EPC 3x-X ERNIPRESS CENTER Hydropneumatic Press with pneumatic control. Operating manual EPC 31-X EPC 33-X EPC 35-X EPC 37-X

Transcription

1 EPC 3x-X ERNIPRESS CENTER Hydropneumatic Press with pneumatic control Operating manual EPC 31-X EPC 33-X EPC 35-X EPC 37-X / BA_EPC 3x-X

2 Copyright Copyright The technical documentation consists of operating manual calibration certificate CE declaration of conformity Copyright - ERNI Electronics GmbH, Adelberg This document is intended only for the recipient of the machine. It may only be used for the intended purpose. The technical documentation must not be reproduced in any form whatsoever or translated into other languages, even in extract form, without written consent. All information and illustrations correct as of March All rights reserved ERNI Electronics GmbH Seestr. 9 D Adelberg Telephone 0049(0)7166/50-0 Fax 0049(0)7166/ info@erni.de BA_EPC 3x-X

3 Confirmation of reading by operating personnel Confirmation of reading by operating personnel Read through the following operating manual and the accompanying documentation before working with the press! You may only work on the press if you have read and understood the operating manual and accompanying documentation. Do not hesitate to contact your supervisor or ERNI GmbH if you have any questions. Declaration: I hereby confirm that I have read and understood the following operating manual in full. No. Date First name, surname / dept. Signature BA_EPC 3x-X

4 Contents Contents Copyright... 1 Confirmation of reading by operating personnel... 2 Contents Introduction General advice Abbreviations and symbols Brief description Technical data Main dimensions Type plate General safety advice Symbols for safety advice- and warnings in the OM Proper use and exclusion of liability Warranty General advice on conduct and safety Duties of the supervisor Duties of the operating personnel Information about particular dangers Pneumatics Hydraulics Lubricants and other operating resources Maintenance and repair Sources of potential risk in the press Transport and installation Transport Installing the press Connecting the press Pneumatic connection BA_EPC 3x-X

5 Contents 4 Commissioning Switching the press on Switching the press off Operating elements Hand lever Control panel Installing the tools Description of the pressfit device Bottom tool Top tool Setting the slide table Setting the press-in depth Operation Pressing in Operating faults Care and maintenance Environmental protection Cleaning the machine Lubrication Compressed air maintenance unit BA_EPC 3x-X

6 1 Introduction 1 Introduction Appropriate operation and proper care are essential if the reliability and usefulness of the machine are to be maintained. The safety of all people coming into contact with the machine depends to a large extent on how the machine is used and treated. Therefore: It is essential that you read this operating manual before initial start-up of the machine! 1.1 General advice The manual will enable you to get to know the press and its capabilities before you start to operate it so that you can then put it to its proper use. It contains important information to ensure fully functional, economical and safe operation. The operating manual is not only an indispensable introduction for new operating personnel undergoing training - it also contains useful tips, advice and ideas for experienced operators. It is an essential point of reference for all users of the press. Reading the manual will help to avert dangers, optimise and accelerate work procedures, minimize repair costs and down times, improve reliability and lengthen service life. The operating manual should also be read attentively by machine owners and supervisors. In particular with regard to transportation and erection, and warranty issues. Chapter 2 contains important safety and hazard information that will enable you to prepare for any dangerous situations that might occur. It will be too late to look this up during operation! You must also follow this principle: The best way of avoiding accidents is to take care and precautions when working! The quality of the press as far as output is concerned depends largely on how it is serviced and maintained. Regular servicing and maintenance operations are described in the operating manual. We would be happy to help you with any repairs that may be necessary and to supply original spare parts EPC3x-X_01.doc 1-1

7 1 Introduction 1.2 Abbreviations and symbols fig. no fig. OM AMU Chap. PCB Figure No figure Operating manual Compressed air maintenance unit Chapter Printed circuit board UDC Upper dead centre SO Special option s.above see above LDC Lower dead centre Handling instructions for the operator List Reaction of the press Danger to life and limb. DANGER OF CRUSHING! Danger to life and limb. PERSONAL PROTECTIVE EQUIPMENT! Danger to life and limb. RAISED LOAD! Danger to life and limb. Danger for the press, workpieces or other items. Advice or tip for improving handling of the press EPC3x-X_01.doc 1-2

