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S -1688 Stencil Cleaner Machine USER MANUAL for PCB Assembly

Meet the Needs of the SMT Age

 

 

Please read this user manual carefully before running

 

 

 

 

 

 

 

 

S-1688 Stencil Cleaner Machine

 

 

 

USER MANUAL

 

 

 

 

 

 

 

 

 

 

 

 

TEL : 0755-83203237

FAX : 0755-23240492

ADD : Room 1806, Block 3, Jinyun COFCO, Qianjin 2nd Road ,Baoan District,
Shenzhen City, China

 

 

CONTENTS

 

1.0 safety warning……………………………………………………………………………….3

 

2.0 product presentation
…………………………………………………………………3

 

3.0 installation requirements……………………………………………………………….4

 

4.0 Operations Guide……………………………………………..…….………………………………..5

 

5.0 The cleaning of the solvent is added, platoon and storage tank………………………………………………………..………….…………………………………………..13

 

6.0 Replacement of filter element………………………………………………………15

 

7.0 Product use precautions……………………………….…………..……………….…………………………………..16

 

8.0 working principle………………………………………….………………………………………..16

 

9.0 Maintenance, fault handling ……………………….………………………………………16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.0 safety warning

1.1 Please read this manual carefully.

 

1.2 Please strictly follow the installation requirements in this instruction and the guide to operation. The installation and use of this equipment.

 

1.3 Please equip a person to operate the equipment

 

1.4 The operator must wear protective glasses, protective gloves, protective respirators and other protective products.

 

2.0 product presentation

 

2.1 Name: full pneumatic steel net cleaning machine

 

2.2 model: S-1688

 

2.3 Product features

 

1)
Use full pneumatic logic control, one-click operation, easy to finish cleaning and drying

 

2) No power supply, no fire hazard.

 

3) The cleaning frequency system is automatically counted to facilitate the replacement of consumables in time to ensure the quality of cleaning work.

 

4) The cleaning pressure can be adjusted according to the need to ensure the stability of steel mesh tension, thus ensuring the longer service life of the steel net.

 

5) The whole operation process is completely closed, avoiding the direct contact between the workers and the cleaning fluid

 

6) Various types of cleaning fluid can be used for efficient cleaning

 

7)
Can effectively remove solder paste, such as red glue residue and more from steel mesh, wire mesh, copper mesh, microporous network, scraper, fixture, PCB, etc.

 

8) The three – level filtration device ensures the recycling of cleaning fluid, and realizes the minimal loss of cleaning fluid.

 

9)
Asymmetric rotating spray arm: ensure the cleaning of fine PCB holes.

 

10)
Digital free setting cleaning and drying time

 

 

2.5. Main technical parameters:

 

Application stencil, glue screen , copper screen
Stencil size Standard 29 inch and below
Clean liquid capacity Max 50L , Min 20 L
Cleaning fluid volume 40L
Cleaning method  Rotary double-sided pressure injection and
high-pressure air spraying ( cleaning and drying )
Clean time 2~4 min (stencil and copper net)
Rinse time 2~4 min (stencil and copper net )
Dry time 2~5 min
External air supply 0.4Mpa~0.6Mpa
Air consumption 400~600L/Min*2
Air outlet size Φ125*25mm
Weight  320Kg
Dimension  980mm(L)*700mm(W)*1730mm(H)
Tin filter method Three class filter (10μm,5μm,1μm)

 

3.0 installation requirements…

 

3. 1. Installation site

 

In order to ensure safe production and prevent possible damage to the equipment, the equipment should be installed in a place that meets the following environmental conditions

 

1) Stay away from sources and heat sources

 

2The air is dry and well ventilated

 

3) Clean, clean, flat and unshaken ground

 

3. 2. Installation accessories, required energy and precautions

 

1) The source pressure is : 0.4Mpa~0.6Mpa

 

2)Taken the air over diameter for : 12mm, a quick joint is needed

 

3) The top of the equipment is designed : The 125mm exhaust port shall be connected to the outside by independent air duct

 

 

4) matters need attention: In order to ensure safe production, customers must ensure that the following security measures are installed in place. Otherwise, the company does not assume any responsibility for security

It is at least 3 meters away from the electric equipment, away from fire source and heat source

 

The ground wire must be connected, and the earth shall not be connected to any other electrified equipment

 

The exhaust duct of this equipment shall not be connected to any equipment that can produce heat source. (such as reflow soldering wave soldering of SMT, etc.)

