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APC-7000 Polishing System User Manual

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1. Do not run a polishing cycle without the proper stack up of polishing media rubber pad glass plate or grinding media all stacked and sitting in the removable platen Doing so may damage these items Abort using the CLEAR KEY If aborted make sure the connectors are prepared properly prior to running them through the recipe again Prepare for the next polishing step The display indicates the next step in the recipe NOTE If a step has zero time entered in its recipe then it is skipped Step 2 Clean between polishing steps Use a soft lint free cloth with water so as not to damage the polished surfaces Thoroughly clean the fixture with water taking care to clean out residue from all the entrapment areas on the underside of the fixture Care must be taken to not cause cross contamination of the polishing media Step 3 Complete the preparation by following preparatory Steps 6 through 10 of Section 11 3 Preparation This includes selecting a different rubber pad if specified by the recipe and changing polishing films as specified by the recipe Step 4 Repeat all the steps in this section for each recipe step until the polishing cycle has been completed Upon completion the display will return to Step 1 Step No 1 Proc_time 30 Step 5 Remove the fixture from the fixture spindle by lifting it off of the mounting pins Step 6 Thoroughly clean the connectors ferrules the fixture and all rotational surfaces 2 Clean th
2. Photonic Components Inc APC 7000 Polishing System User Manual Revision D August 2003 We provide superior solutions for global fiber connections APC 7000 2 of 62 THIS DOCUMENT IS PROVIDED ONLY FOR APC 7000 CUSTOMER USE 2002 Photonic Components Inc All Rights Reserved This document is for informational purposes only and the Company assumes no responsibility for any errors or omissions in this document Photonic Components reserves the right to make changes to specifications and product descriptions at any time without notice and shall have no responsibility for conflicts or incompatibilities arising from such changes and makes no commitment to update the information contained herein The information in this document is current only as of the date of release of this document Photonic Components makes no warranty for the use of its products other than those expressly contained in the Company s standard warranty provided as part of Photonic Component s Sales Terms and Conditions for such products PCI has granted to Buyer rights to use the APC 7000 only as specifically set forth in this manual and for no other purposes and PCI reserves all rights not expressly granted herein Without limiting the generality of the foregoing PCI is and shall remain the owner of all right title and interest including copyright trademark patent and all other intellectual property rights in and to the APC 7000 and any softw
3. INCIDENTAL INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY NATURE INCLUDING WITHOUT LIMITATION LOST PROFITS BUSINESS INTERRUPTION OR LOSS OF BUSINESS INFORMATION EVEN IF PCI OR BUYER OR THEIR AFFILIATES SHALL HAVE BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES THE FOREGOING SHALL APPLY REGARDLESS OF WHETHER SUCH LIABILITY SOUNDS IN CONTRACT TORT NEGLIGENCE STRICT LIABILITY OR ANY OTHER THEORY OF LIABILITY EXCEPT AS EXPRESSLY SET FORTH IN THIS LIMITED PRODUCT WARRANTY SENKO MAKES NO AND HEREBY EXPRESSLY DISCLAIMS ANY REPRESENTATIONS OR WARRANTIES EXPRESS OR IMPLIED REGARDING THE APC 7000 OR THE OPERATION OR OTHER USE OF THE APC 7000 INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE PCI DOES NOT WARRANT THAT THE FUNCTIONS OF THE APC 7000 WILL MEET BUYER S REQUIREMENTS OR THAT THE OPERATION OF THE APC 7000 WILL BE ERROR FREE For use by APC 7000 Customers ONLY 5 of 62 APC 7000 Warranty Registration Return the following registration information to PCI within 30 days after receipt of product to ensure valid warranty coverage Photonic Components Inc APC 7000 Warranty Registration Company Name Address 1 Address 2 City State Province Zip Postal Code Country Technical Contact Information Name Email Phone Product Information Product Receipt Date Serial Number Email information to sales senko com or
4. 8 2 Keypad Functionality 26 of 62 A closeup of the keypad is shown in Figure 8 1 Note that there is an LED associated with each numeric key these are lighted at various times to indicate different meanings Some of the keys CLEAR have different functions depending on the operating mode of the machine and are described below for each of the APC 7000 operating modes Figure 8 1 K d and LCD KJ EJ KJ E eI Display MAN 7000 Rev D August 2003 While in the System Ready State This is the state where the Production Edit Mode screen is displayed Press 1 Production 2 Edit recipe The unit powers up into this state Also completed and aborted polishing steps return to this state ENTER KEY held for 3 5 seconds displays the System Configruation Screen LEFT ARROW KEY held for 3 5 seconds displays the software version Pressing it again or pressing the CLEAR KEY returns the unit to the System Ready state While running a polishing cycle polishing motor running REMINDER CLEAR KEY immediately halts all polishing operations shuts down the polishing motor and forces the robotic head assembly to retract to its home up position The current and any remaining recipe steps are cancelled This key should be used for emergency aborts or for full resets to the beginning of the recipe For EMERGENCY ABORT Press CLEAR HELP KEY pauses a polishing step The robotic head returns home Pres
5. Fax this form to SENKO Sales at 1 858 623 3303 Please complete registration within 30 days after receipt of product 6 of 62 MAN 7000 Rev D August 2003 Revision History Revision Date Description Cc March 2002 Updates to reflect v 3 0 software release including adding separate coarse and fine load settings added use of key to select Setup Mode Added section 4 Specifications Added requirements for partial fixture loading Expanded a number of sections Fold in user feedback New style and formatting August 2003 Updated Section 14 Routine Maintenance including the addition of 15 2 Calibration removal of 15 3 Robotic Head Spindle Lubrication and addition of 15 5 Motor Hours Meter Updated Section 11 4 Setup Procedure For Proper Load For use by APC 7000 Customers ONLY 7 of 62 APC 7000 Contact Informations i eer i en a AEE ai Ae 3 PCI Limited Product Wat ida iba 4 1 Operator and Equipment Sai A A AA did 10 1 1 Safety Terms used in this Ma li ide 10 1 2 Selected Warning Sree e a E E a E E A E 11 PAE A O 12 2 1 PCI Development and Evaluation Lab Support ocooonoccnonncocanonanonaconcconncanncnnncnnonnn ono nonanonancnnnonns 12 2 2 Important Terms used in this Manada aid da 13 Be IMIOdUCAO Na ra A A A a a a eE E RER 14 Ae E S e BE Orn CO a IARE AT E E EREE E E E A Sue 18 4 1 Product Specifications ero
6. and alignment There is no need to remove the Turntable For use by APC 7000 Customers ONLY 51 of 62 APC 7000 15 1 Periodic Cleaning 52 of 62 The fixtures require frequent cleaning to avoid cross contamination during polishing Their many surfaces and crevices trap contaminants and micron particulate which requires ultrasonic cleaning for effective removal Use a machine such as the APC 2000 Ultrasonic Cleaner Non ionic cleaning solutions should be used for best results The front panel must be cleaned using plain soap and water as cleaning solutions or solvents can harm the plastic Although the front panel is sealed it is important to use water sparingly to avoid forcing any behind the panel A CAUTION Do not immerse the unit in water or other liquids Equipment is designed for indoor use only Although the APC7000 uses a water spray the product is NOT intended to be used in very wet environments or immersed in water Only the Water Tray is watertight Do NOT immerse the Base in water or other liquids MAN 7000 Rev D August 2003 16 User Notes For use by APC 7000 Customers ONLY 53 of 62 Appendix for APC 7000 User Manual Appendix A Maintenance Log Date Motor Hours Maintenance Performed Engineer For use by APC 7000 customers ONLY MAN 7000 Rev D August 2003 54 of 62 Appendix for APC 7000 User Man
7. entering data The unit must be in the Unlocked State see section 8 4 Password The unit must be in the System Ready state where the Select Production Edit Mode screen is displayed Press 1 Production 2 Edit recipe Step 1 Press 2 to select Edit mode The list of recipes is displayed Press 1 LC UPC for 2 MU UPC Step 2 Select the recipe to edit Use the arrow keys to scroll and the numeric keys to select To go to the second page of recipes press the ENTER KEY NO OF STEPS 9 STEP 1 30 The first line shows the number of steps Change this value only after reading and understanding Number of Steps in section 9 1 SENKO strongly recommends leaving this set to nine 9 Remember that for data entry press INSERT use the ARROW keys to move the blinking cursor to the desired parameter enter the data and finally press ENTER Step 3 By scrolling down one line all 3 programmable parameters for step 1 will be displayed Remember use the UP ARROW and DOWN ARROW keys for scrolling STEP 1 30 T1 0 T2 O You will now have the opportunity to enter the parameters for each of the 9 recipe steps For each step there are three parameters displayed on two lines for a total of 18 lines of data These are scrolled through two lines at a time Note If you have chosen to use fewer than 9 programming steps all parameters stored for steps after the chosen number of steps will be ignored Step 4 Select a
8. is still paused While the robotic head is travelling upwards press the HELP KEY Then the unit will display the next recipe step indicating that it has skipped the current step Abort the current polishing cycle altogether 1 Whether the unit is paused or not press the CLEAR KEY and the entire polishing cycle will be aborted For use by APC 7000 Customers ONLY 47 of 62 APC 7000 12 Manual Polishing WARNING CAUTION 12 1 Preparation 48 of 62 Prior to running a polishing cycle the APC 7000 must be installed properly as per the Installation section and checked out to ensure proper operation as per the Initial System Checkout section The unit must be in the Unlocked State to enable access to the manual polishing settings Prior to starting you must have the appropriate fixture for mounting the connectors or ferrules to be polished The fixture must be loaded according to Section 11 1 Balanced Fixture Loading Patterns The Coarse and Fine Load adjustments may be set according to Section 11 2 Setup for Proper Load Alternatively one may use manual polishing while making experimental adjustments to the Load settings Many of the steps for preparation polishing and cleaning are identical to those in Section 11 3 Preparation and 11 4 Polishing Automated Instead of repeating the details here the same step numbers are used and reference is made to the corresponding steps in Sections 11 2 and 11 3 The WARNIN
