Dover UniversaL 4797X Instruction Manual
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Dover UniversaL 4797X Instruction Manual

Dover UniversaL 4797X Instruction Manual

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0503-002 AIJ01EOPP
INSTRUCTION MANUAL
4797X 4797R
Volume 1 : Operation (Operator)
UIC MANUAL ID No. 50112801
This instruction manual can be used only for the machines whose
rating plates have manufacturing Nos. that end with "D".
Read this instruction manual carefully and keep it at hand.
• Before operating the machine, read these safety instructions
carefully and fully understand them.
• Always keep this instruction manual carefully at hand to refer it
anytime and anywhere.

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Summary of Contents for Dover UniversaL 4797X

  • Page 1 INSTRUCTION MANUAL 4797X 4797R Volume 1 : Operation (Operator) UIC MANUAL ID No. 50112801 This instruction manual can be used only for the machines whose rating plates have manufacturing Nos. that end with "D". Read this instruction manual carefully and keep it at hand. •...
  • Page 2 INSTRUCTION MANUAL 4797X 4797R Volume 1 : Operation (Operator) The instruction manual of this machine is made up of six separate volumes and is compiled especially for those who operate the machine. Please read this manual carefully for correct operations and pay special attention to safety precautions.
  • Page 3 Before using this manual, please note the following items. 1. The contents of this manual are subject to change for improvement without prior notice. Please pay attention to the latest information that will be provided or issued by our company. 2.

  • Page 4: Before Use

    Before Use We are grateful to you for purchasing our direct-drive turret mounter (chip mounter). This instruction manual describes the functions, handling, and operations of the machine for those who have finished the basic training of the chip mounter. Before operating the machine, please read this instruction manual carefully to fully understand the instructions and precautionary measures for safety purposes.

  • Page 5: About The Instruction Manual

    About the Instruction Manual This instruction manual is divided into the following six volumes (booklets) on subjective basis. Volume 1: Operation (Operator) This describes the fundamentals for those who read this INSTRUCTION MANUAL instruction manual and use the component placement machine 4797X 4797R for the first time.
  • Page 6 Volume 5: Pneumatic and Electrical Diagrams This provides various kinds of material such as pneumatic INSTRUCTION MANUAL and electrical circuit diagrams for those who are in charge of 4797X or 4797R machine servicing operations. Volume 5 : Pneumatic and Electrical Diagrams Coverage: This covers the checking items, the safety precautions, the pneumatic diagram, the parts location, and the electrical circuit diagrams, etc.
  • Page 7 0412-001 AIJ01E-P...

  • Page 8: Caution And Warning

    Caution and Warning Limited Warranty UIC represents and warrants the following based on the specifications in the instruction manual as long as this machine is used in accordance with the provided instructions. (1) Coverage Should the machine fail or malfunction because of a manufacturing defect in materials or workmanship, we will repair it free of charge.
  • Page 9 In no event shall UIC be liable for any warranty other than the express one here and any implied warranties of merchantability or fitness for any particular purpose. In addition, UIC is not liable for any direct or indirect loss or damages whatsoever, whether based upon express or implied warranty.

  • Page 10: Installation/Transfer And After-Sale Service

    Installation/Transfer and After-Sale Service (1) Installation/Transfer (a) Do not install or transfer the machine on the customer side after shipment. To ensure perfect operation of the machine, including safety and accuracy, only our installation service department will install the machine or transfer it to another place.

  • Page 11: About Specification Change

    About Specification Change Consult the marketing department of UIC for desired changes of the machine specifications. In no event will we be liable for any direct, indirect, special, incidental, or consequential damages resulting from any modification made without any prior notice in a written form. About Disposal of Machine (1) This machine (4797 series) uses a strong permanent magnet in the moving mechanism of the feeder carriage section (F axis).

  • Page 12: Safety Precautions

    Safety Precautions "Safety Precautions" describes the precautionary items that should be kept to prevent personal injury or property damage beforehand and use the machine safely. Before using this machine, please understand the contents of the following safety precautions. 1. About Safety Precaution Labels The safety precautions are expressed, using the combinations of safety alert symbols "...
  • Page 13 Safety Precautions • • • • • Identifying Alert Icons : This symbol mark represents danger or prompts warning. : This symbol mark represents prohibited operations. : This symbol mark represents forced operations or instructions. 0412-001 Safe-2 AIJ01E-P...

  • Page 14: Common Precautionary Items

    Safety Precautions 2. Common Precautionary Items Basic Precautions Only a well-trained person should operate the machine. Do not allow any untrained person to operate the machine. Mishandling of the machine can cause a serious accident. Before operating the machine, please read the instruction manual carefully for correct operations.

  • Page 15: Precautions Before Use

    Safety Precautions Precautions before Use Do not modify the machine nor use any parts other than the specified ones. Be sure not to use the machine with its safety devices detached. Doing otherwise may cause personal injury. Do not change the settings of OS (Operating System) or install any applications additionally.
  • Page 16 Safety Precautions Precautions before Use (continued) Even after the [EMERGENCY STOP] switch is pressed, note that electrical power is supplied to the control device. To shutdown the power to all loads, set the power breaker to "OFF". When an "Emergency Switch Off" function is required, it must be prepared on the customer side.

  • Page 17: Notes On Machine Operations

    Safety Precautions Notes on Machine Operations This machine uses energetic driving systems and high voltage to run at high speed. This power and voltage is high enough to DANGER cause death or serious injury. To avoid this danger, respect the following guideline. The machine must be used with the covers being attached.
  • Page 18 Safety Precautions Notes on Machine Operations (continued) When the blue lamp of the light tower is ON or flickering (ON and OFF), it indicates that the static machine is in the "Automatic" mode (standby mode). CAUTION In case of a disaster of any kind, earthquake, storm, flood, fire, or lightning, immediately stop the machine and turn off the power supply.