 

3.3 installation space

 

To facilitate the maintenance and replacement of spare parts for equipment operation, please leave more than one meter space around the equipment

 

4.0 Operations Guide

 

A Preparation before operation

 

4.1.1 connect the air source to the machine, the gas source is connected well, the display lamp is highlighted and the subsequent work can be continued

 

4.1.2 check if air pressure in the standard rating (04-0.6 MPa) range. Lower than 0.4mpa will affect the cleaning effect and reduce production efficiency (too low will not activate the machine).

Higher than 0.6mpa can result in damage to the mechanical gas system and all parts of the system.

Adjust the pressure method: pull upward gently to adjust the knob and rotate to the right————- Increase pressure

Go to the right ————– reduce stress

After reaching the required pressure, press the adjusting knob, air pressure lock and pressure to complete the gas connection, and the lamp is highlighted





 

 

4.1.3 check whether the top exhaust duct is unblocked or unblocked, which will result in damage to the environment and other consequences of the cleaning effect


 

 

 

 

4.1.4 check the glass viewport of the door panel through the liquid road to check the solvent reserves. The normal state is above the M position, and the machine can meet the various cleaning effects. The amount of liquid stored in this model is the maximum amount (40L).


 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.1.5 if the solvent is not enough, please add adding method in time: see adding solvent method

 

4.1.6 the pump access panel is opened with a randomly attached triangle key to check whether the ball valves are in normal condition

Ball (the ball valve of pump outlet filter) A ball valve D (pump inlet connection of the reservoir fluid Xiang ball valve) opens, B ((the ball) of white PE tube pump discharge ball valve C (white PE tube pump inlet ball valve) closed


 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.2 time setting

 

4.2.1The setting of the cleaning time (see figure below), gently rotate the timer protection cap to the left and pull up the cover.

 

General cleaning time is

Minutes, depending on the actual situation, will be different.

This timer is measured in seconds (S) with a range of 10-999 seconds (S).

It can be set to 0, otherwise the machine will not start and may damage the timer and other components.

 


 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.2.2 setting of drying time

Operation method and cleaning time setting.

The general drying time is 4-6 minutes depending on the actual situation.There will be an elongation of the aqueous solvents.

 

4.2.3The cleaning and drying time are automatic reset.

That is, one set, multiple times (N times).

When the pressure is less than the required number, the timer can be reset and the device cannot be started.

At this point, the black reset button on the upper row of the timer can be reset manually.

 

 

 


 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.2.4The counter’s use of this counter is the increment counter, each cleaning a steel net, automatically into the system,

One of them is going up.

The count range is 0-999999.

Mainly used for cleaning work statistics, timely replacement of consumables (filter element), etc.

The filter cartridge should be changed when cleaning up to 1500.

Specific visual cleaning products are different and different.

When the counter displays the number to reach the target number, press the 4.2.3 method to open the cover, then press the black reset button on the left of the timer and the counter is reset.

 

4.3 placement of steel mesh

4.3.1 press the inner door safety button to open the cleaning room


 

 

 

 

 

 

 

4.3.2 lift the steel net with both hands, gently place the front in the cleaning room chute roller and push it gently forward to the sliding channel steel

Fixed fixture on the net.

The steel net is in the middle of the fixture and chute. The top of the steel net is at the top of the cleaning room

Steel mesh fixture middle.(see below.)


 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.3.3 when placing the steel mesh, the steel mesh shall not be in contact with the door to avoid damaging the steel net and sealant


 

 

 

 

 

 

 

 

 

 

 

 

 

4.3.4After the steel net is placed, close the cleaning door.

The inner door should be kept in good condition, otherwise, the solvent will be expelled outside, causing machine damage or environmental damage, more likely to cause personal injury



 

 

 

 

 

 

 

 

 

 

 

 

4.3.5 after the inside door is closed, continue to close the outer security door.

The security door is closed and the light is on, so that the following operation can be continued.

