Read Pin Header Trimmer 1213600-[] text version

409­10005 Pin Header Trimmer 1213600­[ ]

14 SEP 98 Rev O

Customer Manual

409­10005

Pin Header Trimmer 1213600­[ ]

14 SEP 98 Rev O

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3. RECEIVING INSPECTION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.1. Receiving Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.2. Considerations Affecting Machine Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.3. Machine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4. MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4.1. 4.2. 4.3. 4.4. Pin Header Strip Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin Header Strip Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming the Pin Header Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Production Operation (Continuous Cutting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8 8 8

5. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5.1. Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5.2. Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 6. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6.1. Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6.2. Clearing Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 7. REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 7.1. 7.2. 7.3. 7.4. Replacing the Saw Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin Header Trimmer Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 14 14 14

8. REVISION SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

AMP Incorporated, Harrisburg, PA 17105 TOOLING ASSISTANCE CENTER 1­800­722­1111 This document is Engineering controlled. It is subject to change. Contact TOOLING ASSISTANCE CENTER for latest revision. Copyright 1998 by AMP Incorporated. All Rights Reserved. *Trademark

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LOC B Form 404­43 1/98

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DANGER

SAFETY PRECAUTIONS PREVENT INJURY

Safeguards are designed into AMP* machines to protect operating personnel from certain hazards during normal machine operation. However, as with most machinery, certain precautions must be taken by the operator and repairman. Never insert hands into an installed machine/applicator, or any part of a machine that is operated by electricity or compressed air, without first pulling the machine power cable plug from the outlet receptacle and/or shutting off the compressed air at the line valve and disconnecting the air hose. This will prevent injury in the event that switches or other controls are accidentally activated. A grounded electrical outlet should always be used to receive the plug on the machine power cable. To improve clarity, photographs and drawings may not show machine/applicator guards. In some cases, it is impractical to show the variety of guards designed to meet specific safety requirements, as set forth in codes and standards adopted by customers and/or enforced in a given locale. Though a guard may not be shown, and procedures may not reflect the need for its removal, the guard must be in place during normal operation of the machine/applicator.

TOOLING ASSISTANCE CENTER

CALL TOLL FREE 1­800­722­1111

(CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)

RETENTION MACHINE POLICY

All retention machines remain the property of AMP Incorporated. The customer shall have no title to the machine(s) and its interest shall be limited to the use of said machine(s) for the purpose indicated, during the stated term, at the specified plant. No major change or modification shall be made without prior written consent of AMP Incorporated. Spare and component parts are available at nominal prices. A list of component parts is included in the instructional material or drawings supplied with each machine. The customer shall be fully responsible for the maintenance of the machine(s) including servicing, repair, and replacement of damaged or broken parts. Each machine shall be returned in usable condition -- reasonable wear and tear excepted. Before returning the machine, contact AMP Incorporated, Harrisburg, Pennsylvania requesting instructions for shipping and disposition. AMP Field Service Engineers are available to provide assistance in the adjustment or repair of the machine when operating issues arise which your maintenance personnel are unable to address. Contact AMP Incorporated.

INFORMATION REQUIRED WHEN CONTACTING AMP INCORPORATED

AMP Incorporated offers the Tooling Assistance Center as a means of providing technical assistance when required. When contacting AMP Incorporated by telephone regarding service to a machine or tool, it is suggested that a person familiar with the device be present with a copy of the manual (and drawings) to receive instructions. Many questions can be addressed in this manner. When calling the Tooling Assistance Center, be ready with the following information: 1. Customer name 2. Customer address 3. Person to contact (name, title, telephone number and extension) 4. Person calling 5. Machine or tool number (and serial number if applicable) 6. Product part number (and serial number if applicable) 7. Urgency of request 8. Nature of problem 9. Description of inoperative component(s) 10. Additional information/comments that may be helpful

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Figure 1

1. INTRODUCTION

This manual provides information concerning the setup, operation, maintenance, and basic troubleshooting of the AMP Reeled Pin Header Trimmer 1213600­[ ], shown in Figure 1. This machine cuts a continuous length of single or double row pin header strip into various lengths. NOTE Dimensions in this manual are in metric units [with U.S. customary equivalents in brackets] unless otherwise indicated.

