GPD Global CF-9 Operator's manual

Documentation Package
for CF-9 Taped Radial Component Lead Former
PN 901-1-01
CONTENTS of CF-9 Documentation Package
Operating Guide
In addition to installation, set up, and operating
procedures, this guide includes electrical schematics and
maintenance, troubleshooting, spare parts, and
specifications details.
Bills of Material
Includes an illustrated bill of material with associated
part numbers for each CF-9 subassembly.
Die Catalog
Catalog of dies precisely manufactured by GPD Global®
to accurately form Radial components into a wide
variety of component shapes.
Set Up Form
Fill out this Set Up form and then use it as a guide for
consistent results for each component part number.
611 Hollingsworth Street
Grand Junction, CO, USA 81505
tel: +1.970.245-0408
fax: +1.970.245-9674
[e-mail]
www.gpd-global.com

CF-9
Radial Lead Forming Machine
User's Guide
Version 2.1
June 4, 2014
Prepared by
GPD Global
®
Documentation Department
Copyright
©
2014 GPD Global
®
All Rights Reserved
GPD Global®
611 Hollingsworth Street
Grand Junction, CO 81505
[phone]
CF-9 User's Guide CF-9 Radial Lead Forming Machine
Part No. 901-1-07 Serial No.

CF-9 User's Guide
09/30/92 GPD Global i
Warranty
GPD Global (GPD) warrants that this product will be free from defects in material and
workmanship for a period of one (1) year from the date of original purchase. GPD will repair, or
at its option, replace this GPD product during the warranty period at no charge, provided it is
returned (shipping-postage paid) to the GPD, Colorado service facility.
The one year warranty does not cover normal wear and tear to the cutting and forming tooling,
since life usually depends on use.
This warranty does not apply if the GPD product has been damaged by accident, abuse, misuse,
or misapplication, has been modified without the written permission of GPD, or if any GPD serial
number has been removed or defaced.
GPD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES
RESULTING FROM THE BREACH OF ANY EXPRESS OR IMPLIED WARRANTY INCLUDING
ANY COSTS OR DAMAGE TO PROPERTY, AND, TO THE EXTENT PERMITTED BY LAW,
DAMAGES FOR PERSONAL INJURY. THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES. ANY IMPLIED WARRANTIES, INCLUDING IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN
DURATION TO ONE (1) YEAR FROM THE DATE OF RECEIPT OF THIS PRODUCT. GPD'S
LIABILITY ON ANY CLAIM OF ANY KIND INCLUDING NEGLIGENCE, FOR LOSS OR
DAMAGE ARISING OUT OF, CONNECTED WITH OR RESULTING FROM THE BREACH OF
ANY EXPRESS OR IMPLIED WARRANTY OR THE DELIVERY, REPAIR, OR USE OF ANY
GPD PRODUCT SHALL IN NO CASE EXCEED THE PRICE ALLOCABLE TO THE GPD
PRODUCT WHICH GIVES RISE TO THE CLAIM.
Specifications, descriptions, and all information contained in this manual are subject to change
and/or correction without notice.
Although reasonable care has been exercised in the preparation of this manual to make it
complete and accurate, this manual does not purport to cover all conceivable problems or
applications pertaining to this machine.

CF-9 User's Guide
ii GPD Global 09/30/92
Safety Instructions
Symbol samples and definitions for the DANGER, WARNING, CAUTION, IMPORTANT and
NOTE safety notices used in this document are as follows:
** D A N G E R **
Danger notices are used in this document to emphasize life threatening or potentially
harmful situations.
W A R N I N G
Warning notices are used in this document to emphasize chance of injury, harm to life or
limb due largely to something beyond one's control.
C A U T I O N
Caution notices are used in this document to alert one to avoid danger or harm and where
equipment might be damaged if care is not taken.
I M P O R T A N T
Important notices are used in this document to call attention to imperative information.
NOTE
Note is used in this document to call attention to information that is especially significant in
understanding and operating the equipment.

