JUKI FX-1 Maintenance Manual
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JUKI FX-1 Maintenance Manual

JUKI FX-1 Maintenance Manual

High-speed modular mounter
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High-Speed Modular Mounter
FX-1/FX-1R
MAINTENANCE GUIDE
JUKI CORPORATION 
ELECTRONIC ASSEMBLY & 
TEST SYSTEMS DIVISION 
SMT CENTER

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Summary of Contents for JUKI FX-1

  • Page 1 High-Speed Modular Mounter FX-1/FX-1R MAINTENANCE GUIDE JUKI CORPORATION  ELECTRONIC ASSEMBLY &  TEST SYSTEMS DIVISION  SMT CENTER...
  • Page 2 (3) This manual is written as carefully as possible. However, if you have a question, or find a mistake or missing information, contact our dealers or JUKI Corp. (4) JUKI Corp. is not responsible for any defects or malfunction due to your abnormal operation.
  • Page 3 Warning For the safe operation of machinery!! All personnel engaged in the operation of the chip placer and its accessories (here after referred to as "machines") including the operators, service and maintenance personnel are required to read through this safety warning to make familiar with its handling to prevent accidents and injuries.
  • Page 4 DANGER To prevent accidents due to electric shock, turn off power supply if it is necessary to open the electrical equipment box. For added precaution, open the lid of the box only after a lapse of more than five minutes. CAUTION Basic Matters of Precaution Be sure to read all documents included in this Manual and the attached booklet...
  • Page 5 CAUTION To turn off power supply means to turn off a power supply switch and then to draw out a power plug from a receptacle or to separate the power cable from the supply side. Hereinafter the same. Situations in Which It Is Necessary to Turn Off Power Supply In the case of an abnormality or an accident, or in the event of power failure, immediately turn off power supply.
  • Page 6 CAUTION Greasing Regarding greasing, use Albania Grease. To prevent the occurrence of an inflammation or rash, immediately wash the related portions if grease adheres to your eyes or other parts of your body. If grease is mistakenly swallowed, immediately consult a physician to prevent diarrhea or vomiting.
  • Page 7 CAUTION Label Sticking Positions CAUTION label for getting caught CAUTION label for moving parts CAUTION label for high voltage [Front view] [Rear view] CAUTION label for moving parts [Right side view] [Left side view]...
  • Page 8 Matters of Caution for Safe Use of FX-1 Series To prevent accidents due to electric shock, do not open the electrical equipment box while power supply is on. To prevent electric shock, do not operate the machine, with the DANGER grounding line unlinked.

  • Page 9: Table Of Contents

    FX-1/FX-1R Maintenance Manual CONTENTS X-Y UNIT....................1-1 1-1. Replacing the Timing Belt and Adjusting the Belt Tension........1-1 1-1-1. Timing Belt YM........................1-1 1-1-2. YB-Belt..........................1-2 1-1-3. Adjustment Procedure ......................1-3 1-1-4. Measurement Positions and Specification Values..............1-3 1-1-5. Adjusting Method ......................... 1-4 1-2.
  • Page 10 FX-1/FX-1R Maintenance Manual 2-3. Replacing the Z-Sensor ..................2-7 2-3-1. MNLA Head.......................... 2-7 2-4. Replacing the Laser Sensor ..................2-8 2-4-1. Replacing the MNLA ......................2-8 2-5. Replacing the Head Up Spring................2-9 2-5-1. MNLA Head.......................... 2-9 2-6. Replacing the Belts .....................2-10 2-6-1.
  • Page 11 FX-1/FX-1R Maintenance Manual 4-6. Adjusting the OCC Light Quantity .................4-6 4-7. List of Readjustment Items After Replacement .............4-6 BOARD TRANSPORT UNIT ..............5-1 5-1. Replacing the Transport Belt.................5-1 5-2. Replacing the Transport Pulley ................5-2 5-2-1. CONVEYOR PULLEY A: E21117150A0 ................5-2 5-2-2.
  • Page 12 FX-1/FX-1R Maintenance Manual ATC ......................7-1 7-1. Replacing the Air Cylinder..................7-1 7-2. Replacing the ATC OPEN and CLOSE Sensors...........7-4 7-3. Adjusting the Speed Controller................7-4 FEEDER BANK AND REPLACEMENT TABLE (OPTIONAL) ....8-1 8-1. Overall Drawing.....................8-1 8-2. Replacing the Drive Cylinder.................8-2 8-3. Adjusting the Speed Controller of the Drive Cylinder ..........8-4 8-4.
  • Page 13 13-5-1. Structure of X-Y Unit ......................13-22 13-5-2. XY-Axis Driver Indication Display ..................13-23 13-5-3. Scale I/F Unit ........................13-23 13-5-4. Magnescale detector (Used in FX-1; not used in FX-1R)..........13-24 13-6. Z-θ Unit ......................13-25 13-6-1. Structure of Z-θ Unit......................13-25 13-6-2.
  • Page 14 [15] FEEDER POSITION INDICATOR (FPI) ..........15-1 15-1. Detaching the FPI from the Machine Main Unit...........15-1 15-2. Structure of components inside FPI ..............15-2 [16] FX-1 JIG LISTS..................16-1 Note) The YA-axis described in this manual is equivalent to the Y-TBL-axis. Rev. 2.00...

  • Page 15: X-Y Unit

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. X-Y UNIT 1-1. Replacing the Timing Belt and Adjusting the Belt Tension 1-1-1. Timing Belt YM (1) Remove the pulley cover.

  • Page 16: Yb-Belt

    FX-1/FX-1R Maintenance Manual 1-1-2. YB-Belt To make the work efficient, remove the side cover. Remove the side cover mounting screws to pull out the cover. (1) Remove the SL6063092TN fixing the YB-belt joint to the X-beam end. (2) Loosen the SL6062092TN fixing the YB-pulley bracket assembly.

  • Page 17: Adjustment Procedure

    FX-1/FX-1R Maintenance Manual 1-1-3. Adjustment Procedure (1) Make measurements with a Yunitta's tension meter placed at the positions indicated by the arrows in the figure below and check to make sure that the values are within the specification value range.

  • Page 18: Adjusting Method

    FX-1/FX-1R Maintenance Manual 1-1-5. Adjusting Method (1) Timing belt YM 1. Loosen the SL6062592TN fixing the YB-motor bracket. 2. Adjust the tension using the SM6085502TN. 3. Tighten the SL6062592TN firmly YA-PULLEY BRACKET L ASM: L142E0210A0 YA-PULLEY BRACKET R ASM: Chassis, Y-axis frame...

  • Page 19: Replacing The Pulleys

    FX-1/FX-1R Maintenance Manual 1-2. Replacing the Pulleys 1-2-1. Replacing the Pulley YA (1) Carry out the replacement work in the same manner as for the timing belt YM in 1-1-1. 1-2-2. Replacing the Pulley YM (1) Carry out the replacement work in the same manner as for the timing belt YM in 1-1-1.

  • Page 20: Replacing The Magnescale (For Fx-1R, See Section 1-8.)

    FX-1/FX-1R Maintenance Manual 1-4. Replacing the Magnescale (For FX-1R, see Section 1-8.) (1) Detach the magnescale head from the bracket. (2) Detach the old magnescale. (3) Degrease the magnescale mounting surface and magnescale completely. Note 1: Before replacing the magnescale, leave a new magnescale near the machine for 1 hr.

  • Page 21: Y-Axis Magnescale Affixing Position (For Fx-1R, See Section 1-8-2.)

    FX-1/FX-1R Maintenance Manual 1-4-2. Y-axis Magnescale Affixing Position (For FX-1R, see Section 1-8-2.) (1) Affix the magnescale with the 1.5mm-thick block gauge made tightly in contact with the side surface of the Y-linear guide. MAGNESCALE (Y-AXIS) Block gauge L902E121000 Figure 1-4-2-1 1-4-3.

  • Page 22: Replacing The Limit Sensor And The X-Axis Home Position Sensor

    FX-1/FX-1R Maintenance Manual 1-5. Replacing the Limit Sensor and the X-Axis Home Position Sensor (1) If only the sensor is replaced, it is not necessary to adjust the position. (2) If the sensor is replaced together with the bracket, it is necessary to adjust the position. (X-axis only) 1-5-1.

  • Page 23: Replacing The Home Position Sensor

    FX-1/FX-1R Maintenance Manual 1-6. Replacing the Home Position Sensor 1-6-1. Y-Axis The Y-axis home position sensor is an important device that determines the squareness between the X-axis and Y-axis. If the position of the Y-axis home position sensor is not adjusted correctly after it has been replaced, the squareness between the X-axis and Y-axis may deviate, causing the mounting accuracy to lower.

  • Page 24: Replacing The Plastic Rail

    FX-1/FX-1R Maintenance Manual 1-7. Replacing the Plastic Rail 1-7-1. Replacing the X-Axis Plastic Rail (1) Remove the SM0050801SC and SM0061201SC. (2) Open the flap of the X cable bear to remove the cables, and replace the X-axis plastic rail. (3) Apply the grease to four surfaces inside the plastic rail thickly and evenly.

