vcd sequencer 5 (6241d/6248d) - prosperityprosp913/wp-content/uploads/... · 2018-02-09 ·...

Universal Part Number: GS-367-00CReference Configuration 6241D-#419416116248D-#46097601, 46097701, 46097901, 46098001, and41941613

Issued 7/98

VCD Sequencer 5(6241D/6248D)

6241D / 6248DGS-367-00C

6241D / 6248D GS-367-00C

Inserter

VCD Sequencer 5Axial Lead Sequencer / Inserter

6241D

Sequencer

Chain-to-ChainControl Cabinet

Shown withAutomatic Board HandlingFront Covers

IMCProduct Line

IMCProduct Line

Insertion Machine DivisionProduct Line


6241D / 6248DGS-367-00C

6241D / 6248D GS-367-00C

VCD Sequencer 5Axial Lead Sequencer / Inserter

6248D(Shown With Loader/Unloader: Magazine-to-Magazine)

Unloaderwith CE-MarkedSafety Screens

Loaderwith CE-MarkedSafety Screens

IMCProduct Line

IMCProduct Line



6241D / 6248DGS-367-00C

6241D / 6248D GS-367-00C

Contents

Supporting Documents .......................................................................................... ivIntroduction .............................................................................................................. 1Functional Description ............................................................................................ 1Standard Features .................................................................................................... 3

X-Y Positioning System ....................................................................................... 3Controller ............................................................................................................. 3Metric/Inch Dimensioning ..................................................................................... 3Machine Light Tower ............................................................................................ 4Control Panel ....................................................................................................... 4Add-On Sequencer Module .................................................................................. 5

Dispensing Stations ....................................................................................... 5Dispensing Heads ......................................................................................... 5Optical Refire Circuit ..................................................................................... 6Low Part Sensing/Display .............................................................................. 6

VCD Insertion Head ............................................................................................. 7Insertion Rate Determination ......................................................................... 7Insertion Span ............................................................................................... 8Insertion Depth Stop ...................................................................................... 8Component Centering ................................................................................... 8

VCD Cut and Clinch ............................................................................................. 9Board Error Correction ....................................................................................... 11Setup Tooling Kit ............................................................................................... 12

Selectable Features ............................................................................................... 12Insertion Tooling ................................................................................................ 12

Optional Features .................................................................................................. 13U-Teach® Hand-Held Programmer .................................................................... 13Universal Control Terminal (UCT) ...................................................................... 13Expanded Range Component Verifier ................................................................ 13The Jumper Wire Dispenser System ................................................................. 14

Wire Material Property ................................................................................. 15Make-Up Trays .................................................................................................. 15Workboard Holders ............................................................................................ 15Automatic Board Handling ................................................................................. 15

Technical Specifications ....................................................................................... 17Input Specification.............................................................................................. 17

Input-to-Output Taping Classes ................................................................... 17Maximum Size of Component Reels (Outer Edge-to-Outer Edge) .............. 18Sequencer Input Config.: Loc. of Dispensing Stations by Compon. Class .. 19

Dispensing Head Specifications ......................................................................... 20Insertion Head Input Specifications ................................................................... 21

Body Centering Assembly ........................................................................... 22Component Input Specifications ........................................................................ 23

Tooling Configuration ................................................................................... 23Insertion Tooling Specifications ......................................................................... 24

Recommended Component Clearances ...................................................... 25Component Body Length Considerations .................................................... 26Standard Tooling ......................................................................................... 275mm Tooling ................................................................................................ 28Large Lead Tooling ...................................................................................... 29

Insertion Specifications ...................................................................................... 30Positioning System ............................................................................................ 30Sequencer Specifications .................................................................................. 30

6241D / 6248DGS-367-00C

Contents

Controller ........................................................................................................... 30VCD Sequencer 5 Configuration ........................................................................ 31Installation Considerations ................................................................................. 32

Dimensions - 6241D .................................................................................... 32Environmental Requirements—6241D / 6248D ........................................... 33Service Requirements—6241D ................................................................... 33

Appendix A, Automatic Board Handling (Magazine-to-Magazine) ................ A-35Introduction .....................................................................................................A-35Technical Specifications ................................................................................. A-36Board Handling System Specifications ...........................................................A-36Board Specifications ....................................................................................... A-36Magazine Loader/Unloader Transfer Specifications ........................................ A-37Table Rotation ................................................................................................. A-38Magazine Loader/Unloader Configuration ....................................................... A-39Installation Considerations .............................................................................. A-40Magazine Loader/Unloader .............................................................................A-40Service Requirements..................................................................................... A-40

6241D / 6248D GS-367-00C

All specifications are subject to periodic review and may be changed withoutnotice.

© Universal Instruments Corporation, 1998. All rights reserved.

The following are trademarks of Universal Instruments Corporation, registered U.S.Patent and Trademark Office: Satellite Control, UICS, U-Teach, Universal,U-Design.

Indicates a change to the document from the previous edition.

6241D / 6248DGS-367-00C

Supporting Documents

GS-055 Indexing Rotary Tables, Series 6100GS-061 Lead Tape Reel Packaging of Axial Lead

Components, Series 2500GS-072 Satellite Control® System, Series 8000GS-112 Board Error Correction, Series 8000GS-134 Workboard Holders, Series 6810GS-167 Expanded Range Component Verifier, Series

2860GS-255 U-TEACH Hand-Held Programmer, Model

8345AGS-319-XX Pattern Programming Utility (PPU), Model 86721GS-354-01 Through Hole Design GuidelinesEIA-RS-296-E Lead Taping of Components in Axial

Configuration for Automatic Insertion

GS-367-00CPage iv

GS-367-00C

Introduction

The VCD Sequencer 5 (Model 6241D) automatically sequences andinserts class A—52mm axial leaded components into a printedcircuit board (PCB). The Model 6241D is controlled by a UniversalInstruments Control Processor (UICP) and features an X-Y posi-tioning system, high speed VCD insertion head, cut and clinch andfrom one (standard) to 11 (10 additional) sequencer modules, with 20dispensing stations per module.

