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UIC GSM FlexJet Manual

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FlexJet Head
Assembly
T47541109
Rev. J
01-01djh,fg,djh
This document supports
assembly
47541109 Rev. F

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Summary of Contents for UIC GSM FlexJet

  • Page 1 FlexJet Head Assembly T47541109 Rev. J 01-01djh,fg,djh This document supports assembly 47541109 Rev. F...

  • Page 2: Table Of Contents

    TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Table of Contents Assembly Drawings ............................... 1 Notes ..................................9 Lubricants and Adhesives: ........................... 9 Bill of Materials ..............................10 Functional Description ..............................12 Maintenance Concept ..............................12 Adjustments and Other Procedures for Maintenance Technicians ..............12 Preventive Maintenance .............................
  • Page 3 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Position the FlexJet Head ......................... 35 Lower the Spindles ........................... 36 Clean the Reflective Surfaces of the Mirrors ................... 36 Raise the Spindles ............................ 37 Perform Adjustments and Calibration ...................... 38 Setting the Touch-Down Sensors ........................38 Prerequisites .............................
  • Page 4 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Install the New PCA FlexJet Control ....................... 72 Install the Electrical Cabling ........................73 Final Steps ..............................74 Advanced Support Information ........................... 76 Replacing the Stop Brake Belt ........................... 76 Prerequisites ............................. 76 Initial Steps ...............................
  • Page 5 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Replace the Spindle Assembly ..................... 106 Connect the Spindle to the Platform Assembly ................106 Perform Final Installations and Adjustments ................108 Final Steps .............................. 108 Changes To This Revision ............................109 This Document Supports Assembly 47541109 Rev.

  • Page 6: Assembly Drawings

    Page 1 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J This Document Supports Assembly 47541109 Rev. F...
  • Page 7 Page 2 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly 80 IN-OZ (2) 22 .56 NM (Ref) - 80026810 (2) 47813303 - (Ref) (6) 16 (6) 15 (Ref) - 47814003 (Ref) - 80029805 (3) (Ref) - 80026907 (2) 20 IN-LB 2.26 NM This Document Supports Assembly 47541109 Rev.
  • Page 8 Page 3 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Detail A (Page 4) Detail B (Page 4) (4) 17 (4) 31 (Ref) (4) 22 (Ref) This Document Supports Assembly 47541109 Rev. F...
  • Page 9 Page 4 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly (Ref) 80055601 (Ref) 80031705 (Ref) 80031302 40659579 (Ref) Detail A (Ref) 47749501 ,Clearflo Tubing 7 x 4in Detail B This Document Supports Assembly 47541109 Rev. F...
  • Page 10 Page 5 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J (2) 21 This Document Supports Assembly 47541109 Rev. F...
  • Page 11 Page 6 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly (7) 17 This Document Supports Assembly 47541109 Rev. F...
  • Page 12 Page 7 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J This Document Supports Assembly 47541109 Rev. F...
  • Page 13 Page 8 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Diagnostic LED Definitions for PC Boards Mounted on FlexJet Heads (For Heads with Serial Numbers Beginning with FJ09) Diagnostic Function ON Indicates… OFF Indicates… Theta counts value is negative See Notes 1, 2, and 4 Below See Notes 3 and 5 Below from the Home Pulse.

  • Page 14: Notes

    Page 9 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Notes Adjust belt tension until .200 inch (0.508 cm/5.08mm) of deflection is achieved with 2 oz. of force. Lubricants and Adhesives: Loctite #222 Threadlocker This Document Supports Assembly 47541109 Rev. F...

  • Page 15: Bill Of Materials

    BRACKET 47546501 BRACKET 47561904 ASSY, MANIFOLD 47586101 BELT, TIMING ALTERED 47586201 BELT, TIMING ALTERED 47804001 GSM FLEXJET,COVER 80008407 PHMS 4-40 X 1/2 80019002 ITLW #4 80026803 MSHCS M3 X 8MM 80026806 MSHCS M3 X 16MM 80026809 MSHCS M3 X 30MM...
  • Page 16 Page 11 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J USED BUT NOT SHOWN ITEMS 30885705 TUBING, POLY 1/4 OD-BLUE 47571101 LABEL, FLEXJET HD 47612101 AIRKISS HD CABLE ASSY 47612201 VACUUM HD CABLE ASSY T47541109 HEAD ASSY, FLEXJET This Document Supports Assembly 47541109 Rev. F...

