Page 1 Fast Smart Modular Mounter RS-1/RS-1XL/RS-1R MAINTENANCE GUIDE...
Page 2 (3) This manual is prepared with extreme care. However, if you have any question or ﬁnd any error or omission in writing, contact our dealer or JUKI Corporation. (4) JUKI Corporation shall disclaim all the responsibility for any trouble resulting from the user's abnormal operation regardless of Item (3).
Page 3: Table Of Contents
Maintenance Guide Table of Contents 1. X-Y UNIT ........................1-1 1-1. Replacing the Servomotor ....................1-1 1-1-1. Replacing the X-Motor ..................... 1-1 1-1-2. Replacing the YL-Motor ................... 1-2 1-1-3. Replacing the YR-Motor ..................1-5 1-2. Replacing the Limit Sensor and Origin Near Sensor ............1-8 1-2-1.
Page 4 Maintenance Guide 2 Head ..........................2-1 2-1 8-Nozzle Head ........................2-1 2-1-1 Replacing the Head Unit................... 2-1 2-1-2 Replacing the Z-Motor ....................2-9 2-1-3 Replacing the θ-Motor .................... 2-14 2-1-4 Replacing the Timing Belts Z .................. 2-18 2-1-5 Replacing the Timing Belt θ ..................2-18 2-1-6 Replacing the Ball Screw..................
Page 5 Maintenance Guide 4-3 Replacing the OCC Coaxial/Angle Light Board ..............4-3 4-4 Replacing the Lens Filter ....................4-4 4-5 Adjusting the Focus and the OCC Light Quantity .............. 4-5 4-6 Readjustment Items After Replacing OCC Unit ..............4-5 5 Board Transport ......................5-1 5-1 Replacing the Transport Belt .....................
Page 6 Maintenance Guide 5-15-2 Replacing the Stopper Cylinder ................5-36 6. CAL BLOCK ........................ 6-1 6-1. Replacing the CAL Block Board Assembly ............... 6-1 6-2. Replacing the Ejector ....................... 6-2 7. ATC ..........................7-1 7-1. Replacing the Air Cylinder ....................7-1 7-2.
Page 7 Maintenance Guide 12. Electrical Components ..................12-1 12-1 Layout of Electrical Components ................. 12-1 12-2 Electrical Component Unit ................... 12-3 12-2-1 Electrical Component Unit A ................12-3 12-2-2 Electrical Component Unit B ................12-6 12-3 Control Unit ....................... 12-13 12-3-1 CPU BOARD (40123242) .................. 12-14 12-3-2 IO CONTROL PCB ASM (40128871) ..............
Page 8 13-2-2 Setting Up the Network (Setup is required when communicating with the JaNets.) ......... 13-7 13-2-3 RS-1 System Programs ..................13-18 13-2-4 Upgrading the RS-1 System Version ..............13-26 13-2-5 McAfee Embedded Control ................13-31 13-3 JaNets (ISM/MES Cooperation) Option ..............13-32 13-3-1 Replacing the Bar-code Reader ................
Page 9 18-1 Changing the CONTACT SUB UNIT ................18-1 18-2 Changing the CVS Board ....................18-4 19 Nozzle RFID READER ..................... 19-1 19-1 Changing the RFID READER/WRITER ................. 19-1 RS-1 Appendix Jig Lists ..................... A-1 RS-1 Appendix List of Measuring Instruments ............B-1...
Page 10: X-Y Unit
Maintenance Guide 1. X-Y UNIT 1-1. Replacing the Servomotor 1-1-1. Replacing the X-Motor Remove the B_COVER_SCREW to detach the MOTOR_COVER_R. Loosen the COUPLING_X_screw (do not remove the screw at this time) and disconnect the connector of the SERVO MOTOR 750W cable. Remove the SL6062042TN and replace the SERVO MOTOR 750W.
Page 11: Replacing The Yl-Motor
Maintenance Guide 1-1-2. Replacing the YL-Motor Remove the B_COVER_SCREW to detach the MOTOR_COVER. Loosen the COUPLING_Y_screw (do not remove the screw at this time) and disconnect the connector of the SERVO MOTOR 1500W cable. Remove the SM6082002TN and replace the SERVO MOTOR 1500W. B COVER SCREW（×4）...
Page 12 Maintenance Guide Adjust the Z phase of the motor. ∗ The clearance between the COUPLING and motor is 4 mm. The tightening torque of the COUPLING Y screw is 7 N⋅m. (Figure 1-1-2-4) Connect the Y-axis motor connector to the top ➀...
Page 13 Maintenance Guide Move the Y axis to the mechanical end, check the position of the coupling. ∗ If it is not in the following state, please do the work in 5) again. Check that the cut on the motor side of ②...
Page 14: Replacing The Yr-Motor
Maintenance Guide 1-1-3. Replacing the YR-Motor Remove the SL3061232TN to detach the COVER_FBR. Remove the SL6041092TN, NM3060810SF to detach the SUB_COVER_FUR. Loosen the COUPLING_Y_screw (do not remove the screw at this time) and disconnect the connector of the SERVO MOTOR 1500W cable. Remove the SL6082002TN and replace the SERVO MOTOR 1500W.
Page 15 Maintenance Guide Adjust the Z phase of the motor. ∗ The clearance between the COUPLING and motor is 4 mm. The tightening torque of the COUPLING_Y_screw is 7 N⋅m. (Figure 1-1-3-5) Connect the Y-axis motor connector to the top ➀ Fix the coupling to the motor shaft so that the ②Rotate the motor shaft, set the Z phase ③...
Page 16 Maintenance Guide Move the Y axis to the mechanical end, check the position of the coupling. ∗ If it is not in the following state, please do the work in 5) again. Check that the cut on the motor side of ②...
Page 17: Replacing The Limit Sensor And Origin Near Sensor
Maintenance Guide 1-2. Replacing the Limit Sensor and Origin Near Sensor When replacing only the sensor, it is not necessary to adjust the position. When replacing the sensor together with the bracket, it is necessary to adjust the position. 1-2-1. Replacing the X-Axis Limit Sensor and the X-Axis Home Proximity Sensor Loosen the screw fixing the X-limit sensor bracket and make the adjustment so that the distances from the X-frame L and R are those shown in the figure below.
Page 18 Maintenance Guide Part B Part A Part A 0.8 to 1.5 (target: 1.0mm) Part B 0.8 to 1.5 (target: 1.0mm) Figure 1-2-1-2...
Page 19: Replacing The Y-Axis Limit Sensor And The Y-Axis Home Proximity Sensor
Maintenance Guide 1-2-2. Replacing the Y-Axis Limit Sensor and the Y-Axis Home Proximity Sensor ∗ If only the sensor is replaced, it is not necessary to adjust the position. ∗ If the sensor is replaced together with the bracket, it is necessary to adjust the position. Loosen the screws fixing the Y-limit sensor bracket and make the adjustment so that the distances from the split pin mounting center position of the base frame are those shown in the Figure below.
Page 20 Maintenance Guide Make the adjustment so that the clearance between the Y sensor dog and the sensor surface is 1.8 to 2.5 mm (target: 2.0 mm), and then tighten the screw. (Figure 1-2-2-2) 0.8 to 1.5mm (target: 1.0mm) Figure 1-2-2-2 1-11...
Page 21: Checking The Sensor Operation
Maintenance Guide 1-2-3. Checking the Sensor Operation Manually move each axis and select [Manual Control] → [Sensor information] to check that the near sensor (indication is the origin sensor) and each limit sensor turn ON or OFF. 1-12...
Page 22: Replacing The Cableveyor
Maintenance Guide 1-3. Replacing the Cableveyor 1-3-1. Replacing the X-Axis Cableveyor X_CABLE_BEAR (Part No.: 40110451) Remove the hexagon socket head cap bolt (M4×10) to detach the X_CABLE_BEAR. Remove B_COVER_SCREW and M4 nut and remove CABLE_CLAMP_X2 and FC_RUBBER. Remove the arm of the X-axis cableveyor, take out the cables, and replace the cableveyor. Reassemble the components in the reverse order of disassembly.
Page 23: Replacing The Y-Axis Cableveyor
Maintenance Guide 1-3-2. Replacing the Y-Axis Cableveyor Y CABLE BEAR (E) (40060210) Remove the SL3061232TN to detach the Y-Axis cableveyor from the CB_BR. Remove the SM3051052TN to detach the Y-Axis cableveyor from the X-Axis assembly. Remove the SL6061292TN to detach the FC_SUPPORT_Y_V2. Reassemble the components in the reverse order of disassembly.
Page 24 Maintenance Guide [RS-1XL] Remove the SL3061232TN to detach the Y-Axis cableveyor from the CB_BR. Remove the SM3051052TN to detach the Y-Axis cableveyor from the X-Axis assembly. Remove the SL6061292TN to detach the FC_SUPPORT_Y_V2. Reassemble the components in the reverse order of disassembly. At this time, pay special attention so that the cables inside the cableveyor are not entangled.
Page 25: Replacing The Cables In The X/Y Veyor-Cable
Maintenance Guide 1-4. Replacing the Cables in the X/Y Veyor-Cable 1-4-1. Removing the X Cable Detach the head top cover and disconnect the connectors connected to XY veyor-cable and OPTICAL FIBER CABLE 7M. XY veyor-cable XY veyor-cable (40182272) XY veyor-cable XL (40214920) Figure 1-4-1-1 OPTICAL FIBER CABLE 7M OPTICAL FIBER CABLE 7M (40048070)
Page 26 Maintenance Guide Remove the movable part side CABLE_CLAMP_X2 and cut off the tie-up band. Figure 1-4-1-4 Figure 1-4-1-3 Remove the fixed end side CABLE_CLAMP_X. Figure 1-4-1-5 4) Remove the connectors of the XY bare cable on the fixed side of the Y axis cable bare and OPTICAL FIBER CABLE 7M.
Page 27 Maintenance Guide Remove the movable part side FC_SUPPORT_Y_V2 and cut off the tie-up band. Figure 1-4-1-7 Remove the Fixed side FC_SUPPORT_Y_V2 and cut off the tie-up band. Figure 1-4-1-8 Remove the cover of the cable bear and remove the XY cable. 1-18...
Page 28: Checking The Cable Marking (X)
Maintenance Guide 1-4-2. Checking the Cable Marking (X) Check the marking position of the XY veyor-cable . (Check that the bonding edge has the black markings.) Figure 1-4-2-1 Check the marking positions of the optical fiber cable 7M. OPTICAL FIBER CABLE 7M White marking on OPTICAL FIBER CABLE 7M Figure 1-4-2-2 1-19...
Page 29: Assembling The Cable
Maintenance Guide 1-4-3. Assembling the Cable Apply the grease to portions where the cables (XY veyor-cable, and the optical fiber cable 7M) are put in the cableveyor, and place the cables and air tubes in the X-axis cableveyor as shown in the figure below (figure viewed from A). ∗...
Page 30 Maintenance Guide Set the marking position of the XY cable to the following location. X axis Cable Bear Match the OPTICAL FIBER CABLE 7M and the marking of the air tube to the marking position of the movable XY cable and fix. Adjust the marking of fiber and air tube to marking (black).
Page 31 Maintenance Guide Push the cables inside the cableveyor by hand to check that they are flexible. Push the cables inside the cableveyor by hand to check that they are flexible. Pull the Y veyor-cable, XY veyor-cable in the direction ① and put the white marking at the movable end (rear side) of the Y-cableveyor in the cable arrangement direction.
Page 32: Removing The Y Veyor-Cable
Maintenance Guide 1-4-4. Removing the Y Veyor-Cable Disconnect the binding of the connector bracket at the entrance of the Y-axis cableveyor and the relay connector. Figure 1-4-4-1 Disconnect the binding of the connector bracket at the Exit of the Y-axis cableveyor and the relay connector.
Page 33: Assembling The Cable
Maintenance Guide 1-4-5. Assembling the Cable Apply the grease to portions where the cables (Y veyor-cable, XY veyor-cable, and the optical fiber cable 7M) are put in the cableveyor. Arrange the cables as shown in Figure 1-4-5-1 and adjust their lengths. OPTICAL FIBER CABLE 7m Air tube (black) Air tube (blue)
Page 34 Maintenance Guide Pull the Y veyor-cable, XY veyor-cable in the direction  and put the white marking at the movable end (rear side) of the Y-cableveyor in the cable arrangement direction. Push in the cables in the direction  and put the white marking at the movable end (rear side) of the Y-cableveyor in the cable arrangement direction.
Page 35 Maintenance Guide Bundle the cables on the rear of the X-axis according to the Figures below. Figure 1-4-5-7 Figure 1-4-5-8 Move the Y-axis to the foremost position and push the cables inside the Y-cableveyor by hand to check that they are flexible. ...
Page 36: Wiring Around The Head
Maintenance Guide 1-4-6. Wiring around the Head Connect the cables coming from the XY veyor-cable (40182272) to the following locations. When connecting the cables, do not bend any cable excessively nor apply any load. In particular, carefully handle the fiber cables. Insert the LNC-1, CN0601, CN0610, and CN0614 into the locations shown in the Figure 1-4-6-1.
Page 37: Replacing The Cableveyor Link
Maintenance Guide 1-5. Replacing the Cableveyor Link 1-5-1. X Cableveyor Structure and Part Names Part No./Part name: Bracket at movement end 40110451 X_CABLE_BEAR Joint link Link Joint link Lock stay Bracket at fixed end 1-5-2. Detaching the Arm and Lock Stay Follow the steps below to detach the arm and lock stay.
Page 38: Separating The Link
Maintenance Guide 1-5-3. Separating the Link Follow the steps below to separate the link and detach it. 1) Insert a slotted screwdriver 2) Pry the slotted screwdriver in the direction indicated by an arrow into the hole in the bottom of to detach the link.
Page 39: Mounting The Arm And Lock Stay
Maintenance Guide 1-5-5. Mounting the Arm and Lock Stay Follow the steps below to mount the arm and lock stay on the link. 1) Insert the arm shaft into the 2) Push the portions about 20 mm 3) Pinch the link stay and arm by away from the both ends of the link.
Page 40: Replacing The X Ball Screw
Maintenance Guide 1-6. Replacing the X Ball Screw 1-6-1. Preparations for X Ball Screw Replacement (1) Detach the X_FRAME_END_SUPPORT_F on the left side. [To be conducted in the RS-1R only.] X_FRAME_END_SUPPORT_F ① Remove SL6042592TN (2 pcs.). ② Remove SL6054592TN (2 pcs.). ③...