  • Page 25: Replacing The Y-Axis Plastic Rail

    FX-1/FX-1R Maintenance Manual 1-7-2. Replacing the Y-Axis Plastic Rail (1) Remove the SM0050801SC and SM0061201SC. (2) Open the flap of the Y cable bear to remove the cables, and replace the Y-axis plastic rail. (3) Apply the grease to four surfaces inside the plastic rail thickly and evenly.

  • Page 26: Replacing The Magnescale (Fx-1R)

    FX-1/FX-1R Maintenance Manual 1-8. Replacing the magnescale (FX-1R) (1) Remove the scale head from the bracket. (2) Remove the old magnescale. (3) Degrease the magnescale mounting surface and a new magnescale completely. Note 1: Before replacing the magnescale, put a new magnescale near the machine and leave it for 1 hour or longer.

  • Page 27: Yb-Axis Magnescale Affixing Position (Fx-1R)

    FX-1/FX-1R Maintenance Manual 1-8-2. YB-axis magnescale affixing position (FX-1R) (1) Affix the magnescale with the 4mm-thick block gauge made tightly in contact with the side surface of the Y-linear guide. Block gauge Figure 1-8-2-1 1-8-3. YA-axis magnescale affixing position (FX-1R) (1) Affix the magnescale on the YA-scale base evenly.

  • Page 28: Gap Of Magnescale (Fx-1R)

    FX-1/FX-1R Maintenance Manual 1-8-4. Gap of magnescale (FX-1R) (1) Loosen the screw fixing the sensor and put the 0.3mm-thick tool in the gap between the magnescale and sensor head. (2) Tighten the screw and remove the 0.3mm-thick tool. Figure 1-8-4-1 (YB-axis)

  • Page 29: Head Unit

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. HEAD UNIT 2-1. Replacing and Adjusting the Head 2-1-1. MNLA Head (1) Detach the head top cover .
  • Page 30 FX-1/FX-1R Maintenance Manual (4) Remove the ejector base . (4 mounting screws)   Ejector base Figure 2-1-3 (5) Remove the head sensor PWB base and base support D . (4 mounting screws)   Head sensor PWB base   Base support D Figure 2-1-4 Rev.
  • Page 31 FX-1/FX-1R Maintenance Manual (6) While keeping the head by hand so that it does not fall down, remove the SEMS cap bolts (6 pcs.). SEMS cap bolts Figure 2-1-5 (7) Pull out the two parallel pins at the top and bottom of the head from the head plate. Then raise the head to detach it so that it is not in contact with other components.

  • Page 32: Replacing The Motor

    FX-1/FX-1R Maintenance Manual 2-2. Replacing the Motor 2-2-1. Z-Motor (MNLA Head) After the Z motor has been replaced, it is absolutely necessary to re-input the MS parameters related to the Z-axis height and laser. (For details of input items, see section 2-9.)
  • Page 33 FX-1/FX-1R Maintenance Manual <Procedure> Put the screw in the tap of the Z-motor and lock the mounting screw with the screw pulled in the direction indicated by an arrow with a force of 21.6 N (2.2 kgf) using a tension gauge.

  • Page 34: Θ-Motor (Mnla Head)

    FX-1/FX-1R Maintenance Manual 2-2-2. θ-Motor (MNLA Head) After the motor has been replaced, it is absolutely necessary to re-input the MS parameters related to the axis home. (For details of input items, see section 2-9.) (1) Follow the steps (1) to (5) described in...

  • Page 35: Replacing The Z-Sensor

    FX-1/FX-1R Maintenance Manual 2-3. Replacing the Z-Sensor After the Z-sensor has been replaced, it is absolutely necessary to re-input MS parameters related to the height of the Z-axis. (For details about input items, see section 2-9.) 2-3-1. MNLA Head (1) Remove the peripheral components following the steps (1) to (5) in the section 2-1-1.

  • Page 36: Replacing The Laser Sensor

    FX-1/FX-1R Maintenance Manual 2-4. Replacing the Laser Sensor 2-4-1. Replacing the MNLA After the MNLA has been replaced, it is absolutely necessary to re-input the MS parameters related to the laser. (See section 2-9.) After the laser sensor has been replaced, wipe the laser window on the MNLA with clean wastes, etc.

  • Page 37: Replacing The Head Up Spring

    FX-1/FX-1R Maintenance Manual 2-5. Replacing the Head Up Spring 2-5-1. MNLA Head Replacing the head up SP (1) Follow step (1) described in section 2-1 to detach the head top cover. (2) Replace the head up SP. Head up SP...

  • Page 38: Replacing The Belts

    FX-1/FX-1R Maintenance Manual 2-6. Replacing the Belts 2-6-1. MNLA Head <Replacing the timing belt Z （L151E421000）> After the timing belt Z has been replaced, it is absolutely necessary to re-input the MS parameters related to the Z-axis height. (For details of input items, see section 2-9.) (1) Loosen the timing belt Z following the steps (1) through (3) in section 2-2-1.

  • Page 39: Replacing The Spline Housing

    FX-1/FX-1R Maintenance Manual 2-7. Replacing the Spline Housing To replace the spline housing, it is necessary to detach the MNLA head and the θ-motor. It is also necessary to re-input the MS parameters related to the θ-axis home position, Z-axis home position adjustment, Z-axis height, and laser.

  • Page 40: Replacing The Nozzle Outer Shaft Assembly

    FX-1/FX-1R Maintenance Manual 2-8. Replacing the Nozzle Outer Shaft Assembly Since the nozzle outer shaft assembly has been assembled to the spline shaft at a position where the run-out is minimized, always remove the nozzle outer shaft assembly with great care. (Unlike the conventional machine, it is not necessary to remove the nozzle outer shaft assembly when performing the maintenance work of the filter.)

  • Page 41: List Of Readjustment Items After Replacement

    FX-1/FX-1R Maintenance Manual 2-9. List of Readjustment Items After Replacement Mounting Laser offset Head offset general offset Head unit assembly        Z-motor        θ-motor        Z-sensor        Laser sensor       ...

  • Page 42: Parts Around The Head

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. PARTS AROUND THE HEAD 3-1. Replacing the Ejector Unit Before replacing the ejector unit, always shut-down the main compressed air.

  • Page 43: Replacing The Bad Mark Sensor

    FX-1/FX-1R Maintenance Manual 3-2. Replacing the Bad Mark Sensor 3-2-1. Sensor Assembly SEMS cap bolt Camera bracket D Sensor fiber BM lens holder Washer Fiber lens Figure 3-2-1 Replacing the Bad Mark Sensor Secure the fiber with the nut and washer supplied with the fiber. After the fiber lens is secured as illustrated in the figure above, mount the zoom lens.

  • Page 44: Amplifier

    FX-1/FX-1R Maintenance Manual 3-2-3. Amplifier Camera bracket U Bad mark sensor amplifier SEMS cap bolt (× 2) Figure 3-2-2 Mounting the Amplifier See Subsection 4-4-3 "HMS offset" and Section 3-5 of MS Parameter manual. 3-2-4. Assembling the Fiber Unit to the Amplifier Make the projection on the fiber unit facing toward a position where the LED does not exist on the amplifier and insert it completely until it is in contact with the far side.

  • Page 45: Running The Bad Mark Sensor Cables

    FX-1/FX-1R Maintenance Manual 3-2-6. Running the bad mark sensor cables • Bundle the sensor fiber unit cables as shown in the Photo below and fix them with tie-up bands. Bundle excess cables of the fiber unit like a circle and fix them with tie-up bands.

  • Page 46: Replacing The Hms

    FX-1/FX-1R Maintenance Manual 3-3. Replacing the HMS 3-3-1. Replacing the HMS Head Camera bracket D HMS sensor head SEMS cap bolt (× 2) Figure 3-3-1 Replacing the HMS Head 3-3-2. Replacing the HMS Amplifier After the HMS amplifier has been mounted, try to move it to check that it does not come off.

  • Page 47: Sticking The Label

    FX-1/FX-1R Maintenance Manual 3-3-3. Sticking the Label After the label sticking surface has been degreased, stick the label.   Figure 3-3-3 Left: label/right: label stuck 3-3-4. Mounting the Board To mount the height sensor board 2 assembly, insert the connector into the head main board completely and press the head main PWB cover from the top to secure it.

  • Page 48: Running The Hms Cables

    FX-1/FX-1R Maintenance Manual 3-3-5. Running the HMS cables Run the cables coming from the HMS sensor as shown in the Photo below. Fix each part with tie-up bands. Left head Right head Carefully run the cables so that any excessive stress is not applied to the cables.
  • Page 49 FX-1/FX-1R Maintenance Manual Left head Amplifier アンプ From amplifier to board From sensor to amplifier Since the cable from the amplifier is long, round it appropriately as shown in the Photo above to run it. Carefully run the cables so that any excessive stress is not applied to the cables.

  • Page 50: Adjusting The Hms Height

    FX-1/FX-1R Maintenance Manual 3-3-6. Adjusting the HMS Height Move the HMS sensor to a point above the calibration block. Loosen the SEMS cap bolts at four places so that the distance between the bottom surface of the height sensor and the top surface of the calibration block becomes 40 ±...