  • Page 17: Functional Description

    Page 12 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Functional Description The FlexJet® Head Assembly is a high-speed, 7-spindle flexible-placement head. This head can gang pick components up to 12 mm square, inspect components on the fly using an On-The-Head (OTH) Camera, and place components in sequential order.

  • Page 18: Preventive Maintenance

    Page 13 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Preventive Maintenance The following procedures should be performed regularly as prescribed in the table below. All references to hours in the Recommended Frequency column are equivalent to hours of machine use. Recommended Minimum Skill Spares Kit...

  • Page 19: Calibration Table

    Page 14 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Calibration Table The following table lists maintenance procedures which require calibrations after completing the maintenance. Refer to the Calibration, CPE, and Measurement manual when performing the calibrations required to help ensure that the component placements are within specifications.

  • Page 20: Prerequisite Information

    Page 15 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Prerequisite Information • Refer to the Prerequisite Information and Introduction module for Adhesive and Lubricant icon information and definitions. Use Electro-Static Discharge (ESD) precautionary measures when maintaining, adjusting, or repairing the platform machine and the FlexJet Head.

  • Page 21: Related Information

    Page 16 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Related Information The following table defines documents that may be required while performing the procedures in this document. Also use the table as a reference to find maintenance procedures for the FlexJet Head that are located in other documents supporting the FlexJet subassemblies.

  • Page 22: Procedures And Adjustments

    Page 17 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Procedures and Adjustments The following subsections contain the maintenance procedures that are required for proper FlexJet Head Assembly operation. Prepare the Machine for Maintenance Always perform the following steps before beginning maintenance on the head.

  • Page 23: Installing The Flexjet Head

    Page 18 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Power up the machine. After the machine initializes, select System Setup > Machine > Setup > Zero Axes. The machine zeros. If the machine does not complete zeroing, check Machine Status > Display Status > Current Messages for error messages.

  • Page 24: Initial Steps

    Page 19 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Initial Steps Complete the steps in the Prepare the Machine for Maintenance section of this document to ensure that the machine is in a safe state for maintenance. The machine must be powered down and the site's Lockout/Tagout procedure executed during this procedure to ensure personal safety.
  • Page 25 Page 20 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly It is important to connect the HD INTF2 (Power) Cable Assembly first to protect the circuitry from ESD. Connect the HD INTF2 (Power) Cable Assembly to the head first. Refer to the following diagram. HD INTF 2 Cable Assembly (Power) CAM INTF Cable Assembly...

  • Page 26: Final Steps

    Page 21 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J CAM INTF IGUS Cable Cable Assembly INTF.V-OUT PEC1.V-OUT Pec1.V-DRIVE Pec1.V-DRIVE Pec1.H-DRIVE Pec1.H-DRIVE Install the 3 video connectors on CAM INTF Cable Assembly to the appropriate video connectors on the PEC box. Refer to the following table.

  • Page 27: Removing The Flexjet Head

    Page 22 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Removing the FlexJet Head Remove a FlexJet Head from a platform machine using the following procedure. Use Electro-Static Discharge (ESD) precautionary measures, such as a grounded wrist strap, when working on the FlexJet Head. Initial Steps Complete the steps in the Prepare the Machine for Maintenance section of this document to ensure that the machine is in a safe state for maintenance.

  • Page 28: Remove The Head From The Carriage

    Page 23 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Disconnect the 3 video connectors from the PEC box. Disconnect the 3 video connectors on CAM INTF Cable Assembly from IGUS Cable. Connect the 3 video connectors on the IGUS Cable to the PEC Box.

  • Page 29: Verifying The Vacuum Level

    Page 24 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Verifying the Vacuum Level The correct vacuum level is essential for picking components. Verify the FlexJet Head Assembly vacuum level using the following procedures. Prerequisites Ensure that the following items are available before beginning the procedure. •...

  • Page 30: Install The Panel And Covers

    Page 25 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Turn the locking knob clockwise until the pressure adjustment knob locks. Verify that the pressure is still 85 psi (5,86 bar). If the pressure is not 85 psi (5.86 bar), repeat from step 6. Pneumatic Panel Assembly Center Rear Cover Assembly Handle...