  • Page 19: General Precautions (Feeder Carriage Section)

    Safety Precautions General Precautions (Feeder Carriage Section) • If a person or an object comes in contact with the feeder carriage, a major injury or damage will result. The feeder carriages are driven by strong motors and move right and left at high speed.
  • Page 20 Safety Precautions General Precautions (Feeder Carriage Section) • Before working at the rear side of the machine, be sure to turn on the "LOCK" lamp. When you operate the powered machine or perform the maintenance work at the rear side of the machine, press the [PNL CHANGE] button on the rear operation panel to turn on the "LOCK"...
  • Page 21 Safety Precautions General Precautions (Feeder Carriage Section) • In principle, the machine must be operated by only one person. If there are more than one, ensure good communication by giving loud verbal instructions. DANGER Fig. 1X10 0412-001 Safe-10 AIJ01E-P...
  • Page 22 Safety Precautions Precautionary Items on Feeder Carriage Section during Automatic Operation • Never operate the machine with the feeder carriage cover and any of the feeder work area safety doors being kept open. If a person or an object comes in contact with the feeder carriage, a major injury or a damage will result.
  • Page 23 Safety Precautions Precautionary Items on Feeder Carriage Section during Setup Operation • A tape feeder or a bulk feeder must be installed or replaced with another one at the feeder work area safety door. Otherwise, you or an object may come in contact with the moving feeder carriage and a major injury or a damage will result.

  • Page 24: Notes On Installation, Transfer, And Maintenance

    Safety Precautions Notes on Installation, Transfer, and Maintenance Do not install or transfer the machine on the customer side after shipment. To ensure perfect operation of the machine, including safety and accuracy, only our installation service department will install the machine or transfer it to another place.

  • Page 25: Notes On Maintenance

    Safety Precautions Notes on Maintenance Only qualified personnel should perform the maintenance work carefully for the machine in compliance with the specified instructions. Before the maintenance work, be sure to turn off the power breaker and the air source and lock them with padlocks. Power Breaker: Set the power breaker to the "OFF"...

  • Page 26: Safety-Related Functions

    Safety Precautions 3. Safety-Related Functions Safety Switches When an error is detected in the machine, the safety switches are designed to stop the dangerous moving mechanisms of the machine. Everything is processed on the machine Œx••‚Æ•\•¦‚³‚ê‚Ä‚¢‚é‚à‚Ì side (hardware) without using any software application on the computer side. [EMERGENCY STOP] Switches Press one of the [EMERGENCY STOP] switches to immediately stop the machine in an emergency.
  • Page 27 Safety Precautions Table 1X1 Switch Name Countermeasures [EMERGENCY STOP] Switch (1) Pressing one of the [EMERGENCY STOP] switches [EMERGENCY STOP] Switch (2) cuts power to the following modules. [EMERGENCY STOP] Switch (3) [EMERGENCY STOP] Switch (4) • All power sources for loads are shut off. The power supply to the mechanisms of all motor shafts and 24-voltage loads in the solenoid system (SOL and SV) is shut off.
  • Page 28 Safety Precautions [Front Safety Door Check] Switch When the front safety door is opened with the [OPERATION] switch set to "RUN", the switch is activated and an error occurs. When the switch is set to "SETUP", it is not activated. Front Safety Door [Front Safety Door Check] Switch...
  • Page 29 Safety Precautions [Feeder Work Area Safety Door] Switches F2 Work Area Safety Door F1 Work Area Safety Door [F2 Work Area Safety Door] [F1 Work Area Safety Door] Switch Switch Fig. 1X17 Rear View Each feeder work area safety door is provided with a [Feeder Work Area Safety Door] switch inside as shown below.
  • Page 30 Safety Precautions Table 1X3 Switch Name Countermeasures • When the feeder carriage is located in the work [F1 Work Area Safety Door] Switch area and the work area safety door in the work [F2 Work Area Safety Door] Switch area is opened, the power to drive the feeder carriage is shut off.
  • Page 31 Safety Precautions [FEEDER CARRIAGE COVER] Safety Switch [FEEDER CARRIAGE COVER] Safety Switch Feeder Carriage Cover Fig. 1X20 Rear View The [FEEDER CARRIAGE COVER] safety switch is mounted inside the cover as shown below. Fig. 1X21 Table 1X4 Switch Name Countermeasures •...

  • Page 32: Module Protection Sensors

    Safety Precautions Module Protection Sensors Feeder Installation Error Detection Sensors When a tape feeder is not installed correctly, these sensors are used to prevent the machine from being operated. Table 1X5 Sensor Name Symbol Countermeasures When one of the left sensors has detected an error, Installation Error (+) BPX30 the following measures are taken.
  • Page 33 Safety Precautions Feeder Carriage Collision Error Detection Sensors When some feeder carriage collide with each other, these sensors are used to stop the machine. Table 1X6 Sensor Name Symbol Countermeasures When one of the left sensors has detected an error, the fol- Carriage Collision 12 BPH57 lowing measures are taken.
  • Page 34 Safety Precautions X/Y Table P.C.B. Detection Sensors When a P.C.B. is not positioned correctly on the X/Y table, these sensors are used to stop the machine. Table 1X7 Sensor Name Symbol Countermeasures X/Y Table P.C.B. Detection (Fixed) BPH47 When one of the left sensors has X/Y Table P.C.B.

  • Page 35: Alert Labels

    Safety Precautions 4. Alert Labels The alert labels (described below) are used for this machine. Please read the instructions on each label carefully and check the contents, observing the actual object. Be sure to follow the instructions for safety purposes. These labels should be kept clean and easily legible at a far safe distance.

