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Detail G
Bridge Beam Assy
3
Tooling Plate
Rotary Table

Page 7
Dual Head Board Handling System L/R T46365906 Rev. D
This Document Supports Assembly 46365906 Rev. C

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Page 8
T46365906 Rev. D Dual Head Board Handling System L/R
DET
NO.
ITEM NO. DESCRIPTION QTY U/M
1 26465000 PLUNGER, SPRING 1 EA
2 40516601 BUSHING 1 EA
3 40516701 BRACKET 1 EA
4 45001001 PLATE, BEC MTG. 2 EA
6 46182602 BRKT, AUTO MISS MARKER 1 EA
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8 46217104 R. BRIDGE ASSY (L-R) 1 EA
9 46217204 L. BRIDGE ASSY (L-R) 1 EA
14 46248301 BAD BD LIFT ASSY 1 EA
16 46268402 AUTO MISS MARKER ASSY 2 EA
17 46275101 BLOCK, SHAFT SUPPORT 4 EA
18 46275301 SHAFT 2 EA
19 46277602 BAD BD HOPPER ASSY 1 EA
24 46312801 BRACKET, HOPPER MTG 2 EA
25 46366401 PLATE, WASHER 2 EA
26 46388801 WASHER 8 EA
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27 46411401 NUT, TEE 1 EA
28 46476102 TRANSFER ASSY 1 EA
29 46477101 BRACKET 1 EA
30 46477201 BRACKET 2 EA
33 80000403 SHCS 8-32 X 1/2 1 EA
34 80000515 SHCS 10-32 X 1/2 10 EA
35 80000516 SHCS 10-32 X 5/8 8 EA
36 80000604 SHCS 1/4-20 X 5/8 6 EA
37 80000607 SHCS 1/4-20 X 1 2 EA
38 80000608 SHCS 1/4-20 X 1 1/4 4 EA
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40 80000715 SHCS 5/16-18 X 3 1/4 8 EA
41 80002502 SFHS 8-32 X 1/2 4 EA
43 80011003 SHSS 1/4 X 5/8 1 EA
44 80013802 SPRG PIN .062 X .250 1 EA
45 80013807 SPRG PIN .062 X .562 2 EA
This Document Supports Assembly 46365906 Rev. C

Page 9
Dual Head Board Handling System L/R T46365906 Rev. D
46 80015003 HEX NUT 5/16-18 8 EA
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48 80018704 SLW #8 1 EA
49 80018705 SLW #10 18 EA
50 80018706 SLW 1/4 8 EA
51 80018707 SLW 5/16 16 EA
53 80018805 FW #10 14 EA
54 80018807 FW 1/4 4 EA
55 80018812 FW 3/8 16 EA
56 80023508 HEX NUT-MS 10-32 7 EA
58 BLKM07122 WASHER, SPRING 1 EA
USED BUT NOT SHOWN ITEMS
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59 46303606 DHVCD BH ELECT.ASSY L TO R 1 EA
60 46366006 L-R DHVCD PNEU ROUTING ASSY 1 EA
61 50546801 DOC, DH BHS MACH 46365905-08 1 EA
62 T46365906 DOC, L/R DHBH SYSTEM 1 EA
This Document Supports Assembly 46365906 Rev. C

Page 10
T46365906 Rev. D Dual Head Board Handling System L/R
Functional Description
The Board Handling System receives two boards from an input mechanism.
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The boards are then lowered and transferred to the positioning system of the
insertion machine for population. The populated boards are then raised and
transferred to an output mechanism.
The Board Handling System can interface with a wide variety of input/output
mechanism and can handle a full range of board widths.
Maintenance Concept
The customer is required to perform periodic maintenance. Included procedures
are cleaning, lubricating and checking for correct function. Customer
performed adjustments and corrective maintenance procedures are identified
in the following table. Adjustment or corrective maintenance procedures not
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identified in this document and those procedures in the advanced support information
paragraphs are to be performed by Universal Instruments field engineering
personnel only.
Maintenance Procedures
Recommended
Frequency
Minimum Skill
Required
Spares Kit
Required
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Clean/Lubricate Bridge Slides Quarterly
Maintenance
Technician
No
Clean/Adjust Belts Quarterly
Maintenance
Technician
Yes
Clean Board Support Inserts Annually
Maintenance
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Technician
No
Lubricate Idler Pulley Shafts Quarterly
Maintenance
Technician
No
Lubricate Board Locator Flanged
Bearings
Quarterly
Maintenance
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Technician
No
Lubricate Actuator Contact Surfaces Quarterly
Maintenance
Technician
No
Lubricate Board Pusher Quarterly
Maintenance
Technician
No
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Clean Rodless Cylinder Quarterly
Maintenance
Technician
No
Clean/Lubricate Bad Board Lift Slide
Shafts
Quarterly
Maintenance
Technician
No
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Lubricate Board Stop Shoulder Screws Quarterly
Maintenance
Technician
No
Lubricate Auto Miss-Mark
Slide/Housing
Quarterly
Maintenance
Technician
No
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This Document Supports Assembly 46365906 Rev. C

