DOMAILLE ENGINEERING HDC-5200 User manual

APM MODEL
HDC-5200
OPTICAL FIBER
POLISHING
MACHINE
USER’SGUIDE
DomailleEngineering,LLC
7100DresserDriveNE
Rochester,MN55906
Phone507.281.0275•Fax507.281.5694
www.DomailleEngineering.com
Domaille Engineering LLC

TABLE OF CONTENTS
Welcome
Overview..............................................................................................................1
Getting Started
Unpacking & Setup ............................................................................................2
Precautions ..........................................................................................................3
Machine Diagram
Front View.....................................................................................................4
Back View ......................................................................................................5
Machine Setup
Initial Setup..........................................................................................................6
System Configuration.........................................................................................6
Load Cell Calibration.................................................................................... 7
Process Variables: Setting & Copy/Backup Procedure ...........................8
User Rights & Settings ...............................................................................10
Process Setup ....................................................................................................14
Inter-Machine Process Transfer .....................................................................17
Deleting Processes............................................................................................18
Machine Operation
Polishing Fixture Installation ..........................................................................19
Polishing Pad and Film Placement.................................................................20
Machine Operation...........................................................................................20
Power Up .....................................................................................................20
Polishing Process Selection and Polishing Procedure............................21
Rework Start Step .......................................................................................22
Pause Step ....................................................................................................22
Reset Step.....................................................................................................22
Select Step ....................................................................................................23
Cancel Polishing Process ...........................................................................23
Machine Shut Down .....................................................................................23
Machine and Polishing Fixture Maintenance
Daily ...................................................................................................................24
Monthly..............................................................................................................25
Service & Support
Technical Specifications...................................................................................28
CE Notice..........................................................................................................29
Limited Warranty..............................................................................................30
Company Information ...................................................................................... --
WelcomeWelcome
Congratulations on selecting the APM HDC-5200, the premier fiber optic con-
nector polishing machine.
This User’s Guide will assist you in the set up, operation, and maintenance of the
APM HDC-5200 machine to maximize the use and life of this equipment.
Overview
The APM HDC-5200 is designed to address the need to efficiently polish a large
volume of connectors while maintaining a consistent high level of quality.
The APM HDC-5200 allows you to program your processes through an easy-to-use
touch-screen panel. The panel displays your programmed settings for speed, time,
pressure, polishing film used, lubricant type and pad durometer. In addition, the
user can program specific ramp up speed and pressure setting, set maintenance in-
tervals and program polishing film counters. Operators need minimal training to
follow the touch-screen prompts of your programmed processes.
The number of processes that can be defined and stored within the HDC-5200
machine is only limited by the amount of internal memory. This means hundreds of
processes can be stored on a single machine. Additionally, the HDC-5200 provides
you with total flexibility in the number of steps you define within each of your pol-
ishing processes
The APM HDC-5200 provides the capability to store your processes in machine
memory as well as on a USB storage device. A USB storage device can be used to
backup your defined processes and to copy processes from one machine to another.
This not only saves process setup time for each machine, but also ensures consistent
process settings.
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Getting StartedGetting Started
Unpacking & Setup
NOTE: Due to the weight of the APM HDC-5200, it is recommended that
two people lift it from the shipping case.
1. Remove all loose components from machine area in shipping case.
2. Remove the plastic bag from around the Overarm to provide access to
the Overarm.
3. Use the Overarm as a lifting handle by grabbing as close to the Overarm
pivot point as possible.
Lift the machine straight up while firmly holding the case down on the
outside edges. If the machine is lifted at an angle, it will cause binding in
the case.
Gently place the machine on a suitable, stable work surface.
4. Remove remaining plastic wrapping from machine and touch screen
panel.
5. Inspect the machine for any damage that may have occurred in shipping.
6. Remove the blue Koby Air Filter from the shipping case. Remove plastic
cap from air supply fitting on back of machine. Connect plastic air line
provided by pushing line firmly into fitting. Connect other end of air line
to black capped end of Koby Air Filter.