9. or ratings neglected improperly installed used with non standard consumables or otherwise abused Buyer must claim under the warranty in writing not later than thirty 30 days after the claimed defect is discovered The Buyer must make all claims under this warranty and no claim will be accepted by any third party Any warranty claims will require a maintenance log to show that maintenance was performed according to the schedule described in this manual In the event that any tamper seals are removed or damaged this warranty will be void PCI will only accept returns for which an approved Returned Authorization Number RMA has been issued by PCI Any returns must be shipped in the original container or an approved replacement container provided by PCI This warranty will be void if returns are made in any other shipping container Buyer is responsible for all freight costs duties insurance and applicable taxes when shipping products pursuant to an approved RMA including shipments from Buyer to PCI and shipments from PCI to Buyer Where goods contain software Software PCI does not transfer ownership but only grants the Buyer a perpetual non exclusive license to use Software restricted only to use related to the operation of the products Such license is transferable only with the transfer of ownership of the product in which it is used Except to back up copies as permitted by law Buyer shall not i modify reproduce copy
10. plate and is attached using either adhesive or water surface tension For grinding the grinding plate is used without any additional polishing media A Fixture holds the Components securely in place while being ground or polished Fixtures are specific to each type of component with a wide selection available to handle all standard fiber connectors and ferrules Fixtures are provided separately by SENKO The Robotic Head Assembly holds the Fixture and travels vertically to engage the components with the Polishing Media The Fixture is mounted on the fixture Spindle and attached by the Quick Mount Dismount Chuck The robotic motor located in the Base pulls the entire robotic head assembly down over three rigid guide columns Contact force applied to the Fixture and hence the components being polished is determined by the degree of compression of the spring located in the robotic head when the head is down all the way The Coarse Load Adjustment dial adjusts the head s vertical position which in turn changes the load on the spring when the head is in the down position Fine load adjustments are made by the Fine Load Adjustment micrometer dial which adjusts the pre load compression on the spring Built into the APC 7000 is a flexible hose Water Directing Arm that can be pointed by the operator to direct a jet of water to a defined area Water flow is controlled automatically by parameters in the recipe or manually by pressing the Water Jet pushbu
11. the dial are in 0 5 unit increments and each turn of the dial advances one of these markings See Figure 11 2 Figure 11 2 Adjusting the Fine Load setting Step 5 Select the rubber pad called out for the first step of the recipe It is critical that the correct one be selected as its height will directly affect the proper setting of the connector load Insert the pad into the platten pressing down to ensure that it is fully seated No water or adhesive is necessary or recommended See Figure 11 3 The polishing film does not get installed at this point Figure 11 3 Rubber pad installed Step 6 Mount the appropriate APC 7000 Polishing Fixture onto the spindle by hooking it over the pins of the Quick Mount Dismount Chuck For use by APC 7000 Customers ONLY 39 of 62 APC 7000 40 of 62 WARNING Step 7 Press the PLUS MINUS KEY to enter Setup Mode Step 8 Press the TWO CYCLE START PUSHBUTTONS Press and hold while the robotic head descends the fixture makes contact with the rubber pad and stops The spindle motor will not run in Setup Mode Then release the buttons Crushing of finger or hand by the robotic head or attached fixture if any body part is located above the water tray or forward of the front edge of the water tray anytime a setup or polishing step is in progress d WARNING Keep l back from the front edge of the water tray a Figure 11 5 Using the 2 CYCLE START PUSHBUTTONS
12. the operator only needs to change polishing films and rubber as instructed by the recipe 2 Full range of Highly skilled users can fine tune factory recipes or create capabilities their own 2 High Productivity Up to 36 fiber optic ferrules or 24 connectors can be polished simultaneously 2 Water Built in programmable water jet to automate rinsing of particles and contaminants between and during each polishing step 2 Pressure Manually adjustable with coarse and fine controls 2 Recipe Selection Front panel selection MAN 7000 Rev D August 2003 2 Control system Automatically sets polishing duration and water spray on off duration 2 Monitoring LCD Readout shows current processing step and time remaining 2 Recipe Front panel input recall review and editing of 14 stored Programming recipes 2 Security Recipe parameters are password protected The APC 7000 Polishing System is a self contained unit that runs under microprocessor control The components of the APC 7000 are shown in Figures 3 1 and 3 2 The Turntable is powered from a motor located in the Base which drives the Removable Platen in a dual concentric pattern at a programmed speed The rubber pad glass plate or grinding plate is mounted by the operator onto the platen It is captured and held by the platen s tabs which extend upwards to form a cup Polishing Media typically film is used with either the rubber pad or glass
13. there is the risk of electrocution All reasonable precautions have been taken in the design of the APC 7000 to ensure operator safety including Grounded AC Mains power source 2 No user serviceable components inside the housing 2 Starting requires operator to use both hands to press separate start buttons 2 Electrical components sealed from water areas Safe operation requires that all operators read and understand the instructions in this manual Although all efforts have been made throughout this manual to highlight risks and dangers there can be no assurance that other risks don t exist and that dangerous situations could not be created Safety information provided here is for the Operator Engineer or any other person handling using or maintaining the APC 7000 Safety warnings and cautions relating to proper usage are also found throughout this manual in the applicable sections Safety Terms used in this manual WARNING CAUTION Identifies conditions or practices that could result in personal injury or loss of life to the operator or others Identifies conditions or practices that could result in damage to the equipment or other property MAN 7000 Rev D August 2003 1 2 Selected Warnings WARNING WARNING WARNING WARNING Equipment must be connected to AC Mains with a known good safety ground as described in Installation Electrical cord must be maintained in good condition Electrical
14. to keep hands safe Step 9 Using the correct pin gauge called out by the Coarse Load value Insert between the Chuck metallic color and the bottom nose of the robotic head black color The pin should have a sliding fit That is it will slide smoothly in and out without force but at the same time there is no appreciable rocking to the fixture when the pin is inserted There is a set srew on the backside and right underneath the Adjustment dial This screw should be kept loose backed out 1 2 turn from tight There is no need to tighten it once the Coarse Load Adjustment has been made If necessary use a 3 32 Hex key to loosen the screw MAN 7000 Rev D August 2003 11 3 Preparation Adjust the height of the robotic head as needed using the Coarse Load Adjustment dial Step 9 Exit Setup mode by pressing the PLUS MINUS KEY The robotic head will return home Remove the Polishing Fixture The unit is now set up to apply the proper load for the selected recipe Step 10 Press the ENTER KEY to go to step 1 of the recipe Step No 1 Proc_time 30 The next step is to prepare the fixture the connectors and the unit for polishing The polishing media pad or plate and turntable area must be clean prior to starting to avoid cross contamination from debris left over from previous polishing cycles If necessary first perform the cleaning step Step 7 in Section 11 4 Polishing prior to beginning this new
15. values for polishing duration displayed as Proc_timer Water T1 and Water T2 12 2 Manual Polishing Step 1 Press the two CYCLE START PUSHBUTTONS Press and hold while the robotic head descends the connectors in the Fixture make contact with the film and the rotation motor starts Then release the buttons The display will show both the polishing duration value that was entered and time remaining Proc time is the countdown timer Proc_time 19 s Enter Proc _ timer 30 At the end of the polishing step the motor will stop and the robotic head will return up to its home position Step 2 Clean between manual polishing steps follow Section 11 4 Step 2 Step 3 For each additional polishing step then repeat the prepratory steps of Section 12 1 Step 4 Remove the fixture follow Section 11 4 Step 5 Step 5 Thoroughly clean the connectors ferrules the fixture and all rotational surfaces follow Section 11 4 Step 6 For use by APC 7000 Customers ONLY 49 of 62 APC 7000 13 Guide to Proper Polishing 50 of 62 Following the instructions in this manual will ensure the high quality repeatable results for which the APC 7000 is capable Key points are made in this section which help ensure such results 1 Regular replacement of rubber pads Rubber pads will typically last 6 months in moderate production use but if your production usage is higher then they should be replaced sooner Monitor wear out by usi
16. 0 0 35 dB ete handy 30m SC APC 0 15 0 35 dB FC UPC 0 13 0 30 dB SC UPC 0 10 0 30 dB ST UPC 0 25 0 35 dB MU UPC 0 10 0 30 dB LC UPC 0 10 0 30 dB MT RJ 0 25 0 50 dB MTP 12 0 25 0 60 dB MPO 12 0 25 0 60 dB Insertion Loss FC APC 0 10 0 15 dB Repeatability SC APC 0 10 0 15 dB FC UPC 0 07 0 10 dB SC UPC 0 05 0 10 dB ST UPC 0 12 0 15 dB MU UPC 0 05 0 10 dB LC UPC 0 05 0 10 dB MT RJ 0 15 0 25 dB MTP 12 0 17 0 30 dB MPO 12 0 17 0 30 dB Return Loss FC APC 68 60 dB SC APC 68 60 dB FC UPC 57 50 dB SC UPC 58 50 dB ST UPC 56 50 dB MU UPC 59 50 dB LC UPC 58 50 dB MT RJ 35 25 dB MTP 12 Angle 54 50 dB MPO 12 Angle 54 50 dB Notes To achieve these values on a consistent basis a properly trained operator must use the APC 7000 according to the instructions in this manual using factory supplied recipes and PCI brand consumables that are replaced on the appropriate schedule Ferrule and connector quality can significantly affect these numbers MAN 7000 Rev D August 2003 5 Receiving and Unpacking CAUTION WARNING CAUTION The APC 7000 is carefully packaged at the factory using specially designed shipping containers to prevent damage during shipment When you receive your new APC 7000 inspect the shipping containers for damage prior to accepting delivery Containers that show signs of damage may contain damaged product and