CF-9 User's Guide
09/30/92 GPD Global iii
Table of Contents
Introduction ................................................................ 1
Function ................................................................... 3
Theory of Operation .......................................................... 4
Machine Part Identification ..................................................... 5
PrincipalParts ........................................................ 5
AdjustmentParts ...................................................... 6
Control Panel ......................................................... 7
DieBlockAssembly.................................................... 8
DieMarkings ......................................................... 9
Installation ................................................................. 11
OperatingInstructions ........................................................ 13
Setup ............................................................... 13
DieInstallation .................................................. 14
StationAdjustment............................................... 16
Component Alignment ............................................ 17
Load Components ..................................................... 18
PowerOn ............................................................ 18
Process Components ................................................... 19
PowerOff ............................................................ 19
Preventive Maintenance ...................................................... 21
Troubleshooting ............................................................. 23
SlideTravel .......................................................... 24
SlideClearance ....................................................... 25
Specifications............................................................... 29
Suggested Spare Parts ....................................................... 31
Appendices ................................................................ 33
Appendix A - Die Information ............................................. 35
Appendix B - Common CF-9 Lead Forms ................................... 37
Appendix C - CF-9 Accessories ........................................... 39
Appendix D - Electrical Schematic & Assembly Drawing ....................... 43
Index ...................................................................... 45
Reference CF-9 Component Forming Die Catalog

CF-9 User's Guide
iv GPD Global 09/30/92
Table of Figures
Figure 1 PrincipalParts .................................................. 5
Figure 2 AdjustmentParts ................................................ 6
Figure 3 Control Panel .................................................... 7
Figure 4 DieBlockAssembly,Station1...................................... 8
Figure 5 DieFormingStyleSeries ......................................... 9
Figure 6 Die&StationMarkings ........................................... 9
Figure 7 CF-9Installation................................................. 11
Figure 8 Die Mounting Surface & Die Block Slide .............................. 14
Figure 9 DieAlignment&KnifeClearance ................................... 14
Figure 10 EjectorBrackets................................................. 15
Figure 11 AdjustLargeEjectorBracket ....................................... 15
Figure 12 AdjustSmallEjectorBracket ....................................... 15
Figure 13 StationPositionAdjustment........................................ 16
Figure 14 DieBlockAssemblyAdjustingBolts ................................. 16
Figure 15 Component Position Relative to Tape Hole ........................... 17
Figure 16 Align & Load Components ......................................... 18
Figure 17 Die Block Assembly Lubrication .................................... 21
Figure 18 Die Block Assembly Maintenance ................................... 21
Figure 19 DieBlockAssemblySlideTravel.................................... 24
Figure 20 DieBlockAssemblySlideClearance................................. 25
Figure 21 Die Block Assembly Lubrication .................................... 26
Figure 22 GPD's CF-9 Taping Specification Requirements ....................... 30
Figure 23 FormingStyleSeries ............................................. 35
Figure 24 ExamplesofDieNumbers......................................... 35
Figure 25 ExamplesofDieNumberLocation .................................. 35
Figure 26 Electronic Component Counter Installation ............................ 40
Table of Charts
Chart 1 Preventive Maintenance Schedule .................................. 21
Chart 2 Troubleshooting Guide ........................................... 23

