CAB MAESTRO 6 User manual

Operator's Manual
MAESTRO 6
PCB Searator

2
Description Type
PCB Separator MAESTRO 6
Edition: 12/2018 Part No.: 9003354
Copyright
This documentation as well as translation hereof are property of cab Produkttechnik GmbH & Co. KG.
The replication, conversion, duplication or divulgement of the whole manual or parts of it for other intentions than its original
intended purpose demand the previous written authorization by cab.
Editor
Regarding questions or comments please contact cab Produkttechnik GmbH & Co. KG.
Topicality
Due to the constant further development of our products discrepancies between documentation and product can occur.
Please check www.cab.de for the latest update.
Terms and conditions
Deliveries and performances are effected under the General conditions of sale of cab.
This Operator's Manual is delivered to the device:
Operator's Manual - Translation of the Original Version
for the following products
Germany
cab Produkttechnik GmbH & Co KG
Karlsruhe
Phone [phone]
www.cab.de
USA
cab Technology, Inc.
Chelmsford, MA
Phone [phone]
www.cab.de/us
Taiwan
cab Technology Co., Ltd.
Taipei
Phone [phone]
www.cab.de/tw
China
cab (Shanghai) Trading Co., Ltd.
Guangzhou
Phone [phone]
www.cab.de/cn
France
cab Technologies S.à.r.l.
Niedermodern
Phone [phone]
www.cab.de/fr
Mexico
cab Technology, Inc.
Juárez
Phone [phone]
www.cab.de/es
China
cab (Shanghai) Trading Co., Ltd.
Shanghai
Phone [phone]
www.cab.de/cn
South Africa
cab Technology (Pty) Ltd.
Randburg
Phone [phone]
www.cab.de/za

3
Table of Contens
1 Introduction............................................................................................................................................4
1.1 Instructions...............................................................................................................................................4
1.2 Intended Use............................................................................................................................................4
1.3 Safety Instructions....................................................................................................................................4
1.4 Safety Marking.........................................................................................................................................5
1.5 Environment.............................................................................................................................................5
2 Technical Data........................................................................................................................................6
3 Contents of Delivery..............................................................................................................................7
4 Control Panel..........................................................................................................................................8
5 Installation..............................................................................................................................................9
5.1 Electrical Links.........................................................................................................................................9
5.2 Adjustable Platform..................................................................................................................................9
5.3 Switch on................................................................................................................................................10
5.4 Adjustment the distance between Circular and Linear Blade..................................................................11
5.5 Recommendation for cutting Circular Blade 60......................................................................................12
5.6 Recommendation for cutting Circular Blade 125 / 185 (FR4) ................................................................12
5.7 Adjustment the Cut Length.....................................................................................................................13
5.8 Reset the counters.................................................................................................................................13
5.9 Setting the speed of cut .........................................................................................................................14
5.10 Select the cut mode ..............................................................................................................................15
6 Operation..............................................................................................................................................16
7 Types of Circular Blades .....................................................................................................................17
7.1 Circular Blade
Ø 60.................................................................................................................................17
7.2 Circular Blade Ø 125...............................................................................................................................17
7.3 Circular Blade Ø 185...............................................................................................................................18
8 Replacement of the Blades.................................................................................................................19
8.1 Circular Blade
Ø 60.................................................................................................................................19
8.2 Circular Blade Ø 125/185........................................................................................................................19
8.3 Removal and installation of linear blades...............................................................................................20
8.4 Aligning the linear blade.........................................................................................................................20
8.5 Change of blade type.............................................................................................................................21
8.6 Alignment of the blade carriage .............................................................................................................21
9 EU Declaration of Conformity.............................................................................................................22

4
1.1 Instructions
Important information and instructions in this documentation are designated as follows:
Danger!
Draws your attention to an exceptionally grave, impending danger to your health or life.
!
Warning!
Indicates a hazardous situation that could lead to injuries or material damage.
!Attention!
Draws attention to possible dangers, material damage or loss of quality.
iNotice!
Gives you tips. They make a working sequence easier or draw attention to important working processes.



