Nu-tek Ntm110ll-hw User manual

NUTEK NUTEK NUTEK NUTEK NUTEK NUTEK NUTEK NUTEK NUTEK NUTEK NUTEK NUTEK NUTEK NUTEK

MULTI

MAGAZINE

LINE

LOADER

NTM110LL-HW

NUTEK PTE LTD

In the compilation of this manual, attention has been given to

avoid errors and mistakes in an attempt to provide a clear

structure to the content.

In spite of this, errors cannot be completely avoided.

If in going through this manual should you:

- discover incorrectness

- encounter unclear statements

- meet with parts that in your opinion needs further explanation,

please inform us. We will appreciate any comments which will

help us to improve this document.

For corrections or clarification, please contact:

Address: NUTEK PTE LTD

39 Joo Koon Circle

Singapore 629105

Tel: (065) 6862-0255

Fax: (065) 6862-0040

E-mail Address: [email protected]

Internet Address: http://www.nutek-sg.com

Machine Name:

Multi magazine line loader, L-size

Job Description: NTM110LL-HW

Job No: 2010-0633A01

Voltage: 230 Vac

Phase: 1

Power Consumption: 350 VA Max

Product: PCB

Product Size: L - 70.00~407.00 mm (W) / 80.00~457.00 mm (L)

Product Edge Clearance: 3 mm

Product Thickness: 0.60 ~ 1.60 mm

Component Height: Top: 30 mm (Max) Below: 30 mm (Max)

Transfer Height: 950 (+/- 25mm)

Weight: 310 kg (Approx.)

Air Pressure: 4-6 bars

Machine Colour: RAL 9002 (8093A)

Direction: L to R

Magazine Type / Model: NKAJ-0525R / CAB 716

Noise Level: < 70 dBA

* Please refer to 3D drawing for physical dimension.

Fix Rail: Front

1.0 INTRODUCTION

Machine specification1.1

Membrane Multi Magazine Line Loader

Teeth Type

Standard

1.2 Terms of Reference

The following list some of the terms that could be used in this Manual.

PCB − Printed Circuit Board,

Magazine − Container that holds the PCBs,

Transfer of PCB − The process in which the PCB is transported between

machines,

Load/Loaded − The process in which the PCB is transferred from the

magazine into the production line,

Transfer height/

PCB height

− Board flow height from the floor level,

Pitch − Distance between two slots in the magazine (usually

10mm),

Index/Indexing − The distance in which the magazine is raised or

lowered per request,

Full magazine − Magazine that contains PCB (either full or partially

full),

Empty magazine − Magazine that is completely empty,

Slot 1 − The lowest slot of the magazine.

Slot 50 − The highest slot of the magazine.

Downstream

Board

Available (DBA)

− A signal sent from Nutek machine to the Downstream

machine to inform the availability of a PCB at Nutek

machine;

Downstream Busy

(DSB)

− A signal sent from the Downstream machine to Nutek

machine to confirm ready to receive a PCB from

Nutek machine.

Membrane Multi Magazine Line Loader

Teeth Type

Standard

1.2.1 Abbreviation Use in Manual

Abbreviation Description

BK Brake

BZ Buzzer

C Capacitor

CN Connector

CS Curtain Sensor

CYL Cylinder

D Diode

DBA Downstream Board Available

DSB Downstream Busy

E Earth

EM Emergency Switch

F Fuse

FS Foot Switch

H Indicator light

INV Inverter

K Relay

LS Limit Switch

M Motor

MCB Main Circuit Breaker

N Neutral

OL Overload Relay

PB Push Button

PCB Printed Circuit Board

PHS Photo Sensor, Gap Sensor

PS Power Supply

RS Reed Switch

SV Solenoid Valve

SW Switch

TB Terminal Block

TP Terminal Point

UBA Upstream Board Available

USB Upstream Busy

Membrane Multi Magazine Line Loader

Teeth Type

Standard

1.2.2 Label Definition

Label Description

Danger! High Voltage! Do not detach

the protective covers. Operating this

equipment without covers may cause

electric shock.

Do not touch the equipment while it is

running. Working near moving

machinery or live parts may result in

electrocution or getting entrapped in

machine.

Membrane Multi Magazine Line Loader

Teeth Type

Standard

1.2.3 Safety Section

It is essential for the operator to understand how the machine functions before

he/she handles the machine. Understanding the machine will help to create an

awareness of the machine’s capability & limitation which play an important role in

safety. Below are the recommended sections to read in order to be familiarized

with the machine.

i. Expected use and Limit of use (Section 1.3)

ii. Machine Functions (Section 2.0)

iii. Switches Function & Description (Section 6.0)

iv. Operating Conditions & Machine Sequence (Section 5.0 & 7.0)

In addition, if the operator requires to adjust or calibrate the machine to cater for

product changes, please refer to Installation & Calibration (Section 3.0 & 4.0).