8 1 Introduction 1.3 Brief description The press is designed for the joining of connectors to a PCB. Pressing-in is a rational, reliable and environmentally friendly way of joining these components. Fig. 1-1: Functional assemblies of the press EPC3x-X_01.doc 1-3

9 1 Introduction Pos. no. Functional assembly Pos. no. Functional assembly 100 MACHINE CONSTRUCTION 400 OPERATING ELEMENTS 101 Press frame 401 Hand lever 102 Foot bars 402 Force stroke trigger 103 Front panel 404 Control panel 200 FUNCTIONAL ASSEMBLIES 600 PNEUMATIC EQUIPMENT 201 Force element 601 Compressed air maintenance unit with shut-off valve 202 Ram with tool holder 602 Compressed air connection 203 Knurled screw 603 Pneumatic module 204 Top tool 700 OTHER 205 Bottom tool 701 Workpiece PCB or plug and socket 300 OPTIONS 301 Slide table (optional) The pressing-in process is performed by pressfit tools. The tools always consist of a top and a bottom tool. The press works with a hydropneumatic drive. The pressure transducer charges the lifting cylinder with oil so that the cylinder has a purely hydraulic force stroke. The return stroke of the ram is pneumatic. With an input air pressure of approx. 7.5 bar, a maximum pressing force of between 10 and 70 kn (depending on the version of press) is achieved. The top tool is connected to the ram by a quick-change adapter. The bottom tool is set into the table. The press-in depth is set mechanically using a knurled nut. The EPC 3x-X can be equipped with optional features: Slide table for positioning the PCB to the press-in position EPC3x-X_01.doc 1-4

10 1 Introduction 1.4 Technical data Mode of operation: Permanent sound pressure level: Air supply: Pressure output for press type at air input pressure of 6.5 bar EPC 31 EPC 33 EPC 35 EPC 37 Air consumption per stroke: Hydropneumatic < 80 db (A) min 1/4" - max. 7.5 bar 10 kn 30 kn 50 kn 70 kn approx. 5 l Ambient temperature: Air humidity: Total stroke: Of which force stroke: Tool height when fitted: Weight: 0 to 35 o 10 to 95 % at 40 o non-condensing 48 mm mm 110 to 145 mm approx. 350 kg Dimensions: see Fig. 1-2 The operating pressure at the press must not exceed 7.5 bar. Observe the manometer on the maintenance unit of the press EPC3x-X_01.doc 1-5

11 1 Introduction 1.5 Main dimensions Fig. 1-2: Main dimensions of the press 1.6 Type plate The type reference of the press is made up of the press-in force and the options. "x" represents the max. pressure force [x 10 kn]. Type plate of the press. The type plate is located at the back on the right side of the press frame. It shows the technical data for the press. Fig. 1-3: Type plate EPC3x-X_01.doc 1-6

12 2 General safety advice 2 General safety advice Before starting work with the press, all operating personnel must read carefully through and understand this OM together with all the annexes in the accompanying documentation. Always adhere to the following principle: The best way of avoiding accidents is to take care and precautions when working! It is essential that you also follow all the safety advice in the accompanying documentation! ERNI will be happy to offer advise if you have any problems or queries. The OM must always be held at the place where the press is installed. If your OM is incomplete or illegible, it must be replaced immediately. ERNI will happily help you. 2.1 Symbols for safety advice- and warnings in the OM DANGER SPOT! This symbol warns of a danger spot. It is used for all actions which involve a risk to the life and limb of the operator or other people. It is absolutely essential that you follow this advice and take particular care in these situations. Pass on all safety advice to other users as well. This symbol is often used in the text together with additional pictures to highlight the type of danger. DANGER OF CRUSHING! PERSONAL PROTECTIVE EQUIPMENT! RAISED LOAD! This symbol represents advice given so that you can avoid danger to the press, workpieces or other items. Note: This symbol represents advice and tips that enable you to use the press more effectively and economically EPC3x-X_02.doc 2-1