  • Page 51: Replacing The Head Board

    FX-1/FX-1R Maintenance Manual 3-4. Replacing the Head Board 3-4-1. Replacing the Head Main Board VR7 TP14 Figure 3-4-1 Head Main Board After the head main board has been replaced, adjust the vacuum level. (At this time, use TP1 for the GND terminal.)

  • Page 52: Replacing The Sensor Relay Board Assembly

    FX-1/FX-1R Maintenance Manual 3-4-2. Replacing the Sensor Relay Board Assembly SEMS cap bolt   (× 2) Head sensor PWB cover   Stud (× 2) Head sensor board assembly   Figure 3-4-2 Replacing the sensor relay board assembly 3-11 Rev. 2.00...

  • Page 53: Occ Assembly

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. OCC ASSEMBLY 4-1. Replacing the OCC Assembly (1) Remove the SEMS cap bolt to detach the camera bracket D.

  • Page 54: Replacing The Ccd Camera And Lens

    FX-1/FX-1R Maintenance Manual 4-2. Replacing the CCD Camera and Lens (1) Detach the camera assembly from the XM base using the procedure described in section 4-1, Replacing the OCC Assembly. (2) Remove the screws fixing the CCD camera and lens to replace the CCD camera and lens.

  • Page 55: Replacing The Occ Coaxial/Angle Light Board Assemblies

    FX-1/FX-1R Maintenance Manual 4-3. Replacing the OCC Coaxial/Angle Light Board Assemblies (1) Detach the light assembly from the XM base using the procedure described in section 4-1, Replacing the OCC Assembly. (2) Remove the SEMS cap bolts to replace the OCC coaxial light board assembly.

  • Page 56: Replacing The Lens Filter And Light Filter

    FX-1/FX-1R Maintenance Manual 4-4. Replacing the Lens Filter and Light Filter (1) Detach the light assembly from the head plate using the procedure described in section 4-1, Replacing the OCC Assembly. (2) Remove the lens filter and light filter to replace them.

  • Page 57: Adjusting The Focus

    FX-1/FX-1R Maintenance Manual 4-5. Adjusting the Focus <Procedure> Place the camera adjustment jig on the top surface of the calibration block, facing its etching surface down. Loosen the hexagon socket head cap bolts (total of 6 locations) that secure the camera, move the camera up and down, and when lines up to 2 on the etching surface are clearly visible (see the figure below), secure the camera in position.

  • Page 58: Adjusting The Occ Light Quantity

    FX-1/FX-1R Maintenance Manual 4-6. Adjusting the OCC Light Quantity <Procedure> Check that the OCC light goes on with manual control. Carry out "Adjustment of OCC Light" in the MS parameters. (See the section related to OCC light quantity adjustment in the specifications for the MS parameter operation.) 4-7.

  • Page 59: Board Transport Unit

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. BOARD TRANSPORT UNIT 5-1. Replacing the Transport Belt (1) Loosen the transport belt tension adjustment pulley.

  • Page 60: Replacing The Transport Pulley

    FX-1/FX-1R Maintenance Manual 5-2. Replacing the Transport Pulley Two kinds of transport pulleys are available. If the mounting position is changed or the pulley is mounted incorrectly, this may cause incorrect pulley rotation or incorrect alignment of the transport belt, resulting in wear on the belt.

  • Page 61: Replacing The In And Out Motors

    FX-1/FX-1R Maintenance Manual 5-3. Replacing the IN and OUT Motors (1) Disconnect the connector of the motor relay cable. (2) Loosen the set screws fixing the motor bracket A to detach the drive belt from the motor pulley (3) Detach the motor and gear head.
  • Page 62 FX-1/FX-1R Maintenance Manual (5) Reassemble the components in the order of steps (3) to (1). Drive belt tension must be adjusted as explained below. <Procedure> Loosen the set screws fixing the IN/OUT motors to the rail stand F and lock screw located on the top of the motor bracket A.

  • Page 63: Replacing The Cent Motor And Awcc Motor

    FX-1/FX-1R Maintenance Manual 5-4. Replacing the CENT Motor and AWCC Motor <Replacing the CENT motor> L900E221000 (1) Disconnect the connector of the motor relay cable. (2) Loosen the bracket fixing bolts of the conveyor motor bracket C to detach the conveyor motor belt C from the...
  • Page 64 FX-1/FX-1R Maintenance Manual <Adjusting procedures of conveyor motor belt C Tension > Loosen the bracket fixing bolt to move the conveyor motor bracket C rightward or leftward. Adjust the tension of the belt considering the interference with other parts. III.

  • Page 65: Adjusting The Width Adjust Link Belt (Center)

    FX-1/FX-1R Maintenance Manual 5-5. Adjusting the Width Adjust Link Belt (CENTER) <Procedures> (1) Set the PWB width to 300 mm. (2) Loosen the tensioner bolts of the tensioner unit to move the tensioner pulley up or down. (3) Adjust the tension of the belt considering the interference with other parts.

  • Page 66: Adjusting The Width Adjust Link Belt (In/Out)

    FX-1/FX-1R Maintenance Manual 5-6. Adjusting the Width Adjust Link Belt (IN/OUT) <Procedures> (1) Loosen the bracket fixing bolts of the adjuster bracket R to move the tensioner pulley idler pulley rightward or leftward (2) Adjust the tension of the belt considering the interference with other parts.

  • Page 67: Replacing The In And Out Sensors

    FX-1/FX-1R Maintenance Manual 5-7. Replacing the IN and OUT Sensors Bind the cables A and B with binding bands, taking care that they are not pulled or loosened excessively during adjustment of sensor position. ① ① ③ ② Ａ ③...

  • Page 68: Replacing The Wait Sensor And C Out 2 Sensor

    FX-1/FX-1R Maintenance Manual 5-8. Replacing the WAIT Sensor and C OUT 2 Sensor 5-8-1. Replacing the Fiber (1) Detach the fiber from the WAIT sensor amplifier. Loosen the fixing set screw to detach the light receiving fiber. (2) Detach the light receiving fiber from the WAIT sensor block.

  • Page 69: Replacing The Amplifier Unit

    FX-1/FX-1R Maintenance Manual 5-8-2. Replacing the Amplifier Unit 5-8-2-1. Attaching the fiber to the amplifier (1) Using a finger nail or slotted screwdriver, raise the lever on the top of the amplifier unit slightly. (2) Insert the fiber into the amplifier unit completely and push down the lever.

  • Page 70: Replacing The Stop And C Out Sensors

    FX-1/FX-1R Maintenance Manual 5-9. Replacing the STOP and C OUT Sensors (1) Remove the set screws fixing the STOP and C OUT sensors from the stopper to replace the sensors. L164E0210A0 STOPPER L UNIT L825E1210A0 STOP SENSOR ASM L832E1210A0 C OUT SENSOR ASM...
  • Page 71 FX-1/FX-1R Maintenance Manual Set the adjustment screw to the center between positions A and B. Position A Position B Set position Figure 5-9-2 (5) Perform the fine adjustment of the sensor position. Select [Manual Control] and [Individual Transfer Control] in that order to turn ON the stopper and raise the stopper.

  • Page 72: Replacing The Stopper Cylinder

    FX-1/FX-1R Maintenance Manual 5-10. Replacing the Stopper Cylinder Loosen the nut at the top end of the rod. Remove the mounting nut Turn the cylinder shaft to detach the cylinder from the stopper clevis (4) When installing a new stopper cylinder, reassemble the components in the order of steps (3) to (1).

  • Page 73: Replacing The Stbl Home Position Sensor

    FX-1/FX-1R Maintenance Manual 5-11. Replacing the STBL Home Position Sensor ) Detach the nsor from the sensor bracket. Table 5-11-1 L168E021000 BU SENSOR BRACKET SUPPORT TABLE NEAR L812E8210A0 SENSOR ASM SCREW SUPPLIED WITH SENSOR Figure 5-11-1 Adjust the distance between the sensor and sensor dog to 1 mm.

  • Page 74: Replacing The T-Pin Sensor

    FX-1/FX-1R Maintenance Manual 5-12. Replacing the T-PIN Sensor (1) Remove the fixing screw to detach the sensor bracket and replace the sensor. With the centering pin lowered by a -0.5 specification value Adjustment Sensor bracket (dimension A), loosen the adjustment...

  • Page 75: Adjusting The Position In The Y-Direction (Outer Shape Reference)

    FX-1/FX-1R Maintenance Manual 5-13. Adjusting the Position in the Y-direction (Outer Shape Reference) Figure 5- 13-1 (1) Put the gaug e block a nd tighten the bolts to make the adjustment so that the gap between the rail base R nd bushing omes 6.6 mm.

  • Page 76: Adjusting The Check Cylinder Speed

    FX-1/FX-1R Maintenance Manual 5-15. Adjusting the Check Cylinder Speed Clockwise rotation: Decreases the pressure. Lock nut Pressure reducing valve Clockwise rotation: Makes the speed slower. Speed controller Figure 5-15-1 Adjust the check cylinder speed of the IN/BUFFER. (1) Adjust the pressure reducing valve to 0.15MPa. (Adjust the pressure while turning ON and OFF the cylinder.)

