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Page 18 52489101 Rev . B IM T roubleshooting This document supports Radial 88, VCD Seq 88, and Jumper Wire 88 machines. Troubleshooting Table - Clinch Assembly The following tables lists possible error scenarios for the …

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Page 17
IM Troubleshooting 52489101 Rev. B
This document supports Radial 88, VCD Seq 88, and Jumper Wire 88 machines.
Troubleshooting Table - Component Transfer Errors
(VCD and Radial Only)
The following table lists possible error scenarios for component transfer
errors.
Probable Cause Corrective Action
Refire error. Check refire board and optical sensor.
Dispensing head not adj usted for
component type.
Adjust dispensing head as required.
Faulty MMIT I/O board. Replace faulty board.
Worn or leaky air cylinder on a particular
feeder.
Replace seals on cylinder.
Chain misaligned or dispensing head pitch
wheels incorrectly set.
Check chain alignment or adjust
dispensing head pitch wheels.
Input components binding. Check component input and clear binding.
Drop timing improperly set. Correct drop timing and reset as required.
Chain to chain transfer not properly set.
Check chain to chain and adjust as
re quired.
Refire malfunctioning or disabled.
Repair, replace or enable refire as
re quired.
Worn or leaky air cylinder on a particular
feeder.
Replace seals on cylinder.
Spans are increasing more than .300 inch
(7,6mm) between pattern steps.
Reprogram pattern steps to eliminate span
increases more than .300 in. (7,6mm).
Shear blocks edges are dull. Replace shear blocks.
Broken or worn compression springs in
chain clips.
Replace faulty compression springs.
Worn chain clips. Repla ce faulty chain clips.
Home pulse not generated, encoder failed.
Refer to maintenance procedures and
re place encoder.
Home pulse not detected. Motion control
board failed.
Refer to maintenance procedures and
re place motion control board.
Faulty limit switch or wiring.
Troubleshoot wiring or replace faulty
switch.
Transfer stroke is too long or short.
Adjust CTA to head stroke per
maintenance manual.
CTA latch timing adjustment/worn or
broken spring .
Adjust timing per maintena nce man ual/
re place spring.
CTA is not aligned with the insertion head.
Align CTA to head per maintenance
manual.
4
Troubleshooting Table - Component Transfer Errors
VCD only:
Two or more components in one
sequencer chain position.
1
VCD only:
Components intermittently
missing from sequence.
Indicated Trouble
5
VCD only:
Scrap leads falling out of chain
clips.
VCD only:
Head chain goes into limit error
when START is pushed.
Radial only:
Component leads are bent.
2
3
Page 18
52489101 Rev. B IM Troubleshooting
This document supports Radial 88, VCD Seq 88, and Jumper Wire 88 machines.
Troubleshooting Table - Clinch Assembly
The following tables lists possible error scenarios for the clinch assembly.
VCD and Jumper Wire Only
This table is for VCD and Jumper Wire.
Probable Ca use Correc tive Action
Pattern step list has an "ignore continuity"
command.
Determine why the command is there, and
take corrective action.
VCD O nly:
Clinch cutter stroke too long.
Refer to maintenance procedures and
adjust cutter stroke.
Multi input card bit switch settings are
incorrect.
Refer to maintenance procedures and set
bit switches.
Multi input card failure. Replace failed card.
Broken continu ity cable/wires. Replace faile d cable.
Clinch set up incorrect.
Refer to maintenance procedures and
adjust clinch setup.
Multi input card bit switch settings are
incorrect.
Refer to maintenance procedures and set
bit switches.
Multi input card failure. Replace failed card.
VCD O nly:
Leads clogging clinch or scrap tubes
causes shortened clinch.
Clean clinch and scrap tubes.
Broken continu ity cable/wires. Replace faile d cable.
Clinch dirty. Clean clinch.
Worn cutter bushings. Replace cutter bushings.
Clinch jammed. Remove clinch jam.
Clinch failed.
Refer to Clinch Functional Problems in this
document.
Incorrect tooling to printed circuit board
clearance.
Refer to maintenance section and adjust
tooling to board clearance.
Clinch height set too low.
Refer to maintenance section and adjust
clinch height.
Incorrect head to clinch alignment.
Refer to maintenance section and align
head to clinch.
Printed circuit board not properly
positioned .
Correct board positioning problem.
CAP span value set too small. Reset CAP to correct value.
Clinch cu tter stro ke ou t of a djustme nt.
Refer to Maintenance manual (Cutter
Stroke Adjustment section).
1
2
Troubleshooting Table - Clinch Assembly
Jumper Wire and VCD Only
4
Component leads are clinched
but leads are too long.
Indicated Trouble
3
Machine does not detect insert
errors.
Machine reports insert errors
when insertion is good.
Leads not clinched.
Page 19
IM Troubleshooting 52489101 Rev. B
This document supports Radial 88, VCD Seq 88, and Jumper Wire 88 machines.
Radial Only
This table is for Radial.
Probable Ca use Correc tive Action
1 Waiting for clinch in.
Clinch in sensor not made when cylinder is
actuated.
Check for faulty sensor and adjust per
Maintenance Manual.
2 Shorted clinch.
Debris in cutter head assembly or
continuity gap incorrect.
Clean and PM cutter head, adjust
continuity gap per Maintenance Manual.
3
Insert error, continuity not
sensed.
Incorrect continuity gap, loose or broken
continuity cable.
Set continuity gap per Maintenance
Manual, check cable, replace if bad.
4
Component clinched to PCB OK
but insert error detected.
Continuity not sensed on one side or the
other of cutter head.
Check continuity gap, check pre-load
adjustment on plunger screw.
5 Insert errors, loose components.
Worn cutters pulling leads instead of
cutting.
Check for worn/damaged cutter tooling;
replace as needed.
6
Leads not clinched or bent when
inserting through PCB holes.
Clinch assembly not properly aligned to
insertion head.
Align clinch assembly to insertion head,
check theta per Maintenance Manual.
7 Lead too long or loose in PCB. Clinch height too low.
Set clinch up position per Maintenance
Manual.
8 Bottom side of PCB damaged. Clinch height too high.
Set clinch up position per Maintenance
Manual.
Troubleshooting Table - Clinch Assembly
Ra dial Only
Indicated Trouble