  • Page 36: Location Of Alert Labels

    Safety Precautions Location of Alert Labels The alert labels are affixed on dangerous and caution-required areas. Refer to "Alert Labels and Description" for details. This label location shown below is based on 4797R. Note (28) Fig. 1X25 Front View 1 0503-002 Safe-25 AIJ01E-P...
  • Page 37 Safety Precautions This label is used (10-1) This label is used only for 4797X. only for 4797R. (27) Dust Box of 4797X (1-2) (1-2) (1-2) (1-2) (1-2) (13) This label is used only for 4797R. Left Side View of 4797X Fig.
  • Page 38 Safety Precautions (28) (15) (1-2) (1-2) (23) This label is used only for 4797X. (1-2) This label is used only for 4797X. (1-2) (15) (1-2) (26) (1-2) Right Side View of 4797X Fig. 1X27 Rear View 0503-002 Safe-27 AIJ01E-P...
  • Page 39 Safety Precautions (10-1) (10-1) (25) (2-1) (23) This label is used only for 4797R. (12) (16) (2-2) (16) Fig. 1X28 Frame Structure (Top View 1) 0503-002 Safe-28 AIJ01E-P...
  • Page 40 Safety Precautions (1-1) (10-2) (14) (1-2) (20) (1-2) (17) (17) (11) (22) (21) (17) (1-2) (17) (19) Fig. 1X29 Frame Structure (Top View 2) 0503-002 Safe-29 AIJ01E-P...
  • Page 41 Safety Precautions (1-1) Frame Structure of 4797X (Bottom Rear View) (1-2) This label is used only for 4797X (1-1) (1-1) Voltag e Area! High electri c shock. Avoid (1-1) DANGER DANGER High Voltage Area! Avoid electric shock. (1-1) (1-1) (1-2) (1-2) (24) Fig.

  • Page 42: Alert Labels And Description

    Safety Precautions Alert Labels and Description Table 1X8 Alert Labels and Description DANGER High Voltage Area! Avoid any electric shock. *1-1 *1-2 Description This label indicates that high voltage is applied. Do not touch the labeled areas. Otherwise, you will be given an electrical shock. DANGER *2-2 Moving Mechanisms!
  • Page 43 Safety Precautions Table 1X9 Alert Labels and Description WARNING WARNING Strong Magnetic Field Those who wear an implanted pacemaker are not allowed to work inside the door. Otherwise, the pacemaker may be affected by magnetism. Description Those who wear implanted pacemakers are not allowed to work inside the machine. Otherwise, the pacemakers may be affected by magnetism, causing a serious accident.

  • Page 44: Trained Personnel Only

    Safety Precautions Table 1X10 Alert Labels and Description WARNING WARNING Trained Personnel Only! Electric Shock or Hazardous Area Description Only the trained personnel should operate the machine. Otherwise, a serious accident such as an electric shock and an injury may not be avoided. Description Before operating the machine, please read the instruction manual carefully for correct operations.

  • Page 45: Hot Surface

    Safety Precautions Table 1X11 Alert Labels and Description CAUTION During "SETUP" Side Safety door function is deactivated. No Other Operations Allowed except for Setup If other operations are performed, part of your body may be trapped in the moving mechanisms, causing an injury.
  • Page 46 Safety Precautions Table 1X12 Alert Labels and Description CAUTION CAUTION Hold the wheel handle firmly. Otherwise, heavy load will turn the handle abruptly, causing an injury. Description Do not touch any part of these sections. Otherwise, heavy load will turn the handle abruptly, causing an injury.
  • Page 47 Safety Precautions Table 1X13 Alert Labels and Description Description Keep your hands away from the cutter section. Otherwise, an injury may not be avoided. Description When a door is opened or closed, be sure to hold the grip firmly and slowly move the door up or down.
  • Page 48 Safety Precautions Table 1X14 Alert Labels and Description Description Secure the component drop prevention cover by tightening the screws of the bolt holders. Otherwise, the cover will collide with the X/Y table. Description Secure the component drop prevention cover by tightening the screws of the guides. Otherwise, the cover will collide with the feeder carriages and the X/Y table.
  • Page 49 Safety Precautions Table 1X15 Alert Labels and Description CAUTION Power Outlet Only for Recognition Lighting Maximum Rating 100 V AC 4.7 A 4 Outlets Description This power outlet must be used exclusively for recognition lighting. Be sure not to use it for other purposes. Otherwise, the machine will break down. CAUTION Only for Maintenance Work Maximum Rating (100 V AC 7.5A)
  • Page 50 Safety Precautions Table 1X16 Alert Labels and Description Description Install the feeders correctly. Otherwise, the machine and feeders may break down. Description This machine uses fluorocarbon as a refrigerant. This product must be abandoned by the purchaser according to related laws in local area.
  • Page 51 Safety Precautions Table 1X17 Alert Labels and Description Description Never perform the automatic operation with the feeder carriage cover(s) and the feeder work area safety door(s) being kept open. Never modify the [EMERGENCY STOP] switches, the safety doors, etc. Do not put your hand or head in the moving ranges of the machine during operation.

  • Page 52: Precautionary Items For Correct Operations

    Safety Precautions 5. Precautionary Items for Correct Operations Requirements for Installation Be sure to fulfill the following requirements for safety purposes. • Overvoltage Category : Category III • Pollution Degree Overvoltage Categories refer to the level of Impulse Withstand Voltage protection provided at the specified Pollution Degree.

  • Page 53: Precautionary Measures Before Installation

    Safety Precautions Precautionary Measures before Installation If the machine is installed in unsatisfactory environmental conditions, it may malfunction due to damage or breakdown. To avoid this, make preparations to install the machine as follows. When the machine is scheduled to be transferred to another place, please contact the marketing department of UIC beforehand.

  • Page 54: Power Supply

    Safety Precautions Ensure that the selected place is free of electric noise, etc. Precautionary measures (prevention of noise generation, etc.,) must be taken for other equipment to prevent the machine from malfunctioning. Do not expose the machine to combustible or corrosive gas. Select a place free of lamp soot and dust.

  • Page 55: Air Supply

    Safety Precautions Air Supply Supply dry and clean air (Pressure: 0.5 to 0.69 MPa (5.1 to 7 kgf/cm )) that does not contain moisture, oil, and dust to the machine. When the supplied air contains much moisture, etc., the machine may not work normally due to the moisture, etc., accumulated in the machine.

  • Page 56: Power Failure

    Safety Precautions Power Failure Instantaneous voltage drop due to power failure or lightning will cause the built-in computer to break down and the basic and application programs to corrupt. It is recommended that a DC uninterruptive power supply be used as a countermeasure against instantaneous voltage drop.
  • Page 57 Safety Precautions 0503-002 Safe-46 AIJ01E-P...

  • Page 58: Table Of Contents

    Contents Page Before Use .................... About the Instruction Manual ..............Caution and Warning ................Limited Warranty ................Installation/Transfer and After-Sale Service ........Requirements, Orientation, and Training for Operators ....About Specification Change ............About Disposal of Machine ............Other Precautionary Items ............. Safety Precautions About Safety Precaution Labels .............Safe- 1 Common Precautionary Items ............Safe- 3...