7. Using the proper air supply fittings, connect the red capped end of the
Koby Air Filter into your compressed air system. The inlet of the Koby
Air Filter is ¼” NPT pipe thread. The compressed air requirements are:
80-120 pounds per square inch (5.5—8.5 bar), clean, dry, oil-free air.
8. Remove Cable Management Bracket located in side compartment of
shipping case. Remove the two thumb screws on back of machine.
Attach Cable Management Bracket by sliding the base tabs into the slots
provided on the machine. Reattach screws to secure.
A 1/4” (6 mm) rod can be inserted through the holes on the cable man-
agement system to extend its width.
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9. Connect Drain Hose provided to Drain Hose Fitting on back of ma-
chine. Route Drain Hose to a collection container.
10. In order to raise and lower the Overarm, you must release the Over-
arm locking mechanism. Press the Overarm Quick-Release button
located at the front of the Overarm and lift up. Releasing the Quick
-Release button will allow the Overarm to lock in one of three fixed
positions.
Remove foam placed under the Overarm shaft by raising the Overarm
to the vertical position and locking in place.
11. Remove Drip Tray and Drip Tray Bracket. The Drip Tray can be at-
tached on either the left of right side of the machine. This diagram illus-
trates how the Drip Tray Bracket slides
onto the back right corner of the machine
(when facing machine). Place the bracket
snug against the corner and firmly tighten
the bracket screw. Slide the Drip Tray rod
into the bracket hole.
Precautions
For safe, effective operation of the HDC APM-5200 Polishing Machine, please
observe the following:
 Keep hands, jewelry, hair and loose clothing away from the r o t a t i n g
Platen while the machine is in operation.
 Keep all surfaces of the machine clean at all times. Confine water and
slurry to Platen area.
 WARNING: Do not use an air hose on or around the P l a t e n .
This forces water and contaminants into the wear surfaces and
mechanical drive unit, potentially causing machine failure.
Damage caused by air hose use is not covered under warranty.
 Do not attempt to repair or service any components inside the APM
HDC-5200 machine. Contact Domaille Engineering, LLC if service is
required.
 Use only the stylus provided or fingers when touching screen panel.
Do not use sharp objects.
3

4
Cable Management System
Overarm
Quick-Release Button
Drip Tray
Platen
Step Start
Button
Step Pause
Button
Step
Reset
Button
Touch Screen
Machine
Start Button
Emergency
Stop Button
(EPO)
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Power Switch Air Supply Fitting
Drain Hose Fitting
Fan Filter
USB Port

Precautions
For safe, effective operation of the APM-4000 Polishing Machine, please ob-
serve the following:
 Keep hands, jewelry, hair and loose clothing away from the rotating platen
while the machine is in operation.
 Keep all surfaces of the machine clean and dry at all times.
 WARNING: Do not use an air hose on or around the platen. This
forces water and contaminates into the wear surfaces and mechanical
drive unit, thus causing failure.
 Do not attempt to repair or service inside the APM4000. Contact Do-
maille Engineering, LLC if service is required.
 The APM is capable of operating between air temperatures of 5ºC and
40ºC.
 The APM is capable of operating at a maximum altitude of 1000M above
sea level.
 Noise emitted by the APM is less than 70.0dBA.
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Machine SetupMachine Setup
Initial Setup
Before operating the APM HDC-5200, you must configure the system and define
your processes.
Plug the power cord into the back of the machine and into a properly grounded
outlet—100-240VAC, 50/60Hz. If your power cord is equipped with a large yellow
plug, you MUST push the reset button on the plug to supply power to the machine.
1. Turn on power switch located at the back of the machine.
2. Lift screen cover. (Note: screen cover should be down when machine
is operating.)
3. The touch screen will default to the home tab screen. If the red emer-
gency screen is displayed, reset by turning the Emergency Stop button
clockwise.
4. Press Machine Start button.
System Configuration
System Configuration allows you to set the following:
1. Load cell calibration
2. Process variables
3. User rights and process control settings
4. Maintenance Schedule
Two interface methods are available for entering system configuration data, (1) the
touch screen keypad, or (2) a Windows CE USB keyboard.. If using a keyboard,
plug the USB connection into the port at the back of the machine AFTER the ma-
chine and program have powered up.