17. 18 ia ala SCUPG connector SCUPC2 5 24 SCUPC one piece connector fixture 24 oo Ser eran STUPC2 5 12 STUPC one piece connector fixture 12 For use by APC 7000 customers ONLY MAN 7000 Rev D August 2003 55 of 62 Appendix for APC 7000 User Manual Max of Product Name Part Number Description connectors ferrules ail STUPC connector STUPC2 5 18 STUPC one piece connector fixture 18 12 position FCAPC CONE FCAPC2 5 12 C FCAPC cone tip one piece connector 12 connector fixture fixture 12 position SCAPC CONE Eey SCAPC CONE TIP one piece connector fixture SOARGE lee connector fixture ie 12 position FCAPC STEP ECAPC2 5 12 S FCAPC STEP TIP one piece 42 connector fixture connector fixture 12 position SCAPC STEP Pry SCAPC STEP TIP one piece connector fixture id SNES connector fixture de Each Fixture Kit includes Polishing Fixture 2 Polishing Fixture Certification Geometry Test Results 2 Course Pressure Pin Gauge 2 Polishing Recipe 77 Polishing Rubber To place an order or for additional information please visit our website at www senko com for the sales office that services your area or email sales senko com For use by APC 7000 customers ONLY MAN 7000 Rev D August 2003 56 of 62 Appendix for APC 7000 User Manual Appendix C Related Products that support the APC 7000 Polishing System Product Model Number Description Ultrasonic Cleaner APC 2000 For
18. 2 Connector Fixture For use by APC 7000 customers ONLY MAN 7000 Rev D August 2003 59 of 62 Appendix for APC 7000 User Manual 18 Connector Fixture For use by APC 7000 customers ONLY MAN 7000 Rev D August 2003 60 of 62 Appendix for APC 7000 User Manual 24 Ferrule Fixture For use by APC 7000 customers ONLY MAN 7000 Rev D August 2003 61 of 62 Appendix for APC 7000 User Manual 36 Ferrule Fixture For use by APC 7000 customers ONLY MAN 7000 Rev D August 2003 62 of 62
19. 9 Fixture installed and cables routed properly Step 5 If the setup steps in section 11 2 were just performed then the recipe has already been selected If not select the recipe by repeating steps 1 2 and 3 of that section The correct Recipe must be selected Failure to do so will very likely result in poor quality connectors Step 6 Prepare the rubber pad Select the proper rubber pad or metal or glass plate according to the recipe Insert the pad into the platen pressing down to ensure that it is fully seated No water or adhesive is necessary or recommended Rubber Pad Color Coding Scheme PCI uses a color coding scheme to reduce the possibility of operator error All PCI rubber pads are supplied using this color coding scheme as listed in Table 11 1 Newer recipes call out the color as well as the Duro number Metal grinding plates and glass plates use special Duro numbers as shown in Table 11 2 MAN 7000 Rev D August 2003 CRITICAL Table 11 1 Color key for Rubber Pads Rubber Pad Color Duro Number Orange 40 Burgundy 45 Red 50 Rust 55 Blue 60 Dark Blue 65 Violet 70 Brown 75 Green 80 Gray 85 Black 90 Table 11 2 Metal and Glass Plates Metal and Glass Duro Number Metal 95 Glass 99 Step 7 Following the recipe sheet select the proper polishing film Use water surface tension to adhere the film to the rubber as follow
20. C Line Frequency 50 60 Hz Fusing 2 A 250V Slow blow Mechanical Outside Dimensions 105Wx19Dx23H Inches Outside Dimensions 26 7 W x 48 3 D x 58 4 H Centimeters Weight 50 Pounds Weight 23 Kilograms Standard commercial Water Supply pressure pressure Milliliters per Flow rate 80 to 120 minute Filter 0 5 Micron Inlet connector diameter 0 125 Inches 3 18 Millimeters Drain connector diameter 0 375 Inches 9 53 Millimeters Environmental Operating Temperature 10 to 40 Degrees C Storage Temperature 55 to 85 Degrees C MAN 7000 Rev D August 2003 4 2 Polishing Specifications The APC 7000 produces polished connectors that exceed the requirements per Telcordia GR 326 CORE Sept 1999 Issue for optical connector geometry Polished connectors will repeatedly meet the maximum values for geometric consistency per Table 4 2 Single Fiber Polishing Geometry Specifications and Table 4 3 Ribbon Fiber Polishing Geometry Specifications In standard production environments polished connectors will meet the typical values shown in these tables Optical performance will repeatedly meet the values of Table 4 4 with typical values achievable in standard production environments Table 4 2 Single Fiber Polishing Geometry Specifications GR 326 CORE Specification Parameter Sept 1999 Issue Typ Max Units End face geometry only Radius for APC 5 R 12 6 R 10 5 R 12 Millimeters Radius
21. GS and CAUTIONS from Section 11 are fully applicable when operating in manual mode They are not repeated here The operator MUST REVIEW AND FOLLOW ALL APPLICABLE WARNINGS AND CAUTIONS IN SECTION 11 when running the APC 7000 in manual mode Step 1 Load the fixture follow Section 11 3 Step 1 Step 2 Place container on Fiber Management Tray or behind or next to the Polisher follow Section 11 3 Step 2 Step 3 Route fibers cables through the Fiber Manager follow Section 11 3 Step 3 Step 4 Mount the fixture follow Section 11 3 Step 4 Step 5 n a Step 6 Prepare the proper rubber pad follow Section 11 3 Step 6 Step 7 Select the proper polishing film and adhere it to the rubber pad follow Section 11 3 Step 7 Step 8 If using water wet the polishing film follow Section 11 3 Step 8 Step 9 Verify cleanliness follow Section 11 3 Step 9 Step 10 If using water aim the water jet nozzle follow Section 11 3 Step 10 MAN 7000 Rev D August 2003 The unit should be in the System Ready state Press 1 Production 2 Edit recipe Step 11 Press 1 to select Production The Auto Manual screen is displayed Press 1 for Auto 2 for Manual Step 12 Press 2 to select Manual If you cannot select Manual the unit is still in the Locked State Follow the instructions in section 8 4 Once selected the Manual control screen is displayed Enter Proc timer TI 0 T2 0 Step 13 Enter
22. MAN 7000 Rev D August 2003 T1 999 and T2 999 Water will be sprayed for the entire polishing step A gatit using 999 for T1 if the polishing duration is later increased the water will remain on as desired 2 T1 0 and T2 999 Water will remain turned off during the entire polishing step 2 T1 5 and T2 3 Water will be sprayed for the first 5 seconds water will remain off for the next 3 seconds then this on off cycle will repeat throughout the 30 second polishing step In practice this complicated pattern is rarely required Actual Number of Connectors All the factory recipes are calibrated for a fully loaded fixture The APC 7000 is capable of doing fewer connectors in a partially loaded fixture but they must be loaded in a pattern that ensures balanced polishing The Balanced Patterns are specified in Section 11 1 When using a partially loaded fixture the load must be reduced in order to maintain the desired load per connector The load is reduced by using a larger pin gauge and or using a higher Fine Load setting There is a minimum load that can be applied to the connectors due to the fixture weight That is even with the largest pin gauge values and highest Fine Load setting the fixture places a load on the connectors Reducing the load per connector further requires increasing the number of connectors in the fixture Number of Steps Each recipe consists of up to nine 9 polishing steps Factory provided recip
23. Shock Hazard if cover is removed There are no user adjustments or user serviceable components inside If cover is removed for any reason unit must be physically disconnected from AC Mains Crushing of finger or hand by the robotic head or attached fixture if any body part is located above the water tray or forward of the front edge of the water tray anytime a polishing step is in progress Catching of body part or loose clothing in the rotating elements including the platen turntable and any items sitting on or attached to them anytime a polishing step is in progress For use by APC 7000 Customers ONLY 11 of 62 APC 7000 2 2 1 12 of 62 Overview This manual is written for the engineer or technician who is responsible for installation and maintenance of the APC 7000 as well as the operator using the equipment It provides all the necessary information for installation daily use and periodic maintenance Repair information and software upgrade information is not provided These actions must be performed by factory authorized service personnel and are outside the scope of this manual PCI provides a series of Fixtures that attach to the APC 7000 and hold different types of components These are supplied separately along with instructions for their use Polishing recipes are provided with each fixture for each type of component If the unit is being unpacked and installed for the first time follow the instructions startin
24. ains Power cord from the unit to the AC Mains Use only the power cord supplied with the APC 7000 If the unit is installed in an area where the Mains Power tends to fluctuate or has excessive electrical noise a surge protector and or UPS system with a capacity of at least 150 watts should be installed to provide clean power In all cases ensure that the voltage to the APC 7000 is within the specification limits of Table 4 1 Prior to connecting the unit to AC Mains and prior to operating the unit ensure that there is no physical damage to any part of the unit DO NOT connect to AC mains and DO NOT operate unit if you detect physical damage Equipment must be connected to AC Mains with a known good safety ground as described in Installation Electrical cord must be maintained in good condition Electrical Shock Hazard if cover is removed There are no user adjustments or user serviceable components inside If cover is removed for any reason unit must be physically disconnected from AC Mains 6 2 Water Source Use the supplied inlet hose with to connect from the Water Inlet Connector to a source of pressurized filtered tap water The water must be filtered to 0 5 micron or better It is recommended that in installations of multiple APC 7000 Polishers that each unit be connected to its own dedicated filter to ensure adequate pressure For use by APC 7000 Customers ONLY 23 of 62 APC 7000 It is not necessary to use de ionized wat