  • Page 31: Install The Vacuum Gauge

    Page 26 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Remove feeders that are obstructing the work. The machine cover must remain open during this procedure to place the Interlock circuit in the violated state, disabling machine servo axes. Failure to comply could result in serious personal injury. Remove the safety cover below the hinged cover and open the hinged cover to access the FlexJet Head.
  • Page 32 Page 27 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Perform the following procedure to turn vacuum on for all 7 spindles. It is recommended to measure each spindle vacuum level with vacuum on all spindles simultaneously. Select Tool > 1. Select VACUUM and MAIN_VACUUM_CONTROL in the Select Outputs field.

  • Page 33: Raise The Spindles

    Page 28 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Check the upper section of the Manifold for the selected spindle. If the upper LED is on at the Manifold, but there is no vacuum, then manually push the button in front of the manifold. If vacuum appears when the button is pushed, the Manifold must be replaced.

  • Page 34: Final Steps

    Page 29 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Select Production Control > Manual Control. Select the correct Head. Select Tool > All. Select Device > Z. Select Increment > 1.0 (inches). Click the up arrow button 4 times. The spindles raise to the upper position.

  • Page 35: Check The Air Kiss

    Page 30 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly The Discrete I/O - Head Subsystem I/O dialog box displays. Select the correct Head # (number) option button. Perform the following steps to enable air kiss on the spindles. Select the Tool #. Begin with tool number 1. Highlight AIR_KISS and MAIN_VACUUM_CONTROL in the Select Outputs field.

  • Page 36: Final Steps

    Page 31 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J If air kiss is present for all 7 spindles, continue with the next step. Perform the following steps to turn off air kiss for all spindles. Select the Tool #. Begin with tool number 1. Verify that AIR_KISS and MAIN_VACUUM_CONTROL are highlighted in the Select Outputs field.

  • Page 37: Check The Belts

    Page 32 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Palm down the platform machine and open the hinged cover to access the FlexJet Head. The machine cover must remain open during this procedure to place the Interlock circuit in the violated state, disabling machine servo axes. Failure to comply could result in serious personal injury.

  • Page 38: Final Steps

    Page 33 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Final Steps After all 3 belts are inspected, install the FlexJet Head cover. For a dual-beam machine, repeat from the Check the Belts section, then proceed to the next step. After the head on a GSM1™...

  • Page 39: Check The Signal Strength

    Page 34 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Select Absolute Locations > Units > Inches to view the spindle depth. Select Tool > All. Select Increment > 1.0”. Move the spindle down 3 inches (76,2 mm) by selecting the down- arrow button 3 times.

  • Page 40: Cleaning The Pin Mirrors

    Page 35 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J For a GSM2™ platform machine, it is recommended to verify the sensors for both FlexJet Heads. Cleaning the Pin Mirrors Use the following procedure to clean the Pin Mirrors in the Spindle Housings to help ensure proper touch-down sensor operation.

  • Page 41: Lower The Spindles

    Page 36 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Lower the Spindles Use the following steps to lower the 7 spindles to access the Pin Mirrors. Select Machine Status > Diagnostics > Discrete I/O > Heads The Discrete I/O - Head Subsystem I/O window displays. Select the correct Head # (number) and select Tool #1.

  • Page 42: Raise The Spindles

    Page 37 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Moisten a lint-free swab (ESD Swab) with isopropyl alcohol or a solution approved for use on sensitive optical surfaces and roll the tip with the thumb and index fingers to compact the fibers. Refer to the diagram below.

  • Page 43: Perform Adjustments And Calibration

    Page 38 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Perform Adjustments and Calibration Complete the Verifying the Touch-Down Sensors procedure in this document to ensure that the Pin Mirrors are reflecting the light at an acceptable intensity. This system verification is important because it is difficult to visually verify the reflectivity of the Pin Mirrors.

  • Page 44: Machine Preparation

    Page 39 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Machine Preparation Perform the following procedure to prepare the machine for touch-down sensor setup. Move the head to a maintenance location using Manual Control. The machine cover must remain open during this procedure to place the Interlock circuit in the violated state, disabling machine servo axes.
  • Page 45 Page 40 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Verify that the gauge is seated against the tool housing and tighten the set screw. Install the Impact Sensor Setup Tool to the bottom of the Platform Assembly, below the selected spindle. Refer to the following diagram. FlexJet Head Mounting Platform...

