INSTALLATION, USER and MAINTENANCE MANUAL (Cod. 210-0137-e00)

© COPYRIGHT EQUI-TEC 2025

ALL RIGHTS RESERVED

This manual applies to the equipment
with serial #: i2ES 3401 - 2510091

EQUI-TEC di Daniele Reggi

via Canaletto 25/3 - 48022 Lugo (RA) - ITALIA

tel. +39 0545 1920230

e-mail: service@equi-tec.com

Partita IVA: 02685120392
VAT #: IT02685120392 

Certification 

equi-tec certifies that this product met its published specifications at the time of shipment from the factory.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of equi-tec.

Software License Agreement i2ES 3401

This product contains software embedded in the system Eproms that is developed, copyrighted and owned by equi-tec. Title to the program and all other proprietary rights applicable there to remain with equi-tec. Copying, reverse compiling, or disassembling the programs is prohibited. There is no obligation of confidentiality provided you do not reverse compile or disassemble the program. Violation of any of these terms results in immediate termination of this license.

Warranty Certificate

equi-tec warrants this equipment i2ES 3401 against defects in materials and workmanship for a period of twelve months from the date of shipment. During warranty period, equi-tec will, at its option, either repair or replace parts that prove to be defective. 

Warranty service consists of the free repair or replacement of the defective parts. Shipping fees for parts returned to or sent by  equi-tec or authorized service center shall be charged to the Buyer. 

Every substitute part will be under warranty for the remaining original warranty period and, in any event, for not less than 30 days.

equi-tec warrants that its software and firmware designated by  equi-tec for use with this equipment will execute its programming instructions when properly installed on that equipment. equi-tec does not warrant that the operation of the equipment or software, or firmware will be uninterrupted or error free.

Parts and tools not manufactured by equi-tec are subject to the conditions specified by the respective supplier

Limitation of Warranty

The foregoing warranty shall not apply to defects resulting from improper or inadequate maintenance by Buyer, buyer-supplied software or interfacing, unauthorized modification or misuse, operation outside the environmental specification for the product, or improper site preparation or maintenance. 

NO OTHER WARRANTY IS EXPRESSED OR IMPLIED. EQUI-TEC SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Exclusive remedies

THE REMEDIES PROVIDED HEREIN ARE BUYER'S SOLE AND EXCLUSIVE REMEDIES.

EQUI-TEC SHALL NOT BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

0. Standards and general warnings

0.1 Definition of operator

According to the provisions of Directive 2006/42/EC of 17 May 2006, Attachment I, Essential Safety Requirement 1.1.1, in this manual “operator” means: 

"the one or more personnel assigned to the installation, running, adjustment, maintenance, cleaning, repair, and movement of the machine".

0.1.1 Requirements for operators

Operators should possess full physical capabilities and be in full possession of their mental faculties, aware and responsible in relation to the dangers that can occur during the use of a machine.

Before starting any operations, the employer must provide adequate training and instruction of operators as provided for in Directive 89/391/C.

0.1.2 Prohibitions for operators

If operators are not in perfect psychological and physical condition they should not conduct any operations on the machine.

⚠️ DANGER OF SERIOUS INJURY!

The state of health of operators is very important for avoiding accidents in the workplace.

It is essential to be aware that operators who are not in perfect psychological and physical condition may cause serious damage, not only to themselves, but also to other individuals, animals or material goods within the workplace. 

The operator assigned to running the machine must not assume substances that might alter his or her physical and mental capacity (medicines, alcohol, drugs, etc.).

If an operator is obliged, for a limited period, to assume substances that reduce their capacities, they must inform the site (or company) safety officer. The latter will temporarily suspend the operator's responsibilities. 

The procedure of suspension and reinstatement must e documented with suitable medical certification.

⚠️ WARNING!

Operators must not permit unauthorised individuals to approach the machine during operation, and must not allow unauthorised persons to use the machine. 

The minimum recommended age for operators is 16 years.

⚠️ WARNING!

Operators must be suitably dressed for the type of work conducted on the machine.

0.2 Safety officer

According to the provisions of Draft Directive 89/391/EEC "Measures to promote the improvement of safety and health of workers in the workplace", installers and fitters of systems, machines, and other technical equipment must abide by the rules of safety and hygiene at work, as well as the instructions provided by the respective manufacturers of the machinery and equipment for which they are responsible. 

The Safety Officer should fill in and sign the following form:

0.3 Workers' obligations

The Directive of the Council of 12 June 1989 no. 391, concerning the application of measures intended to improve safety and health at work, lays down the basic criteria that workers must respect in the workplace in order to avoid accidents.

In particular article 13, in Section III of the Directive, specifically defines the obligations of workers:

1. Each worker must take reasonable responsibility for their own safety and that of others who might suffer the consequences of their actions or omissions at work, in accordance with their training and the instructions provided by their employer.