If the security door is not closed, the lamp will be retracted and the machine will not be able to start.

After closing the door again, the machine can be started

 


 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.4 the start of the machine

 

4.4.1 press the start button lightly and the machine will start to run.

The machine will be automatically restored until the cleaning is completed


 

 

 

 

 

 

 

 

4.4.2 use the emergency stop button to press the emergency stop button when the emergency situation is in place. The machine will stop running.

The emergency situation is eliminated and the machine is restarted



 

 

 

 

 

 

 

4.5 adjustment of cleaning pressure

After the machine starts, pay attention to the pump input air source pressure and output cleaning pressure.

In order to achieve the best cleaning effect and maintain the tension of the steel mesh, the pressure should be adjusted


 

 

 

 

 

 

 

4.5.1 pump input air source pressure is generally maintained at about 0.4mpa

 

4.5.2 cleaning pressure is generally maintained at about 0.2-0.3MPa


 

 

 

 

 

 

 

 

 

4.5.3 adjustment of pump pressure: gently pull the adjusting knob of the pressure-reducing valve and turn the pressure on the right to increase the pressure to the left.

After adjusting well, press the adjusting knob to lock and adjust the work.

Note: this valve is the pressure reducing valve, the pressure adjustment will not be higher than the air source


 

 

 

 

 

 

 

 

4.6 the setting time is terminated and the machine is automatically stopped.

A cleaning cycle is over

 

5. Add, drain, and container for the solvent

 

5.1 addition of solvent

5.1.1 let the machine stop and open the access panel.

5.1.2 close ball valve B, D, open ball valve A, C.

Insert the “IN” pipe IN the ball valve C into the container containing the solvent.

Control the “IN” tube and start the machine until the machine drains the solvent.

 


 

 

 

 

 

 

 

 

 

 

 

 

 

5.2 discharge solvent and storage tank cleaning

5.2.1 open the liquid access panel and start the machine according to the normal procedure.

Close the ball valve D, open the ball valve C, and leave the machine idle for 1 minute.

In order to take out the solvent in the filter.

5.2.2 Open 8 screws on the tank and remove the reservoir cover..

 

5.2.3 press the stop switch to stop the machine.

Close the ball valve A and C, insert the “OUT” pipe of ball valve B into the container and slowly open the ball valve D.

Take care to control the “OUT” pipe at this time so as not to cause an accident.

 

5.2.4 when the solvent location of the reservoir is lower than the outlet filter of the reservoir, close the ball valve C and open the ball valve D.

Insert the white PE tube into the storage tank to remove the remaining solution

 

5.2.5When the solvent is removed, loosen the filter to fix the wire, remove the filter bag, remove the filter of the outlet and clean it with water or other means.

When the storage tank is cleaned and reloaded, cover the tank and lock the container

 

 

5.2.6 the liquid storage tank shall be cleaned and the solvent shall be drained and the machine shall be turned off.

Use a shovel knife to clean up the thick residues, leaving the small residue with a cloth strip

 

5.3 precautions for solvents

 

5.3.1 please wear protective equipment, such as protective gloves, protective glasses, protective masks, etc. to avoid direct contact with the human body and affect health and other safety accidents.

When operating, please pay special attention to the “IN” and “OUT” piping that controls the activity so as not to cause unnecessary security

 

6. Replacement of filter element

Replace the filter cartridge when cleaning a certain amount of steel net, the filter element needs to be replaced to satisfy the cleaning effect.

The replacement method is as follows

 

6.1. Remove the bottom of the filter with the left hand of the filter and remove the wrench into the disassembly hole, rotate the wrench to the left, remove the filter, then remove the filter element


 


 

 

 

 

 

 

 

 

 

 

6.2 installation of filter element

Wipe the filter clean and put in the new filter. (note that you can install a 5-micron filter on the outside by installing a 1-micron filter.

Then the left hand holds the bottom of the filter, and the right hand moves the filter nut.

When the hands are wrung, remove the wrench and hold it until it is unscrewed.

Pay attention to the filter cartridge when operating, the position of the filter should be put in place, for the positive

 

6.3 Replacement of seal rings

The sealing ring of the filter shall be soaked in the solvent for a long time because the chemical function will become larger. When the filter is removed, it will be difficult to install again.