  • Page 46: Lower A Spindle

    Page 41 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Lower a Spindle Select Machine Status > Diagnostics > Discrete I/O > Heads The Discrete I/O - The Head Subsystem window displays. Select the correct Head # (number). Select the Tool # option button for the spindle to be adjusted. Select SPINDLE_CLUTCH in the Select Outputs field.

  • Page 47: Adjust The Sensor

    Page 42 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Position the cursor over the Set Outputs button, but do not select the button. This aids in selecting the button when the spindle is in the proper lower position. Manually drive the spindle down by turning the Z-Axis Drive pulleys and install a 10 MPF nozzle when the Coupler Body is accessible.
  • Page 48 Page 43 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Pushing and holding the Set button for more than 2.5 seconds and then releasing will cause all Incident-Level-Indicator LEDs to turn green. If this occurs, push the Mode Selector switch to Run Mode and then push the switch back to Teach.

  • Page 49: Setup Verification

    Page 44 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Select the Tool # of the spindle just returned to the home position. Select SPINDLE_CLUTCH in the Select Outputs field. Select Reset Outputs to disengage the clutch. Repeat the entire Sensor Setup section for any other spindle touch- down sensors which need adjustment.

  • Page 50: Comprehensive Head Maintenance

    Page 45 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Record on the appropriate copied sheet from the Maintenance Log document that this setup procedure was performed and include the date. Comprehensive Head Maintenance Perform Comprehensive Head Maintenance if the head is removed for repair or adjustment.

  • Page 51: Initial Steps

    Page 46 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Initial Steps Complete the steps in the Prepare the Machine for Maintenance section of this document to ensure that the machine is in a safe state for maintenance. The machine must be powered down and the site's Lockout/Tagout procedure executed during this procedure to ensure personal safety.
  • Page 52 Page 47 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Remove the 7 CCD Camera Assembly and the Stiffener using the following procedure. Also refer to the following diagram. Stiffener 7 CCD Camera Assembly Stiffener Screws and Washers (6 ea) 7 CCD Camera Assembly Screws and Washers (4 ea) Use Electro-Static Discharge (ESD) precautionary measures when...
  • Page 53 Page 48 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Manually move the selected spindle down so that both Pin Mirrors are accessible. Refer to the following diagram. View A Do not dry wipe the Pin Mirrors or scratching may occur. Also, it is not recommended to use denatured alcohol, which has a high level of contaminants compared to isopropyl alcohol.

  • Page 54: Verify/Adjust The Camera Mirror Cable

    Page 49 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Then use a dry swab to clean the same Pin Mirrors before the solution dries on them. Do not let go of the Spindle until it is fully in the up position, or the return spring may cause the Spindle to abruptly impact the Optic Bracket.

  • Page 55: Inspect The Mirror Spring Shaft

    Page 50 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly With the rocker switch in the ON position, test pins 1 and 2 of the P15 connector of the FlexJet Prism Setup Fixture found in the FlexJet Tool Kit. If the voltage is below 13 volts, replace the Top of Connector batteries before continuing with the procedure.

  • Page 56: Inspect The Linear Bearings

    Page 51 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J • Inspect the 2.6 OTH Camera Mirror Spring Shaft for wear. This shaft is located inside of a spring on the inner, right portion of the camera. Check the shaft with the movable mirror in both the upper and lower positions.

  • Page 57: Clean The Camera Mirrors

    Page 52 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Inspect the clear hoses connected to the Manifold Assembly for proper seating. If a hose is loose, but appears in good condition, firmly connect the hose to the fitting. If a hose is damaged, it must be replaced.
  • Page 58 Page 53 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Inspect the 7 CCD Camera Assembly glass plates for visible particles. If particles are present on the glass plates, use clean, compressed air to remove the particles. It is preferable to perform this task at least several feet (or about 1 meter) away from the head.

  • Page 59: Install The Flexjet Head

    Page 54 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Verify proper cable orientation and attach the Camera Cable Assembly to the PCA Flex Jet Control. Refer to the following diagram. 7 CCD Camera Assembly Cable Port Tighten the Stiffener screws and torque them to 80 inch-ounces (0,56 NM)..