2. In order to achieve these objectives workers must, in accordance with their training and the instructions provided by the employer, abide by the following:

• • Use the machinery, equipment, tools, dangerous substances, means of transport, and other devices correctly.

  • Use the personal safety equipment made available correctly, and return the same to the correct position after use

  • Do not disable, change, or arbitrarily move the safety devices of machinery, equipment, tools, systems or buildings, and use these safety devices correctly.

  • Immediately inform the employer and/or workers who have a specific responsibility for the safety and protection of workers, of any work situation which, for reasonable motives, is considered to be a serious and immediate danger to safety and health, including any defect in the safety systems.

  • Assist in the carrying out of all necessary procedures and the satisfaction of all obligations, in accordance with normal practice, collaborating with the employer and/or workers who have a specific responsibility for the safety and protection of workers. 

  • Actively assist, within the relevant area of activity, the employer, and/or personnel who have a specific responsibility for the safety and protection of workers, to ensure that the working conditions and environment are safe and risk free.

In accordance with the provisions of Section II article 10, the employer will take the necessary measures to ensure that this directive and relative safety standards are known and observed. 

The employer will take the appropriate measures to ensure that workers and/or their representatives in the company and/or site receive, in conformity with laws and/or national practice (taking into account the size of the company and/or site), all the necessary information to safeguard the health and safety of operators.

⚠️ WARNING!

The present manual of use and maintenance for the machine must be kept by the person responsible in an easily accessed location, in good and usable condition and available to all those who are in some way involved in the operation of the machine and who explicitly requestto see it.

0.4 Importance of the manual

This manual provides information for the installation, use, and maintenance of the machine defined as i2ES 3401.

The machine must be used as described in the present manual, which should be studied before installing and starting up the machine. No parts of the manual may be skipped and particular attention must be paid to the framed text boxes. Compliance with the rules and advice contained in the manual ensures safe use and appropriate intervention. If discrepancies are found between the manual and the machine itself, users must inform the manufacturer before putting the machine into operation.

The manual of use and maintenance is an integral part of the machine. It must be kept intact, in a safe place throughout the life of the machine, and accompany the machine in cases of change of ownership.

It is forbidden to copy this manual, even in part, without prior authorisation from the company equi-tec.

For reasons only of clarity some illustrations in this manual show the machine or details of the same without cover panels and guards. The machine must never be used without all its covers and guards in place.

⚠️ WARNING!

Failure to abide by the instructions in the present manual of use and maintenance frees the manufacturer from all responsibility.

The manufacturer should be contacted directly for any information not included in or deducible from the following pages.

0.5 Technical assistance and maintenance

Routine and extraordinary maintenance must be carried out according to the instructions in the present manual. For all cases not included and for any type of assistance the manufacturer should be contacted directly. The data on the machine identification plate should be given for reference purposes:

• Machine model

• Serial number

• Year of production

Correct reference data ensures a quick and accurate response.

In cases of maintenance not conforming with the instructions in the present manual, with the use of non original spare parts, or without the written authorisation of the manufacturer, or in any way that might compromise the integrity or modify the characteristics of the machine, the manufacturer declinesall responsibility for the safety of individuals and the malfunctioning of the machine.

Any unauthorised form of modification annuls the guarantee/warranty stipulated in the contract.

 ⚠️ WARNING!

In cases of significant and complex maintenance work, refer to the drawings, electrical and pneumatic  circuit diagrams included with the documentation, and in the instructions in the present manual.

If in doubt, contact the machine distributor or manufacturer in order to guarantee safety in all cases.

When dismantling heavy or bulky parts check that adequate lifting equipment is available.

Check that the equipment available is suitable for the purpose, and never use inappropriate tools or equipment.

⚠️ DANGER OF SERIOUS INJURY!

Any modification that alters the characteristics of the machine from the point of view of safety and the prevention of accidents may only be made by the manufacturer, who will certificate theconformity of the machine with safety standards.

Therefore, any modifications or maintenance intervention not contemplated in the present manual is considered inappropriate. 

If the required maintenance operations are not included in the present manual of use and maintenance, the machine manufacturer must be contacted.

0.6 Requesting assistance or spare parts

When requesting assistance or spare parts, use the following address:

COMPANY ADDRESS

EQUI-TEC di Daniele Reggi
via Canaletto 25/3
48022 Lugo (RA) - Italy
telephone: +39 0545 1920230
WhatsApp: +39 334 574 2549
e-mail: service@equi-tec.com

1. General points

1.1 Symbols used in the manual

It is important to be aware of the significance of the symbols used in the present text, which highlight residual risks associated with the use of the machine:

 ⚠️ WARNING!