Each Reeled Pin Header Trimmer{ weighs approximately 18 to 20 kg [40 to 45 lbs], and requires a power source of 105 ­ 160 Vac, 1 A, 50/60 Hz. The machine requires compressed air at a minimum of 552 kPa [80 psi] ­­ maximum 690 kPa [100 psi] for proper operation. For information beyond the scope of this manual, contact the Tooling Assistance Center at 1­800­722­1111. When reading this manual pay particular attention to DANGER, CAUTION, and NOTE statements. DANGER CAUTION NOTE Denotes an imminent hazard which may result in moderate or severe injury. Denotes a condition which may result in product or equipment damage. Highlights special or important information.

2. DESCRIPTION

Product for Reeled Pin Header Trimmer 1213600­[ ] (a continuous length of pin headers) is contained on a reel that attaches to a reel bracket on the trimmer frame. As the pin header strip unreels, the paper separator between the rows of product strip is removed by a curved sheet metal strip located to the right of the reel.

{ 1213600­1 Machines Only

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The pin header strip feeds through tracks and is engaged by a sprocket, driven by a stepper motor. The sprocket feeds the strip toward the saw blade. The rotating saw blade, driven by an air cylinder, shears the strip to the desired length. A scrap bin, under the saw blade, collects scrap from the shear process. Paper Interface Extension Reel Bracket Assembly Take­Up Bearing Basic Operating Instructions

Operator's Control Panel

Main Power Switch

Figure 2

The front panel of the pin header trimmer contains an operator's control panel (Figure 4), basic operating instructions, and a main power switch. See Figure 2. Removing two screws at the top of the front panel allows the panel to fold forward, giving access to the electrical controls of the trimmer, as well as the saw blade locking screw. See Figure 3. NOTE Refer to Figure 6 for an in­depth description of the Pin Header Trimmer 1213600­[ ] operator control panel.

Saw Blade Locking Screw

Scrap Bin

Front Panel Folded Forward

Figure 3

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Control Panel Display Error Indicator

EMERGENCY STOP Button

Cycle Finished Indicator

Keypad

Figure 4

3. RECEIVING INSPECTION/INSTALLATION 3.1. Receiving Inspection

Reeled Pin Header Trimmer 1213600­[ ] is inspected thoroughly during and after assembly. Prior to packaging and shipping, a final series of tests and inspections is made to ensure proper functioning of the machine. Although the header trimmer should require no adjustments before placing it into operation, the following inspection should be performed as a safeguard against potential problems generated in transit. 1. Carefully uncrate the header trimmer and place it on a sturdy bench or table with proper light to permit a careful examination. DANGER Reeled Pin Header Trimmer 1213600­[ ] weighs approximately 18 to 20 kg [40 to 45 lb.]. To avoid personal injury exercise caution when lifting the unit out of the crate.

2. Clean any packing material and dust from the the trimmer components (especially the track and sensors). 3. Thoroughly inspect the entire machine for evidence of damage that may have occurred in transit. If the machine is damaged in any way, file a claim against the carrier and notify AMP Incorporated immediately. 4. Check all components to be certain that they are secure. 5. Check all wiring for loose connections, cuts, or other possible causes of electrical short circuits. 6. Inspect all pneumatic lines for evidence of loose connections and cuts that may cause leakage. NOTE It is important that this manual and other documents (such as drawings and parts lists), as well as any enclosed product samples, remain with the header trimmer for the benefit of personnel responsible for installation, operation, and maintenance.

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Pin Header Trimmer 1213600­[ ] 3.2. Considerations Affecting Machine Placement

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The location of the header trimmer in relation to the operator is essential to both safety and efficiency. Studies have repeatedly shown that fatigue will be reduced and efficiency increased if particular attention is paid to the bench, the operator's chair, and the placement of the foot switch, if one is used.

A. Bench

A sturdy bench, 711 to 762 mm [28 to 30 in.] high, aids comfort by allowing the operator's feet to rest on the floor. The operator's weight and leg position can be easily shifted. The bench should have rubber mounts to reduce noise. The open area under the bench should allow the chair to slide in far enough for the operator's back to be straight and supported by the back rest.

B. Reeled Pin Header Trimmer Location on Bench

The machine should be located near the front of the bench and the tooling area should be 152 to 203 mm [6 to 8 in.] from the front edge. Access to the back of the machine must be provided.

3.3. Machine Installation

1. Place the machine on a bench as described in Paragraph 3.2. 2. Hook up the required air and electrical power to the machine. 3. Close the control panel and install the scrap bin. 4. Be sure the On/EMERGENCY STOP button is in the "On" position and turn on power to the machine at the main power switch (Figure 2). NOTE Turn off the "Out of Product" alarm by pressing the ENTR/RESET key.

5. Allow the batteries to charge for 15 minutes. This is required any time the machine is turned off for more than 48 hours. After the batteries are charged, the Pin Header Trimmer is ready to be loaded and operated.

