Page 1 YAMAHA SMT Assembly System Surface Mounter Maintenance Manual EMKMG-21A-0110...
Page 2: Table Of Contents
Safety instructions Safety instructions Be sure to read these safety instructions before using YAMAHA surface mounters or related products. Contents CE marking 1. Safety To ensure safety 1.1.1 Defining safety 1.1.2 Causes of injuries and accidents Using safety gear Restrictions on machine use 1.3.1...
Page 3 Warning labels 3.2.1 Handling safety covers 3.2.2 Pinching or crushing injury xvii 3.2.3 Effects on human body xviii 3.2.4 Handling each section Caution labels xxiii 3.3.1 Machine damage xxiii Label positions xxviii...
Page 4: Ce Marking
CE marking This equipment conforms to the EU Machinery Directive 2006/42/EC (description A1 below) and EMC Directive 2014/30/EU (description A2 below). However, this equipment does not bear CE marking if a custom order item was installed. Cautions regarding the official language of EU countries and the language used in operation manuals, CE declarations, operation screen characters, and warning labels when this equipment is installed in an EU countr y.
Page 5: Safety
1. Safety To ensure that the machine you purchased is used safely and correctly, always comply with the instructions and rules in this manual regarding safety. However this manual cannot cover all items regarding safety in detail. So it is extremely important that the operator or person handling the machine make correct decisions regarding safety.
Page 6: Restrictions On Machine Use
Restrictions on machine use 1.3.1 Defining the operator and ser vice personnel CAUTION Only the operator and service personnel having sufficient knowledge of this machine should handle this machine. Operator: The operator is someone who has been trained by us in machine operation, has a thorough knowledge of the machine operation manual and demonstrates adequate knowledge of machine operation and safety.
Page 7: Cautions During Machine Operation
YAMAHA or your distributor. Handling the internal tape cutter • Never supply electrical power and air to the machine while the covers for the tape cutter are removed. • Tape cutter maintenance tasks must be performed by YAMAHA service personnel.
Page 8: Keeping Hands Away From Moving Parts
Keeping hands away from moving parts During use of this machine, the customer’s equipment and operating conditions might allow the operator’s hands to come into contact with moving parts. Use the following safety measure options to avoid possible danger where openings or gaps are found on the machine.
Page 9 YS24X,YSD YSM40/YSM40R 0 to 44.0mm 0 to 39.0mm Z:LEX(YSM20/YSM20W) 0 to 36.0mm 4 to 40.0mm From board conveyor plane YSM10 0 to 44.0mm 4 to 40.0mm 13.4 to 80.4mm 4.6 to 39.2mm YSB55w 0 to 10mm 6mm (fixed) 0 to 6.6mm 0 to 26.4mm...
Page 10: Handling Solvents (Including Solder, Adhesive And Flux)
Handling solvents (including solder, adhesive and flux) Cleaning organic solvents, such as isopropyl alcohol (IPA) and ethanol are used for the maintenance of this machine (including optional units). Additionally, the solder paste printers, dispensers, and some hybrid placers and flip chip bonders use solder, flux, or bond, etc. during normal production. Since many of these materials include organic solvents, great care should be taken when handling them.
Page 11: Handling The X-Ray Unit
4. Safety education about X-ray Appropriate measures are taken for YAMAHA's X-ray unit so that the amount of the X-ray leak to the outside of the equipment is very small. Therefore, when using this equipment in Japan, it is not necessary to set controlled areas defined in Article 3 of the Ordinance on Prevention of Ionizing Radiation Hazards.
Page 12: Handling Grease And Oil
When disposing of a battery, dispose of it in compliance with the laws and regulations of the country where the machine is used. If you have any questions about disposal of the battery, please contact YAMAHA or your distributor. 1.14 Handling heavy objects This machine (including optional units) may require the operator to handle heavy objects during work.
Page 13: Components And Materials To Be Used
4. Select components and materials that meet the specifications of the machine. NOTE Check the detailed specifications of the components and materials with the suppliers beforehand. If you have any questions about the specifications of the machine, please contact YAMAHA or your distributor.
Page 14: Safety Message
2. Safety message This section describes information you should always comply with to prevent unforeseen accidents that might lead to injury of the operator and others or damage the machine. Hazards and injuries that might result from ignoring safety instructions and operating the machine incorrectly are categorized as follows. Safety message and categories in this manual This manual uses the following safety alert symbols, signal words, and format styles according to the degree of hazard.
