vcd single head 8 axial lead inserter (6687c) jumper wire...

Universal Part Number: GS-398-00Reference Configuration # 47609501

Issued 12/99

VCD Single Head 8Axial Lead Inserter

(6687C)and

Jumper Wire Single Head 8(6683C)

6687C/6683C GS-398-00

6687C/6683CGS-398-00

VCD SH 8Single Head Axial Lead Inserter

Model 6687C

IMCProduct Line

IMCProduct Line

Insertion Machine DivisionProduct Line


VCD SH 8 FeaturesHigh-performance insertion machine with insertion rates up to 25,000 components perhour, and insertion PPM of 150 or better

Insertion span capabilities from 5mm (0.197") to 22.43mm (0.883") with standard tapeinput, depending on tooling selected

VME-based control system with embedded P.C.

IM-Universal Platform Software with graphical user interface

Servo-motor driven insertion head, clinch, insertion span axis, and positioning system

Uninterruptable Power Supply (UPS) included with each machine

6687C/6683C GS-398-00

6687C/6683CGS-398-00

JW SH 8Single Head Jumper Wire Inserter

Model 6683C

JW SH 8 FeaturesHigh-performance insertion machine with insertion rates up to 22,000 wires per hour,and insertion PPM of 75 or betterInsertion span capabilities from 5mm (0.197") to 33.00mm (1.300")

VME-based control system with embedded P.C.IM-Universal Platform Software with graphical user interface

IMCProduct Line

IMCProduct Line



Servo-motor driven insertion head, clinch, insertion span axis, and positioning systemUninterruptable Power Supply (UPS) included with each machine

6687C/6683C GS-398-00

6687C/6683CGS-398-00

VC SH 8 (6687C)and

JW SH 8 (6683C)(Shown as Pass Through, Loader/Unloader: Magazine-to-Magazine Configuration)

CE-Compliant

Board Handling System ConfigurationsLoader/Unloader: Magazine-to-Magazine, CE-compliant with Long Buffers only

Loader/Unloader: Vacuum Bare Board-to-Magazine, not CE-compliant

Loader/Unloader: Destacker on 29", 44", or 58" Conveyor-to-Magazine, CE-compliantwith 44" or 58" Conveyor and Long Buffers only

Internal Board Handling System (BHS) for in-line assembly, CE-compliant

Elevator and LongBuffer Loader,

with CE-CompliantSafety Screens

Elevator and LongBuffer Unloader,

with CE-CompliantSafety Screens

IMCProduct Line

IMCProduct Line



6687C/6683C GS-398-00

6687C/6683CGS-398-00

Contents

Standard Features .................................................................................................... 1Control System .................................................................................................... 1

Power Input and Distribution ......................................................................... 1Uninterruptible Power Supply (UPS) ............................................................. 1VME Chassis ................................................................................................. 2Input/Output Box ........................................................................................... 2High Power Servo Chassis ............................................................................ 2Head Drive .................................................................................................... 3Insertion Span Axes ...................................................................................... 3Clinch Anvil Drive .......................................................................................... 3Push Button Panel ......................................................................................... 3Board Error Correction (B.E.C.) .................................................................... 3

System Software .................................................................................................. 4System Setup ................................................................................................ 4Advanced Product Editor (APE) .................................................................... 4Product Changeover ...................................................................................... 4Production Control ......................................................................................... 4Machine Status .............................................................................................. 5Management Information ............................................................................... 5IM Diagnostics ............................................................................................... 5On-Line Documentation ................................................................................. 5

CAD Data Requirements ..................................................................................... 6CAD File Requirements ................................................................................. 6Sample CAD File Format Notes .................................................................... 8Additional APE Features ............................................................................... 8Off-Line Pattern Programming Specifications ............................................... 9

System Mechanics ............................................................................................. 10X-Y Positioning System ............................................................................... 10Machine Console/Covers ............................................................................ 10Machine Status Light/Audible Alarm ............................................................ 11

Optional Features .................................................................................................. 12Workboard Holders ............................................................................................ 12Automatic Board Handling Configurations ......................................................... 12Network Kit ........................................................................................................ 13Host Computer Interface Kit .............................................................................. 13Remote P.C. Software/Off-Line Programming ................................................... 13Remote P.C. ...................................................................................................... 13

Supporting Documents ......................................................................................... 14Technical Specifications: VCD SH 8 (Model 6687C) ........................................... 15

Insertion Head.................................................................................................... 15Insertion Hole Span ........................................................................................... 15Insertion Tooling ................................................................................................ 16Insertion Tooling Footprint ................................................................................. 18Insertion Specifications ...................................................................................... 19Cut and Clinch ................................................................................................... 20Scrap Tape Remover ......................................................................................... 20Input Components.............................................................................................. 20Component Definitions ....................................................................................... 21Insertion Tooling Specification ............................................................................ 22Component Body Length Considerations........................................................... 23Minimum Insertion Hole Span Formulas for Maximum Body Lengths ............... 23Recommended Component Clearances1 .......................................................... 24Set-Up Template Assembly (B.E.C. Alignment Template) ................................ 25

6687C/6683C GS-398-00

Contents

Positioning System ............................................................................................ 25Board Error Correction Detection Area .............................................................. 26Insertable Area .................................................................................................. 26

Technical Specifications: JW SH 8 (Model 6683C) ............................................. 27Wire Feeder ....................................................................................................... 27Insertion Head.................................................................................................... 27Insertion Hole Span ........................................................................................... 27Cut and Clinch Footprint .................................................................................... 28Specifications for Wire Input and Insertion Span ............................................... 30Wire Material Property ....................................................................................... 30Positioning System ............................................................................................ 31Board Error Correction Detection Area .............................................................. 32Insertable Area .................................................................................................. 32

Installation Considerations: VCD SH 8 (Model 6687C) and ...................................JW SH 8 (Model 6683C) ................................................................................... 33Single Head 8 Non-Pass Through (Stand-Alone): Side View ........................... 34

Machine Dimensions & Weights ........................................................................... 35Service Requirements (including Uninterruptible Power Supply) ....................... 36Environmental Requirements ............................................................................. 37

Appendix: Automatic Board Handling Systems ............................................. A-39Index .................................................................................................................... A-39Introduction ........................................................................................................ A-40

Technical Specifications for Internal Board Handling System (BHS) .............. A-42Workboard Clearances at Table Rotation Locations ...................................... A-43

Single Head 8 with Internal BHS Only ....................................................... A-44Technical Specifications for Loader/Unloader: Elevator/Buffer Configuration .A-45Magazine Elevators ........................................................................................A-45Magazine Input/Output Buffers ....................................................................... A-45Magazines.......................................................................................................A-46Universal Magazine Specifications ................................................................. A-47Technical Specifications for Loader/Unloader: Vacuum Bare Board-to-Magazine

Configuration ............................................................................................ A-50PC Board Specifications for Between Machines 22" Conveyor ................A-50

Technical Specifications for Loader/Unloader: Destacker/Conveyor-to-MagazineConfiguration ............................................................................................ A-53

PC Board Specifications for Destacker/Conveyor Loader ...............................A-53Destacker/Conveyor Specifications ..........................................................A-53

Installation Considerations: Loader/Unloader .................................................A-56Service Requirements .....................................................................................A-57

6687C/6683CGS-398-00

All specifications are subject to periodic review and may be changed withoutnotice. Illustrations may not be drawn to scale.

© Universal Instruments Corporation, 1999. All rights reserved.

The following are trademarks of Universal Instruments Corporation, registered U.S.Patent and Trademark Office: Satellite Control, UICS, U-Teach, Universal,U-Design.

Ethernet is a trademark of Xerox Corporation. Intel is a trademark of IntelCorporation. OS/2 is a registered trademark of International Business MachinesCorporation. VME is a trademark of Motorola Corporation.