Page 41 Maintenance Guide (2) Detach the X_OIL_GUARD_F. X_OIL_GUARD_F Remove SM3040652TN (2 pcs.). Move the HEAD_PLATE to the right. Remove SM3040652TN (2 pcs.). Remove SM3030552TN (4 pcs.). Move the HEAD_PLATE to the left and detach the X_OIL_GUARD_F. 1-32...
Page 42 Maintenance Guide (3) Detach the X_OIL_GUARD_3010. Detach the X_OIL_GUARD_3010. Remove SM3040652TN (1 pc.). Remove SM3030552TN (4 pcs.). Remove SM3040652TN (1 pc.). (4) Disconnect the X_MOTOR cable. Disconnect the connector. 1-33...
Page 43: Removing The X Ball Screw
Maintenance Guide COUPLING_X_screw 1-6-2. Removing the X Ball Screw (1) Loosen the coupling on the X motor ball screw side. COUPLING_X (2) Loosen the set screw, remove the set screw and set piece, and loosen the lock nut. ∗ After the set screw has been removed, pay special attention so that the set piece is not lost.
Page 44 Maintenance Guide (5) Detach the X ball screw support from the X ball screw. X_ball screw support (6) Remove the screws that secure the X ball screw_nut. Move the X_ball screw nut to the left. (7) Remove the lock nut and collar. Collar Lock nut Turn the lock nut to remove it while...
Page 45 Maintenance Guide (8) With the HEAD_UNIT moved to the right, detach the X ball screw. MOTOR_FRAME side (L side) X_BS_NUT_FRAME Status after the X ball screw has been detached. X_BS_NUT_FRAME side (R side) (9) Remove the C-retaining ring and bearing from the X ball screw that has been detached. Detached X ball screw (10) Remove the C-retaining ring, and then remove the bearing from the X ball screw.
Page 46: Mounting The X Ball Screw
Maintenance Guide 1-6-3. Mounting the X Ball Screw (1) Mount the C-retaining ring and bearing that have been removed in step 1-6-2 (10) on a new X ball screw (part No.: 40098047). Apply the NSL grease. Bearing X ball screw New ball screw C-retaining ring (2) Mount the X ball screw that has been assembled in step 1-6-3 (1).
Page 47 Maintenance Guide (3) Fit the collar and lock nut into the X ball screw and secure them temporarily. Put the set piece and secure it with the set screw. ∗ At this time, be careful not to drop the set piece. Put the stepped part of the lock nut in contact with the collar.
Page 48 Maintenance Guide (5) Mount the X ball screw frame assembly. X ball screw frame assembly Tighten SL6053092TN (2 pcs.). (6) Secure the X ball screw support temporarily. ∗ At this time, secure temporarily so that two surfaces match with each other. Make two surfaces matched with each other.
Page 49: Adjusting The X Ball Screw
Maintenance Guide 1-6-4. Adjusting the X Ball Screw (1) Move the HEAD_UNIT to the right and tighten the fixing screws (SM6061602TN, 4 pcs.) of the X ball screw nut firmly that has been secured temporarily in step 1-6-3 (3). Enlarged photo Move the HEAD_UNIT to the right.
Page 50 Maintenance Guide (3) Reciprocate the HEAD_UNIT several times until it is in contact with the X_STOPPER, and then check that the movement is smooth. Measure the sliding load and check that the measured value is 50[N] or less. If the measured value does not satisfy the standard level, make the adjustment again from step 1-6-4 (1).
Page 51 Maintenance Guide (5) How to measure the sliding load of the X-axis 1) Move the HEAD_UNIT to the left. 2) Push the HEAD_UNIT from the left to the right repeatedly to measure the maximum value three times, and then calculate the average value. 3) Push the HEAD_UNIT from the right to the left repeatedly to measure the maximum value three times, and then calculate the average value.
Page 52 Maintenance Guide (7) Tighten the screw of the coupling_X. (Screw tightening torque: 3.7 [N⋅m]) COUPLING_X_screw COUPLING_X (8) Mount the X_OIL_GUARD. Mount the X_MOTOR cable, the X_OIL_GUARD_F_L and X_OIL_GUARD_U_3010. (Perform the work in the reverse order of the work described in Chapter 1-6-1.) (9) Mount the X_FRAME_END_SUPPORT_F.
Page 53: Replacing The Y Ball Screw
Maintenance Guide 1-7. Replacing the Y Ball Screw 1-7-1. Preparations for Y Ball Screw Replacement (1) Detach the COVER_SUR_F_MOTOR_BR, MOTOR_COVER from the machine front_F side. B COVER SCREW（×4） B COVER SCREW（×4） COVER SUR F MOTOR BR MOTOR COVER (2) Detach the MOTOR_COVER_R from the machine rear_R side. MOTOR_COVER_R B COVER SCREW（×4）...
Page 54 Maintenance Guide (3) Detach the MOTOR_COVER from the machine front_L side. B COVER SCREW（×4） MOTOR COVER (4) Detach the MOTOR_COVER_R from the machine rear_L side. B COVER SCREW（×4） MOTOR COVER R 1-45...
Page 55 Maintenance Guide (5) Disconnect the Y_MOTOR cable. 1-46...
Page 56: Removing The Y Ball Screw
Maintenance Guide 1-7-2. Removing the Y Ball Screw (1) Loosen the coupling Y screw. ∗ Be careful not to remove the coupling screw. ●YL Coupling screw Y_MOTOR Coupling 1-47...
Page 57 Maintenance Guide (2) Loosen the set screw of the lock nut. Put the wrench 22 on the lock nut and wrench 17 on the groove of the ball screw, and then loosen the lock nut. ∗ Pay special attention so that the set screw of the lock nut does not project from the lock nut surface.
Page 58 Maintenance Guide To loosen the lock nut on the rear of the ball screw on the YR side, put the wrench wrapped in cloth rag into the clearance between the Y motor frame and base frame. View of A Utilize this clearance. Y_MOTOR_FRAME BASE_FRAME YR rear side...
Page 59 Maintenance Guide (4) Remove the C-ring on the rear side. C-ring (5) Push out the bearing from the Y_ADJUST_PLATE in the direction indicated by an arrow to take it out. Bearing Bearing Y_ADJUST_PLATE 1-50...
Page 60 Maintenance Guide [RS-1XL] (6) Remove the screws that fix END_BRACKET and remove the bracket as shown below. END_BRACKET (7) Remove the lock nut from the Y-axis ball screw and remove the bearing. Lock nut Bearing 1-51...
Page 61 Maintenance Guide [RS-1R] (8) Remove the screws that fix END_BRACKET and remove the bracket as shown below. END_BRACKET (9) Remove the lock nut from the Y-axis ball screw and remove the bearing. Lock nut Bearing 1-52...
Page 62 Maintenance Guide (10) Remove the screws that secure the Y ball screw nut. L side R side Before starting the work, move the HEAD_UNIT to the front. To replace the ball screw on the R side, move the HEAD_UNIT to the L side.
Page 63: Mounting The Y Ball Screw
Maintenance Guide (12) Pull out the Y ball screw. ∗ Do not touch the ball screw by bare hand. (Doing so may cause the ball screw to rust.) After the lock nut and spacer on the front have been removed, pull out the Cloth rag ball screw while holding the ball screw shaft by your left hand.
Page 64 Maintenance Guide (2) Fit the collar and lock nut into the ball screw on the front (same procedures as described in steps 1-7-2 (8) and 1-7-2 (9)). ∗ Be careful not to drop the set piece. Put the stepped part of the lock nut in contact with the collar. Collar Lock nut Y ball screw...
Page 65 Maintenance Guide (3) Apply the NSL grease (40094361) evenly to the side surface of the bearing that has been pulled out in step 1-7-2 (5). NSL grease (4) Apply the NSL grease to the hole in the Y_ADJUST_PLATE evenly (portion where the bearing is inserted).
Page 66 Maintenance Guide (6) Assemble the C-ring to the ball screw. ● Assemble the bearing to the C-ring groove on the ball screw. [RS-1XL] (7) Insert the bearing in the Y-axis ball screw and fix it with the lock nut. Lock nut Bearing (8) Attach END_BRACKET to the bearing.
Page 67 Maintenance Guide [RS-1R] (9) Insert the bearing in the Y-axis ball screw and fix it with the lock nut. Lock nut Bearing (10) Attach END_BRACKET to the bearing. (Secure the fixing screws temporarily.) END_BRACKET 1-58...
Page 68: Adjusting The Y Ball Screw
Maintenance Guide (11) Tighten the lock nut on the front with the wrenches 17 and 22. Tighten the set screw of the lock nut. Wrench 22 turning direction Set screw of lock nut Wrench 17 Wrench 22 (12) Tighten the lock nut on the rear with the wrenches 17 and 22. ∗...
Page 69 Maintenance Guide [For RS-1XL and RS-1R only] (3) For XL and RS-1R, move the END_BRACKET to the rear side and tighten the fixing screws firmly. END_BRACKET (4) After checking, move the X_AXIS_FRAME_ASM to the front until it is in contact with the Y_STOPPER, and then retighten the screws (SM6062002TN, 2 pcs.) outside the machine.
Page 70 Maintenance Guide (6) Move the X_AXIS_FRAME_ASM to the front until it is in contact with the Y_STOPPER. Tighten four fixing screws (SM6062002TN) of the Y ball screw nut. Y_ball screw_nut (7) How to measure the sliding load of the Y-axis. 1) Move the HEAD_UNIT to the center, and then move the X-axis frame to the front.
Page 71 Maintenance Guide Move the X-axis frame to the rear and push it from the rear to a portion close to the ATC repeatedly to measure the maximum values three times, and then calculate the average value. (8) Check that the difference between the average values obtained in (7)-2) and (7)-3) is 15 [N] or less.
Page 72 Maintenance Guide Check that the cut on the motor side of the coupling ② faces upward. ① Move the X frame to the mechanical end. (11) Connect the Y_MOTOR encoder cable that has been disconnected in step 1-7-1 (8). Connect the connector. (12) Readjust the home position rough adjustment and check the operation.
Page 73 Maintenance Guide (13) Before starting the aging, apply the NSL grease and move the HEAD_UNIT from the front to the rear and from the rear to the front conform it to the entire shaft. ∗ Wipe off the oozed grease with a cloth rag. Wipe off the oozed grease with a Grease gun cloth rag.
Page 74 Maintenance Guide Portions needing cautions during replacement of the X ball screw and Y ball screw (edge and burr portions)  X_FRAME_END_L  X_FRAME_END_R Y_MOTOR_FRAME BASE_FRAME_B Y_STOPPER_ASM  Y_BASE_FRAME_L  Y_BASE_FRAME_R 1-65...
Page 75: Readjustment After Xy Part Exchange
Maintenance Guide 1-8. Readjustment after XY part exchange Replacing Replacing Replacing Replacing the Ball Replacing the motor the LMT the Home Screw Limit Proximity Cableveyor X-Axis Y-Axis X-Axis Y-Axis Sensor Sensor Z phase － ① － ① －－－ position Rough adjustment of...
Page 76: Head
Maintenance Guide 2 Head To prevent any trouble caused by accidental machine start, DANGER always shut-down the power before starting the maintenance and adjustment work. 2-1 8-Nozzle Head 2-1-1 Replacing the Head Unit 1) Shut down the air to the main unit. 2) Remove the head PCB cover.
Page 77 Maintenance Guide Head PCB cover Round screw M4 L=6 Head main board and bracket Washer assembled hexagon socket head cap bolt M3 L=6 Head-up cylinder sensor cable connection destination Head relay board...
Page 78 Maintenance Guide Zθ motor cable (connection of connector) Power Encoder Connection of Zθ motor cable connector Motor cable fixing...
Page 79 Maintenance Guide Solenoid valve Air tube & cable fixing (on top of head SV bracket) Air tube (negative pressure φ8) Solenoid valve cable connector Solenoid valve cable fixing Air tube (positive pressure φ6，negative pressure φ8)
Page 80 Maintenance Guide Routing path of solenoid valve cable, OCC camera cable and Solenoid valve for temperature board head-up cylinder sensor cable OCC camera cable Temperature sensor board Solenoid valve cable Air tube connected to solenoid valve OCC camera cable Temperature sensor board cable...
Page 81 Maintenance Guide Relay connector part θ axis origin sensor amplifier θ axis origin sensor amplifier Order [T1 / T2 / T3 / T4] Cable routing path of θ axis origin sensor amplifier Fiber...
Page 82 Maintenance Guide LNC120 cable (spiral tube) Cable fixing (on top of head SV bracket) Cable fixing (on the head right side)
Page 83 Maintenance Guide Washer assembled hexagon socket head cap bolt M5 L=16 Hexagon socket head cap bolt M4 L=10 Head unit...
Page 84: Replacing The Z-Motor
Maintenance Guide 2-1-2 Replacing the Z-Motor After the Z motor has been replaced, it is absolutely necessary to reacquire the MS parameters related to the Z-axis height and laser. (For the items to be acquired, see section 2-2, Re-adjustment after Replacing the Head.) Replace the Z motor with the head mounted to the machine.
Page 85 Maintenance Guide Connection of Z motor connector Z motor cable fixing Air tube Cable fixing on top of head SV bracket Solenoid valve cable Washer assembled hexagon socket head cap bolt M3 L=16 Air tube (φ4) 2-10...
Page 86 Maintenance Guide Head SV bracket Washer assembled hexagon socket head cap bolt M3 L=6 Air tube connection & routing θ axis origin sensor amplifier Order [T1 / T2 / T3 / T4] Cable fixing (Z motor cable stay part) 2-11...
Page 87 Maintenance Guide Z motor cable stay Washer assembled hexagon socket head cap bolt M3 L=6 T sensor bracket Washer assembled hexagon socket head cap bolt M3 L=8 2-12...
Page 88 Maintenance Guide <Belt tension adjustment procedure> Provisionally assemble the Z motor and fix it while pulling it in the direction indicated by an arrow with a force of 21.6 N (2.2 kgf) using a tension gauge. Tension meter input value •...
Page 89: Replacing The Θ-Motor
Maintenance Guide 2-1-3 Replacing the θ-Motor After the θ-motor has been replaced, it is absolutely necessary to reacquire the MS parameters related to the axis home. (For the items to be acquired, see section 2-2, Re-adjustment after Replacing the Head.) Replace the θ...
Page 90 Maintenance Guide <Belt tension adjustment procedure> Pull the θ motor to the operator’s side, and adjust the tension of the timing belt to the following adjustment value. Tension meter input value • Weight: 0.9 g/m • Width: 6.0 mm • Span: Implemented in a measurable span of the figure below •...