The Model 6248D is equipped with automatic PCB handling,including magazine-to-magazine input and output and uses the basicmachine elements as the 6241D. See Appendix A for board handlingdetails. Insertion rates up to 16,000 components per hour can beachieved by the VCD Sequencer 5.

For optimized machine performance, follow GS-354-01, “ThroughHole Design Guidelines,” when designing PC boards. Consult yourUniversal Sales Engineer.

In consideration of essential health and safety requirements, mostconfigurations of the VCD Sequencer 5 are CE-marked.

Functional Description

The VCD Sequencer 5 places up to 220 axial components (EIA ClassI, I, or III), or jumper wire, in sequence on a chain, and then insertsthem in sequence in printed circuit boards (PCBs), at speeds up to16,000 cycles per hour. A pattern program controls the sequence,location, and orientation of the component insertion.

With the machine powered up and zeroed, a PCB is located andclamped, either manually or automatically depending upon configu-ration, into the workboard holder. The pattern program activates thedispensing heads, located on up to 11 sequencer modules. Thedispensing heads cut axial lead components from input tape reels orammo packs, and place them on the sequencer chain in a programmedsequence.

GS-367-00C

The components are then transferred to the VCD chain for transportto the insertion head, where they are centered, verified (optional), andtransferred to the insertion tooling. The insertion tooling cuts thecomponent leads to the required length determined by the patternprogram and forms the leads for insertion.

After insertion through the PCB, the component leads are cut andformed (clinched) to mechanically secure them to the PCB. Theprocess continues until all axial components defined in the patternprogram for the PCB are in place. When the pattern program iscomplete, the PCB is removed or transferred from the machine.

GS-367-00C

X-Y Positioning System

The X-Y positioning system locates the printed circuit board underthe insertion tooling.

The X-Y positioning system is equipped with an indexing rotarytable that indexes in 90° increments from 0° to 360° in a clockwiserotation. The rotary table is air motor driven under pattern programcontrol and requires less than one second to execute each 90° index.Refer to GS-055, “Indexing Rotary Tables,” for a description of thisfeature.

Standard Features

Controller

A series 8223 Universal Instruments Control Processor (UICP)Assembly and Universal Instruments Control Software (UICS® ) arestandard with the base machine. These provide a pattern programlibrary, management information display, full on-line editing, pat-tern queuing, machine self-diagnostics, and a diagnostic display.

The series 8223 is installed in the machine console. Refer to GS-072,“Satellite Control System.”

Metric/Inch Dimensioning

Positioning system dimensioning is user selectable through softwarefor metric or inch operation.

X-Y Positioning System

GS-367-00C

Machine Light Tower

The machine light tower indicates the status of machine operationwith the following color lights.

• Red — severe machine error stops machine

• Yellow — machine problem or operator has stopped machine

• Green — machine running

• Blue —feeder issues (dispensing head or jumper wire feederassembly)

Control Panel

The control panel contains all controls and indicators necessary formachine operation. The controls and indicators are functionallyarranged for ease of use and to reduce the possibility of operatorerror.

The control panel includes a STEP switch and SINGLE CYCLEpush button/indicator that permit the operator to step the machinethrough each sequential function of the insertion cycle. Alsoincluded is a HEAD ON switch that, when in the off condition,permits programmed positioning without component insertion dur-ing machine setup.

The REPAIR function is controlled with a latching push button.When the REPAIR push button is in the “On” position, the machinestops for all insert errors, missing parts, and components verified asbad. When the REPAIR push button is in the “Off” position, themachine bypasses insert errors, missing parts, and componentsverified as bad. The machine stops after one complete insertioncycle.

OFF .001

ON

CHAIN FAULT

CLEAR

RESET

OFF

REMOVE

FAILED PART

TOLERANCE

STATION NUMBER

REMOVE

OFF

BYPASS

INTERLOCK

REPAIR SEQ

ENABL E ON

HEAD

MODEMAINT

ENABL ECOMMAND

FULL

HALTLINK

AIRLOW

ZEROOFF

AIR

FAUL TCHAIN

MISSIN G PART

ERRORINSERT

ZERO

SET

ZERO

REF-JOG+JOG

ERRORLIMIT

RIDE

OVER

CYCLE

SINGLESTART

STEPINTERLOCK

STOP

FAILD.F.

FAILTOL.

ENABLEVERIFY

GS-367-00C

Add-On Sequencer Module

The VCD Sequencer can accommodate up to 11 Sequencer Modules.Each Sequencer Module has 20 dispensing stations for a totalmachine capacity of 220 stations.

Dispensing Stations

The capacity of each module is 20 dispensing stations, for processing20 discrete component types or values. Each station must beequipped with a dispensing head. An unused dispensing station doesnot affect normal machine operation, but must contain a blankdispensing head.

Dispensing Heads

The VCD Sequencer 5 uses rotary dispensing heads to cut and placecomponents in sequence on the conveyor chain. Rotary dispensingheads are available in two models: 5mm (0.200") pitch and 9mm/10mm (0.375"/0.400") pitch, with optical refire for each of the pitchvariables.

Dispensing heads are not included and must be ordered separately tomeet individual machine requirements.

The rotary dispensing head has several unique features:

• High operating speed of 25,000 cycles/hour.

• Fast and easy output taping class changeover.

• One cut component is staged during component load.

• Symmetrical cutter provides two cutting surfaces for a minimumof 6 million cuts per cutter.

• Low friction assembly requires minimal lubrication.

• Tape guide setting with lead screw allows fine adjustment of tapeguides for accurate component centering.

• Detent provides an accurate method of determining componentposition.

GS-367-00C

Optical Refire Circuit

The optical refire circuit in the Sequencer Module senses a missingcomponent from the input tape and recycles (refires) the dispensinghead index mechanism to bring a component into position forprogrammed dispensing. Because of its ability to cycle throughblank areas of the input tape, it reduces the need for operatorattention, thus increasing the effective output rate. This refire featureis most useful when processing pre-inspected component reels, inwhich gaps are left because of the removal of verifier-failed compo-nents.