Page 11
Dual Head Board Handling System L/R T46365906 Rev. D
This Document Supports Assembly 46365906 Rev. C
Procedures and Adjustments
Adjustments and corrective maintenance procedures required of the customer
are presented in the following subsections.
Belt Replacement and Adjustment
When periodic maintenance indicates that the belts need to be replaced, perform
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the following procedure for all belt replacement. Refer to the beam assembly
illustrations for belt routing.
1. Power the insertion machine down.
2. Loosen the screws that secure the right angle drive motor into the motor
block.
3. Raise the right angle drive motor to release the tension on the belt and
slide the belt off the drive sprocket.
4. Slide the belt off the convex pulleys, drive pulley and idler pulleys.
5. Install the new belt onto the convex pulleys, drive pulley and idler pulleys
as shown.
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6. Raise the right angle drive motor and slide the belt onto the drive
sprocket.
7. Allow the weight of the right angle drive motor apply tension on the
belt. Mark the position of the right angle drive motor relative to the
motor block.
8. Lower the right angle drive motor .125 inch from the mark made in
step 7 to increase the belt tension and secure it in position by tightening
the screw against the motor block.
Do not over tighten the drive belts. Excessive tension will put too much
pressure on the pulleys and drive mechanism causing premature failure.
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When properly adjusted, the drive belts will transfer a five pound board
without slipping.
End of procedure.

Page 12
T46365906 Rev. D Dual Head Board Handling System L/R
This Document Supports Assembly 46365906 Rev. C
Motor Block
Right Angle
Drive Motor
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Output Beam Assemblies
Input Beam Assemblies

Page 13
Dual Head Board Handling System L/R T46365906 Rev. D
This Document Supports Assembly 46365906 Rev. C
Belt Speed Adjustment Procedure
Purpose
The board handling distribution board must be adjusted to provide correct
belt speed for board transfer.
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Special Tools
VOM (meter)
This procedure must be performed with the machine power on. Care
must be exercised to prevent personal injury due to contact with
exposed electrical circuits.
Wear a wrist strap connected to ground to prevent electrostatic
discharge from causing damage to PCBs.
Procedure:
1. Power on the machine as described in the Operation documentation.
2. Push the INTERLOCK push button.
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3. Turn the INTERLOCK BYPASS key switch to the ON position.
4. Slide open the front covers to access the distribution boards.
5. Connect the positive lead of the VOM to TP1 and the negative lead to
TP2 on the board handling distribution board being adjusted.
6. Set the VOM for DC volts.
7. While observing the VOM, adjust the potentiometer POT 1 for 36 +/- 1
VDC.
Turning the potentiometer clockwise increases the voltage, while
turning the potentiometer counterclockwise decreases the voltage.
8. Remove the VOM test leads from the distribution board.
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End of procedure.

Page 14
T46365906 Rev. D Dual Head Board Handling System L/R
This Document Supports Assembly 46365906 Rev. C
Potentiometer POT 1 Test Point TP 1 Test Point TP 2
DISTRIBUTION BOARD