6687C/6683C GS-398-00

Glossary of Acronyms and Specialized Terms

Acronym/Term MeaningAC Alternating Current: type of electrical power generationAPE Advanced Product Editor (Universal brand name)ASCII American National Standard Code for Information InterchangeAWG American Wire Gauge: wire size standardBEC Board Error Correction (Universal brand name)BHS Board Handling System: means of transporting PCBsCAD Computer-Aided DesignCD-ROM Compact Disc-Read Only MemoryCE Conformité Europeanne: European safety standardCFM Cubic Feet per Minute: measurement of air flowCPH Components per HourCTA Component Transfer AssemblyDC Direct Current: type of electrical power generationERV Expanded Range Component Verifier (Universal brand name)GEM Generic Equipment ModelGS General Specification (Universal brand name)GUI Graphical User InterfaceHSMS High Speed SECS Message Service: implements SECS2 messaging over a

network linkHz Hertz (cycles per second): measurement of electrical frequencyIM Insertion Machine: equipment for through hole component insertionIMC Insertion Machine ComponentsIM-UPS Insertion Machine-Universal Platform Software (Universal brand name):

operating software for Universal Series 8 through hole equipmentI/O Input/OutputIP Index of Protection: resistance of machine to contamination by foreign objectsLED Light Emitting Diode: electrical componentMIT Machine Interface Translator (VME to I/O bus)MMIT Mini Machine Interface Translator (VME to I/O bus)OS/2® Operating System 2 (IBM Corp. brand name)PAC Positive Axis ControlP.C. Personal ComputerPCB (or PC board) Printed Circuit BoardPPM Parts Per Million: measurement of machine performanceSCFM Standard Cubic Feet per Minute: measurement of air flowSECS Semiconductor Equipment Communications Standard: interface between host

computer and assembly machinesSEMI Semiconductor Equipment & Materials InternationalSMC Surface Mount ComponentsSMEMA Surface Mount Equipment Manufacturers AssociationTCP/IP Transfer Control Protocol/Internet Protocol: network communication protocolUCT Universal Control Terminal (Universal brand name): personal computer for

operating IM equipmentUICS Universal Instruments Control Software (Universal brand name)UPS Uninterruptible Power SupplyVA Volt-Amps: measurement of electrical power consumptionVAC Volts Alternating CurrentVCD Variable Center DistanceVDC Volts Direct CurrentVGA Video Graphics Array: type of CRT monitor standardVME® Versa Module Eurocard (Motorola brand name): industry standard for 32-bit

computer bus

GS-398-00

Standard Features

Control System

The Single Head 8 machines (both the VCD SH 8 and the JW SH 8)employ a control system, including input power/distribution, VMEbus, I/O, and servo system. Brief descriptions of major elements ofthis control system follow.

Power Input and DistributionThe input power to this machine is 230 VAC, single phase, 15 amps,50 or 60 Hz. All functions of the machine can operate over the rangeof 47-63 Hz without configuration change. In combination with thesupplied Uninterruptible Power Supply (UPS), the machine willaccept a wider range of inputs (see “Service Requirements” section)and provide power to run the machine briefly in the event of a shortpower interruption. There are filters on the power lines to preventmachine generated noise from getting on the power lines as well aspreventing noise on the power lines from interfering with the machineoperation. The machine has a lockable disconnect switch for safetyduring service.

Internal to the machine, the 230 volts is directly used for amplifierpower for the heads, clinches, insertion span drives, and X, Ydrives. There is a power conditioner transformer used for convert-ing to 120 VAC for the remainder of the machine functions. Thisincludes the fan panels, the power chassis, the VME chassis, themonitor, and sequencer module power supplies. This transformerwill also supply 120 VAC for the attached elevators and bare boardloaders.

The power chassis, in turn, provides DC power for machine opera-tion. This includes 56 VDC for Board Handling motors; +5 and ±15VDC for the I/O box; and 12 VDC for general purpose use (valvesolenoids, sensors, indicators, etc.). The 56 VDC and switched 12VDC are disconnected from the machine when interlocks are vio-lated. The power chassis also provides 12 VAC for the worklight and24 VAC for the machine status light and the interlock circuits.

Uninterruptible Power Supply (UPS)Offered standard with the Single Head 8 and external to the machine,the Uninterruptible Power Supply (UPS) provides continuous, on-line power at all times. This eliminates an interruption in power whentransferring to battery power.

GS-398-00

Battery capacity at full charge should allow full machine operationfor up to 10 minutes after loss of main input power. During this time,the machine should be brought to a controlled stop until main poweris restored.

VME ChassisThe VME chassis is a state-of-the-art, multi-processor rack-mountedcontroller. It has an embedded Intel®-based P.C. which is used forthe main operator interface. Attached to it are standard VGAmonitor, keyboard, and pointing device. The main machine control-ler is a 680X0-based unit. This board handles all of the machinefunctions and timing. It does not directly handle the motor control,but does direct the motion controllers.

Two, four-axis intelligent motion controllers are used. These are68000-based dedicated processors. The motion controllers providespeed and destination information to the servo amps, which drive themotors. Encoders, tachometers, and resolvers provide positional andvelocity feedback to the motion controllers, for precise positioncontrol. Three of these motion controllers are used with the Loader/Unloader configuration.

As an interface between the VME controller and the machinecontrols, there is a VME/Satellite interface board in the chassis. Thisconnects to the I/O box using a Universal MIT cable.

Input/Output BoxThe I/O box has a standard Universal MIT card in slot 1, which isthe interface to the VME controller. The I/O box contains two Multi-Input cards, two 32 DC Output cards, a Board Error Correction card,and, for machines with board handling, a 32/16 I/O card. Anadditional 32 DC Input card and 32 DC Output card are used formachines with the Loader/Unloader configuration.

High Power Servo ChassisThe high power servo chassis contains the high voltage servo ampsused for controlling the head, clinch, clinch span, head span, and X,Y axes. There are contactors in this chassis to disconnect power tothe servo amps when interlocks are violated. The high power servochassis has additional power line filtering for the 230 VAC used inthe chassis.

GS-398-00

Head DriveThe head drive is a servo-controlled axis for precise and rapidcapability. The insertion depth is controlled by this servo. The servomotor contains an integral resolver used for position feedback. Thissignal is sent back to the high power servo chassis where it isconverted to a quadrature line driver signal that is needed by themotion controllers in the VME chassis.

Insertion Span AxesThe head and clinch insertion spans utilize independent servo driveswith integral encoders for position feedback. This provides theflexibility through program control to independently adjust theclinch.

Clinch Anvil DriveThe clinch anvil drive is a servo-controlled axis for precise and rapidanvil positioning. The anvil height is controlled by the servo. Theservo motor employs an integral encoder used for position feedback.

Push Button PanelThe PB panel includes the Emergency-Stop switch, cycle counter,the Interlock Reset button, the Start and Stop buttons, the Overrideor Transfer Error button, and the Interlock Bypass Key Switch. Allother machine functions are accessed through the graphical userinterface via the keyboard, trackball, and monitor.

Board Error Correction (B.E.C.)Board Error Correction allows the positioning system to compensatefor lead hole location variations between printed circuit board lots.A light source and sensor are mounted relative to the insertion toolingcenterline. On a maximum dimension PC board — 508mm x457.2mm (20" x 18") — a small area cannot be sensed due to sensoroffset. Detectable area is 508mm x 434.34mm (20" x 17.1") (Seesection in Technical Specifications on BEC Detection Area).

B.E.C. uses a four quadrant sensor and amplitude controlled lightsource to find the center of holes in printed circuit boards. Thesignals are processed and provide the X and Y corrections to themotion controller via an analog signal, as well as to the span axis forits correction. The motion controller has 8 bit analog-to-digitalconverters to receive the information. The motion controller thenuses the full power of the control algorithms to find the center of thehole. Screens for B.E.C. setup are now integrated into machinediagnostics.

B.E.C. is also used in “Teach” to fit an insertion pattern to a PCboard. This greatly improves pattern accuracy and reduces insertionPPM.

STOP START OVERRIDE/TRANSFER ERROR

INTAKERESET

OFFREMOVE

ON

INTERLOCK BYPASS

GS-398-00

System Software

IM-Universal Platform Software (IM-UPS), and an OS/2 WARPoperating system, are standard with the base machine. This graphicalinterface provides a number of capabilities, including:

System Setup• Machine Configuration — User configuration of machine op-

tions, such as board handling and tooling.

• Event Configuration — Configuration of events for display andcontrol of machine status light.

• Security — Security based upon user/function.

Advanced Product Editor (APE)• Graphical Program Generation and Editing — Component

location can be programmed/edited in either text or graphicalformat. Graphically displays all component insertions relativeto PC board.

• Import of CAD Data for Program Generation (see followingsection).

Graphical UserInterface

System Setup Icon

APE Icon

Product Changeover• Load Product — User selection of previously stored product

programs.

Production Control• Counts — Allows setting inserter counts.

• Manual Control — Manually controls (zero, move) any axes ofthe machine.

Product Changeover Icon

Production Control Icon

GS-398-00

Machine Status Icon

Management Information Icon

IM Diagnostics Icon

Machine Status• Current Messages — Displays current controller messages and

events.

• Product Status — Displays status of running product.

• Diagnostics:

• Discrete I/O — Ability to read each input and set eachoutput individually.

• Message History — Ability to view message log.

• Operations — Sets machine modes: Step, Single Cycle, Insert,Pattern.

• Error Recovery — Recovery processes for operational errors,i.e., mis-insertion.

Management Information• Timers — Collection and display of machine timers.

• Counters — Count of machine events: insertions, insert errors,boards, Bad Board Reject, Board Error Correction, circuits.

• Component Data — Counts by component ID: placements,errors.

From these databases, a variety of reports can be created.

IM Diagnostics• Ability to exercise machine subsystems on an individual or

combined basis outside of machine control software.

• B.E.C. Set-Up/Analysis

On-Line Documentation Icon

• Machine Set-Up Support

On-Line Documentation• IM-UPS documentation is available on-line.

GS-398-00

CAD Data RequirementsASCII File Format — Incoming CAD files must conform to theAmerican National Standard Code for Information Interchange(ASCII). In order to accommodate a wide variety of CAD fileformats, the APE uses either a generic columnar or separatordata translation technique. All data contained in the CAD file isidentified by a position in a definition created by the user.

CAD File RequirementsX Coordinate: The X centroid coordinate location on the board.