The sealing ring should be removed at this time, with the spare ring installed.

Close the sealing ring after getting bigger, and substitute elastic back for backup

 

7. Use precautions

7.1. The installation site of the equipment is strictly prohibited near the source of fire, heat source and power supply.

The ground wire and exhaust duct must be installed and installed completely independently. It shall not be connected or connected with any other equipment

 

7.2. Replace the solvent, add, discharge the solvent, change the filter core, and when the steel net is taken, please wear protective equipment.To ensure the operator’s health and safety accidents.

 

7.3. Require strict access, adjustment and use of air source pressure according to the rated standard.Operate the machine according to the operating instructions and procedures of the machine.

 

7.4. It is not possible to bring cloth, paper scraps or other sundries into the machine cleaning room, or leave it in the storage tank, or it may cause blockage of the pipe and damage to the machine.

 

7.5. When operating the machine, please pay attention to the moderate intensity to avoid damage to the machine components.

 

7.6. No solvent cleaning machine surface or other non-stainless steel components shall be used to ensure the service life of the machine

 

8. Working principle

 

S-1688 Stencil Cleaner Machine

9.0 maintenance and fault handling

 

9.1 maintenance

 


 

 

 

 

 

 

 

 

 

 

 

9.2 fault handling

 


 

 

 

 

 

 

 

 

 

 

 


PCB Board handling system in Smart factory

The Southern Machinery is a Shenzhen-based company, providing professional automatic insertion machines tailor-made for Electronic Manufacturing Factory. Our team works with recognized experts that have many years of working experience in the industry.

As an industry leader with over 20 years of experience in electronic manufacturing, we provide comprehensive guidance from the AI / PCB design (DFM), AIprocess (NPI) to equipment importing, installation, and auto insertion technology (THT) training, machine troubleshooting/ upgrading/ overhauling / relocating/ fittings. We also offer an affordable line-up of all brand spare parts.
By saving your time and money through getting your PCB Assembly automated, your long-term return on invest (ROI) will also increase with producing PCBs in-house. Working with a proven industry leader allows you to focus on your core business with PCB assembly handled by the proven specialists at Southern Machinery.
We are committed to conducting any level of EMS design work and providing electronic design services. These value-added design services can verify the accuracy and precision of electronic designs, leading to significant improvements for production output and resulting in superior products with higher quality that your target market will love.

       

       

       

       

      Ensuring the Best Design for Final PCB Production Stage with Testing!

      Ensuring the Best Design for Final PCB Production Stage with Testing! Ensuring the Best Design for Final PCB Production Stage with Testing!

      Avoiding Design Mistakes with Testing

      Improve EMS Productivity by Testing Early

      http://www.smthelp.com/product/high-speed-in-line-circuit-board-test-machine/

      PC Board errors are a drain to EMS productivity. Through analysis and testing PCBs in the pilot stages, a smoother and more educated production set-up can be achieved. By performing automatic impedance measurements and testing of components (chip resistors and capacitors) early on, you can ensure the best design for production.

      We recommend applying the best design logics when creating your PCB layout and Test, Test, Test for maximum efficiency and output. According to Circuits Assembly’s December 2016 Magazine, here is the list of 5 Most Common PCB Design Mistakes: “1. The components do not suit the production technology 2. Thermal imbalance 3. Incompatibility between fabrication and assembly technology 4. Component placement at PCB edge 5. Placing fiducials on the PCB’s edge.”

      Once you have planned your PC Board with best practices, Southern Machinery’s High-Speed In-line Circuit Board Test Machine will help with testing by incorporating a visual inspection function which allows mounting status checks on each component (e.g.: typo descriptions in alphanumeric characters, orientation, size) on the operator’s monitor will serve to best analyze testing up close. As well as automatically generating test data from mounting data and component list.  

      http://image.slidesharecdn.com/highspeedin-linecircuitboardtestmachine-fai-161223080028/95/high-speed-in-line-circuit-board-test-machinefai-14-638.jpg?cb=1482480094

      http://image.slidesharecdn.com/highspeedin-linecircuitboardtestmachine-fai-161223080028/95/high-speed-in-line-circuit-board-test-machinefai-3-1024.jpg?cb=1482480094

      http://www.smthelp.com/product/high-speed-in-line-circuit-board-test-machine/

      35000 CPH ! High Speed SMT pick&Place machine

       S-520 Pick&Place machine
      Thickening marble platform,No shaking when working, guarantee the fuselage stability and accuracy !
      Core motor adopts imported servo motor, 35000 CPH !
      PCB max size: 1200 * 390, meet the demand of market LED diversity !

