Manual insertion is slow and shift-dependent.
Relays, transformers and connectors require attention from skilled operators.
S7900 solution: Automated insertion with customer-specific feeder and gripper tooling for repeatable cycle output.
S7900 Odd Form Insert Machine
Automate the awkward THT parts your SMT line cannot place.
The S7900 is built for relays, transformers, connectors, large capacitors, coils and other odd-form through-hole components. It combines flexible feeding, vision-guided insertion and optional lead clinching for high-mix EMS production.
Pain to Solution
Designed for the manual insertion bottleneck after SMT.
Odd-form THT components usually remain manual because every package, body size and lead condition is different. S7900 turns that variation into a configurable automation process.
Floating parts affect wave soldering quality.
Heavy components may tilt or lift before soldering when leads are not secured.
S7900 solution: Optional clinching bends leads under the PCB; catalog notes lead diameter < 1.0 mm and exposed lead ≥ 2 mm, subject to final design.
Component packaging is inconsistent.
Factories receive odd-form parts in tape, tube, tray and bulk packages.
S7900 solution: Tape, tube, tray and bowl feeder configurations can be matched to each BOM item.
Changeover needs engineering time.
High-mix EMS production needs fast setup for new assemblies.
S7900 solution: Windows-based operation, vision programming and quick-plug clamp replacement support faster job setup.
Bent pins can damage PCB holes.
Forcing a misaligned component creates scrap and hidden quality risk.
S7900 solution: Top mark CCD and bottom component CCDs support visual alignment and insertion checking.
Manual labor cost is hard to stabilize.
Output varies by operator skill, fatigue and available staffing.
S7900 solution: The ROI model can compare current manual labor against automated insertion using the customer's actual BOM and shift data.
Catalog-backed Features
Flexible odd-form automation, not a one-part special machine.
Use the S7900 as a platform for multiple components, feeders and insertion requirements.
Multiple feeder families
Supports radial tape, vertical taping, horizontal tape, tube, bowl and tray feeder layouts.
Four insertion heads
S7900IV and S7900IV-W specifications list four insertion heads for multi-component configurations.
Nozzle or clamp pickup
Component feeding type supports nozzle or clamp, selected according to component shape and packaging.
Vision-guided insertion
Top mark CCD and bottom component CCDs help align PCB and components before insertion.
0-360 degree direction
Insertion direction is specified as 0-360 degrees for both S7900IV and S7900IV-W.
Lead clinching option
S7900IV-W lists lead clinching as standard configuration for securing selected components.
Windows operation
The operating system is specified as Windows, with operation manual support for software setup.
Flexible conveyor flow
Conveyor direction supports left-to-right or right-to-left layouts for line integration.
Operational Impact
Automation impact your production and finance teams can validate.
Use these as planning indicators, then confirm with a BOM review, sample test and final quotation.
4700/H*Example relay output
One source example compares manual relay insertion at 1000/H with S7900IV at 4700/H.
5 workers*Labor-equivalent example
One S7900IV example states one machine equivalent to 5 workers for the referenced relay case.
<2 years*Indicative payback
ROI depends on labor cost, shifts, component mix, tooling and final machine configuration.
5%Insertion/loss improvement example
The S7900 bending-foot material notes a 5% insertion-rate increase and 5% loss reduction in the cited scenario.
*Indicative examples from S7900 source material. ROI, output and labor savings are validated case-by-case during quotation.
Specifications
S7900IV and S7900IV-W machine data.
Values below are taken from the S7900 THT odd form insertion machine PDF. Any customized tooling value remains subject to final technical confirmation.