Y Coordinate: The Y centroid coordinate location of thecomponent insertion.

Theta: The rotation of the component on the board.

Insertion Lead Span: The distance between the centerlines ofthe component leads.

Reference ID: The name assigned to the component whichmakes it unique to all other components in the product.

Component ID: The name of the component as it is found in thecomponent database.

Alias ID: The name of a component in the database to which thiscomponent is aliased (optional).

Centroid (Top View)

Feeder: The number of the feeder from which the component isdispensed. This is a three-digit number (001, 117, etc.). If thefeeder field is used, the feeder numbers are automatically enteredinto the feeder list when the CAD file is imported.

BOM-CAD Link: A user-defined alphanumeric string whichlinks a line of data in the CAD file to a component ID in the Billof Material (BOM) file.

Ignore: If the CAD file contains data that does not fit any of thefields, it should be identified with IGNORE.

A sample CAD file format is given with a brief explanation. Thisfile format is provided for reference only and is an example of atypical CAD output.

Length = "L"

L2

L2

X,Y

GS-398-00

This is a typical CAD file which may be output from a wide variety of different CAD systems.

This file includes SMC and IMC information, with component information stored for the IMC components.The component information for Surface Mount components will be obtained from the master .DEF files.IMC component information will be obtained from this file and placed into the Component Library.

Information in the CAD file:A = REFERENCE DESIGNATOR F = SPANB = X COMPONENT CENTROID COORDINATE G = NUMBER OF LEADSC = Y COMPONENT CENTROID COORDINATE H = AXIAL BODY DIAMETERD = ORIENTATION I = MACHINE TYPEE = PART NUMBER/COMP ID J = DIP SOCKET

K = AXIAL LEAD DIAMETER

GS-398-00

Sample CAD File Format Notes1. Maximum file width can not exceed 256 columns.

2. Headerlines, often output by the CAD system, may be used. TheCAD Translator allows the user to define the quantity of linescontaining the file header. This information is for operator useonly and is not used by the CAD Translator.

3. Format Type: The format of file. This can be either Table orSeparator format (Table is the default).

Table format uses predefined columns for each data type. For example,the reference ID column may be defined as 10 characters. The actualreference ID in the CAD file can contain up to 10 characters. It does notmatter if there is data in every column.

Separator format uses a character (comma, space, dash, etc.) toseparate data fields. Each line of data must contain the same datatypes in order for auto detect to work.

# of Fields: The number of fields in the file.

# of Lines: The total number of lines in the file.

4. The CAD file must be devoid of all special control characterssuch as Tabs. (Note that special characters shown are forillustration purposes only and cannot be contained in the actualCAD file. These characters include boxes, arrows.)

5. CAD data is limited to one component per data file line or row.Additional components are specified on additional lines of theCAD file. There must be no blank lines or rows between anyrows of CAD data. Markers such as {EOF} must not be presentat the end of the CAD file.

Additional APE Features• Import of Existing UICS Patterns — UICS patterns are con-

verted to IM-UPS products.

• Program Optimization — Optimization via “Nearest Neighbor”insertion path.

• Component Identifier and Reference Designator in ProductInformation — The addition of component identifier and refer-ence designator in programs supports improved status messagereporting and management data tracking by componentidentifier.

GS-398-00

Off-Line Pattern Programming SpecificationsThe creation of a “product” (pattern program) can be completed on-line, utilizing the machine’s embedded P.C., or off-line, using asuitable stand-alone P.C. loaded with IM-UPS software.

Note: IM-UPS software supplied with the machine is licensed onlyfor use in the machine. Software for an off-line P.C. isavailable as an option at extra cost.

Universal recommends that pattern programming be generated off-line to eliminate production interruptions. The stand-alone P.C. andIM-UPS software for off-line pattern program generation are notstandard features of the machine, but can be purchased as extra costoptions.

Minimum P.C. requirements for creating the product off-line (pat-tern programming) include:• 486 processor

• 12 megabyte memory

• CD-ROM drive

• IBM OS/2 Warp 3.0

• 200 megabyte available disc space, on OS/2-compatible parti-tion

For optimum performance in generating the pattern programmingoff-line, the following capabilities are recommended:• Intel Pentium® processor

• 16 megabyte memory

• 500 megabyte available disc space, on OS/2-compatible parti-tion

Note: Installation of OS/2 on an existing P.C. system may requirepartitioning of the hard drive.

GS-398-00

System Mechanics

X-Y Positioning SystemThe X-Y positioning system locates the printed circuit board underthe insertion tooling and is equipped with a rotary indexing table thatindexes in 90° increments, from 0° to 360° in a clockwise rotation.This rotary table is air motor driven under pattern program controland requires less than one second to execute each 90° rotation.

The X-Y positioning system employs high performance brushlessmotors, with integrated encoder feedback. The system is controlledby the 680X0-based motion controllers. Automatic belt tensioningassures that belts are properly adjusted.

Machine Console/CoversThe machine covers serve two primary purposes. The first is toprovide safety by preventing access to dangerous mechanical andelectrical hazards. The second is to further reduce the sound level ofthe operating machine. It is important that the machine coversremain in place and fully functional for operational safety.

On Non-Pass Through, manual load machines, the positioningsystem and work board holders are exposed to allow the operator toload and unload printed circuit boards. There is a hinged cover thatprotects the operator from the moving parts of the insertion head.This cover is interlocked and will stop the machine if moved, and iscoated to prevent damage from electrostatic discharge (ESD).Note: This configuration is not CE-compliant.

On Pass Through, Automatic Board Handling configurations, thecovers completely enclose the machine. The sliding covers on thefront of the machine are interlocked, and are coated to preventdamage from electrostatic discharge (ESD). To minimize recoveryprocedures, the machine should be at a controlled stop beforeopening the covers. Note: This configuration may be CE-compliant, depending on the selection of the Loader/Unloader.

When a head runs out of components, a “pop-up” screen is displayedon the monitor, indicating which head needs to be reloaded.

GS-398-00

Machine Status Light/Audible AlarmThe machine status light/audible alarm indicates the status ofmachine operation. Each of the lights are user configurable via themachine software. Defaults are set as follows:

• Red - machine stop for any error.

• Yellow - normal operation, machine waiting.

• Green - normal operation, machine running.

• Blue - not configured for Single Head 8.

• Audible alarm - activated for low parts warning.

GS-398-00

Optional FeaturesWorkboard Holders

Workboard holders are required to accurately secure PC boards tothe rotary table during the insertion process when manual PCB load/unload is being considered. Universal provides a wide range ofworkboard holder products which can be ordered separately or witha new machine purchase. For stand-alone operation either custom oradjustable fixtures are available with 508mm x 457mm (20" x 18")insertion areas.

Automatic Board Handling Configurations

The Single Head 8 machines are available in several materialhandling configurations (left-to-right, or right-to-left):

n Loader/Unloader: Magazine-to-Magazine with Short Buffer(not CE-compliant), or with Long Buffer with extra cost covers(CE-compliant).

n Loader/Unloader: Vacuum Bare Board-to-Magazine with ShortBuffer (not CE-compliant), or with Long Buffer (not CE-compliant).

n Loader/Unloader: PCB Destacker-to-Magazine.

• Destacker on 29" Conveyor with Short or Long Buffer (notCE-compliant).

• Destacker on 44" Conveyor with Short Buffer (not CE-compliant).

• Destacker on 44" Conveyor with Long Buffer with extracost covers. Input PCBs, including any installed compo-nents, can not exceed 25.4mm (1") thickness (CE-compli-ant).

• Destacker on 58" Conveyor with Long Buffer with extracost covers (CE-compliant).

n Internal Board Handling System (BHS) - Internal BHS for in-line systems integration is also available. Two PC boards, onefor input and one for output, quickly and reliably transfer. Boardtransfer from last insertion to first insertion on the next boardoccurs in 5.0 seconds. Transfer direction may be specified whenordering the machine, prior to manufacture, and quick and easymanual width adjustment handles a wide range of PC boardsizes. The front fixed rail is standard and all operator PC boardchangeover adjustments are readily accessible.

GS-398-00

Network Kit

Package for connection includes an Ethernet network card and IBMOS/2 TCP/IP client software. This provides high speed, reliablecommunications and data transfer to all computers connected to thenetwork.

Host Computer Interface Kit

This kit is used to interface the Single Head 8 with a Host computerusing the SECS/GEM Standard. The Generic Equipment Model(GEM) Standard defines a standard implementation of the SECS II(Semi Equipment Communications Standard 2) communicationsinterface for all semiconductor manufacturing equipment. SeeSEMI International Standards document E30-93 for details. Note:Requires customer’s Host computer to be compliant with SECS/GEM standard SEMI E37, HSMS.

Remote P.C. Software/Off-LineProgramming

Each base machine includes software licensed only to the machine.Universal recommends that “product” programs be created off-lineto ensure maximum use of machine production time. This off-linesoftware is licensed for use on a P.C. whose basic configuration isas shown in the “Off-Line Pattern Programming Specifications”found in this document.

Remote P.C.