Precautions
For safe, effective operation of the APM-4000 Polishing Machine, please ob-
serve the following:
 Keep hands, jewelry, hair and loose clothing away from the rotating platen
while the machine is in operation.
 Keep all surfaces of the machine clean and dry at all times.
 WARNING: Do not use an air hose on or around the platen. This
forces water and contaminates into the wear surfaces and mechanical
drive unit, thus causing failure.
 Do not attempt to repair or service inside the APM4000. Contact Do-
maille Engineering, LLC if service is required.
 The APM is capable of operating between air temperatures of 5ºC and
40ºC.
 The APM is capable of operating at a maximum altitude of 1000M above
sea level.
 Noise emitted by the APM is less than 70.0dBA.
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The following keyboards and keyboard adapters have passed compatibility testing
with the APM HDC-5200:
StarTech PS/2 to USB Keyboard Adapter USB2PS2
Allows use of a standard Windows PS/2 keyboard.
Microsoft Natural Keyboard E06401COMB
Has a PS/2 to USB adapter for USB use included.
Samsung Multimedia Keyboard SEM-M2A
Has integral two port USB hub. No support for the multimedia keys.
Load Cell Calibration
The APM HDC-5200 load cell has been calibrated at Domaille Engineering prior to
shipment. Recalibration is not typically necessary. However, recalibration of the
machine to your own master load cell can be done using the following steps:
1. Remove the polishing fixture from the Overarm and the pad from the
top of the Platen.
2. Clean top of Platen to remove any water, grit or dirt to ensure that the
master load cell will be set on a clean, dry surface.
3. Place the master load cell on the Platen and center it under the Overarm
plunger.
4. On the touch screen, select the System Config. tab, then select Load
Cell Calibration in the “Configuration” box, using the down arrow as
necessary.
5. Raise the Overam just enough for plunger to clear the master load
cell, then press the “Tare” button on the touch screen, checking to see if
master load cell meter is at 0.
6. Lower Overarm onto master load cell, release lock button and press
“Apply Pressure” button on the touch screen to apply a test pressure of
12.00 pounds. Press the “Increase” or “Decrease” button on the touch
screen until the master load cell meter reads 12.00 pounds or matches
the pressure readout on the touch screen.
7. Recalibration is complete. Press the “Span” button on the touch screen
to save the calibration.
If you wish to cancel the calibration at any time during setup, press the
“Cancel” button on the touch screen.

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A “Default Calibration” button appears if the factory calibration has been changed.
Pressing this button will reload factory calibration.
Process Variables: Setting & Copying/Backup Procedures
The APM HDC-5200 allows you to define valid variables that can be used in the defini-
tion of your polishing processes. These variables include (1) a list of polishing films, (2) a
list of types of polishing pads, (3) a list of lubricants that can be defined for polishing
processes, (4) Film Change Interval settings. A maximum quantity of connectors (Max
Quantity) setting is displayed, but not modifiable at this time.
To modify process variables, first select the System Config. tab, then select Process Vari-
able Settings in the “Configuration” box, using the down arrow as necessary.
Maximum Quantity Setting:
 This variable has been pre-set to 36 and is not modifiable at this time.
Film Settings:
1. Select “Film” in the “Select Setting” box, using the down arrow as necessary.
2. Touch the “New” button to access the keypad.
3. Type in a film name for your polishing processes.
4. Select “OK”.
5. Repeat the above for all films used in all polishing processes.
The film name can be up to 32 characters in length.
To delete a film name, highlight the name, then touch the “Delete” button.
Pad Settings:
1. Select “Pad” in the “Select Setting” box, using the down arrow as necessary.
2. Touch the “New” button to access the keypad.
3. Type in a pad name for use in your polishing processes.
4. Select “OK”.
5. Repeat the above for all pad types used in all polishing processes.
The pad name can be up to 16 characters in length.
To delete a pad name, highlight the name, then touch the “Delete” button.
Lubricant Settings:
1. Select “Lubricant”, using the down arrow in the “Select Setting” box as
necessary.