      SMT line
      Provide SMT whole line solution

      SMT and Auto Insertion Machine Critical 1 Spare Parts Definition

      Critical 1 Spare Parts Definition

      What are Critical 1 Spare Parts?

      Critical 1 (C1) parts are parts that may fail with no warning, may not show signs of wear, or may cause other parts to fail.  They cause a machine failure with no work around.  These are the parts that most concern our customers as their failure can stop a production line.  

      C1 parts are identified by engineering and product support teams during the product development/introduction process.  

      C1 lists are generated and tracked as part of the development cycle and are made available prior to shipments of production volumes to customers.

      As a guideline C1 parts will not be duplicated in RPKs.  There may be exceptions that will require cross functional agreement.  

      What is NOT typically considered a Critical 1 Spare Part:

      Consumables or wear parts

      High usage spares

      Exceptionally robust parts or assemblies

      General Hardware (typically) 

      What is the key difference between Critical 1 and Replacement Parts Kits (RPK)?

      Replacement parts kits (RPK) include items customers are expected to need within 6 months of use.  Examples of parts in the RPK includes consumables items, wearable parts and predictable failures.  

      Typical RPK items:

      Fuses

      Light bulbs

      Belts 

      Wearable tooling

      Hardware associated with general maintenance

      AI spare parts、Universal Parts,UIC,TDK.VCD
      AI spare parts、Universal Parts,UIC,TDK.VCD

      PC Board Design Checklist For Through Hole Components

      PC Board Design Checklist

      For Through Hole Components

      This
      document should be used as a supplement to existing machine General
      Specifications and IM Design Guidelines. This document is designed as a checklist rather than a reference for use
      when examining an existing or new product. For detailed specifications
      refer to the appropriate General Specification.

       

      PC board considerations

      For Axial or Radial auto insertion:

       

      *  Is the overall size of the board within specification? (max/min size varies by machine and board handling type)

      *  Is the board thickness within specification?

      Possible challenges:

      Radial
      can accept boards from 0.032” to 0.093” thick with no set up change,
      axial machines require mechanical adjustment to handle thickness
      variations.

      *  If using automatic board handling, is the board shape acceptable? (i.e. contiguous edges.)

      Possible challenges:

      Non-contiguous edges, may work but requires testing. Example, instrument cluster.

      *
       Is the board a good candidate for panelization? (i.e. creating
      multiple images of the same board on one panel for ease of assembly and
      increased throughput.)

      *  Is the board warpage within specification?

      Possible challenges:

      Warpage can cause issues with insertion as well as clinch angle/length, especially on radial machine.

      *  Does the PC board contain location reference holes to allow proper fixturing?

      Possible challenges:

      If product was previously hand assembled it may not have locating holes.

      *  Are the components positioned at 0º and/or 90º with respect to the X axis?

      Possible challenges:

      Sometimes
      components are arranged at odd angles because of space constraints or
      because designer wanted to keep component body straight. (example: ECCO
      board.)

      *  Are the component hole diameters within specification for each component type (lead diameter) being inserted?

      Possible challenges:

      Boards currently hand assembled are most likely to have undersize holes.

      *  Is there sufficient clearance below the board for the clinched component leads? Consider the following:

      *  Solder bridging to other component leads

      *  Solder bridging to via holes or adjacent pads

      Note:
      Universal does not specify required clearance to prevent solder
      bridging, this should be determined by the customer. However, obvious
      cases of conflict should be noted.

      *  Is there sufficient clearance for the insertion and clinch tooling? Take into consideration:

      *  Previously inserted IM components

      *  Previously placed SM components

      *  Workboard holder locating and support fixtures

      *  Obstructions on the bottom of the board that could interfere with the clinch or board transfer.