The Universal Control Terminal (UCT), using optional IM-UPSsoftware, allows a Universal approved personal computer to be usedas an intelligent terminal. It is connected to the Single Head 8 via theoptional Network Kit. This package includes a visual displayterminal, keyboard, data storage unit, printer and stand, cableassembly, and manual. For additional information on this option,refer to GS-319. This can be used for off-line programming andmachine data transfer.

GS-398-00

Supporting Documents

GS-055 Indexing Rotary TablesGS-061 Lead Tape Reel Packaging of Axial Components,

Series 2500GS-134 Workboard Holders, Series 6810GS-354-01 Through Hole Design GuidelinesEIA RS-296-E Lead Taping of Components in Axial Configura-

tion for Automatic Insertion

GS-398-00 Technical Specifications: VCD SH 8 (Model 6687C)

Technical Specifications: VCD SH 8 (Model 6687C)

Insertion Head

A servo motor activates the insertion head through a rack and piniondrive, providing insertion rates up to 25,000 components per hour.Close coupled software provides controlled acceleration/decelera-tion and velocity during the insertion process for increased reliabilityand reduced noise.

The machine handles varying component body diameters by soft-ware selectable depth stops. Depth stops, at insertions, are softwareselectable via the Advanced Product Editor and based on componentsize, programmable in increments of 0.01mm in metric environ-ments, or 0.001" in English–measure environments, from 0mm to5.49mm (0" - 0.216"). Actual driver tip down position is controlledthrough the closed loop servo drive system.

Insertion Hole Span

The tooling span for component insertion is automatically calculatedby the Advanced Product Editor and based on lead diameter andcenter to center hole spacing on the PC board. Insertion hole spansare dependent upon head tooling configuration and component inputclass and are variable under servo program control.

Refer to Technical Specifications section for insertion hole spanranges that apply to the four basic tooling types.

GS-398-00Technical Specifications: VCD SH 8 (Model 6687C)

Insertion Tooling

Universal offers four types of insertion tooling: standard, large lead,5mm, and 5.5mm. Tooling type is selected to provide optimumperformance depending upon board density (footprint), componentlead wire size and material, component body size, hole spans, andboard configurations. For non-standard applications, consult aUniversal sales engineer.

Standard, large lead, 5mm, and 5.5mm tooling have been designedfor improved reliability, longer tooling life, and better handling ofbent lead component input. This tooling incorporates generousamounts of carbide inserts and has increased cross-sections forgreater robustness.

Refer to Technical Specifications section for tooling specifications.

Above board clearance beneath the retracted tooling is approxi-mately 20.32mm (0.800"). See Tooling Footprints and ComponentClearances sections relating to tooling footprints.

Standard Tooling

Standard tooling is designed to insert components with leads from0.38mm (0.015") to 0.81mm (0.032") in diameter and hole spansfrom 7.62mm (0.300") to 22.43mm (0.883") at standard input class.(Maximum hole span, which is dependent upon component inputclass, is 32.44mm [1.277"]).

Refer to Technical Specifications for your specific application.

Large Lead Tooling

Large lead tooling is designed to insert components with leads from0.63mm (0.025") to 1.07mm (0.042") in diameter and hole spansfrom 7.62mm (0.300") to 22.17mm (0.873") at standard input class.(Maximum hole span, which is dependent upon component inputclass, is 31.95mm [1.258"]).

While increasing the insertion ability for large leaded components,this tooling reduces the allowable component density during PCboard assembly.



5mm Tooling

5mm tooling is designed to insert components with leads from0.38mm (0.015") to 0.81mm (0.032") in diameter and hole spansfrom 5.0mm (0.197") to 20.00mm (0.787") at standard input class.(Maximum hole span, which is dependent upon component inputclass, is 29.89mm [1.177"]).


5.5mm Tooling

5.5mm tooling is designed to insert components with leads from0.38mm (0.015") to 0.81mm (0.032") in diameter and hole spansfrom 5.5mm (0.216") to 20.00mm (0.787") at standard input class.(Maximum hole span, which is dependent upon component inputclass, is 29.89mm [1.177"]).

This tooling selection provides wider driver tips for more leadcontact and improved insertion reliability when the applicationrequires 5.5mm (0.216") hole spans, rather than 5.0mm (0.197")hole spans.



Insertion Tooling Footprint

6.35 (0.25)

3.81 (0.150)

Tooling FootprintStandard Large Lead 5mm and 5.5mm

Fron

t Vie

wS

ide

Vie

wB

otto

m V

iew

0.84 (0.033)

3.18 (0.125)

2.36 (0.093)

0.48 (0.019)

1.27 (0.050)

2.29 (0.090)

2.29 (0.090)

12.19 (0.489)

2.29 (0.090)

6.35 (0.25)

6.35 (0.25) 3.81 (0.150)

1.27 (0.050)

15o

Dimensions are in millimeters;inch equivalents are bracketed.

2.36(0.093)

1.27(0.050)15°

0.48 (0.019)

1.27 (0.050)

2.29 (0.090)

2.29 (0.090)


Insertion SpecificationsType VCD (Variable Center Distance)

Hole Span Minimum MaximumStandard Tooling 7.62mm (0.300") 22.43mm(0.883")Large Lead Tooling 7.62mm(0.300") 22.17mm(0.873")5.0mm Tooling 5.0mm(0.197") 20.00mm(0.787")5.5mm Tooling 5.5mm(0.216") 20.00mm(0.787")

Programmable 0.01mm in metric environments, or 0.001" inSpan Increments English–measure environments. There are no

hole span limitations between consecutiveinsertions, within the specified hole span ranges.

Depth Stops Programmable from 0.2mm to 5.28mm (0.008"to 0.208") in 0.2mm (0.001") increments

Board to Tooling 20mm (0.8"), maximum with tooling in full upClearance position

Cut and Clinch Adjustable from 45° to 90° clinch angle

Insertion Rate Up to 25,000 insertions per hour with factory testspecifications. Refer to Insertion RateDetermination section.


Cut and ClinchOnce a component has been inserted into the PCB, the cut and clinchmechanism clinches the two leads to a repeatable angle, and then cutsthe leads to an adjustable length. The cut and clinch contains a servo-driven rocker/slide up/down mechanism and provides PC boardsupport during the insertion cycle, then trims and clinches thecomponent leads to the underside of the PC board with a pneumaticactuated cutter.

Two-step operation allows the clinch to return to its lowest positionduring a table rotation and only half the distance during the insertionprocess, saving time and wear on mechanical parts. Insertion spanis servo controlled over the same span as the insertion head, and leftand right anvils are coupled.

Clinch angle is inward and may be adjusted over a range from 0º to45º from the PC board bottomside. Clinch lead length is adjustablefrom 1.28mm (0.050") to 1.80mm (0.071"). Lead length is measuredfrom the center of the insertion hole to the end of the lead. Thetolerance on the lead length is ±0.29mm (0.011").

The Single Head 8 cut and clinch uses a dual lead continuity checkto verify component insertion. The failure of either lead to passthrough the PC board and be clinched will generate an insert errorand cause the machine to stop.

Scrap Tape Remover

For assured and continuous removal of scrap tape and leads from therear of the machine, this roller system works with a 24 VAC motor,50/60Hz, and is internal to the machine covers.

Input Components

Available for Tape Reels or Amno Pack (selectable).

ClinchLength Clinch

Length

Clinch Pattern Options

0° Clinch 45° Clinch


Input Specifications for the VCD Insertion Head

F

C

A

E

note 1

B

Directionof componentfeed

Scrap as it leavesinsertion head

Point ofinsertion

B

Componentsbefore reachinginsertion head

note 2,3

Outside Former

D

A = TAPE SPACING D = COMPONENT BODY DIAMETER - note 2Input Class Distance Between TapesStd 43.7mm (1.72") E = COMPONENT SPACING

5.08mm (0.200")B = HOLE SPAN - hole center distance,

notes 1, 2F = COMPONENT LEAD DIAMETER

C = COMPONENT BODY LENGTH

Notes:

1. The recommended maximum consecutive plus hole span change is 5.08mm (0.200") to prevent leadscrap problems. There is no limit to consecutive minus hole span change.

2. At 5mm hole spans, the maximum component body diameter is 2.29mm (0.090")

Component Definitions


Insertion Tooling Specification 1

Standard Large Lead 5mm 5.5mm

Minimum Hole Span 2 7.62 (0.300) 7.62 (0.300) 5.00 (0.197) 5.50 (0.216)(with minimum leaddiameter)

Maximum Hole Span 2 Std Input Tape 22.43 (0.883) 22.17 (0.873) 20.00 (0.787) 20.00 (0.787)(with maximum leaddiameter shown byinput class)

Steel Wire Lead Size Minimum 0.38 (0.015) 0.63 (0.025) 0.38 (0.015) 0.38 (0.015)Maximum 0.81 (0.032) 0.81 (0.032) 0.81 (0.032) 0.81 (0.032)

Copper Wire Lead Size Minimum 0.38 (0.015) 0.64 (0.025) 0.38 (0.015) 0.38 (0.015)Maximum 0.81 (0.032) 1.07 (0.042) 0.81 (0.032) 0.81 (0.032)

Component Body Minimum Wire lead dia. Wire lead dia. Wire lead dia. Wire lead dia.Diameter Maximum 3 10.69 (0.420) 10.69 (0.420) 11.68 (0.460) 11.68 (0.460)

minus 2 X minus 2 X minus 2 X minus 2 Xboard board board boardthickness thickness thickness thickness

1 Dimensions are given in millimeters; inches are in parentheses. 2 Insertion hole span is defined as the hole center distance. Wider insertion spans are possible with the use of wider tape spacing. Consult your Universal Sales Engineer. 3 At 5mm and 5.5mm hole spans, maximum component body diameter is 2.29mm (0.090").