  • Page 60: Zeroing The Theta Encoder

    Page 55 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Zeroing the Theta Encoder The Theta Encoder must be zeroed after installing the Theta Encoder or the (theta) Timing Belt. Prerequisites Ensure that the Theta Alignment Tool from the FlexJet Tool Kit is available. The assistance of another person is required to complete this procedure.

  • Page 61: Adjust The Encoder Counts Value

    Page 56 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Manually position the Theta Alignment Tool under the FlexJet head. Align and insert the tool into the Coupler Body assemblies. Refer to the following diagram. If the tool is correctly seated against the Coupler Bodies, the spindles cannot rotate when the Timing Belt (theta) pulley is rotated.
  • Page 62 Page 57 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Select Machine Status > Diagnostics > Global Memory > Alter Memory The Alter Global Data window displays. Select OS_READONLY > OS_READONLY (A-M) > ID_OS2_READONLY_AXIS_LOC_AREA The ALTER ID_OS2_READONLY_ AXIS_LOC_AREA window displays. Choose one of the following options to enter a number in the Axis field.

  • Page 63: Verify The Encoder Counts Value

    Page 58 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Verify the Encoder Counts Value The 3 left-most diagnostic LEDs on the FlexJet Control PCA indicate a count range for theta. (These LEDs can be helpful to indicate theta if the PC board is easily visible during the setup.) Refer to the diagnostic-LED drawing and chart in the Assembly Drawings section of this document.

  • Page 64: Verifying/Adjusting The Z-Safe Sensor

    Page 59 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Install any feeders removed earlier. Ensure that the feeders match the feeder configuration in UPS. Push [ ] to return the spindles to the upper position. START Record on the appropriate copied sheet from the Maintenance Log document that this procedure was performed and include the date.
  • Page 65 Page 60 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Select Machine Status > Diagnostics > Discrete I/O > Heads The Discrete I/O - Head Subsystem I/O window displays. From the Select Head # group box, select the number of the head. Select 1 for front of beam or 2 for rear of beam.

  • Page 66: Verify The Z Safe Sensor Signal

    Page 61 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Rotate a Z Driven Pulley clockwise until the Stop Bracket comes in contact with the Head MNT Platform. Refer to the following diagram. If the Stop Brake is still engaged, the Z Driven Pulleys will not rotate. Z Driven Pulleys Head MNT...

  • Page 67: Adjust The Sensor Signal

    Page 62 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Verify that the digital Z-Safe sensor switches are set to Run and L. Refer to the following diagram. Lock Button Level Display Setting Buttons TEACH MODE Operation Indicator Operation Mode Indicator Mode Selector (Orange) (SET, ADJ, or RUN)

  • Page 68: Final Steps

    Page 63 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Loosen the nuts and slowly move the Z Safe emitter and receiver up, then down until a signal of 100 or greater displays and the orange indicator LED illuminates. (Move the emitter and receiver in the same direction.) Then tighten the nuts.

  • Page 69: Adjusting The Spindle Drive Belt Tension

    Page 64 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Adjusting the Spindle Drive Belt Tension Complete the following steps to adjust the Timing Altered Belt tension following belt replacement. Prerequisites Ensure that the following items are available before beginning the procedure. •...
  • Page 70 Page 65 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Place the 2 OZ. Weight on the tension rod for the selected Spindle as seen in the diagram below. The upper line (mark) of the weight support should appear just above the bracket on the Z Belt Tension Tool.

  • Page 71: Final Steps

    Page 66 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Move the weight to the next spindle and repeat from step 2. When all 7 Spindle belt tensions are verified and/or adjusted, continue with the Final Steps section. Final Steps Remove the Z Belt Tension Tool.

  • Page 72: Adjusting The Stop Bracket Belt Tension

    Page 67 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Loosen the screw shown in the following diagram. The Tensioner Assembly will self-adjust the belt tension. Metric Socket Head Screw Tighten the screw shown above. If the head is installed on the machine, perform the following steps. If the head is off the machine, go to step 5.

  • Page 73: Initial Steps

    Page 68 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly • Calibration Placement Enhancement (CPE) Kit for FlexJet • Theta Alignment Tool from the FlexJet Tool Kit • Torque wrench • T-handle 3 mm wrench for camera removal and installation. •...