Each refire dispensing head is equipped with a light source and anoptical light sensor. As a taped component is indexed into positionfor dispensing onto the conveyor chain, one of its leads interrupts thelight beam.

If the light beam is not interrupted, a “part missing” signal isgenerated causing the dispensing head to automatically index on thenext machine cycle. This “refire” action repeats until a componentis detected at the dispensing position or a programmed maximumcount is reached. Any missing components in the input tape willcause refiring of the dispensing head, reducing effective machinecycle rate.

The refire dispensing head processes components that meet thespecifications contained in GS-061, “Lead Tape Reel Packaging ofAxial Lead Components.” To prevent the sensor from giving a falseindication by sensing a scrap lead end, component removal from theinput tape should not leave a lead end after cutout that extends morethan 7.6mm (0.30") beyond the inside tape edge.

Low Part Sensing/Display

The low part sensing feature provides the operator with a visualalarm display whenever any input tape station nears empty withineach add-on module. Each input station contains a roller-type sensorflag assembly that interrupts a light beam when the tape runs out. Asingle tower alarm light illuminates when a run-out condition issensed. The tower light is reset when a new reel or box of componentsis installed.

7.6mm (0.30") Max.

Low Part Sensor Roller-Type Flag Assembly

GS-367-00C

Row 1

VCD Insertion Head

The servo-driven VCD insertion head installed on a base machinewithout options is capable of inserting up to 16,000* axial leadcomponents per hour (cph). Insertion rates are determined using: (1)criteria established or referenced in this General Specification, (2)equipment that is properly set up and maintained, and (3) establishedpatterns enabled in the machine executive program.

* Note: When the SBT and ERV are both configured on the basemachine, the maximum insert rate is reduced by up to 400 cph.

Insertion Rate Determination

To determine the maximum insertion rate of the VCD Axial LeadSequencer, the user must create a pattern program that conforms tothe following pattern criteria. An example of a pattern program isshown below in row 1 of a typical VCD insertion PC board.

• All pattern steps must contain the same insertion hole span.

• All pattern steps must contain the same X-axis coordinate.

• The Y-axis move between consecutive pattern steps must be2.54mm (0.100").

• The pattern must contain at least 20 insertion steps.

• Five runs should be averaged to determine the insertion rate.

A function (SET INSERTION.RESET.RATE) ofthe machine executive program can be enabled tocalculate the insertion rate.

Insertion Rate Formula:

Number of inserts - 1= x 3600

Time in seconds

50 - 1= x 3600

11.02

= 16,000 insertions per hour

Insertion Head Assembly

GS-367-00C

Insertion Span

The insertion span (Z1 and Z2 axes) is variable under programcontrol. Refer to Insertion Head Input Specifications section forinsertion span ranges that apply to the four basic tooling types.

Insertion Depth Stop

The insertion depth stop determines the distance the formed leads ofthe component are positioned above the PCB. Depth stops (Z3 axis)may be programmed in letter code (A through Z), in increments of0.2mm (0.008"), from 0.2mm to 5.28mm (0.008" to 0.208"). Depthstops may also be programmed numerically at 0.02mm (0.001")increments.

Component Centering

Component centering takes place one carrier clip before insertion.This ensures that the component body is at the center of the insertionspan, which provides protection against damage to lead junctions ofthe component during insertion. Refer to Insertion Head InputSpecifications.

Z1=Head Tooling SpanZ2=Clinch Tooling Span

Z1Insertion Depth Stop

Z2

Centering Assembly

GS-367-00C

6.15 (0.242)

3.61 (0.142)

2.11 (0.083)

7.98 (0.314)

3.58 (0.141)

8.13 (0.320)

2.72 (0.107)

6.10 (0.240)11.51

(0.453)2.62

(0.103)

45°23°

Insertion Center

Distance

VCD Cut and ClinchThe VCD cut and clinch provides printed circuit board supportduring the insertion cycle, then trims and clinches the componentleads to the underside of the printed circuit board. The Z2 axis spanis independently controlled and may be offset from the head by up to±0.46mm (0.018"). Clinch angle may be adjusted over a range from45° to 90°. Cutter bushings are easily replaced, which minimizesmachine downtime.

The standard style cut and clinch uses a dual lead continuity check.The failure of either lead to pass through the printed circuit board andbe clinched will generate an INSERT ERROR signal and cause themachine to halt. In the event of such a “shorted clinch,” the inserterror signal flashes and the status command indicates which anvil hasbeen shorted. The repair function can then be initiated to ensurecomponent wire insertion. The addition of solid state sensing switchesenhances the overall machine performance.

The illustration shows standard clinch footprint dimensions.

Dimensions are in millimeters;inch equivalents are bracketed.

Cut and Clinch Footprint

GS-367-00C

Component Clearances for Cut and Clinch Anvil Assembly


Side View

Axial leaded componentsto previously insertedaxial leaded components.

Side View

Axial leaded componentsto previously insertedDIP components, with bothoutward and inward clinch.

End View

Axial leaded componentsto previously insertedaxial leaded and DIPcomponents shown with bothoutward and inward clinch.

A B C

3.68 2.54 2.54 (0.125) (0.100) (0.100)

A

B

C

2.54 (0.100)

2.79 (0.110) 2.54 (0.100)

Outward DIP Inward DIP

Outward DIP Inward DIP

Continuity Style Lead Sense

GS-367-00C

457.200mm (18.000") x 457.200mm (18.000")Insertable Area

This area cannot be scanned byBoard Error Correction Sensor.

+Y InsertionCenterline

22.86mm(0.900")

457.2mm(18.000")

457.2mm (18.000")

BEC SensorOffset

FRONT OF MACHINE

+X

22.86mm(0.900")


Board Error Correction

The board error correction (BEC) option is designed to correct fortolerance buildup between tooling holes in relation to the holepatterns. It will also aid in the detection of missing insertion holesand insertion hole positional accuracy.

A light source and sensor, mounted near the centerline of the insertiontooling, are used to detect the location of printed circuit board holes.The coordinates of the sensor location and the small area notavailable for detection due to sensor offset are shown below.

This option also includes a bad board sensing feature. Preinspectedand identified reject board segments can be automatically bypassedduring the insertion sequence.