Component Body Length Considerations

After the tooling type and the variables have been determined fromthe Insertion Tooling Specification table, the minimum allowablehole span can be determined for a known body length.

Machine capabilities allow components to be inserted using theminimum hole span formulas below. Due to body length variations,it is recommended to design hole spans greater than the calculatedminimum.

Use the following formulas, depending on tooling type -- standard,large lead, 5mm, or 5.5mm -- to calculate the minimum insertion holespan for a known body length. The formulas apply to the body lengthranges shown and are based on a ±0.41mm (0.016") componentcentering accuracy on the input tape.

Minimum Insertion Hole Span Formulas for Maximum Body LengthsStandard Tooling [Body Length Range: 5.08mm (0.200") to 15.75mm (0.620")]

Metric Formula: Minimum Hole Span = [(Component Body Length1 x 1.112) + 2.36mm] - Lead Diameter

Inch Formula: Minimum Hole Span = [(Component Body Length1 x 1.112) + 0.093"] - Lead Diameter

Large Lead Tooling [Body Length Range: 3.81mm (0.150") to 15.75mm (0.620")]



5mm Tooling [Body Length Range: 3.61mm (0.142") to 15.75mm (0.620")]



5.5mm Tooling [Body Length Range: 3.61mm (0.142") to 15.75mm (0.620")]

Metric Formula: Minimum Hole Span = [(Component Body Length1 x 1.067) + 2.03mm] - Lead DiameterInch Formula: Minimum Hole Span = [(Component Body Length1 x 1.067) + 0.080"] - Lead Diameter1 Subtract an additional 0.41mm (0.016") from the maximum body length for non-symmetrically shaped

components.

HOLE SPAN


A

B C

D

C

Note:Dimension A is measured at the smallest possible footprint for 5mm and 5.5mm tooling. See Tooling Footprints for related dimensions.

Recommended Component Clearances 1

Standard Large Lead 5mm & 5.5mm

Lead 0.38 0.81 0.63 1.07 0.38 0.81Diameter (0.015) (0.032) (0.025) (0.042) (0.015) (0.032)

A Dimension 1.78 2.01 1.80 2.08 0.97 1.22(0.070) (0.079) (0.071) (0.082) (0.038) (0.048)

B Dimension 1.14 (0.045) 1.57 (0.062) 1.14 (0.045)

C Dimension 0.25 (0.010) 0.25 (0.010) 0.25 (0.010)

D Dimension 0.76 (0.030) 0.76 (0.030) 0.76 (0.030)1 Dimensions are given in millimeters; inches are in parentheses.


Positioning SystemMaximum PCB Size 559mm x 457mm (22" x 18")

Insertable Area 470mm x 470mm (18.5" x 18.5")

Accuracy ±0.05mm (±0.002")

Repeatability ±0.025mm (±0.001")

Table Capacity 22.7 kg (50 lbs) maximum, includingworkboard holder

Programming ±0.01mm (metric dimensioning)Capability ±0.001" (inch dimensioning)

Speed 368mm (14.5") per second7.62mm (0.3") in 0.07 seconds

Set-Up Template Assembly (B.E.C. AlignmentTemplate)

This template, formerly referred to as “B.E.C. Alignment Template”is a multi-purpose tool to (1) calibrate the B.E.C., (2) set Home Zeroof the Positioning System to the head, and (3) verify table squareness.


Board Error Correction Detection Area

Due to the position of the Board Error Correction sensor relative tothe insertion point, there is an area which cannot be scanned by thesensor. The non-scannable area is at the rear of the positioningsystem regardless of rotary table rotation.

470mm (18.500") x 470mm (18.500")Insertable Area

This area cannot be scanned byBoard Error Correction Sensor.

22.86mm(0.900")

470mm(18.500")

470mm (18.500")

FRONT OF MACHINE


+YInsertionCenterline

BEC SensorOffset

+X

22.86mm(0.900")

Insertable AreaRefer to figures below.

220,900 square mm(342 square inches)

Non-Board HandlingConfiguration

Board HandlingConfiguration


470mm(18.500")

470mm (18.500") 470mm (18.500")

406mm(16")

GS-398-00 Technical Specifications: JW SH 8 (Model 6683C)

Jumper Wire Feeder Assembly(Top View)

Technical Specifications: JW SH 8 (Model 6683C)

Wire Feeder

The wire feeder assembly consists of a drive mechanism and astraightener assembly. The drive assembly pulls wire from the inputspools through the straightener assembly, and dispenses the straightwire to the insertion head tooling. It is controlled by a stepping drivemechanism with indexing capabilities and a matched stepper-drivemotor. The drive mechanism automatically dispenses the requiredwire length depending upon the insertion span.

The straightener assembly consists of two sets of opposing rollers.The roller sets are mounted at right angles to remove wire bends intwo planes. Adjusting knobs on each set of rollers provide controlof the straightening pressure.

Insertion Head

A servo motor activates each insertion head through a rack andpinion drive, providing insertion rates up to 22,000 formed barewires per hour. Close coupled software provides controlled accel-eration/deceleration and velocity during the insertion process forincreased reliability and reduced noise. Actual driver tip downposition is controlled through the closed loop servo drive system.

Insertion Hole Span

The insertion hole span for component insertion is automaticallycalculated by the Advanced Product Editor and based on wirediameter and center-to-center hole spacing on the PC board. Inser-tion hole spans are variable under servo program control.

GS-398-00Technical Specifications: JW SH 8 (Model 6683C)

Cut and Clinch Footprint

6.15 (0.242)

3.61 (0.142)

2.11 (0.083)

7.98 (0.314)

3.58 (0.141)

8.13 (0.320)

2.72 (0.107)

6.10 (0.240)11.51 (0.453)

2.62 (0.103)

Insertion Center Distance

45°23°



Component Clearances for Cut and Clinch Anvil Assemblies

Side View

Jumper Wiresto previously insertedaxial leaded components.

Side View

Jumper Wiresto previously insertedDIP components, with bothoutward and inward clinch.

End View

Jumper Wiresto previously insertedaxial leaded and DIPcomponents shown with bothoutward and inward clinch.

A B C

3.68mm 2.54mm 2.54mm 0.125" 0.100" 0.100"

A

B

C

2.54 (0.100)

2.79 (0.110) 2.54 (0.100)

Outward DIP Inward DIP

Outward DIP Inward DIP

Continuity Style Lead Sense Dimensions are in millimeters;inch equivalents are bracketed.


Specifications for Wire Input and InsertionSpan

• Insertion hole span (hole center distance) — 5mm to 33mm(0.197" to 1.300").

• Wire diameter — 0.51mm (0.020") to 0.81mm (0.032"); but0.6mm (0.024") solder coated copper is standard. The wire sizesbelow are tested with the expected results listed. Contact yourUniversal Sales Engineer for details.

• Minimum Printed Circuit Board Hole Diameter =wire diameter + 0.483mm (0.019") ±0.080mm (0.003") + 2times printed circuit board hole location tolerance.

• Wire Input — Wire input is available in various package sizes.The preferred package is the cardboard drum which measures345.95mm (13.62") high by 285.75mm (11.25") in diameter.Reel packages containing smaller amounts of wire are alsoavailable. These provide adequate wire for shorter runs, butrequire more frequent changeover when performing extensiveproduction runs. Also, reel packages tend to jam and unreelunevenly.

All wire input should be wound on drums/reels using an eventension and winding so that the wire on each layer is evenlydistributed from top to bottom. Each layer should overlapwithout interference so that the wire does not tangle whenunwound.

The suggested source for wire input is Hitachi Cable AmericaInc. (White Plains, NY; 1-800-394-0234). The product isSolder Coated Copper Wire, ITPA 0.60 (SP-EM/SWP-191).

Wire Material PropertyWire Tensile Elongation Insertion HoleDiameter Strength Span

0.5mm 27-35 kg/mm2 4% maximum 5-20mm 1

0.6mm 27-35 kg/mm2 5-33mm

0.45mm 30 kg/mm2 28% maximum 5-20mm 1

0.45mm 22-30 kg/mm2 10-20% 5-20mm 1

1. When insertion span increases to 21-33mm range, expect anincrease in the machine PPM.

286mm(11.3")

346mm(13.6")

Cardboard Drum


Positioning SystemMaximum PCB Size 559mm x 457mm (22" x18")

Insertable Area 470mm x 470mm (18.5" x 18.5")

Accuracy ±0.05mm (±0.002")

Repeatability ±0.025mm (±0.001")

Table Capacity 22.7 kg (50 lbs) maximum, includingworkboard holder

Programming ±0.01mm (metric dimensioning)Capability ±0.001" (inch dimensioning)

Speed 368mm (14.5") per second7.62mm (0.3") in 0.07 seconds


Board Error Correction Detection Area

Due to the position of the Board Error Correction sensor relative tothe insertion point, there is an area which cannot be scanned by thesensor. The non-scannable area is at the rear of the positioningsystem regardless of rotary table rotation.