4. OPERATION 4.1. Pin Header Strip Loading

1. Install reel of pin headers to the reel support assembly so that the continuous strip of headers unreels off the right side of the reel. 2. Thread the spacer paper over the paper interface extension. Thread the continuous strip of headers under the paper interface extension. Be sure to lock the paper interface quick pin in the retracted position so the paper interface extension can pivot and hug the reel CAUTION DANGER The spacer paper must be separated from the pin header strip before the strip of headers enters the track. If the paper enters the track and begins to travel through the machine, tooling will be damaged. To avoid personal injury, DISCONNECT POWER before feeding the header strip and adjusting the guide track.

3. Thread the header strip under the take up bearing and into the saw guide track (Figure 5) up to the feed gear. If necessary, adjust the track as follows: a. Loosen the two screws in the back track (see Figure 5). b. Adjust the slide fully forward for single­row pin header strip; adjust the slide against the back stops for double­row pin header strip. c. Tighten the two screws, securing the back track. NOTE Do not overtighten the screws, or future adjustment will be difficult.

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Saw Track Guide

Pin Header Strip

Front of Header Trimmer

Header Strip

Loosen Track Adjustment Screws

Back of Header Trimmer

Figure 5

4. Connect power and turn the machine on. The strip will feed forward and calibrate in the tracks. 5. If necessary, gently push the strip of headers forward and press the STOP/CAL key to allow the pin header strip to load to the home position. See Figure 6. 6. Press the STOP/CAL key again to verify that the strip is in the home position.

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Pin Header Trimmer 1213600­[ ] 4.2. Pin Header Strip Unloading

409­10005

1. Press the EJECT key. The pin header strip will move backward through the trimmer and disengage from the drive sprocket. 2. Carefully pull the strip out of the track. 3. Wind the strip up onto the reel. 4. Pull the paper interface extension away from the reel and engage the quick pin to lock in this position. 5. Remove the reel of product from the reel bracket assembly.

4.3. Programming the Pin Header Trimmer (Figure 6)

1. Load the pin header strip as described in Paragraph 4.1. 2. Turn power on using the main power switch. 3. Set the Pin Header Trimmer cutting parameters as follows: a. Set the part size of the pin headers by pressing the PART SIZE key, entering the desired number of positions per row using the numeric keypad (1 to 40), and then pressing the ENTR/RESET key. b. Set the batch size (part quantity) by pressing the PART QTY key, entering the desired number of parts to be cut using the numeric keypad, and then pressing the ENTR/RESET key. 4. Cut a sample part by pressing the SMPLE/PART key. The Pin Header Trimmer will cycle one time, cut one pin header, increase the count by one, and then stop. At this point the machine will be set for Production Operation (continuous cutting), or another sample part.

4.4. Production Operation (Continuous Cutting)

1. Load product into the Pin Header Trimmer as described in Paragraph 4.1. 2. Turn power on using the main power switch. 3. Program the Pin Header Trimmer as described in Paragraph 4.3. 4. Place a box or bin at the end of the machine to collect parts as they are cut. 5. Press the START key. The machine will begin to automatically cut the selected number of pin headers until the desired number of headers has been cut. NOTE The machine will stop when the desired number of headers has been cut, when the EMERGENCY OFF button is pressed, when the main power switch is turned off, or when the machine is out of product.

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HEADER: QUANTITY: COUNT: CYCLE COMPLETE:

6 00003 00003

Control Panel Display

EMERGENCY STOP Button

1 2 3

START STOP/ CAL.

Keypad

4

5

6

FEED

EJECT

Error Indicator

7

CLEAR COUNT

8

9

ENTR/ RESET

PART QTY

PART SIZE

0

SAMPLE PART

Cycle Finished Indicator

Control

On/EMERGENCY STOP Pushbutton O

Function

Press the On/EMERGENCY­STOP Pushbutton to immediately stop the pin head trimmer. Twist the On/EMERGENCY­STOP Pushbutton clockwise, then release to reset the EMERGENCY STOP and turn on the pin head trimmer. Lights when the total number of programmed pin headers has been cut. Lights when an error occurs. Refer to to Clearing Errors Section to clear errors.