13 2 General safety advice 2.2 Proper use and exclusion of liability The press must be used only for appropriate work as described in the instructions. Appropriate work includes: the pressing of connectors into suitable PCBs, the pressing of single contacts into suitable PCBs, the pressing of accessories into suitable PCBs, the pressing of other components into suitable PCBs. Any other use will be considered improper. ERNI will not be liable for any resulting damage, the risk of which will be borne solely by the user. Proper use also includes the observance of advice given in this OM, particularly the safety advice. 2.3 Warranty Warranty claims can only be asserted if the warranty conditions set out in our General Terms of Sale and Supply are met. You must also observe the conditions and advice in the OM. ERNI will only guarantee and be responsible for the safe and proper functioning of the press if ERNI connectors and ERNI pressfit tools are used. ERNI will not be liable for damage resulting from improper treatment of the press or failure to comply with the operating instructions. Our liability covers damage that arises despite normal use in accordance with the operating instructions. The values and settings applicable for the relevant components must be observed when setting the press-in force. ERNI will not be liable for damage to workpieces or PCBs caused by inappropriate settings. You must inform ERNI's customer services department immediately if the press suffers significant damage within the warranty period and the cause of the damage is not known and may lead to claims under warranty being asserted. It is essential that you wait for our further instructions. The press must be left in the condition it is in after the damage until the cause has been clarified and ERNI has expressly released it. In the case of personal injury, you must also inform the competent employer's liability insurance association immediately. Unauthorised modifications to the press and the use of spare parts, accessories, attachments and special equipment not tested and approved by ERNI could have a negative effect on the function of the press. ERNI will not be liable for any resulting damage EPC3x-X_02.doc 2-2

14 2 General safety advice ERNI will not accept any liability for damage resulting from failure to comply with the OM, breach of the duty of care in the transport, erection, handling, operation, servicing and maintenance or repair of the press even if these duties of care are not expressly indicated in the OM. 2.4 General advice on conduct and safety Do not work in any way that impairs safety! Always make sure that the press is safe to operate before starting it up! There must only ever be one person working at the press while it is in operation. The press must only be used when in a technically perfect condition and in accordance with instructions. You must be aware of all safety and hazard issues and operate the press in compliance with the OM. You must not exceed the permitted load ratings for the press (see Technical data chap. 1.4). If any safety-related changes in the press or how it behaves are noticed, the press must be shut down immediately and the fault reported to the competent office or person. Safety-related damage or malfunctions of the press must be rectified immediately. Depending on how often it is used, but at least once a week, the press and its additional equipment, especially the safety devices, must be inspected for proper condition and function. The following must be kept under particular observation: Pneumatics Hydraulic cylinder power package In addition to the OM, you must also observe statutory, generally applicable and other legal regulations on accident prevention and environment protection. The general safety regulations of the employer's liability insurance association, technical associations or the owner must always be observed when operating the press. Unauthorised design modifications and changes to the parameters beyond the scope of the OM are not permitted for safety reasons. The operating manual must always be held at the place where the machine is installed. If your operating manual is incomplete of illegible, it must be replaced immediately. Additional protective measures may be necessary depending on how the press is used and the materials that are processed. Operating personnel The personnel tasked with activities on the press must have read and understood the OM before starting work and must confirm this by signing the "Confirmation of operating personnel" list. This applies even for personnel who only occasionally work on the press EPC3x-X_02.doc 2-3

15 2 General safety advice 2.5 Duties of the supervisor The owner of the press has a duty to appoint a supervisor for the press at the place where the press is installed. The supervisor has a duty to only operate the press when it is in a perfect and completely safe condition. The supervisor is also bound to only let people work on the press who are familiar with the basic regulations governing safety at work and the prevention of accidents and have been trained in how to handle the press; only to let people work on the press who have read and understood the OM and have confirmed this by their signature (see Safety and health instructions); to clearly specify the competence of the personnel for operation, conversion, maintenance and repair; to only allow trainees to work on the press under supervision; to monitor the safety-conscious behaviour of the personnel; to provide the personnel with the necessary safety equipment. The supervisor must carry out checks to ensure that the operating and maintenance personnel are aware of safety and hazard issues in their work. 2.6 Duties of the operating personnel Before first working on the press, new operators must familiarize themselves with how to operate it safely by performing trial work under the supervision of experienced operating personnel. All persons tasked with working on the press are bound to do the following before starting work: observe the basic regulations governing safety at work and the prevention of accidents; read the OM and confirm this by their signature - see the "Confirmation of operating personnel" list; follow the instructions and safety advice of the OM without fail; inspect the press for safety and function before starting work; ask the supervisor or ERNI if they have any questions. Training of the operating personnel The supervisor must instruct the operating personnel in the work and the hazards associated with the machine. Operating personnel must be at least 16 years old and be both physically and mentally capable of operating the press EPC3x-X_02.doc 2-4

