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Philips Assembleon AX-201 Installation Manual
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Philips Assembleon AX-201 Installation Manual

Philips Assembleon AX-201 Installation Manual

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AX-201

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Summary of Contents for Philips Assembleon AX-201

  • Page 1 Installation Manual AX-201...

  • Page 2: Feedback On This Manual

    DOCUMENT DATA Document ....Installation Manual AX-201 Based on ....Order number .

  • Page 3: Table Of Contents

    CONTENTS Installation Manual Table of Contents CHAPTER 1 Introduction ....... . . 5 1.1 Introduction .
  • Page 4 CONTENTS 4.5.1 Power and safety circuit PA 2410/01 ..40 4.5.2 Power and safety circuit PA 2410/00 ..41 CHAPTER 5 Communication ......42 5.1 SMEMA interfacing .

  • Page 5: Chapter 1 Introduction

    Chapter 1 CHAPTER 1 Introduction 1.1 Introduction Figure 1 AX-201 Before installing this machine, make sure that the site is in accordance with the pre-installation instructions (see Pre-installation Manual AX-201). The information in this manual is intended to be a guide for the installation of this machine, including built-in options.

  • Page 6: Machine Dimensions And Weights, Crated And Uncrated

    Chapter 1 1.4 Machine dimensions and weights, crated and uncrated NOTE: For some (European) markets this machine can be packed in just foil and placed on a crate bottom, leading up to a simplified unpacking procedure. Crated Uncrated Name of crate Weight (kg) Dimensions (mm) Weight (kg) Dimensions (mm)

  • Page 7: Chapter 2 Safety

    Chapter 2 CHAPTER 2 Safety 2.1 General For the correct and safe use of this machine, it is essential that all personnel should follow the safety procedures specified in this manual. All manuals have danger, warning and cautionary statements where applicable. Danger, warning and cautionary statements and / or symbols are present on the machine where applicable.

  • Page 8: Danger, Warning And Caution

    Chapter 2 2.5 Danger, warning and caution ■ Danger Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. A danger statement is displayed in this manner: HAZARD IDENTIFICATION DANGER DANGER Hazard consequence. Hazard avoidance.

  • Page 9: Safety Stickers

    Chapter 2 2.6 Safety stickers Pictogram Category Meaning Warning DANGER OF CLAMPING FINGERS Serious injury to fingers. Keep hands away from moving parts. Warning DANGER OF STRONG MAGNETIC FIELD Pacemaker and metal prosthetic users are at risk of serious injury or death. Stay away from the magnets.

  • Page 10: Safety Devices

    Chapter 2 2.7 Safety devices Machine condition Hazard Safety device Detection method after safety device is protected activated 1 Emergency stop Hazardous Safety circuit interruption by pushing the All moving parts will be button front and moving parts. emergency stop button. stopped and power to rear servo systems is turned...

  • Page 11: Enabling Switch Front/Rear, Usage

    Chapter 2 Figure 9 Location of safety devices, rear Lock the electrical main switch (7) and the air main switch (8) by a padlock to avoid unauthorized use. 2.7.1 Enabling switch front/rear, usage DANGER OF MOVING PARTS CAUTION CAUTION Serious injury to fingers and body parts. Keep fingers and body parts outside the machine.

  • Page 12: Noise Levels

    Chapter 2 2.8 Noise levels Location Noise level ≤ 72 dB(A) Sound pressure at operator’s position ≤ 58 dB(A) Average environmental noise level during measurement Figure 10 Noise levels 2.9 Emergency contact In case assistance is needed during an emergency situation, contact the regional Assembléon organization.

  • Page 13: Chapter 3 Installation

    Chapter 3 CHAPTER 3 Installation Use the table as guide line, see 3.1 Checklist installation . 4022 593 51853 Installation Manual 08.03 AX-201...

  • Page 14: Checklist Installation

    Chapter 3 3.1 Checklist installation Subject Reference information Checked Before installation Check if the site is prepared See Pre-Installation Manual Unpacking and transportation Check if there is enough space to manoeuvre the 3.3 Machine, transportation machine (fork-lift truck) Remove all packing materials 3.2 Machine, unpacking Transportation to the site 3.3 Machine, transportation...