Page 91 Maintenance Guide Head SV bracket θ motor T sensor bracket Z motor cable stay θ motor Washer assembled hexagon socket head cap bolt M3 L=8 T motor plate Flat head screw M3 L=8 T pulley flange top Motor convex surface (φ20) T pulley &...
Page 92 Maintenance Guide Lot number (print) Motor shaft mark Lot number 2-17...
Page 93: Replacing The Timing Belts Z
Maintenance Guide 2-1-4 Replacing the Timing Belts Z After the timing belt Z has been replaced, it is absolutely necessary to reacquire the MS parameters related to the Z-axis height and laser. (For the items to be acquired, see section 2-2, Re-adjustment after Replacing the Head.) The timing belt Z replacement method is the same as the Z motor replacement method.
Page 94 Maintenance Guide Rotary Joint Setscrew M2.5 L=2.5 Spline shaft Spline pulley Timing Belt T Bearing plate L Hexagon socket head cap bolt M2 L=6 Setscrew (Upper two) M3 L=3 2-19...
Page 95: Replacing The Ball Screw
Maintenance Guide 2-1-6 Replacing the Ball Screw When replacing the ball screw, it is necessary to dismount the Z motor. When dismounting the Z motor, reacquire the MS parameters related to the Z axis height and the laser. (For the items to be acquired, see section 2-2, Re-adjustment after Replacing the Head.) Replace the ball screw with the head dismounted from the machine.
Page 96 Maintenance Guide Assemble so that the print is on the right side. Ball screw nut Hexagon socket head cap bolt M3 L=8 Lock nut Z pulley φ10 clearance hole for removing the ball Ball screw Be careful not to lose the set piece! 2-21...
Page 97 Maintenance Guide After sliding the ball screw up and down several times while temporarily fastening the left side of the ball screw nut fixing screw and temporarily fixing the right side, if it is confirmed that the movement is smooth, tighten the four screws at the top. ∗...
Page 98 Maintenance Guide If the nut holder interferes or the shaft slides heavily, adjust the position and inclination of the nut holder. Nut holder Assembly adjustment screw Use a short wrench to adjust the position of the nut holder. If you try to access from the vertical direction with a straight wrench, you will not be able to adjust the position and inclination of the nut holder because the wrench interferes with the ball screw shaft and a load is...
Page 99: Replacing The Lnc120-8
Maintenance Guide 2-1-7 Replacing the LNC120-8 After the LNC120-8 has been replaced, it is absolutely necessary to re-input the MS parameters related to the laser. (For details about input items, see section 2-2, Re-adjustment after Replacing the Head.) 1) Remove cable fixing of LNC 120-8. 2) Remove the LNC120-8 on the underside.
Page 100: Replacing The Z-Slide Shaft
Maintenance Guide 2-1-8 Replacing the Z-Slide Shaft When the Z-slide shaft has been replaced, it is necessary to re-input the MS parameters related to the Z-axis height and laser. (For details about input items, see section 2-2, Re-adjustment after Replacing the Head.) 1) Remove the Z motor if necessary.
Page 101: Replacing The Head Up Cylinder
Maintenance Guide 2-1-9 Replacing the Head Up Cylinder 1) Off to the air machine. 2) Remove the nut at the air cylinder tip and remove the release bar. 3) Disconnect the φ4 air tube from the air cylinder. 4) Remove the air cylinder. 5) Remove the elbow union, speed controller, cylinder bracket, and auto switch.
Page 102 Maintenance Guide Air cylinder Elbow union. Auto switch Speed controller Washer assembled hexagon socket head cap bolt M4 L=10 Cylinder bracket 2-27...
Page 103: Replacing The Θ-Origin Sensor
Maintenance Guide 2-1-10 Replacing the θ-Origin Sensor 2-1-10-1 Replacing the Fiber Sensor 1) Remove the T Sensor Bracket. See section 2-1-3 [Replacing the θ-Motor]. 2) Remove the fiber sensor from the T Sensor Bracket. 3) Reassemble the components in the reverse order of disassembly. 4) After mounting, turn the Z-axis to check that the belt origin (printed character) is detected.
Page 104 Maintenance Guide 2-1-10-2 Replacing the Sensor Amplifier 1) Raise the sensor amplifier protective cover, stand the lever near the fiber insertion part, and disconnect the fiber connector from the amplifier. 2) Disconnect the fixing connectors from both sides of the sensor amplifier. 3) Raise the fiber insertion side with the sensor amplifier pushed downward to detach the sensor amplifier.
Page 105 Maintenance Guide 2-1-10-3 Setting the Sensor Threshold Value [L/D indicator] Shows the setting status, [△L/D button] [DPC indicator] ON (L) at light entry/ Switches between ON (L) at light Lit when the dynamic power control function ON (D) at light interruption. entry and ON (D) at light is enabled.
Page 106: Replacing The Za-Motor
Maintenance Guide 2-1-11 Replacing the ZA-Motor After the ZA motor has been replaced, it is absolutely necessary to obtain the MS parameters related to the ZA-axis height. (For details about input items, see section 2-2, Re-adjustment after Replacing the Head.) 1) Remove the head unit.
Page 107: Replacing The Head Unit (When The Head Revision Number Is A Or Later)
Maintenance Guide 2-1-12 Replacing the Head Unit (When the Head Revision Number Is A or Later) To replace the head whose revision number is earlier than A with the head whose revision number is A or later, replace the air tube connected to the head solenoid valve and that connected to the solenoid valve for the head up cylinder with new ones or cut them short.
Page 108 Maintenance Guide For the [★] parts of the work procedures below, also refer to the work contents of “2-1-1 Replacing the Head Unit”. 1) Shut down the air to the main unit. 2) ★ Remove the head PCB cover. 3) ★ Remove the head main board bracket assembly screw. Lift to the top and remove the connector of the head up cylinder sensor cable connected to the head relay board on the bottom side.
Page 109 Maintenance Guide Zθ motor cable (connection of connector) Power Encoder Connection of Zθ motor cable connector Motor cable fixing 2-34...
Page 110 Maintenance Guide Head cover Washer assembled hexagon socket head cap bolt M3 L=6 Solenoid valve cable connector Solenoid valve cable fixing Air tube (positive pressure φ6， negative pressure φ8) Air tube (negative pressure φ8) 2-35...
Page 111 Maintenance Guide Solenoid valve for head-up cylinder Routing path of OCC camera cable solenoid valve cable, OCC camera cable and Temperature temperature board sensor board sensor cable Head SV bracket Solenoid valve cable Air tube connected to solenoid valve Temperature sensor board cable OCC camera cable 2-36...
Page 112 Maintenance Guide θ axis origin sensor amplifier Relay connector part θ axis origin sensor amplifier Order [T1 / T2 / T3 / T4] Fiber 2-37...
Page 113 Maintenance Guide Cable fixing (on the head right side) Cable fixing (on top of head SV bracket) LNC cable (spiral tube) 2-38...
Page 114: Replacing The Z-Motor (When The Head Revision Number Is A Or Later)
Maintenance Guide 2-1-13 Replacing the Z-Motor (When the Head Revision Number Is A or Later) When you replace the existing Z-motor with another one, you have to obtain the MS parameters related to the height of the Z-axis and the laser again. (See Section 2-2 “Readjustment after Replacement of Head Unit”...
Page 115 Maintenance Guide Replace the Z motor with the head mounted to the machine. For the [★] parts of the work procedures below, also refer to the work contents of “2-1-12 Replacing the Head Unit (When the Head Revision Number Is A or Later)”. <Replacing the Z-motors of the odd-numbered shafts>...
Page 116 Maintenance Guide φ4 air tube Y-union φ6 air tube Solenoid valve for a head-up φ4 air tube cylinder 2-41...
Page 117 Maintenance Guide Head SV bracket (upper part) Air tubes, cables Motor cable Motor connector 2-42...
Page 118 Maintenance Guide Head SV bracket Two locations on the back side are U grooves. Washer assembled hexagon socket head cap bolt M4 L=8 2-43...
Page 119 Maintenance Guide T sensor bracket Washer assembled hexagon socket head cap bolt M3 L=8 Z-motor assembly 2-44...
Page 120 Maintenance Guide <Replacing the Z-motors of the even-numbered shafts> Remove the amplifier of the θ axis origin sensor from the DIN rail. Remove the cable fixing on the side of the Z motor cable stay. Remove the motor connector from the relay connector of the Z motor cable stay. ★...
Page 121 Maintenance Guide Z motor cable stay Washer assembled hexagon socket head cap bolt M3 L=6 Motor connector Motor cable 2-46...
Page 122 Maintenance Guide Z-motor assembly Measure the tension from the aperture. 2-47...
Page 123 Maintenance Guide < Procedure for adjusting the belt tension> Temporarily assemble the Z-motor, and use a tension rod to fix it by pulling it with 24 N (2.4 kgf). Input values to a tension meter - Weight: 0.9 g/m - Width: 10.0 mm - Span: 66.4 mm - Appropriate tension: 12±1N * Apply Loctite 243 to the Z-motor mounting screws (four), and then fix them with the tightening...
Page 124: Replacing The Θ-Motor (When The Head Revision Number Is A Or Later)
Maintenance Guide 2-1-14 Replacing the θ-Motor (When the Head Revision Number Is A or Later) When you replace the existing θ-motor with another one, you have to obtain the MS parameters related to the origin of each axis again. (See Section 2-2 “Readjustment after Replacement of Head Unit”...
Page 125 Maintenance Guide <Procedure for adjusting the belt tension> Pull the θ-motor toward you, and then adjust the tension of the timing belt T to the adjustment values shown below. Input values to a tension meter Weight: 0.9 g/m Width: 10.0 mm Span: Adjust the tension with the span shown below so that you can measure the tension easily.
Page 126 Maintenance Guide θ-motor assembly <Assembling method: Example (where the white mark is aligned on the left side> ① Align the (white) characters on the belt with the black mark on the motor pulley. ② Rotate the motor pulley while keeping the state of ① and place the white mark on the left side.
Page 127: Replacing The Timing Belt Z (When The Head Revision Number Is A Or Later)
Maintenance Guide 2-1-15 Replacing the Timing Belt Z (When the Head Revision Number Is A or Later) Follow the instructions described in Section 2-1-4. 2-1-16 Replacing the Timing Belt θ (When the Head Revision Number Is A or Later) Follow the instructions described in Section 2-1-5. 2-52...
Page 128: Replacing The Ball Screw (When The Head Revision Number Is A Or Later)
Maintenance Guide 2-1-17 Replacing the Ball Screw (When the Head Revision Number Is A or Later) When replacing the ball screw, it is necessary to dismount the Z motor. When dismounting the Z motor, reacquire the MS parameters related to the Z axis height and the laser. (For the items to be acquired, see section “2-2 Re-adjustment after Replacing the Head”.) Replace the ball screw with the head dismounted from the machine.
Page 129 Maintenance Guide Assemble so that the print is on the right side. Ball screw nut Hexagon socket head cap bolt M3 L=8 Lock nut Be careful not to lose the set piece. Z pulley * Pay attention to the vertical orientation (i.e.
Page 130 Maintenance Guide After sliding the ball screw up and down several times while temporarily fixing the ball screw nut fixing screw, if it is confirmed that the movement is smooth, tighten the two screws at the top of the ball screw. * Since the lower screw greatly affects the sliding, make fine adjustments with the lower screw.
Page 131: Replacing The Lnc120 (When The Head Revision Number Is A Or Later)
Maintenance Guide 2-1-18 Replacing the LNC120 (When the Head Revision Number Is A or Later) Follow the instructions described in Section 2-1-7. 2-1-19 Replacing the Z-Slide Shaft (When the Head Revision Number Is A or Later) Follow the instructions described in Section 2-1-8. 2-56...
Page 132 Maintenance Guide 2-1-20 Replacing the Head-up Cylinder (When the Head Revision Number Is A or Later) 1) Cut off the air supply to the main unit. 2) Remove the nut from the tip of the air cylinder to remove the release bar. 3) Disconnect the φ4 air tube connected to the air cylinder.
Page 133 Maintenance Guide Air cylinder Elbow union Auto switch Speed controller Hexagon socket head cap screw with a washer M4 L = 10 Cylinder bracket 2-58...
Page 134: Replacing The Θ-Origin Sensor (When The Head Revision Number Is A Or Later)
Maintenance Guide 2-1-21 Replacing the θ-Origin Sensor (When the Head Revision Number Is A or Later) 2-1-21-1 Replacing the Fiber Sensor 1) Remove the T sensor bracket. See section 2-1-14 [Replacing the θ-Motor]. 2) Remove the fiber sensor from the T sensor bracket. 3) Assemble the removed parts and the new sensor in the reverse procedure.
Page 135 Maintenance Guide 2-1-21-2 Replacing the Sensor Amplifier 1) Lift up the sensor amplifier protection cover to raise the lever located near the fiber insertion part, and then pull out the fiber connector from the amplifier. 2) Remove the fixed connectors on both sides of the sensor amplifier. 3) While pushing the sensor amplifier downwards, raise the fiber insertion side to remove it.
Page 136 Maintenance Guide 2-1-21-3 Setting the Sensor Threshold Value Operation mode switching button: Manual adjustment buttons: Switches the operation mode Manually adjusts a threshold value TEACH (teaching) indicator between L-ON and D-ON. (UP/DOWN) Operation indicator Locking the fiber unit L-ON/D-ON indicators TEACH button: Performs Digital indicator: Displays the a teaching operation...
Page 137: Readjustment After Replacement Of Head Unit
Maintenance Guide 2-2 Readjustment after Replacement of Head Unit ZA Axis Laser Head Measurement Extended Multi- height offset offset of component T axis (laser) camera recognition (Vision) offset speed offset offset offset Head unit       ...
Page 138: Parts Around The Head
Maintenance Guide 3. PARTS AROUND THE HEAD To prevent any trouble caused by accidental machine start, DANGER always shut-down the power before starting the maintenance and adjustment work. Solenoid valve unit 3-1-1 Replacing the Solenoid Valves 1) Shut-down the main compressed air. 2) Remove the head SV bracket.
Page 139: Replacing The Filter
* Filter with flat tip and no protrusion. Part No.：40046646 * Filter with protrusion at the tip. Part No.：E3052729000 (RS-1 machine Rev. N, RS-1R machine Rev. D, RS-1/1R head Rev. C or later) Reassemble the parts and components in the reverse order of disassembly.