      Component and tooling considerations

       

      Axial

      *  Are components packaged properly for automatic insertion? (Tape and reel/ammo pack)

      Possible challenges:

      Customer may have “sample” components in bulk, are these components readily available in a taped format?

      *  Is the component input tape width (i.e. 26mm or “standard”) compatible with the component hole span?

      Possible challenges:

      Universal
      does not offer a machine that can accept 26mm input. Virtually all
      components are available in 52mm format, however, a subcontractor may
      have to deal with “kits” from an OEM that contain 26mm components.

      *  Is the insertion tooling (i.e. 5mm, 5.5mm or standard) compatible with the component hole span?

      Possible challenges:

      Does
      the product include both very wide and very narrow span components?
      Use tooling selection matrix to evaluate best tooling fit.

      *  Is the component hole span compatible with the component body length?

      Possible challenges:

      Be especially careful when moving product from hand assembly to automatic assembly.

      *  Is the component body diameter compatible with the board thickness and insertion tooling requirements?

      Possible challenges:

      Watch out for very thick boards and/or large diameter components.

      *  Is the component lead diameter compatible with the insertion tooling? (i.e. standard vs. large lead)

      Possible challenges:

      May have to sacrifice (to hand assembly) some insertions at either the large end or the small end of the spectrum.

      *
       Does the component require a stand off between the body and the PC
      board? Components requiring a stand off cannot be inserted with an
      axial inserter, but may be auto insertable with a radial inserter if
      packaged in the proper format.

      Possible challenges:

      “Stand-off” type resistors are more common where high power handling is required, power supplies, monitors, etc.

      Radial

      *  Are components packaged properly for automatic insertion? (Tape and reel/ammo pack)

      Possible challenges:

      Customer may have “sample” components in bulk, are these components readily available in a taped format?

      *
       If components are packaged on tape, use the following “quick check”
      list to get a general idea of which components may be automatically
      inserted: (See note 1 below)

      *  Body diameter 13.0mm or less

      *  “H” dimension (distance from centerline of feed hole to bottom of component) within acceptable limits

      *  Lead diameter within acceptable limits

      Possible challenges:

      Radial
      taping specifications are quite involved, use “quick check” list as a
      sanity check, forward component samples to applications group for
      detailed evaluation.

      *
       Are the lead spans of the components compatible with standard
      automatic radial insertion? (i.e. 2.5mm, 5.0mm, 7.5mm or 10.0mm) (See
      note 2 below)

      Possible challenges:

      1)  May have to “sacrifice” some components to hand assembly because of tooling footprint issues or span requirements.

      2)  Some PCB’s contain components are non-standard span’s, i.e. 2.0mm, 4.0mm.

      *  Are transistor leads in line? (i.e. not in a “triangle” configuration)

      *  If the component is required to stand off the PC board, are features built into the component lead to accomplish this?

      Possible challenges:

      Board
      designer may “require” a certain type of standoff without checking to
      see if the package is readily available, common with LED applications.

       

      Notes:

      1) The
      simplified guidelines were created to draw attention to the most common
      areas where components fall outside the limits for auto insertion.
      These simplified guidelines should only be used as a general guide.
      Component input must meet all criteria called out in the Radial General
      Specification.

      2)  Tooling selection will depend upon insertion span requirements as well as board density considerations.   Muniak98-052B  Revised 01-00

      1

       

        

      Southern Machinery WARRANTY POLICY ON ALL NEW Machines

      WARRANTY POLICY ON ALL NEW Machines

      Southern Machinery warrants its products to be free from defects in materials and workmanship for a period of one year from completion of installation, provided the products are installed as specified by Southern Machinery, maintained by qualified service personnel and the products are operated in accordance with published operating procedures.  For purposes of the foregoing warranties the “completion of installation” shall be that date, within 90 days of shipment of Southern Machinery’s products from its factory, on which the products are installed and operating to the published specifications.  If the customer believes a product to be defective in material or workmanship, or failing to meet the specifications, the customer shall notify Southern Machinery of such alleged defect or failure.  Southern Machinery shall have a reasonable opportunity to investigate any alleged defect or failure, and upon confirmation of its existence Southern Machinery shall promptly remedy the same by repair or replacement, at its discretion and without charge.  The seller warrants parts repaired or replaced for the duration of the original warranty period.