Insertable AreaRefer to figures below.


Non-Board HandlingConfiguration

Board HandlingConfiguration


470mm(18.500")

470mm (18.500") 470mm (18.500")

406mm(16")

470mm (18.500") x 470mm (18.500")Insertable Area

This area cannot be scanned byBoard Error Correction Sensor.

22.86mm(0.900")

470mm(18.500")

470mm (18.500")

FRONT OF MACHINE


+YInsertionCenterline

BEC SensorOffset

+X

22.86mm(0.900")

GS-398-00

762(30)

PushButtonPanel

EP1

1800(70.9)

Pneumatic Connection

Electrical ConnectionE

P1VCD SH 8 or JW SH 8Height 1575 (62.75)

1358.9(53.5)


UPS

610(24)

305(12)

Jumper Wire Spool(for JW SH 8 only)

Operator

Installation Considerations: VCD SH 8 (Model 6687C) and JW SH 8 (Model 6683C)

Single Head 8 Non-Pass Through (Stand-Alone) Installation Considerations

GS-398-00

181.9(7.16)

133.4 (5.25)

1435.1(56.5)

812.8(32)

1333.5(52.5)

88.9(3.5)

1270(50)

88.9(3.5)

1403.4(55.25)Typical

647.7(25.5)

Single Head 8 Non-Pass Through (Stand-Alone): Side View


GS-398-00

Machine Dimensions & Weights 1

(See Appendix for Loader/Unloader configurations)

Uncrated Air Ride Van(no skid or crating material) (skidded and plastic covering

banded over machine)

L X D X H1 Weight 1, 2 L X D X H1 Weight 1, 2

Inserter 3 1800 x 1575 x 1594 1025 2210 x 1829 x 1727 1191(crated separately) (70.88 x 62 x 62.75) (2260) (87 x 72 x 68) (2625)

Air Crating Ocean Crating(partial wood crating) (full wood crating)

L X D X H1 Weight 1, 2 L X D X H1 Weight 1,2

Inserter 3 2235 x 1854 x 1905 1340 2235 x 1854 x 1905 1456(crated separately) (88 x 73 x 75) (2955) (88 x 73 x 75) (3210)

Notes:1. Measurements and weights are in metric figures; inch and pound equivalents are

bracketed. Measurements are rounded to the nearest whole number.2. Weight varies as a result of pallet construction and moisture content of wood.3. The dimension, 953.5mm (37.54") measured from the floor to the top of the rotary

table, must be maintained at installation.4. Height dimension including the machine light tower is 1861mm (73.25"). The light

tower is removed for shipment.

Floor Space A minimum clear area of one meter (39.4") around the machineperimeter is recommended for machine operation and servicing.

GS-398-00

Service Requirements (including UninterruptiblePower Supply)

Electrical (insertion machine)

Electrical connection located at the rear of themachine, 736.6mm (29.0") from the floor and152.4mm (6.0") from the right-hand side.

Machine is shipped with a power cord frommachine to Uninterruptible Power Supply. Amating connector is supplied to attach the userprovided power cord to the UPS.

The UPS has an external 5mm ground stud whichmust be permanently connected to earth/buildingground with a 14 AWG or 2.5mm2 wire that isappropriately protected from mechanical damage.

A circuit breaker is the overcurrent device for boththe machine and the UPS. The machine breakerhas a short circuit interrupting capacity of10,000A, and the UPS breaker has a short circuitinterrupting capacity of 1000A.

The branch circuit supplying the machine must beprotected by an approved 15 amp circuit breakerwith a delay suitable for "high inrush current" or"transformer loads."

Air Consumption A quick disconnect with a male barbed fitting for12.7mm (0.50") ID flexible hose is shipped witheach machine.

Pneumatic connection located in the back of themachine, 228.6mm (9") from the right side and558.8mm (22") from the floor.

Air Quality Non-lubricated, dry air, maximum contaminationparticle size of 5.0 microns.

Note:• Without loader/unloader, for voltages other than 230 VAC, current is

1725 / (input voltage). Power factor may vary with input voltage.

• With loader/unloader, for voltages other than 230 VAC, current is1725 / (input voltage). Power factor may vary with input voltage.

• CFM (Cubic Feet per Minute): Volumetric flow rate at a specifiedpressure. This is used to describe the air flow requirement.

• SCFM (Standard Cubic Feet per Minute): Cubic foot of air at 20° C(68º F) at atmospheric pressure. This is used to describe averageair consumption flow requirement.

PNEUMATIC REUIREMENTS(Base Machine) ELECTRICAL REQUIREMENTS

Minimum Air FlowRequirements

AirConsumption

UPSInput

Voltage

InputFrequency

InputBreaker

Actual PowerDraw Without

Loader/Unloader

Actual PowerDraw With

Loader/Unloader

Insertion MachineLocation 3.0 CFM @ 90 PSI 7.6SCFM

SinglePhase

180-264VAC

47 - 63 Hz 15A1725 VA

7.5A @ 230 VAC 7.5A @ 230 VAC

GS-398-00

Environmental RequirementsAmbient 10° C. to 35° C.Temperature (50° F. to 95° F.)

Operating 10% to 90%, non-condensingHumidity

Contaminants The machine, UPS included, carries an IP coderating of 20. IP 20 signifies that the equipmenthas limited protection against ingress of solidforeign objects and is not protected against theingress of water. Consequently, the intendedenvironment is that of manufacturing/officewhere the machine is not subject to suchelements.

Transportation -25° C. to +55° C. (-13° F. to +131° F.); notand Storage exceeding 24 hours up to 70° C. (158° F.), 10%

to 95%, non-condensing humidity.

Universal provides suitable means to preventdamage from humidity, vibration, stress andshock during transport.

Noise Level, 75 dbA in accordance with National MachinePass Through Toolbuilders Assoc. Noise MeasurementConfiguration Technique Standard — June 1986.

Noise Level, 77 dbA in accordance with National MachineNon-Pass Through Toolbuilders Assoc. Noise MeasurementConfiguration Technique Standard — June 1986.

GS-398-00

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A - 39GS-398-00, Appendix: Automatic Board Handling Systems

Index

Appendix: Automatic Board Handling Systems

Introduction .......................................................................................................... A-40Technical Specifications for Internal Board Handling System (BHS) ............... A-42Workboard Clearances at Table Rotation Locations .......................................... A-43Single Head 8 with Internal BHS Only ................................................................ A-44Technical Specifications for Loader/Unloader:

Elevator/Buffer Configuration ....................................................................... A-45Universal Magazine Specifications ............................................................... A-46Magazine-to-Magazine Configuration, with Long Buffer ............................. A-48Magazine-to-Magazine Configuration, with Short Buffer ............................. A-49

Technical Specifications for Loader/Unloader:Vacuum Bare Board-to-Magazine Configuration ......................................... A-50Vacuum Bare Board-to-Magazine Configuration, with 22" Conveyor and LongBuffer .............................................................................................................. A-51Vacuum Bare Board-to-Magazine Configuration, with 22" Conveyor and ShortBuffer .............................................................................................................. A-52

Technical Specifications for Loader/Unloader:Destacker / Conveyor-to-Magazine Configuration ........................................ A-53Destacker / Conveyor-to-Magazine Configuration,with Long Buffer ............................................................................................ A-54Destacker / Conveyor-to-Magazine Configuration,with Short Buffer ............................................................................................ A-55

Installation Considerations: Loader/Unloader .................................................... A-56Service Requirements .......................................................................................... A-57

A - 40 GS-398-00, Appendix: Automatic Board Handling Systems

IntroductionThe Single Head 8 machines are available in a number of automaticboard handling configurations:n Magazine-to-Magazine Configuration: Magazines contain-

ing PC boards are placed on the input Elevator (Loader) and thePC boards are then automatically transferred into the machinefor component insertion. Once completed, the boards areunloaded into an output magazine Elevator (Unloader). EachElevator includes a magazine Buffer. Buffers are available intwo sizes:

• Long Buffer: 1270mm (50") for magazines 21" long (CE-compliant)

• Short Buffer: 1016mm (40") for magazines 16" long (notCE-compliant)

n Vacuum Bare Board-to-Magazine Configuration: BarePC boards are placed in a Vacuum Bare Board Loader and thePC boards are then automatically transferred onto a 558.8mm(22") conveyor, which transports them into the machine forcomponent insertion. Once completed, the boards are unloadedinto an output magazine Elevator (Unloader). The output Eleva-tor includes a Long or Short Buffer (as above); neither of theseconfigurations is CE-compliant. Note: This unit is bestsuited for PC boards with eyelets.