  • Page 77: Replacing The Centering Pin

    FX-1/FX-1R Maintenance Manual 5-16. Replacing the Centering Pin (1) Loosen the screws of the guide block A and B to detach the centering pin together with the guide blocks. Figure 5-16-1 Figure 5-16-2 (2) At this time, also detach the T-PIN sensor (together with its bracket) from the reference side.

  • Page 78: Replacing The Stbl Motor

    FX-1/FX-1R Maintenance Manual 5-17. Replacing the STBL Motor (1) Widen the rail width to its maximum level. (2) Remove the support table fixing screws (15 screws in total) to detach the support table (3) Remove the encoder unit fixing screws...

  • Page 79: Adjusting The Tension Of The Stbl Driving Timing Belt

    FX-1/FX-1R Maintenance Manual 5-17-2. Adjusting the Tension of the STBL Driving Timing Belt To adjust the tension of the BU driving timing belt, loosen the encoder unit fixing screws and move the assembly in the arrow direction, input the said values to the sonic...

  • Page 80: Replacing The Stbl Encoder

    FX-1/FX-1R Maintenance Manual 5-18. Replacing the STBL Encoder (1) Detach the support table in the same manner as described in section 5-17, Replacing the STBL motor. (2) Loosen the fixing screws and move the encoder unit assembly to loosen the tension of the timing belt.

  • Page 81: Layout Of Solenoid Valves

    FX-1/FX-1R Maintenance Manual 5-19. Layout of solenoid valves The following figure shows the layout of solenoid valves. STOPPER CHK CYL ATC R ATC L Figure 5-19-1 5-23 Rev. 2.00...

  • Page 82: Replacing The Support Pin Detection Sensor

    FX-1/FX-1R Maintenance Manual 5-20. Replacing the support pin detection sensor (1) Remove the screw Front reference, L → R flow Front reference, R → L flow to detach the Rear reference, R → L flow Rear reference, L → R flow...

  • Page 83: Replacing The Ya-Motor

    FX-1/FX-1R Maintenance Manual 5-21. Replacing the YA-motor 5-21-1. Replacing the YA-motor (1) Disconnect the motor relay cable connector. (2) Remove the bolts fixing the protection cover from the YA-motor bracket (3) Loosen the bolt of the coupling (4) Remove the YA-motor fixing bolt...

  • Page 84: Adjusting The Z-Phase Of The Ya-Ball Screw

    FX-1/FX-1R Maintenance Manual 5-21-2. Adjusting the Z-phase of the YA-ball screw NEAR SENSOR LIMIT SENSOR Sensor YA-ball screw (1) In the status that YA-motor and coupling are fixed YA-ball screw and coupling are free, move the table position where Free →...

  • Page 85: Cal Block

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. CAL BLOCK 6-1. Replacing the CAL Block Board Assembly (1) Disconnect two bundled cables from the CAL board.

  • Page 86: Replacing The Ejector

    FX-1/FX-1R Maintenance Manual 6-2. Replacing the Ejector (1) Shut down the main air pressure to the machine main unit and disconnect the cable and air tubes (2) Remove the screw fixing the ejector to detach the ejector. (3) Remove the elbow unions from the detached ejector and mount them on a new ejector.

  • Page 87: Replacing The Vacuum Calibration Sensor

    FX-1/FX-1R Maintenance Manual 6-3. Replacing the Vacuum Calibration Sensor (1) Insert a slotted screwdriver into the groove at the top end of the nozzle CAL piece and turn it to replace the sensor Rev. 2.00...

  • Page 88: Atc

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. 7-1. Replacing the Air Cylinder (1) Shut down the main air pressure to the machine main unit.
  • Page 89 FX-1/FX-1R Maintenance Manual (4) After the air cylinder has been replaced, adjust the air cylinder rod fixing position. With the slide plate open, visually adjust the position so that the hole on the ATC base matches the center of the arc of the slide plate, then fix the rod supplied with the ATC cylinder to the ATC joint.
  • Page 90 FX-1/FX-1R Maintenance Manual (5) Adjust the sensor dog position When opened. → The OPEN sensor is turned ON at a position where is 1 mm before the slide plate is opened. When closed. → The CLOSE sensor is turned ON at a position where is 1 mm before the slide plate is closed.

  • Page 91: Replacing The Atc Open And Close Sensors

    FX-1/FX-1R Maintenance Manual 7-2. Replacing the ATC OPEN and CLOSE Sensors (1) Remove the SEMS cap bolts fixing the ATC OPEN and CLOSE sensors to replace the ATC OPEN and CLOSE sensors. (2) Secure the cables to the fixing base with tie-up bands.

  • Page 92: Feeder Bank And Replacement Table (Optional)

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. FEEDER BANK AND REPLACEMENT TABLE (OPTIONAL) 8-1. Overall Drawing Component at opposite position Figure 8-1-1 Figure 8-1-3  Connector...

  • Page 93: Replacing The Drive Cylinder

    FX-1/FX-1R Maintenance Manual 8-2. Replacing the Drive Cylinder (1) Turn off the power to the main unit. (2) Shut-down the main compressed air to the main unit (with the hand valve). If the machine is equipped with an optional replacement table, detach it and move it outside the main unit. Turn on the selector switch, push the right and left roller levers to move the lifter up.
  • Page 94 FX-1/FX-1R Maintenance Manual (5) Replace the drive cylinders with new ones and put them upside down as shown in Figure 8-2-3. <CAUTION> Carry out this work on the leveled table or the top surface of the bank. Standard specification Figure 8-2-3...

  • Page 95: Adjusting The Speed Controller Of The Drive Cylinder

    FX-1/FX-1R Maintenance Manual 8-3. Adjusting the Speed Controller of the Drive Cylinder Adjust the up speed of drive cylinders. (1) Detach the drive cylinders to be adjusted from the driver bracket. (See subsections 8-2 1) to 4).) (2) Connect the air tube and connector.

  • Page 96: Replacing The Feeder Bank Board And Feeder I/F Board

    FX-1/FX-1R Maintenance Manual 8-4. Replacing the Feeder Bank Board and Feeder I/F Board (1) Disconnect the feeder bank relay cable and air coupler nipple from the main unit. (2) Remove the mounting screws to detach the connector bracket. (3) Disconnect the connectors from the feeder bank board and feeder I/F board.

  • Page 97: Replacing The Bank-Up Cylinder

    FX-1/FX-1R Maintenance Manual 8-5. Replacing the Bank-Up Cylinder (1) Turn off the power to the main unit. (2) Turn on the selector switch, and the left and right roller levers to raise the bank lifter. (3) Loosen the rod and lifter cylinder shaft of the air cylinder to detach the air cylinder (cylinder to be replaced).

  • Page 98: Adjusting The Speed Controller Of The Bank-Up Cylinder (Optional Replacement Table)

    FX-1/FX-1R Maintenance Manual 8-6. Adjusting the Speed Controller of the Bank-Up Cylinder (Optional Replacement Table) (1) Adjust the speed controller on the cylinder, which has been replaced in the previous section. (2) The speed controllers have been set so that the bank-up cylinder completes ascent/descent operation in two to three seconds.

  • Page 99: Replacing The Bank-Up Detection Sensor (Optional Replacement Table)

    FX-1/FX-1R Maintenance Manual 8-7. Replacing the Bank-Up Detection Sensor (Optional Replacement Table) (1) Turn off the power to the main unit. (2) Remove the bank cable cover B. (3) Loosen the sensor fixing screw to detach the sensor and replace it.

  • Page 100: Replacing The Selector Switch (Optional Replacement Table)

    FX-1/FX-1R Maintenance Manual 8-8. Replacing the Selector Switch (Optional Replacement Table) (1) Shut-down the main compressed air to the main unit (with the hand valve). (2) Turn the selector switch cap counterclockwise to detach the selector switch from the cover.

  • Page 101: Replacing The Roller Lever (Optional Replacement Table)

    FX-1/FX-1R Maintenance Manual 8-9. Replacing the Roller Lever (Optional Replacement Table) Before replacing the roller lever, always shut-down the main compressed air. The following figure (Figure 8-9-1) shows the machine with the FR (front right) and RL (rear left) specifications.

  • Page 102: Pneumatic Units

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. PNEUMATIC UNITS 9-1. Replacing the Main Pressure Detection Cable Assembly (1) Detach the pressure gauge from the cover FBL.

  • Page 103: Replacing The Filter Element

    FX-1/FX-1R Maintenance Manual 9-2. Replacing the Filter Element (1) Turn the filter element main unit 45° clockwise or counterclockwise to pull it out downward while lowering the slide part. (2) When replacing the filter element B on the air filter side, turn the resin part fixing the filter element B counterclockwise to detach it.
  • Page 104 FX-1/FX-1R Maintenance Manual Mist separator Air filter PF901002000 PF901006000 Filter element A Filter element B Resin part Slide part Rev. 2.00...