This means that failure to obey safety standards could result in minor injuries or minor damage to things. 

⚠️ DANGER!

This means that failure to obey safety standards could result in significant injuries or significant damage to things.

⚠️ DANGER OF SERIOUS INJURY!

Il mancato rispetto delle norme di sicurezza può provocare lesioni gravi o gravi danni materiali.

⚠️ CAUTION, RISK OF ELECTRIC SHOCK

Il mancato rispetto delle norme di sicurezza può provocare lesioni gravi.

👉 Particular care should be taken to abide by the instructions marked with this symbol.

1.2 Machine i2ES 3401

The present manual is relevant to: i2ES 3401, referred to for brevity as the MACHINE.

1.2.1 Description of the machine i2ES 3401

The machine consists of:

A  Machine body

B  Reel support

1.2.2 Intended and foreseen use

i2ES 3401 is a semi-automatic single in line package lead frame strip cutting machine for SIL LF (total height 18,1 mm pitch 1,27 mm – 2,54 mm thickness 0,25 mm).

During development of this machines a certain number of targets were kept in mind and, as a result, you have now the opportunity to take advantage of standard features as:

• Contact reel support

• Unwanted lead removal unit

• Stepping motor transport

• Double pitch indexing - 2,54 mm (0.100"), 1,27 mm (0.050")

• Upper tie-bar removal toothed shear

optional features as:

• Upper tie-bar scrap cutter

⚠️ WARNING!

ANY FORM OF USE OTHER THAN THAT STATED IS NOT ADMITTED BY THE MANUFACTURER.

1.2.3 Forms of use that are not permitted

⚠️ DANGER OF SERIOUS INJURY!

1. It is forbidden to connect the machine to energy sources other than those for which it was designed;

2. It is forbidden to use the machine with the guards tampered with or removed;

3. It is forbidden to use commercial devices for purposes other than that foreseen by the manufacturer;

4. It is forbidden to climb onto the machine or parts of the same in order to carry out work that is not part of maintenance or other normal operations, or to use auxiliary devices like ladders or catwalks to carry out the maintenance or other work foreseen by the manufacturer;

5. It is forbidden to use lead frames different from those quoted in paragraph 1.2.2.

1.3 Manufacturer

EQUI-TEC di Daniele Reggi

Via Canaletto 25/3

48022 - Lugo (RA), ITALIA

http://www.equi-tec.com

service@equi-tec.com

Tel.  +39 0545 1920230

WhatsApp +39 334 5742549

1.4 Identification plate

Every machine is identified by its type, serial number, and year of construction, which are found on the identification fixed on the machine. 

This plate is very important and the following guidelines must be followed: 

• Never remove the plate from the original position chosen by the machine manufacturer; 

• Do not modify or falsify the technical data; 

• Do not clean the plate with sharp objects (e.g. metal brushes) as they may nullify the above. 

All the data on identification plates must be readable. Use the identification data indicated in communications with the manufacturer when requesting spare parts, information, assistance, etc. 

If the identification plate deteriorates during use and is no longer readable, a replacement should be requested from the manufacturer, citing the data in the present manual or on the original plate.

1.5 Specifications

Machine specifications

LF Alignment: zero reference of Lead Frame guaranteed 

by fiber optic sensor at power-up.

Space requirements: (see general drawing)

Machine body: 530 mm long x 360 mm wide x 565 mm tall
Averall: 1033 mm long x 360 mm wide x 835 mm tall

Weight: about 25 kg

Power requirements

Voltaggio di collegamento: 100..240Vac 50/60 Hz

Potenza: 720W

Fuse: 4 @220V Fast

Auxiliary voltage: 24 Vdc

Working: electromechanical and pneumatic

Machine type: semi-automatic

Compressed air

Pressione: 6 bar (87 PSI)

Pneumatic connection: 1/4"

1.7 Personal safety equipment

Personal safety equipment to be used by operators assigned to the operation of the machine:

• SAFETY SHOES

• GLOVES

• GOGGLES

• PROTECTIVE OVERALLS

For other specific cases see Chapter 2 "Installation" and Chapter 7 "Maintenance".

2. Installation

The machine may, by law, only be installed in environments with the following characteristics:

• INDUSTRIAL

• SHELTERED ENVIRONMENT (not subject to atmospheric agents)

The operator assigned to the installation of the machine must be adequately trained and informed of the work to be carried out. The operator must use adequate means to allow installation in safe conditions. It is important that all the instruments used for installation are in perfect condition and they must be used according to the instructions of the respective manufacturers.

Operators must also know the legislation and standards that govern themselves and other individuals exposed to risk, in relation to the machine and the work environment.