  • Page 15: Machine, Unpacking

    Chapter 3 3.2 Machine, unpacking Estimated time te complete [min.]: Required special tools..Open end spanner 36mm, see 9.1.3.Setup tooling kit (PA 2435/00) Required part(s) ... . . - 1.

  • Page 16: Unpacking The Machine

    Chapter 3 4. Unpacking the machine • Remove the seal (3) from the machine. • Inspect the machine for transport damage. • Remove the nuts (4) from the feet using a 36 mm open end spanner. • Take the machine from the crate bottom with a forklift truck.

  • Page 17: Machine, Transportation

    Chapter 3 3.3 Machine, transportation Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . - 1. Transporting the machine •...

  • Page 18: Machine, Positioning In The Flow Line

    Chapter 3 3.4 Machine, positioning in the flow line Estimated time te complete [min.]: Required special tools..Plumb line, 9.1.3 Setup tooling kit (PA 2435/00) Required part(s) ... . . 1.

  • Page 19: Transport Securities, Removal

    Chapter 3 3.5 Transport securities, removal Estimated time te complete [min.]: Required special tools..9.1.4 Recommended standard tools Required part(s) ... . . - 1.
  • Page 20 Chapter 3 4. Remove transport protection on placement heads DV • Remove four M3x20 bolts and remove transport bracket (5) of placement heads DV. 5. Remove transport brackets on board transport • Loosen the bolts and remove the four brackets (6).

  • Page 21: Machine, Levelling

    Chapter 3 3.6 Machine, levelling Estimated time te complete [min.]: Required special tools..9.1.3 Setup tooling kit (PA 2435/00) Required part(s) ... . . - NOTE: Objective of this procedure is: 1.
  • Page 22 Chapter 3 4. Prepare jig SMEMA • Prepare jig for JIS or SMEMA height levelling. 105-125 mm 67-87 mm 5. Position the jig REAR • Position a jig (being ‘foot 5’) in the middle of feet 3 and 4. • Lift the machine, feet 3 and 4 are free from the floor.
  • Page 23 Chapter 3 7. Level the machine in X direction • Adjust in X direction with jig 5 until the spirit level shows 3 scales lower (on left side, seen from front). • Take care that feet 3 and 4 do not touch the floor.

  • Page 24: Final Check

    Chapter 3 11. Level the machine in X direction • Install two dial gauges (0.01mm) between the floor and machine at feet 3 and 4. Apply a piece of paper to avoid scratches on the machine. • Set both gauges halfway their measuring range, REAR e.g.

  • Page 25: Machine, Anchoring (Seismic Protection)

    Chapter 3 3.7 Machine, anchoring (Seismic protection) Estimated time te complete [min.]: Required special tools..Required part(s) ... . . NOTE: For protection during an earth quake, the machine can be anchored to the floor.

  • Page 26: Accessories And Options, Installing

    Chapter 3 3.8 Accessories and options, installing Estimated time te complete [min.]: Required special tools..9.1.3 Setup tooling kit (PA 2435/00) Required part(s) ... . . - 1.
  • Page 27 Chapter 3 5. Clean contact plates for trolley • Clean the three contact plates (4) on each trolley lift. 4022 593 51853 Installation Manual 08.03 AX-201...

  • Page 28: Chapter 4 Connections To Services

    Chapter 4 CHAPTER 4 Connections to services 4.1 Emergency circuit, external connecting 1. Preparation • Power down the machine. • Open the front door of the machine. 2. Remove panel • Remove the two bolts. • Slide out the panel. •...

  • Page 29: Connecting The Machine To The Mains

    Chapter 4 4.2 Mains supply, connecting PA 2410/01 PA 2410/01 PA 2410/00 Transformer PA 1124/10 Figure 13 Overview 1. Machine without standard transformer. The transformer (PA 1124/10) can be installed as an option. 4.2.1 Connecting the machine to the mains, PA 2410/01 2.