For a complete description of the BEC option, refer to GS-112,“Board Error Correction.”

GS-367-00C

Setup Tooling Kit

A setup tooling kit consists of gauges, tools, adapters, and specialfixtures required to set up and adjust the machine. This setup toolingkit is provided with each machine.

Selectable Features

Insertion Tooling

All tooling is selected to provide optimum performance dependingupon printed circuit board density (footprint), lead wire size andmaterial, component body size, insertion spans, and printed circuitboard configurations.

• Refer to Technical Specifications in this document to determinespecific head and tooling requirements.

• See Component Input Specifications in this document for com-mon tooling configurations.

GS-367-00C

Optional Features

U-Teach® Hand-Held Programmer

The model 8345A U-Teach® Hand-Held Programmer is an optionalhardware/software package that is available for the Model 6241Dmachine. This option enhances the capabilities of creating or editingthe UICS (.PUT) pattern programs. The U-TEACH package con-sists of a U-TEACH Hand-Held Programmer and the U-TEACHsoftware package.

Refer to GS-255, “U-TEACH Hand-Held Programmer,” for acomplete description of the U-TEACH option.

Universal Control Terminal (UCT)

The UCT hardware/software package allows a compatible personalcomputer to be used as an intelligent terminal connected to aUniversal machine control processor.

The UCT package includes a visual display terminal, keyboard, datastorage unit, printer and stand, cable assembly, and manual. Foradditional information on this option, refer to GS-319-XX, “PatternProgramming Utility.”

Expanded Range Component Verifier

The Expanded Range Component Verifier, Model 2864A, providesfor the on-line verification of component value and polarity. It iscapable of verifying most axial leaded components including capaci-tors (value only), refer to GS-167, “Expanded Range ComponentVerifier,” for specific component values. The verifier station islocated on the insertion head assembly. Verification parameters areentered as part of the pattern program commands. The verifier haltsthe machine for components failing verification and allows them tobe replaced at the manual load/replace station of the insertion head.

Using the verifier option greatly reduces the possibility of insertingdefective or out-of-sequence components in the pattern location.

GS-367-00C

The Jumper Wire Dispenser SystemA jumper wire dispensing head and feeder assembly included in thisoption processes jumper wires from a continuous spool of wire,eliminating dispensing from reels of previously taped and reeledjumper wires. It dispenses accurate lengths of cut wire and conve-niently changes to various wire gages and lengths. It is available asa factory installed option and as a retrofit kit. A maximum of twoJumper Wire Dispenser Systems may be installed in any machineconfiguration.

The Jumper Wire Dispenser System operates by drawing wire froma replaceable bulk reel; a cardboard drum package works best. Thewire feeder assembly straightens and then feeds the wire to thedispensing head. Pattern program control cycles the dispensing head,cutting a length of wire from the continuous strand, and dispensingit on to the sequencer chain.

A stepper driver electrically drives the feeder, controlling the lengthof the wire fed for each machine cycle. The operator selects Class Aoutput lengths with a push button and sets a rotary switch on thefeeder for one of 16 wire lengths for A input class. The Class A inputlength adjustment is in 0.10mm (0.004") increments.

Wire input — Wire input is available in various package sizes. Thepreferred package is the cardboard drum, which measures 345.95mm(13.62") high by 285.75mm (11.25") in diameter.

The suggested source for wire input is Hitachi Cable America Inc.(White Plains, NY; 1-800-394-0234). The product is Solder CoatedCopper Wire, ITPA 0.60 (SP-EM/SWP-191).

Reel packages containing smaller amounts of wire are also available.However, these packages are more likely to get jammed, or to unreelor dispense components unevenly. These provide adequate wire forshorter runs, but require more frequent changeover when performingextensive production runs. (An optional de-reeler kit is available forthese type packages.) Consult your Universal Sales Engineer fordetails.

Cut wire length — Class A: 51.61mm ±0.33mm (2.032" ±0.013"),with thumbwheel increments of 0.10mm (0.004").

Power requirements — 24 volts AC is furnished by the sequencerpower supply.

Wire diameter—0.6mm (0.024") solder coated copper wire isstandard. The wire sizes below are tested with the expected resultslisted. Consult your Universal Sales Engineer for details.

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GS-367-00C

Workboard Holders

Workboard holders are required to accurately secure PC boards tothe rotary table during the insertion process. Universal provides awide range of workboard holder products which can be orderedseparately or with a new machine purchase. For stand-aloneoperation, either custom or adjustable fixtures are available with457mm x 457mm (18" x 18") insertion areas.

Workboard holders are not required for the 6248D configuration.See GS-134, "Workboard Holders."

Automatic Board Handling

The VCD Sequencer 5 is available with magazine-to-magazineBoard Handling, as a standard feature on Model 6248D. AutomaticBoard Handling without the input/output elevators is optional onModel 6241D.

PC boards pass left-to-right or right-to-left. Quick and easy manualwidth adjustment handles a wide range of PC board sizes. The frontfixed rail is standard and all operator PC board changeover adjust-ments are readily accessible. Refer to Appendix A of this GeneralSpecification.

Make-Up Trays

Modularized make-up trays are provided for each sequencer modulecomprising the machine. The trays are mounted on a mobile rackassembly that can be positioned in the most convenient location.

Wire Material PropertyWire Tensile Elongation ProgrammedDiameter Strength Z-Span

0.5mm 27-35 kg/mm 4% maximum 5-20mm 1

0.6mm 27-35 kg/mm 5-33mm

0.45mm 30 kg/mm 28% maximum 5-20mm 1

0.45mm 22-30 kg/mm 10-20% 5-20mm 1

1. When Z-span increases to 21-33mm range, expect an increasein the machine ppm.

GS-367-00C

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GS-367-00C

Technical Specifications

Input Specification

The axial lead components prepared and taped to the requirementsestablished in GS-061 "Lead Tape Reel Packaging of Axial LeadComponents," which is an adaptation of EIA standard RS-296-E,may be processed by the VCD Sequencer 5. The standard input forthis machine is Class I.