  • Page 74: Replace The Coupler Body

    Page 69 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Replace the Coupler Body If the following step is performed without removing the 2.6 OTH Camera, damage to the camera mirrors may result. Remove the damaged Coupler Body Assembly from the Bearing Cap by removing the 2 mounting screws and disconnecting the 2 Tubings.

  • Page 75: Adjust The Coupler Body

    Page 70 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Adjust the Coupler Body Manually position the Theta Alignment Tool from the FlexJet Tool Kit under the FlexJet head. Align and insert the tool into Coupler Body Assemblies. Refer to the following diagram. Theta Alignment Tool Inserted into Coupler Bodies...

  • Page 76: Replacing The Pca Flex Jet Control

    Page 71 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Perform CPE. Refer to the Calibration, CPE and Measurement manual. Replacing the PCA Flex Jet Control Complete the following steps to replace the PCA FlexJet Control Prerequisites Ensure that the following items are available before beginning. •...

  • Page 77: Install The New Pca Flexjet Control

    Page 72 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Disconnect the HD INTF1 Cable Assembly and CAM INTF Cable Assembly. Refer to the following diagram. HD INTF 2 Cable Assembly (Power) CAM INTF Cable Assembly HD INTF 1 Cable Assembly Remove all electrical cables from the PCA FlexJet Control except the HD INTF2 (Power) Cable Assembly.

  • Page 78: Install The Electrical Cabling

    Page 73 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Install the Electrical Cabling Connect the HD INTF2 (Power) Cable Assembly to the head first. HD INTF 2 Cable Assembly (Power) CAM INTF Cable Assembly HD INTF 1 Cable Assembly Connect the HD INTF1 Cable Assembly and CAM INTF Cable Assembly.

  • Page 79: Final Steps

    Page 74 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Install the following 2 cables from the 2.6 OTH Camera Assembly to the PC board. Refer to the following wiring chart and diagram. From Mirror Clear Sensor/P15 15PL Mirror In Range/P16 16PL Install the (camera) lighting cables 35PL-39PL to the PC Board.
  • Page 80 Page 75 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Verify that all connectors are firmly seated and install tie wraps as necessary to retain the wiring so that the FlexJet Head Cover can be installed without stressing the wiring. Install the FlexJet Head Cover.

  • Page 81: Advanced Support Information

    Unauthorized implementation of these procedures may result in damage to the machine and may adversely affect your warranty status if performed by other than UIC personnel. The advanced support information procedures are those identified on the maintenance concept table as requiring a minimum skill level of Universal Instruments Field Service Engineer.

  • Page 82: Remove The Damaged Belt

    Page 77 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Remove the Damaged Belt Use ESD precautionary measures when handling the PCA Flex Jet Control and associated cabling. Remove cable ties as necessary to remove the Z Stop Clutch cable (10PL) and the Z Stop Brake cable (11PL) from the PCA Flex Jet Control.

  • Page 83: Final Steps

    Page 78 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Loosen the adjustment screw on the Tensioner Assembly, let it self- adjust the belt tension, and tighten the screw. Install the Z Stop Clutch on the upper shaft and tighten the 2 set screws.

  • Page 84: Replacing The Z Stop Brake Assembly

    Page 79 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Replacing the Z Stop Brake Assembly This section describes how to replace a Z-Stop Brake Assembly due to damage or wear. Replace the Z-Stop Brake using the following procedure. The new design for the Stop Brake includes a fixed gap. So gap adjustment is not necessary.

  • Page 85: Install The New Stop Brake Assembly

    Page 80 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Disconnect the brake cable (11PL) from the PCA Flex Jet Control (P11). Remove the 2 screws securing the Shield Bracket and remove the bracket. Refer to the following diagram. Z Stop Brake Assy Bracket Shield Brake Bracket Securing Screws (4)

  • Page 86: Final Steps

    Page 81 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Final Steps Apply Loctite 222 to the 2 screws and install the Plate and Baffle (flexible strip) on the bottom of the head. Torque the screws to 80 inch-ounces (0,56 NM). Install the FlexJet Head on the machine.