For operator information, the following is a list of tools required for simple and safe installation:

• ALLEN WRENCH SET (included)

• WRENCH SET

• MEASURING TAPE

2.1 Site requirements

The machine must operate in a sheltered environment, with a regulated temperature and limited exposure to dust and humidity.

Generally, an environment that is comfortable for you is adequate for your machine. You should have:

• Easy access to a properly grounded, three-pronged electrical outlet that is on a line separate from that used by heavy equipment.

• Centralised or local air supply system. The air intake is on the right side of machine, where a 1/4" fitting must be installed.

• Adequate lighting that minimises glare on machine.

• No direct sunlight on machine.

Unless otherwise stated on the machine order document, the machine is intended for normal use in the ambient conditions defined below. Ambient conditions other than those defined here may cause malfunctions or breakage with the possibility of danger to individuals.

If ambient conditions are very variable, the means and characteristics of conditioning must be agreed.

ALTITUDE

The altitude of the installation site must not be higher than 1000 m above sea level.

TEMPERATURE

Minimum ambient temperature +5 °C

Maximum ambient temperature +40 °C

ATMOSPHERIC CONDITIONS

The electrical equipment is able to operate correctly in atmospheric conditions with a relative humidity 

below 50% at a temperature of 40°C, and 90% at temperatures below 20°C (without condensation).

LIGHTING

The machine does not have its own lighting.

The lighting system of the site is important for the safety of personnel and the quality of work.

Minimum lighting: adequate for the perception of the symbols and signs (about 300 lux).

Maximum lighting: below the level at which operators are dazzled.

In the case of maintenance operations in areas and/or parts of the site not adequately lit, it is obligatory to use a portable lighting system, avoiding shadows that prevent or reduce visibility in the area in which the work has to be conducted and surrounding areas.

ENVIRONMENTS AT RISK OF EXPLOSION AND/OR FIRE

The machine is not designed to operate in environments which are subject to the risk of explosion or fire.

2.2 Required space for operation

Delimit the operator’s area leaving adequate space for operation and maintenance.

When locating the machine, ensure that the space available around the machine is not less than 1 m (1 yard) in all directions, and one extra meter on the right for mounting the contact reel.

The choice of location and adequate space for positioning the machine is important for the quality of work (maintenance, safety, etc.). The area must be well lit and ventilated.

The ambient and operating conditions must not hinder access to the machine controls, in particular the emergency stop. The full range of machine operation must be guaranteed, also taking maintenance requirements into account.

2.3 Lifting and transport

For transport, the machine is divided into the following components:

• Main machine body;

• Reel holder arm;

For lifting the machine or parts of the same, use means with a higher lifting capacity than the stated machine weight.

The following lifting systems can be used:

• crane or hoist;

• fork lift truck;

• manual lifting.

Before starting to move the machine, ensure that:

• the lifting system functions correctly;

• the capacity of the lifting system is adequate.

During lifting and movement of the machine, every possible precaution must be taken to avoid dangerous movements that could cause accidents or damage to persons or things.

Take extreme care to avoid damage to persons or things.

⚠️ WARNING!

Avoid sudden movements that could cause damage to the machine.

This operation should be conducted by skilled personnel.

Ensure that nobody is exposed to danger in the area at risk.

DURING MOVEMENT THE MACHINE MUST BE MAINTAINED IN A STABLE, SAFE POSITION.

DURING LIFTING THE ENTIRE AREA AROUND THE MACHINE IS CONSIDERED AS A RISK AREA.

Until the groups are completely raised, the correct balance of the same should be constantly monitored. Lifting should be gradual (without jerking).

Keep the load as low as possible during movement in order to maximise stability.

Unpacked machines must be covered during transport.

2.3.1 Lifting and transport with packaging

The machine is divided up as defined in Par. 2.3 and inserted into a closed case.

Packed Machine weight: about 30 kg

The case may be lifted by using:

• crane or hoist;

• fork lift truck

• manual lifting

When lifting the machine while still packed, follow the graphic indications for forks positioning.

For storage, follow the graphic instructions on the package, that is:

• Handle with care (fragile)

• Package orientation (Top/Bottom)

• Store in dry place

• Do not stack

⚠️ DANGER OF SERIOUS INJURY!

Before installation, the machine may suffer serious damage if it is exposed, while still packed, to extreme temperatures. Avoid exposure to temperatures below -10°C and above +50°C.

⚠️ DANGER!

STACKING IS FORBIDDEN.
PACKING CASE COVER AND SIDES CANNOT BEAR A PACKED MACHINE WEIGHT.

2.3.2 Unpacking

Machine is hooked on a pallet and packed into a wooden box to assure a safe transport. Inside box there is place for accessories, disassembled parts like reel support, final cut device, operator console, etc.