Class II and III inputs may be located in a number of different stationsin each add-on module, exclusive of the Jumper Wire option.

Sequencer OutputOutput Class Component Maximum Maximum

Cut Length Body Length Insertion HoleCenter Distance

Standard 50.8mm ±0.254mm 15.7mm (0.620") 21.6mm (0.850")(2.000" ±0.010")

Class B Consult your Universal Sales Engineer

Input-to-Output Taping Classes

Sequencer InputInput Class Distance Between Tapes

I 52.4mm ±1.5mm (2.063" ±0.059"),standard

II 63.54mm ±1.5mm (2.5" ±0.059")

III 73mm ±1.5mm (2.874" ±0.059")

GS-367-00C

Maximum Size of Component Reels (OuterEdge-to-Outer Edge)

Component

Class

Maximum

Reel Size

I68.58mm

(2.7")

II81.28mm

(3.2")

III93.98mm

(3.7")

MaximumReel Size

ComponentReel

GS-367-00C

Sequencer Input Configuration: Location ofDispensing Stations by Component Class

Station Class I Class II Class III Notes

1 �

2 �

3 � � �Without Jumper

Wire

3 With Jumper Wire

4 �

5 � � �If no Jumper Wire

in Station 3

5 � �If Jumper Wire in

Station 3

6 �

7 �

8 �

9 �

10 �

11 � � Any Combination

12 �


14 �


16 �


18 �


20 �

With JumperWire:

14 stations for Class I only5 stations for Class I or II1 station for Jumper Wire only

Without JumperWire:

13 stations for Class I only5 stations for Class I or II2 stations for Class I, II, or III

GS-367-00C

Dispensing Head Specifications

Class Minimum Maximum

A Overall AA 52.1mm (2.05") 101.6mm (4.00" )Component A,B,C 63.5mm (2.5") 101.6mm (4.00")Length

B Body Length A bare wire 15.7mm (0.62")

C Body Diameter 5mm (0.200") pitch bare wire 4.8mm (0.190")9.5mm (0.375") pitch bare wire 9.5mm (0.375")10mm (0.400") pitch bare wire 9.5mm (0.375")

D Lead Diameter copper 0.38mm (0.015") 1.07mm (0.042")steel * 0.38mm (0.015") 0.81mm (0.032")

E Standard 1 5.08mm (0.200")Input Pitch 2 10.16mm (0.400")Distances 3 9.53mm (0.375")

F Tape Width standard 6.4mm (0.25")

* Steel leads may wear tooling faster than copper leads.

A

E

D

C

F

0.79mm (0.031")Maximum, 0.0 Preferred

B

GS-367-00C

Insertion Head Input Specifications

Insertion Head Input Definitions

Component Body Length

Component Body Diameter

OutsideFormer

Component Lead Diameter

Insertion Span

Programmed Z Span = Insertion Span + Lead Diameter

CarrierClip

Carrier Clip Spacing41.1mm (1.62")

Insertion Span

Programmed Z Span

Note:To prevent lead scrap problems, the Z-span within two consecutive insertions cannot vary more than 5mm (0.200") from the lesser to the greater span.

ComponentsBeforeReachingInsertion

Point

Insertion

Point

ScrapLeavingInsertion

Head

GS-367-00C

Body Centering Assembly

For proper component insertion, a body centering assembly is usedto center each component before it is moved into the insertion head.The centering capabilities depend upon the physical configuration ofthe components as stated and shown below.

• All symmetrically shaped components (case 1) are centeredwithin 0.41mm (0.016"). This is measured from the inner clipedge to the component body on each side and subtracting the twomeasurements (D1 minus D2) to determine the specified results.Case 1 = D1 – D2 ±0.41mm (0.016").

• All non-symmetrically shaped components (case 2), those hav-ing dissimilar body diameters at opposite ends or those havingan undefined point where the body ends and the lead begins(meniscus), are centered within 0.69mm (0.027").Case 2 = D1 – D2 ±0.69mm (0.027").

• Components which do not maintain leads on a centerline axis ordo not meet the specifications of case 1 or case 2 above aredesignated as case 3. These components cannot be guaranteedproper component centering or insertion.

Component Case Specifications for Insertion

Case 1

D1 D2

Case 2

D1 D2

Case 3

Case 3Case 1

D1 D2

D1 D2 D1 D2

Carrier ClipMeniscus

GS-367-00C

Component Input Specifications

All components must meet the specifications presented in thissection. See descriptions and notes in this section.


Tooling ConfigurationLarge

Standard 5mm Lead

Copper Wire Size Minimum 0.38 (0.015) 0.38 (0.015) 0.64 (0.025)(Note 1) Maximum 0.81 (0.032) 0.81 (0.032) 1.07 (0.042)

(Note 3)

Steel Wire Size Minimum 0.38 (0.015) 0.38 (0.015) 0.64 (0.025)(Note 1) Maximum 0.81 (0.032) 0.81 (0.032) 0.81 (0.032)

(Note 3)

Hole Center Minimum 7.62 (0.300) 5.0 (0.197) 7.62 (0.300)Distance Maximum 23.32 (0.918) 20.78 (0.818) 23.06 (0.908)(Note 2)

Component Body Minimum wire dia. wire dia. wire dia.Diameter Maximum 10.69 (0.420) 11.68 (0.460) 10.69 (0.420)

minus 2 times minus 2 times minus 2 timesboard thickness board thickness board thickness

Notes:

1. Component lead diameters are for optimum performance using the listed tooling.Consult your Universal Sales Engineer for deviations from the figures listed.

2. Increased insertion span is possible with reduction in maximum body diameter.Consult your Universal Sales Engineer for optional tooling.

3. When inserting components at 5mm (0.197") insertion spans, maximum leaddiameter is 0.61mm (0.024").

GS-367-00C

Insertion Tooling Specifications

The table below provides tooling information for determining com-ponent clearances relating to tooling footprints.