  • Page 59: Contents

    Contents Page Section 1 Scope ............What is Component Placement Machine? ........1- Name and Function of Each Section ..........1- General View ................1- 2.1.1 Front Side of Machine .............1- 2.1.2 Rear Side of Machine ............1- Safety Mechanisms ..............1- 2.2.1 [EMERGENCY STOP] Switches ........1- 2.2.2 Front Safety Door ............1- 2.2.3...
  • Page 60 Contents Page Section 2 Basic Knowledge of Operations ....Basic Operations ................2- Selection of Front or Rear Operation Panel ......2- Touch Screens ................2- 1.2.1 Operation Windows ............2- 1.2.2 Notes on Handling Touch Screens ........2- Starting or Exiting from the Application ..........2- Getting Started .................2- Structure of Operation Windows ..........2- Exiting from Operation Window..........2-...
  • Page 61 Contents Page "PASS" Mode ..................3- 24 Start of Pass Operation ............3- 24 Temporary Stop of Pass Operation .........3- 27 2.2.1 Temporary Stop (Pause) with [STOP] Button ....3- 27 Interruption of Pass Operation ..........3- 27 2.3.1 Interruption with [CANCEL] Button ........3- 27 2.3.2 Interruption with [EMERGENCY STOP] Switch ....3- 27 End of Pass Operation ............3- 28...

  • Page 62: Section 1 Scope

    Section 1 Scope This section explains the name and function of each sec- tion and the mechanism of the surface mounting about the component placement machine. 0305-001 AIJ01EOPP...
  • Page 63 0305-001 AIJ01EOPP...

  • Page 64: What Is Component Placement Machine

    1. What is Component Placement Machine? What is Component Placement Machine? The component placement machine places various types of electronic components (called "Components" hereinafter) precisely on the speci- fied spots of P.C.B. surfaces at high speed. Placement Head Electronic Components P.C.B.

  • Page 65: Name And Function Of Each Section

    2. Name and Function of Each Section 2. Name and Function of Each Section 2.1 General View Refer to the items described in "2.2", "2.3", and "2.4" for each section. 2.1.1 Front Side of Machine Light Tower [EMERGENCY STOP] Switch (Front) Front Operation Panel Front Service Panel Front Safety Door...

  • Page 66: Rear Side Of Machine

    2.1 General View 2.1.2 Rear Side of Machine [EMERGENCY STOP] Switch (Rear) Light Tower Ethernet LAN R Conveyor Feeder Carriage Cover Rear Operation Panel Rear Service Panel Fig. 1A3 Rear Side of Machine 0305-001 AIJ01EOPP...

  • Page 67: Safety Mechanisms

    2.2 Safety Mechanisms 2.2 Safety Mechanisms 2.2.1 [EMERGENCY STOP] Switches [EMERGENCY STOP] Switches (Rear) [EMERGENCY STOP] Switches (Front) Fig. 1A4 Use the [EMERGENCY STOP] switches to immediately stop the ma- chine in an emergency. When an [EMERGENCY STOP] switch is pressed, the power is turned off and the machine stops immediately.

  • Page 68: Front Safety Door

    2.2 Safety Mechanisms 2.2.2 Front Safety Door Front Safety Door [FRONT SAFETY DOOR CHECK] Switch Fig. 1A5 The machine is provided with a safety door on the front side of the ma- chine to keep any part of body, clothes and any object away from the moving parts of the machine, avoiding any danger during automatic op- eration.

  • Page 69: Feeder Work Area Safety Doors

    2.2 Safety Mechanisms 2.2.3 Feeder Work Area Safety Doors Feeder Work Area Safety Door F1 Work Area Safety Door F2A Work Area Safety Door [F1 READY] Button [F2A READY] Feeder Ready Buttons Button Fig. 1A6 Feeder Work Area Safety Doors and Feeder Ready Buttons The machine is provided with feeder work area safety doors on the rear side of the machine to avoid any danger possible to be caused while the feeder carriage is moving during automatic operation.
  • Page 70 2.2 Safety Mechanisms Special caution is required to avoid any danger while CAUTION the feeder carriage is activated with the feeder work area safety door being kept open. When a door is opened or closed, be sure to hold the grip firmly and slowly move the door up or down.

  • Page 71: Feeder Carriage Covers

    2.2 Safety Mechanisms 2.2.4 Feeder Carriage Covers Feeder Carriage Covers Fig. 1A7 The machine is provided with feeder carriage covers at the central sec- tion of the rear side, allowing the operator to stay clear of any danger possible to be caused while the feeder carriages are moving during au- tomatic operation.

  • Page 72: Feeder Ready] Buttons

    2.2 Safety Mechanisms 2.2.5 [FEEDER READY] Buttons Feeder Work Area Safety Door F1 Work Area Safety Door F2A Work Area Safety Door [F1 READY] Button [F2A READY] Feeder Ready Buttons Button Fig. 1A8 [FEEDER READY] Buttons • • • • • The [FEEDER READY] buttons are used to inform the machine that the tape feeders on the feeder carriages are set ready for use after replacement or component replenishment.
  • Page 73 2.2 Safety Mechanisms (a) Unless the lamp of the [FEEDER READY] button illumi- nates, the automatic operation cannot be started. While Note the lamp of the [FEEDER READY] button is ON, the feeder work area safety door is locked and cannot be opened. (b) When the [FEEDER READY] button is pressed right after the feeder work area safety door is closed, the lamp may not illuminate soon.

  • Page 74: Operational Measures

    2.3 Operational Measures 2.3 Operational Measures 2.3.1 Power Breaker Lock Lever Power Breaker Padlock Push to trip Fig. 1A9 The power breaker is provided to supply or shut off power to the machine. The power breaker can be locked with a padlock. Refer to "1.7.2 Locking the Power Breaker with the Padlock"...