Environment!
Gives you tips on protecting the environment.
Handling instruction
Reference to section, position, illustration number or document.
Option (accessories, peripheral equipment, special ttings).
1.2 Intended Use
• The device is manufactured in accordance with the current technological status and the recognized safety rules.
However, danger to the life and limb of the user or third parties and/or damage to the device and other tangible
assets can arise during use.
• The device may only be used for its intended purpose and if it is in perfect working order, and it must be used with
regard to safety and dangers as stated in the operating manual.
• The device is intended exclusively for separating pre-scored PCB's. Any other use or use going beyond this shall
be regarded as improper use. The manufacturer/supplier shall not be liable for damage resulting from unautho-
rized use; the user shall bear the risk alone.
• Usage for the intended purpose also includes complying with the operating manual, including the manufacturer‘s
maintenance recommendations and specications.
iNotice!
The complete documentation can also currently be found in the Internet.
1.3 Safety Instructions
• The device is congured for voltages of 115 or 230 V AC. It only has to be plugged into a grounded socket.
• Hazard by electrical charge. Provide an earthing connection via press stud.
• Only connect the device to other devices which have a protective low voltage.
• Switch off all affected devices (e.g. conveyor belt) before connecting or disconnecting.
• Risk of hand injury. Wear protective gloves while PCB separating.
• Ensure that people‘s clothing, hair, jewelry etc. do not come into contact with the exposed rotating blade.
• In an emergency situation, actuate the emergency stop switch in the control panel by tight pressing. This inter-
rupts the voltage supply to the device.
• The device may only be used in a dry environment, do not expose it to moisture (sprays of water, mists, etc.).
• Do not use the device in an explosive atmosphere.
• Do not use the device close to high-voltage power lines.
• Work going beyond this may only be performed by trained personnel or service technicians.
1 Introduction

5
• Unauthorized interference with electronic modules or their software can cause malfunctions.
• Other unauthorized work on or modications to the device can also endanger operational safety.
• Always have service work done in a qualied workshop, where the personnel have the technical knowledge and
tools required to do the necessary work.
• There are various warning stickers on the device. They draw your attention to dangers.
Warning stickers must therefore not be removed, as then you and other people cannot be aware of dangers and
may be injured.
Danger!
Danger to life and limb from power supply.
Do not open the device casing.
1.4 Safety Marking
1Emergency Switch
Press it in a hazardous situation!
2Risk of hand injury!
Wear protective gloves while PCB separating.
3Possible damage of electronics!
Disconnect the PCB separator from the electrical outlet before mounting or
removing an optional conveyor belt.
4Hazard by electrical charge!
Provide an earthing connection via press stud.
Table 1 Safety marking
1.5 Environment



Obsolete devices contain valuable recyclable materials that should be sent for recycling.
Send to suitable collection points, separately from residual waste.
The modular construction of the printer enables it to be easily disassembled into its component parts.
Send the parts for recycling.
1 Introduction