Page 140: Replacing The Hms
Maintenance Guide 3-1-4 Replacing the HMS 1) Remove the HMS sensor head. 2) Assemble the distance to the upper surface of the CAL block to 50 ± 0.2 mm. 3) After assembly, obtain MS parameter of HMS sensor offset. Hexagon socket head cap bolt M3 L=25 HMS sensor Washer assembled hexagon...
Page 141: Replacing The Electromagnetic Valve
Maintenance Guide 3-1-5 Replacing the Electromagnetic Valve (When the Head Revision Number Is A or Later) 1) Cut off the air supply to the main unit. 2) Remove the head SV bracket. See Section 2-1-12 [Replacing the Z-motor] for the procedure. 3) Remove the electromagnetic valve unit from the head SV bracket when necessary.
Page 142: Replacing The Head Board
Maintenance Guide Replacing the Head Board 3-2-1 Replacing the Head Main Board 1) Remove the head PCB cover. 2) Remove the connector connected to the head main board. 3) Remove the head main board bracket. 4) Remove the head main board from the bracket. 5) Reassemble the parts and components in the reverse order of disassembly.
Page 143: Replacing The Servo Amplifier Board
Maintenance Guide 3-2-2 Replacing the Servo Amplifier Board 1) Remove each connector connected to the servo amplifier board. 2) Remove the fan motor on the rear side. 3) Remove 3 ZT driver support (pull out to the back side). 4) Remove the servo amplifier board from 3 ZT driver support. 5) Reassemble the parts and components in the reverse order of disassembly.
Page 144: Occ Unit
Maintenance Guide 4 OCC Unit To prevent any trouble caused by accidental machine start, DANGER always shut-down the power before starting the maintenance and adjustment work. 4-1 Replacing the OCC Unit Remove the HMS bracket. Remove the connector connected to the light unit and remove the light unit. Remove the camera cable and remove the camera unit.
Page 145: Replacing The Ccd Camera And Lens
Maintenance Guide 4-2 Replacing the CCD Camera and Lens Remove the camera unit. See section 4-1 [Replacing the OCC Unit]. Remove the CCD camera and lens. Reassemble the components in the reverse order of disassembly. After replacement, refer to 4-7 [Readjustment Items After Replacing OCC Unit]. Perform necessary adjustments and enter MS parameters.
Page 146: Replacing The Occ Coaxial/Angle Light Board
Maintenance Guide 4-3 Replacing the OCC Coaxial/Angle Light Board Remove the light unit. See section 4-1 [Replacing the OCC Unit]. Remove the OCC coaxial light board. Remove the OCC angle light board. Reassemble the components in the reverse order of disassembly. After replacement, refer to 4-7 [Readjustment Items After Replacing OCC Unit].
Page 147: Replacing The Lens Filter
Maintenance Guide 4-4 Replacing the Lens Filter Remove the light unit. See section 4-1 [Replacing the OCC Unit]. Remove the filter plate. Remove the filter from the filter plate. Reassemble the components in the reverse order of disassembly. After replacement, refer to 4-7 [Readjustment Items After Replacing OCC Unit]. Perform necessary adjustments and enter MS parameters.
Page 148: Adjusting The Focus And The Occ Light Quantity
Maintenance Guide 4-5 Adjusting the Focus and the OCC Light Quantity Refer to the QA table [RS-1_QA table M04_OCC] for the procedure of focus adjustment and light quantity adjustment. 4-6 Readjustment Items After Replacing OCC Unit Table 4-6-1 List of Readjustment Items after Replacement of OCC Unit Lens Light CCD camera...
Page 149: Board Transport
Maintenance Guide 5 Board Transport To prevent any trouble caused by accidental machine start, DANGER always shut-down the power before starting the maintenance and adjustment work. 5-1 Replacing the Transport Belt Loosen the transport belt tension adjustment pulley. IN・OUT conveyor Center conveyor Be careful.
Page 150: Replacing The Transport Pulley
Maintenance Guide 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. Always refer to relevant mounting procedure when mounting the transport pulley.
Page 151: Replacing The Conveyor (Board Transport) Motor
Maintenance Guide 5-3 Replacing the Conveyor (Board Transport) Motor Loosen the screws (4 pcs.) of the conveyor motor bracket and remove the timing belt from the conveyor motor pulley to detach the conveyor motor together with the conveyor motor bracket. Loosen the setscrews (2 pcs.) of the conveyor motor pulley to detach it from the motor and remove the screws (4 pcs.) to detach the motor from the conveyor motor bracket.
Page 152 Maintenance Guide Remove the conveyor motor pulley. Adjust the surface Remove the motor from the bracket when pulley assembly. and replace it. Figure 5-3-2 Conveyor Motor Bracket Reassemble the components in the reverse order of disassembly and adjust the tension of the timing belt. Figure 5-3-3 Conveyor Motor Bracket Loosen the setscrews of the side conveyor motor bracket, and remove the timing belt to detach the motor together with the bracket.
Page 153 Maintenance Guide Remove the conveyor motor pulley. Adjust the surface Remove the motor from the bracket when pulley assembly. and replace it. Figure 5-3-4 Conveyor Motor Bracket Reassemble the components in the reverse order of disassembly and adjust the tension of the timing belt.
Page 154: Replacing The Awc (Board Width Adjustment) Motor
Maintenance Guide 5-4 Replacing the AWC (Board Width Adjustment) Motor Disconnect the motor relay cable connectors. Loosen the screws (4 pcs.) of the AWC motor bracket to remove the timing belt from the timing pulley. Remove the screws (4 pcs.) of the motor to detach the motor. Align the motor shaft end face of a new motor with the timing pulley, apply Loctite 243 to the setscrews, and tighten them.
Page 155: Replacing The Timing Belt
Maintenance Guide 5-5 Replacing the Timing Belt 5-5-1 Replacing the Timing Belt for Adjustment of the Transport Width Disconnect the motor relay cable connectors. Loosen the screws (4 pcs.) of the AWC motor bracket and move the motor upward to secure it temporarily.
Page 156: Replacing The Conveyor Motor Timing Belt
Maintenance Guide 5-5-2 Replacing the Conveyor Motor Timing Belt Remove the screw fixing the supporting bearing of drive shaft C. Figure 5-5-2-1 Conveyor motor bracket Move the drive shaft S to replace the timing bel. Figure 5-5-2-2 Conveyor motor bracket Adjust in reverse order, adjust the idler pulley and adjust the timing belt tension to 17.6 to 21.6 N.
Page 157: Replacing The Transport Width Adjustment Connection Timing Belt
Maintenance Guide 5-5-3 Replacing the Transport Width Adjustment Connection Timing Belt Loosen the screw of the idler pulley, shift the idler pulley, loosen the timing belt. Idler pulley Idler pulley Figure 5-5-3-1 Loosen the idler pulley Remove the AWC encoder. Figure 5-5-3-2 Remove the AWC encoder...
Page 158 Maintenance Guide Remove the screw fixing the support bearing shaft of the screw shaft. Figure 5-5-3-3 Remove the screw fixing the supporting bearing Replace the timing belt by shifting the screw shaft. Figure 5-5-3-4 Remove the screw shaft support bearing Adjust in reverse order, adjust the idler pulley and adjust the timing belt tension to 20.0 N to 25.5 N.
Page 159: Replacing The Left/Right Sensors
Maintenance Guide 5-6 Replacing the LEFT/RIGHT Sensors 5-6-1 Replacing the LEFT/RIGHT Sensors Carefully secure the cables with the tie-up bands so that they are not stretched or loosened excessively when adjusting the sensor position. When moving the sensor in the direction indicated by an arrow mark, the Front side cable has an allowance or...
Page 160: Adjusting The Sensor Sensitivity
Maintenance Guide 5-6-2 Adjusting the Sensor Sensitivity <Adjusting the sensitivity> Make an adjustment so that a (matte) black glass epoxy PWB placed on the transport path can be detected. Place a (matte) black glass epoxy PWB under the sensor and rotate the sensitivity adjustment knob of the sensor counterclockwise.
Page 161: Replacing The Stop Sensor
Maintenance Guide 5-7 Replacing the STOP Sensor 5-7-1 Replacing the Front STOP Sensor Fiber Pull out the fiber from the sensor amplifier. Loosen the screws ③ (2 pcs) and remove the bracket ②. Front-side fiber assembly on conveyor Front side Pass the fiber through the hole in each attachment Figure 5-7-1-1 Front side fiber position...
Page 162 Maintenance Guide 1. Bend the fiber sensor 2. Attach the fiber sensor to the bracket with the dimensions shown with the dimensions in the figure Front inside 1 set x 2 Figure 5-7-1-2 Front side Mounting the Fiber φ1.2 mm or less φ1.3 mm or more Fiber top end position...
Page 163: Replacing The Rear Stop Sensor Fiber
Maintenance Guide 5-7-2 Replacing the Rear STOP Sensor Fiber Pull out the fiber from the sensor amplifier. Loosen the screws ③ (2 pcs) and remove the bracket ②. Rear-side fiber assembly on conveyor Rear side Pass the fiber through the hole in each attachment Figure 5-7-2-1 Rear side fiber position Bend a new fiber as shown in the Figure.
Page 164 Maintenance Guide φ1.2 mm or less φ1.3 mm or more Fiber top end position Stainless tube Figure 5-7-2-3 Fiber Bending Jig Reassemble the components in the reverse order of disassembly. 5-16...
Page 165: Replacing The Fiber Amplifier
Maintenance Guide 5-7-3 Replacing the Fiber Amplifier (1) Assembling the fiber into the amplifier Raise the lever on the top of the amplifier unit. Insert the fiber into the amplifier unit completely until it is in contact with the far position, and then lay down the lever.
Page 166 Maintenance Guide ① ② ③ ④ ⑤ ⑥ ⑧ ⑨ ⑩ Upper portion is the front (light emission). ⑦ Lower portion is the rear (light receiving). Figure 5-7-3-3 Amplifier Unit Mounting Position Table 5-7-3-2 Amplifier, solenoid valve name Amplifier, solenoid valve Remarks For stopper For side beam change-over 1...
Page 167 Maintenance Guide (3) Adjusting the gain of the amplifier unit After the amplifier and fiber have been replaced, follow the steps below to adjust the gain. Main digital display Sub-digital display (red display) (green display) Displays the light receiving Displays the threshold value amount or function contents.
Page 168: Replacing The Bu Pin Detection Sensor
Maintenance Guide 5-8 Replacing the BU Pin Detection Sensor Disconnect the sensor connectors from the board. Cut the tie-up bands. Remove the screws to detach the sensor. Mount a new sensor. Insert the sensor connectors to the board and secure the cables with the tie-up bands. Adjust the light emission and light receiving sensor orientations to check that the sensor receives the light correctly.
Page 169: Replacing The Support Table Origin Sensor (Bu Origin Sensor)
Maintenance Guide 5-9 Replacing the Support Table Origin Sensor (BU Origin Sensor) Disconnect the sensor connectors from the board. Remove the screws to detach the sensor bracket. Remove the screws to detach the sensor. Mount a new sensor. Mount the sensor bracket and adjust the clearance between the sensor and sensor dog to 1 ±...
Page 170: Replacing The Awc Origin Sensor
Maintenance Guide 5-10 Replacing the AWC Origin Sensor Disconnect the sensor connectors from the board. Remove the screws to detach the sensor. Mount a new sensor. Adjust the clearance between the sensor and sensor dog to 1 ± 0.2 mm. Sensor Front side Sensor dog...
Page 171: Replacing The Support Table Motor (Bu Table Motor)
Maintenance Guide 5-11 Replacing the Support Table Motor (BU Table Motor) 5-11-1 Removing the support table Remove the support table. ① Stretch the transport width as much as possible. ② Remove the air tube and cable from the left and right air cylinders on the back of the support table.
Page 172: Support Table Motor
Maintenance Guide Loosen the encoder bracket setscrew and move the encoder bracket in the direction indicated by an arrow mark to loosen the tension of the timing belt for driving of the support table ball screw. If the belt tension is not loosened completely, move also the backup stopper in the direction indicated by an arrow mark.
Page 173: Adjusting The Tension Of The Support Table Driving Timing Belt
Maintenance Guide Loosen the setscrew to detach the support table assembly. Remove the torque supporter assembly setscrews and motor fixing screws to detach the torque motor supporter assembly and motor from the bracket. Torque supporter assembly setscrews Motor fixing screws Figure 5-11-1-3 Support Table Motor Assembly Replace the motor with a new one and reassemble the components in the reverse order of disassembly.
Page 174 Maintenance Guide 5-11-2 Adjusting the Gap between Torque Supporter Assembly and Support Table Motor The gap between the torque supporter assembly and support table motor must be adjusted to 1.1 1.1mm Figure 5-11-2-1 Gap between Torque Supporter Assembly and Support Table Motor 5-26...
Page 175 Maintenance Guide 5-11-3 Adjusting the Tension of the Support Table Driving Timing Belt To adjust the tension of the timing belt, loosen the fixing screw of the encoder bracket and move the assembly in the arrow direction, input the said values to the sonic belt tension meter (manufactured by UNITTA), measure the tension at the locations shown below, and then adjust the tension within the required range.
Page 176 Maintenance Guide 5-11-4 Placing the Support Table Surface Horizontally Use the HMS to measure the values at around the centers of the round marks shown below, and adjust the flatness of the support table so that difference at three locations is 0.02 mm or less. (Four locations for XL) Figure 5-11-4-1 Support Table Flatness Measurement Positions <Adjustment Procedure>...
Page 177: Replacing The Backup Stopper
Maintenance Guide 5-11-5 Reacquiring the Support Table Offset To require the support table offset, see the separate document, MS Parameters. 5-12 Replacing the Backup Stopper For the front and rear positions of the backup stopper, check that the dimension A shown in the Figure is 5 mm when the air is ON and the backup stopper (rubber part) is in contact with the outer periphery of the tension pulley flange.
Page 178: Replacing The Support Guide Cylinder
Maintenance Guide 5-13 Replacing the Support Guide Cylinder Detach the support table while referring to section 5-11, Replacing the Support Table Motor (Replacing the BU Table Motor). Remove the nuts and screws to detach the cylinder. (Two points on the left and right) Install the new cylinder on the support table and fix the nut so that the distance between the support table end and U_RELEASE_SUPPORT_BS is 22.5 mm at the position where the cylinder rod is extended.