  • Page 105: Switches

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. [10] SWITCHES 10-1. Replacing the Push-Button Switch Name Front Rear ONLINE Standard − ORIGIN Standard −...
  • Page 106 FX-1/FX-1R Maintenance Manual Part No. Part name Q’ty L180E321000 SWITCH PANEL OP HX00354000D Board stud 12 40012050 OPERATION SW PCB ASM HX00354000H Board stud 12.5 HA005520030 Flat bezel, 25mmφ, aluminum silver HA005340020 Switch actuator HA00534006A LED, green HA005340060 LED, orange HA00552001B Flat-type illumination lens, 25mmφ, green...

  • Page 107: Replacing The Emergency Stop Switch

    FX-1/FX-1R Maintenance Manual 10-2. Replacing the EMERGENCY STOP Switch (1) Locations of EMERGENCY STOP switches 10-3 Rev. 2.00...
  • Page 108 FX-1/FX-1R Maintenance Manual (2) Disconnect the cables from the rear of the switch with a screwdriver to replace the switch with a new one. Rear Front Figure 10-2-2 10-4 Rev. 2.00...

  • Page 109: Replacing The Cover Open Switch

    FX-1/FX-1R Maintenance Manual 10-3. Replacing the Cover Open Switch 10-3-1. Switch Main Unit L125E521000 SAFETY SWITCH BRACKET NM6060001SC Hexagon nut, M6 40002254 COVER OPEN SW CABLE ASM Round head screw, M4 × 16 SM4041601SC 10-5 Rev. 2.00...

  • Page 110: Operation Key

    FX-1/FX-1R Maintenance Manual 10-3-2. Operation Key (1) Remove two mounting screws to replace the operation key. Figure 10-3-2 10-6 Rev. 2.00...

  • Page 111: Replacing And Adjusting The Feeder Float Sensor

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. [11] REPLACING AND ADJUSTING THE FEEDER FLOAT SENSOR (1) Check the position of a sensor to be replaced in the machine while referring to the figure below, and detach the sensor together with the bracket.
  • Page 112 FX-1/FX-1R Maintenance Manual (2) Replace the sensor in the detached bracket assembly with a new one. FRR bracket assembly Figure 11-2 Pan head screw M2 × 5 L212E121000 FLOAT SENSOR PLATE SM4020501SC FF EMITTER FF RECEIVER L829E3210A0 L829E9210A0 SENSOR (FR-F) ASM...
  • Page 113 FX-1/FX-1R Maintenance Manual FLR bracket assembly Figure 11-4 Pan head screw M2 × 5 L212E121000 FLOAT SENSOR PLATE SM4020501SC FF EMITTER FF RECEIVER L825E6210A0 L826E2210A0 SENSOR (FL-F) ASM SENSOR (FL-R) ASM FLL bracket assembly Figure 11-5 Pan head screw M2 × 5...
  • Page 114 FX-1/FX-1R Maintenance Manual RRR bracket assembly Figure 11-6 Pan head screw M2 × 5 L212E121000 FLOAT SENSOR PLATE SM4020501SC FF EMITTER FF RECEIVER L830E1210A0 L830E7210A0 SENSOR (RR-F) ASM SENSOR (RR-R) ASM RRL bracket assembly Figure 11-7 Pan head screw M2 × 5...
  • Page 115 FX-1/FX-1R Maintenance Manual RLR bracket assembly Figure 11-8 Pan head screw M2 × 5 L212E121000 FLOAT SENSOR PLATE SM4020501SC FF EMITTER FF RECEIVER L826E4210A0 L827E0210A0 SENSOR (RL-F) ASM SENSOR (RL-R) ASM RLL bracket assembly Figure 11-9 Pan head screw M2 × 5...
  • Page 116 FX-1/FX-1R Maintenance Manual (3) Adjust the height of a newly mounted sensor. Adjust the distance between the top surface of the feeder bank and the top surface of the sensor on the front side to 121.75±0.1mm and the distance between the top surface of the feeder bank and the top surface of the sensor on the rear side to 120.75±0.1mm, and then...

  • Page 117: Other Units

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. [12] OTHER UNITS 12-1. Replacing the FDD (Floppy Disk Drive) L112E521000 FDD BRACKET E9619729000 SL4030691SC SEMS cap bolt, M3 ×...

  • Page 118: Replacing The Cd-Rom Drive

    FX-1/FX-1R Maintenance Manual 12-2. Replacing the CD-ROM Drive L112E621000 CD-ROM BRACKET HX002940000 Fixing base SM4040601SC Round head screw, M4 × 6 40003285 CDD (CD-ROM DRIVE) SL4030691SC SEMS cap bolt, M3 × 6 SM6066002TN Hexagon socket head cap bolt, M6 × 60...

  • Page 119: Replacing The Lcd Monitor

    FX-1/FX-1R Maintenance Manual 12-3. Replacing the LCD Monitor 12-3-1. Replacing the LCD Monitor L180E221000 LCD FRAME L910E121000 SL4030691SC SEMS cap bolt, M3 × 6 NM6040001SC Hexagon nut, M4 WS0410002KN Spring washer, M4 L180E121000 OPERATION BOX 12-3 Rev. 2.00...

  • Page 120: Setting Up The Touch Panel (Optional)

    When the machine has the touch panel specifications, you must set up the touch panel after the LCD monitor has been replaced. From the Start menu, select [Programs (P)], [Gunze], [U-tp], and [Calibrate] (for FX-1) or select [All programs (P)], [Gunze TPDD], and [Calibrate] (for FX-1R).

  • Page 121: Replacing The Lcd Back Light

    FX-1/FX-1R Maintenance Manual 12-3-3. Replacing the LCD back light Follow the steps below to replace the LCD back light. L877E321000 LCD back light (1) Disconnect the connector. (2) Hold the claw fixing the back light to pull out the back light.

  • Page 122: Adjusting The Lcd

    FX-1/FX-1R Maintenance Manual 12-3-4. Adjusting the LCD Before starting the adjustment, remove “OP VR COVER” from the rear of the operation unit. As shown in the figure below, five switches and six LEDs are provided inside the cover. Adjust the LCD using these switches.
  • Page 123 FX-1/FX-1R Maintenance Manual For each input resolution, the initial value of each setting item becomes that as shown below. VGA is input. Video pixel adjustment: 32 (100000b)/ Phase adjustment: 08 (001000b)/ Horizontal adjustment: 32 (100000b)/ Vertical adjustment: 32 (100000b) SVGA is input.

  • Page 124: Replacing The Ssd

    Chinese FX-1/FX-1R system program installation disks These disks contain the software for the FX-1/FX-1R. All system programs for the FX-1/FX-1R are saved into these disks. Japanese, English, and Chinese versions are available. You may specify the same language as that used for the SSD.

  • Page 125: Replacing The Hdd

    FX-1/FX-1R Maintenance Manual 12-4-2. Replacing the HDD L877E221000 SILICON DISK L112E321000 HDD BRACKET SL4040691SC SEMS cap bolt, M4 × 6 SL4030691SC SEMS cap bolt, M3 × 6 12-9 Rev. 2.00...

  • Page 126: Setting Up The Bios

    This BIOS is an important program necessary to control the data input/output of the computer (FX-1 in this manual). Therefore, always set up the BIOS with great care. Additionally, note that this program is saved into the flash memory on the CPU board.
  • Page 127 FX-1/FX-1R Maintenance Manual (2) "Basic CMOS Configuration" screen The following shows the "Basic CMOS Configuration" screen. The contents displayed on the screen show the default values. (3) Changing the "BOOT ORDER:" field Specify a search order of the boot drive.
  • Page 128 FX-1/FX-1R Maintenance Manual (6) Changing "Custom Configuration" When the screen is transited to the Main screen, move the cursor to "Custom Configuration" and display the following screen. The contents displayed on the screen show the default values. (7) Changing IDE 1 MOTOR OFF TIME Using the arrow key, move the cursor to "IDE 1 MOTOR OFF TIME".