Note: Always switch off the power supply before opening any protective cover

over an electrical circuit.

Membrane Multi Magazine Line Loader

Teeth Type

Standard

1.3 Expected use and limit of use

1. This machine is intended for loading PCB from the magazine to the

production line or another machine.

2. This machine is not intended to be a standalone unit. It must always be

installed beside a machine with integral covers or guards at the vicinity of

its opening for a PCB transfer (see fig.1).

3. During production, this machine operates under Auto mode with no

operator intervention except for putting filled magazine/s onto the lower

Conveyor and removing empty magazine/s from the upper Conveyor.

4. This machine is intended for used with the specified magazine only (see

section 1.0). The type and size of the PCB that can be handled by this

magazine is specified by the manufacturer or the supplier.

5. This machine is intended for use in an industrial environment that is well

ventilated, clean and dry with the maximum humidity at 90% and the

temperature range from 150C to 350C.

6. This machine is intended for both air and electrical supplies stated on the

specification (see section 1.0).

7. This machine is designed for a lifespan of 7 years with adequate

maintenance and replacement of worn parts.

8. Before start-up, the operators are expected to have read and understood the

safety section (see section 1.2.3) of the instruction manual that

accompanies the machine, and to be familiar with the location and

operation of each control.

Membrane Multi Magazine Line Loader

Teeth Type

Standard

FLOW CONFIGURATION FOR MULTI MAGAZINE LINE LOADER

Direction of PCB Flow

Fig 1

Membrane Multi Magazine Line Loader

Teeth Type

Standard

2.0 Machine Functions

The Loader is divided into three main assemblies:

1. Lifter

2. Input (Lower) Conveyor

3. Output (Upper) Conveyor

2.1 Lifter

The Lifter accepts a full magazine from the Input (lower) Conveyor. It will index

upwards until Slot 50 (for Pitch 1), Slot 49 (for Pitch 2), Slot 48 (for Pitch 3) or

Slot 47 (for Pitch 4) of the magazine is at the transfer height. Upon receiving a

Downstream Busy (DSB) signal, it will load a PCB onto the Downstream machine.

Loading is done by means of a pusher cylinder assembly located inside the Output

(upper) Conveyor. The Lifter will index upwards until the next slot of the

magazine is again at the transfer height.

The loading process repeats until the last PCB in the magazine is transferred out.

The empty magazine will be brought to the highest position and transferred onto

the Output (upper) Conveyor.

2.2 Input (Lower) Conveyor

The Input (lower) Conveyor allows a full magazine to be placed at its entrance and

transfer it over to the Lifter assembly. It can accept and hold up to three

magazines. Stoppers are used to provide separating action, allowing only one

magazine to be transferred onto the Lifter. Cam switches or sensors are used in

conjunction with the stoppers.

2.3 Output (Upper) Conveyor

The Output (upper) Conveyor receives the empty magazine from the Lifter. It can

accept and hold up to two magazines.

Membrane Multi Magazine Line Loader

Teeth Type

Standard

3.0 Installation

3.1 Pre-installation

The following list the general procedures before installation:

− Ensure that the space catered for is sufficient;

− Connect the power supply and air supply (ensure that the supplies are within

the specifications of the machine);

− Place one magazine (that contains some PCBs) onto the Input Conveyor;

− Power up the machine and switch to Auto mode. Allow the magazine to reach

the transfer height;

− Adjust and level the machine to the desired loading height by the six footing

(the machine allows for a levelling of ± 30mm);

− Disconnect the power and air supply.

The machine is now ready for installation.

Note: This machine is allowed a levelling adjustment of ± 30mm. However, problems

may arise during the installation and levelling if the discrepancy between the

specified and desired height is more than 15mm.

Membrane Multi Magazine Line Loader

Teeth Type

Standard

3.2 Installation

The following list the general procedure, during installation:

− Place the machine into the required position while ensuring correct orientation.

(The loader is usually placed at the beginning of the production line);

− Connect the power and air supply. The interface between the Loader and the

Downstream machine is to be connected after the installation;

− Switch the machine to Manual mode;

− Clamp the magazine;

− Index the Lifter until the Slot 49 of the magazine is at the transfer height

position;

− Align the machine by adjusting the position and the footing. (See 3.3 for the

procedure used by Nutek);

− After confirming the alignment, test by depressing the PUSHER membrane

switch to activate the pusher;

− Align the magazine by adjusting the 2 magazine clamps at the top of the

support bridge (see 3.5 for the procedure);

− Ground the machine either by raw bolt or by link-plate as required.

The machine is now installed.

Membrane Multi Magazine Line Loader

Teeth Type

Standard

3.3 Alignment of Machines

There are many ways of aligning two machines. Nutek makes use of two similar

PCBs and the general procedure is as follows:

− Place a PCB on the Conveyor as shown in figure 1a;

− Adjust the Conveyor until the angular misalignment and the offset is minimum;

− Adjust the height so that the Upstream machine is slightly higher than the

Downstream machine as shown in figure 1b;

− Test the alignment with the PCBs and repeat the steps again if necessary.