62 Technical Data
MAESTRO 6/X03 MAESTRO 6/X01
Technical data 6/603 6/903 6/1203 6/1503
Type of Component side 3 circular blades adj. one by one
separation Solder side linear blade
Separation path-optimized
Separation speed up to mm/s 500
250 with aluminum
Material FR4, CEM3, aluminum
Separation length up to mm 600 900 1,200 1,500
Support table depth mm 160
Buttons
- Home / Error acknowledgment during operation
- Adjustment of initial carriage position
- Adjustment of nal carriage position
- Separate carriage movement to and fro
- Continuous carriage movement to and fro
- Separation speed increase
- Separation speed reduction
- “Number of separations”selection
- “Separation length”selection
- Deletion of current selection
With a conveyor belt in use
- Start conveyor belt
- Adjustment of belt speed
Power switch ON/OFF
Foot switch START separating
Safety switch E-stop
Power supply 100 - 240 VAC, 50/60 Hz
Emission sound pressure level LpA < 70 dB (A)
Temperature / Operation +5 - 40°C / 10 - 85 % not condensing
humidity Storage 0 - 60°C / 20 - 80 % not condensing
Transpor t –25 - 60°C / 20 - 80 % not condensing
Weight kg 50 55 - -
Height x Depth mm 350 x 450
Width mm 1,150 1,450 1,750 2,050
Approvals CE, FCC
Technical data 6/601 6/601.70 6/901
Type of Component side 1 circular blade
separation Solder side linear blade
Separation path-optimized
Separation speed up to mm/s 500
Material FR4, CEM3
Separation length up to mm 600 900
Support table depth mm 160
Buttons
- Home / Error acknowledgment during operation
- Adjustment of initial carriage position
- Adjustment of nal carriage position
- Separate carriage movement to and fro
- Continuous carriage movement to and fro
- Separation speed increase
- Separation speed reduction
- “Number of separations”selection
- Auswahl der Anzeige „Schnittlänge“
- “Separation length”selection
With a conveyor belt in use
- Start conveyor belt
- Adjustment of belt speed
Power switch ON/OFF
Foot switch START separating
Safety switch E-stop
Power supply 100 - 240 VAC, 50/60 Hz
Emission sound pressure level LpA < 70 dB (A)
Temperature / Operation +5 - 40°C / 10 - 85 % not condensing
humidity Storage 0 - 60°C / 20 - 80 % not condensing
Transpor t –25 - 60°C / 20 - 80 % not condensing
Weight kg 50 55
Height x Depth mm 410 x 450
Width mm 1,150 1,450
Approvals CE, FCC
Table 2 Tecnical Data

7
3 Contents of Delivery
5
7
4
2
1
3
6
Fig.1 Contents of Delivery
1 Maestro 6
2 Power Cable
3Dial Gauge Assembly
4 Food Switch
5 Hexagonal Wrench
DIN911 2,5mm
6 Hexagonal Wrench
DIN911 4mm
7 Hexagonal Wrench
DIN911 5mm
8 Documentation

8
8
7
6
21 45
3
11 12 13 15 16 17 18 19 20 21109 14
Fig.2 Control Panel
1Emergency Switch Press it in a hazardous situation!
2LED home Is blinking in case of device is outside home position.
3Taste home - To run the device in home position after switching on
- Quit errors in operation
4 LED forward and
backward separate Lights up when the separate forward and backward movement mode of the blade carriage is activated.
5 Button forward and
backward separate Activation of the blade carriage movement mode forward and backward separate.
6 Display speed Display the selected speed.
7 Display cut count /
mileage Display the cut count or the mileage (cut length).
8LED conveyor belt Indicates the activation of a connected conveyor belt.
9 Button conveyor belt Activation of a connected conveyor belt.
10 Button conveyor belt
speed Function button to set the spped of the conveyor belt in combination with the button speed 1 and speed 2.
11 Button Position 1 Set Position 1 of the cut length.
12 Button Position 2 Set Position 2 of the cut length.
13 LED forward and
backward continued Lights up when the forward and backward movement mode of the blade carriage without interruption is activated.
14 Button forward and
backward continued Activation of the forward and backward movement mode of the blade carriage without interruption.
15 Button speed 1 Increase the speed of the blade carriage and the speed of the conveyor belt
while pressing the button conveyor belt speed.
16 Button speed 2 Reduce the speed of the blade carriage and the speed of the conveyor belt
while pressing the button conveyor belt speed.
17 LED cut count In case of activated display cut count.
18 Button cut count Selection of the display cut count.
19 Button DEL Reset display cut count or mileage
20 LED mileage In case of activated display mileage (cut length).
21 Button mileage Selection of the display mileage (cut length)
Table 1 Control Panel Elements
4 Control Panel