25. are or components related thereto or incorporated therein and no such ownership rights are transferred to Buyer hereunder TO THE MAXIMUM EXTENT PERMISSIBLE UNDER APPLICABLE LAW IN NO EVENT SHALL PCI OR ITS AFFILIATES BE LIABLE TO BUYER OR ITS AFFILIATES FOR ANY SPECIAL INCIDENTAL INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY NATURE INCLUDING WITHOUT LIMITATION LOST PROFITS BUSINESS INTERRUPTION OR LOSS OF BUSINESS INFORMATION EVEN IF PCI OR BUYER OR THEIR AFFILIATES SHALL HAVE BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES THE FOREGOING SHALL APPLY REGARDLESS OF WHETHER SUCH LIABILITY SOUNDS IN CONTRACT TORT NEGLIGENCE STRICT LIABILITY OR ANY OTHER THEORY OF LIABILITY PHOTONIC COMPONENTS INC and APC 7000 and APC 7000 are trademarks of Photonic Components Inc All other trademarks service marks or trade names referred to in this manual including without limitation 3 IN ONE The WD 40 Company are the property of their respective owners MAN 7000 Rev D August 2003 Contact Information Sales Offices To locate the sales office that services your area please visit the SENKO website at www senko com or email sales senko com Technical Support For all equipment or fixture related issues including custom fixture development contact SENKO Advanced Components Inc 13741 Danielson Street Suite F Poway CA 92064 USA Tel 1 858 623 3300 Fax 1 858 623 3303 Lenny Analetto Osenko com SENKO Advanced C
26. convenient cleaning of polishing films and grinding disks APC 2000 Ultrasonic Cleaner To place an order or for additional information please visit our website at www senko com for the sales office that services your area or email salesO senko com For use by APC 7000 customers ONLY MAN 7000 Rev D August 2003 57 of 62 Appendix for APC 7000 User Manual Appendix D SENKO Brand Consumables for use with the APC 7000 PCI Brand Consumables provide the quality and consistency required to achieve high quality polishing results For the most current list please email sales senko com Contact the appropriate Sales office for pricing availability and ordering PCI also sells Pressure Sensitive Adhesive PSA films not listed here Please contact sales senko com for information Product Part Number Description Metal Diamond Disc PLA 518 MD 15 Angle grind Glass Platen PLA MT Glass Platen Film LFCO30 5N Silicon Carbide SC Epoxy Removal Film Film LFD100 5A Diamond Grinding Film Film LFD200 5A Diamond Rough Polishing Film Film LFD300 5A Diamond Fine Polishing Film Film LFOS 01 5N UPC Final Polishing Film Film LFF500 5N Flocked Cleaning Film Film LFDO50 5B Diamond Rough Grinding Film Film LFD100 5B Diamond Grinding Film Film LFD200 5B Diamond Rough Polishing Film Film LFD250 5B Diamond Medium Polishing Film Film LFD300 5B Diamond Fi
27. cycle Step 1 Rest the fixture on the Fixture Mounting Tool Mount the connectors in the fixture following the specific instructions provided with the Fixture If you are using fewer than the maximum number of connectors you must follow the guidelines in section 11 1 to ensure a balanced pattern which is required to achieve good results Step 2 If the optional Fiber Management Tray has been installed place the container typically a kit box with the fibers or connector pigtails on the tray If the tray has not been installed then place the container behind or to the side of the Polisher Step 3 Lift the Fixture up to the Fixture Spindle with one hand while carefully grouping and lifting the fibers or cables with the other hand Route the fibers cables through the Fiber Manager and lay the fibers cables in the container box either on the Fiber Management tray or to the side of the unit Step 4 Mount the Fixture onto the Fixure Spindle by hooking the Quick Mount Dismount Chuck over the pins on the end of the Spindle There are two models that each mount slightly differently One slides in vertically the other slides in horizontally In both cases make sure the pins are properly seated in the Chuck For use by APC 7000 Customers ONLY 41 of 62 APC 7000 42 of 62 CRITICAL At this point the fixture is installed the chuck locked and the fibers cables dressed as shown in Figure 11 9 Fibers routed properly Figure 11
28. e finished connectors ferrules using a soft lint free cloth and water It is recommended that the fixture be cleaned in an Ultrasonic Cleaner after each polishing cycle Alternatively clean the fixture with water taking care to clean out residue from all the entrapment areas on the underside of the fixture 2 Air dry the fixture after cleaning using filtered dry air 2 Clean the polishing film rubber and platen with water As with the fixture take care to clean all areas of the film rubber and platen to remove all polishing residue MAN 7000 Rev D August 2003 CAUTION Do not use too much water either during the polishing or the cleaning steps Do not get water on the guide columns Pausing Restarting and Aborting HELP KEY pauses a polishing step Once paused the options are Unpause and continue 1 Press HELP to un pause 2 Push the two CYCLE START PUSHBUTTONS 3 The current step will start over again from the beginning Abort current step and skip to next step option 1 1 Press HELP while the robotic head is traveling upwards traveling home This requires pressing the HELP key once to pause and then almost immediately a second time to abort Abort current step and skip to next step option 2 1 With the unit paused press the CYCLE START PUSHBUTTONS as if to restart the unit wait for the robotic head descends all the way then release the buttons The polishing motor will not run as the unit
29. e read and understood the information in this section CYCLE START PUSHBUTTONS there are two must be pressed concurrently within one 1 second of each other to lower the robotic head assembly and start the polishing cycle The buttons must be held until the fixture with its connectors makes contact with the polishing media and the turntable begins rotating Releasing one or both prior to this point will cause the polishing cycle to abort with the robotic head returning to its retracted or home position WATER JET PUSHBUTTON causes water to be dispensed from the Water Jet Nozzle for the duration that the button is held down This button may be used any time the system is powered on MAIN POWER SWITCH located at rear of unit controls AC power to the entire system 8 1 Locked State Unlocked State The APC 7000 powers up and normally operates in the Locked State In this state all data entry functions are disabled These include the ability to edit recipes and to run manual polishing cycles By entering the correct password explained in Section 8 4 the APC 7000 changes from the Locked State to the Unlocked State In the Unlocked State the operator or process engineer can edit recipes and run manual polishing cycles The unit remains in the Unlocked State for 10 minutes at which point it reverts back to the Locked State Powering the unit off and back on will also immediately cause the unit to revert to the Locked State
30. e will call out a Fixture and the Actual Number of Connectors Note All SENKO recipes are calibrated for a fully loaded fixture If you develop your own recipes for partial loading of Fixtures then the Actual Number of Connectors must be called out Each recipe calls out the following parameters which apply to the entire recipe 2 Number of Steps Coarse Load 2 Fine Load All three are programmed into the APC 7000 and stored When an automated polishing cycle is being run the Coarse Load and Fine Load values will be displayed on the LCD screen The operator uses these values to manually adjust the coarse and fine load settings prior to starting the polishing cycle Each step within the recipe calls out the following parameters 2 Specific value of rubber 2 Specific polishing step number Refer to table 9 1 Polishing Duration 2 Water Duration T1 2 Water Duration T2 The operator refers to the recipe sheet to select the rubber and film The parameters Polishing Duration Water Duration T1 and T2 are programmed into the APC 7000 and during the automated polishing cycle will automatically control polishing duration and the water jet 34 of 62 MAN 7000 Rev D August 2003 10 Creating Editing Recipes The flowchart in section 8 provides the overview of the recipe editing process Section 9 describes the parameters that make up a recipe Refer to section 8 1 for using the keypad while navigating menus and
31. ed properly as per the Installation section and checked out to ensure proper operation as per the Initial System Checkout section This section applies to grinding and polishing operations using rubber pads glass plates or metal grinding plates Prior to starting you must have the appropriate fixture for mounting the connectors or ferrules to be polished and a pre programmed recipe If a recipe needs to be created first follow the instructions in section 10 11 1 Balanced Fixture Loading Patterns This section applies only if you are using partially loaded fixtures If the Fixture is loaded only partially then it must be loaded in such a manner that ensures it is balanced and that the load is distributed evenly across all connectors ferrules The Allowed Patterns are shown in Figure 11 1 for fixtures with provisions for 12 and 18 connectors Please see Appendix E for all allowed patterns for 12 18 24 and 36 position fixtures Polishing using a partially loaded fixture will require a recipe to be developed with the appropriate coarse and fine load settings Follow these steps 1 From the figure or from Appendix E select the fixture size that matches your fixture 2 Select one of the Allowed Patterns for the number of connectors ferrules you want to polish 3 Ensure that you have a recipe for this number of connectors 4 When you load the fixture in preparation for polishing load the connectors exactly as shown by the Allo
32. er with the APC 7000 but it can be used without any detrimental effect if so desired Turn on the water source to the unit and visually verify that the fittings are tight and not leaking Turn on the MAIN POWER SWITCH ONLY for the purpose of measuring and setting water flow rate The full checkout of the unit follows in section 7 Measure the water flow rate by collecting water from the water jet nozzle in a suitable container Hold down the WATER JET PUSHBUTTON for 60 seconds Verify that 80 to 120 milliliters 2 7 to 4 liquid ounces is collected which confirms a flow rate of 80 to 120 milliliters per minute If necessary adjust the flow by turning the WATER FLOW ADJUSTMENT either by hand or with a slot blade screwdriver not supplied When finished turn off the MAIN POWER SWITCH 6 3 Waste Water Drain 24 of 62 Use the supplied drainage hose to connect from the Waste Water Drain Connector to a proper drain The Y connection of the hose to each of the Drain Connectors is shown in Figure 3 2 The drain connectors have a ribbed end ensure the tubing is inserted fully over the ribs Waste water flow is gravity driven so the drain must be located lower than the drain connectors with the hose oriented downwards so as to not trap waste water Installation must meet all applicable environmental and other government regulatory requirements for handling industrial waste products MAN 7000 Rev D August 2003 7 Initial Sy