n Destacker/Conveyor-to-Magazine Configuration: BarePC boards are placed in a Destack Loader and the PC boardsare then automatically dropped onto a 736.6mm (29"), 1117.6mm(44"), or 1473.2mm (58") conveyor, which transports them intothe machine for component insertion. Once completed, theboards are unloaded into an output magazine Elevator (Unloader).The output Elevator includes a Long or Short Buffer (as above);only the systems incorporating the Destack Loader with the1117.6mm (44") or 1473.2mm (58") conveyor, and Elevator withLong Buffer, are CE-compliant. Note: This unit will notfunction properly when eyelets are present on the PCboard.


n Magazine- OR Destacker/Conveyor-to-Magazine Con-figuration: Magazines containing partially populated PC boardsare placed on the input Elevator/Buffer (Loader) and the PCboards are automatically transferred into the machine forcomponent insertion. In addition, a second input from a DestackLoader, mounted on either a 736.6mm (29"), 1117.6mm (44"), or1473.2mm (58") conveyor, can be placed in-line after theElevator/Buffer. This permits the flexibility of loading unpopulatedPC boards from a stack, or populated PC boards from amagazine. Once completed, the boards are unloaded into anoutput Elevator/Buffer (Unloader). The output Elevator in-cludes a Long or Short Buffer (as above); only the systemsincorporating the Destack Loader with the 1117.6mm (44") or1473.2mm (58") conveyor, Elevator with Long Buffer, and PCboards with installed components not exceeding 25.4mm (1")thickness, are CE-compliant.

n In-Line Configuration: Machines can be connected in-lineusing the internal Board Handling System (BHS) and intercon-necting conveyors. The BHS transfers two PC boards at a time:an unpopulated board in, and a populated board out. All BoardHandling Systems are factory configurable for either left-to-right or right-to-left direction. This configuration is CE-compli-ant.


Min. 80mm (3.1") Max. 406mm (16")

Min.102mm (4") Max. 483mm (19")

Direction of Board Flow

Technical Specifications for InternalBoard Handling System (BHS)

Internal Board Handling System SpecificationsMinimum Maximum

Transfer Height 1001.5mm (39.43") 1014.2mm (39.93")

Board Changeover Manual

Direction Select right-to-left or left-to-right.

Edge Support 3mm (0.118") 5mm (0.197") 1

Fixed Edge Front

Locator Pins Front

Transfer Time 2 3.5 seconds for 1001.5mm (39.43") Transfer Height

BEC Scan Area All board surface except edge support (withinlimits of BEC Detection Area)

Electrical Interface SMEMA Electrical Interface, standard

Notes:1. Set at factory to 5mm.2. Time from last insertion to first insertion on next board. This

number is based on 254mm (10") positioning system moves.Larger table moves increase transfer time.

PC Board SpecificationsMinimum Maximum

Length 1 x Width 102mm x 80mm 483mm x 406mm(4" x 3.1") 2 (19" x 16") 2, 3

Length to Width >1:1 is recommendedRatio

Thickness 0.8mm (0.032") 2.36mm (0.093")

Warp — 3.17mm (0.125")

Cutouts Contiguous edges; consult factory for others

Datum Hole 2.8mm (0.110") 2 6.35mm (0.25") 2

Diameter

Weight 2.27kg (5 lbs.), maximum

Notes:1. Length is in the direction of board flow.2. Consult Universal Sales Engineer for other than stated sizes.3. Board widths larger than 297mm (11.70") require removal of

270° Rotary Table stop block.


(Table Rotation Dimensions shown are for standard tooling)0° 90° 180° 270°

A 5.99mm (0.236") 1 7.59mm (0.299") 2 9.27mm (0.365") 1 7.59mm (0.299") 2

B 7.09mm (0.279") 2 5.49mm (0.216") 1 7.09mm (0.279") 2 5.49mm (0.216") 1

C 7.09mm (0.279") 2 8.76mm (0.345") 1 7.09mm (0.279") 2 8.76mm (0.345") 1

D 7.09mm (0.279") 2 5.49mm (0.216") 1 7.09mm (0.279") 2 5.49mm (0.216") 1

E 7.09mm (0.279") 2 8.76mm (0.345") 1 7.09mm (0.279") 2 8.76mm (0.345") 1

F 5.33mm (0.210") 1, 3 5.38mm (0.212") 2, 3 5.33mm (0.210") 1, 3 5.38mm (0.212") 2, 3

G 5.33mm (0.210") 1, 3 5.38mm (0.212") 2, 3 5.33mm (0.210") 1, 3 5.38mm (0.212") 2, 3

H 3.17mm (0.125") minimum6.35mm (0.250") recommended

7.62mm (0.300") maximum

J 3.17mm (0.125") minimum3.96mm (0.156") recommended

6.35mm (0.250") maximum

1. Dimensions are to centerline of lead.

2. Dimensions are to the bottom of the 'V' groove in the former.

3. Dimension shown is for 3mm edge support. If using a 5mm edge support, add 2mm(0.079") to dimension shown.

Front at 180°

Front at 270° F

ront

at 9

0°

AB

C D

EF

G

H

diameter J

X

Dimensions shown are minimum distances from either the board edge or the tooling pin hole, to either the standard tooling or the clinch.

3mm edge support

Workboard Clearances at Table Rotation Locations


Plan View:

Operator

181.9(7.16) 133.4

(5.25) 1435.1(56.5)

812.8(32)

1333.5(52.5)

88.9(3.5)

1270(50)

88.9(3.5)

1403.4(55.25)Typical

556.2(22.25)

222.3(8.75)

247.7(9.75)

25.4(1)

647.7(25.5)

Single Head 8 with Internal BHS Only

Side View:

P1

E

Pneumatic connection

Electrical connection

Allow one meter (39.4") around entire machine for work space.


1800 (70.9)

1358.9 (53.5)

P1 E

UPS

Single Head 8


Technical Specifications for Loader/Unloader: Elevator/Buffer Configuration

Long Buffer

Short Buffer

Changeover Time Magazine, 20 seconds

PC Board The insertion machine determines board size.

Magazine ElevatorsMagazine Elevator Controlled through insertion machine software.

Power and air are supplied through the insertionmachine. Elevators are equipped withemergency stops.

Elevator Length Depth HeightDimensions 635mm (25") 838mm (33") 1,835mm

(72")

Magazine Input/Output BuffersLong Buffer The Long Buffer accomodates 2 magazines (in

and out) that are up to 533mm (21") in lengtheach.

Long Buffers are available either withCE-compliant Buffer covers or without thecovers. Covers must be affixed to the Buffers inorder for the Buffers to be CE-compliant.

Long Buffer Length Depth HeightDimensionsWith Full Covers 1,270mm 546mm 1,835mm(CE-compliant) (50") (22") (72")

Long Buffer Length Depth HeightDimensionsWithout Covers 1,270mm 546mm 1,095mm(Not CE-compliant) (50") (22") (43")

Short Buffer The Short Buffer accommodates 2 magazines (inand out) that are up to 406mm (16") in lengtheach. (Short Buffers do not accommodateUniversal magazines.)

Short Buffers are not CE-compliant.

Short Buffer Length Depth HeightDimensions 1,016mm 546mm 1,095mm

(40") (22") (43")

Magazine Transfer Upper level magazine transfer height for bothHeight Long and Short Buffers is 1,056mm (42").

Lower level magazine transfer height for bothLong and Short Buffers is 292mm (12")


MagazinesMaximum 45kg (100lbs) for PC boards plus magazines.Magazine Weight Compatible with most commonly-used

magazines. Consult your Universal SalesEngineer.

Maximum Magazine Maximum Maximum Maximum MaximumDimensions for Length Depth Height WeightLong Buffer (including

PC boards)

533mm 460mm 606mm 45kg(21") (18") (24") (100lbs)

Maximum Magazine Maximum Maximum Maximum MaximumDimensions for Length Depth Height WeightShort Buffer (including

PC boards)

406mm 460mm 606mm 45kg(16") (18") (24") (100lbs)

Optional Magazine An optional magazine gate control is availableGate Control for use with magazines that include a spring-

loaded gate, used to keep PC boards retainedwithin the magazine.


Universal Magazine Specifications

Magazine Views

606.55mm(23.88")

19.1mm(0.75")

Base Pan PC Board Size Reference PC Board Guides

Width A Length BMinimum Maximum Minimum Maximum

Datum D Pitch EWidth C Length

444.5mm17.50"

476.3mm18.75"

108mm4.25"

406.4mm16.00"

149.9mm5.90"

457.2mm18.00"

35.1mm1.38"

10mm0.394"

406.4mm16.00"

476.3mm18.75"

108mm4.25"

368.3mm14.50"

149.9mm5.90"

457.2mm18.00"

35.1mm1.38"

10mm0.394"

292.1mm11.50"

476.3mm18.75"

108mm4.25"

254mm10.01"

149.9mm5.90"

457.2mm18.00"

35.1mm1.38"

10mm0.394"

If Universal magazines are not purchased/used, user must provide magazine specifications or,preferably, a magazine to verify proper function with Universal Loaders/Unloaders. The maxi-mum allowable dimensions for third-party magazines are: L 533mm (21") x D 460mm (18") x H606mm (24").