Cut stripes that hold cover in place, lift it and remove accessory parts. Untighten eight screws to free machine legs from basement. Carefully lift machine and put its feet in place. Level machine when in its 

Position it with one meter (1 yard) of clearance all around and one additional meter (1 yard) on the right for mounting the contact reelfinal position.

A spirit level with a precision of 0.1 mm is recommended for levelling.

2.3.3 Lifting and transport without packaging

The machine is divided up as described in Par. 2.3 and lifted, according to group, in the following way:

• 1st GROUP: MAIN MACHINE BODY
  Lifting system: MANUAL (two persons).

• 2nd GROUP: REEL ARM
  Lifting system: MANUAL..

2.4 Checking of contents

All the materials are carefully checked by the manufacturer before consignment.

Ensure that the contents of the packaging correspond to the packing list included with this documentation and that the machine did not suffer damage during transportation.

Notify equi-tec of any missing or damaged item within 7 days of receiving the goods.

2.5 Initial assembly

During the assembly of the machine all possible safety measures must be taken to avoid dangerous movements that might lead to accidents or damage to persons or things.

⚠️ WARNING!

Before starting assembly the following equipment should be made available:

• SET OF ALLEN KEYS (supplied with machine)

and the following personal safety equipment:

• GLOVES

• SAFETY SHOES

COMPOSITION OF THE MACHINE INSIDE THE CASE

• machine body;

• reel arm.

• Accessories (2 boxes)

2.5.1 Mounting reel support

Unpack the aluminium reel support. Locate the 2 M5 countersunk holes on right side of machine base and mount the supports on the table.

2.5.2 Connection to power supply

CONNECTION TO THE ELECTRICAL SUPPLY

Take the maximum care when connecting to the electrical supply. The line should not be electrically live during connection and all safety precautions should be taken.

The connection of the machine to the electrical supply must carried out by specialised personnel, in conformity with the relevant STANDARDS of good practice and safety.

The machine must be connected to an effectively earthed/grounded supply network, and this should be checked on installation.
If there are doubts about the reliability of the supply network, do not connect the machine.

Users must provide an adequate power breaker switch to disconnect the machine from the supply, in addition to an efficient system of protection against overloading and indirect contacts.

Effective protection against overloading includes:

• fuses

• automatic circuit breakers.

Effective protection against indirect contacts includes:

• differential switches

• fault sensors

When connecting, check:

1. that the supply voltage has the same voltage and amperage as that stated on the label on the base of the machine and in the electrical circuit diagram attached to the machine (the wrong voltage could damage the machine);
   -  No need to select correct voltage as the power supply will function from 100Vac to 240Vac 50/60 Hz

2. that the power supply has an adequate earth/ground system;

3. the correct position and fixing of:

• • guards

  • emergency buttons

Connect the machine using cables appropriate for the absorbed power.

Use connection accessories (lead-in, bolts, etc.) suitable for the cable to connect and the absorbed power, assembled according to the manufacturer’s instructions and good practice.

2.6 Starting Up

Connect the air pipe and supply clean air at 6 bar (87 PSI). Adjust pressure with the regulator.
Connect the power supply cable and switch the machine on from the power switch.

The machine's control panel (see figure below) will show the three button LEDs flashing slowly.

This means that a "HOME" operation must be performed to synchronize the LEAD FRAME with the knives.

If nothing happens, please switch machine off and refer to troubleshooting section, later in this manual.

3. Safety

3.1 Control and safety devices

⚠️ WARNING!

Never tamper with safety devices.

Before putting into operation ensure that safety devices are correctly positioned and check their efficiency by direct activation.

If safety devices malfunction, immediately put the machine out of service and inform the person responsible for maintenance.

The machine is fitted with the following control and safety devices:

• 1 power switch (Image 3-1)

• 1 mushroom emergency switch (Image 3-2) 

SEMI-AUTOMATIC OPERATION

Machine is designed for semi-automatic operation. To guarantee the operator safety during machine cycle, rules explained below are followed:

1. The cycle is started by pressing the START/STOP button.

2. To stop the cycle, you can press the START/STOP button.

3. To restart the cycle, follow the instructions in step 1.

4. The drive wheel is protected by a guard. 

5. The pulleys that move the drive wheel are inside the machine's casing and protected by a guard.

PULSANTE DI ARRESTO DI EMERGENZA

Machine is equipped with a mushroom-like push-button that immediately stops any machine operation when pressed. To restart machine, you have to:

1. Turn the button as shown by the arrows till it is released.

2. Act as usual after a machine power-up.

4. Machine operation

⚠️ DANGER OF SERIOUS INJURY!

BEFORE STARTING ANY OPERATIONS WITH THE MACHINE, MAKE A VISUAL CHECK THAT NOBODY IS WITHIN THE AREA AT RISK.

4.1 Warnings for operators (for the safe use of the machine)

⚠️ WARNING!