CF-9 User's Guide
09/30/92 GPD Global 1
Introduction
This document is intended for use by those who install, operate and maintain GPD's CF-9 Radial
Lead Forming Machine (GPD Part# CF9.BASE.120 or CF9.BASE.230).
CF-9 Radial Lead Forming Machine
GPD's self-contained CF-9 Radial Lead Forming Machine has become the industry standard for
versatility, accuracy, repeatability, and ease of setup and change over. The CF-9 forms and cuts
to length a wide variety of two- and three-leaded taped radial components such as TO-92's,
capacitors, transistors, and LED's. It processes both standard and special forms precisely and
repeatedly.
Two die stations with standard micrometer scale indicators adjust independently. Performing
adjustments with the micrometer scales enables quick setup of proper forming and/or cutting
settings.
As the first component moves through the system, it is presented to two die stations. The first
die station is generally used to form components, and the second to cut components from the
tape. Depending on the components being processed and the desired component lead form,
the second station may be used to both cut and form, just cut, or be excluded in order to leave
components on tape.
The indexing system, the heart of the CF-9, drives the studded transfer belt. The studs, or pins,
on the belt pick up the tape holes and index exactly 1/2" (12.70 mm) every time.
The CF-9 is ruggedly constructed of heavy duty parts and sealed ball bearing shaft assemblies
for low maintenance. All of the machine's parts are precisely made and treated to prevent
corrosion, enhance appearance, or facilitate proper function.
The tape roller guide includes studded protrusions to hold the component tape solidly in place —
the tape cannot run off the drive belt mechanism. Waste tape feeds down a tape exit chute and
out to the side of the machine for easy disposal.
The CF-9's capabilities expand with its Loose/Bulk Component Feeder and Automatic Taped
Component Re-reeler accessories by combining the functions of several machines into one.
Additional accessories such as the Electronic Component Counter, Component Detection
System, Lazy Susan, Work Station, and Footswitch are also available to help increase your
production and profit.

CF-9 User's Guide
2 GPD Global 09/30/92
CF-9 Lead Forming Dies
The CF-9 offers unique versatility through the use of a large selection of dies. The CF-9
operates on a system of dies and die blocks. Each die combination is designed to form a
specific lead configuration. Numerous standard and special CF-9 Lead Forming Die sets are
available to provide a variety of component forms and lead configurations. Many different die
sets for various transistor hole patterns are also available.
A minimal amount of preparation time is required to reset the machine for processing different
component sizes. Dies are easily replaced within minutes.
GPD's CF-9 dies are precisely manufactured using a unique die construction process. Most
dies are built with a sectional, laminated construction method for exceptional wearing ability.
Before lamination, all dies are buffed and polished to exacting smoothness, particularly in the
actual forming and cutting areas.

CF-9 User's Guide
09/30/92 GPD Global 3
Function
CF-9 Radial Lead Forming Machine
The CF-9 performs the following functions:
• Forms and cuts up to 25,000 radial components per hour with a variable speed motor.
• Produces a variety of lead forms.
• Accommodates components with a wide range of lead diameters.
• Handles a diversity of hole-to-hole spacings.
• Controls accuracy and repeatability through the use of a solid gear train, cam, and cam
follower indexing system.
Most cutting and forming needs are covered with the standard dies we offer. Several of the
most common component forms the CF-9 produces are illustrated in the Common CF-9 Lead
Forms appendix.
CF-9 Lead Forming Dies
CF-9 Lead Forming Die sets are available to perform the following functions:
• Produce both common and special configurations. GPD is pleased to design custom dies
for you. If you have unusual requirements, your GPD representative will be happy to assist
you with any custom die orders.
• Form two-leaded components with up to .400" (10.16 mm) center-to-center dimensions.
• Form three-leaded TO-92 transistors.
• Offer unique versatility through the use of a large selection of different dies to form a wide
variety of component shapes.
NOTE
All CF-9 dies will also work on the GPD CF-10 Loose/Bulk Component Lead Former.

CF-9 User's Guide
4 GPD Global 09/30/92
Theory of Operation
The CF-9 performs the following steps during a cycle:
1. Feeds taped radial components from the reel holder through a pair of tape roller guides
into the feeding mechanism and the forming and cutting die stations.
2. Forms the component in the first die station.
3. Indexes the formed component to the second die station while simultaneously indexing the
next component into the first die station.
4. Cuts the formed component from the tape in the second die station, drops the component
in the component bin, and disposes of the tape down a waste tape exit chute while
simultaneously forming the component at the first die station.
5. Initiates next cycle.
NOTE
Depending on the components being processed and the desired component lead form, die
Station 2 may be used to both cut and form, just cut, or be excluded in order to leave
components on tape.