Page 15
Dual Head Board Handling System L/R T46365906 Rev. D
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This Document Supports Assembly 46365906 Rev. C
Sensor Adjustments
The board handling system uses sensors to signal various functional activities.
These signals are utilized by the software to control the timing of events
that occur during the board handling cycle. If a sensor signal is not received
or fails to deactivate as determined by the system, the system will go into a
transfer error condition and remain stopped until the error condition is corrected.
The sensors will not normally require adjustment. If sensor failure should
occur, use the following to determine proper sensor operation. The sensors
on the bridge assemblies are the most critical and a detailed sensor set up for
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these sensors is provided.
Bridge Slide (1003RS, 1004RS, 1103RS, 1104RS)
The sensors on the bridge slide mechanism sense the end of the stroke when
the bridges are fully elevated or lowered. When the piston is sensed in either
position, the red LED is illuminated. The green LED is a power indicator
and should be illuminated regardless of piston position. These sensors ensure
that the bridge mechanisms are either fully elevated or lowered before board
transfer can occur.
Bad Board Lift (1108RS)
The sensor on the bad board lift slide mechanism senses when the bad board
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lift is fully lowered. When the piston is sensed, the green LED is illuminated.
These sensor ensures that the bad board lift mechanism is fully lowered
before board transfer can occur.
Output Pusher (1107HS)
The sensor on the output pusher senses the full retraction of the pusher piston.
When the piston is sensed, the red LED is illuminated. This sensor ensures
that the pusher is fully retracted before board transfer can occur.
Transfer Mechanism (1011RS, 1111RS, 1112RS)
The sensors on the transfer mechanism senses the fully extended and retracted
positions as well as the slow down position. When the piston passes
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the sensors a yellow LED on the sensors is illuminated. The sensors on either
end of the transfer assembly ensure that proper board transfer has occurred.
The slow down sensor ensures that the board transfer mechanism
smoothly transfers the boards to the output bridge, by slowing the transfer
mechanism near the end of its stroke.

Page 16
T46365906 Rev. D Dual Head Board Handling System L/R
Auto Miss Marker (17PRS, 18PRS)
The sensor on the auto miss marker senses the full retraction of the air cylinder
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piston. When the piston is sensed, the red LED is illuminated. This sensor
ensures that the air cylinder is fully retracted before the positioning system
movement can occur.
Bad Board Hopper (1109LS)
The sensor on the bad board hopper is a micro switch that detects when the
bad board hopper is full of boards. This sensor should be adjusted to actuate
when the level of boards in the hopper is near the top of the hopper.
Bridge Sensor Adjustments (1000PS, 1001PS, 1101PS,
1102PS)
The sensors on the bridge assemblies sense the board locations during board
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transfer. The sensor red LED is illuminated when no board is present under
the sensor and extinguished when a board is sensed. The green LED illuminates
when a board is present under the sensor, indicating a stable signal.
The green LED does not illuminate when there is no board present (red LED
illuminated).
There are two types of adjustment that may be required when different
boards are used on the board handling system. The first type of adjustment is
for the sensor sensitivity. This may be required if board color or opaqueness
changes. The second type of adjustment is for the position of the sensor.
This may be required if the board has cut outs or notches.
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These sensors ensure the boards are in a safe position for board handling
functions.
Sensitivity Adjustment
Remove the board from under the sensor and turn the adjustment potentiometer
clockwise to find point A where the red LED extinguishes. If the red
LED does not turn off, turn the potentiometer to the maximum clockwise position
and take this as position A.
With the board in position under the sensor turn the potentiometer counterclockwise
and find point B where the green LED extinguishes.
Set the potentiometer at a point midway between points A and B. Confirm
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sensor operation where the red LED illuminates with no board present and
the red LED extinguishes and the green LED illuminates with a board
present.
This Document Supports Assembly 46365906 Rev. C