Do not carry out any manoeuvres that are not expressly foreseen as part of the operating cycle of the machine. 

Keep the work area clean and free of obstacles, organising the materials to be processed, the finished goods, and the equipment in a logical way.

Do not tamper with or alter the functionality or efficiency of safety devices, sensors, microswitches, or any protective element on the machine.

It must always be kept in mind that dangerous situations may arise when using any machine.
Operators should concentrate on the task to be carried out before starting any procedure.

It is important to be constantly alert and ready to react: attention and good reflexes are essential qualities for an operator

Whenever the operator is subject to any form of illness or unfavourable physical conditioning, even of a minor nature, which could reduce their level of attention, they should not start up the machine or work with the associated or accessory equipment.

⚠️ DANGER OF SERIOUS INJURY!

During the use of the machine it is absolutely prohibited to neutralise, remove, modify, or render ineffective any safety device, guard, or control in any position.

All the safety devices and guards, both on the machine, and the associated and accessory equipment, must be maintained in full and constant efficiency.

The labels and signs bearing instructions, advice, and danger warnings must be maintained clearly readable and in the correct position.

⚠️ DANGER!

Before putting the machine into service check the calibration of the safety devices on the electrical supply line and ensure that the protection against accidental electrical and mechanical contact are correctly positioned and fixed.

4.2 Description of control devices

• MAIN SWITCH: it connects the machine to the main supply

• EQUI-TEC ELECTRONICS: buttons for managing the electronics that control the operation of the machine in the selected operating modes.

• EMERGENCY BUTTON: locking mushroom button which, when pressed, stops the machine in the current processing stage. To restart the machine the button must be reset by rotating it as indicated by the arrow

4.3 Lead frame loading

To mount new reels of contacts on i2ES 3401 machine follow suggested sequence of operations explained below:

• Machine is in STOP mode.

• Mount and secure a new reel of contacts.

• Cut Tie-bar as shown on picture, this will ease loading operation.

• Insert the lead frame along the lead frame path using the knob on the toothed shears.

• Facilitate the diversion of the upper tie-bar towards the scrap cutting unit.

• Feed lead frame up to motorized sprocket wheel and press <Left>/<Right> arrow buttons to make lead frame engage the wheel.

• Continue feeding it up to strip cutting device then press STOP to exit load function. A zero (HOME) function will be automatically executed.

If this is your first time setting up the machine or you have moved the cutting unit or removed the drive wheel or the Lead Frame transport pulleys, then you must position the STRIP cutting unit so that the knife is exactly halfway between the two contacts.

After maintenance on the motor wheel or pulleys, the contact cutting unit must also be repositioned to obtain a centered cut on three contacts.

• At this point you can reactivate the JOG function (press the START/STOP button for at least three seconds and release it when it flashes briefly). Use the <LeftArrow> (◄) button to advance the Lead Frame until the scrap comes out of the scrap cutting unit's knife.

• Press STOP to exit JOG function. A zero (HOME) function will be automatically executed.

4.4 Adjusting the toothed shear

To adjust the cutting position (contact length), you must loosen the screw (M4) that secures the shear to the shaft and move it to the new position.

When tightening the screw, you must align the teeth with the pins on the wheel; otherwise, the contacts will all be bent to the right or left.

4.5 Selective Contact Cut device adjustment

The selective contact cut device, at present, cuts three contact at a time (1,27 mm [0.050”] pitch).

The drawing above shows you different conditions that may happen during device adjust. Condition #1  means Unit has to be moved slightly to the right, while condition #2  means Unit has to be moved slightly to the left, in order to be centred on the three contacts to be cut.

4.6 Optical Sensor Adjustment (lead frame transport)

The optical sensor that monitors the lead frame's position is positioned in a specific slot. If this device fails, check its cleanliness and height. The fiber optic sensor head should be as close as possible to the lead frame, but not touching it. For example, 0.5 mm [0.02 inches] lower than the guide rail so it can read the lead frame without damaging it or getting dirty.

4.7 Emergency stop

Should an hazardous condition occur, press Emergency Stop push button (see paragraph 3.1 and 4.2).

By pressing Emergency Stop push button, entire machine will immediately stop, electrical connection will be disconnected.

To restart normal working condition, release Emergency Stop push button by rotating its knob towards the direction indicated by arrows, then act as usual after a machine power-up.

4.8 Switching machine on

• Connect Mains supply.

• Check that air supply is connected to machine inlet.

• Check correct installation of machine, as described in paragraph 2.5 (Initial assembly).

• Press Emergency Stop push button and verify that it work as described in paragraph 4.6 (Emergency Stop).

• Switch machine on by the switch on the rear of the machine.

• Follow instruction explained in Chapter 5 – Software Description.

