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Page 1 IM T r oubleshooting 52489101 Rev . B This document supports Radial 88, VCD Seq 88, and Jumper Wire 88 machines. Functional Description This document provides troubleshooting information for the electrical and mec…
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IM Troubleshooting 52489101 Rev. B
This document supports Radial 88, VCD Seq 88, and Jumper Wire 88 machines.
Table of Contents
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Use, duplication, disclosure, or transfer restricted by license from Universal Instruments Corporation.
Certain terms are trademarks of Universal Instruments Corporation in the United States and/or other countries. For a list of Universal Instruments
Corporation trademarks, see www.uic.com. All other trademarks are the property of their respective corporations.
Functional Description .................................................................................................................................................. 1
Troubleshooting Concept .............................................................................................................................................. 1
Troubleshooting............................................................................................................................................................. 1
Troubleshooting Techniques ............................................................................................................................... 2
IM Diagnostics ........................................................................................................................................... 2
Machine JOG Mode ................................................................................................................................... 2
Pneumatic Valve Actuators ........................................................................................................................ 3
Troubleshooting Tables ....................................................................................................................................... 3
Machine Sequence of Events ..................................................................................................................... 3
VME System .............................................................................................................................................. 4
Troubleshooting Table - Electrical System ................................................................................................ 8
Troubleshooting Table - Pneumatic System .............................................................................................. 9
Troubleshooting Table - X-Y Positioning System ................................................................................... 10
Troubleshooting Table - Span Axes System (VCD and Jumper Wire Only) .......................................... 12
Troubleshooting Table - Insert Errors ...................................................................................................... 13
Troubleshooting Table - Process Errors ................................................................................................... 15
Troubleshooting Table - Feeder(Radial Only) ......................................................................................... 16
Troubleshooting Table - Cutter Station (Radial Only) ............................................................................16
Troubleshooting Table - Component Transfer Errors (VCD and Radial Only) ...................................... 17
Troubleshooting Table - Clinch Assembly .............................................................................................. 18
VCD and Jumper Wire Only .......................................................................................................... 18
Radial Only ..................................................................................................................................... 19
Troubleshooting Clinch Problems ..................................................................................................................... 20
Clinch Form Problems ............................................................................................................................. 20
Problem: Lead Lengths Not Equal (VCD and Jumper Wire)......................................................... 20
Problem: Unequal Lead Angle (VCD Only) .................................................................................. 20
Problem: Clinch Leads Toed – Same Direction (VCD and Jumper Wire) .................................... 21
Problem: Clinch Leads Toed – Opposite Directions (VCD and Jumper Wire) ............................. 21
Problem: Misformed Lead(s) with Possible Burr (VCD Only) ...................................................... 22
Problem: Misformed Lead –Various (VCD Only) ......................................................................... 22
Problem: Clinch Not Tight to Board (VCD and Jumper Wire) ...................................................... 23
Clinch Functional Problems ..................................................................................................................... 24
Sequence of Adjustments................................................................................................................................... 24
Radial ....................................................................................................................................................... 24
VCD ......................................................................................................................................................... 26
Sequencer Section........................................................................................................................... 26
Inserter Section ............................................................................................................................... 27
Before Calling Technical Support ..................................................................................................................... 28
Changes To This Revision........................................................................................................................................... 30
Page 1
IM Troubleshooting 52489101 Rev. B
This document supports Radial 88, VCD Seq 88, and Jumper Wire 88 machines.
Functional Description
This document provides troubleshooting information for the electrical and
mechanical parts of the following machines:
• Radial 88
• VCD Seq 88
• Jumper Wire 88
Troubleshooting Concept
The troubleshooting procedures in this module identify specific maintenance
requirements to be used when performing maintenance on the machine. Refer
to the specific assembly support document for detailed information
pertaining to the procedures presented.
Troubleshooting
The purpose of this section is to provide the maintenance technician with
information on how to troubleshoot the insertion machine.
Troubleshooting is the process of evaluating a fault condition and isolating
the condition to a cause.
The cause may be evident by the physical condition of the machine and the
point in the operational cycle where the machine malfunctioned.
Where the cause is not evident, various troubleshooting techniques, presented
in this section, should be followed to determine the specific area and/or
component that caused the malfunction.
The insertion machine contains various features that are intended to assist the
technician in the troubleshooting procedure. These elements include the IM
Diagnostics functions, the pneumatic valve actuators, and the troubleshooting
tables.
Before performing the troubleshooting techniques, ensure that the following
criteria have been met.
1. The maintenance technician understands the sequence of events. Refer
to the Machine Operation Guide.
2. The correct pattern programs are resident and the correct program
selected. Refer to the following manuals:
• IM-UPS Reference Manual
• IM Diagnostics Reference Manual
Page 2
52489101 Rev. B IM Troubleshooting
This document supports Radial 88, VCD Seq 88, and Jumper Wire 88 machines.
• Machine Operation Guide
CAUTION
When performing troubleshooting procedures on machine electronics,
wear a wrist strap connected to ground to prevent electrostatic
discharge (ESD) damage to printed circuit boards and encoders.
WARNING
Do not adjust electrical switches or assemblies so that they actuate
switches unless the Emergency Stop switch on the machine is pushed
down or unless the procedure specifically says to have the Emergency
Stop switch released. Failure to press the Emergency Stop switch
before adjusting a switch or moving an assembly to actuate a switch
might result in personal injury.
Troubleshooting Techniques
The following troubleshooting techniques provide various methods for
isolating machine problems.
IM Diagnostics
The IM Diagnostics technique allows the user to display machine operational
feedback on the operator interface. Passive and active diagnostics routines
are available.
Passive diagnostics allows the user to determine the status of the controller
and each machine function that is input or output from the controller.
Refer to the IM Diagnostics Manual for detailed information on how to
perform diagnostics.
The machine IM diagnostics supplies a clear description of the machine
condition. This information is accessed through the operator interface, while
accessing various screens that allow machine interaction and informational
feedback.
Machine JOG Mode
The JOG mode allows machine operation to be manually controlled.
Incremental steps are executed, one function at a time, each time the Jog
button is selected in IM Diagnostics. In this manner, each function can be
observed as it occurs allowing the cause of a specific problem to be more
easily determined.