2. Touch the “New” button to access the keypad.
3. Type in a lubricant name for use in your polishing processes.
4. Select “OK”.
5. Repeat the above for all lubricant types used in all polishing processes.
The lubricant name can be up to 16 characters.
To delete a lubricant name, highlight the name, then touch the “Delete” button.
Film Change Interval Settings:
1. Select “Film Change Interval”, using the down arrow in the “Select Setting”
box as necessary.
2. Touch the “New” button to access the keypad.
3. Type in a number from 0 to 99 for number of polishing cycles between
polishing film changes.
4. Select “OK”.
5. Repeat the above for all Film Change Interval number used in all polishing
processes.
The Film Change Interval number can be up to 2 characters (0-99).
To delete a Film Change Interval number, highlight the name, then touch the
“Delete” button
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APM HDC-5200 USER’S GUIDE
Copy/Backup Procedure
Once your variable settings have been established, they can be copied to a USB data
storage device. This allows process variable data to be transferred to other APM-HDC
-5200 machines as well as providing backup and retrieval capability.
A USB flash drive has been included with the shipment of your APM HDC-5200.
To save process variable data to a USB:
1. Insert USB storage device into USB slot at back of machine.
2. Select System Config. tab, then select Process Variable Settings.
3. Copy settings by selecting “Machine Memory to Memory Card”. You will be
prompted if process variable data already exists on the memory card.
(See NOTE: below for important information.)
NOTE: If the USB storage device already contains variable
data, copying the machine memory to memory card will overwrite the
variable settings on the card. To add process variable data to an already
existing file on a USB storage device, use the following procedure:
1. BEFORE defining process variable data in the machine memory, copy
Memory Card to Machine Memory so that all of your USB storage
settings are contained in the machine memory.
2. Add additional process variable settings as required.
3. Copy from Machine Memory to Memory Card.
User Rights & Settings
The User Rights & Settings screen allows you to define four machine specific parame-
ters, including (1) a password, (2) enablement of connector quantity adjustment by the
operator, (3) enablement of process step selection by the operator, and (4) the display
of pressure in pounds or kilograms.
To modify User Rights & Settings, touch the System Config. tab, then select User
Rights & Settings in the “Configuration” box, using the down arrow as necessary.
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Password Setting
A one to four digit password can be used to password protect the Process Configura-
tion, Process Transfer and System Configuration tabs. One password can be activated
per machine.
When the “Password” box is blank, no password protection is in effect. To activate
password protection and reset the password:
1. Touch “Password” box until large checkmark appears. Current password
will appear in the box to the right.
2. Touch the box with current password in it to access the keypad.
3. Type in a 1 to 4 character password.
4. Select “OK”.
To disable password protection touch “Password” box to un-checkmark box.
Enable Quantity Adjustment
Checking the “Enable Quantity Adjustment” box allows the machine operator to
change the QTY value on the Production tab screen. When this value changes, the
APM HDC-5200 adjusts the pressure in proportion to the original process pressure
value to account for the change in the number of connectors being polished.
For example, if the original process pressure is set at 1.00 lb. and the default number of
connectors for that process is set at 12, and the operator only loads 8 connectors into
the polishing fixture and sets the QTY value on the Production tab screen to 8, the
pressure will automatically be adjusted to 0.67 lbs.
This pressure adjustment due to the change in the QTY value is maintained for one
complete run of the process and then returns back to the original process definition
setting. The change in QTY and Pressure is noted by the yellow highlight of these
values on the Production tab screen.
Touch the “Enable Quantity Adjustment” box to enable and disable this function.
Enable Step Selection
Checking the “Enable Step Selection” box allows the machine operator to start

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polishing at a step other then the first step in the process or to run process steps
out of sequence. If the “Enable Step Selection” box is unchecked, the program
requires that all process steps be run sequentially.
Touch the “Enable Step Selection” box to enable and disable this function.
Pounds or Kilograms
Pressure can be displayed in either pounds (lb) or kilograms (kg). Touch the
“Display Kilograms” box to toggle between these units. A checked box will
display pressure in kilograms and an unchecked box will display pressure in
pounds.