Cycle Finished Indicator (Yellow) Error Indicator (Red)

HEADER Display QUANTITY Display COUNT Display STATUS/ERROR MESSAGE Display Numeric Keys START Key STOP/CAL. Key FEED Key EJECT Key PART QTY Key PART SIZE Key CLEAR COUNT Key ENTR/RESET Key SMPLE PART Key

Displays the current part size. Displays the number of parts to trim for the current run. Displays the number of parts currently cut for the run. Displays a status message or error message. Keys on the keypad used to enter part sizes and quantities. Starts the pin header trimmer when pressed. Stops the pin header trimmer and enables the calibration functions when pressed. Feeds the pin header strip forward in the guide track when the key is pressed. Backs the pin header strip out of the track when pressed. Press PART QTY key and then use numeric keys on the keypad to enter the quantity of parts to cut. Press PART SIZE key and then use numeric keys on the keypad to enter the part size (number of header pins). Clears the accumulated part quantity when pressed. Accepts a part quantity or size setting, or clears an error message when pressed. Makes a sample part when pressed.

Figure 6

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Pin Header Trimmer 1213600­[ ] 5. PREVENTIVE MAINTENANCE

409­10005

The Reeled Pin Header Trimmer 1213600­[ ] is equipped with a self­lubricating stepper motor, saw blade motor, bearings, as well as pneumatic cylinders which require little maintenance. The machine requires no lubrication. Maintenance consists primarily of cleaning the pin header trimmer regularly and inspecting it for loose connections and parts requiring replacement. It is recommended that a regular schedule be established for maintaining the machine.

5.1. Daily Maintenance

DANGER To avoid personal injury, be sure to DISCONNECT POWER when performing daily maintenance.

1. Clean the entire machine with a clean, dry cloth. 2. Inspect for debris buildup that could affect function of the sensors. 3. If necessary, clean around the sensors using a vacuum cleaner, brush, or air hose. DANGER Compressed air used for cleaning must be reduced to less than 207 kPa [30 psi], and effective chip guarding and personal protective equipment (including eye protection) must be used.

4. Remove all evidence of metal chips and other contamination

5.2. Weekly Maintenance

DANGER To avoid personal injury, DISCONNECT POWER when performing weekly maintenance.

1. Clean the trimmer using a clean, damp cloth. 2. Empty and clean the scrap bin (located inside the back panel, surrounding the saw blade). DANGER a. b. c. d. e. To avoid personal injury, DISCONNECT POWER when cleaning the scrap bin. Remove three screws that secure bin to trimmer frame (Figure 9). Slide the bin out of the trimmer using the handle on the bin. Empty the bin. Remove accumulated debris from the bottom of the trimmer. Re­attach bin to trimmer using the screws removed in Step a.

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Pin Header Trimmer 1213600­[ ] 6. TROUBLESHOOTING 6.1. Basic Troubleshooting Problem

The pin header strip was ejected and new strip resists being fed through the drive sprocket. Power to the trimmer is "on," but the control panel display is not lit.

409­10005

Cause

Drive sprocket position does not allow sprocket to engage pins. Blown fuse. Power input cable not connected. EMERGENCY STOP Pushbutton was depressed.

Remedy

Press the EJECT key (Figure 6) again.

Check the fuse and replace it, if necessary. Check the power input cable and connect it, if necessary. Reset the EMERGENCY STOP. (Twist the EMERGENCY STOP Pushbutton clockwise, then release.) 1. Loosen track adjustment screws. 2. Align top track slider (be sure it is moved to its extreme). 3. Tighten the track adjustment screws. CAUTION: Do not overtighten adjustment screws. Over­tightening screws could damage the attached fiber optic cables.

Pin header strip does not fit into tracks.

Track is not aligned properly.

Debris is on the track.

1. Unscrew the top track slide and remove completely. CAUTION: Be careful not to damage the fiber optic sensor cables. 2. Blow compressed air around the mating areas of track. DANGER: Compressed air used for cleaning must be reduced to less than 207 kPa [30 psi], and effective chip guarding and personal protective equipment (including eye protection) must be used. 3. Re­attach top track slide.

Movement of pin header strip through the tracks is impaired.

Tracks are not aligned properly.

1. Loosen track adjustment screws. 2. Align top track slider (be sure it is moved to its extreme). 3. Tighten the track adjustment screws. CAUTION: Do not overtighten adjustment screws. Over­tightening screws could damage the track and create future adjustment problems.

Excessive drag on reel overpowers motor capabilities.

Check positioning of reel on hub to make sure the strip is unwinding smoothly and the reel is not rubbing or scraping. Re­install the reel, if necessary (refer to Paragraph 4.1 ) Check to be sure the the paper interface is not snagging the reel. If necessary, reduce the reel brake drag.

Pin header cuts are not centered between header pins.