16 2 General safety advice Instructed personnel with no technical training may only be used for the following work: Production operation Cleaning Instructed personnel with technical training may also be used for the following work: Setup Troubleshooting and fault rectification Maintenance Repair 2.7 Information about particular dangers Pneumatics Work on the pneumatic equipment may only be carried out by suitably trained specialist personnel. In the event of faults in the pneumatic equipment of the press, the press must be switched off immediately and the fault rectified. Always depressurise the press before working on the pneumatic equipment. Danger of injury caused by high operating pressures. Inspect the pneumatic equipment of the press regularly for leaks and external damage. Defects must be rectified immediately Hydraulics Work on the hydraulic equipment may only be carried out by suitably trained specialist personnel. The power package operates with hydraulic pressures of up to 100 bar. In the event of faults in the hydraulic equipment of the press, the press must be switched off immediately and the fault rectified. Always depressurise the press before working on the hydraulic equipment. Danger of injury caused by high operating pressures. Inspect the hydraulic equipment of the press regularly for leaks and external damage. Defects must be rectified immediately Lubricants and other operating resources Always comply with the safety regulations applicable for the relevant product (safety data sheet) when handling oils, greases and other chemical substances! Ensure that lubricants and operating resources are handled and disposed of in an environmentally compatible way! EPC3x-X_02.doc 2-5

17 2 General safety advice Maintenance and repair Only carry out maintenance and cleaning work when the press has been switched off and depressurised! 2.8 Sources of potential risk in the press The press has been designed to the very latest state of the art and the recognised safety specifications. Nevertheless, failure to comply with the safety instructions when using the press could present risks to the life and limb of the user or third parties or damage to the press or other items of equipment. Therefore: The best way of avoiding injuries is to take care and precautions when working! Sources of potential risk in the press are described below. Pressing in DANGER OF CRUSHING! During pressing in, a force stroke with maximum forces of between 10 and 70 kn is executed - that is equivalent to a weight of between 1 and 7 tons! Hands or parts of the body could be placed between the ram and the bottom tool either deliberately or through lack of attention. If the operator triggers the force stroke in this situation, the ram will descend approximately 5 mm. This limitation of its path will prevent serious injuries during the stroke. Never be careless or negligent when working on the press! In SETUP mode it is possible to trigger the force stroke whatever position the hand lever is in. Never reach into the travel of the press. Work clothing PERSONAL PROTECTIVE EQUIPMENT Unsuitable clothing could, under certain circumstances, lead to parts of the body being dragged in during operation. Therefore: Make sure that clothes and hair are not loose. Remove jewellery before starting work. Suitable protective clothing must be worn when transporting the press! Unauthorised use of the press The press could be switched on and used by unqualified persons after the end of work or during lengthy breaks. Therefore: Take suitable measures to lock the press against unauthorised use during breaks in production! EPC3x-X_02.doc 2-6

18 3 Transport and installation 3 Transport and installation 3.1 Transport The press can be transported using an industrial truck or hall crane. RAISED LOAD! Never reach or walk under the raised press. Use a suitable truck that is capable of carrying the great weight of the press (approx. 350 kg). Check that the means of transport are in a safe and proper condition before transport. No one must be allowed to loiter underneath the press while the machine is being raised, transported and set down. Never lift the machine higher than is absolutely essential! PERSONAL PROTECTIVE EQUIPMENT! During transport all persons involved must wear protective clothing (hard hats, safety shoes, safety gloves). The press is mounted on a pallet for transport. Do not take the press off the pallet until at the place of installation. Make sure that all transporting movements are carried out slowly and carefully, especially when raising and setting down the machine. The press can be raised by means of two eye bolts (A) screwed into the frame of the press. Lead a carrying rope through the eye bolts. The press can be lifted and removed from the pallet using lifting tackle. Secure the carrying rope to prevent it from slipping! Fig. 3-1: Eye bolts EPC3x-X_03.doc 3-1