  • Page 129: Setting Up The Network (This Setup Is Performed When Communicating With The Hlc)

    12-4-4. Setting Up the Network (This setup is performed when communicating with the HLC) It is necessary to set up the network to perform the communication between the FX-1/FX-1R-series and HLC. You must always set up the network to use the HLC in the on-line mode.
  • Page 130 FX-1/FX-1R Maintenance Manual (3) Select the [Protocol] tag and click the [Add] button. (4) Select [TCP/IP Protocol] and click the [OK] button. 12-14 Rev. 2.00...
  • Page 131 FX-1/FX-1R Maintenance Manual (5) The following message will appear. Select the [No] button. (6) The WindowsNT Setup screen will appear. Input C:\WinNT\Options\Cab\i386 and select the [Continue] button. (7) The TCP/IP protocol will be added. Select the [Close] button. 12-15 Rev. 2.00...
  • Page 132 FX-1/FX-1R Maintenance Manual (8) The Microsoft TCP/IP Properties screen will appear. Select the [IP Address] tag. Check on "Specify an IP address" and specify [IP Address] and [Subnet Mask]. If your company determines the rules about IP address setup, you must follow the instructions given by the network administrator of your company.
  • Page 133 FX-1/FX-1R Maintenance Manual (10) The message prompting you to restart the computer will appear. Select the [No] button to continue the process. 12-17 Rev. 2.00...
  • Page 134 FX-1/FX-1R Maintenance Manual 12-4-4-2. Setting Up a Shared Folder (WindowsNT) You may set up a shared folder for the network communication. Create a folder named "D:\machine\Prg" under the D drive and make this Prg folder shared. (1) Start up Explorer.
  • Page 135 FX-1/FX-1R Maintenance Manual (5) Point to the Prg folder, press the right mouse button, and select [Sharing]. (6) Select the "Sharing" tag, check on "Shared As", and input Prg to the [Share Name] field. *Note Set up a shared folder so that the shared folder name “prg”...
  • Page 136 FX-1/FX-1R Maintenance Manual (7) Select the Permissions button. [The Access Through Share Permissions] screen will appear. Check that "Everyone" is set at "Full Control". If this setting is not made, press the [Add] button and set [Everyone] to "Full Control" on the Add User and Group screen.
  • Page 137 FX-1/FX-1R Maintenance Manual 12-4-4-3. Registering a User (WindowsNT) You may register a user name and password in the FX-1/FX-1R, which you must input in order to start up the PC (personal computer) where the HLC is installed. (1) Check the user name and password, which are used to start up the PC on the HLC.
  • Page 138 FX-1/FX-1R Maintenance Manual 12-4-4-4. Setting Up the TCP/IP (WindowsXP) In the WindowsXP environment, the TCP/IP protocol is already added. (1) From the Start menu, select [ControlPanel]. (2) Double-click the [Network Connections] icon. 12-22 Rev. 2.00...
  • Page 139 FX-1/FX-1R Maintenance Manual (3) The “Network Connections” dialog box will appear. In this dialog box, select the [Local Area Connection] icon and press the right mouse button to select [Properties]. (4) The “Local Area Connection Properties” dialog box will appear. In this dialog box, check on...
  • Page 140 FX-1/FX-1R Maintenance Manual (5) The “Internet Protocol (TCP/IP) Properties” dialog box will appear. Check on "Use the following IP address" and specify [IP address] and [Subnet mask]. If your company determines the rules about IP address setup, you must follow the instructions given by the network administrator of your company.
  • Page 141 FX-1/FX-1R Maintenance Manual 12-4-4-5. Setting Up a Shared Folder (WindowsXP) You may set up a shared folder for the network communication. Create a folder named "D:\machine\Prg" under the D drive and make this Prg folder shared. (1) Start up Explorer.
  • Page 142 FX-1/FX-1R Maintenance Manual (5) Point to the Prg folder, press the right mouse button, and select [Sharing and Security…]. (6) The “Prg Properties” dialog box will appear. Select the [Sharing] tab. Check on [Share this folder] and check that “Prg” is set in the [Share name] field.
  • Page 143 FX-1/FX-1R Maintenance Manual (7) The “Permissions for Prg” dialog box will appear. In the "Permissions for Everyone” area, check on [Allow] of [Full Control]. Note) With the default settings of the access authority, [Full Control] is not allowed. Therefore, always check on [Allow] of [Full Control].
  • Page 144 FX-1/FX-1R Maintenance Manual 12-4-4-6. Registering a User (WindowsXP) You may register a user name and password, which you must input in order to start up the PC (personal computer) where the HLC is installed. (1) Check the user name and password, which are used to start up the PC on the HLC.
  • Page 145 FX-1/FX-1R Maintenance Manual (4) The account name setup dialog box will appear. Input a user account name and click the Next button. (5) The account type setup dialog box will appear. Check on [Computer administrator] and click the Create Account button (6) Select the user account you have created.
  • Page 146 FX-1/FX-1R Maintenance Manual (7) The account setting change dialog box will appear. Select [Create a password]. (8) The password creation dialog box will appear. Input the same password to the [Type a new password:] filed and the [Type the new password again to confirm:] field, and then click the Create Password button The network setup is then completed.

  • Page 147: Installing The Fx-1-Series System Programs And Flexline Db

    The FX-1 system disks are composed of FX-1 main unit system disks and FlexlineDB system disks. You must always install the FX-1 main unit system disks and FlexlineDB system disks in that order. 12-4-5-1. Installing the FX-1 Main Unit System Disks (1) Point to the [Start] button, press the right mouse button, and select Explorer.
  • Page 148 FX-1/FX-1R Maintenance Manual (3) The FX-1 installer is then started up. The message screen will appear. Select the [Next] button. The following message will appear. Click the [Install] button to start installation. 12-32 Rev. 2.00...
  • Page 149 FX-1/FX-1R Maintenance Manual 12-4-5-2. Installing the FlexlineDB System Disks (1) Point to the [Start] button, press the right mouse button, and select Explorer. (2) Insert the 1st floppy disk into the FDD (floppy disk drive) in the main unit. Select (double-click) setup.exe.
  • Page 150 FD and select the [Next] button to complete the setup. (6) Select the [Start] button and restart WindowsNT. WindowsNT starts running and the FX-1 system is then started up. Before starting the origin return of the equipment, always restore the backup data.
  • Page 151 FX-1/FX-1R Maintenance Manual 12-4-5-3. Loading the Backup Data to the Hard Disk Drive (Restoring the backup data) Select [File] and [Control Date Management...] to restore the control data in the SSD. (For the detailed procedure of restoration, see Section 12-3, "Control Data Management" in the "Instruction Manual.")

  • Page 152: Changing The Windowsnt Product Id

    12-4-6. Changing the WindowsNT Product ID You may follow the steps below to change the WindowsNT Product ID. If this process is not performed, the customer using the FX-1-series may infringe the copyright law. To avoid such trouble, always perform this process.
  • Page 153 FX-1/FX-1R Maintenance Manual (3) The ProductID input screen will appear. Input the ProductID with hyphen (-) skipped that is shown on the Certificate of Authenticity supplied with the machine. The Certificate of Authenticity (showing the Product ID of WindowsNT) is described on the license label (shown in the figure above) put around the pilot lamp on the right side of the main unit.

  • Page 154: Restoring The C Drive To The Initial Status

    FX-1/FX-1R Maintenance Manual 12-4-7 Restoring the C drive to the initial status (status that the C drive has been updated previously.) WindowsXP provides a write protect function of the C drive called “EWF”. If a corrupted file is written to the C drive and this file hinder the startup, you can restore the C drive to the previous status.

  • Page 155: Electrical Components

      adjustment work. [13] ELECTRICAL COMPONENTS 13-1. Layout of Electrical Components Figure 13-1-1 shows the front view and Figure 13-1-2 shows the rear view. (FX-1) 13-1-1. Part Names Operation unit LCD monitor, Operation switch board (For front) EMERGENCY STOP switch, Keyboard, Trackball...

  • Page 156: Layout Of Top Of Base Frame

    FX-1/FX-1R Maintenance Manual 13-2. Layout of Top of Base Frame Figure 13-2-1 shows the base frame top view. (FX-1) 13-2-1. Part Names YA-axis motor YBL-axis motor YBR-axis motor IN/OUT motor IN/OUT motor CONVEROR board CARRY sensor relay board CARRY sensor relay board BANK/FPI-F board 10.

  • Page 157: Power Supply Unit

    FX-1/FX-1R Maintenance Manual 13-3. Power Supply Unit 13-3-1. Structure of Power Supply Unit The power supply unit is mounted at the left of the rear of the machine (right side when viewed from the rear). Figure 13-3-1-1 shows the structure drawing of the power supply unit.
  • Page 158 FX-1/FX-1R Maintenance Manual 13-3-1-2. Block Diagram of the DC Power Supply Unit CN061 CN062 CN063 CN064 CN065 CN067 CN066 CN072 CN071 CP1 20A CP2 20A CP18 10A CP9 10A CP10 12A CP3 15A CP4 15A CP11 3A CP12 8A CP5 15A BYPASS CP6 40A CP13 4A CP14 10A CP15 12A CP7 10A CP8 10A SW01 CP16 30A CP17 20A...
  • Page 159 FX-1/FX-1R Maintenance Manual Table 13-3-1-2. DC Power Supply Unit <Parts List> Parts No. Name Qty. Remarks 1 L870E621000 Electromagnetic contactor 04 MC1 (For XL), MC2 (For XR) 2 L872E721000 Electromagnetic contactor 03 MC 3(For YL), MC4 (For YR), MC5 (For YA)

  • Page 160: Control Unit

    FX-1/FX-1R Maintenance Manual 13-4. Control Unit 13-4-1. Structure of Control Unit Figure 13-4-1-1 shows the board layout drawing of the control unit; Check that the boards are mounted correctly while referring to these figures. 13-4-1-1. Board Layout Rack ラック ＶＭＥバックボード...
  • Page 161 FX-1/FX-1R Maintenance Manual Part No. SAFETY board LIGHT CTRL board BASE FEEDER board I/O-CTRL board IP-X3 board MCM board Blank panel Bus bridge board Position board, 24-axis Position board, 12-axis CPU board ⑪ Figure 13-4-1-2 Board Layout Drawing (Perspective View) 13-7 Rev.

