly. Used for side to side placement of the Head Assembly over the connector to press.

2. Z-Axis Motor. Located top of Head Assembly. Controls the Z-Axis (up and down) movement of the press assembly. Used to generatc the necessary torque required to properly press the connectors onto the

circuit boards.

3. Z-Axis Gearbox. Located between the Z-Axis motor and the Z-Axis Baliscrew. Used with and in conjunction with the Z-Axis motor to generate the forces required to press connectors to circuit boards.

4. Z-Axis Motor Encoder. Located on the back of the Z-Axis Motor. An optical encoder type unit, which provides the necessary feedback for proper location of press tooling and speeds, associated with the pressing operations.

5. Z-Axis Ballscrew. Located approximately at the center of the press head assembly. Proves Z-Axis motion (up & down), which generates the actual forces necessary for the pressing operation.

6. Press Head Posts, 2 ea. Transfers pressing forces through the Guide Rod Bearings to the Press Hcad Base and Press Plate Tooling Head (Anvil).

7. 10K(10,000lb) Load Cells, 2 ea. Located near middle of Head Assembly. One 10k load cell for each press rod. Provides press force feedback (analog) to the TMO amplifiers.

8. TMO Amplifiers, 2ea. Located on top left side of Press Head Assembly. One amplifier for each load cell used. Used to provide an amplified, analog feedback signal (from load cells), to the computer. For load cell forces used in data processing arid for readouts on the computer screen.

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MEP-6T HARDWARE

Floating Head Assembly:

9. Laser Light. Located between Guide Rod Bushings, attached to Laser Light Mount. Used to help operator center Connector Press Tooling over connector to be pressed.

10. Laser Light Controller. Located top left side of Press Head Assembly. Controller for the Laser Light. Can be programmed and adjusted for laser light sensitivity.

11. Upper and Lower Limits. Used to set the upper and lower limits of the Press Head Assembly. Used to keep press from hitting or crashing either into baliscrew assembly or table.

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Press Head Base

Pressing Plate Tooling Head

(Anvil)

Guide Rod Bearings

10K Load Cell

Lower Limit Flag

TMO Covers

TMO Amplifiers

Z-Axis Encoder

Z-Axis Motor

Z-Axis Gearbox

Upper Limit Flag

Z-Axis Ball Screw

Upper Limit Sensor

Laser Light Mount

MET-6THead Assy.

Press Head Posts

Z-Axis Motor Encoder

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MEP-6T

Sheet Metal

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MEP-6T MonitorStand Assy

APPENDIX D - ELECTRICAL / MECHANICAL SCHEMATICS

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