  • Page 87: Procedure

    Page 82 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Use ESD precautionary measures when handling the PCA Flex Jet Control and associated cabling. Procedure Remove the cable ties securing the faulty Spindle Touch-Down Sensor Assembly to the PCA Flex Jet Control. Disconnect the Spindle Touch-Down Sensor Assembly cable from the PCA Flex Jet Control.
  • Page 88 Page 83 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Install the new Spindle Touch-Down Sensor Assembly and stack the Spindle Touch-Down Sensor Assemblies in the appropriate location. Refer to the following diagram. Spindle Touch-Down Sensor Assemblies 1 through 7 Digital Z-Safe Sensor Slide the stack of Spindle Touch-Down Sensor Assemblies into the Bracket Switch located on the Fiber Optic Block.

  • Page 89: Final Steps

    Page 84 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Connect the Spindle Touch-Down Sensor Assembly cable to the appropriate location on the PCA Flex Jet Control. Refer to the following diagram and wiring chart. Spindle Touch-Down Sensor Assembly 1 Z-Safe Sensor Assemly 8 PCA Flex Jet Control...

  • Page 90: Replacing A Clutch

    Page 85 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Replacing a Clutch This section describes how to replace a Clutch due to damage or wear. Replace the appropriate Clutch using the following procedure. Prerequisites Ensure that the following items are available before beginning the procedure. •...

  • Page 91: Disassemble The Head

    Page 86 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Disassemble the Head Use ESD precautionary measures when handling the PCA Flex Jet Control and associated cabling. Remove the cable ties securing the clutch lead wires to the PCA Flex Jet Control.
  • Page 92 Page 87 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Loosen 3 screws holding top Z-Motor in position. Loosen and remove belt. Clutch 7 Clutch 5 Clutch 3 Z Driven Pulley Clutch 1 Clutch Shaft Z Encoder Assy Z Stop Clutch Timing Belt Mirror Clutch...
  • Page 93 Page 88 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Loosen 8 set screws securing clutches to shaft. Slide the clutches out of the way and remove C clips. Top Shaft Idler Shaft Clutch Shaft E-Ring Idler Shaft Z Encoder Idler Pulley Timing Belt Pulley Clutch Assembly...

  • Page 94: Install The New Clutch

    Page 89 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Disconnect the clutch wire of the clutch to be replaced from the PCA Flex Jet Control. Refer to the following diagram. 7PL (P7) Clutch 5 3PL (P3) Clutch 1 12PL (P12) Mirror Clutch 8PL (P8) Clutch 6 4PL (P4) Clutch 2 5PL (P5) Clutch 3...
  • Page 95 Page 90 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Cable Tie Mount Clutch Cables Route wire with label of Plug # through the grommet. Refer to the Z- Axis Index Housing Assembly document for information on clutch cable routing. Insert the shaft through the clutch assembly diameters.

  • Page 96: Final Steps

    Page 91 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J As the Z axis cycles, the clutch shaft will make a squeaking sound if the Z Encoder is not centered on the clutch shaft. Install the timing belt onto the pulleys. Verify belt tension using the Z- Axis Spindle Drive Belt Tension Adjustment procedure located in this document.

  • Page 97: Replacing A Manifold Tubing

    Page 92 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Complete the steps in the Prepare the Machine for Production section of this document to ensure that the machine is in a safe operational state. Verify that all covers removed for maintenance are installed, including the safety covers below the hinged covers and the FlexJet Head Cover.

  • Page 98: Procedure

    Page 93 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Procedure Use pliers to carefully remove the flaired portion of the Manifold Tubing from the fitting on the bottom of the Manifold Assembly. Refer to the following diagram. Fittings for Manifold Tubings Use pliers to carefully remove the Manifold Tubing from the Vacuum Cap (top portion of spindle).

  • Page 99: Final Steps

    Page 94 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Carefully install the flaired end of the new (cut) Manifold Tubing to the fitting on the bottom of the Manifold Assembly. Refer to the following diagram. New Manifold Tubing Straight End Attaches to Flaired End Attaches to Fitting on Bottom of Manifold Vacuum Cap...

  • Page 100: Initial Steps

    Page 95 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Initial Steps Complete the steps in the Prepare the Machine for Maintenance section of this document to ensure that the machine is in a safe state for maintenance. The machine must be powered down and the site's Lockout/Tagout procedure executed during this procedure to ensure personal safety.