Page 179: Switching The Conveyor Direction
Maintenance Guide 5-14 Switching the Conveyor Direction 5-14-1 Switching the Conveyor Direction 1) Switching WAIT 2 sensor ① There are two sensors at the center of conveyance, select either one according to flow direction. Left to right flow Use the sensor on the front left side of the unit. Right to left flow Use the sensor on the front left side of the unit.
Page 180 Maintenance Guide 2) Replacement of WAIT1 sensor and C-CUT sensor Replace the fibers inserted in the amplifier of C-OUT and that of WAIT1. (Emission and reception of light) Amplifier of WAIT1 Amplifier of C-OUT 5-32...
Page 181 Maintenance Guide WAIT1 のアンプ C-OUT のアンプ 5-33...
Page 182 Maintenance Guide 3) Relocation around the stopper ① Remove the stopper unit, stopper base, stopper base support. ② Assembled to the opposite side. The long hole of the stopper base is on the outside. Note the orientation of the long hole Stopper unit Relocation Stopper base...
Page 183 Maintenance Guide 4) To switch the conveyor direction, specify the desired direction in the “Basic specification” tab on the “MS Parameter > Initial setup > Mech specifications” window. After specified, reboot the main unit. 5-35...
Page 184: Replacing The Mechanical Stopper
Maintenance Guide 5-15 Replacing the Mechanical Stopper 5-15-1 Replacing the Stopper Sensor Disconnect the sensor cable connector. Replace the stopper sensor. Reassemble the components in the reverse order of disassembly. Light emitting surfaces Figure 5-15-1-1 Replacing the Stopper Sensor 5-36...
Page 185: Replacing The Stopper Cylinder
Maintenance Guide 5-15-2 Replacing the Stopper Cylinder Shut down the air to the main unit. Disconnect the air tubes that are connected to the cylinder. Remove the cylinder from the mechanical stopper body together with the stopper connect. Remove the stopper connector from the cylinder. Remove the fitting.
Page 186: Cal Block
Maintenance Guide 6. CAL BLOCK To prevent any trouble caused by accidental machine start, always DANGER shut-down the power before starting the maintenance and adjustment work. 6-1. Replacing the CAL Block Board Assembly 1) Disconnect two bounded cables  from the board. 2) Disconnect the φ4 air tube ...
Page 187: Replacing The Ejector
Maintenance Guide 6-2. Replacing the Ejector 1) Close the hand valve at the lower left portion of this main unit. 2) Disconnect the φ4 air tube  and φ6 air tube . 3) Disconnect the cable  of the CAL VCUM SV assembly. 4) Remove the mounting screws ...
Page 188: Atc
Maintenance Guide 7. ATC After the ATC base has been replaced, it is necessary to obtain “ATC Offset” of the MS parameters again. To prevent any trouble caused by accidental machine start, always DANGER shut-down the power before starting the maintenance and adjustment work.
Page 189 Maintenance Guide 4) 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 fit the nut supplied with the ATC cylinder to the ATC joint.
Page 190: Replacing The Atc Open And Close Sensors
Maintenance Guide 7-2. Replacing the ATC OPEN and CLOSE Sensors 1) Detach the sensor dog, and cut and remove the tie-up bands from the fixing base on the side of the ATC base. 2) Replace the ATC OPEN or CLOSE sensor assembly. 3) Secure the cables to the fixing base with the tie-up bands and assemble the sensor dog.
Page 191: Feeder Bank
Maintenance Guide 8 Feeder Bank To prevent any trouble caused by accidental machine start, DANGER always shut-down the air and the power before starting the maintenance and adjustment work. 8-1 Feeder Bank • Fixed bank • Exchange trolley...
Page 192: Replacing The Bank Pcb
Maintenance Guide 8-1-1 Replacing the Bank PCB Confirm that the air supply to the equipment is cut off, and remove the following 5 air tubes. Remove the fixing bolts (hexagon socket head cap bolt with washer M4 L=8) to detach the bank PCB cover.
Page 193 Maintenance Guide Remove the PCB mounting screws (round head screw with washer, M3 L=6) to replace the PCB. Bank Board retaining screws Round head screw with washer, M3 L=6 40183784 40183783 ELEC BANK R-SIDE PCB ASM ELEC BANK L-SIDE PCB ASM ∗...
Page 194: Replacing The Fdc
Maintenance Guide 8-1-2 Replacing the FDC Detach the PCB cover. (See Figure 8-1-1.) Cut off the cable tie-up bands. Remove the connector mounting screws. Refer to the following for the connector bundle, and replace the two connectors at the same time. Bundle wire Bundle wire Feeder position...
Page 195: Replacing The Slide Rail
Maintenance Guide 8-1-3 Replacing the Slide Rail Remove the fixing screws (round screws M4 L=10) to detach the slide rail. Assemble the slide rail according to the positioning pin. Secure with the fixing screws (round screws M4 L=10). (Tightening torque 1.3 N · m)
Page 196: Replacing The Bank Connector A (Exchange Trolley Only)
Maintenance Guide 8-1-4 Replacing the Bank Connector A (Exchange Trolley Only) Start the work after the exchange trolley has been removed from the machine main unit. ∗ Remove the cable fixing of the bank connector A. Disconnect the bank connector from the bank connector A bracket. Detach the bank connector A bracket from the bank.
Page 197: Replacing The Inline Filter (Exchange Trolley Only)
Maintenance Guide 8-1-5 Replacing the Inline Filter (Exchange Trolley Only) Start the work after the exchange trolley has been removed from the machine main unit. ∗ Disconnect the air tube that is connected to the inline filter. Detach the inline filter and replace the filter. ①...
Page 198: Bank Lifter
Maintenance Guide 8-2 Bank Lifter 8-2-1 Replacing the Mechanical Valve Disconnect the air tube that is connected to the elbow union. Remove the mechanical valve from the stopper bracket. Detach the elbow union and silencer, and then replace the mechanical valve. Reassemble the components in the reverse order of disassembly.
Page 199: Replacing The Bank Up Cylinder
Maintenance Guide 8-2-2 Replacing the Bank Up Cylinder Remove the flat head screw that secures the bank lifter and lifter shaft (hexagonal rod). Remove the cylinder fixing screws and pull the cylinder downward to remove the lifter shaft. Detach the speed controller and sensor from the cylinder, and then replace the cylinder. Reassemble the components in the reverse order of disassembly.
Page 200: Replacing The Selector
Maintenance Guide 8-2-3 Replacing the Selector Disconnect the air tube that is connected to the selector. 2） Remove the selector cap to detach the selector from the cover. Detach the elbow union, check valve, half-union, and silencer, and then replace the selector. Reassemble the components in the reverse order of disassembly.
Page 201: Replacing The Bank Connector B
Maintenance Guide 8-2-4 Replacing the Bank Connector B Remove the cover for the connector B. Remove the cable fixing until the relay connector, and then replace the bank connector B. Reassemble the components in the reverse order of disassembly. Connector cover Round screw M3 L=5 Hexagon socket head cap bolt M3 L=8...
Page 202: Replacing The Actuator Valve
Maintenance Guide 8-2-5 Replacing the Actuator Valve Disconnect the air tube that is connected to the actuator valve. Remove the actuator valve. Detach the half-union and elbow union, and then replace the actuator valve. Reassemble the components in the reverse order of disassembly. 8-2-6 Replacing the O-Ring Remove the ring holder, and then replace the O-ring.
Page 203: Replacing The Bank Limit Switch (En Only)
Maintenance Guide 8-2-7 Replacing the Bank Limit Switch (EN Only) Remove the cable fixing until the relay connector. Detach the bank limit switch and replace it. Reassemble the components in the reverse order of disassembly. Bank limit sensor Flat washer M4 Round head screw M4 L=25 8-13...
Page 204: Tape Cutter
Maintenance Guide 9 Tape Cutter To prevent any trouble caused by accidental machine start, DANGER always shut-down the air and the power before starting the maintenance and adjustment work. Only certificated service engineers are allowed to replace the DANGER movable cutter blade and fixed cutter blade. 9-1 Overall Drawing Chute Cutter (inside)
Page 205: Replacing The Tape Cutter Blade
Maintenance Guide 9-2 Replacing the Tape Cutter Blade Handle the cutter blade with great care. DANGER Please work with two or more people. ∗ Replace the cutter blade without lowering the cutter unit from the machine. Please prepare for falling of the blade using the following protective equipment. Reference protective equipment Face shield (with chin guard) (SWB 934 made by AS ONE) Shut down the main air of the main unit.
Page 206 Maintenance Guide Remove the fixing bolts (hexagon socket head cap bolt with washer M5 L=12) to detach the lower blade cover. Remove the left and right lower blade covers. Attach a protective tape (duct tape, etc.) to the blade face (total length 346 mm) of the lower blade.
Page 207 Maintenance Guide Attach a protective tape (duct tape, etc.) to the edge of the upper blade (total length 684 mm). Remove the fixing bolts (hexagon socket head cap bolt with washer M4 L=30) to detach the upper blade set. ∗ The fixed blade falls when removing the set screw. Always be sure that workers other than the operator who removes the fixing bolts support the upper blade and do not fall.
Page 208 Maintenance Guide Remove the fixing bolts (round screw M4 L= 6) from the upper blade set and remove the felt support and felt. 10) Assemble felt and felt support on new upper blade set. Fixing bolts (round screw M4 L= 6 2 locations) Apply the martemp grease to the felt as shown in the figure below.
Page 209 Maintenance Guide 12) Attach protective tape (gummed tape etc.) to the blade face of the lower blade. Assemble the left and right lower blades. The fixing bolts (hexagon socket head cap bolt with washer M5 L=12) ∗ Fix the tip corners of the left and right lower blades together. 13) Remove the protective tape attached to the blade face of the upper blade and the lower blade, and measure the clearance.
Page 210 Maintenance Guide (3) Select the shim with the value minus 0.1 mm from the measured clearance from the following. Apply a small amount of grease to the edge base mounting base mounting surface and paste it. (Left and right respectively) Part No.
Page 211 Maintenance Guide ② How to adjust the pressure using shims Add shims to the following places. The additional number of shims varies depending on the type of the cutter blade. Add shims as shown in the table below according to the specified insertion amount. Use the same shims as those used in the step 14).
Page 212 Maintenance Guide Add the shims at B to the position 100 mm from the end face of the cutter blade on the side opposite to A. Position it while pressing it against the screws fixing the cutter blade. Press it using the screws as reference. 10 mm Add the shims at C to the center of the right and left cutter blades.
Page 213 Maintenance Guide 17) Confirm the cut performance again. If there is a cut failure, return to the step 16) and check the number and positions of shims. Points to be checked at the time of cut failure are as follows. 1.
Page 214: Feeder Float Sensor
The feeder float sensors are laid out as follows. * Note that the feeder float sensor differs depending on the revision of the machine. ●RS-1 [Rev. N or earlier], RS-1XL [Rev. N or earlier], RS-1R [Rev. C or earlier] REAR...
Page 215 Maintenance Guide ●RS-1 [Rev. O or later], RS-1XL [Rev. O or later], RS-1R [Rev. D or later] REAR 40154796 CN13/28 Receive Emit CN13/31 40154797 CN13/33 40154796 Receive 40154797 CN13/27 Emit 40154796 CN13/25 Receive Emit CN13/29 40154797 CN13/25 40154796 40154797 CN13/29...
Page 216: Replacing The Light Receiving Side Sensor
Maintenance Guide 10-1-1 Replacing the old type sensor * Applicable to RS-1 [Rev. N or earlier], RS-1XL [Rev. N or earlier] and RS-1R [Rev. C or earlier]. 10-1-1-1 Replacing the light receiving side sensor 1) Cut the tie-up bands that secure the sensor cable to disconnect the connector.
Page 217 Maintenance Guide 4) Remove the fixing bolts (round head screw etc.) and replace the sensor. Hexagon nut（Sensor accessories） Spring washer（Sensor accessories） 40153419 “CHANGER_COLLAR” Washer（Sensor accessories） Screw（Sensor accessories） Fix at the position where the end face of the sensor is 0.25 mm from the end face of the bracket. 5) Fix the end of the sensor bracket to the mark.
Page 218 Maintenance Guide 10-1-2 Replacing the new type sensor * Applicable to RS-1 [Rev. O or later], RS-1XL [Rev. O or later] and RS-1R [Rev. D or later]. 1) Cut the tie-up bands that secure the sensor cable to disconnect the connector.
Page 219: Switch Related
Maintenance Guide 11 Switch Related To prevent any trouble caused by accidental machine start, DANGER always shut-down the power before starting the maintenance and adjustment work. 11-1 Replacing the Push-Button Switch Replacing the Push-Button Switch Front Rear ① Coplanarity laser power switch (Provided when the optional coplanarity is mounted.) ②...
Page 220 Maintenance Guide To detach the switch, first push the terminal cover toward the switch side to pull out the element. Remove the switch root part (mounting nut) from the rear of the cover and pull out the case from the cover surface to replace the switch. Reassemble the components in the reverse order of disassembly.
Page 221: Replacing The Emergency Stop Switch
Maintenance Guide 11-2 Replacing the EMERGENCY STOP Switch To detach the EMERGENCY STOP switch, check that no button on the operation unit is pressed, remove the lever stopper, and lay down the lock lever to release the lock. The contact unit is then detached from the operation part. After that, loosen the lock nut to detach the operation part.
Page 222 Maintenance Guide For the machine with the EN specifications, insert the switch whirl-stop (HA006260010). G part (Groove on Projection part (▲ mark) side non-screw part) ∗ Align the notch of the panel, the G part on the TOP TOP mark mark side of the operation unit, and the detent ▲...
Page 223: Replacing The Cover Open Switch
Maintenance Guide 11-3 Replacing the Cover Open Switch Disconnect the connector of the cover open switch ① from the relay connector. Cut the tie-up band and remove the M4 bolt to replace the cover open switch main unit ①. Reassemble the components in the reverse order of disassembly. ∗...
Page 224: Replacing The Safety Cover Lock Cylinder
Maintenance Guide 11-4 Replacing the Safety Cover Lock Cylinder [Removal] 1) Loosen the M4×10 SEMS cap bolts  (2 pcs.) and pull out the COVER  in the direction indicated by an arrow to detach it. 2) Remove the M6×12 SEMS cap bolts  (2 pcs.) to detach the SC_LOCK unit . SC_LOCK unit is located at 2 locations inside the machine main unit.
Page 225 Maintenance Guide [Assembly] 1) Assemble the SC_LOCK unit  with the M6×12 SEMS cap bolts  (2 pcs.). 2) At this time, adjust the clearance between the square hole in the main unit cover and the bottom of the SCL_HOOK  to 1 to 2 mm. ...