| Model | S7900IV | S7900IV-W |
|---|---|---|
| Size (L × W × H) | 1300 × 1700 × 2000 mm | 1550 × 1900 × 2100 mm |
| Weight | 1650 kg | 1750 kg |
| Operating system | Windows | Windows |
| Door type | Double-sided unilateral | Single-sided |
| Air supply | 0.5-0.65 MPa (ANR) | 0.5-0.65 MPa (ANR) |
| Max power / running power | 5.4 kW / 3.3 kW | 6.6 kW / 3.5 kW |
| Number of insertion heads | 4 | 4 |
| Max component size | φ30 (17 × 17) mm | φ50 (35 × 35) mm |
| Component height | ≤30 mm | ≤25 mm |
| Component feeding type | Nozzle / Clamp | Nozzle / Clamp |
| Speed per component | 0.7 s | 2 s with bent feet |
| Placement accuracy | ±0.06 mm (CPK≥1.0) | ±0.05 mm (CPK≥1.0) |
| Insertion force | ≤98 N | ≤29.4 N |
| Insertion direction | 0-360° | 0-360° |
| PCB size (L × W) | 70 × 70 - 410 × 500 mm | 70 × 70 - 450 × 400 mm |
| Carrier size (L × W) | Max 500 × 500 mm | Max 500 × 550 mm |
| PCB thickness | 0.6-2.0 mm | 0.6-2.0 mm |
| Max PCB weight | 2 kg | 5 kg |
| PCB fixing type | Servo top plate / cylinder clamping | Servo top plate / cylinder clamping |
| Conveyor type | Chain | Belt |
| Conveyor direction | Left → Right / Right → Left | Left → Right / Right → Left |
| Conveyor height | 900 ± 20 mm | 750 ± 20 mm |
| Lead clinching unit | Not applicable | Standard configuration |
| Vision system | Top mark CCD (1 unit), bottom component CCD (4 units) | |
Compatibility
Match the feeder to the component package.
Final feeder, gripper and nozzle design should be confirmed after reviewing your BOM, component drawings, PCB files and samples.
Feeder and component chips
Radial tape feederVertical taping 90°Horizontal tape feederTube feederBowl feederTray feederRelaysTransformersConnectorsCapacitorsCoilsFusesYamahaFUJIJUKISamsungPanasonicUniversalSiemens-ASM
Gallery
Real S7900 product images from Southern Machinery photo bank.
All gallery assets are loaded from ph.smthelp.com so this HTML can be shared with customers remotely.
Working Videos
See odd-form automation in motion.
Videos are embedded from Southern Machinery YouTube sources indexed in the S7900 NotebookLM product notebook.
Remote Resources
Catalog, manual and 3D model access
Open the company product drive and search the listed terms. This avoids broken private-share links and keeps the customer on the official Southern Machinery file portal.
Sample Review
Before final quotation
Please send PCB Gerber/CAD data, BOM, component drawings, package photos, target UPH, manual-worker count, current defect points and wave soldering flow. Southern Machinery will confirm feeder, gripper, nozzle and clinching feasibility before final pricing.
Start Sample ReviewFree Installation & Training
Engineer-guided startup and operator training.
1-Day Spare Parts
Fast response for critical spare-parts support.
Worldwide Support
Remote and on-site support for global EMS factories.
12-Month Warranty
Warranty support subject to final quotation terms.
FAQ
Common questions from EMS engineers.
Answers are based on S7900 source documents and NotebookLM product notes, with uncertain items marked for confirmation.
What components can S7900 insert?
It is designed for odd-form and THT parts such as relays, transformers, connectors, capacitors, coils and similar non-standard components. Final feasibility depends on package, lead geometry and sample testing.
Can it handle different component packaging?
Yes. The S7900 material lists tape feeders, tube feeders, tray feeders and bowl feeders. Feeder choice is configured after reviewing your BOM and component packaging.
Does the machine prevent components from floating before wave soldering?
The S7900IV-W includes a lead clinching unit as standard configuration. The catalog notes automatic lead bending to help prevent floating during welding; final clinching design depends on lead diameter, exposed lead length and PCB layout.
What is the typical speed?
The specification lists 0.7 s per component for S7900IV and 2 s with bent feet for S7900IV-W. Real UPH depends on component type, feeder, clinching requirements and board route.
How accurate is placement?
The S7900IV specification lists ±0.06 mm, and S7900IV-W lists ±0.05 mm, both with CPK≥1.0 in the source table.
What data should we send for evaluation?
Send PCB files, BOM, component drawings, photos of packaging, target throughput, existing manual process, and any wave soldering or clinching constraints. Samples are recommended before final confirmation.
Can it connect with a full THT line?
Yes. The S7900 supports left-to-right or right-to-left conveyor direction and can be paired with PCB loaders, unloaders and downstream soldering equipment. Exact layout needs line-design confirmation.
Is ROI guaranteed?
No generic ROI should be treated as a guarantee. The page shows only source examples. Southern Machinery validates ROI case-by-case using your labor cost, shifts, volume, component mix and final configuration.
Ready to test your odd-form BOM?
Email Jason with your PCB and component details. We will review feeder selection, gripper/nozzle tooling, clinching feasibility and line layout before quotation.