19 3 Transport and installation 3.2 Installing the press The press must be set down on a suitable underframe. This could be a stable workbench or an underframe made from steel profiles, for instance. Make sure that the underframe is capable of bearing the great weight of the press (up to 350 kg). An even mounting base is essential if the press is to work without malfunctioning. The area around the place of installation should be kept clean and as free of dust as possible. When installing the press, make sure that the compressed air maintenance unit and the electrical control module on the rear of the press can be easily accessed by all users. Fixing the press in position The press must be bolted to the workbench or bed. Use bolts (M10) that correspond in type and strength to the material of the work surface. There are drill holes in the foot rails to enable mounting on the workbench. Bolt the press to the workbench using M10 bolts. The press must be bolted down at all fixing points (2 x each foot rail)! Fig. 3-2: Fastening screws Workplace lighting Make sure that the working area of the press and the area around the workplace are well lit up. The working area and surroundings of the press must be sufficiently illuminated in accordance with DIN Nominal luminance: min. 1,000 LUX EPC3x-X_03.doc 3-2

20 3 Transport and installation Workbench or bed of the press Follow the principles of workplace design when installing the press. The press-in height should be between 1,000 and 1,100 mm above floor level. Suitable workbenches can be obtained from ERNI as optional extras. Adjusting the hand lever The upper position of the hand lever can be adjusted to the size of the operator or the type of workplace. Swing the hand lever all the way up. Loosen the hexagon socket screw (A) on the bearing about 5 turns. Pull the hand lever out of the toothing (B). Turn the hand lever to the desired position (C). Push the hand lever back onto the toothing. Tighten the hexagon socket screw (A) again. Fig. 3-3: Adjusting the hand lever EPC3x-X_03.doc 3-3

21 3 Transport and installation 3.3 Connecting the press The press must only be connected by specialist personnel. Make sure that the main valve on the compressed air connection blocks. Route the pneumatic supply cable in such a way that there is no danger of stumbling; the function of the press is not impaired; the press is not exposed to mechanical or other stresses (e.g. pushing and pulling or aggressive media) Pneumatic connection Connection is by means of the compressed air maintenance unit (AMU) on the right-hand side of the press. Connect the pneumatic supply line (A) to the AMU. The pneumatic pressure is connected by turning the shut-off valve (B) in the direction of flow. Set the operating pressure to 7.5 bar using the adjusting screw (C). Check the current operating pressure on the manometer (D). The connected operating pressure must be no more than 7.5 bar. A pressure relief valve will open if the operating pressure is higher. The press is operated with oil-free air. Fig. 3-4: Compressed air maintenance unit The accompanying documentation contains a comprehensive OM for the AMU EPC3x-X_03.doc 3-4

22 4 Commissioning 4 Commissioning 4.1 Switching the press on Connecting the compressed air Turn the shut-off valve (A) on the AMU in the direction of flow Press is pressurised with compressed air. The connected operating pressure must not exceed 7.5 bar. 4.2 Switching the press off Fig. 4-1: Connecting the compressed air Turn the shut-off valve on the AMU so that it is positioned across the direction of flow. The press is switched off EPC3x-X_04.doc 4-1

23 4 Commissioning 4.3 Operating elements Hand lever The operating sequence is broken down into Preliminary stroke Force stroke The preliminary stroke is executed manually by shifting the hand lever downwards. The hydropneumatic force stroke can only be triggered in the lower position - knee lever extended. The force stroke is performed by pressing the triggering button (A): The piston rod moves down Force stroke to lower dead centre The piston rod moves back Fig. 4-2: Hand lever You must not under any circumstances push the hand lever up during the force stroke. The ram is under high pressure. If the hand lever is moved away from the lower dead centre, the ram and power package could suffer damage Control panel PRESS BACK. Press the button to return the force stroke. This is necessary when the piston rod does not reach the limit switch at the lower dead centre. SETUP key switch. To set up the press - see chap the force stroke is triggered in setup mode regardless of the position of the hand lever - key switch position 1. Fig. 4-3: Control panel After completing setup, remove the key. Keep the key in a safe place where it is not accessible for third parties. The key must not remain inserted on the press during production EPC3x-X_04.doc 4-2