33. es assign each of the nine polishing steps to specific operations as listed in Table 9 1 This approach provides structure from recipe to recipe greatly reducing the likelihood of operator error especially in production environments where multiple recipes are in use When one of the nine specific operations is not required by a specific recipe in fact most recipes use less than nine steps the recipe still adheres to this assignment scheme but the unused steps are given polishing duration values of zero Some additional points 2 During the polishing cycle when a step having zero duration is encountered it is simply skipped 2 SENKO recommends always setting this value to nine 9 so that the structure described above can be followed 2 Ifa value less than nine is used the parameters programmed for steps beyond this value are ignored 2 Note that for each recipe operation listed in Table 9 1 there are different specific polishing films that will be specified by the individual recipe Table 9 1 Assignment of Recipe Operation to Polishing Step Number Polishing Step Number Recipe Operation None done by hand Fiber Removal 1 Epoxy Removal Ferrule Grind Rough Grind Grinding Rough Polish Medium Polish Fine Polish Finishing O O0 J DO OI BA O N Final Cleaning For use by APC 7000 Customers ONLY 33 of 62 APC 7000 9 2 Programmed vs Manual Recipe Elements Each recip
34. fit A smaller pin gauge results in a smaller radius of curvature of the polished connector by increasing the load The size of the pin gauge its diameter is used as the value for Coarse Load Values range from 100 to 430 representing pin gauges ranging from 0 100 to 0 430 The appropriate pin gauges are supplied with each specific polishing fixture For sizes other than that supplied with the Polishing Fixture can be purchased seperately Pin Guages are available with different diameters this range is diameters from 0 100 to 0 430 can be used please contact SENKO for availability and ordering information Fine Load The Fine Load Adjustment provides fine adjustments to the load placed on the connectors by varying the pre load compression on the spring A smaller values results in a smaller radius of curvature of the polished connector by increasing the load Values range from 0 0 to 3 0 Typically increments of 0 5 are used Routine Maintenance The APC 7000 requires no routine maintenance due to the use of the New Labyrinth Seal Assembly The moving parts have sealed bearings that do not require additional oil or grease A CAUTION Do not apply oil to the guide columns Oil will drip into the Base and damage internal elements There is no need to lubricate the guide columns A CAUTION Do not attempt to remove the screws that attach the Turntable to the drive mechanism Doing so will damage the factory seal
35. for UPC 7 R 25 7 R 15 7 R 25 Millimeters Apex Offset lt 50 lt 25 50 Microns Fiber Height 50 20 50 Nanometers Ferrule End face Angle 0 15 0 25 Degrees Notes R stands for radius To achieve these values on a consistent basis a properly trained operator must use the APC 7000 according to the instructions in this manual using factory supplied recipes and SENKO brand consumables that are replaced on the appropriate schedule Ferrule and connector quality can significantly affect these numbers Table 4 3 Ribbon Fiber Polishing Geometry Specifications Parameter Typ Max Units Tilt Long axis 0 15 0 25 Degrees Tilt Short axis 0 12 0 25 Degrees Fiber Height 1400 3000 Nanometers Adjacent Fiber Height 8 20 Percent Differential Fiber Height 11 20 Percent Notes To achieve these values on a consistent basis a properly trained operator must use the APC 7000 according to the instructions in this manual using factory supplied recipes and PCI brand consumables that are replaced on the appropriate schedule Ferrule and connector quality can significantly affect these numbers For use by APC 7000 Customers ONLY 19 of 62 APC 7000 20 of 62 Table 4 4 Optical Performance Specifications Parameter Connector Typ Max Units Insertion Loss FC APC 0 2
36. g in section 5 Receiving and Unpacking If the equipment is subsequently moved or shipped follow the instructions provided for re packing and subsequent unpacking Each time the equipment is installed or re installed follow in sequence the instructions in section 6 Installation and section 7 Initial System Checkout prior to operating the equipment for production purposes Operation of the controls is described in section 8 Operating the Controls The APC 7000 uses recipes to partly automate the polishing process These are described in section 9 Understanding Recipes and section 10 Creating Editing Recipes With all the earlier sections providing background section 11 describes how to perform automated polishing and section 12 manual polishing Section 13 provides key information on how to obtain the best polishing results Routine Maintenance information is provided in Section 14 Routine Maintenance A place for you to make notes is provided in section 15 User Notes Then when a new version of this manual is published you can easily transfer your notes Appendices attached at the back of this manual list the Fixtures and Consumables that are available at the time of publication of this manual PCI Development and Evaluation Lab Support PCI evaluates new components on the market and on a regular basis develops fixtures and polishing recipes for all major manufacturer s components In addition to fiber connectors and ferrules th
37. he cursor will already be blinking Use the arrow keys to select PSW Press the ENTER key to display the Password Prompt Step 3 Enter the password 7000 Press the ENTER key If entered correctly the unit switches to Unlocked State and the system will return to the System Ready state In Unlocked State you will be able to select Edit Mode from the Select Production Edit Mode screen and Manual Polishing Mode from the Select Auto Manual screen For use by APC 7000 Customers ONLY 29 of 62 APC 7000 8 5 Screen Contrast 30 of 62 The screen contrast can be adjusted to provide the best view for the operator given the height of the operator relative to the unit Step 1 Place the unit in the Unlocked State by following the instructions in Section 8 4 Password Step 2 From the System Ready State press and hold the ENTER key for 3 5 seconds The System Configuration screen will appear PGS ALM EVT PSW CFG TIM ACC SYS EXT Step 3 The cursor will already be blinking Use the arrow keys to select SYS Press the ENTER key to display the Contrast Adjustment screen LO lt DISPLAY gt HI Step 4 Use the DOWN ARROW KEY to scroll one line down Step 5 Use the LEFT ARROW KEY and RIGHT ARROW KEY to adjust the display Step 6 When done press the ENTER KEY to return to the Production Edit screen MAN 7000 Rev D August 2003 8 6 Menu Navigation Flowchart System Ready Enter Password Unlocked State After 10 min
38. ii sa 18 42 Polishing Specifications a a ae a E R ia 19 Table 4 2 Single Fiber Polishing Geometry Specifications ooocnoonnoccnonanonononononaconncnnnonnnonano nano cano nonocnnonns 19 Table 4 3 Ribbon Fiber Polishing Geometry Specifications oonocnoccnonncnoncnancnancnanonnonanononononcnanananccnnonns 19 Y Reservo and Unpacking A od 21 5 1 Repacking prior to Moving or Shipping e seeeeseseesssssesressesressesressesrersesrersesreesrsretsreseesresresresrese 22 Oa Estalla rd 23 6 1 AC ROW AAA A dudes a tal ven bn a a a Dea 23 602 Water A Seri O a a a E E EE 23 6 3 Waste Water Dr td e a io 24 E dal System Cect A A AA AN AGS 25 Op ratine the COMO at da 26 8 1 Locked State amp Unlocked Sata io 26 8 2 LE A A taaa ROHR mee 26 8 3 Data Ent a a o e 28 O A A O NN 29 8 5 ii A e ae slid ich r E E ae etemued atti kei iera ene 30 8 6 Menu Navigation ONO ea 31 Oe Understand AS 32 9 1 Elements of RE is nase ds ond woe aa insten Eaa Ra E ena aa e Dae 32 9 2 Programmed vs Manual Recipe Plone di 34 10 Creatine Editie RECIPES oth cinta tie ia 35 11 Running an Automated Polishing Cicle aia A 37 141 Balanced Fixture Loadins Patterns stetec ennet ei E a E utah 37 12 Setup Procedure forProper Load ad abc ctl ae id 38 S A O 41 WEE ES A A ected eae Gide a uti aie tah int aes een eb a E Somes 45 12 Manual Polishes ann e a a a pt Mat ea io Ain 48 Dake Preparati Onenean O ANN 48 12 2 Manual A so SE a aa Seu te PRE er aac SESE a
39. ing data The APC 7000 must be in the Unlocked State before any data entry is allowed INS 0 KEY selects data entry mode and selects the currently displayed parameter for editing That parameter will be highlighted by a grey flashing cursor UP AND DOWN ARROW KEYS and the LEFT AND RIGHT ARROW KEYS will navigate to select a different parameter displayed on the current screen and the grey flashing cursor will follow 0 through 9 KEYS are used for data entry PERIOD KEY is used to enter decimal data ENTER KEY causes a new data value to be accepted by the system The cursor will no longer be flashing indicating that the system is no longer in data entry mode CLEAR KEY clears data that has been keyed in and is displayed on the screen but has not yet been saved by pressing the ENTER key When navigating menus 8 3 Data Entry 28 of 62 0 through 9 KEYS are used for selecting menu options UP AND DOWN ARROW KEYS scroll vertically to select from recipe choices or parameter choices The LCD screen only displays two lines of information at a time vertically so this key is used any time there are more than two menu choices or more than two lines of parameter information ENTER KEY is pressed when recipe 9 is shown in the display to jump to the second page of recipes recipes 10 through 14 Combining the above information about individual functions the data entr
40. is includes components such as glass capillaries v groove arrays specialty metals and others In addition PCI develops custom fixtures and recipes for custom component applications PCI maintains a Polishing Process Development and Support Laboratory for custom recipe development and to provide assistance to customers with their polishing and or recipe problems MAN 7000 Rev D August 2003 2 2 Important Terms used in this Manual CRITICAL Indicates that this action or step must be followed to prevent unacceptably poor polishing results REMINDER Important reminder about operating the Polisher Repeated from the Safety section CAUTION Identifies conditions or practices that could result in damage to the equipment or other property WARNING Identifies conditions or practices that could result in personal injury or loss of life to the operator or others For use by APC 7000 Customers ONLY 13 of 62 APC 7000 3 14 of 62 Introduction Congratulations on your purchase of APC 7000 Polishing System This model from PCI is part of the growing family of solutions that PCI is known for We provide superior solutions for global fiber connections The APC 7000 Polishing System is designed for polishing fiber connectors in either a production or laboratory environment to meet both low volume and high volume demands Connectors polished on the APC 7000 exceed industry standards and the design of the product ensu