  • Page 162: Cpu Board (40003280)

    FX-1/FX-1R Maintenance Manual 13-4-2. CPU Board (40003280) [Functions] This is a circuit board that controls the equipment totally. This circuit board is connected to other circuit boards by the VME bus through the CPCI bus and bus bridge. [Switch settings] This CPU board is used with the jumper switch settings made before shipment.

  • Page 163: Position Board (12-Axis: L901E621000, 24-Axis: L901E721000)

    FX-1/FX-1R Maintenance Manual 13-4-3 Position board (12-axis: L901E621000, 24-axis: L901E721000) [Functions] This position board is a CPCI bus applicable board that controls the servomotors and stepping motors through SSCNET II, Mitsubishi Electric’s control communication network. Up to 12/24-axis motors are controlled.

  • Page 164: Bus Bridge Board (40003313)

    FX-1/FX-1R Maintenance Manual 13-4-4. Bus Bridge Board (40003313) [Functions] The bus bridge board connects the Compact PCI bus and VME bus for accessing from CPCI to VME. [Dip switch settings] When setting a board in the control unit, set up the dip switches as shown below:...

  • Page 165: Mcm (Multi Nozzle Control Module) Board (E9609729000)

    FX-1/FX-1R Maintenance Manual 13-4-5. MCM (Multi Nozzle Control Module) Board (E9609729000) [Functions] This board controls the part centering sensors (MNLA). Two 4-axis MCM boards for the MNLA (E9609729000) are used (for left and right heads). [Switch settings] MCMR (for Left) ＭＣＭＲ（左）...

  • Page 166: Safety Board (40007368)

    FX-1/FX-1R Maintenance Manual 13-4-6. SAFETY Board (40007368) [Functions] The EMERGENCY STOP switch, limit sensor, or X_collision sensor is detected to shut down the servo power. The cover open switch is detected to inform it to the software control unit. The sensor and solenoid valve signals of the board transport unit and ATC are exchanged with the CONVEYOR sensor relay board through the I/F circuit.
  • Page 167 FX-1/FX-1R Maintenance Manual Use the switch 1 to set the function Rev. and pattern Rev. of the board. The following figure shows the assignment and weight of each bit. The setting shown in this figure means that the function Rev. is set at “02” and the pattern Rev. is set at “02”.

  • Page 168: Base Feeder Board Assembly (40007370)

    FX-1/FX-1R Maintenance Manual 13-4-7. BASE FEEDER Board Assembly (40007370) [Functions] This BASE FEEDER board provides various functions, such as the feeder knock, signal light control, and head I/F. [Switch settings] Jumper switches are provided on the BaseFeeder board assembly to be used in the control unit.
  • Page 169 FX-1/FX-1R Maintenance Manual [Switches on front panel] RESET switch: Resets this board. ABORT switch: Issues NMI to the host CPU. Normally, do not operate these two switches. [Meaning of LED] LED 1 (Green): Lit while the CPU is running correctly.

  • Page 170: I/O Control Board (40001943)

    FX-1/FX-1R Maintenance Manual 13-4-8. I/O Control Board (40001943) [Functions] This board receives signals input from each sensor and outputs relevant control signals to other boards. This board also relays the cables to the MTC. [Switch settings] The jumper and DIP switches have already been set at delivery. However, check that they are set as shown below before setting the I/O control board assembly in the control unit.
  • Page 171 FX-1/FX-1R Maintenance Manual Use the switch 4 to set the function Rev. and pattern Rev. of the board. The following figure shows the assignment and weight of each bit. The setting shown in this figure means that the function Rev. is set at “01” and the pattern Rev. is set at “01”.

  • Page 172: Light Ctrl Board (40001918)

    FX-1/FX-1R Maintenance Manual 13-4-9. Light Ctrl Board (40001918) [Functions] This LIGHT CTRL board controls the illumination and light quantity of the OCC light. [Switch settings] Jumper switches are provided on the LIGHT CTRL board assembly to be used in the control unit.

  • Page 173: Ip-X3 Board (40001920)

    FX-1/FX-1R Maintenance Manual 13-4-10. IP-X3 Board (40001920) [Functions] This IP-X3 board is image processing board which processes the image data captured by the OCC camera such as board marks, IC marks and IC chips, and calculate the values necessary for correcting the positions of board and parts.
  • Page 174 FX-1/FX-1R Maintenance Manual [7-segment LED] • Period display ON/OFF Period display status Classification Software Hardware • Notification of cause of boot error The IP-X3 board notifies the cause of the boot error through the 7-segment LED display. The code assignments should conform to the LED bit pattern expressions of conventional models.

  • Page 175: Pos-Cnn Board (40007372)

    FX-1/FX-1R Maintenance Manual 13-4-11. POS-CNN board (40007372) [Functions] This POS-CNN board is a relay board that mainly arranges the limit sensor, home position sensor, and emergency stop signals of each drive axis in units of drive axes, and then inputs them to the position board.

  • Page 176: X-Y Unit

    FX-1/FX-1R Maintenance Manual 13-5. X-Y Unit The X-Y unit is composed of AC servo driver that drives the X/Y-axes and a magnescale that detects the movement position. Note) The YA-axis described in this section is equivalent to the Y-TBL-axis. 13-5-1. Structure of X-Y Unit Five single-axis drivers (two AC servo drivers to drive the X-axis, one AC servo driver to drive the YA-axis, and two AC servo drivers to drive the YB-axis) are mounted on the AC servo driver.

  • Page 177: Xy-Axis Driver Indication Display

    FX-1/FX-1R Maintenance Manual 13-5-2. XY-Axis Driver Indication Display An indication display showing the status is mounted on the front of the XY-driver. Normally, this indication shows the status as shown in the following. ＃ LED indication LED 表示 Ａｂ C＃ D＃...

  • Page 178: Magnescale Detector (Used In Fx-1; Not Used In Fx-1R)

    FX-1/FX-1R Maintenance Manual 13-5-4. Magnescale detector (Used in FX-1; not used in FX-1R)   TSC6185-01-1120 8S Connector (Female) Made by Hosiden. Mounting screw at 4 locations 4-M5 tapping (M4 bolt mounting hole) The following shows the assignment of each axis.

  • Page 179: Z-Θ Unit

    FX-1/FX-1R Maintenance Manual 13-6. Z-θ Unit The Z-θ unit is composed of an AC servo driver that drives the Z/θ-axes. 13-6-1. Structure of Z-θ Unit In the AC servo driver for the Z-θ unit, one driver can drive 4 axes. Therefore, 4 drivers are installed in FX-1.

  • Page 180: Led Indications

    FX-1/FX-1R Maintenance Manual 13-6-2. LED Indications Ten LEDs are mounted on the 4-axis integral amplifier. These LEDs show the operating status of the 4-axis integral amplifier as shown below. AL4 AL3 AL2 AL1 CHARGE No. LED name Function CHARGE Lights up if electric charge exists in the main power supply.

  • Page 181: Transport Unit

    FX-1/FX-1R Maintenance Manual 13-7. Transport Unit 13-7-1. Structure of Transport Unit A part of the cables in the transport unit is changed according to the reference and PWB flow direction of the machine. The following tables show the cables assemblies.

  • Page 182: Adjusting The Conveyor Board

    FX-1/FX-1R Maintenance Manual The cable assemblies shown in the table below are to be added in automatic PWB width adjustment motor option. Connect them according to the instructions shown in the table. Part No. Part name Star point End point...

  • Page 183: Adjusting The Stepping Driver

    FX-1/FX-1R Maintenance Manual Not used. Not used. C.OUT2 SENSOR Delay time hardware control ON/OFF Short-circuit Open C.OUT2 SENSOR Delay time setting Basic clock x 1 Basic clock x 2 Basic clock x 3 Basic clock x 4 OUT SENSOR Delay time hardware control ON/OFF...
  • Page 184 FX-1/FX-1R Maintenance Manual • Support table motor driver (STBL) L900E121000 • Center motor driver (CENT) L900E021000 • Automatic PWB width adjustment motor driver (AWCC) L900E021000 When using the optional automatic PWB width adjustment unit, the following driver is added. • Automatic PWB width adjustment motor driver (AWCS) L900E021000 The following figure shows the layout of the drivers inside the base frame.

  • Page 185: Thermal Sensor Board

    FX-1/FX-1R Maintenance Manual 13-7-4. Thermal sensor board • FX-1 is equipped with following thermal sensor PCBs under the Y-table frame. E86217290A0 THERMAL SENSOR PCB L838E9210A0 THERMAL SENSOR CABLE ASM • FX-1R is equipped with a thermal sensor PCB near the conveyor PCB.

  • Page 186: Head Unit

    FX-1/FX-1R Maintenance Manual 13-8. Head Unit 13-8-1. Boards Used on the Head Unit Five kinds of boards shown below are mounted on the head unit. Head main board assembly (40001926) Head sensor relay board assembly (L861E0210A0) (Two boards used.) OCC C light board assembly (40001979)

  • Page 187: Adjusting The Boards Of The Head Unit

    FX-1/FX-1R Maintenance Manual 13-8-2. Adjusting the Boards of the Head Unit 13-8-2-1. Adjusting the Head Main Board Assembly (1) Switch Settings The switches have already been set corresponding to the status of the board assembly. DSW1 DSW2 DSW3 DSW4 Make the jumper switch W1 VR2 VR3 VR4 VR5 short-circuited.
  • Page 188 FX-1/FX-1R Maintenance Manual DSW3 This switch is used to set the function Rev. and pattern Rev. of the board. The following shows the weight of each bit. 1: Function Rev 2 2: Function Rev 2 3: Function Rev 2 4: Function Rev 2...