      The warranty does not apply to:

      1. Consumable parts as they are defined in this document.

      or

      2. Defects or failures as a result of non-compliance with U Southern Machinery’s installation specifications.

      or

      3. The customer’s failure to perform the recommended normal maintenance, set up and the adjustment of the equipment.

      or

      4. The customer’s alteration / modification to the equipment without Southern Machinery’s prior written approval.

      or

      5. Damages to the equipment resulting from non-compliance with published operating procedures.

      or

      6. The use of replacement parts not supplied by Southern Machinery or Southern Machinery’s approved suppliers.

      Definition of Consumable Parts (Non Warranty):

      A) Machine parts that come in direct contact with component processing.

      Examples are, but are not limited to, insertion head tooling, chain clips, lead cutter tooling, etc.

      B) Maintenance/bulk items.

      Examples are, but are not limited to, lubricants, adhesives, light bulbs, fuses, seals, o-rings, etc.

      All other machine parts are warranted for 12 months from the machine in-service date, completion of installation.

      Disclaimer Statement:  

      The life expectancy of consumable tooling is dependent on proper preventive maintenance, proper machine set-up, and the type of component used by the customer.  A customer may experience greater life expectancy or less life expectancy depending on the above.

      Axial Insertion machine Competitive Analysis – Amistar AI-6448 vs Universal 6241D

      This paper compares Amistar’s Model AI-6448 Inserter/Sequencer and Universal’s Model 6241D VCD/Sequencer machines.  

      Amistar Corporation, head quartered in San Marcos, California, is a small company – 154 employees and ~ $20 mil in annual sales.  Both resources and exposure are limited and Amistar predominantly sells via representatives.  To my knowledge, manufacture of the Amistar Model AI-6448 was discontinued approximately 7 years ago.  Because of this, current information about Amistar is limited.

      Amistar advertises the AI-6448 on their web page as follows:

      The Amistar AI-6448 is a fully automated Axial component inserter. 

      Stand alone automation: sequences & inserts in one operation 

      Cycle rate of 9,600 insertions per hour 

      Capacity: 64 cartridges, 88 reels 

      Automatic optical position correcting via PCS (Position Correcting Servo) 

      Axial component verifier 

      Lead protrusion inspection 

      Microprocessor control 

      Easy to program 

      Easy to use

      Amistar’s approach to axial insertion with their model AI-6448 is very different from Universal’s.  Axial lead components are cut at the dispensing head and dispensed down a tube via free fall (gravity) compressed air. The component is then recaptured at the transfer station for eventual insertion into the PCB.  The Amistar machine has capacity for 88 reels and 64 cartridges, but no ammo pack capability.  Each cartridge is kitted off line and capable of handling a maximum of 75 components.  Some customers believe this feature works well for small production runs, although it does add another preparation step to the process, as well as additional component handling, which increases the potential for component damage and or errors.

      Other differences from the method in which Universal handles axial components include the way in which components are centered.  Amistar centers on lead end instead of the component body.  This can lead to components being cut off-center and consequently effect insertion reliability.  

      In order to utilize the AI-6448’s method of transferring components to the insertion area, the positioning system is very low to the floor making it difficult to maintain and/or access.  Universal FE’s have had the opportunity to evaluate AI-6448’s installed at customer locations and have reported concerns with the durability, accuracy and repeatability of the rotary table.  

      While the Amistar Model AI-6448 can be equipped with board handling, the method utilized is limited to stand-alone applications, not allowing for pass-through or in-line capability and takes up a lot of floor space.  

      In the past, Amistar has sold the AI-6448 when the prospective customer is interested in combined sequencing and insertion and price is a major factor.  Typically, the price of the AI-6448 is much less than the 6241 in a similar configuration (similar in a sense that there are similar number of inputs).  When speed, capability and machine performance are added to the equation, the AI-6448 is not as attractively priced.  Because Amistar has not manufactured the AI-6448 in 7 years, no current pricing information is available to us.

