Auto Insertion Machine – Insert Errors troubleshooting for Electronic Manufacturing PCBA

TroubleshootingTable-InsertErrors

The following table lists possible error scenarios for insert errors.

Troubleshooting Table – Insert Errors
Indicated Trouble Probable Ca use Corrective Action
1 Component leads do not enterprinted circuit board. Prin ted circuit board dril led incorrectly. Replace out of tolerance printed circuit boards.
Printed circuit board not properly located. Correct board location problem.
Pattern program coordinates are incorrect. Enter correct coordinates.
Machinezerosetup out of tolerance (X, Y,

head, or clinch axes).

Refer to maintenance manual and set each

axis to specification.

Incorrect offset values. Enter correct offset values.
BEC setup out of to lerance. Referto maintenance section and set up

BEC.

Worn tooling. Replace worn tooling.
Bent or out of spec input. Correct badinput. Refer to Component Transfer Errors table.
VCD Only:
Centering mechanism out of adjustment.
Refer to maintenance section and adjust centering mechanism.
VCD and Radial Only:
Incorrect component loaded in dispensing head.
Load dispensing head with correct component.
Radial Only:

Poor transfer of component from

component transfer assembly to head.

Set up component transfer assembly per maintenance manual.
Radial Only:

Incorrect dispensing head alignment/setup.

Set up andalign dispensing head per maintenance manual.
Radial Only:

Insert headjaws sluggish orout of

alignment.

Perform preventive maintenance, set up, and aligninsert head jaws per

maintenance manual.

Radial Only:

Defective carrier clip spring or clamp.

Repair or replace as necessary.
Radial Only:
Insertion tooling clamp worn or spring fatigued.
Repair or replace as necessary.
2 VCD and Jumper Wire Only:

Machine does not detect insert

errors.

Continuity error fai lure. Referto theClinchAssembly tableinthis document.
3 Machine reports insert errors when inserts are good. Clinch malfu nctio n. Refer toClinch Assembly tab le.
Continuity circuit problem. Debug continuity circuit.
Clinch setup inco rrect/clinch is di rty. Perform clinch preventive maintenance per

maintenance manual.

4 Component not centered. Centering mechanism out. Refer to maintenance section and adjust

centering mechanism or replace centering inserts.

5 Machine fails to report insert errors Sho rted or ja mmed clinch. Perform clinch preventive maintenance per maintenance manual.
Switches not set correctly or/failed Multi Input I/O card. Set switches per PC Jumper Config/Replace Multi Input I/O card.
6 One Component lead does not enter printed circuit board Printed circuit board is not drilled correctly. Replace out of tolerance printed circuit boards.
Printed circuit board is not properly located. Correct board location problem.
Defective carrier clip spring or clamp. Repair or replace as necessary.
Pattern program coordinates are incorrect. Enter correct coordinates.
Radial Only:
Incorrect component loaded in dispensing head.
Load dispensing head with correct component.
Radial Only:

Poor transfer of component from

component transfer assembly to head.

Set up component transfer assembly per maintenance manual.
Radial Only:

Incorrect dispensing head alignment/setup.

Set up and align dispensing head per maintenance manual.
Radial Only:

Insert head out of alignment.

Set up and align insert head jaws per

maintenance manual.

Radial Only:

Insertion tooling clamp worn or spring

fatigued.

Repair or replace as necessary.
7 Component leads are not cut and clinched Clinch is jammed . Clear clinch jam.
Clinchheight is set toolow. Adjust clinch height per maintenance

manual.

Head to clinch alignment is not correct. Adjust alignment per maintenance manual.
8 Component leads are too long after cut and clinch Clinchheight is set toolow. Adjust clinch height per maintenance manual.
Head to clinch alignment is not correct. Adjust alignment per maintenance manual.
Head to circuit board clearance is not set prop erly. Adjust head height per maintenance manual.
Radial Only:

Pusher tip height is incorrect.

Ensure pusher tip is installed properly.

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