41. ize of the pin gauge its diameter is used as the value for Coarse Load Values range from 100 to 430 representing pin gauges ranging from 0 100 to 0 430 The factory provided recipes that accompany each fixture are set for a nominal Coarse Load of 300 using a 300 pin gauge Fine Load The Fine Load Adjustment provides fine adjustments to the load placed on the connectors by varying the pre load compression on the spring A smaller values results in a smaller radius of curvature of the polished connector Values range from 0 0 to 3 0 Typically increments of 0 5 are used The factory provided recipes that accompany each fixture are set for a nominal Fine Load of 1 0 Water Duration Water can be sprayed automatically onto the polishing film during the polishing step Two variables T1 and T2 control the application of water T1 specifies the number of seconds that the water jet is turned on starting from the beginning of the polishing step duration Once this time is reached T2 specifies the number of seconds that the water jet remains off Values range from 0 to 999 Here are some examples for a Polishing Duration of 30 seconds along with recommended settings 2 T1 5 and T2 999 Water will be sprayed for the first 5 seconds of the 30 second polishing step and off for the remaining The reason for selecting 999 for T2 is so that if the polishing duration is later increased the water will remain off as desired
42. l packaging material Any factory return must be made in the original shipping container using the custom foam packing material Repacking prior to Moving or Shipping The unit should be repackaged in the original shipping containers prior to shipping The container has been designed specifically to protect and cushion the APC 7000 while in transit If the original shipping containers are not available please contact SENKO to arrange the purchase of a new shipping containter SENKO will not accept returns that are not in the original shipping container or in a replacement container provided by SENKO MAN 7000 Rev D August 2003 6 Installation CAUTION CAUTION 6 1 AC Power WARNING WARNING WARNING The APC 7000 must be installed on a flat and level surface to enable water to drain properly The unit produces little vibration so a table or bench of standard sturdy construction should be adequate Install on a level surface so that water drains properly Keep unit upright at all times This ensures that the Robotic Head Assembly Cable Tray and supporting structure is not damaged Verify that the AC Mains outlet is properly grounded prior to connecting to the unit Since water is present in the unit when operating it is highly recommended that Ground Fault Interruption GFI AC Mains outlets be used to provide additional operator safety Ensure the Main Power Switch is in the OFF position Connect the M
43. nd edit the 3 parameters of Step 1 Duration Water T1 and Water T2 This completes the data entry for Step 1 Note To skip a step during polishing enter a value of zero for Polishing Duration Step 5 Scroll down two lines to view and edit the parameters for Step 2 For use by APC 7000 Customers ONLY 35 of 62 APC 7000 Continue in this manner until all 18 lines of data for all 9 steps have been entered Step 6 Scroll down to reveal two lines with the remaining four parameters T3 0 T4 340 COARSE 230 FINE 2 0 Step 7 The parameters T3 and T4 must be set to zero to ensure proper automated operation of the water jet Step 8 Set the parameters for Coarse Load and Fine Load This completes the data entry for this recipe The data was saved into the non volatile memory as each parameter was entered Step 9 Press CLEAR to exit edit mode and return to the Select Production Edit screen REMINDER The system remains in the Unlocked State for 10 minutes giving unauthorized personnel access to the editing functions Tips for editing recipes If a step is to be bypassed then set the time equal to zero All other parameters with that step will then be ignored At any time during the editing process you can use the UP ARROW and DOWN ARROW keys to review the settings 36 of 62 MAN 7000 Rev D August 2003 11 Running an Automated Polishing Cycle Prior to running a polishing cycle the APC 7000 must be install
44. ne Polishing Film Film LFC200 5NP Silicon Carbide SC Medium Polish 1 Film LFFC200 5NP Flocked Medium Polish 2 Film LFFA0250 5NP Flocked Fine Polish Film LFFAO300 5NP Flocked Final Polish Film LFFCO300 5NP Flocked Final Polish Rubber Pads RUBNG55 0 90 Precision Ground Polishing Rubber 5 X5mm 90 Duro Rubber Pads RUBNG55 0 85 Precision Ground Polishing Rubber 5 X5mm 85 Duro Rubber Pads RUBNG55 0 80 Precision Ground Polishing Rubber 5 X5mm 80 Duro Rubber Pads RUBNG55 0 75 Precision Ground Polishing Rubber 5 X5mm 75 Duro Rubber Pads RUBNG55 0 70 Precision Ground Polishing Rubber 5 X5mm 70 Duro Rubber Pads RUBNG55 0 65 Precision Ground Polishing Rubber 5 X5mm 65 Duro Rubber Pads RUBNG55 0 60 Precision Ground Polishing Rubber 5 X5mm 60 Duro Rubber Pads RUBNG55 0 55 Precision Ground Polishing Rubber 5 X5mm 55 Duro Rubber Pads RUBNG55 0 50 Precision Ground Polishing Rubber 5 X5mm 50 Duro Rubber Pads RUBNG55 0 45 Precision Ground Polishing Rubber 5 X5mm 45 Duro Rubber Pads RUBNG55 0 40 Precision Ground Polishing Rubber 5 X5mm 40 Duro Maintenance Kit APC MAINT Includes grease oil and hex key for platen removal To place an order or for additional information please visit our website at www senko com for the sales office that services your area or email sales senko com For use by APC 7000 customers ONLY MAN 7000 Rev D August 2003 58 of 62 Appendix for APC 7000 User Manual Appendix E Balanced Fixture Loading Patterns 1
45. ng SPC techniques see 6 below Wear out is indicated by degradation in Apex Offset values or poor end face quality 2 Regular replacement of polishing film The lifetime and hence replacement period for the polishing films is dependent on the product being polished the hardness of the rubber pad and the polishing time As a result there is no fixed replacement period applicable to all films SENKO provides the replacement schedule for films with each supplied recipe Note that all polishing films are not of the same quality SENKO sells only the best quality films and the replacement schedules provided with the recipes are applicable only to these particular films 3 Technique for adhering the polishing film to the rubber pad Use minimal water spread it around with your finger and then lay the polishing film on the rubber pad offset from its final position 2 Method 1 Press into place with one forward motion increasing finger pressure as you slide the film to its final location The increasing pressure will force excess water out and create the necessary adhesion 2 Method 2 Rotate the film into place by simultaneously pushing and rotating it again with increasing finger pressure 4 Avoiding cross contamination which will result in scratches on the finished polished connector or ferrule All micron particulate must be removed by careful washing between each polishing step and between polishing cycles 5 Periodic clea
46. ning with ultrasonic cleaner The easiest way to ensure repeatable results is to clean the fixtures using an ultrasonic cleaner between every polishing cycle 6 Use of Statistical Process Control SPC techniques In production environments SPC techniques should be used to monitor the ongoing polishing process Three types of criteria can be used Interferometer measurements of consistency of end face geometry and apex offset 2 Optical Power Reflection Meter measurements of insertion loss and return loss 2 Visual inspection for scratches and or pits Using SPC will provide near real time detection of degradation in quality whether due to wear out of the consumables poor cleaning operator errors or equipment problems 7 Dedicate the Polisher to one product By dedicating the Polisher to one product the unit can be set up by the process engineer and then used by the operator without the operator being involved in performing the Setup Procedure MAN 7000 Rev D August 2003 14 15 Polishing Pressure Coarse and Fine Loads Coarse Load The load applied to the connectors during polishing is a determined by the compression of the spring in the robotic head when the head is in the down position The coarse load is set by inserting a pin gauge between the Unloaded Polishing Fixture and the robotic head when the head is in the down position and adjusting the Coarse Load Adjustment dial for the pin to have a sliding
47. of the polishing step the motor will stop and the robotic head will return up to its home position Crushing of finger or hand by the robotic head or attached fixture if any body part is located above the water tray or forward of the front edge of the water tray anytime a polishing step is in progress Catching of body part or loose clothing in the rotating elements including the platen and turntable and items sitting on or attached to them WARNING Keep H back from the front edge of the water tray Figure 11 11 Using the 2 CYCLE START PUSHBUTTONS to keep hands safe Eye Protection is required at any time the moving parts are running and at any time the water spray is operating to ensure that particles and liquids from the grinding and polishing processes do not get into eyes For use by APC 7000 Customers ONLY 45 of 62 APC 7000 46 of 62 WARNING WARNING CAUTION CAUTION CAUTION REMINDER IMPORTANT Immediately abort the polishing process and disconnect the unit from AC Mains if any abnormal sounds abnormal odors or unexpected mechanical motions are noticed Fixture Spindle and Fixture if attached must return to their home position and processing cycle must be complete before touching any of the moving parts Ensure nothing is lose and the rotating parts are rotating smoothly Do not run a polishing cycle without connectors installed in the Fixture Doing so will damage the bottom of the Fixture
48. omponents Euro Ltd 5 Fortuna Court Calleva Park Aldermaston Berkshire RG7 SUB United Kingdom Tel 44 0 118 9821600 Fax 44 0 118 9821900 Paul Newbury Osenko com Polishing Process Development and Support Laboratory Sales Osenko com For all polishing issues recipe issues or custom recipe development For use by APC 7000 Customers ONLY 3 of 62 APC 7000 PCI Limited Product Warranty 4 of 62 PCI warrants only the original buyer that all products other than Software made by PCI are free from defects in material and workmanship for a period of one 1 year from date of shipment For this warranty to be valid Buyer must register purchase with PCI pursuant to Warranty Registration Under warranty PCI will repair returned products or provide a replacement at its own discretion for any product made by PCI which upon inspection by PCI are determined to be defective in material and or workmanship within the above mentioned time frame All products repaired or replaced under warranty are only covered for the remaining unexpired period of time in the original warranty for the particular defective product These warranties shall extend to any product that has proven to be defective and has failed through normal use However the warranty excludes and does not cover any products or parts thereof which have been accidentally damaged disassembled modified misused used in applications which exceed their specifications