4.9 Switching machine off

Press red push button or main switch on the rear of the machine (see paragraph 4.2).

Once HOME is completed, all LEDs are switched off. This is STOP mode.

To start producing strips, RUN push button has to be pressed. To return to STOP mode, RUN/STOP push button has to be pressed.

To return to initial (power-up) status, RUN/STOP push button has to be pressed and retained for at least 3 seconds.

5.1 Machine Cycle description

The machine cycle is very simple.

•  Lead Frame is transported (7 contacts) then stopped and 3 contacts are cut. This operation is repeated 10 times per machine cycle.

•  At the end of the 10x 7_pin_pattern a strip is cut and tie-bar (rejects) is cut.

•  If STOP push button has not been pressed, another cycle will begin.

5.2 STOP Mode

When in Stop mode the Mode keys perform the following functions:

<START> [short press] machine cycle will start. Green LED on denotes you are in RUN mode.

<LeftArrow> not active (◄)

<RightArrow> not active (►)

<START> [3 second press] machine resets to power-up status. Three LEDs blink slowly (one second ON, one second OFF)

5.3 RUN Mode

When in Run mode machine continuously produces 10x 7_pin_pattern strips. Press STOP to exit RUN mode.

5.4 POWER-UP Mode

After machine power-up or when in STOP mode, by pressing RUN push button for at least 3 seconds, all LEDs blink slowly.

In this mode operator can slowly rotate motor wheel to load a new reel of Lead Frame (left / right arrows push buttons to move ◄ forward / backward ►) or press RUN/STOP push button to start a HOME function.

6. Error Messages / Operator Messages

When machine is switched on, The three LEDs on console push button blink slowly (1 second on – 1 second off). This is a warning that a “HOME” function has to be done. 

It also signals that “JOG” functionality is available and motor wheel can be turned counter-clockwise (◄ forward) or clockwise (backward ►) for lead frame loading purposes.

When performing a “HOME” function, lead frame is moved backwards so the sensor finds a transport hole and then it is moved forwards to detect the edge of the same hole. This operation gives repetitiveness the the positioning of lead frame with respect to the knives.

When the correct sequence is not completed successfully, an error is shown by blinking the green LED in a dash-dot way (long blink then short blink). Fiber Optic sensor should be checked at this time.

7. Maintenance

⚠️ WARNING!

It is extremely important that site managers and operators assigned to the maintenance of the equipment are aware of the need to strictly obey all the rules stipulated by safety authorities, in addition to the specific measures listed in the present chapter.

Only the assigned specialised personnel may carry out maintenance, cleaning, and dismantling of machine parts and devices.

7.1 Warnings for operators

⚠️ WARNING!

BEFORE STARTING MAINTENANCE CHECK THE FOLLOWING CONDITIONS:

• ELECTRICAL ENERGY DISCONNECTED

• PNEUMATIC ENERGY DISCONNECTED

• MANUAL PNEUMATIC CUT-OFF VALVES CLOSED

• NO RESIDUAL PRESSURE OF ANY KIND PRESENT

• NO UNAUTHORISED PERSONS PRESENT

• PORTABLE LIGHTING SYSTEM AVAILABLE

• EQUIPMENT AVAILABLE FOR EFFICIENT MAINTENANCE

• NO RISK OF THE EJECTION OF PRESSURISED FLUIDS

• AREA CLOSED OFF

• PERSONAL SAFETY EQUIPMENT REQUIRED:

- GLOVES

- GOGGLES

- PROTECTIVE OVERALLS

- SAFETY SHOES

SAFETY RESTRICTIONS MAY ONLY BE REMOVED AFTER MAINTENANCE HAS BEEN COMPLETED AND ALL ELECTRICAL AND MECHANICAL SAFETY GUARDS HAVE BEEN REPLACED AND FIXED IN PLACE. 

⚠️ WARNING!

It is good practice to use only original materials for repairs in order to ensure the safety of the machine.

If additional instructions are required or if particular problems arise, do not hesitate to contact the distributor or machine manufacturer directly.

It is very important that all the instructions on the machine, on the circuit diagrams, in the attached documentation, in the service instructions, and in the present document are obeyed, in order to avoid malfunctions which in turn could lead directly or indirectly to serious accidents or damage to persons or things

In cases of substantial and complex maintenance, refer to the drawings included in the attached documentation.

When dismantling heavy or bulky parts, ensure that adequate lifting equipment is available.

Check that the tools and equipment available are suitable for the purpose, and never use tools or equipment incorrectly.

⚠️ WARNING!

Tighten fixing screws, bolts, or ring nuts of all mechanical elements subject to adjustment or fine-tuning with normal tightening torque without using additional levers or hammering the spanners.

7.2 Checking the pneumatic system

Periodically check the air handling unit settings.