  • Page 75: Light Tower

    2.3 Operational Measures 2.3.2 Light Tower Yellow Green Blue Buzzer Fig. 1A10 The light tower indicates the condition of the machine with the lamps and buzzer sounds. Lamp Colors The machine is factory-adjusted upon shipment. Table 1A2 Lamp Colors Machine Condition Error (Machine Stop) Yellow Component Shortage (Warning)

  • Page 76: Front Operation Panel

    2.3 Operational Measures 2.3.3 Front Operation Panel *11 Front Touch Screen *8 [EMERGENCY STOP] Switch EMERGENCY STOP *10 Pointing Device *7 [OPERATION] Switch *6 [LOCK] Lamp RUN SETUP *1 [POWER ON] START ENABLE PNL CHANGE OPERATION POWER ON Button LOCK STOP 4797 HSP *2 [START] Button...
  • Page 77 2.3 Operational Measures *3 [STOP] Button • This button is used to stop the automatic operation. • When this button is pressed during X/Y table test, the test operation stops. • When this button is pressed during zeroing operation, the zeroing opera- tion of each device is interrupted, excluding the P.C.B.
  • Page 78 2.3 Operational Measures *7 [OPERATION] Switch • The selection key must be inserted to change over the [OPERATION] switch to "RUN" or "SETUP". The [OPERATION] switch must be set to the "RUN" side for automatic operation. The switch can be changed over to "RUN" or "SETUP" only when the machine is in the "STOP"...
  • Page 79 2.3 Operational Measures *9 Keyboard Fig. 1A12 This keyboard can be used to enter alphanumeric characters in edit windows for pattern programs and component data. To enter numerals in one of the windows that belong to "AUTO OPN." or "MAINT.", the edit window on the screen can be used. Note How to set up and store the keyboard •...
  • Page 80 2.3 Operation Measures • Storage Procedure (1) Hold the B-marked area and turn it in the D-marked arrow direction until it clicks. Be sure to turn it until it clicks. Otherwise, the keyboard will be damaged when stored. Note (2) Press the E-marked two buttons at the same time. (3) Push down the F-marked area.
  • Page 81 2.3 Operation Measures *10 Pointing Device and Trackball Right Button Right Button Left Button Joystick Trackball Left Button Fig. 1A15-1 (Pointing Device) Fig. 1A15-2 (Trackball) This device is used to indicate where the pointer is on the operation screen. Basic Operations of Pointing Device •...
  • Page 82 2.3 Operational Measures *11 Front Touch Screen Front Touch Screen Fig. 1A16 The operation windows will be displayed on the front touch screen. Various types of operations become available by touching the operation buttons and tabs on the screen. Since the touch screen uses the molecules in liquid crystals, handle it like glass.

  • Page 83: Rear Operation Panel

    2.3 Operational Measures 2.3.4 Rear Operation Panel *1 [POWER ON] Button POWER *2 [START] Button START *3 [STOP] Button STOP *4 [ENABLE] Button ENABLE *5 [PNL CHANGE] Button *6 [LOCK] Lamp CHANGE LOCK *7 Rear Touch Screen Fig. 1A17 *1 [POWER ON] Button •...
  • Page 84 2.3 Operational Measures *4 [ENABLE] Button • When the [ON] button (entitled "MOVE") is pressed in the active operation sheet, the lamp of the [ENABLE] button illuminates for two seconds. When the [ENABLE] button is pressed with its lamp "ON", the machine performs various operations selected in the operation sheets.

  • Page 85: Front Service Panel

    2.3 Operational Measures 2.3.5 Front Service Panel *1 Working Lamp Switch *3 Selector Switch LIGHT ON OFF OPE-TAB *4 Connector for Secondary Operation Panel *2 Ground Terminal for Wrist Band Fig. 1A18 *1 Working Lamp Switch This switch is used to turn on or off the working spot lamp. *2 Ground Terminal for Wrist Band This terminal is used to clear a ground through the wrist band.

  • Page 86: Rear Service Panel

    2.3 Operational Measures 2.3.6 Rear Service Panel *3 Ground Terminal for Wrist Band OPE-TAB *1 Selector Switch *2 Connector for Secondary Operation Panel Fig. 1A19 *1 Selector Switch This switch is used to select either the operation panel of the main machine or the secondary operation panel for maintenance.

  • Page 87: Ethernet Lan

    2.3 Operational Measures 2.3.7 Ethernet LAN Data can be exchanged between the network terminal (option) and the machine in the Ethernet LAN system. • Do not exchange data through Ethernet cabling (Local Area Network) between the system and a computer that is not pro- Notice vided with any viral strategies.

  • Page 88: Main Units

    2.4 Main Units 2.4 Main Units 2.4.1 Feeder Carriages Feeder Feeder Carriage Fig. 1A21 The carriages carry feeders for component supply. The tape or bulk feeders can be installed on the feeder carriages. The carriages move right and left to supply components. Never operate the machine with the feeder carriage covers being open.

  • Page 89: L And R Conveyor Sections

    2.4 Main Units 2.4.2 L and R Conveyor Sections L Conveyor R Conveyor Fig. 1A22 These conveyors are used to receive a P.C.B. from the input machine and transfer it to the place right before the X/Y table or carry the compo- nent-placed P.C.B.

  • Page 90: Transfer Section

    2.4 Main Units 2.4.3 P.C.B. Transfer Section Rotary Turret L Conveyor P.C.B. Transfer Claw X/Y Table Fig. 1A23 The P.C.B. transfer section is equipped with a feed claw that pushes and transfers the P.C.B. (the P.C.B. received from the input machine by the L conveyor when the flow direction is "L R") onto the X/Y table.

  • Page 91: X/Y Table Section

    2.4 Main Units 2.4.4 X/Y Table Section X/Y Table Fig. 1A24 The X/Y table section is provided with a mechanism that holds a P.C.B. (sent from the conveyor on the input side) firmly on the X/Y table. The firmly-held P.C.B. moves and stops under the placement heads together with the X/Y table according to the pattern program data.

  • Page 92: Placement Head Section

    2.4 Main Units 2.4.5 Placement Head Section Fig. 1A25 The machine is provided with a rotary turret that has several heads. Each head is rotated by a direct-drive motor and several vacuum nozzles can be attached to one head. The attached vacuum nozzles are used to pick up components and place them on a P.C.B.