Page 15: Typical Warning Text Found In Manual
Typical warning text found in manual The following are typical warning message text found in the YAMAHA surface mounter or related product manual. 2.2.1 Safety instruction When you see the following cautions or warnings, always read them thoroughly and make sure you fully understand them.
Page 16: Operation And Handling Precautions
2.2.2 Operation and handling precautions When you see the following cautions or warnings, always read them thoroughly and make sure you fully understand them. n Warnings WARNING INFLAMMATION MAY OCCUR IF GREASE OR LUBRICANT GETS IN THE EYES. BEFORE HANDLING THE GREASE, WEAR SAFETY GOGGLES TO ENSURE THE GREASE WILL NOT COME IN CONTACT WITH THE EYES.
Page 17: Facilities And Environmental Condition
2.2.3 Facilities and environmental condition When you see the following cautions or warnings, always read them thoroughly and make sure you fully understand them. n Warnings WARNING ALWAYS SHUT OFF THE POWER AND AIR SUPPLY BEFORE REPLACING PARTS OR PERFORMING REPAIRS. WARNING DURING TEACHING OR WHEN MAKING MACHINE ADJUSTMENTS, ALWAYS KEEP ALERT SO THAT YOU CAN STOP THE MACHINE WHENEVER NEEDED.
Page 18: Warning Labels
3. Warning labels To use the YAMAHA machines safely and correctly, warning labels are attached to the machine body and peripheral equipment. Check that the information on each warning label is clearly legible and comply with the instructions. Warning label format and mark description 3.1.1...
Page 19: Warning Labels
Warning labels 3.2.1 Handling safety covers Potential Injury from touching moving parts during machine operation hazard To avoid Do not touch or tamper with safety cover switches and do not operate machine if any safety cover hazard switches were deactivated. Applicable All YS series machines, tray changers, etc.
Page 20: Pinching Or Crushing Injury
3.2.2 Pinching or crushing injur y Potential · Hands or fingers might be caught between moving parts and covers, causing injury. hazard · Hands or fingers might be pinched by moving parts, causing injury. To avoid Never place hands or fingers in machine during operation such as when handling tray magazines. hazard Applicable Z:LEX(YSM20/YSM20W), YSM40/YSM40R, all YS series machines,...
Page 21: Effects On Human Body
3.2.3 Effects on human body Potential Electrical shock hazard hazard To avoid Do not touch and disassemble ionizer discharge needles. Keep them away from water. hazard Applicable Machines equipped with ionizer (option) All case Case machines To prevent the electric shock or damage. Do not touch electrodes.
Page 22 Potential Burn hazard hazard To avoid Heater becomes very hot during and shortly after operation, so do not touch it. hazard • Setup Applicable YSD,YSH20 machines equipped with heater (option) Case machines • Maintenance Potential Electrical shock hazard hazard To avoid Do not touch while power is supplied.
Page 23 Potential Electrical shock hazard To avoid Keep the ionizer away from eyes. Do not disassemble or touch the discharge needles. hazard Applicable Machines equipped with ionizer (option) All case Case machines Potential Electrical shock hazard To avoid Always turn off UPS switch when performing maintenance work. hazard Applicable Machines equipped with UPS (option)
Page 24: Handling Each Section
3.2.4 Handling each section Potential Solvent may catch fire. hazard To avoid Keep solvents such as alcohol away from fire or flame. hazard Applicable • Setup All solder paste printers Case machines • Maintenance Potential Electrical shock hazard hazard To avoid Before opening covers wait at least 100 seconds after turning power off.
Page 25 Potential Damage to machine or injury to person hazard To avoid Before handling the product (equipment) always read manuals and make sure you fully understand hazard the contents. Applicable Z:LEX(YSM20, YSM20W), YSM40/YSM40R, all YS series machines, All case Case machines etc.
Page 26: Caution Labels
Caution labels 3.3.1 Machine damage Potential Adverse effects on component mounting accuracy hazard To avoid Do not touch camera unit or apply impacts to it. hazard Applicable • Setup All machines Case machines • Maintenance Potential Risk of damage hazard To avoid Remove shipping bolts and clamps before using machine.