9
8
7
6
5
4
3
2
1
CF-9 User's Guide
09/30/92 GPD Global 5
Figure 1 Principal Parts
Machine Part Identification
The CF-9's principal machine and die elements are identified and illustrated in this section.
Information for elements not defined elsewhere is also included here.
Principal Parts
Item 1 Reel Holder Item 6 Die Block Assembly, Station 1
Item 2 Component Reel / Ammo Pack Item 7 Die Block Assembly, Station 2
Item 3 Tape Roller Guide Item 8 Component Bin
Item 4 Tape Guide Arm Item 9 Tape Exit Chute
Item 5 Taped Components
Die Stations
Station 1 is adjustable and normally used as a forming station. Station 2, also adjustable,
is normally used as a cutting station. More complicated forms may require Station 2 to
complete the forming function prior to cutting the component from the tape, or special
flattening blocks can be inserted if additional dimple alignment is required.

1
2
3
4
5
CF-9 User's Guide
6 GPD Global 09/30/92
Figure 2 Adjustment Parts
Adjustment Parts
Item 1 Belt Tension Release Bar Item 4 Component Tape Pressure Plate
Item 2 Transfer Belt Lever
Item 3 Safety Shield Lock Item 5 Drive Pulley (adjusts Transfer Belt timing)
Hand Crank
Not shown. The hand crank port is located in the lower left corner of machine's back
panel. By inserting the supplied Allen Key in this port, the operator can slowly operate the
CF-9 manually, moving all mechanisms during setup, adjustment, testing, or
troubleshooting to assure proper die and component positioning. The hand crank can be
used to move mechanisms in reverse only during setup and only when no components are
loaded.
Safety Shield
Not shown. The safety shield must be in place during machine operations. Machine
operations cease whenever the shield is opened.

STOP
RUN
AUX.
RESET
010
9
8
7
6
2
1
345
CF9
Component
Former
1
2
3
4
5
CF-9 User's Guide
09/30/92 GPD Global 7
Figure 3 Control Panel
Control Panel
Item 1 Speed Control Item 4 Fuse
Item 2 Power Switch (RUN, STOP, AUX) Item 5 Accessory Outlet
Item 3 Reset Button
Speed Control
The speed control regulates both the variable speed motor and power supply and enables
the machine to operate in a range from 0 to 25,000 cycles per hour. The operator has full
freedom to select whatever speed is appropriate to the work being performed.
Reset Button
As a safety feature, power is not automatically restored by closing the safety shield. To
restore power, it is necessary to close the shield and then push the reset button. Normal
operation can then be resumed.

T
1
B1
1
2
3
4
5
4
6
7
8
9
10
11
2
CF-9 User's Guide
8 GPD Global 09/30/92
Figure 4 Die Block Assembly, Station 1
Die Block Assembly
Item 1 Eccentric Crank Item 7 Die Mounting Area
Item 2 Crank Shaft Item 8 Cover Plate
Item 3 Micrometer Scale Indicator Item 9 Crank Adjuster
Item 4 Die Station Guide Shaft Item 10 Die Block
Item 5 Die Block Adjusting Bolt Item 11 Wear Plate
Item 6 Die Block Slide
Micrometer Scale Indicator
The micrometer scale indicator mounted on each die station makes the lead cut length
adjustment operation quick, easy, and highly accurate to .0005" (0.0127 mm).