Page 17
Dual Head Board Handling System L/R T46365906 Rev. D
This Document Supports Assembly 46365906 Rev. C
Position Adjustment
Correct positioning of the sensors is very critical. Improperly
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positioned sensors may cause damage to the board and the Board
Handling System. Refer to the operation manual for details relating to
specific sensor designations for right to left or left to right transfer
directions.
The PCB in Gap Outside Left sensor (1001 PS) on the input bridge senses
that a board has completely entered the input bridge. If the board fails to
fully enter the bridge and the sensor remains activated, the system prevents
the bridges from being raised or lowered. The sensor must be set so the
green LED is illuminated when any part of the board is not completely on the
input bridge.
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The PCB at Outer Left Belt sensor (1000 PS) on the input bridge senses the
first board to enter the input bridge, starting a time delay to drive this board
against the inner board stop. The sensor then senses the second board to enter
the input bridge and stops the input bridge drive belts. The sensor must
be set to sense the second board when it is against the outer board stop. This
sensor continually monitors board position and, if a board is not seen, activates
the drive mechanism to keep the boards positioned against the input
bridge stops.
The PCB at Inner Right Belt sensor (1102 PS) on the output bridge senses
that the boards have properly entered the bridge when it senses both boards.
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If the boards fail to fully enter the bridge and the sensor is not activated
twice, the system prevents the bridges from being raised or lowered. The
sensor must be set so the red LED extinguishes when the board from
workboard holder 2 is fully on the output bridge.
The PCB in Gap Outside Right sensor (1101 PS) on the output bridge senses
that a board has been completely removed from the output bridge before allowing
the bridges to be lowered. The sensor must be set so the green LED
is illuminated when any part of the board is not completely on the output
bridge. The sensor also senses the leading edge of each board during transfer
and sets a time delay before the output board pusher is activated.
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Page 18
T46365906 Rev. D
Dual Head Board Handling System L/R
1006 PS1005 PS
TRANSFER DIRECTION
WORKBOARD
HOLDER 1
WORKBOARD
HOLDER 2
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1101 PS
RIGHT BRIDGELEFT BRIDGE
1001 PS
PCBPCB
1111 RS
1103 RS
1104 RS
SENSOR
OUTPUT
DEVICE
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SENSOR
INPUT
DEVICE
1102 PS
1107 HS
INPUT
DEVICE
OUTPUT
DEVICE
1112 RS
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BOARD
STOP
PUSHER
TRANSFER ASSEMBLY
1011 RS
1003 RS
1004 RS
INNER
BOARD
STOP
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OUTER
BOARD
STOP
1000 PS
PCBPCB
Board Located at Head Sensor Adjustment (1005PS,
1006PS)
The board located at head 1 sensor (1005 PS) on the actuator assembly
senses when the tooling pins are properly engaged in the board locating
holes. If the tooling pins fail to properly engage the locating holes and the
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sensor remains activated, the system prevents the bridges from being raised
or the insertion process to start and causes a TRANSFER ERROR. Improper
location of the tooling pins is when the pins are hitting the board or no board
is present and the pins rotate beyond the correct position. The sensor must be
set so the red LED is illuminated when the tooling pins are engaged in the locating
holes in the board.
The board located at head 2 sensor (1006 PS) on the actuator assembly
senses when the tooling pins are properly engaged in the board locating
holes. If the tooling pins fail to properly engage the locating holes and the
sensor remains activated, the system prevents the bridges from being raised
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or the insertion process to start and causes a TRANSFER ERROR. Improper
location of the tooling pins is when the pins are hitting the board or no board
is present and the pins rotate beyond the correct position. The sensor must be
set so the red LED is illuminated when the tooling pins are engaged in the locating
holes in the board.
The tooling pin sensors require adjustment when the board thickness changes
or the size of the locating holes changes. If either of the conditions accur, adjust
the tooling pin sensors as follows.
1
Insert the production board in the workboard holder and ensure that the
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tooling pins properly engage the locating holes.
2
Raise the sensors by turning the height adjusting screw clockwise until
the red LED extinguishes.
This Document Supports Assembly 46365906 Rev. C

Page 19
Dual Head Board Handling System L/R T46365906 Rev. D
This Document Supports Assembly 46365906 Rev. C
3. While counting the number of counterclockwise rotations, lower the
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height adjusting screw beyond the actuator until the red LED extinguishes
again.
4. Raise the sensor by rotating the height adjusting screw clockwise one
half the rotations counted in step 3.
5. Adjust the sensitivity of the sensors by turning the pot on the sensors
counterclockwise until the red LED extinguishes, then turning the pot
clockwise until the red LED just illuminates.
6. Verify the settings by improperly engaging the tooling pins as detailed
previously. In both cases the red LED should remain extinguished.
Properly engage the tooling pins to ensure that the red LED on the sensors
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illuminate.
Pneumatic Settings
The pneumatic controls and regulators on the board handling system are set
at the factory for optimum function of the system and should not require any
adjustment. If the controls and/or regulators have to be replaced or adjusted
for any reason, refer to the following adjustment procedures.
Assumption: Board handler sensor adjustments have been performed. Refer
to the Sensor Adjustments topic in this module.
Perform the following board handler setup procedures using IM Diagnostics.
. Adjust Bridge Up/Down Timing
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. Adjust Transfer Extend Slow Timing
. Adjust Transfer Extend Fast Timing
. Operate BHS and Measure Total Time
Setting the flow controls to an excessively high rate can cause damage
to the board handling system and the boards being processed.
Adjust Bridge Up/Down Timing
There are 4 bridge timing adjustments.
. Bridge up left
. Bridge down left
. Bridge up right
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