  • Page 93: Component Recognition Section

    2.4 Main Units 2.4.6 Component Recognition Section Component Recognition Scope Section Fig. 1A27 The machine is provided with a mechanism that inspects (recognizes) the components picked up by vacuum nozzles, using two component recognition cameras and three light sources. The following three operations are performed in the compo- nent recognition system.

  • Page 94: Recognition Section

    2.4 Main Units 2.4.7 P.E.C. Recognition Section Rotary Turret P.E.C. Recognition Camera Fig. 1A28 The P.E.C. recognition camera is used to detect the fiducial marks on a P.C.B. and the amount of the positional deviation from the fiducial mark coordinate data is calculated to automatically correct the position of a placed component.

  • Page 95: Surface Mounting Mechanism

    3. Surface Mounting Mechanism Surface Mounting Mechanism The following briefly describes how components are mounted on P.C.B.’s. (a) The explanation is based on the P.C.B. flow direction "From Left to Right (L R)". Note (b) Refer to "1. Scope of Actions" in "Section 2" of "Volume 2: Operation (Supervisor)"...

  • Page 96: Component Picks And Placement

    3.2 Component Picks and Placement 3.2 Component Picks and Placement Component Pick-Up Components are picked up from the tape feeder by the vacuum nozzles on the placement heads. Placement Head Vacuum Nozzle Component Tape Feeder Fig. 1A31 Component Pick-Up Section (Station #12) Component Placement The component picked up by the vacuum nozzle is placed on the P.C.B.

  • Page 97: Transfer (To The Output Machine)

    3.3 P.C.B. Transfer (to the output machine) 3.3 P.C.B. Transfer (to the output machine) The P.C.B. where all required components are placed is transferred from the P.C.B. transfer section to the R conveyor and carried further to the output machine. R Conveyors P.C.B.

  • Page 98: Section 2 Basic Knowledge Of Operations

    Section 2 Basic Knowledge of Operations This section describes the basic items to be understood for proper machine operations. 0305-001 AIJ01EOPP...
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  • Page 100: Basic Operations

    1. Basic Operations 1. Basic Operations 1.1 Selection of Front or Rear Operation Panel Front Touch Screen Rear Touch Screen Front Operation Panel Rear Operation Panel Rear Side of Machine Front Side of Machine Fig. 1B1 The machine is equipped with operation panels on both front and rear sides.

  • Page 101: Touch Screens

    1.2 Touch Screens 1.2 Touch Screens 1.2.1 Operation Windows Various operation windows appear on the touch screen for parameter settings (data input). Basically, operations become available by touching the buttons in a win- dow. To enter alphanumeric characters, open the ten-key pad or the keyboard by pressing the pertinent key in an operation window and press the de- sired keys on the ten-key pad or the keyboard.

  • Page 102: Notes On Handling Touch Screens

    1.2 Touch Screens 1.2.2 Notes on Handling Touch Screens • • • • • Since the touch screen uses the molecules in liquid crystals, do not apply a strong pressure or a shock on the touch screen. It should be handled like glass.

  • Page 103: Starting Or Exiting From The Application

    2. Starting or Exiting from the Application 2. Starting or Exiting from the Application 2.1 Getting Started (1) When the [POWER ON] button on the operation panel is pressed, it illuminates in yellowish green and the self-diagnostics function starts. (a) Press and hold the [POWER ON] button for more than 1 second.
  • Page 104 2.1 Getting Started This machine is provided with a password function which pre- vents various types of data groups from being deleted by mis- Note take and keeps unauthorized user (third party) from operating the machine. The following three kinds of passwords are available and each gives individually approved user’s access to the computer sys- tem of the machine.

  • Page 105: Structure Of Operation Windows

    2.2 Structure of Operation Windows 2.2 Structure of Operation Windows *4 Operation Window (Menus for Automatic Operation) *5 Current Mode *3 Tab *2 Sub Menu Bar *1 Main Menu Bar *6 Supplementary Explanation Fig. 1B4 Main Menu Bar and "AUTO OPN." Window •...
  • Page 106 2.2 Structure of Operation Windows *3 Tabs When a window is composed of several sheets, all sheets are pro- vided with extensions called "Tab" and laid on top of each other so that the tab of each is visible. Refer to "Section 4" in "Volume 2: Operation (Supervisor)" for the tabs.

  • Page 107: Exiting From Operation Window

    2.3 Exiting from Operation Window 2.3 Exiting from Operation Window (1) To exit from the "AUTO OPN." window or the "MAINT." window, just press the [Logout] button on the main menu bar. The "Login Type Selection" window opens. Fig. 1B5 Whenever an edit window such as the "Pattern Program Data"...

  • Page 108: Section 3 Scope Of Automatic Operation

    Section 3 Scope of Automatic Operation This section outlines the items to be prepared and con- firmed before automatic operation and how to start or end the operation. 0305-001 AIJ01EOPP...
  • Page 109 0305-001 AIJ01EOPP...

  • Page 110: Normal Automatic Operation

    1. Normal Automatic Operation 1. Normal Automatic Operation Flow of Automatic Operation Program Change Operation Refer to "Volume 2: Operation (Supervisor)" for details. Fig. 1C1 nspections before Automatic Operation 1.1.1 Confirmation of Power Supply and Air Pressure 1.1.2 Confirmation of Front Safety Door and Feeder Carriage Sections Fig.

  • Page 111: Inspections Before Automatic Operation

    1.1 Inspections before Automatic Operation 1.1 Inspections before Automatic Operation 1.1.1 Confirmation of Power Supply and Air Pressure (1) Confirmation of Power Supply Confirm that the local main breaker (the power supply to the ma- chine) is "ON". • Power Supply : 180 to 220 V AC, 3-Phase •...
  • Page 112 1.1 Inspections before Automatic Operation (a) When the air pressure is not set correctly, adjust it to meet Note the specified range. (b) The pressure switch is correctly set. Be sure not to adjust Ref.: 0.40 MPa for P1 and 0.35 MPa for P2 (c) Use of Dry and Clean Air Be sure to use dry and clean air.