9
5 Installation
5.1 Electrical Links
!Attention!
The device and printing materials will be damaged by moisture and wetness.
Set up the device only in dry locations protected from splash water.
i
Notice!
Clean the blade with a soft cloth before you start the machine at rst time!
7
4
5
3
2
1
6
Fig.3 Connections
Set up device on a level surface. For a secure stand you can change the foot highness by turning.
Put in the foot switch round connector (4) from the foot switch (7) in the 5 pin female connector (2) and tighten it.
Connect the electrical ground on the earth connection (6).
Switch off the power module (1).Connect the power cable (5) to the power input module (3) and to an earthed socket.
5.2 Adjustable Platform
2
1
Fig. 1 Adjustable platform
The adjustable platform delivered with the machine is designed for use as a hand-rest, easing the placement of the
PCB on the lineal blade. Thereby it is also preventing a possible premature tiring for the user.
1. By turning the knurled screw (2), the platform (1) can be raised or lowered sensitively. Rotating the knurled screw
anti-clockwise will lift up the platform.

10
iNotice!
The device offers the possibility to separate the circuit board benets in several steps and thus gently.
The cutting is more gentle for the PCB's with a higher number of cuts.
5.3 Switch on
1. Switch on the device by power switch (1). LED home is blinking
iNotice!
Are all connections ready and the device is swiched on and not in function check the emergency swith!
1
Fig.4 Power Switch
Fig. 2 Taste home drücken.
2. Press button home. .
3. Device will run to the home position and the LED home is permanently on.
5 Startup

11
5.4 Adjustment the distance between Circular and Linear Blade
1
5
6
7
1
2
4
3
Fig. 3 Adjustment the blade distance
The following settings apply to all three circular blades and must be done individually.
1. Loosen the clamping lever (4) by turning it counterclockwise until the adjusting knob (1) can be turned.
2. Turn the adjusting knob (1) to the desired value.
One graduation corresponds to 0.1 mm distance between the circular blade (6) and the linear blade (7)..
For orientation, the mark (5) on the carriage housing is used.
With the screw (2) screwed in, the circular blade can be turned down to a minimum distance of 0.03 mm from the
linear blade.
This serves to protect the knives in conguration FR4!
only for Al circular blades (
Ø 60 8936507.001)
With the Al-blades installed unscrew the screw (2) to set the roller blade at a negative distance to the linear blade.
Thats only for Al-blades due to the lateral offset of theAl knives to the linear knife.
The screw (3) now secures the lower stop at -0.4 mm and must not be unscrewed.
+
0
-
FR4-blade Al-blade (
Ø 60 8936507.001)
Fig. 4 Blade offset
!
Attention!
When using FR4 blades, always leave the stop screw (2) tightened to avoid contact between the roller
blade and the linear blade.
The stop screw (2) prevents the setting of a negative value for the distance.
5 Startup