Page 226 Maintenance Guide 8) Turn OFF the lock of the safety cover through the operation screen to release the safety cover and move up the SC_LOCK_BRACKET . At this time, be careful not to move up the bracket excessively. When the bracket is moved up excessively, the conditions may become those stated in 6)_c). The reference position is the center of the slotted hole.
Page 227: Replacing The Assist Hinge
Maintenance Guide 11-5 Replacing the Assist hinge Assist hinges are arranged on the left and right inside the front and rear safety [Removal] Remove the left and right M5 x 10 SEMS cap bolts (6 pcs) and remove the safety cover. ①...
Page 228: Electrical Components
Maintenance Guide 12. Electrical Components 12-1 Layout of Electrical Components 1. Signal tower 2. LCD monitor 3. Operation panel 4. Head unit [Head main board assembly, Z/ZA/T-axis servo amplifier] 5. OCC camera, Vertical light board, Angle light board 6. Power switch 7.
Page 229 Maintenance Guide Figure 12-1-2 Rear View 11,12 Figure 12-1-3 Side View 12-2...
Page 230: Electrical Component Unit
Maintenance Guide 12-2 Electrical Component Unit 12-2-1 Electrical Component Unit A The electrical component unit A is mounted on the rear of the machine base frame. Figures 12-2-1-1-1 to 12-2-1-1-2 show the external view. Figures 12-2-1-1-3 show the configuration diagram. Figures 12-2-1-1-4 show the EU connection diagram.
Page 231 Maintenance Guide Table 12-2-1-1-1 Electrical Component Unit A ST <Part List> JUKI part No. Part name Q’ty Location Remarks HA006510000 CIRCUIT PROTECTOR (30A) HA00651000A CIRCUIT PROTECTOR (15A) HA006300000 MAGNETIC CONTACTOR HA006190000 MAGNETIC CONTACTOR K2&TH 12-4...
Page 232 Maintenance Guide Figure 12-2-1-1-4 PSU A WIRING DIAGRAM [ST] 12-5...
Page 233: Electrical Component Unit B
Maintenance Guide 12-2-2 Electrical Component Unit B The electrical component unit B is mounted on the bottom left of the machine base frame. Figures 12-2-2-1-1 to 12-2-2-1-2 show the external view. Figures 12-2-2-1-3 show the configuration diagram. Figures 12-2-2-1-4 to 12-2-2-1-6 show the EU connection diagram and POWER board circuit diagram The power supply unit B is composed of DC power supplies, control relays, and circuit protectors, and designed to supply the DC power to the units (head unit including the Zθ-unit, X-Y unit, bank,...
Page 234 Maintenance Guide Figure 12-2-2-1-2 Front View of Electrical Component Unit B (Front cover removal status) Figure 12-2-2-1-3 Rear View of Electrical Component Unit B 12-7...
Page 235 Maintenance Guide Figure 12-2-2-1-4 Electrical Component Unit B 12-8...
Page 236 Maintenance Guide Table 12-2-2-1-1 Electrical Component Unit B <Part List> JUKI part No. Part name Q’ty Location Remarks HA00650000A CIRCUIT PROTECTOR (20A) HA006500000 CIRCUIT PROTECTOR (30A) CP4, CP6, CP7 HA00542000B CIRCUIT PROTECTOR (8A) HB00128000C RELAY RL1, RL2, RL3 40128877 POWER PCB ASM...
Page 237 Maintenance Guide Figure 12-2-2-1-5 PSU B WIRING DIAGRAM 12-10...
Page 238 Maintenance Guide 12-2-2-2 Adjusting Method of DC Power Source Voltage Level Table 12-2-2-2-1 DC Power Source Voltage Level Settings Power Power Measurement terminals of power supply unit specifications symbol +48V CN2 Pin No. 4 (+48V) and Pin No. 8 (+48VRTN) +24V CN2 Pin No.
Page 239 Maintenance Guide ・ The DC power output voltage is adjusted using CN2 and PS4,PS5 of the electrical component unit. (For measurement locations, see Figure 12-2-2-2-1.) ・ Detach the switching power supply cover and adjust the output voltage variable change potentiometer of each DC power supply so that the DC power supply voltage become the specified adjustment values.
Page 240: Control Unit
Maintenance Guide 12-3 Control Unit Figure 12-3-1 shows the board layout drawing of the control unit. IPX-11 ASM 40133294 (BLANK) POSITION BOARD 40129648 IO CONTROL PCB ASM 40128871 CPU BOARD 40123242 Figure 12-3-1 Board Layout Drawing 12-13...
Page 241: Cpu Board (40123242)
Maintenance Guide 12-3-1 CPU BOARD (40123242) [Functions] This is a circuit board that controls the equipment totally. This circuit board is connected to other circuit boards by the Compact PCI (hereafter referred to as “cPCI”) bus. Additionally, this board communicates with the laser sensor LNC120 through its EtherNET port. SOLID STATE DRIVE 16GB (hereafter referred to as “SSD”) is mounted on this board.
Page 242 Maintenance Guide 12-3-1-1 Setting the Network Drivers Again after Replacement of CPU BOARD This work is needed when the combination of the CPU board and SSD is changed as the SSD that is not a copy disk has been replaced or the CPU board has been replaced. According to Windows specifications, if the combination of setting data inside the SSD and the CPU board is changed, the driver allocations of the network adapters are initialized and all drivers become the Intel drivers.
Page 243 Maintenance Guide Conduct the installation work for the network adapter of the “PCI bus 3”. The combination of the indication order and the number varies according to the machine. The indication is confusable such as “PCI Slot 2 (PCI bus 3, device 0, function 0)”. Conduct the work while checking the indication carefully.
Page 244 Maintenance Guide Select “Browse my computer for driver software”. Select [Let me pick from a list of device drivers on my computer.] 12-17...
Page 245 Maintenance Guide Select and install “Intel(R) 82574L Gigabit Network Connection #2 RTX Supported”. Start up [RTX Properties] from Control Panel. Select the [Hardware] tab and click the [Settings…] button in the “Devices” area. The device tree will appear. 12-18...
Page 246 Maintenance Guide There is one “Intel(R) 82574L Gigabit Network Connection” under RTX. Double-click the item and check the property. Check to make sure it is “PCI bus 3” and uncheck “Obtain line-based resources”. Then click OK, and the Pnp Device Settings dialog box will reappear. Click “Apply” on it. 12-19...
Page 247 Maintenance Guide Commit the C-drive. ewfmgr C: -commit In this step, Windows needs to be restarted. 10) Check that the installation has been completed. Select [Control Panel] -> [RTX Properties] -> [Hardware] tab and click the [Settings…] button in the “Device” area. The device tree will appear. Check to make sure again that there is one device under RTX.
Page 248 Maintenance Guide Check the properties of the network devices under RTX. Device is MSI and MSI-X capable and should work properly for message-based and extended message-based interrupts. When the message above is shown in the “Status” area, this means that the installation has been completed successfully.
Page 249: Io Control Pcb Asm (40128871)
Maintenance Guide 12-3-2 IO CONTROL PCB ASM (40128871) [Functions] This IO CONTROL board communicates with the control board arranged adjacent to each unit inside the machine through the serial communication. The I/O CONTROL board is connected to the cPCI bus at 32Bit/33MHz to perform the processes other than those directly controlled from the CPU board such as image processing and motion control.
Page 250 Maintenance Guide [Adjustment items after replacement] Execute [SSD ====> Flash] and back up the control data into IO CONTROL board from Application management > Control data management. 12-23...
Page 251: Position Board (40129648)
Maintenance Guide 12-3-3 POSITION BOARD (40129648) [Functions] This POSITION BOARD is applicable to the cPCI bus and intended to control servomotors through the SSCNET III/H, Mitsubishi Electric’s high-speed optical communication network. The POSITION board can control up to 40-axis servomotors per board. The POSITION BOARD is connected to the servo amplifier of each axis through daisy chain connections of optical fiber cables.
Page 252: Ip-X11 Set Gen Asm (49133294)
Maintenance Guide 12-3-4 IP-X11 SET GEN ASM (49133294) [Functions] This board is an image processing board that processes the images captured by the OCC, and VCS, such as board mark, IC mark, IC pin, and supply component before pickup to calculate the values necessary to correct the board position, component pickup position, and detect the supply component reversal.
Page 253: Superimpose Board (40129641)
Maintenance Guide 12-3-5 SUPERIMPOSE BOARD (40129641) [Functions] Part layout: This SUPERIMPOSE BOARD processes the images to impose the images captured by the camera on the Windows screen. The board is controlled from the CPU BOARD through the RS-232C. The control function not only imposes the images on the screen, but also changes the image signals, captures the touch panel control signals, and switches the CH...
Page 254: Atx Power Supply
Maintenance Guide 12-4 ATX Power Supply To avoid serious personal injury caused by electric shock, always turn OFF the main switch completely. Make sure that the main circuit breaker and main switch of the WARNING main unit are turned OFF. The main switch is a power switch mounted inside the building and does not mean a switch on the machine main unit.
Page 255: Battery Unit
Maintenance Guide 12-5 Battery Unit To avoid serious personal injury caused by electric shock, always turn OFF the main switch completely. Make sure that the main circuit breaker and main switch WARNING of the main unit are turned OFF. The main switch is a power switch mounted inside the building and does not mean a switch on the machine main unit.
Page 256: Xy-Driver Unit
Maintenance Guide 12-6 XY-Driver Unit The XY-unit consists of an amplifier for the X-axis that drives the X-axis motor and an amplifier for the Y-axis that drives the Y-axis linear motor. 12-6-1 Structure of XY Unit YL-axis YR-axis X-axis 40129654 40129654 40129652 12-29...
Page 257: Adjustment Items After Replacement Of Xy Driver
Maintenance Guide 12-6-2 Adjustment Items after Replacement of XY Driver When replacing the servo amplifier, it is necessary to set the axis selection with the rotary switch (SW1) on the servo amplifier of each axis. Open the front cover of the servo amplifier and turn the rotary switch (SW1) for the axis selection so that the arrow mark indicates the following set value.
Page 258: Z,T Unit
Maintenance Guide 12-7 Z,T Unit The Z unit is composed of an AC servo amplifier that drives the Z-axes. The T unit is composed of an AC servo amplifier that drives the T-axes. The servo amplifier for the Z-axis is a 3-axis integrated servo amplifier that one board can drive the 3 axes.
Page 259: Configuration Of 8-Nozzle Head
Maintenance Guide 12-7-1 Configuration of 8-Nozzle Head The following shows the relationship between each motor and servo amplifier, and each switch setting for the 8-nozzle head. Relationship of 8-Nozzle Head Axes Axis No. on amplifier Symbol Part No. Axis No. 1 Axis No.
Page 260 Maintenance Guide LED Indications Nine LEDs are mounted on the T-servo amplifier. The status indication by each LED is shown as follows. Indication No. LED name Operation color Lights up when any electric charge exists in the main circuit. CHARGE Shows the status of axis No.
Page 261 Maintenance Guide Seven LEDs are mounted on the Z-servo amplifier. The status indication by each LED is shown as follows. Indication No. LED name Operation color Lights up when any electric charge exists in the main circuit. LED7 Shows the status of axis No. 1. LED1 Green For details about the status expressed by the combination of LED1...
Page 262: Transport Unit
Maintenance Guide 12-8 Transport Unit 12-8-1 Structure of Transport Unit Figure 12-8-1-1 shows the structure drawing of the transport unit. 12,13 10,16 18,19 Figure 12-8-1-1 Side sensor L Support table origin sensor 17 Transport motor Side sensor R 10 Auto width adjustment origin 18 Stopper sensor L sensor BU pin detection sensor light...
Page 263: Connecting The Conveyor Board And Sensors
Maintenance Guide 12-8-2 Connecting the CONVEYOR Board and Sensors The connection destination boards of sensors are shown in Table 12-8-2-1, Cable Assemblies Connected to the CONVEYOR Board. Connect the sensors while referring to the table. Table 12-8-2-1 Cable Assemblies Connected to the CONVEYOR L Board Applicable cable CONVEYOR Connector...
Page 264 Maintenance Guide Table 12-8-2-1 Cable Assemblies Connected to the CONVEYOR R Board Applicable cable CONVEYOR Remarks Connector board Part No. Part Name 40129041 CN1002 AWC ENC/ORG RELAY (S) CABLE ASM ----- －－－－－－－－－－－－－－－ 40129039 AWC MOTOR (S) CABLE ASM CN1004 40182344 MOTOR DRIVER CABLE ASM CN1006 40182331 BU AXIS ENCODER CABLE ASM...
Page 265: Connecting The Transport Motor
Maintenance Guide 12-8-3 Connecting the Transport Motor The cables to be connected to the motors of the transport unit are shown in Table 12-8-3-1, Motor Assemblies and Connection Cables. Table 12-8-3-1 Motor Assemblies and Connection Cables Applicable cable Connection cable Part No.
Page 266: List Of Other Sensors, Solenoid Valves, And Cable Assemblies
Maintenance Guide 12-8-4 List of Other Sensors, Solenoid Valves, and Cable Assemblies The sensors, solenoid valves, and other cables currently used are shown in Table 12-8-4-1, List of Other Sensors, Solenoid Valves, and Cables. Table 12-8-4-1 List of Other Sensors, Solenoid Valves, and Cable Assemblies Applicable cable Connection destination Applicable...
Page 267: Conveyor Pcb Asm (40128875)
Maintenance Guide 12-8-5 CONVEYOR PCB ASM (40128875) The jumper switches and DIP switches on the CONVEYOR board assembly used in the transport unit have already been set at delivery. However, check that they are set as shown below before setting the CONVEYOR board assembly in the transport unit.
Page 268: Adjusting The Stepping Motor Driver
Maintenance Guide 12-8-6 Adjusting the Stepping Motor Driver A stepping motor is used for the transport motor and auto width adjustment motor of the transport unit. To rotate the stepping motor correctly, it is necessary to adjust the 5-phase stepping driver. •...
Page 269 Maintenance Guide 12-8-6-2 Setting the Support Table Axis Driver (Servo Motor Driver) The support table axis driver, The parameters have already been written. Therefore, no setting is needed. Figure 12-8-6-2-1 shows the outside view of the support table axis servo driver. Figure 12-8-6-2-1 Support Table Axis Servo Driver One LED that shows the status is mounted on the servo driver.