6.43(0.253)

3.81(0.150)

0.48 (0.019)

2.29 (0.090)

1.27 (0.050)

Tooling FootprintStandard Large Lead5mm

Fron

t Vie

wS

ide

Vie

wB

otto

m V

iew

0.84 (0.033)

3.18 (0.125)

2.36 (0.093)

0.48 (0.019)

1.27 (0.050)

2.29 (0.090)

2.29 (0.090)

6.43(0.253)

2.29(0.090)

6.35(0.25)

6.35(0.25)3.81

(0.150)

1.27(0.050)15°

2.29 (0.090)

15°

1.27 (0.050)

GS-367-00C

Recommended Component ClearancesLarge

Standard 5mm Lead

Lead 0.38 0.81 0.38 0.81 0.64 1.07Diameter (0.015) (0.032) (0.015) (0.032) (0.025) (0.042)

A 0.97 1.22 0.97 1.22 1.80 2.08(0.038) (0.048) (0.038) (0.048) (0.071) (0.082)

B 1.14 (0.045) 1.14 (0.045) 1.57 (0.062)

C 0.38 (0.015)

D 0.76 (0.030)

Note: C and D are recommended clearances for all tooling styles.

A

B CC

Note:Dimension A is measured at the smallest possible footprint for standard and 5mm tooling. See Tooling Footprints for related dimensions.

D


GS-367-00C

Component Body Length Considerations

After the tooling type and the variables have been determined fromthe Component Input Specifications section, the application rangefor the desired tooling type is provided in this section.

The shaded areas in each of the following graphs indicates accept-able component body lengths when compared to programmed Zspans. Maximum component body length is a function of theintended insertion span, tooling configuration, and component cen-tering accuracy.

Subtract an additional 0.41mm (0.016") from the maximum bodylength for non-symmetrically shaped (case 2) components. Thegraph is based on component centering within 0.41mm (0.016") andstandard component input class.

Programmed Z span = hole center distance (insertion span) + onelead diameter.

Outside Former Driver Tip

ProgrammedZ-Span

Note: Machine capabilities will allow components to be inserted using theminimum Z span formulas on the following pages. Due to body lengthvariations, it is recommended to design hole center spacings greater thanthe calculated minimum.

GS-367-00C

Standard Tooling

Metric Formula: Minimum programmed Z span =(component body length) x (constant C) + 2.36mm

Inch Formula: Minimum programmed Z span =(component body length) x (constant C) + 0.093"

Constant C = 1.112Dimensions are in millimeters;

inch equivalents are bracketed.

PR

OG

RA

MM

ED

Z-S

PA

N

BODY LENGTH

7.62(0.300)

10.16(0.400)

12.70(0.500)

15.24(0.600)

17.78(0.700)

20.32(0.800)

22.86(0.900)

17.78(0.700)

15.24(0.600)

12.70(0.500)

10.16(0.400)

7.62(0.300)

5.08(0.200)

2.54(0.100)

ACCEPTABLEAPPLICATION

RANGE

GS-367-00C

PR

OG

RA

MM

ED

Z-S

PA

N

17.78(0.700)

15.24(0.600)

12.70(0.500)

10.16(0.400)

7.62(0.300)

5.08(0.200)

2.54(0.100)

7.62(0.300)

10.16(0.400)

12.70(0.500)

15.24(0.600)

17.78(0.700)

20.32(0.800)

5.08(0.200)

22.86(0.900)


RANGE

21.59(0.850)

5mm Tooling





BODY LENGTH

GS-367-00C

BODY LENGTH

Large Lead Tooling





7.62(0.300)

10.16(0.400)

12.70(0.500)

15.24(0.600)

17.78(0.700)

20.32(0.800)

22.86(0.900)

17.78(0.700)

15.24(0.600)

12.70(0.500)

10.16(0.400)

7.62(0.300)

5.08(0.200)

2.54(0.100)


RANGE

24.13(0.950)

PR

OG

RA

MM

ED

Z-S

PA

N

GS-367-00C

Insertion SpecificationsType VCD (Variable Center Distance)

Span 7.62mm to 24.13mm (0.300" to 0.950")standard and 5mm (0.197") to 21.59mm (0.850")spans. See Component Input Specifications.

Programmable 0.02mm (0.001")Span Increments

Depth Stops Programmable from 0.2mm to 5.28mm (0.008"to 0.208") in 0.2mm (0.001") increments

Board to Tooling 20mm (0.8"), maximum with tooling in full upClearance position

Cut and Clinch Adjustable from 45° to 90° clinch angle

Insertion Rate Up to 16,000 insertions per hour with factory testspecifications. Refer to Insertion RateDetermination section

Positioning SystemTable Size 457mm x 559mm (18" x 22")

Insertable Area 457mm x 457mm (18" x 18")

Accuracy ±0.05mm (±0.002")

Repeatability ±0.025mm (±0.001")

Table Capacity 22.7 kg (50 lbs) maximum, includingworkboard holder

Programming ±0.01mm (metric dimensioning)Capability ±0.001" (inch dimensioning)

Speed 20.3m (66.67') per minute:2.5mm (0.1") in 0.10 seconds5.1mm (0.2") in 0.12 seconds

ControllerThe series 8223 Universal Instruments ControlProcessor (UICP) Assembly, UICS® software,and machine self diagnostics are standard.

Sequencer SpecificationsInput Class I (52mm), standard. Per EIA Standard

RS-296-E and this General Specification.

Dispensing Heads Required, must be ordered separately. Refer tothe Optical Refire Dispensing Head paragraph.

Sequencer Up to 11 sequencer modules in multiples of 20Modules dispensing stations (220 stations maximum);

optional jumper wire dispensing heads can beinstalled.

GS-367-00C

VCD Sequencer 5 Configuration

Dimensions are in millimeters:inch equivalents are bracketed.