24 4 Commissioning 4.4 Installing the tools Description of the pressfit device Fig. 4-4: pressfit tools The tools must be suitable for the components used Bottom tool The bottom tool (A) is mounted on the table plate (B). It is fixed in position by inserting the two index pins of the base plate (B) into the receiving holes of the table plate. Fig. 4-5: Bottom tool EPC3x-X_04.doc 4-3

25 4 Commissioning Top tool Tool holder on the ram The ram has a tool adapter with T-slot grooves in the X and Y direction (A and B). Insert the tool. The top tool (B) is pushed into the X or Y groove, depending on the particular use. Push in the tool as far as it will go (limit stop (A)). No additional fixing is required. Fig. 4-6: Tool holder on the ram Fig. 4-7: Pushing in the top tool EPC3x-X_04.doc 4-4

26 4 Commissioning 4.5 Setting the slide table Fig. 4-8: Setting the slide table Setting the width of the PCBs The upper guide rails must be set to the width of the PCBs. Loosen two clamping levers (A) on each of the upper guide rails (B). Set the guides to the width of the PCBs. Lock the setting by tightening the clamping levers (A). Setting the connector position The parallel upper guide rails must be set to the right position for the pressing-in process. Loosen one clamping lever on each of the lower guide rails (C). Push the two upper guide rails to the desired position (Y lateral direction). Lock the setting by tightening the clamping levers (C). Once the PCB has been aligned to the pressing-in position of the ram, it can be pushed by hand on the upper guide rails to the next pressing-in position (X longitudinal direction). PCB holders (D) are mounted in the centre of the slide table. The holders protect the surface of the PCB during pushing movements. If several pressing-in positions in the Y lateral direction are required during production, stops (E) can be set for the relevant pressing-in positions EPC3x-X_04.doc 4-5

27 4 Commissioning 4.6 Setting the press-in depth Only personnel who have been trained and are familiar with how the press works should set or adjust the press-in depth. This is why setup mode is protected by a key switch. Only hand the key switch to trained personnel. DANGER OF CRUSHING! When the press-in depth is being set, the force stroke may be initiated using the key switch whatever position the hand lever is in. This can create squeeze points between the tool and workpiece or components. Never reach into the travel of the tool. You could suffer serious injuries and crushing! Before the press-in depth can be set, the manual preliminary stroke of the press for centring the connector must be set. The setting adapts the press for use with a variety of tools and PCB thicknesses. The setting must be performed after every change of PCB thickness. Requirement for the setting Insert a PCB with connectors into the lower pressfit section. The hand lever is in the UDC position. Setting procedure: 1 Turn the key switch (A) to the right the force stroke is performed. the press is in setup mode DANGER OF CRUSHING! Never reach into the travel of the tool. You could suffer serious injuries and crushing! Fig. 4-9: Control panel EPC3x-X_04.doc 4-6

28 4 Commissioning 2 Unfasten the clamping screw (A) of the spindle locking mechanism. 3 With the force stroke extended, now carefully push the hand lever down. Depending on what press-in depth is set, there is a danger of collision between the tool and PCB. 4 Turn the knurled screw on the spindle (B) this sets the position of the LDC - and thus the press-in depth. Turn to the left = lower the tool. Turn to the right = raise the tool 1 turn = 1.25 mm height difference Fig. 4-10: Setting the press-in depth The distance between the bottom tool holder and the top tool holder with the force stroke extended must not be less than mm. Adjust the press-in depth until the tool is lying evenly on the connector. 5 Push the hand lever upwards. 6 Turn the key switch back to the left the force stroke is retracted The press is in production mode. 7 Push the PCB to the press-in position. 8 Move the lever to the LDC the component is precentred. 9 Press the force stroke trigger on the hand lever the component is pressed in. 10 Check the gap between the component and the PCB. Correct the press-in depth if necessary. Fig. 4-11: Initiating the force stroke EPC3x-X_04.doc 4-7