      Feature

      Amistar Model AI-6448

      Axial Insertion Machine

      Universal Model 6241D

      VCD Sequencer/Inserter

      Speed

      9,600 cph

      16,000 cph

      Max PCB Size w/Board Handling

      20″ x 20″

      (508mm x 508mm)

      19″ x 16″ 

      (483mm x 406mm)

      Max PCB Size w/out Board Handling

      20″ x 20″

      (508mm x 508mm)

      18″ x 22″ 

      (457mm x 559mm)

      Max # of Inputs

      52mm only:  64 cartridges, 88 reels 26mm not available

      ammo pack not available

      52mm: 220 stations in 20 station increments

      26mm: 220 stations in 20 station increments

      Reel and/or Ammo Pack

      Insertion Span

      Std:.300″ – .800″ 7.62mm – 20.3mm)

      5mm:  Not available

      Std: .300″ – .950″ (7.6mm – 24.1mm)

      5mm: .197″ – .850″ (5mm – 21.6mm)

      Component Centering

      Component Leads

      Component Body

      Board Error Correction

      Yes

      Yes

      Verification

      Yes  – limited capability

      Yes

      Lead Sensing

      Yes

      Yes – dual lead

      Rotary Table

      Yes

      Yes

      On-Line Programming

      Yes

      Yes

      Automatic Board Handling

      Yes

      Yes – designed and manufactured by Universal

      Part Transfer

      Chute

      Sequencer

      Refire

      Yes

      Yes

      Part Repair

      Automatic

      Semi-automatic

      Max Body Length

      .400″(10.2mm)

      .620″(15.7mm)

      Max Body Diameter

      .175″(4.5mm)

      .420″(10.69mm) – 2 x PCB thickness

      Lead Diameter

      Standard Tooling: 

      copper lead

      .015″- .036″(.38mm – .9mm)

      .015″- .032″(.38mm – .81mm)

      Standard Tooling: 

      copper lead

      .015″- .026″(.38mm – .66mm)

      .015″- .032″(.38mm – .81mm)

      5mm Tooling: copper lead

      Not available

      .015″- .032″(.38mm – .81mm)

      5mm Tooling: copper lead

      Not available

      .015″- .032″(.38mm – .81mm)

      Jumper Wire Capability

      Yes

      Yes

      Low Part Sensing

      No

      Yes

      Universal’s 6241D is still manufactured and design development activities continue to enhance and improve the machine as part of Universal’s ongoing commitment to the through-

      hole market.  In addition to the items listed above, recent enhancements in the Model 6241D product line include:

      Axial Tech Advisor is available which provides Operators and Maintenance Technicians on-line, menu-driven diagnostic information and assistance on machine operation, troubleshooting, maintenance and repair at the time of need.  It is available in English, Chinese and Spanish.

      Newly designed jumper wire dispensing system provides fast, reliable and accurate wire feed and accommodates .45mm to .6mm wire diameters

      Newly designed dispensing heads are easy to operate, greatly extend life of wearable parts and allow for quick changeover with minimal scrap.

      The 6241D now offers a low-level Sequencer Add-On Module for easy reach loading.  It features low part sensing to alert the operator before parts are depleted, allowing replenishment without interrupting machine operation, removable end scrap bins for easy clean out, and refire is offered on each dispensing head.

      Precision WBH’s, both adjustable and fixed are available.  Universal can also accommodate Amistar WBH’s.   

      The 6241D contains a 4 color light tower which signals machine operating status.

      New and improved board handling increases system reliability, ease of PCB changeover and ease of assembly. (See SH BHS Improvements Presentation).

      Newly designed 5mm tooling is now available for increased reliability, longer life and better handling of bent lead component input.  (See 5mm Tooling Improvements Presentation).  Customers have told us this tooling lasts three times longer than the old style tooling

      Universal offers a AAA version of the VCD Sequencer machine that is capable of inserting 26mm input.

      The 6241D is CE marked to meet all European health and safety standards.

      While Universal does not offer conversion software for converting Amistar pattern programs, the Amistar programs could be treated as CAD data and translated via the CAD translator available in PPU.  If your prospective customer would like to supply us with one of their programs and briefly explain the fields, we will review the program and offer suggestions for performing the translation.

      And last, but not least, Universal offers a support infrastructure which includes a knowledgeable and experienced Field Service organization, world wide Training Centers and Parts Distribution Centers as well as an extensive installed base.