  • Page 30: Connecting The Machine To The Mains, Pa 2410/01

    Chapter 4 4.2.1 Connecting the machine to the mains, PA 2410/01 Estimated time te complete [min.]: Required special tools..Panel key 9.1.3 Setup tooling kit (PA 2435/00) Required part(s) ... . . - DANGER, HIGH VOLTAGE PRESENT AFTER MAIN SWITCH OFF DANGER DANGER...
  • Page 31 Chapter 4 2. Precautions • Switch off the electrical main switch. • Ensure that the mains supply to the machine is inactive by removing the relevant factory fuses. • Machine without transformer (A): ∗ Open all circuit breakers: F1, F2, F3, F4 and ∗...
  • Page 32 Chapter 4 4. Adapting machine to mains voltage 480V • Measure the factory voltage between the phase 480V 400V 230V 208V 480V 400V 230V 208V 480V 400V 230V 208V L1, L2, L3 and change the settings of the machine if necessary. Note: If the measured voltage differs more than 10% of one of the values listed, then the customer 400V...
  • Page 33 Chapter 4 7. Connect the power supply cable • Tightening torque 1.2 - 1.6 Nm. Cable Power supply Ground ground screw Neutral Only for machines without transformer Phase 1 Phase 2 Phase 3 • Install the main switch cover. 8. Switching on and checking the mains •...

  • Page 34: Connecting The Machine To The Mains, Pa 2410/00

    Chapter 4 4.2.2 Connecting the machine to the mains, PA 2410/00 Estimated time te complete [min.]: Required special tools..Panel key 9.1.3 Setup tooling kit (PA 2435/00) Required part(s) ... . . - DANGER, HIGH VOLTAGE PRESENT AFTER MAIN SWITCH OFF DANGER DANGER...
  • Page 35 Chapter 4 1. Precautions • Switch off the electrical main switch. • Ensure that the mains supply to the machine is inactive by removing the relevant factory fuses. • Open all circuit breakers: F1, F2, F3, F4, F5 and 2. Remove panel at the left side of the base •...
  • Page 36 Chapter 4 3. Adapting machine to mains voltage • 480V Measure the factory voltage between the phase L1, L2, L3 and change the settings of the machine if necessary. • Check and change the interconnections of the transformer if necessary, see step 4. Note: If the measured voltage differs more than 10% 400V of one of the values listed, then the customer...
  • Page 37 Chapter 4 6. Leading the power supply cable • Route the mains cable (4 x 2.5 mm max., diameter max. 16 mm) through a separate metal duct or pipe. This duct or pipe must be grounded, to avoid EMI (electromagnetic interference) problems. •...

  • Page 38: Air Supply, Connecting

    Chapter 4 4.3 Air supply, connecting Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . - 1.
  • Page 39 Chapter 4 4.4 Vacuum supply, connecting Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . - 1.

  • Page 40: Power And Safety Circuits

    Chapter 4 4.5 Power and safety circuits 4.5.1 Power and safety circuit PA 2410/01 Figure 14 Emergency and safety circuit PA 2410/01 Installation Manual 4022 593 51853 AX-201 08.03...

  • Page 41: Power And Safety Circuit Pa 2410/00

    Chapter 4 4.5.2 Power and safety circuit PA 2410/00 Figure 15 Emergency and safety circuit PA 2410/00 4022 593 51853 Installation Manual 08.03 AX-201...

  • Page 42: Chapter 5 Communication

    Chapter 5 CHAPTER 5 Communication 5.1 SMEMA interfacing To let the machine work with adjacent equipment in a flow line, it complies with the SMEMA standards. To sequence boards properly from machine to machine two signal lines are used: “Busy” and “Board available”. 5.1.1 SMEMA, interface cable One SMEMA interface cable (length 2000 mm) is supplied with the machine.

  • Page 43: Smema, Connecting

    Chapter 5 5.2 SMEMA, connecting Figure 17 SMEMA connections on board transport Connector upstream machine Connector downstream machine 24V from upstream machine 24V to downstream machine AX is: Downstream machine is: NOT BUSY... 1 - 2 Closed NOT BUSY: .

  • Page 44: External Network, Connecting

    Chapter 5 5.3 External network, connecting Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . Network cable 1.

  • Page 45: Chapter 6 Software Installation

    Chapter 6 CHAPTER 6 Software installation The machine software is completely installed before the machine is delivered. During installation of the machine no additional steps have to be performed. Installation or upgrade of software is described in Service Manual AX-201 chapter •...