29 4 Commissioning If the connectors are pressed in too hard or you see deformation on the PCB, you must reduce the press-in depth. If the connectors are pressed in too loosely, you must increase the press-in depth. After completing the setting: 11 Tighten the clamping screw (A) of the spindle locking mechanism. Fig. 4-12: Locking the setting After completing the setting, remove the key. Keep the key in a safe place where it is not accessible for third parties. The key must not remain inserted on the press during production EPC3x-X_04.doc 4-8

30 5 Operation 5 Operation Components must only be pressed in by means of the hydropneumatic force stroke. Never carry out the pressing-in process manually with the preliminary stroke. It is a precondition for press-in operation that all commissioning settings given in Chap. 4 have been made and checked. The press is used to process preassembled PCBs, i.e. the components are already fixed in position on the PCB. 5.1 Pressing in You must not under any circumstances push the hand lever up during the force stroke. The ram is under high pressure. If the hand lever is moved away from the lower dead centre, the ram and power package could suffer damage. If faults occur or connectors are not correctly pressed in during operation, Check the result of pressing in. Correct the press-in depth if necessary - chap Pressing the components in 1 Place the assembled PCB into the PCB holder or slide table. 2 Position the first component underneath the tool. 3 Press the hand lever all the way down as far as it will go (A). The components are precentred by means of the manual preliminary stroke. The force stroke can only be triggered with the knee lever fully extended. Fig. 5-1: Executing preliminary stroke EPC3x-X_05.doc 5-1

31 5 Operation 4 Press the force stroke trigger on the hand lever (A) the force stroke is triggered. The ram with the tool descends about 5 mm. The ram with the tool returns to the starting position. You must not under any circumstances push the hand lever up during the force stroke. 5 Swing the hand lever up the press is back in the starting position. 6 Push the PCB to the next insert position. Once all components have been pressed in, remove the PCB and insert the next one. Fig. 5-2: Initiating the force stroke EPC3x-X_05.doc 5-2

32 5 Operation 5.2 Operating faults If faults occur during operation, the high pressure is switched off. Causes of faults The hand lever is pushed upwards out of the extended position during the force stroke. The knee lever does not reach the LDC. The press moves onto the block, i.e. does not reach the LDC. The force stroke is cancelled by the PRESS BACK button. Fault remedy Check that the press is functional. Repeat the pressing in procedure. Retract the force stroke by pressing the PRESS BACK button. Repeat the pressing in procedure. Contact ERNI's service department if you experience any problems in troubleshooting or if the same faults keep occurring. Telephone: 0049(0)7166/ EPC3x-X_05.doc 5-3

33 6 Care and maintenance 6 Care and maintenance 6.1 Environmental protection The care and maintenance of your machine will involve substances that must be disposed of in an environmentally-friendly way. Help to protect the environment by disposing of machine parts, operating resources and auxiliary materials in an environmentally-friendly way and in line with statutory requirements (see also Chap ). Take the problem substances that you want to dispose of only to authorised receiving points. For more information, please refer to your local administrative authority (e.g. mayor's office, water management and environmental service offices at local level). 6.2 Cleaning the machine The press must be completely cleaned every week. Clean the slide table particularly thoroughly using a non-fluffy cloth. Do not under any circumstances used compressed air for cleaning. Using compressed air will endanger both you and the components of the press. Do not use any abrasive cleaning agents to clean the press. Clean shiny surfaces, the protective enclosure and the operating display using a lint-free cloth. 6.3 Lubrication The functional components of the press are virtually maintenance-free. The guides of the slide table must be oiled at regular intervals. Use a high-grade machine oil to do so. Use the oil very sparingly when oiling the spindle and guides. Inspect the guides weekly and oil them as required EPC3x-X_06.doc 6-1

34 6 Care and maintenance 6.4 Compressed air maintenance unit All components of the pneumatic system are designed for oil-free operation. ERNI strongly recommends that you use only oil-free compressed air. The compressed air maintenance unit of the press is located on the right on the base frame. Check the level of condensation water in the unit at regular intervals. If the MAX mark (A) on the condensate container of the unit has been reached, drain the condensate off by pressing the drain device (B). For further information, please refer to the enclosed OM for the compressed air maintenance unit. Fig. 6-1: Compressed air maintenance unit EPC3x-X_06.doc 6-2