Mechanical setup is required. Offset position in software requires re­programming.

Contact AMP Incorporated. Contact AMP Incorporated.

Figure 7

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Pin Header Trimmer 1213600­[ ] 6.2. Clearing Errors

409­10005

If an error occurs, a message is displayed on the control panel display and the error indicator is lit. To clear errors, proceed as follows: 1. Resolve the error using the table in Figure 8. 2. Press the ENTR/RESET key to clear the error message and turn off the indicator. If the error message is not cleared and the indicator remains lit, check for other possible fault conditions.

ERROR MESSAGE Low Parts POSSIBLE CAUSE There are no parts loaded. REMEDY 1. Press the ENTR/RESET key or load product as described in Paragraph 4.1. 2. Press the FEED key. 1. Clear the obstruction. 2. Press the FEED or STOP/CAL. key. 1. Press the ENTR/RESET key. 2. Re­enter valid data. See Paragraph 4.3. 1. Remove debris blocking the calibration sensor. 2. Press the STOP/CAL. key.

Motor Timeout Invalid Part Pin Sensor

Pins are obstructed and are unable to advance. The motor is timed out. The pin header size is smaller than one position or greater than 40 positions. A pin was not sensed when expected due to a build­up of debris or obstructed parts.

Figure 8

7. REPLACEMENT

NOTE Do NOT modify the trimmer mechanism. Contact AMP Incorporated if the trimmer mechanism requires modification.

7.1. Replacing the Saw Blade

To change the blade, proceed as follows: DANGER The saw blade is extremely sharp. To avoid personal injury, DISCONNECT POWER before replacing the saw blade.

1. Turn off electrical power to the unit by turning off the main power switch on the front panel. 2. Disconnect the air supply. 3. Remove the three screws securing the scrap bin to the frame. See Figure 9. 4. Pull the handle/knob on the scrap bin to remove it from the frame. 5. Remove two screws from front panel (Figure 4) and fold the front panel forward. 6. Press the button on the saw blade motor mount that locks the saw blade in position. See Figure 10. 7. From the end of the pin header trimmer, remove the button head cap screw, the saw blade cap, and the saw blade. See Figure 11. 8. Replace with new saw blade, making sure the new saw blade is located on the center of the saw blade holder and the saw blade is oriented so that the cut direction is counterclockwise, looking at the end of the saw blade holder. See Figure 11.

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Track Adjustment Screws

Scrap Bin Screws Securing Scrap Bin to Frame

Handle

Figure 9

DANGER

The saw blade is extremely sharp. To avoid personal injury, exercise caution when handling the saw blade.

9. Tighten button head cap screw securing the saw blade cap to the saw blade holder. 10. Check the button on the saw blade motor mount to be sure that the saw blade is unlocked and free to turn. See Figure 10. DANGER Very carefully turn the saw blade to be sure it moves freely. The saw blade is extremely sharp. To avoid personal injury, exercise caution when handling the saw blade.

11. Replace scrap bin in the back panel and secure with three screws. 12. Close the front panel and secure it with two screws.

Button Head Cap Screw Securing Blade to Saw Blade Holder Saw Blade Cap

Saw Blade

Button Locking the Saw Blade in Position

Motor Mount

Figure 10

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Button Head Cap Screw Securing Blade to Saw Blade Holder

Saw Blade Cap

Saw Blade

Figure 11

7.2. Replacing the Fuses

DANGER To avoid personal injury, DISCONNECT POWER before replacing the fuses.

The fuses are located at the power inlet, on the back panel of the pin header trimmer. To replace the fuses, disconnect the machine power, remove the plastic cover over the fuses. remove and replace the fuses, and replace the plastic cover. Connect machine power and determine that the machine power is on.

7.3. Recommended Spare Parts

Saw blades and fuses are wearable parts. AMP Incorporated recommends that the following parts be stocked for immediate replacement:

AMP PART NUMBER 1213601­1 1213638­1 DESCRIPTION BLADE, Slotting Saw FUSE RECOMMENDED QTY 5 2

7.4. Pin Header Trimmer Parts Replacement

For further parts replacement information, refer to drawing 1213600­1 (shipped with the machine). Order replacement parts through your AMP representative, or call 1­800­526­5142, or send a facsimile of your purchase order to 717­986­7605 or write to: CUSTOMER SERVICE (038­035) AMP INCORPORATED PO BOX 3608 HARRISBURG PA 17105­3608

8. REVISION SUMMARY

Per EC 0990­0669­98

S Initial release of customer manual

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Information

Pin Header Trimmer 1213600-[]

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