SequencerDrive Module

PushButtonPanel

1016(40)

2

5

SequencerAdd-On ModulesHeight 1448 (57)

305 (12)

889(35)

Allow 1M (39.37")around entire machine forwork space

11

10

Sprocket Cover

1

P4

3

4

VCD Sequencer 5

E

P1

P2

P3

6

P5

1800(70.88)

VCD Inserter Pneumatic Connection

Pneumatic connections required for:20 to 100 Stations P2120 Stations P2 + P3140 Stations P2 + P3160 Stations P2 + P4180 Stations P2 + P4200 Stations P2 + P5220 Stations P2 + P5

Electrical Connection

P3

P4

P5

E

P1

P2

VCD InserterHeight 1575 (62.75)

(3225.8)(127)

2210(87)

1575(62)

GS-367-00C

Dimensions - 6241DUncrated Air Ride Van(no skid or crating material) (skidded and plastic covering

banded over machine)

L X D X H1 Weight1, 2 L X D X H1 Weight1, 2

Inserter 4 1800 x 1562 x 1594 908 2210 x 1829 x 1727 977(crated by itself) (70.88 x 61.5 x 62.75) (2000) (87 x 72 x 68) (2153)

Drive Module 5 991 x 635 x 1321 226 1168 x 864 x 1473 271(crated by itself) (39 x 25 x 52) (498) (46 x 34 x 58) (598)

Add-On Module 3 1016 x 889 x 1448 214 1193 x 1067 x 1600 256(each crated (40 x 35 x 57) (473) (47 x 42 x 63) (563)separately)

Last Add-On Module1346 x 889 x 1448 227 1727 x 1066 x 1600 272(one per machine, (53 x 35 x 57) (500) (68 x 42 x 63) (600)has chain tensioneron end)

Air Crating Ocean Crating(partial wood crating) (full wood crating)

L X D X H1 Weight1, 2 L X D X H1 Weight 1,2

Inserter 2235 x 1854 x 1905 1125 2235 x 1854 x 1905 1189(crated by itself) (88 x 73 x 75) (2479) (88 x 73 x 75) (2618)

Drive Module 5 1194 x 889 x 1676 321 1194 x 889 x 1676 342(crated by itself) (47 x 35 x 66) (706) (47 x 35 x 66) (754)

Add-On Module 3 1219 x 1092 x 1676 286 1219 x 1092 x 1676 300(each crated (48 x 43 x 66) (631) (48 x 43 x 66) (660)separately)

Last Add-On Module1753 x 1092 x 1676 332 1753 x 1092 x 1676 390(one per machine, (69 x 43 x 66) (732) (69 x 43 x 66) (859)has chain tensioneron end)

Notes:1. Measurements and weights are in metric figures; inch and pound equivalents are

bracketed.2. Weight varies as a result of pallet construction and moisture content of wood.3. Height dimension including low part alarm light is 1930mm (76"). Low part alarm

light is removed for shipment.4. The dimension, 953.5mm (37.54") measured from the floor to the top of the rotary

table, must be maintained at installation.5. Height dimension including the machine light tower is 1861mm (73.25"). The light

tower is removed for shipment.

Floor Space A minimum clear area of one meter (39.37") around the machineperimeter is recommended for machine operation and servicing.

Installation Considerations

GS-367-00C

Service Requirements—6241DElectrical (base machine, no light curtain)

Input Input Actual CurrentVoltage Breaker Draw (50/60 Hz)

100 VAC 20 amps 17.5 amps110 VAC 20 amps 15 amps120 VAC 20 amps 15 amps

200 VAC 20 amps 9 amps208 VAC 20 amps 9 amps220 VAC 20 amps 9 amps230 VAC 20 amps 9 amps240 VAC 20 amps 9 amps

Voltage and frequency requirements must bestated at time of order.

Allowable input:Voltage fluctuation ±10%Frequency fluctuation ±2%

A point is provided for connection to protectiveearth. A 20 ampere circuit breaker / fuse is theovercurrent protective device and the shortcircuit interrupting capacity is 2000 amperes.

Pneumatic 212 liters/minute at 6.3 bar(7.5 CFM at 90 psi). Non-lubricated,dry air, maximum contamination particle size of5 microns.

An additional air drop is required at differentlocations for 120 stations and up. SeeSequencer Module Configuration.

Equipment is adequately protected againstingress of solid and liquid contaminants.

Air Quality Non-lubricated, dry air, maximum contaminationparticle size of 5.0 microns.

Environmental Requirements—6241D / 6248DAmbient 10° C to 35° CTemperature (50° F to 95° F)

Operating 10% to 90%, non-condensingHumidity

Operating 1000m. Consult your Universal Sales EngineerAltitude for installations above 1000m.

Storage -25° C to 55° C (-13° F. to 131° F );Temperature not exceeding 24 hours up to 70° C (158° F),

10% to 95%, non-condensing. Universalprovides suitable means to prevent damagefrom humidity, vibration, stress and shock.

Noise 78dbA with board handling cover package(82dbA for cover package without boardhandling cover package), in accordance withNational Machine Toolbuilders Assoc. Standards.

GS-367-00C

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A - 35GS-367-00C, Appendix A, Automatic Board Handling

Appendix A, Automatic Board Handling (Magazine-to-Magazine)

Introduction

The VCD Sequencer 5 (Model 6248D) sequences and inserts axiallead components into printed circuit boards. Magazines containingPC boards are placed on the input loader where PC boards areautomatically transferred into the machine for axial insertion. Whencomplete, the PC boards are transferred out of the machine and intothe output magazine. When full, the output magazine is automati-cally transferred to the unloader.

In addition, the VCD Sequencer 5 with Automatic Board Handlingis self-certified (CE) to meet essential health and safety require-ments.

VCD Sequencer 5, Model 6248D

A - 36 GS-367-00C, Appendix A, Automatic Board Handling

Technical Specifications

Board Handling System SpecificationsMinimum Maximum

Transfer Height1 1001.5mm (39.43") to 1014.2mm (39.93"), or955.8mm (37.63") to 968.5mm (38.13")

Above Board 25.4mm (1.00"), restricted by theClearance VCD Sequencer 5

Board Changeover Manual

Direction Select right-to-left or left-to-right.

Edge Clearance 5mm (0.197") or 3mm 2 ( 0.118")

Fixed Edge Front

Locator Pins Front

Transfer Time3 3.5 seconds, maximum for 1007.9mm (39.68")transfer height6.5 seconds, maximum for 962.2mm (37.88")transfer height

Notes:1. Transfer height can be configured, and alters transfer time.