  • Page 113: Confirmation Of Front Safety Door And Feeder Carriage Sections

    1.1 Inspections before Automatic Operation 1.1.2 Confirmation of Front Safety Door and Feeder Carriage Sections Confirm that the front safety door, the feeder work area safety doors, and the feeder carriage covers are completely closed. Feeder Work Area Safety Door Feeder Carriage Cover Front Safety Door Fig.

  • Page 114: Preparation Before Automatic Operation

    1.2 Preparation before Automatic Operation 1.2 Preparation before Automatic Operation 1.2.1 Power ON Operation (1) Ensure the safety around the front safety door and the feeder car- riage sections. (2) Remove the padlock from the lock lever of the power breaker. Feeder Carriage Sections Front Safety...
  • Page 115 1.2 Preparation before Automatic Operation (4) Hold down the [POWER ON] button on the operation panel for one second or more. The lamp of the [POWER ON] button illuminates in yellowish green and the self-diagnostics function starts. RUN SETUP START ENABLE OPERATION POWER ON...

  • Page 116: Auto Opn." Window And Zeroing Of Each Device

    1.2 Preparation before Automatic Operation This machine is provided with a password function which pre- vents various types of data groups from being deleted by mis- Note take and keeps unauthorized user (third party) from operating the machine. The following three kinds of passwords are available and each gives individually approved user’s access to the computer sys- tem of the machine.

  • Page 117: Operation Procedure

    1.2 Preparation before Automatic Operation (2) Press the [Origin/Signal Info.] tab to open the "Origin/Signal Info." tab sheet and perform the zeroing operations. Fig. 1C12 • When the origin marks " " are not displayed for all devices except "L Cnvr. Wd.", "R Cnvr. Wd.", "X/Y Chute Wd.", and Note "PCB Support Pins"...

  • Page 118: Preparation For Components And P.c.b.'s

    1.2 Preparation before Automatic Operation 1.2.3 Preparation for Components and P.C.B.’s • • • • • Installation of Tape Feeders (1) Open the feeder work area safety door of the feeder carriage where the tape feeders should be installed. Feeder Work Area Safety Doors Fig.
  • Page 119 1.2 Preparation before Automatic Operation Refer to "Attachment and Detachment of Tape Feeders onto Feeder Carriage" in the instruction manual of tape feeders for Note details. (3) After the tape feeder has been attached, close the feeder work area safety doors. Press the [FEEDER READY] buttons and check that the lamps of these buttons are ON.

  • Page 120: Start Of Automatic Operation

    1.3 Start of Automatic Operation 1.3 Start of Automatic Operation Operation Procedure (1) Confirm that the front safety door is closed. (2) Set the [OPERATION] switch on the front operation panel to the "RUN" side and be sure to remove the selection key from the ma- chine.
  • Page 121 1.3 Start of Automatic Operation (5) Press the [Origin/Signal Info.] tab in the "AUTO OPN." submenu window. The "Origin/Signal Info." tab sheet opens. Check the origin marks. Fig. 1C20 (6) When the [START] button on the front operation panel is pressed while the lamp is flickering, the automatic operation (placement) starts.

  • Page 122: Temporary Stop And Restart Of Automatic Operation

    1.4 Temporary Stop and Restart of Automatic Operation 1.4 Temporary Stop and Restart of Automatic Operation 1.4.1 Replenishment of Components and P.C.B.’s There will be two cases of component supply replenishment during au- tomatic operation - Component Replenishment with Machine in Short of Components and Intentional Component Replenishment.
  • Page 123 1.4 Temporary Stop and Restart of Automatic Operation • • • • • Intentional Component Replenishment during Automatic Operation (1) Press the [STOP] button on the front operation panel to stop the machine temporarily. (2) Press the [ALL] button (entitled "ZERO") in the "Control Switch" group box of the "AUTO OPN."...
  • Page 124 1.4 Temporary Stop and Restart of Automatic Operation • • • • • Countermeasures against Shortage of P.C.B.’s When the machine gets short of P.C.B.’s during automatic opera- tion, the input machine issues an error alarm or the machine stops automatically.

  • Page 125: Stop] And [On] (Entitled "Stop") Buttons

    1.4 Temporary Stop and Restart of Automatic Operation 1.4.2 [STOP] and [ON] (entitled "STOP") Buttons Press the [STOP] button to temporarily stop the automatic operation whenever it is found that a wrong production model is applied or the placement condition should be checked after the machine has started the automatic operation.

  • Page 126: Stop Operation By Selection Of "Auto Stop Mode

    1.4 Temporary Stop and Restart of Automatic Operation When "CYCLE" is set as "Stop Mode" (*1), select the [STEP] button (entitled "STOP") in the "Run Mode" tab sheet ("OPN. Note MODE" submenu window). 1.4.3 Stop Operation by Selection of "Auto Stop Mode" Stop the input machine.

  • Page 127: Interruption Of Automatic Operation

    1.5 Interruption of Automatic Operation 1.5 Interruption of Automatic Operation 1.5.1 Interruption of Automatic Operation with [CANCEL] Button To discontinue the production due to wrong selection of the current pat- tern program or product P.C.B.’s, interrupt the automatic operation. (1) Press the [STOP] button on the front operation panel. Fig.

  • Page 128: Interruption With [Emergency Stop] Switch

    1.5 Interruption of Automatic Operation 1.5.2 Interruption with [EMERGENCY STOP] Switch Use the [EMERGENCY STOP] switch to immediately stop the machine in an emergency. An error alarm is issued and the LED of the [POWER ON] button illumi- nates in red. Fig.

  • Page 129: End Of Automatic Operation

    1.6 End of Automatic Operation 1.6 End of Automatic Operation 1.6.1 Stop of Automatic Operation (1) Confirm that "CYCLE" (*1) is set as "Stop Mode". (2) When the [ON] button (*3, entitled "STOP") is pressed, each device returns to its stationary position after the machine has placed com- ponents on the P.C.B.’s inside the machine.