12
5.5 Recommendation for cutting Circular Blade 60
depend of notch thickness and cut mode
Restdicke
iNotice!
The cutting is more gentle for the PCB's with a higher number of
cuts.
The deepness of the last cut must be so that the PCB's are easily to
separate.
The values are recommendation and it's possible to change it if it is
necessary.
number of blades in direction of cutting
123
direction of cutting Omode
Fig. 5 Arrangement of the blades
Recommendation for FR4 boards
Notch thickness cutting mode
settings in direction of cutting Blade 1 Blade 2 Blade 3
0,3 mm O0,25 mm 0,15 mm 0,10 mm
F0,20 mm 0,10 mm 0,20 mm
0,4 mm O0,30 mm 0,20 mm 0,10 mm
F0,25 mm 0,15 mm 0,25 mm
0,5 mm O0,40 mm 0,25 mm 0,15 mm
F0,35 mm 0,15 mm 0,35 mm
0,6 mm O0,45 mm 0,30 mm 0,15 mm
F0,40 mm 0,20 mm 0,40 mm
0,7 mm O0,55 mm 0,35 mm 0,20 mm
F0,45 mm 0,25 mm 0,45 mm
0,8 mm O0,60 mm 0,40 mm 0,20 mm
F0,55 mm 0,25 mm 0,55 mm
Table 3 Distance between the blades for circular blade 60 - circular blade to linear blade
5.6 Recommendation for cutting Circular Blade 125 / 185 (FR4)
FR4
Notch thickness Distance between the
blades
0,3 mm 0,15 mm
0,4 mm 0,20 mm
0,5 mm 0,25 mm
0,6 mm 0,30 mm
0,7 mm 0,35 mm
0,8 mm 0,40 mm
Table 4 Distance between the blades for circular blade 125 /185 - circular blade to linear blade
5 Startup

13
5.7 Adjustment the Cut Length
iNotice!
The adjusted cut length must be orientated on the separated PCB. Then, the display "mileage" for the cut
length shown a realistic value.
1 2
Cut length
P1 P2
Cut direction
Fig. 6 Limit cutting length
1. Press P1 (1) until the blade carriage has moved to position P1.
2. Press P2 (2) until the blade carriage has moved to position P2.
The cutting length results from the distance between the front edge of the carriage (in the cutting direction) in the
position P1 and the trailing edge of the carriage (in the cutting direction) in the position P2.
5.8 Reset the counters
2 3 4
51
Fig. 7 Display section counter
Display (2) select count cunt (number of cuts) or (4) mileage (cut length).
Press the button (3) for approx. 3 seconds to reset the display (5) to zero.
Display speed (1) lights for the duration of the counter reset.
5 Startup

14
5.9 Setting the speed of cut
2
3
1
Fig. 8 Setting the speed
It is possible to set the speed level in 5 steps.
The speed level is displayed in the speed (1) display.
Step Speed of the blades
1≙100 mm/sec
2≙200 mm/sec
3≙300 mm/sec
4≙400 mm/sec
5≙500 mm/sec
1. Press key (2) to increase the speed by one step.
2. Press key (3) to reduce the speed by one step.
5 Startup

15
5.10 Select the cut mode
2
1
Fig. 9 Cut mode
Mode (1)
- Press the foot switch and the carriage only moves in one direction between P1 and P2.
- Press the foot switch again and the carriage moves in the other direction between P1 and P2.
There are only two cutting depths adjustable, as in both directions of the carriage movement can be cut.
 „5.5 Recommendation for cutting Circular Blade 60“
1. Mode (2)
- Press footswitch and carriage moves in one direction between P1 and P2
and then moves back to position P1.
There are three cutting depths adjustable, because only in one direction of the carriage movement is cut,
from P1 to P2
 „5.5 Recommendation for cutting Circular Blade 60“
5 Startup

16
Switch on the device by power switch (1). LED home is blinking..
1
Fig. 10 Power Switch
1. Press button home.
2. Device will run to the home position LED home is permanently on.
3. Press the foot-switch and hold it.
- Device will run to the start position (dened by P1) or from the start position short out and back into the start
position.
- Blade synchronization.
4. Deblock the foot switch and the device is ready. LED home is permanently on.
5. Choose mode or mode . Chapter 5.10
6. Put in the PCB panel.
Pre-scored groove in the PCB (2) put onto the linear blade (3) and hold the PCB in the horizontal plane by hand.
Ensure that the PCB is positioned within the area between and , the pre-selected area of cutting way of
the upper blade. Chapter 5.7
2
3
Fig. 11 Put on PCB
7. Press the foot-switch to start the program. Foot-switch must be pressed over the length of the program.
Press the foot-switch and hold it. Device performs a cut without return transport of the blade carriage.
Deblock and press the foot-switch again to start the next cut in the reverse direction.
Press the foot-switch and hold it. Device performs a cut with return transport of the blade carriage.
8. Deblock the foot-switch after program end.
iNotice!
In the mode Fwill be an other start position for the next program start.
6 Operation