  • Page 189: Covers

    FX-1/FX-1R Maintenance Manual 13-9. Covers 13-9-1. Structure of Operation Unit The operation unit is composed of the following two kinds of boards. Since the OPERATION SW PCB ASM is mounted on the front and rear, two PCBs are used in total.

  • Page 190: Mounting The Switches On The Operation Sw Pcb Asm

    FX-1/FX-1R Maintenance Manual 13-9-3. Mounting the Switches on the OPERATION SW PCB ASM According to the specification, mount the pushbutton switches SW1 to SW7 on the sockets on the OPERATION SW PCB ASM as shown in the figure below. 13-9-3-1. Structure...
  • Page 191 FX-1/FX-1R Maintenance Manual (2) Rear Switch components Specification Switch name Actuator  LED  Lense/Front Bezel Standard EN Rear OP NON-STOP OP START HA005340020 L875E921000 L875E521000 STOP HA005340020 L875E721000 L875E521000 SERVO FREE HA005340020 HA005340060 L875E821000 L875E621000 CYCLE HA005340020 HA00534006A L875E921000 L875E521000 EMERGENCY...
  • Page 192 FX-1/FX-1R Maintenance Manual 13-9-3-2. Mounting Switches (1) ONLINE, ORIGIN, START, STOP, SERVO FREE and CYCLE switches Lens +5V LED Bezel, with cover Green,Red, Yellow Green or orange or without cover Projection part is put on the left when viewed from the front.
  • Page 193 FX-1/FX-1R Maintenance Manual (2) SET UP switch Projection part is put Bezel on the left when viewed from the front. Switch key supplied with the machine Bezel for key switch Key switch actuator • Parts used Key cover (HA00535003A) Key switch actuator (HA005350020) Bezel (HA005520020) Fit the bezel (black) into the cover FUR panel.

  • Page 194: Jumper Switch Settings Of Operation Sw Pcb Asm (40012050)

    FX-1/FX-1R Maintenance Manual 13-9-4. Jumper switch settings of operation sw PCB ASM (40012050) Check the jumper switch settings of the OPERATION SW PCB ASM while referring to the following figures. Front Check that the receptacle is mounted between 1 and 2...

  • Page 195: Ups (40003292)

    FX-1/FX-1R Maintenance Manual 13-10. UPS (40003292) 13-10-1. Checking the UPS Battery (E9659729A000) Voltage If the power is not supplied to the machine for an extended period of time, the UPS battery may run out. If the machine has not been used for an extended period of time (for 3 months or longer), follow the steps below to check the battery voltage.

  • Page 196: Replacing The Ups Battery

    FX-1/FX-1R Maintenance Manual 13-10-2. Replacing the UPS Battery To prevent fatal accidents due to electrical shock, always turn OFF the main switch firmly. Make sure that the main circuit breaker and the main switch of the   WARNING machine main unit are turned OFF. The main switch described above is the power switch installed in the building and is not the power switch of the machine main unit. ...
  • Page 197 FX-1/FX-1R Maintenance Manual 13-10-2-2. Replacing the Battery (1) Take off all metallic objects, such as wrist watch, ring, and/or necklace before starting the work.   WARNING (2) Always use tools with insulated handles. (3) Do not put any tools or metallic parts on the battery.
  • Page 198 FX-1/FX-1R Maintenance Manual (4) Draw out the battery. (5) Disconnect the two leads connecting the battery and the UPS. Connect the leads to the new battery with the red one to the positive (+) pole while the black one to the negative (−) pole.

  • Page 199: Hod

    FX-1/FX-1R Maintenance Manual 13-11. HOD 13-11-1. Adjusting the light quantity of the HOD LCD The brightness can be adjusted using the volume knob for adjustment of the light quantity located on the rear. If the HOD LCD becomes dark as it is used for an extended period of time or if the HOD LCD is difficult to read due to adverse effect of the external light, adjust the brightness correctly.

  • Page 200: Replacing The Hod Lcd

    FX-1/FX-1R Maintenance Manual 13-11-2. Replacing the HOD LCD Follow the steps below to replace the HOD LCD. L980E108000 TFT LCD monitor L239E008000 LCD protector (1) Remove the connector, FG crimp terminal, and LCD bracket fixing screws (at three locations). (2) Remove the screws fixing the HOD LCD I/F PCB. (At this time, pay special attention so that any flat washer and spring washer are not lost.)
  • Page 201 FX-1/FX-1R Maintenance Manual (3) Disconnect the FPC on the LCD side and replace the LCD with a new one. Always insert or remove the FPC with the FPC connector lock released. Unlock status Lock status (4) Stick the LCD protector with the upper left corner of the LCD used as reference.

  • Page 202: Bank/Fpi-F(R) Board Assembly

    FX-1/FX-1R Maintenance Manual 13-12. BANK/FPI-F(R) board assembly This board provides the feeder knock drive circuit and FPI interface function. Two kinds of BANK/FPI-F(R) board assemblies are provided, one is used for the front bank and the other is used for the rear bank. Note that they do not have any interchangeability with each other.

  • Page 203: Auto Board Width Adjustment

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. [14] AUTO BOARD WIDTH ADJUSTMENT 14-1. Assembling the AWC Bracket E4855729000 AWC MOTOR PULLEY...

  • Page 204: Assembling To The Machine Main Unit

    FX-1/FX-1R Maintenance Manual 14-2. Assembling to the Machine Main Unit 14-2-1. Mounting the AWC Bracket Assembly SM8040402TP E4561729000 SET SCREW×2 AWC SHAFT PULLEY RAIL STAND RR Belt tension measuring point SL6051492TN L173E721000 BRKT FIX BOLT ×4 AWC MOTOR BELT Shaft of the IN/OUT ball screw is projected 1.0 mm from the pulley.

  • Page 205: Mounting The Origin Switch Dog

    FX-1/FX-1R Maintenance Manual Measure the belt tension using UNITTA’s belt tension meter. The following shows the set values. WEIGHT 0.025 WIDTH 009.0 SPAN 0070 Adjust the belt tension to 45N±5N. 14-3. Mounting the Origin Switch Dog RAIL PLATE RR RAIL STAND RR SL6030692TN DOG FIX BOLT×2...

  • Page 206: Running The Cables And Setting Up The Driver

    FX-1/FX-1R Maintenance Manual 14-4. Running the cables and setting up the driver The following shows how to run the cables and set up the driver. Front reference Position relay board • Connect the sensor cables to CN25.   IN/OUT AWC driver 機ﾝ定Ｄ...
  • Page 207 FX-1/FX-1R Maintenance Manual Rear reference Run the cables to the inside of the chassis together with 前頁 the YA-cable guide cables. Run the cables to the top of the transport unit together with the YA-cable guide cables. ④ ③ ①...

  • Page 208: Feeder Position Indicator (Fpi)

    FX-1/FX-1R Maintenance Manual To prevent any trouble caused by accidental machine start, always   DANGER shut-down the power before starting the maintenance and   adjustment work. [15] FEEDER POSITION INDICATOR (FPI) 15-1. Detaching the FPI from the Machine Main Unit As shown in the figure below, the FPI assembly is secured to the ATC base with the SEMS cap bolts (SL6040892TN).

  • Page 209: Structure Of Components Inside Fpi

    FX-1/FX-1R Maintenance Manual 15-2. Structure of components inside FPI FPI insulation sheet M3 × 3, Binding machine screw Plastic slider Timer spacer A Wire fixing part Wire fixing part M4 x 6, Flat head screw Connector of FPI LED CABLE ASM...

  • Page 210: Jig Lists

    FX-1/FX-1R Maintenance Manual [16] FX-1 JIG LISTS Part No. Part name Purpose Figure Remarks E2101998000  Jig nozzle A  Laser offset Common for KE2010/20/30/40  E3622721000 CAL piece A  Head offset Common for KE2010/20/30/40 and KE730/740/750/760  E2106998000  Camera OCC camera offset  Common for adjustment jig ...
  • Page 211 P. 13-1, 3, 8, 10, 11, 13 to 15, 17, 19 to 25, 27, 28, 30 to 34, 36 to 40, 42, 45 to 48 P. 14-2 to 5 P. 15-2 P. 16-1 • Specifications are subject to be changed without notice. Copyright © 2004 JUKI CORPORATION All rights reserved throughout the world.
  • Page 212 Sales agent   TECHNICAL SERVICE DEPT ELECTRONIC ASSEMBLY & TEST SYSTEM DIVISION 8-2-1, KOKURYO-CHO, CHOFU-CITY, TOKYO 182-8655, JAPAN PHONE: 81-3-3488-9201 FAX: 81-3-3480-0281...

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