  • Page 46: Chapter 7 Final Test

    Chapter 7 CHAPTER 7 Final test 7.1 Checks before operation Before operating the machine for the first time after (re-)installation a few checks have to be done: ■ Power up the machine. ■ Place calibration nozzles ■ Execute a ‘refresh front’ calibration to update the module calibration values. 7.2 Starting operation ■...

  • Page 47: Chapter 8 Machine, Relocating

    Chapter 8 CHAPTER 8 Machine, relocating Instructions how an installed machine can be transferred to another location. ■ Remove the installed trolleys and feeder banks, use the special lift plate feeder bank. ■ Disconnect: • the power supply • the air connection •...

  • Page 48: Chapter 9 Special Tools

    Chapter 9 CHAPTER 9 Special tools 9.1 Tools needed for installation, overview 9.1.1 Maintenance kit (PA 2440/00) 9.1.3 Setup tooling kit (PA 2435/00) 9.1.4 Recommended standard tools Installation Manual 4022 593 51853 AX-201 08.03...

  • Page 49: Maintenance Kit (Pa 2440/00)

    Chapter 9 9.1.1 Maintenance kit (PA 2440/00) Description Ordering code Amount Used for Lubricating kit Grease gun 5322-395-10615 Flexible hose 9498-396-02040 Protection cap (Kluber) Isoflex Topas NCA52 5322-390-10151 Grease for XY robot bearings Lithium based grease NSK 1 5322-390-20159 Transport spindles, guides Anti score EP lube 3 grease 9498-396-00143 Placement head HA Z-motor, guide...
  • Page 50 Chapter 9 Description Ordering code Amount Used for Encoder tool 9498-396-02059 Adjustment of encoders on Y-axes Plastic distance plate 9498-396-02075 X encoder adjustment Linear scale mounting tool 9498-396-02024 on X-axis Linear scale mounting tool 9498-396-02026 on Y-axes Assortment box Dust catch filter 5322-480-10169 Nozzle placement head HA Carbon brushes...
  • Page 51 Chapter 9 Description Ordering code Amount Used for Washer PF 3.2X7 9498-396-00951 Protection boards, manifold, DV controllers Washer 4.3X9 9498-396-00904 All M4 screws placement head DV on bracket Washer PF-CP M2,5 9498-396-01068 Manifold placement head HA Earth washer STL ST 4.3X8 9498-396-01069 Fans, brackets Earth washer STL ST 5.3X10...

  • Page 52: Lubricating Tool For Placement Head Dv And Z-Lift

    Chapter 9 9.1.2 Lubricating tool for placement head DV and Z-lift Placement head lubrication tool 9498-396-01954 A Needle (set of 6) 9498 396 01998 Container 9498 396 02000 Plunger Dispenser 9498 396 01999 Nylon ring Flange screw Plunger arm Screw Grease (IKO) 9498 396 02001 Needle guidance...

  • Page 53: Setup Tooling Kit (Pa 2435/00)

    Chapter 9 9.1.3 Setup tooling kit (PA 2435/00) Figure 20 Setup tooling kit , contents Item Description Qty Ordering code Application Identification and picture Calibration nozzle 5322-360-10311 Calibration, placement head Nozzle set 5 x L8 9498-396-01874 Calibration, placement head Spirit level 9498-396-00097 Levelling Plumb line...

  • Page 54: Setup Tooling, Optional Tools

    Chapter 9 9.1.3.1 Setup tooling, optional tools Description Ordering code Application Identification and picture Installation wheel set 9498 396 00145 Set of 4 lorries for manual machine 4022 510 1763 transportation. Description Ordering code Application Identification and picture Placement head cleaning tool 9498-396-00558 Installation Manual 4022 593 51853...

  • Page 55: Recommended Standard Tools

    Chapter 9 9.1.4 Recommended standard tools Quantity Description Open end/ring wrench 5 mm Open end/ring wrench 5.5 mm 1 set Open end/ring wrenches 6 - 24 mm Socket screwdriver 4 mm Socket screwdriver 5 mm Socket screwdriver 7 mm Socket screwdriver 8 mm Socket screwdriver round-head 2.5 mm Socket screwdriver round-head 3 mm Socket screwdriver round-head 4 mm...