1
T
2
B 1 2
Forming
Style Series
Tape
1
TT2
T2
1
T
25
B 1 2 B 2 5
B1
B2
1
2
3
2
1
CF-9 User's Guide
09/30/92 GPD Global 9
Figure 5 Die Forming Style Series
Figure 6 Die & Station Markings
Die Markings
Dies and knives are paired and stamp marked with the following
symbols so each can be readily identified and installed in the
correct station position:
• Forming Style Series Number
• Installation Marking
• Installation Color Dot
Forming Style Series
The forming style series is stamped on its right hand side of
each die and knife (Figure 5). Refer to the Die Information
appendix for specifics.
Installation Marking
Installation Color Dot
Characters are stamped on the left hand side of
each die half (Figure 6, Item 1) to indicate proper
die position in the forming and cutting stations.
Corresponding markings are stamped on each
station's stationary plate (Item 2). A color dot
(Item 3) associated with installation location is
also stamped on each die half and stationary
plate.
Marking Color Dot Location
T1 Black Top die, Station 1
B1 Red Bottom die, Station 1
T2 Yellow Top die, Station 2
B2 Green Bottom die, Station 2

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10 GPD Global 09/30/92
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2
1
3
CF-9 User's Guide
09/30/92 GPD Global 11
Figure 7 CF-9 Installation
Installation
1. Carefully unpack and check your CF-9 for possible shipping damage. If any obvious
damage is observed, contact GPD's service department prior to operating the machine.
2. Standard equipment included with the CF-9:
1 Standard Die Set 1 Reel / Ammo Pack Holder
1 Standard Knife Set 1 Operating Manual
1 Anti-static Shield and Bin Package 1 Set of Wrenches
1 LCD Micrometer Adjustment Package
3. Position the CF-9 on a level, stable working surface. If using the optional Lazy Susan or
Work Station, install CF-9 on these at this time.
4. Assemble reel holder and tape guide arm. Refer to Figure 7, Items 1 & 2 for proper
placement on the machine. The screws (1/4-20x1/2") for securing the reel holder and tape
guide arm are located in the appropriate holes in the CF-9's main frame.
C A U T I O N
Never pull, push or lift machine by reel holder or tape guide arm - this could bend
them out of alignment and seriously affect machine performance.
5. Assemble safety shield with hinges and 10-32x3/8" screws attached to shield.
6. Position component bin (Item 3).
7. Install any accessory equipment to be used
during processing. Refer to CF-9
Accessories appendix.
8. Set speed control to zero (0) position.
9. Hook up electrical power per your local
electrical code and machine specifications.
Refer to Specifications.
W A R N I N G
Make sure the power supplied is of proper voltage and is fused at the proper
amperage. This information is recorded in Specifications and on the serial number
plate located on the power cord side of the machine.

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CF-9 User's Guide
09/30/92 GPD Global 13
Operating Instructions
I M P O R T A N T
Read this manual before turning the power on. Failure to follow the instructions in this
manual could result in damage to the machine and/or dies. Uneven forming of the
component leads and/or machine failure could result.
Requirements
• The component reel tape must be sturdy enough to maintain adequate component pitch to
prevent improper component feeding. If tape integrity is acceptable, the component body
will be supported and stress will not be placed on leads during lead forming.
• Taped component leads must be straight to prevent misfeeding and unacceptable lead
forms. GPD's Component Detection System identifies bent components and stops
machine operations to prevent die breakage. Refer to the CF-9 Accessories appendix.
Suggestions
• Use quality components on quality tape.
• Planning prior to lead forming operations is suggested as this enables users to quickly
produce the maximum number of components for a given system configuration.
W A R N I N G
For operator and machine safety, keep fingers, clothing, and foreign objects away from the
machine's moving mechanisms while in operation. Failure to do so may result in bodily
injury or damage to the machine.
Setup
1. Turn power switch to OFF.
2. Plug machine into appropriate power supply. Refer to Specifications.
3. Select appropriate dies and knives. Refer to CF-9 Component Forming Die Catalog.
4. Install proper dies and knives according to the following die installation instructions.
5. Use hand crank to check for proper die setup.