The machine is now aligned.

Membrane Multi Magazine Line Loader

Teeth Type

Standard

3.4 Handling

A The following list the general guidelines on the production floor

(Refer to Figure 1c):

− The machine can be handled by a pallet truck.

− A short length of wood (about 50mm x 50mm) long enough to rest

securely across the fork of the truck (more than 600mm in length).

− Insert the pallet truck under the machine as shown; a piece of wood

would help to absorb the height difference at the bottom.

− A trolley could be used instead of the wooden support beam to give

better support especially for the LL size machine.

B The following list the general handling guidelines when using the forklift:

− As the machine is constructed from aluminium profiles, it must be

handled with care to prevent damage to the machine through rough

handling.

− A short length of wood about 2" square and about 600mm must be

used.

− Ensure that the fork could reach the entire width of the machine.

Fig.1c

Membrane Multi Magazine Line Loader

Teeth Type

Standard

3.5 Alignment of Magazine

Magazine alignment is carried out after machine alignment. The procedures are as

follows (refer to figure 1d):

− Load in a magazine, preferably a reference magazine, onto the machine;

− Allow it to transfer onto the Lifter in Auto mode;

− Switch the machine to Manual mode;

− Clamp the magazine;

− Index the Lifter until Slot 1 of the magazine is at the transfer height;

− Check the magazine alignment with the two PCBs method (see section 3.3);

− Loosen all mounting fixtures that hold the machine is at the transfer height;

− If adjustment is necessary, release the magazine and loosen the two reference

clamping cylinders/ guiding bracket at the top of the bridge support;

− Clamp the magazine again and adjust the reference cylinders to align the

magazine. Check for both angular and offset misalignment;

− Tighten the reference cylinder/bracket;

− Check that the magazine top clamp can engage the magazine properly during

clamping operation;

− Test the setting by using the pusher (PUSHER membrane switch) to check the

transfer of the PCB;

− Confirm the setting with other magazines and fix the mounting.

Membrane Multi Magazine Line Loader

Teeth Type

Standard

Fig.1d

Membrane Multi Magazine Line Loader

Teeth Type

Standard

4.0 Calibration & Adjustment

Caution: Ensure that the correct magazine racks are used with its width

correctly adjusted and properly positioned on the machine.

4.1 Width Adjustment

A removable crank is provided for Input (Upper), Output (Lower) and Lifter

Conveyors' width adjustment. Clockwise rotation reduces the width and vice versa.

Remove and keep the crank during operation to avoid accidental width change.

LOCATION OF WIDTH ADJUSTMENT FOR

LIFTER CONVEYOR

LOCATION OF WIDTH ADJUSTMENT

FOR INPUT & OUTPUT CONVEYORS

Width adjustment here

Membrane Multi Magazine Line Loader

Teeth Type

Standard

4.2 Pusher Adjustment

This is done whenever the width of the PCB is changed.

Cautions: Before any adjustment, the adjacent equipment must be stopped or

even powered down. Ensure that the machine is in the transfer

position.

− Load in a magazine, preferably a reference magazine, onto the machine;

− Allow it to transfer into the Lifter in Auto mode and index until the Slot 1 of

the magazine is at the transfer height;

− Depress STOP followed by MANUAL membrane switch to switch the

machine to Manual mode;

− Remove the cover of the top Conveyor;

− Loosen the two clamp levers located at the pusher cylinder brackets;

− Slide the cylinder assembly until it is along the centre of the PCB;

− Check that the pusher cylinder is parallel to the magazine and tighten the

clamp levers;

− Depress PUSHER membrane switch to test;

− Confirm the setting.

Membrane Multi Magazine Line Loader

Teeth Type

Standard

4.3 Magazine number of slot requirement

The Loader is factory set to use the reference magazine from Slot 1 to Slot 50. If

this setting has to be changed, please note the following steps (Refer to figure 1e):

− Load in a magazine, preferably a reference magazine, onto the machine;

− Allow it to transfer into the Lifter in Auto mode;

− Switch the machine to Manual mode;

− Clamp the magazine;

− Index the magazine until the required slot (e.g. Slot 50) is at the transfer

height;

− Turn off the power supply;

− Adjust the teeth sensor plate so that the lowermost teeth of the teeth

sensor plate is aligned with Slot 50 of the magazine;

− Power up the machine and test the adjustment by indexing in the

Manual mode, making sure that the sensor and the sensor plate does not

crash during indexing;

− Index the Lifter until Slot 1 of the magazine is at the transfer height and

adjust the Last Pitch sensor above the indexing sensor plate;

− Confirm the slot setting with other magazine by operating under the

Auto mode.

Nu-Tek NTM110LL-HW User manual

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