  • Page 130: Shut-Down Operation

    1.7 Shut-Down Operation 1.7 Shut-Down Operation 1.7.1 Shut-Down Procedure The following explains how to shut down the power to the machine. Be sure to log out from an operation window to open the "Login Type Selection" window and go through the shutdown procedure by pressing the [SHUT DOWN] button before turning off the power to the CAUTION...
  • Page 131 1.7 Shut-Down Operation (2) The "Login Type Selection" window opens. Fig. 1C29 (3) When the [SHUT DOWN] button is pressed in the "Login Type Se- lection" window, the "SHUT DOWN" dialog box opens for the con- firmation. Fig. 1C30 "SHUT DOWN" Dialog Box for Confirmation (4) When the [Yes(Y)] button is pressed, the power to the machine is turned off.

  • Page 132: Locking The Power Breaker With The Padlock

    1.7 Shut-Down Operation (5) Set the lever of the power breaker to the "OFF" position. Fig. 1C31 1.7.2 Locking the Power Breaker with the Padlock When the machine is not used for a long period of time, lock the power breaker using the padlock.

  • Page 133: Pass" Mode

    2. "PASS" Mode 2. "PASS" Mode When the machine is set in the "PASS" mode, it just carries the P.C.B. (input conveyor P.C.B. positioning section output conveyor) to the output conveyor without placing any components on the P.C.B. When the machine must transfer P.C.B.’s to the output machine without placing any components, follow the steps below.
  • Page 134 2. "PASS" Mode (4) Press the [OPN. MODE] button on the submenu bar to open the "OPN. MODE" submenu window. After that, press the [PASS] but- ton entitled "RUN MODE" in the "Run Mode 1 (or Run Mode 2)" tab sheet.
  • Page 135 2.1 Start of "PASS" Operation • When the origin marks " " are not displayed for all devices except "L Cnvr. Wd.", "R Cnvr. Wd.", "X/Y Chute Wd.", and Note "PCB Support Pins" in the "Origin Monitor" group box of the "Origin/Signal Info."...

  • Page 136: Temporary Stop Of Pass Operation

    2.2 Temporary Stop of Pass Operation 2.2 Temporary Stop of Pass Operation 2.2.1 Temporary Stop (Pause) with [STOP] Button When the [STOP] button on the front operation panel is pressed, each device returns to its stationary position and the "PASS" operation stops temporarily.

  • Page 137: End Of Pass Operation

    2.4 End of "PASS" Operation 2.4 End of Pass Operation 2.4.1 Stop of Pass Operation (1) Press the [STOP] button on the front operation panel. The LED of the [START] button and the blue lamp of the light tower extinguish and the automatic operation stops. Remove the P.C.B.

  • Page 138: Section 4 Remedy Of Simple Trouble

    Section 4 Remedy of Simple Trouble This section describes how to troubleshoot simple problems that can be solved by the machine operator. When the operator cannot solve a problem, he/she should get in contact with the supervisor (a person in charge of machine management).
  • Page 139 0305-001 AIJ01EOPP...

  • Page 140: Power Operation Impossible

    1. Power Operation Impossible 1. Power Operation Impossible Table 1D1 Symptom When the [POWER ON] button on the operation panel is pressed, the ma- chine is not powered. Cause (Cause 1) The [POWER ON] button on the operation panel is not held down for more than two seconds.

  • Page 141: Nothing Displayed On Touch Screen

    2. Nothing Displayed on Touch Screen 2. Nothing Displayed on Touch Screen Table 1D2 Symptom Nothing is displayed on the touch screen. Cause (Cause 1) The screen saver function is activated. (Cause 2) Power is not supplied from the source. Remedy (Remedy 1) Touch a part of the touch screen.

  • Page 142: Remedial Procedure From "Error" Window

    3. Remedial Procedure from "ERROR" Window 3. Remedial Procedure from "ERROR" Window 3.1 [EMERGENCY STOP] Switch Pressed 3.1.1 During Automatic Operation Table 1D3 Symptom (1) The [POWER ON] button turns red and the following window opens. Fig. 1D3 Cause (1) An [EMERGENCY STOP] switch was pressed. Remedy (1) Press the [RETURN] button.
  • Page 143 3.1 [EMERGENCY STOP] Switch Pressed Table 1D4 (8) When the message "Warm Start Enable" is displayed in the "Operator Message" pane in the "AUTO OPN." window, it means that the "Warm Start" operation is feasible. (a) "Warm Start Enable" means that the production is interrupted in the middle of component placement.
  • Page 144 3.1 [EMERGENCY STOP] Switch Pressed Table 1D5 (10) Check how the last component was placed when the operation was in- terrupted. The last placement step is indicated in the "Start Step" group box in the "OPN. MODE" window (submenu). Note Check visually whether or not the relevant component is placed on the P.C.B.

  • Page 145: During Pass Operation

    3.1 [EMERGENCY STOP] Switch Pressed 3.1.2 During Pass Operation Table 1D6 Symptom (1) The LED of the [POWER ON] button illuminates in red and the following window opens. Fig. 1D7 Cause (1) An [EMERGENCY STOP] switch was pressed. Remedy (1) Press the [RETURN] button. Remove the P.C.B.

  • Page 146: Continuous Operation Disabled During Component Placement

    3.2 Continuous Operation Disabled during Component Placement 3.2 Continuous Operation Disabled during Compo- nent Placement Table 1D7 Symptom The continuous operation became impossible during component placement. No error message is issued on the touch screen and the machine is kept in the "RUN"...
  • Page 147 3.2 Continuous Operation Disabled during Component Placement Table 1D8 (3) Press the [RETURN] button in the "ERROR" window. The "ERROR" win- dow closes. (4) Press the [ALL] button (entitled "ZERO") in the "AUTO OPN." window to zero all axis. (5) Check whether or not the P.C.B. in the middle of component placement is located out of the positioning section on the X/Y table or the components are normally placed (not dispersed).
  • Page 148 3.2 Continuous Operation Disabled during Component Placement Table 1D9 (a) When the "Warm Start" operation is feasible, the [WARM] button appears in the "OPN. MODE" window (submenu). Note (b) When the [WARM] button is not displayed, it means that the "Warm Start"...
  • Page 149 1st Edition Issued May, 2003 Copying Prohibited 7th Edition Issued Jan., 2006 0601-007 AIJ01EOPP...

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