Maintenance Schedule
The maintenance screen allows you to define six specific maintenance parame-
ters including Platen Grease, Fan Filter, Lubricate Lock Pins, Replace Koby Fil-
er, Replace Rubber Pad and Annual Maintenance. This section is also used to
reset values after set parameters are reached.
Setting Platen Grease maintenance schedule
The Platen Grease maintenance is tied to the amount of hours the platen is
rotating. To set the Platen Grease maintenance interval:
1. Use stylus to press the number located under “Hour Interval” tab. This
will access the key pad for data entry.
2. Use key pad to set hours of use before changing platen grease. The
recommended interval is 400 hours. This can be modified as needed based
Setting Fan Filter maintenance schedule
The Fan Filter maintenance is tied to the amount of hours the machine is
powered on. To set the Fan Filter maintenance interval:
1. Use stylus to press the number located under “Hour Interval” tab. This
will access the key pad for data entry.
2. Use key pad to set hours of use before cleaning the Fan Filter. The
recommended interval is 600 hours. This can be modified as needed based
on actual working conditions.
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Setting Lubricate Lock Pins maintenance schedule
The Lubricate Lock Pins maintenance is tied to the amount of hours the platen is
rotating. To set the Lubricate Lock Pins maintenance interval:
1. Use stylus to press the number located under “Hour Interval” tab. This
will access the key pad for data entry.
2. Use key pad to set hours of use before lubricating the Lock Pins. The
recommended interval is 400 hours. This can be modified as needed based
on actual working conditions.
Setting Replace Koby Filter maintenance schedule
The Replace Koby Filter maintenance is tied to the amount of hours the platen
is rotating. To set the replace Koby Filter maintenance interval:
1. Use stylus to press the number located under “Hour Interval” tab. This
will access the key pad for data entry.
2. Use key pad to set hours of use before replacing the Koby filter. The
recommended interval is 5000 hours. This can be modified as needed
based on actual working conditions.
Setting Replace Rubber Pad maintenance schedule
Replacing the Rubber Pad maintenance is tied to the amount of hours the platen
is rotating. To set the replace Rubber Pad maintenance interval:
1. Use stylus to press the number located under “Hour Interval” tab. This
will access the key pad for data entry.
2. Use key pad to set hours of use before replacing the Rubber Pad. The
recommended interval is 3000 hours. This can be modified as needed
based on actual working conditions.
Setting Annual Maintenance schedule
The Annual Maintenance is tied to the amount of hours the platen is rotating. .
To set the Annual Maintenance interval:
1. Use stylus to press the number located under “Hour Interval” tab. This
will access the key pad for data entry.
2. Use key pad to set hours of use before performing Annual Maintenance.
The recommended interval is 5000 hours. This can be modified as needed
based on actual working conditions.

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To re-set a maintenance schedule
Once a maintenance task has reached it set interval, an alarm will be triggered in the
production screen (Maint OK will turn from blue to red). The user will be able to con-
tinue polishing even if the maintenance is not reset. To re-set the maintenance:
1. Go to System Config tab in the menu system.
2. Select Maintenance Schedule from configuration drop down box.
3. All maintenance intervals needing re-set will be highlighted in red.
4. With stylus, press the red re-set tab.
5. The re-set tab will change from red to blue. The hours accumulated
(Accum) will revert to zero hours upon a successful re-set.
Process Setup
The number of processes that can be defined and stored on the APM HDC-5200 is
only limited by the amount of internal memory. Hundreds of processes can be stored
on a single machine. Additional processes can be stored on a USB data storage device,
thus allowing an unlimited number of processes to be pre-defined and readily available
for use.
To define a process:
1. Select the Process Config. tab.
2. A new process can be setup in two ways.
 Select the “New” button to define a process from scratch.
To begin with a copy of an existing process, select the process you want to
copy using the down arrow in the “Process” selection box to display a list
of processes stored in machine memory. Select the desired process to
copy and then touch the “Duplicate” button.
3. Enter a new process name as prompted. The process name can include up
to 16 alphanumeric characters and will not allow spaces, dashes and punctua-
tion. Select “OK”.