Page 270 Maintenance Guide Table 12-8-6-2-2 List of Support Table Axis Servo Driver Alarm Codes Alarm Name Contents Occurrence status Major cause code This alarm occurs only when turning The driver is faulty. ON the power. The motor wiring is short-circuited. This alarm occurs when turning ON The motor winding is Over Error or overcurrent in...
Page 271: Safety Pcb Asm (40128872)
Maintenance Guide 12-9 SAFETY PCB ASM (40128872) [Functions] Various sensors for monitoring the safety inside the machine, operation switches, and signal tower are connected to the SAFETY board to monitor the statuses of various sensors or switches or control the signal tower lighting, cover, or lock. Additionally, this board transfers the emergency stop information or limit information to the XY-servo amplifier and POSITION BOARD to control the urgent stop of the XY-axis.
Page 272 Maintenance Guide [Switch settings] The switch 3 is intended for the special-order. So, this switch is used with the default settings. The switch 4 is intended for the function revision. So, this switch is used with the default settings. [Meaning of LED] LD1: When this LED is lit, this shows that +5V used in the board is correct.
Page 273: Head Unit
Maintenance Guide 12-10 Head Unit 12-10-1 HEAD MAIN PCB ASM (40128873) [Functions] Lights up or goes off each light unit for the OCC and adjusts the light quantity. ① (Only either the left or right light goes on.) Changes the image signals of the left and right OCCs. ②...
Page 274: Head Relay Pcb Asm (40128874)
Maintenance Guide 12-10-2 HEAD RELAY PCB ASM (40128874) [Functions] Acquires the vacuum sensor value. ① Acquires the θ-origin line sensor value. ② Acquires the nozzle up sensor value. ③ Operates the solenoid valve for the vacuum. ④ Operates the solenoid valve for the blow. ⑤...
Page 275: E Bank Relay Pcb Asm (40128876)
Maintenance Guide 12-11 E BANK RELAY PCB ASM (40128876) 12-11-1 Outside View of Board Figure 12-11-1-1 shows the outside view of E BANK RELAY PCB ASM. Use this outside view as reference for the switch settings and volume adjustment described in the following sections.
Page 276: Others
[DIP switch settings] The SW2 is intended for the function REV check. The SW3 is a switch for switching front/rear when using this board with other models. RS-1 is with the following settings. SW3 setting SW-1 ：OFF SW-2 ：OFF SW-3 ：OFF...
Page 277: Replacing The Filter Element
Maintenance Guide 12-12-2 Replacing the Filter Element Close the finger valve knob. Close status Open status Turn the knob 45° left or right while pushing it to pull it out downward. Turn the resin part left that secures the filter element B to detach the filter element B, and turn the filter element A left to detach it.
Page 278: Replacement Of Vacuum Pump Parts
Maintenance Guide 12-12-3 Replacement of Vacuum Pump Parts A pressure drop may have been caused by abrasion of the following parts. <Table of consumables> Replacement parts set No.: 40138045 Check Quantity Check point How to check Cup packing Abnormal abrasion, hardening, and crack Visual check Cylinder gasket Deformation, abrasion, crack...
Page 279 Maintenance Guide Disconnect the air tubes and power connector from the vacuum pump and loosen the hexagon socket head cap bolts (M6 ×2) that secure the vacuum pump bracket to detach the pump support. Air tube Pump support Hexagon socket head cap bolt (M6 × 2) Power connector 12-52...
Page 280 Maintenance Guide Take out the vacuum pump from the main unit. ∗ When taking out the vacuum pump, pull out ① toward the front and lay down ② slightly toward the rear to pull out ③ toward the front. ∗ When detaching the vacuum pump, do not hold the connection pipe. Hexagon socket head cap bolt (M6 ×...
Page 281 Maintenance Guide Replacing the gasket  Remove the 4 hexagon socket head bolts (M6 × 95) (8 pieces in total on the left and right sides) of the pump head cover. Remove two black gaskets in the pump head cover and replace it with new ones. ∗...
Page 282 Maintenance Guide Replacing the suction exhaust valve  Detach the valve holder. Detach the suction exhaust valve and replace it with a new one. ∗ Install the cover according to the procedure for replacing the gasket. To replace other consumables, do not close the cover but refer to the item of replacing each portion. Valve holder Suction exhaust valve...
Page 283 Maintenance Guide Replacing the cylinder gasket  Detach the cylinder plate. Detach the cylinder gasket and replace it with a new one. ∗ Install the cover according to the procedure for replacing the gasket. To replace other consumables, do not close the cover but refer to the item of replacing each portion. Cylinder plate Cylinder gasket 12-56...
Page 284 Maintenance Guide Replacing the cup packing  Detach the cylinder. Remove the hexagon socket head cap bolts (M8 × 20). Detach the cup packing holder and replace the cup packing with a new one. Carefully check the orientation of the cup packing. Fit the connecting rod. After replaced, tighten the hexagon socket cap bolt (M8 ×...
Page 285 Maintenance Guide Vacuum pump pressure apartment diagram Name Name Hexagon socket head bolt (M6×95) Cylinder gasket 8pcs. Pump head cover-1 Cylinder Coupling pipe Hexagon socket head bolt (M8×20) O-ring P-10 Cup packing holder Pump head cover-2 Cup packing Gasket Connecting rod Valve holder Suction exhaust valve Cylinder plate...
Page 286: Other Units
Maintenance Guide 13. Other Units To prevent any trouble caused by accidental machine DANGER start, always shut-down the power before starting the maintenance and adjustment work. 13-1 LCD Monitor 13-1-1 Replacing the LCD Monitor 1) Disconnect the connectors (3 locations) from the LCD monitor. 2) Remove the thumb screws and shoulder screws from the LCD bracket F to detach it from the machine.
Page 287: Setting Up The Touch Panel
Maintenance Guide 13-1-2 Setting Up the Touch Panel 1) Touch the LCD monitor at the positions ①, ② and ③, in this order, as shown in the figure. Then the OSD appears. ② ① ③ 2) Use “+” and “−” of the OSD to move the cursor to “Touch Panel”. 13-2...
Page 288 Maintenance Guide 3) Next, use “Select” of the OSD to move the cursor to “Manual Calibration”. 4) Then operate “Select” and a “+” mark appears on the screen for the calibration. “+” is shown at the upper left corner of the screen. Touching the center of “+” will give the buzzer sound.
Page 289 Maintenance Guide 5) After you touch all the four “+” marks, the screen returns to the following one. Operate “Exit” to finish the OSD. This completes the operation. CAUTION To adjust the touch panel, use finger or touch pen with a round tip. Do not use any propelling pencil or sharp object.
Page 290: Replacing The System Disk
Maintenance Guide 13-2 Replacing the System Disk In the RS-1, the system disk configuration is stored into the Solid State Disk (hereafter referred to as “SSD”). The inside of the SSD is separated into two portions, “C-drive” that contains Windows or operating system, such as RTX, and “D-drive”...
Page 291 Maintenance Guide 13-2-1-2 Replacing Procedures 1) Detach the CPU BOARD ① from the control unit. 2) Remove the screws ③ from the bottom of the board and pull out the SSD ② from the connector CN8. 3) Detach the studs ④ from the SSD. 4) Reassemble the components in the reverse order of disassembly.
Page 292: Setting Up The Network
Maintenance Guide 13-2-2 Setting Up the Network (Setup is required when communicating with the JaNets To use the communication between the RS-1 and the JaNets, it is absolutely necessary to set up the network. <Setting procedures> ① Setting up the TCP/IP ②...
Page 293 Maintenance Guide 13-2-2-1 Setting Up the TCP/IP 1) From the [Start] button, select [Control Panel]. 2) Select the [Network and Sharing Center] icon from the control panel. 3) The “Network and Sharing Center” dialog box appears on the screen. Select the [Change adapter settings]. 13-8...
Page 294 Maintenance Guide 4) The "Network Connections" dialog box will appear. Four "Local Area Connection" icons are displayed. So, follow the steps below to find a device that is used for external communication, such as JaNets, etc. (Since the No. at the end of the [Local Area Connection] item may vary depending on the machine, this No.
Page 295 Maintenance Guide 7) A device with [PCI bus 1, device 0, function 0] set in the “Location” area is used for the external communication. So, repeat steps 5) ad 6) until relevant device is found. When relevant device is found, move to the next step. There is an indication that easily causes a mistake like “PCI Slot 1 (PCI bus 2, device 0, function 0)”, but this is a different device.
Page 296 Maintenance Guide 10) The “Internet Protocol Version 4 (TCP/IPv4) Properties” dialog appears on the screen. On this window, click the “Use the following IP address” ① and specify the “IP address,” “Subnet mask” ②. Additionally, input [ 255.255.255. 0 ] to [Subnet Mask]. If necessary, set the “Default gateway”...
Page 297 Maintenance Guide 13-2-2-2 Setting Up a Shared Folder You may set up a shared folder for the network communication. In this description, create “D:¥machine¥Prg” folder under the D drive and make the setting to share the Prg folder. 1) Start up Explorer. 2) Open the [drive D].
Page 298 Maintenance Guide 6) The “File Sharing” dialog box will appear. Input “Everyone” by opening the combo-box ① or through the direct input, and then click [Add] ②. ② ① 7) On the screen above, [Permission Level] of Everyone is set at “Read” with the default setting. Click this portion to select [Read/Write].
Page 299 Maintenance Guide 13-2-2-3 Registering a User You may register a user name and password, which you must input to start up the PC (personal computer) where the JaNets has been installed. 1) Check the user name and password, which are used to start up the PC. 2) Select the “User Accounts”...
Page 300 Maintenance Guide 4) The “Manage Accounts” dialog box appears on the screen. Select “Create a new account” from the menu. 5) The “Create a new account” dialog box will appear. Input a user account name and select “Administrator”, and then click [Create Account]. ∗...
Page 301 Maintenance Guide 6) The screen returns to the “Manage Accounts” dialog box and the account is then added. Select the user account you have created. 7) The screen that allows you to change the account settings appears on the screen. Select the item “Create a password”.
Page 302 Maintenance Guide 8) The “Create Password” dialog box will appear. To set a new password and check it, input the same password twice. Input a hint for the password (as necessary) and click the [Create password] button. ∗ The default password of the JaNets client PC is “is_user_2008”. After you have finished all necessary settings, perform the update operation of the “C”-drive described in Section 13-2-3-2.
Page 303: System Programs
Maintenance Guide 13-2-3 RS-1 System Programs The RS-1 system disks are composed of RS-1 main unit system disks. 13-2-3-1 Installing the RS-1 System Programs 1) Prepare the USB memory or other media containing the system program installation files. 2) Click the [Start] button of Windows and run Explorer from Programs in the Start menu.
Page 304 Maintenance Guide 4) When running “Setup.Exe”, the “Preparing to Install…” screen will appear. This screen will disappear quickly and the operation automatically moves to step 5). 5) The “Welcome to the InstallShield Wizard” screen will appear. Clicking the [Next] button will move to step 6). 13-19...
Page 305 Maintenance Guide 6) The “Confirmation” screen for the License Agreement will appear. Check on [I accept the terms in the license agreement] and click the [Next] button to move to step 7). (If you do not agree with the license agreement, you cannot advance the operation further.) 7) The Confirmation prior to installation screen will appear.
Page 306 Maintenance Guide 8) The progress status is shown using the progress bar during installation. 9) When the installation is completed, the “InstallShield Wizard Completed” screen will appear. Click the [Finish] button to complete the installation. 13-21...
Page 307 Maintenance Guide 13-2-3-2 Updating the C-drive This system uses the C-drive write-protect function called “EWF”. If the system is installed or if the setting, such as network setting is changed, it is necessary to update the C-drive. 1) Click the [Start] button of Windows and run Command Prompt from Programs in the Start menu. 2) In the Console window (DOS screen), type “ewfmgr.exe c: -commit”.
Page 308 Maintenance Guide 13-2-3-3 Loading the Backup Data to the Hard Disk Drive (Restoring the backup data) Always start the home position return of the machine after CAUTION the backup data has been restored. Failure to do so may cause system runaway. Select [File] and [Control Date Management...] to restore the control data in the SSD.
Page 309 13-2-3-4 Changing the OS Language (Perform this work only when necessary.) The OS language change is written into the C-drive. In the RS-1, the C-drive update operation is performed using the main unit software. Therefore, it is not necessary to update the C-drive beforehand.
Page 310 Maintenance Guide 3) The “Safety direction setting” dialog box will appear. Click the [OK] button. 4) The “Exit” dialog box will appear. Click the [OK] button. (As this operation is performed, the OS will be shut down automatically.) Subsequently, the OS is started up with the specified language. 13-25...
Page 311: Upgrading The Rs-1 System Version
Maintenance Guide 13-2-4 Upgrading the RS-1 System Version The following describes the upgrading steps to install the RS-1 system with a new version onto the RS-1 system with any existing version. 1) Prepare the USB memory or other media containing the system program installation files.
Page 312 Maintenance Guide 4) The “Preparing to Install…” screen will appear. This screen will disappear quickly and the operation automatically moves to step 5). 5) The “Welcome to the InstallShield Wizard” screen will appear. Clicking the [Next] button will move to step 6). 13-27...
Page 313 Maintenance Guide 6) The screen will appear that allows you to select the mechanism control parameter initialization and existing software backup. <Mechanism control parameter initialization> (Do you renew Mech Control Parameter?) Mechanical control parameters are initialized and the default values are set. Currently set mechanical control parameters are succeeded to a new version.
Page 314 Maintenance Guide 7) If you have selected [Yes] in the “Is the existing soft backup performed?” area in step 6), the Existing software backup screen will appear. 8) The progress status is shown using the progress bar during installation. 13-29...
Page 315 Maintenance Guide 9) When the installation is completed, the “InstallShield Wizard Completed” screen will appear. Click the [Finish] button to complete the installation. 10) Follow the steps stated in section 13-2-3-2, Updating the C-drive, to update the C-drive. ∗ CAUTION If the system is started up again without updating of the C-drive, the installation information is cleared from the C-drive due to C-drive protect function, causing the system not to be started up correctly.
Page 316: Mcafee Embedded Control
As the “white list” system is used, the software cannot be installed into the mounter or the execution file cannot be changed while the MEC is running. The RS-1 uses the MEC as standard. Since the MEC is incorporated into the master disc, no work, such as installation, etc. is needed.
Page 317: Janets (Ism/Mes Cooperation) Option
Maintenance Guide 13-3 JaNets (ISM/MES Cooperation) Option To prevent any trouble caused by accidental machine start, DANGER always shut-down the power before starting the maintenance and adjustment work. 13-3-1 Replacing the Bar-code Reader <Work procedures> 1) Remove the USB cable from the USB port (front) and USB connector bracket (rear) of the mounter.