49. ontamination which will lead to degraded polishing performance Debris must be removed to prevent cross contamination from previous polishing steps Step 10 If the recipe step uses water aim the Water Jet Nozzle Do this by briefly pressing the WATER JET PUSHBUTTON while aiming the nozzle so that it directs a jet onto the film During the polishing steps the rotation action will spread the water so the only requirement is that the jet be directed generally onto the film NOTE DO NOT do this if the first step of the recipe calls for a dry polishing step Instead do it prior to loading the film and rubber and or just prior to the first step that requires water l Water surface tension holds v film to pad Pressure sensitive y adhesive optional Rubber Pad Rubber must be pressed down Yy v and seated flat Removable Platen Figure 11 10 Stack up of Film and Rubber mounted on Polishing Platen MAN 7000 Rev D August 2003 11 4 Polishing WARNING WARNING WARNING All preparations are complete and the screen is currently displaying the first step Step No 1 Proc_time 30 Step 1 Press the two CYCLE START PUSHBUTTONS Press and hold while the robotic head descends the connectors in the Fixture make contact with the film and the rotation motor starts Then release the buttons The polishing duration or Proc_time on the screen will begin counting down showing the time remaining At the end
50. operation Main AC power to the unit is controlled by the Main Power Switch Control over the polishing parameters and selection and editing of recipes is done through the Keypad Status and recipe readouts are displayed on the LCD Display MAN 7000 Rev D August 2003 The APC 7000 supports 14 stored recipes The recipe parameters are stored in non vqk memory so that they are retained indefinitely even if the AC power is disconnected Recipes are supplied by PCI and can be input in a matter of minutes by the operator Once input these recipes can be fine tuned as required Additionally the user can create recipes Water tube from base to arm Areco Cs Drain Modei Wo AE connectors 2 Water flow adiustment Fuse Main Power Switch AC Mains Power Connector Waste Water Drain Connector Water Inlet Connector Figure 3 2 APC 7000 Polishing System Rear View For use by APC 7000 Customers ONLY 17 of 62 APC 7000 4 Specifications 4 1 Product Specifications 18 of 62 Table 4 1 Product Specifications Parameter Specification Units Number of programmable Recipe recipes 14 Recipes Number of polishing steps per Up to 9 user St A eps recipe programmable Polishing Step Duration 0 to 999 Seconds is 40 to 99 95 and 99 Rubber pad resiliency range reserved Duro AC Power Type of Power Supply Universal Voltage 100 120 200 240 VA
51. r eae iet 49 13 G id to Proper Oli STD tir Roel 50 14 POLSHIRSPrESSUTE scsi o5w Aste aaa E a a a e E autaoannuiia a E S 51 15 Route Maintenance s Aas thi cast e T Ea a E a aoe a E 51 AN les Ol AAA a aaa o a ao aa AEE Ea a RE enie 52 16 User Ni o Ns 53 Apperidix A Maintenance Log acatar a iria 54 Appendix B Fixtures Available for the APC 7000 Polishing SySteM ooconccnnnnnnonononcnoninanonancnanananacanonns 55 Appendix C Related Products that support the APC 7000 Polishing System 57 8 of 62 MAN 7000 Rev D August 2003 Appendix D SENKO Brand Consumables for use with the APC 7000 cece eee ceseesseeeeeeees Appendix E Balanced Fixture Loading Patterns sss cvccesisoaueoetedtaresoswediuddseestausnssdidobeses deidad 59 For use by APC 7000 Customers ONLY 9 of 62 APC 7000 Operator and Equipment Safety 1 1 1 10 of 62 The APC 7000 has been designed to provide safe operation when used in the manner in which it was designed and by an operator following the instructions provided in this manual The APC 7000 uses rotating machinery and robotic moving parts that are exposed to the operator It uses AC Mains electrical power and also uses both water supply and drain As with all equipment using rotating machinery and robotic moving parts the APC 7000 presents risks to the operator including the risk of serious injury loss of limb and loss of life As with all equipment that uses both AC Mains electrical power and water
52. res a high degree of repeatability and reliability in the finishing of connectors Pre programmed recipes control polishing duration and application of water Once set up for a specific connector type the operator can achieve consistent high quality results Its rugged design allows it to be quickly set up and operated in production environments Minimal maintenance is required allowing the APC 7000 to meet rigorous factory up time needs Key features of the unit are presented in Table 3 1 Table 3 1 Key Features of the APC 7000 Polishing System Polishing Quality of polished connectors exceeds Geometry Performance Specifications as described by Telcordia GR 326 CORE Sept 1999 Issue 2 Interchangeable Polishing fixtures designed for handling specific connector Fixtures types are quickly loaded or removed Supports all major LC UPC MU UPC SC UPC FC UPC ST UPC SC APC connector types FC APC E2000 APC E2000 UPC MT RJ MT Angled MT 2 Specialty PCI designs fixtures for specialty applications applications 2 Operator Robotic head rises between polishing steps allowing Convenience operator to easily change rubber and polishing films 2 Operator Safety Two button start requires two hands ensuring safe placement of hands during descent of head and fixture Ease of Operation In production environments pre programmed recipes provide consistent results when operated by lesser skilled personnel Once set up
53. reverse engineer decompile or disassemble all or any portion of the software ii distribute market disclose rent lease or sublicense the use of the software to any third party or iii permit or authorize anyone within Buyers reasonable control to do any acts in 1 or ii PCI warrants that the software under normal use and service as originally delivered to Buyer will function substantially in accordance with the function description set out in the product specifications and or user manual supplied with for a period of ninety 90 days from the date of shipment PCT s sole liability and Buyer s sole remedy for a breach of this warranty shall be PCI s efforts in good faith to rectify the non conformity This warranty is void if Failure of the software has resulted from accident misuse abuse misapplication or modification As far as product performance is concerned please note that PCI does not warranty any specific performance levels due to differing factors as to fiber optic components used consumables etc Further any claims made as to performance characteristics are based on MAN 7000 Rev D August 2003 the proper documented use of the products as well as the exclusive use of PCI appro optic components PCI branded rubber pads and PCI branded polishing grinding media TO THE MAXIMUM EXTENT PERMISSIBLE UNDER APPLICABLE LAW IN NO EVENT SHALL SENKO OR ITS AFFILIATES BE LIABLE TO BUYER OR ITS AFFILIATES FOR ANY SPECIAL
54. s 2 Spray a light film of water onto the rubber The harder the Durometer as indicated by higher Duro numbers the less water that is required Using too much water will cause the film to slip 2 Use your fingers to spread the water over the pad 2 Lay the film onto the pad 2 Use strong finger pressure to press down on the film which presses out excess water and forms a strong bond 2 Ensure pushing with medium finger pressure adequately bonds the film The film should not move 2 Ensure that the film is centered on the pad exposing no more than 1 8 inch on any one side Optionally you may choose to use adhesive backed polishing films The resulting stack up is shown in Figure 11 10 The correct rubber and polishing film must be selected by the operator during these preparatory steps For use by APC 7000 Customers ONLY 43 of 62 APC 7000 44 of 62 CRITICAL Step 8 If the recipe step uses water wet the surface of the polishing film as the final preparation step DO NOT do this if the step is a dry polishing grinding step Step 9 Verify cleanliness of contact areas The surfaces of the fixture and the mounted connectors ferrules and the surface of the polishing film and surrounding areas of the rubber must be completely clean of any polishing debris that may be remaining from previous polishing cycles If necessary perform the cleaning described in Step 3 of Section 11 3 Polishing This is necessary to avoid cross c
55. sing it again prepares the unit to restart the current polishing step from the beginning However for safety restarting always requires pushing the two CYCLE START PUSHBUTTONS To abort and then skip the current step the HELP KEY must be pressed a second time as if to unpause the unit while the robotic head is travelling upwards travelling home To abort and skip the current step while the unit is paused press the CYCLE START PUSHBUTTONS as if to restart the unit wait for the robotic head descends all the way then release the buttons The polishing motor will not run as the unit is still paused While the robotic head is travelling upwards press the HELP KEY Then the unit will display the next recipe step indicating that it has skipped the current step While running a polishing cycle motor not running CLEAR KEY aborts the entire polishing cycle returning to the System Ready state PLUS MINUS 2 KEY puts the unit into Setup Mode While in Setup Mode CYCLE START PUSHBUTTONS will cause the robotic head to descend but the polishing motor will not run No timer is running so the head will stay in the down position so the operator can perform setup until the PLUS MINUS KEY is pressed PLUS MINUS KEY exits Setup Mode If the robotic head is in the down position then it will return home and the unit returns to the System Ready state For use by APC 7000 Customers ONLY 27 of 62 APC 7000 When enter
56. stem Checkout After unpacking visual inspection and installation follow the steps below to run a polishing cycle to ensure that your APC 7000 system is functioning properly These checks will verify proper operation of the electronic electrical robotic and water systems No initial calibration is required as this was set at the factory and is not affected by proper shipping No initial lubrication is required as the unit was factory lubricated These checks should also be followed after any re installation occurs System Checkout Procedure 1 Carefully read and understand section 8 Operating the Controls 2 Carefully read and understand all safety warnings in this manual 3 Select a factory provided recipe that includes water disbursement Have ready the required consumables 4 Carefully follow the instructions in section 11 Running an Automated Polishing Cycle During the checkout listen for any unusual sounds and watch for any unexpected behavior If any is detected turn off the AC power immediately and contact the factory or your sales representative If the unit fails to function as described in this manual please turn the unit off and contact Technical Support for instructions This completes the initial system checkout For use by APC 7000 Customers ONLY 25 of 62 APC 7000 8 Operating the Controls This section describes each of the controls on the APC 7000 in detail Later sections assume you hav