4. Select the quantity (QTY) of connectors that will be polished for this process
using the down arrow to display a valid range of numbers. If you have cho-
sen to allow the machine operator to change the quantity on the Production
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screen (based on the number of connectors actually loaded into the fixture),
the maximum connectors the operator can select is based on the number
selected on this screen.
NOTE: Processes can only be deleted under the Process Transfer tab.
Defining steps within a process:
Index tab “A” allows you to define Time, Speed, Speed Ramp Up, Pressure and
Pressure Ramp Up for each step in the process. Index tab “B” allows you to
select Pad, Lubricant, Film, Film Change Interval and Step Notes for each step.
1. Select tab “A”.
2. Touch the “Time” box to access the keypad. Enter the number of seconds
to run this step. Select “OK”.
3. Touch the “Speed” box to access the keypad. Enter the RPM’s desired in
this step. Select “OK”.
4. Touch the “Speed Ramp Up (Sec)” box to access the keypad. This feature
will slow start the platen. Enter the number of seconds desired from zero
RPM to the programmed speed. The maximum value is 20 seconds. Select
“OK”
5. Touch the “Pressure” box to access the keypad. Enter the pressure in
pounds or kilograms, depending on the unit selected in System Config. and
displayed in this box. Select “OK”.
6. Touch “Pressure Ramp Up” box to access keypad. This feature will slow
start the pressure. Enter the number of seconds desire to go from zero pres-
sure to programmed pressure. The maximum value is 20 seconds. Select
“OK”.
7. Select tab “B”. The parameters under tab “B” are used to communicate to
the operator the pad, lubricant, film, film change interval and step notes.
8. Touch the “Pad” down arrow. Select the desired pad for this step in the
process.
9. Touch the “Lubricant” down arrow. Select the desired lubricant for this step
in the process.
10. Touch the “Film” down arrow. Select the desired film for this step in the
process.

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11. Touch “Film Change Interval” box to access keypad. Enter the numeric value
of the number of cycles the film is used for that polishing step. The APM-HDC-
5200 will track the number of uses of the film and send an alarm message when
the film needs to be re-set. The maximum numeric input for the film change
interval is 99. Select “OK”.
12. Touch “Step Notes” box to access key pad. The text box is used to convey pro-
cess information to the users. Enter in pertinent information as needed. Select
“OK”.
13. Select “New” or “Copy” in the Step definition area to define the next step. Repeat
the above instructions for all steps in a process. See Copy Function below to
begin a new step based on a previously defined step within the same process.
Testing During Process Setup: To test a process set while in Process Setup mode,
select the step and press the Step Start Button. This allows you to run and test an indi-
vidual step without having to access the process under the Production tab.
Rework: The “Rework” box allows an operator to restart the polishing process from a
predefined point. The number selected is the step in the process where rework will
begin. The rework program will then execute this step plus all remaining steps. Upon
completion, the program will return to step #1.
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Inter-Machine Process Transfer
The APM-HDC-5200 is equipped with a USB data storage slot. This feature allows
machine-stored processes to be copied onto a USB data storage device, thus allow-
ing duplication of process definitions across multiple APM-HDC-5200 machines.
This feature significantly reduces multiple machine set up time and assures con-
sistency in the definition of polishing processes.
This process transfer feature can also be used as a backup and retrieval tool.
To copy from machine memory to a USB data storage device:
1. Insert USB flash drive into the USB slot.
2. Select Process Transfer tab.
3. Highlight the process name on the “Machine Memory” list that you want
to copy to the memory card.
4. Touch the “<“ button to copy to the USB data storage device.
All processes in machine memory can be copied to the USB storage device by
selecting the “<All” button.
To copy from a USB data storage device to machine memory:
1. Insert USB flash drive into the USB slot.
2. Select Process Transfer tab.
3. Highlight the process name on the “Memory Card” list that you want to
copy to machine memory.
4. Touch the “>“ button to copy to machine memory.
All processes on the USB data storage device can be copied to machine
memory by selecting the “>All” button.
To copy process variable settings refer to the System Configuration section in
this guide. The process variables settings reside in a separate file.