See transfer time specification.2. Set at factory to 5mm.3. Time from last insertion to first insertion on next board. This

number is based on 254mm (10") positioning system moves.Larger table moves increase transfer time.

Board SpecificationsMinimum Maximum

Length1 x Width 100mm x 80mm 2 483mm x 406mm 2

(4" x 3.1") (19" x 16")

Length to Width 1:1 or greater is recommended.Ratio

Thickness 0.8mm (0.032") 2.36mm (0.093")

Cutouts Contiguous edges

Datum Hole 3.18mm 2 (0.125") 6.35mm 2 (0.25")Diameter

Warp Total warp of 1.6mm (0.063") per board or0.004" / 1"

Weight 2.27 kg (5 pounds), maximum

Notes:1. Length is in the direction of board flow.2. Consult Universal Sales Engineer for other than stated sizes.

Insertable Area

PC Board

Left-to-Right Transfer

Right-to-Left Transfer

Board Transfer Direction

Maximum Board Size

Minimum Board Size

Fixed Front Edge

25.4mm (1.0")

L

25.4mm (1.0")

W

Fixed Front Edge

Maximum Board Size

Board Transfer Direction

Minimum Board Size


Magazine Loader/Unloader Transfer SpecificationsChangeover Time Magazine, 20 seconds.

PC Board The VCD Sequencer 5 determines board size.

Magazine Elevator Push button control panel under programmablecontroller. Capabilities include master/slavecontrol configuration, variable indexing,magazine dump, and set control.

Magazines 45.4 kg (100 lbs), PC boards plusmagazines. The maximum magazine depth is460mm (18.10"). Compatible with mostcommonly-used magazines. Consult yourUniversal Sales Engineer.

Magazine Input / Output Buffers

Upper Level Two magazine capacity at 1056mm (41.56")height.

Lower Level Two magazine capacity at 292mm (11.50")height. Motorized roller transfer.

Notes:1. Length is in the direction of board flow.2. Consult Universal Sales Engineer for other than stated sizes.


Table Rotation0° 90° 180° 270°

A 5.99mm (0.236")1 7.59mm (0.299") 2 9.27mm (0.365")1 7.59mm (0.299")2

B 7.09mm (0.279") 2 5.49mm (0.216")1 7.09mm (0.279")2 5.49mm (0.216")1

C 7.09mm (0.279") 2 8.76mm (0.345")1 7.09mm (0.279")2 8.76mm (0.345")1

D 7.09mm (0.279") 2 5.49mm (0.216")1 7.09mm (0.279")2 5.49mm (0.216")1

E 7.09mm (0.279")2 8.76mm (0.345")1 7.09mm (0.279")2 8.76mm (0.345")1

F 5.33mm (0.210")1, 3 5.38mm (0.212")2, 3 5.33mm (0.210")1, 3 5.38mm (0.212")2, 3

G 5.33mm (0.210")1, 3 5.38mm (0.212")2, 3 5.33mm (0.210")1, 3 5.38mm (0.212") 2, 3

H 3.17mm (0.125") minimum6.35mm (0.250") recommended

7.62mm (0.300") maximum

J 3.17mm (0.125") minimum3.96mm (0.156") recommended

6.35mm (0.250") maximum

Notes:

1. Dimensions are to centerline of lead.

2. Dimensions are to the bottom of the 'V' groove in the former.

3. Dimension shown is for 3mm edge support. If using a 5mm edge support, add 2mm(0.079") to dimension shown.

4. Dimensions shown are for standard tooling.

Front at 180°

Front at 270° F

ront

at 9

0°

AB

C D

EF

G

H

Diameter J

X

Dimensions shown are minimum distances from either the board edge or the tooling pin hole, to either the standard tooling or the clinch.

3mm Edge Support



Magazine Loader/Unloader Configuration

2210(87.0)

SequencerDrive Module

PushButtonPanel

1016.0(40.0)

2

5

SequencerAdd-On ModulesHeight 1448.0 (57.0)

305 (12.0)

889.0(35.0)

Allow 1M (39.37")around entire machine forwork space

11

10

Sprocket Cover

1

P4

3

4

VCD Sequencer 5

E

P1

P2

P3

6

P5

1800.0(70.88)

VCD Inserter Pneumatic Connection

Pneumatic connections required for:20 to 100 Stations P2120 stations P2 + P3140 Stations P2 + P3160 Stations P2 + P4180 Stations P2 + P4200 Stations P2 + P5220 Stations P2 + P5

Electrical Connection

P3

P4

P5

E

P1

P2

3225.8)(127.0)

For electrical connection of magazine elevator system, one electrical drop is required at floor level.

616.0(24.25)

1140.0(44.88)

610.0

(24.0)1223.0(48.13)

1870.0(73.62)

Pneumatic connection762.0 (30.0) from the floor

19.1(7.50)

76.0 (3.0)

Buffer Module

Elevator Module

Magazine Loader/Unloader Magazine Loader/Unloader

Elevator Module

Buffer Module

114.0 (4.50)

Board Flow

VCD Inserter Height 1575.0 (62.75)

System shown in left-to-rightboard-flow configurationwith fixed front rail.

PE


Magazine Loader/UnloaderDimensions—Magazine Elevator Module

Length 1 Depth Height Weight

Shipping 610mm 1140mm 1911mm 159kgDimensions (24") (44.88") (75.25") (350 lbs)

1 Length is in the direction of board flow.

Installation Considerations

Dimensions—Magazine Buffer Module

Shipping 1223mm 616mm 1223mm 45.4kgDimensions (48.13") (24.25") (48.13") (100 lbs)

Service RequirementsElectrical

Magazine 4.57M (15'), flexible, standard three-prong plugLoader/Unloader 100 to 125 VAC, 50 or 60 Hz, 15 amperes

208 to 250 VAC, 50 or 60 Hz, 8 amperesSeparate drop required.

Pneumatic

Magazine 425 liters/minute at 6.2 barLoader/Unloader (15 CFM at 90 psi).

3.175mm (1/8") NPT internal pipe thread.

Equipment is adequately protected againstingress of solid and liquid contaminants.