57. t To prevent damage when lifting or moving unit DO NOT pick up the unit by or place any loads on the retract arm assembly the pressure control head the guide columns the fixture spindle or fixture itself if attached Unit must be picked up ONLY from the base or the water tray Figure 5 1 Proper way to pick up Polisher DO NOT pick up the unit by any structures above the Water Tray For use by APC 7000 Customers ONLY 21 of 62 APC 7000 5 1 22 of 62 After verifying that there is no indication of shipping damage or excessive shock carefully open the shipping containers Keep the unit upright at all times Remove the equipment verify using the following list that you have received all items and inspect them carefully for damage Contact SENKO immediately if anything is missing or damaged Contents of the APC 7000 Polishing System Please refer to the Packing List 2 2 27 27 27 del 27 APC 7000 Unit Accessory Kit contatining g Removable Platen Fixture Loading Tool Installation Kit containing s Power Cord standard U S 3 prong 2 Water inlet hose 10 feet es Waste water drainage hose 10 feet Pin Gauge kit with 5 pins 230 250 280 300 and 330 Optional Extra Maintenance Kit containing 2 Corrosion Resistant Grease z 3 IN ONE Oil 3 32 inch Hex Key User Manual Warranty and Warranty Registration Packing List It is important to save al
58. the shipping company should be notified immediately SENKO Advanced Components Inc cannot be responsible for damage caused during shipping A Shock Indicator is attached to the shipping container which indicates if the product was subjected to excessive shock levels in excess of 40 60 G s during shipping Prior to opening the container inspect the shock indicator If the bidirectional arrow windows turn from red to blue this indicates that the container and hence the product received excessive shock The surface which received the shock is indicated by the arrow Notify the shipping company immediately Contact SENKO to arrange for the purchase of a replacement unit A Tip Tilt indicator is attached to the shipping container to indicate if the unit was tipped past 90 degrees The arrow shaped window turns from clear to blue permanently if this occurred If so indicated inspect the product carefully for damage Any sign of damage should be reported to the shipping company immediately Unit must be placed in the upright position at all times as indicated by the directional arrows on the side of the shipping container Once unpacked the unit must be kept in the upright position at all times The tip tilt indicator will show if the unit was tipped past 90 degrees during shipping and handling Unit is heavy Unit weighs 50 Ib 23 kilograms Lift carefully to avoid injury In many situations two people will be required to safely lift the uni
59. tor type and ferrule type requires a specific Fixture to correctly align and secure it while polishing Polishing Platter material type Recipes call for Rubber pads glass plates or metal grinding plates Rubber pads Duro number Rubber pads are available in a range of resiliency as measured by Duro number The PCI brand rubber pads are color coded so the operator can easily distinguish between pads Color and Duro number are listed on each package of rubber pads Values range from 40 to 99 duro Special Duro Number Special values are used for the non rubber pads 95 to indicate metal grinding plates 99 to indicate glass plates Polishing Film Grain Size Ten 10 different grain sizes are used with the APC 7000 For each grain size the recipe calls out the specific type of polishing film to use Polishing Duration Polishing duration is the amount of time that the connectors are in contact with the polishing film during a polishing step Values range from 0 to 999 seconds Note to skip a polishing step set the duration to zero Coarse Load The load applied to the connectors during polishing is a determined by the compression of the spring in the robotic head when the head is in the down position The coarse load is set by inserting a pin gauge between the Polishing Fixture and the robotic head when the head is in the down position A smaller pin gauge results in a smaller radius of curvature of the polished connector The s
60. tton The rotating parts protrude through a watertight seal in the Polishing Platform Underneath the polishing platform is the Water Tray which acts as a catch basin into which runs water and grinding and polishing debris The water tray uses a gravity drain which exits the unit at the Waste Water Drain Connector Sitting on the water tray is the Fixture Loading Tool which the operator can use for loading and unloading components by placing and centering the Fixture on the tool For use by APC 7000 Customers ONLY 15 of 62 APC 7000 16 of 62 Water Jet Nozzle Water Directing Arm Optional Fiber Management Tray APC 7000 POLISHER Figure 3 1 APC 7000 Polishing System Front View Fiber Manager Coarse Load Adjustment dial Fine Load Adjustment micrometer dial Robotic Head Assembly Guide Columns 3 total 1 behind not shown Fixture Spindle inside of chuck Quick Mount Dismount Chuck Fixture Removable Platen Polishing Platform Turntable Water Tray Cycle Start Pushbutton Water Jet Pushbutton Keypad LCD Display Base In place of the usual single start button the APC 7000 has two Cycle Start Pushbuttons which must both be pressed and held until the robot arm assembly is fully lowered into position These two buttons are placed at a distance that requires the operator to use both hands ensuring that fingers and hands are kept away from the fixture and the rotating components while in
61. ual Appendix B Fixtures Available for the APC 7000 Polishing System PCI has an ongoing program to develop fixtures for all types of fiber connectors As a result new fixtures become available on a regular basis For the most current list of fixtures please email sales senko com PCI also develops fixtures for custom applications If you need a fixture not listed on our standard product listing please contact sales senko com so that we may discuss your particular requirements Max of Product Name Part Number Description connectors ferrules 12 position AMT ferrule fixture AMT 12 MPO MTP ribbon ferrule fixture 12 re Position E2000 APC ferrule E2000 APC 12 E2000 APC ferrule fixture 12 12 position MT ferrule fixture MT 12 MPO MTP ribbon ferrule fixture 12 24 position MT RJ ferrule fixture MT RJ 24 MT RJ ferrule fixture 24 e ieee 2 5mm UPC ferrule fixture 24 a EN Cee 1 25mm UPC ferrule fixture 36 Sree SARE Sa 1 25mm APC ferrule fixture 36 eet jae em ae oo eee ee a oo LOUFG connector LC1 25 18 LCUPC one piece connector fixture 18 O MU UFC c nnecior MU1 25 18 MUUPC one piece connector fixture 18 R FUF c nnector FCUPC2 5 12 FCUPC one piece connector fixture 12 oo Bee eee eer FCUPC2 5 18 FCUPC one piece connector fixture 18 he ia SCUFC coat SCUPC2 5 12 SCUPC one piece connector fixture 12 oe Se DES connector SCUPC2 5 18 SCUPC one piece connector fixture
62. utes Locked State Must be in Unlocked State Edit Mode Select Recipe 1 of 14 1 page of recipes 1 9 2 page 1 5 Enter Number of Steps Steps 0 N N lt 9 Enter Polishing Duration Water T1 and Water T2 Press CLEAR KEY when done For use by APC 7000 Customers ONLY ENTER KEY Select Production or Edit Mode Edit Manual Setup Mode Press CYCLE START BUTTONS Setup Mode Runs Press KEY Manual Polishing Must be in Unlocked State Enter Duration Water T1 and Water T2 Press CYCLE START Buttons Polishing Step Runs Display shows time remaining Select Auto or Manual Mode 1 Polishing Cycle only Press CLEAR KEY from any step Production Auto Select Recipe 1 of 14 1 page of recipes 1 9 2 page 1 5 Display shows coarse and fine pressure settings Press ENTER KEY Automated Polishing Cycle Next Cycle return to step 1 Steps 1 N Display shows step number and Next Step duration Note Steps with zero time Press CYCLE are START BUTTONS skipped Polishing Step Runs Display shows time remaining Step complete Cycle complete Figure 8 3 Navigating the Menus 31 of 62 APC 7000 9 Understanding Recipes 9 1 Elements of a Recipe 32 of 62 This section describes all the various elements that make up a recipe Recipes are created using the following parameters Fixture Each connec
63. wed Pattern 12 Connector Fixture Figure 11 1 Fixture Loading Patterns That Ensure Balanced Polishing For use by APC 7000 Customers ONLY 37 of 62 APC 7000 18 Connector Fixture Figure 11 1 cont d Fixture Loading Patterns That Ensure Balanced Polishing 11 2 Setup Procedure for Proper Load Prior to running a polishing cycle Coarse Load and Fine Load must be set to the values specified by the recipe This needs to be done each time a recipe calls for different values This section describes this Setup procedure Once the APC 7000 is set up it will hold its settings and provide highly repeatable polishing results indefinitely Good practice dictates however that this Setup procedure be repeated periodically to verify that the adjustments haven t been changed by another operator Starting from the System Ready state Press 1 PRODUCTION 2 EDIT RECIPE Step 1 Press 1 to select Production The Auto Manual screen is displayed Press 1 AUTO 2 MANUAL Step 2 Press 1 to select Automatic The list of recipes is displayed Press 1 LC UPC 2 MU UPC Step 3 Select the recipe The Coarse and Fine Load settings are displayed COARSE 230 FINE 2 5 PRESS ENTER 38 of 62 MAN 7000 Rev D August 2003 Step 4 Set the Fine Load by adjusting the Fine Load Adjustment micrometer dial to the value indicated Each turn of the dial represents 0 5 units Vertical engraved markings under
64. y sequence is as follows Remember the APC 7000 must be in the Unlocked State before any data entry is allowed Step 1 The parameter to be edited must be displayed on the current screen Use the UP and DOWN ARROW keys if required to bring the paramter into view Step 2 Press INSERT KEY Step 3 The Grey Flashing Cursor will highlight the first parameter indicating it is ready to be edited For example in the screen shown in Figure 8 2 the cursor is flashing in the data field for Step 1 s Polishing Duration Figure 8 2 Grey flashing cursor indicates data field active for data entry MAN 7000 Rev D August 2003 8 4 Password Step 4 Use the ARROW keys to move the grey flashing cursor to the desired par Step 5 Use the numeric keys to enter the data Step 6 Press ENTER Repeat the above sequence for each parameter Remember the cursor must be moved prior to entering data The correct password must be entered for the APC 7000 to change from the Locked State to the Unlocked State Remember once the unit changes to the Unlocked State it remains there for 10 minutes at which point it reverts back to the Locked State The password is factory preset to the value 7000 and CANNOT be changed Enter the password as follows Step 1 From the System Ready state press and hold the ENTER key for 3 5 seconds The System Configuration screen will appear PGS ALM EVT PSW CFG TIM ACC SYS EXT Step 2 T

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