Check the general condition of the pipes, fittings and connection assemblies within the system.

Check the condition of valves and cylinders.

REPLACE SYSTEM PIPES WHEN NECESSARY.

7.3 Checking the electrical system

Clean and check the efficiency of the safety microswitches (Emergency STOP).

Check the general condition of the terminals, the tightness of the cables and all other components that, if not perfectly efficient, could cause machine malfunctions.

7.4 Ordinary maintenance

7.4.1 Knives sharpening

Unwanted lead cut (PIN CUT), strip cut (FINAL CUT) and reject cut (TIE-BAR CUT) devices are pneumatic cylinders whose shaft is shaped and sharpened to perform a cut operation when activated.
The counter knife is lead frame guide itself. Unwanted Lead Cut knife and counter-knife are assembled with a play of 0,02 mm (0.0008") while Strip Cut and Reject Cut knife and counter-knife areassembled one near the other (no gap between them).

If you discover some burr on contacts, please check that both parts are correctly positioned.

To sharpen knives, disassemble the device and grind shaft surface. A few hundredths of mm will be enough (0,03 mm = .0012").

After piece is ground a few times it may happen that cylinder stroke is not long enough to accomplish a cutting operation. In this case you have to order a spare piston-knife assembly replacement.

UNWANTED LEAD CUT

Sharpen surfaces, pointed to by an arrow in the drawing, only if needed (i.e. may be only knife need grinding). Re-assemble device adding a few Molykote '55' grease (EQUI-TEC code 104-0098) to the seal only.

The stem must be thoroughly clean and dry (no grease added).
Replace the O-ring on the stem after 20,000 cutting operations or once a year.

STRIP CUT

Sharpen the surfaces indicated by the arrows in the drawing and reassemble the device, adding a littleMolykote '55' grease to the seal only (EQUI-TEC code 104-0098).

The stem must be thoroughly clean and dry (no grease added).
Replace the O-ring on the stem after 20,000 cutting operations or once a year

REJECT CUT

Sharpen the surfaces indicated by the arrows in the drawing and reassemble the device, adding a little 

The stem must be thoroughly clean and dry (no grease added).
Replace the O-ring on the stem after 20,000 cutting operations or once a yearMolykote '55' grease to the seal only (EQUI-TEC code 104-0098).

7.4.2 HOME position (motor) sensor

Check that the sensor has not become dirty due to metal dust deposits during the passage of the Lead Frame. Clean it if necessary.

If you experience a lot of home errors (green LED flashing "dash - dot") try adjusting the sensitivity of its amplifier.

8. Troubleshooting

8.1 Machine does not power-up

Symptom: No operation at all.

The EMI filter socket group fuses have blown, Emergency Stop push button pressed and locked.

Remedy: Replace fuses inside main switch and/or release Emergency Stop push button.

8.2 No machine operation

Symptom: No LEDs lit or flashing. Motor driver LED is on

Probable CPU failure.

Remedy: Try turning it off, waiting a few minutes, and then turning it back on. If the defect persists, change the CPU (Controllino Mini).

Symptom: Buttons are lit/flashing, but do not respond to pressing

Faulty wiring, disconnected cables.

Remedy: Open Console box and check the cable wiring.

8.3 Feeding anomalies

Symptom: Inaccurate unwanted contact cut

Air pressure is not 6 bar (87 PSI) or HOME synchronism has to be performed.

Remedy: Check the air pressure and adjust it to 6 bar (87 PSI). If necessary, press RUN / STOP for more than 3 seconds, then perform a HOME function.

9. Scrapping

9.1 Dismantling and scrapping

In accordance with EC Directives or the laws in force in the country in which the machine is used, the user is responsible for the dismantling and elimination of the materials making up the machine.

Before dismantling the machine the user must inform the manufacturer, communicating all the data on the machine identification plate.

In cases of scrapping of the machine or parts of it, all necessary safety measures must be taken in order to avoid the risks associated with the dismantling of industrial machinery.

Particular care must be taken during the stages of:

• disassembling the machine in the operating area.

• movement and transport.

• dismantling.

• separation of materials.

⚠️ WARNING!

For the operations of separation of materials and their recycling or disposal, refer to national and regional laws for the disposal of solid industrial waste and toxic and harmful waste.

9.2 Dismantling of components and materials

When scrapping, the user, in accordance with local regulations in force, must exercise particular care in the dismantling of materials including:

• GUARD MATERIALS (PVC AND METHACRYLATE)

• PLASTIC PNEUMATIC PIPES

• INSULATED ELECTRICAL CABLES

• PARTS IN RUBBER

If the materials used for the production process, lubricants and water condensation are not disposed of according to the laws and regulations in force, they may represent residual risks of:

• environmental pollution

• intoxication of the personnel assigned to disposal.