  • Page 101: Install The New Manifold

    Page 96 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Disconnect the input pneumatic line from the male elbow fitting on the FlexJet Head. Refer to the following diagram. Male Elbow Fitting Disconnect the Manifold Tubings from the 7 hose fittings underneath the Manifold Assembly.
  • Page 102 Page 97 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Connect the Manifold Tubings to the 7 hose fittings on the Manifold Assembly. If new Manifold Tubings are used, refer to the Replacing a Manifold Tubing section for the proper tubing lengths per spindle. Refer to the following diagram.

  • Page 103: Final Steps

    Page 98 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Install the cable ties securing the AirKiss HD Cable Assembly (17PL) and the Vacuum HD Cable Assembly (25PL). Final Steps Complete the steps in the Prepare the Machine for Production section of this document to ensure that the machine is in a safe operational state.

  • Page 104: Disassemble The Flexjet Head

    Page 99 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Disassemble the FlexJet Head Use ESD precautionary measures when handling the PCA Flex Jet Control and associated cabling. Disconnect all cables from the PCA Flex Jet Control. Remove the PCA Flex Jet Control by removing the 4 side screws and washers and the 2 upper screws and washers.

  • Page 105: Install The New Fiber Optic Cable

    Page 100 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Remove the 7 EXT (Special) Springs. Be careful not to kink the springs, or they must be replaced. Pull all 7 spindle assemblies down and remove Optic Bracket. Loosen the 7 set screws holding the Thin Wall Tubings in place. Then slide all 7 tubes down over housing pins.

  • Page 106: Final Steps

    Page 101 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Carefully connect all cables to the PCA Flex Jet Control. Refer to the following diagram. Install tie wraps as necessary to ensure that the cabling is not stressed when the FlexJet Head Cover is installed. Then install the FlexJet Head cover.

  • Page 107: Replacing The Spindle Drive Belt

    Page 102 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Perform Spindle-Height calibration. Refer to the Calibration, CPE, and Measurement manual. If the head was removed, perform CPE. Replacing the Spindle Drive Belt The Spindle Drive Belt may require replacement in the event of damage to the timing belt To replace the Spindle Drive Belt, perform the following procedure.

  • Page 108: Change The Belt

    Page 103 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Change the Belt Remove the screw securing the Belt Clamp to the Arm Spring. Refer to the following diagram. Arm Spring Screw Belt Clamp Timing Altered Belt Remove the damaged Timing Altered Belt. Install the new Timing Altered Belt onto the pulleys.

  • Page 109: Replacing A Flexjet Spindle Assembly

    Page 104 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Replacing a FlexJet Spindle Assembly This section describes how to replace a FlexJet Spindle Assembly due to damage or wear. Replace a FlexJet Spindle using the following procedure. Prerequisites Ensure that the following items are available before beginning the procedure. •...

  • Page 110: Disassemble The Head

    Page 105 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Disassemble the Head Remove all cables from the PCA Flex Jet Control. Refer to the following diagram. Platform Assembly Head Control Asm PC BD Securing Screws Bracket OTH Camera Assembly Remove the 2 upper screws securing the PC Board to the Platform Assembly, but leave the upper bracket on the head.

  • Page 111: Replace The Spindle Assembly

    Page 106 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Replace the Spindle Assembly Remove the 3 screws securing the top spindle bearing to the Theta Drive Housing. Refer to the following diagram. Theta Drive Housing Screws (3) Remove the Theta Drive Housing from the Spindle Assembly. Install the new spindle Bearing Assembly to Theta Drive Housing, with the 3 screws.
  • Page 112 Page 107 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Justify the Linear Ball Spline to the right as it is installed onto the linear slide. The reference edge on the sliding portion is indicated by the middle groove along its length. Tighten the screws to 46 inch- ounces (0,32 Nm), while keeping the spindle justified to the right.

  • Page 113: Perform Final Installations And Adjustments

    Page 108 TECHNICAL PUBLICATIONS T47541109 Rev. J FlexJet Head Assembly Perform Final Installations and Adjustments Install the 4 screws to secure the PCA Flex Jet Control bracket (with PC board attached) to the Platform Assembly. Then install the 2 upper screws to secure the PC Board to the upper bracket on the Platform Assembly.

  • Page 114: Changes To This Revision

    Page 109 TECHNICAL PUBLICATIONS FlexJet Head Assembly T47541109 Rev. J Changes To This Revision Changed the frequency of belt inspection from 500 to 160 hours of machine use. This Document Supports Assembly 47541109 Rev. F...

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