17
7 Types of Circular Blades
7.1 Circular Blade
Ø 60
Fig. 12 Version with 3x circular blade 60
The version with circular blade60 is available in an arrangement of a row with tree blades. So it's possible to adjust a
different cutting depth per blade and to cut aluminum PCB's.
Fig. 13 Free space - possible height of components for circular blade 60
7.2 Circular Blade Ø 125
Fig. 14 Version with circular blade 125
The version with circular blade 125 is intended to cut FR4 PCB's with component height until 33mm
Fig. 15 Free space - possible height of components for circular blade 125

18
7.3 Circular Blade
Ø 185
Fig. 16 Version with circular blade 185
The version with circular blade 185 is intended to cut FR4 PCB's with component height until 63mm.
Fig. 17 Free space - possible height of components for circular blade 185
7 Types of Circular Blades

19
8 Replacement of the Blades
In case of wasting, damage or material cahange it's necessary to change the upper blade.
Risk of hand injury!
Wear protective gloves while changing the blade.
!
Danger!
Risk of cutting damage by rotating blade!
Disconnect device before you start service work!
8.1 Circular Blade Ø 60
321 3214
5
Fig. 18 Replacement of the Upper Circular Blade 60
1. Set the setting knob (5) on value 9 - blade on the highest position.
2. Fix the rotary disc (4) by a 5 mm Hexagon wrench.
3. Loosen screw (3) by a 4 mm Hexagon wrench.
4. Take out screw (3) and washer (2) and blade (1).
5. Place the new circular blade (1) on the shaft with the inclined side towards the unit and push it on completely.
6. Put in washer (2) and screw (3) and tighten screw (3) .
7. Adjust the blade distance.
8.2 Circular Blade Ø 125/185
321 4
1. Loosen screw (4).
2. Take out screw (4) and washer (3).
3. Unplug the circular blade (2) from the shaft (1).
4. Place the new circular blade (2) on the shaft (1) with the
inclined side towards the unit and push it on completely.
5. Put in washer (3) and screw (4) and tighten screw (4) .
6. Adjust the blade distance.
Fig. 19 Replacement of the Upper Circular Blade 125/185

20
8.3 Removal and installation of linear blades
321 224 35
Fig. 20 Blade change - Linear blade
1. Disassemble the support platform.
2. Loosen screws (4).
3. Remove the linear blade (3) and remove the eccentric (2) or the guide pin (5) on the right-hand linear blade.
4. Thoroughly clean blade, knife and prole (1) before mounting the new linear blade (3).
5. Insert the guide pin (5)into the right side and into the other corresponding openings the eccentric (2).
6. Mount the liner blades from the right and tighten the screws (4) only slightly.
7. Now make the horizontal alignment of the linear blades (3). next chapter
8.4 Aligning the linear blade
121
3
4
Fig. 21 Aligning the linear blade with dial gauge
1. Remove the dial gauge (3) from the accessory pack of the
MAESTRO 6 and t it to the angle arm (4).
2. Srew angle arm (4) with built-on dial gauge (3) to the side
of the blade carriage.
3. The dipstick of the dial gauge (3) must be pressed in
slightly. about 5mm.
4. Turn the roller blade upwards to avoid collision with the
linear blade (2).
5. Starting with the right blade, adjust the horizontal
alignment.
Move slowly over the linear blade with the carriage
and compensate for deviations on the dial gauge by
turning the eccentric (1).
Repeat this process until the deviations over the entire
length of the linear knife maximum 0.03 mm.
Tighten screws (4) of gure 24.
The right linear blade is set rst and serves as a
reference.
8 Replacement of the Blades