Page 318: Operation Check After Replacement
Maintenance Guide 13-3-2 Operation check after Replacement <Work procedures> 1) Turn on the power supply of the mounter. Make sure that “bleep, bleep, bleep” is output after the green operation display LED of the bar-code reader blinks. 2) Turn the bar-code reader toward the plane of the mounter cover. Then, make sure that the aiming mark shown in the following figure is irradiated.
Page 319: Initial Setting After Replacement (Pick Mode)
Maintenance Guide 13-3-3 Initial setting after replacement (pick mode) To increase the read accuracy of the barcode reader, perform the following setting (pick mode). <Operating procedure> 1) Connect the barcode reader to the mounter (front). After the operation display LED of the barcode reader blinks in green, the buzzer sounds like “bleep, bleep, bleep, bleep”...
Page 320: Tape Setting Unit
Maintenance Guide 13-4 Tape setting unit Turn off the power supply in the first place to prevent an DANGER accident due to an unexpected start. 13-4-1 Replacement of the connector cable 1) Cut the harness band of the connector cable. 2) Remove the set screw of the connector.
Page 321: Vcs
Maintenance Guide 14 VCS 14-1 Replacing the VCS Cylinder (Up-Down cylinder) Turn OFF the power to the machine main unit. (All work steps to be performed in Chapter 14 except for camera adjustment are performed with the power turned OFF.) (If such work is performed with the power turned ON, this is very hazardous and may cause the machine to malfunction.) Remove the cover of the VCS frame (hereinafter referred to as a box).
Page 322 Maintenance Guide Remove the air tube outside the box from the Y union. Remove from Y Union location Figure 14-1-3 Removing the air tube Loosen SL 6051492 TN × 4 pieces and remove the entire box. Figure 14-1-4 Removing the VCS frame 14-2...
Page 323 Maintenance Guide Remove the nut with a spanner (use two spanners) and remove the upper unit. Figure 14-1-5 Removing the VCS upper unit 14-3...
Page 324 Maintenance Guide Cut the tie-up bands of the air tube, remove the cylinder together with the air tube, and attach the new cylinder. Cut the tie-up bands fixing the air tube. Figure 14-1-6 Removing the air tube Figure 14-1-7 Removing and assembling the cylinder 14-4...
Page 325 Maintenance Guide After assembly, please confirm that the operation of the light unit is smooth. If there is a malfunction in operation, please adjust the position of the linear bush and shaft. * Adjust the cylinder rod so that the size of a gap between the frame and the sub frame can be 22.4 mm when the cylinder moves up.
Page 326: Replacing The Vcs Sensor (Up-Down Sensor)
Maintenance Guide 14-2 Replacing the VCS Sensor (Up-Down sensor) Remove the VCS cover and disconnect the relay connector of the sensor cable. Remove the VCS sensor bracket and replace the sensor. After changing the sensor, check that the speed of ascending and descending is within the specified value.
Page 327: Replacing The Vcs Camera Switching Cylinder
Maintenance Guide 14-3 Replacing the VCS camera switching cylinder Remove the VCS cover. Remove the air tube and cylinder sensor. Remove the fixing of the VCS slider part and replace the cylinder. After assembly, check that the movement of the light unit is smooth. If there is a malfunction in operation, adjust the mounting position of the cylinder.
Page 328 Maintenance Guide 14-4 Replacing the VCS Light Unit Assembly (Detach as shown in Figure 14-4-1.) Figure 14-4-1 Exploded View of Light Unit Part No. Part name Q’ty 40183370 Light stay V ① 40180852 S-bottom light board ② 40111657 Bottom light diffuser ③...
Page 329: Replacing And Adjusting The Camera
Maintenance Guide 14-5 Replacing and Adjusting the Camera Follow the steps described in section 14-1 to raise the VCS box. Remove the screws (SM6041402TN) that secure the lens holder shown in Figure 14-5-1 to detach the lens holder. See also the Figure below. Figure 14-5-1 Top View of VCS Camera and Base 14-9...
Page 330 Perform the scaling and offset of the VCS. See the QA Table. Note Do not loosen the screw (SL6042592TN) that holds the lens holder and the lens pin screw. Otherwise, the machine becomes beyond the scope of JUKI's guarantee. Do not loosen. Figure 14-5-2 VCS Camera 14-10...
Page 331 Maintenance Guide When installing a high-resolution camera, the camera layout will be the following 3 patterns. Note the camera assembly position. ① Left side: 54 mm Camera + Right side: 27 mm high-resolution camera ② Left side: 54 mm Camera + Right side: 10 mm high-resolution camera ③...
Page 332: Solder Recognition And Placement Position Correction
Maintenance Guide 15 Solder Recognition and Placement Position Correction To prevent any trouble caused by accidental machine start, DANGER always shut-down the air and the power before starting the maintenance and adjustment work. 15-1 Replacing the Solder Recognition Light Board Unscrew the flat head machine screws and remove the board spacer, LIGHT DIFFUSER and the OCC O board.
Page 333: Light Quantity Of The Solder Recognition Light
Maintenance Guide 15-2 Light Quantity of the Solder Recognition Light Check to make sure that both the solder recognition light and the OCC light go on with manual control. Implement the “Adjustment of OCC light quantity” of the MS parameter. When using an optional solder recognition light, adjust the reference current value so that ①...
Page 334: Load Cell
Maintenance Guide 16 Load Cell To prevent any trouble caused by accidental machine start, DANGER always shut-down the air and the power before starting the maintenance and adjustment work. 16-1 Replacing the Load Cell According to the functions of the load cell, it is necessary to match the serial No. of the load cell to that of the load cell amplifier.
Page 335 Maintenance Guide Load cell For the assembly direction, the arrow mark is faced downward. Washer assembled hexagon socket head cap bolt M4, L=16 Load cell base Brazier hexagon socket head cap bolt M6, L=10 Load cell amplifier Washer assembled hexagon socket head cap bolt M4, L=8 →...
Page 336: Coplanarity Sensor
Maintenance Guide 17 Coplanarity Sensor To prevent any trouble caused by accidental machine start, DANGER always shut-down the air and the power before starting the maintenance and adjustment work. The layout of the coplanarity power supply, CPU board, and monitor change-over board inside the electrical component unit is as shown in the Fig.
Page 337: Replacing The Sensor
Maintenance Guide 17-1 Replacing the Sensor Detach the trash guide on the rear and the bottom cover (bank cover C_F). Disconnect each cable from the lower portion of the sensor. * It is not necessary to disconnect the cables that come from the inside of the sensor. Remove the sensor fixing screws to replace the sensor.
Page 338 Maintenance Guide Coplanarity sensor Hexagon bolt M8, L=20 Sensor base Reference hole (lower side) Reference pin (jig) φ6, L=28 Removal is not needed. 17-3...
Page 339: Changing The Ip Address Of The Coplanarity Cpu
Maintenance Guide 17-2 Changing the IP Address of the Coplanarity CPU When setting the IP address of the coplanarity CPU, make the setting while referring to the cautions on the TCP/IP setting in section 13-2-2, Setting Up the Network (Setup is required when communicating with the JaNets.).
Page 340: Changing The Coplanarity Cpu Setting
Maintenance Guide 17-2-3 Changing the Coplanarity CPU Setting Turn ON the mounter power. Put the machine in the operation status that only Windows is running. Open [Control Panel] from the [Start] menu. Select [Network and Sharing Center] in the “Control Panel” window. The “Network and Sharing Center”...
Page 341 Maintenance Guide Only one local connection is displayed. Select it. (The number at the end varies every time the CPU is replaced.) The “Local Area Connection Properties” window will appear. Select [Properties]. [About “Local Area Connection” that is displayed when the LAN cable is disconnected from “LAN4”.] [Local Area Connection] is the network setting for the communication between the coplanarity sensor and coplanarity...
Page 342 Maintenance Guide The “Local Area Connection Properties” window will appear. Select [Internet Protocol Version 4 (TCP/IPv4)] and click the [Properties] button. ① ② The “Internet Protocol Version 4 (TCP/IPv4) Properties” window will appear. Set the IP address and subnet mask you have prepared for the coplanarity CPU board in the “IP address”...
Page 343 Maintenance Guide 11) Update the C-drive of the coplanarity CPU board. Run the command prompt and input “ewfmgr_C:_-commit (_ shows a space.)”. Press the Enter key. Shut down the coplanarity CPU board from the [Start] menu. At this time, do not turn OFF the power to the main unit. The C-drive of the coplanarity CPU board is not updated unless the coplanarity CPU board is shut down.
Page 344: Changing The Mounter Setting
Maintenance Guide 17-2-4 Changing the Mounter Setting Set the coplanarity network setting using [Machine Setting]. From the menu on the desktop screen, select [Setting]-[Machine Setting]. The Machine Setting will start up. From the [Machine Setting] menu, select [Unit Setting]-[Coplanarity]. 17-9...
Page 345 Maintenance Guide The “Coplanarity” dialog box will appear. Input the IP address and subnet mask for the coplanarity CPU board set on the coplanarity CPU board in the [IP Address] and [Subnet mask] fields of [Coplanarity Network Setup]. Click the [OK] button to exit the setting. Save the machine setup and exit the window. ①...
Page 346 Maintenance Guide Put the mounter in a status that the RS-1 system is terminated and only Windows is running. Open [Control Panel] from the [Start] menu. Select [Network and Sharing Center] in the “Control Panel” window. The “Network and Sharing Center” window will appear.
Page 347 Maintenance Guide The “Local Area Connection Status” window will appear. Select [Properties]. 10) The “Local Area Connection Properties” window will appear. Select [Internet Protocol Version 4 (TCP/IPv4)] and click the [Properties] button. ① ② 11) The “Internet Protocol Version 4 (TCP/IPv4) Properties” window will appear. Set the IP address and subnet mask you have prepared for the mounter in the “IP address”...
Page 348 Maintenance Guide 12) Connect the LAN cable you have disconnected to “LAN4” of the mounter CPU. 13) When the screen returns to the “Local Area Connection Properties” window, click the [OK] button to close the “Local Area Connection Properties” window. 14) When the screen returns to the “Local Area Connection Status”...
Page 349: Cvs
Maintenance Guide 18 CVS To prevent any trouble caused by accidental machine start, DANGER always shut-down the air and the power before starting the maintenance and adjustment work. 18-1 Changing the CONTACT SUB UNIT You can change the CONTACT SUB UNIT without detaching the CVS unit when performing the work from the rear.
Page 350 Maintenance Guide Washer assembled hexagon socket cap bolt M6, L=16 * Carefully check the assembly position. Cable connection (2 cables) CVS unit CVS base Rear side CONTACT SUB UNIT CVS cover Flat head screw M3, L=5 18-2...
Page 351 Maintenance Guide Washer assembled hexagon socket head cap bolt M3, L=5 CONTACT SUB UNIT - side + side (Rear) Cable on probe side (Front) Cable on board side Washer assembled round head When checking the insulation screw M3, L=6 with a multi-meter, disconnect the connector connections.
Page 352: Changing The Cvs Board
Maintenance Guide 18-2 Changing the CVS Board Detach the CVS cover. For details about how to detach the CVS cover, see section 18-1, Changing the CONTACT SUB UNIT. Disconnect the connector, remove the spacers and screws, and change the board. Reassemble the components in the reverse order of disassembly.
Page 353: Nozzle Rfid Reader
Maintenance Guide To prevent any trouble caused by accidental machine start, DANGER always shut-down the air and the power before starting the maintenance and adjustment work. 19 Nozzle RFID READER 19-1 Changing the RFID READER/WRITER Detach the chip box and the RFID READER cover. Chip box Washer assembled hexagon socket RFID READER cover...
Page 354 Maintenance Guide Detach the RFID READER/WRITER and replace it with a new one. Washer assembled hexagon socket cap bolt M3 L=8, 6 locations Reassemble the components in the reverse order of disassembly. * Make assembly so that the top surface of the RFID READER/WRITER main unit and that of the CAL plate are flush.
Page 355: Appendix Jig Lists
Maintenance Guide RS-1 Appendix Jig Lists Part No. Part name Purpose Figure Remarks 40128108 Camera Adjustment of OCC focus Common for adjustment jig RX-6/RX-6B/RX-6R OCC camera offset board VCS camera focus offset E2107998000 Ceramic board Adjustment of OCC Common for...
Page 356 Adjustment of VCS light Common for jig plate D quantity KE-3000 series assembly 40183425 Nozzle Adjustment of VCS light Dedicated to RS-1 assembly 7505 quantity 40011453 CAL piece G VCS camera scaling Common for RX-6 / RX-6B / RX-6R 40183428...
Page 357 KE-3020VRA 40001312 Shim, t0.3 Laser offset E3021721000 Shim, t0.03 Laser offset 40231988 Nozzle Check of nozzle Exclusively inspection jig engagement designed for an RS-1 Polishing of the nozzle mounting part 40241829 Bank jig Removal of bank unit assembly...
Page 358: Appendix List Of Measuring Instruments
Maintenance Guide RS-1 Appendix List of Measuring Instruments Required Intended Instrument name Photo Remarks specifications units/Applications Scale Scale interval: Common to all units 0.5 mm Calipers Scale interval: Common to all units 0.05 mm Lever type dial Scale interval: Common to all units gauge 0.01 mm...
Page 359 Maintenance Guide Required Intended Instrument name Photo Remarks specifications units/Applications Loctite 243 Medium Common to all units strength Keyboard with Network setup mouse function system program Level vial Sensitivity: Main unit/Leveling 1 pc. 0.05 mm/m (Setup) Recommended level vial: AD102 Obishi Keiki Seisakusho Spanner for level With across...
Page 360 Revision record  Rev. Date Revised locations Revision contents Remarks Jan. 2017 First edition Apr. 2017 Chapter 8 Step2 Revised Chapters 13, 15, 16, 17 and 18, Jul. 2017 Step3 Revised Jig Lists Oct. 2017 Chapters 3 and 4 Description added. Revised Dec.
Page 361 MANUFACTURER INQUIRY SMT TRAINING CENTER 2-11-1, Tsurumaki, Tama-shi, Tokyo 206-8551, JAPAN PHONE: 81-42-357-2295 https://www.juki.co.jp/ Copyright © 2017-2020 JUKI CORPORATION The specification and appearance may be changed without notice. All rights reserved throughout the world. Original Instructions 2020.03 Printed in Japan...

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