A - 48

GS

-398-00, Appendix: A

utomatic B

oard Handling S

ystems

Single Head 8, Magazine-to-Magazine Configuration,with Long Buffers

System shown in left-to-rightboard-flow configurationwith fixed front rail.


546 (21.5)

838.2(33)

1270 (50)635(25)

Unloader

1905 (75)1800 (70.9)

Loader

P1 E

Single Head 8

P1

E Electrical Connection


5610 (220.9)

UPS

Operator

A - 49

GS


utomatic B

oard Handling S

ystems

Single Head 8, Magazine-to-Magazine Configuration,with Short Buffers



546 (21.5)

838.2(33)

635(25)

Unloader

1800 (70.9)

Loader

1016 (40)

1651 (65)

5102 (200.9)

P1 E

UPS

Single Head 8

P1



Operator


Technical Specifications for Loader/Unloader: Vacuum Bare Board-to-Magazine Configuration

PC Board Specifications for Vacuum Bare Board LoaderMinimum Maximum

Length 1 x Width 127mm x 102mm 457mm x 406mm(5" x 4") 2 (18" x 16") 2

Length to Width $1:1 is recommended.Ratio

Thickness 0.76mm (0.030") 2.36mm (0.093")

Warp — 2.36mm (0.093")

Cutouts Contiguous edges

Stack, Maximum 250 boards at a nominal thickness of 1.57mm(0.062") is the maximum stack height of 394mm(15.5").

Notes:

1. Length is in the direction of board flow.

2. The Single Head 8 determines board size. Consult yourUniversal Sales Engineer for boards larger than 356mm (14").

Vacuum Length Depth HeightBare Board 751.1mm 689.1mm 1574.8mmDimensions (29.57") (29.13") (62")

PC Board Specifications for Between Machines 22"Conveyor

Minimum Maximum

Length 1 x Width 76mm x 51mm 508mm x 457mm(3" x 2") 2 (20" x 18") 2

Length to Width >1:1 is recommended.Ratio

Thickness 0.64mm (0.025") 3.18mm (0.125")

Warp — 3.18mm (0.125")

Notes:

1. Length is in the direction of board flow.

2. The Single Head 8 determines board size. Consult yourUniversal Sales Engineer for boards larger than 356mm (14").

Length Depth Height 1

22" Conveyor 559mm 802.6mm 962.7mmDimensions (22") (31.6") (37.9")

Notes:

1. Height represents pre-set transfer height of conveyor bed.Transfer height is adjustable from 812.8mm (32") to1066.8mm (42").

A - 51

GS


utomatic B

oard Handling S

ystems

Single Head 8, Vacuum Bare Board-to-Magazine Configuration,with 22" Conveyor and Long Buffer

PE E



5015.1 (197.4)

546 (21.5)

838.2(33)

1270 (50)635(25)

Unloader

1905 (75)1800 (70.9)

82.6(3.25 )

Vacuum BareBoard Loader

689.1(29.13 ) 802.6

(31.60)

Loader

559 (22.0)

751.1 (29.57)

P1 EUPS

Single Head 8

P1



1358.9(53.5)

Operator

A - 52

GS


utomatic B

oard Handling S

ystems

Single Head 8, Vacuum Bare Board-to-Magazine Configuration,with 22" Conveyor and Short Buffer

PE E



546 (21.5)

838.2(33)

635(25)

Unloader

1800 (70.9)

82.6(3.25 )

Vacuum BareBoard Loader

689.1(29.13 ) 802.6

(31.60)

Loader

559 (22.0)

751.1 (29.57)

1016 (40)

1651 (65)

4761.1 (187.4)

P1 EUPS

Single Head 8

P1



1358.9(53.5)

Operator


Technical Specifications for Loader/Unloader: Destacker/Conveyor-to-Magazine Configuration

PC Board Specifications for Destacker/ConveyorLoader

Minimum Maximum

Length 1 x Width 76mm x 51mm 508mm x 457mm(3" x 2") (20" x 18")

Length to Width >1:1 is recommended.Ratio

Thickness 1.02mm (0.040") 3.18mm (0.125")

Warp — 3.18mm (0.125")

Cutouts Require Factory Review

Stack, Maximum 190 boards at a nominal thickness of 1.6mm(0.063") is the maximum stack height of304.8mm (12").

Notes:1. Length is in the direction of board flow.2. The Single Head 8 determines board size. Consult your

Universal Sales Engineer for boards larger than 356mm (14").

Destacker/Conveyor SpecificationsDestacker on Length Depth Height 3

29" Conveyor 1 736.6mm 802.6mm 962.7mm(29") (31.6") (37.9")

Destacker on 1,117.6mm 802.6mm 962.7mm44" Conveyor 2 (44") (31.6") (37.9")

Destacker on 1473.2mm 802.6mm 962.7mm58" Conveyor 2 (58") (31.6") (37.9")

Notes:1. Not CE-compliant.2. CE-compliant if configured with safety covers.3. Height represents pre-set transfer height of conveyor bed.

Transfer height is adjustable from 812.8mm (32") to1066.8mm (42"). Add 383.5mm (15.1") to transfer height fortotal height of Destacker sitting atop Conveyor.

A - 54

GS


utomatic B

oard Handling S

ystemsSingle Head 8, Destacker/Conveyor-to-Magazine Configuration,

with Long Buffer

Note: Available with 29", 44", or 58" conveyor


802.64 (31.60)

736.6 (29.0)

Destacker/Conveyor

Loader

4441.6 (174.9)with 29" conveyor

1117.6 (44.0)

4822.6 (189.9)with 44" conveyor


546 (21.5)

838.2(33)

1270 (50)635(25)

Unloader

1905 (75)

1800 (70.9)1473.2 (58.0)

5178.2 (203.9)with 58" conveyor

P1 EUPS

Single Head 81358.9(53.5)

P1



Operator

A - 55

GS


utomatic B

oard Handling S

ystems

Single Head 8, Destacker/Conveyor-to-Magazine Configuration,with Short Buffer

Note: Available with 29", 44", or 58" conveyor


4187.6 (164.9)with 29" conveyor

4568.6 (179.9)with 44" conveyor

Dimensions are in millimeters; inch equivalents are bracketed.

546 (21.5)

838.2(33)

635(25)

Unloader

1651 (65)

1473.2 (58.0)

4924.2 (193.9)with 58" conveyor

1016 (40)

802.64 (31.60)

736.6 (29.0)

Destacker/Conveyor

Loader

P1 EUPS

Single Head 8

P1



1358.9(53.5)

1117.6 (44.0)

1473.2 (58.0) 1800 (70.9)

Operator


Installation Considerations: Loader/UnloaderMagazine-to-Magazine Configuration

Dimensions—Magazine Elevator (x2)

Length 1 Depth Height Weight

Shipping 635mm 838mm 1835mm 154 kgDimensions (25") (33") (72.25") (340 lbs.)

1 Length is in the direction of board flow.

Dimensions—Long Buffer (x2)

ShippingDimensionsNot 1270mm 546mm 1095mm 91 kgCE-compliant (50") (21") (43") (200 lbs.)

ShippingDimensions 1270mm 546mm 1835mm 118 kg.CE-Compliant (50") (21") (72") (260 lbs.)

Dimensions—Short Buffer (x2)

Shipping 1016mm 546mm 1095mm 82 kgDimensions (40") (21") (43") (180 lbs.)

Vacuum Bare Board-to-Magazine Configuration*

Dimensions—Vacuum Bare Board Unloader


Dimensions—22" Between Machine Conveyor


Destacker/Conveyor-to-Magazine Configuration*

Dimensions—Destacker/Conveyor (29")





Shipping 1473mm 803mm 1346mm 170 kgDimensions (58") (32 ") (53") (375 lbs.)

* For installations, add size and weight dimensions for one magazineElevator module and one magazine Buffer module, either Long orShort Buffer.


Note:• CFM (Cubic Feet per Minute): Volumetric flow rate at a specified pressure. This is used to describe the air flow

requirement.

• SCFM (Standard Cubic Feet per Minute): Cubic foot of air at 20°C (68° F) at atmospheric pressure. This is usedto describe average air consumption flow requirement.

MachineDescription Pneumatic Requirements Electrical Requirements

MinimumAir Flow

Requirement

AirConsumption

Voltage

Single Head 8 withBHS

3.0 CFM @ 90 PSI 7.6 SCFM230 VAC (50/60Hz)

Single Head 8 withBHS andLoader/Unloader

3.2 CFM @ 90 PSI 8.4 SCFM230 VAC (50/60Hz)Loader/unloader supplied frominsertion machine

IM Elevator (Loaderor Unloader)

0.2 CFM @ 90 PSI 0.80 SCFM120 VAC (50/60Hz)Supplied from insertionmachine

Vacuum Bare BoardLoader


Destacker/ConveyorLoader


22" ConveyorNonerequired

Nonerequired

120 VAC (50/60Hz)Supplied from insertionmachine


Nonerequired



Nonerequired



Nonerequired


Service Requirements