Page 27 Potential Machine damage hazard To avoid Make sure push-up pins are arranged within specified area. hazard Applicable Z:LEX(YSM20/YSM20W), YS24, YS24X Setup Case machines Potential Machine damage or fire hazard To avoid Do not use other than specified solvent. hazard • Setup Applicable All solder paste printers Case...
Page 28 Potential Machine damage hazard If machine is not to be used for 6 months or more, block off the solvent path to protect solvent To avoid hazard pump. Applicable All solder paste printers Maintenance Case machines Potential Might disable machine functions hazard To avoid Periodically replace USP battery since it has a limited service life.
Page 29 Potential Could cause machine damage (collisions with head, etc.). hazard Verify that no objects have been placed on the top cover of the feeder exchange carriage (for To avoid hazard YSM40). Applicable Feeder exchange carriage (YSM40) Setup Case machines Potential The carrier tape could make contact with the head, possibly causing machine damage.
Page 30 Potential Could cause machine damage (collisions with head, etc.). hazard Verify that no objects have been placed on the top cover of the feeder exchange carriage (for To avoid hazard YSM40 and Z:LEX (YSM20)). Feeder exchange carriage Applicable Setup Case machines (YSM40/YSM40R, Z:LEX(YSM20/YSM20W)) Potential...
Page 31: Label Positions
Label positions The following warning/caution labels are attached to the YAMAHA products to ensure safe and correct use. Check that the information on each label is clearly legible and comply with the instructions. For safety precautions other than those on the labels shown in this section, see the Safety instructions "1.
Page 32 n Label positions Warning/caution labels Rear ■ Safety cover switch (Front/Rear) Feeder unlock sensor ■ (Front/Rear, Right/Left) ■ Safety cover (Front/Rear) ■ Conveyor opening (Right/Left) ■ Tape cutter safety cover switch (Front/Rear) ■ Circuit protector cover ■ Transformer cover ■ Tape cutter safety cover (Front/Rear) 93201-KMG-00 xxix...
Page 33 n Label positions Warning/caution labels Inside of machine ■ Linear motor ■ Linear motor 93202-KMG-00...
Page 34 n Label position Warning/caution labels Control box ■ Upper side of control box 93203-KMG-00 n Label positions Warning/caution labels sATS15 ■ Front of cover ■ Side of cover ■ Rack 93204-KMG-00 xxxi...
Page 35 General Contents Introduction 1. Contents of each chapter 2. Maintenance list Chapter 1 Maintenance 1. Maintaining machine performance Essential conditions and working environment Importance of periodic inspections and cleaning Importance of appropriate humidity management 2. Preparing for maintenance tasks Consumable parts 2.1.1 Head unit 2.1.2...
Page 36 Nozzle cleaning 1.2.1 Cleaning and lubricating the nozzle buffing area 1.2.2 Cleaning the nozzle air path 1.2.3 Cleaning the nozzle tip 1.2.4 ANC nozzle attaching / detaching tool Recognition unit 1.3.1 Cleaning the multi-camera lighting's protective glass 2. Monthly inspection X-axis 3-10 2.1.1...
Page 37 Chapter 4 Maintenance of options 1. Ionizer Cleaning the ionizer discharge needle (Monthly) Replacing the ionizer discharge needle (2-year) 2. UPS (Uninterruptible Power Supply) Replacing the UPS battery (3-year) 3. Nozzle station Checking and cleaning nozzle station sensor (1-year) 4. Maintenance of sATS15 Daily inspection 4.1.1 Checking the pallet and the setting conditions...
Page 38 Replacing the valves 4. Conveyor Replacing the conveyor belt Appendix 1. Specifications Air regulator unit Power connection terminals Connection between machines 1.3.1 PREVIOUS INTERFACE connector 1.3.2 NEXT INTERFACE connector 2. Maintenance parts YSM10 main unit maintenance parts list sATS15 maintenance parts list...
Page 39 Introduction Contents 1. Contents of each chapter 2. Maintenance list The instruction manual of this machine is written for those who operate this machine. Please read this manual carefully for correct operations and pay special attention to safety precautions. After reading through this manual, please use this manual as an occasional reference and keep it within reach.
Page 40 "3-month", "6-month", "1-year" and "2-year". Chapter 4 Maintenance of options Describes the maintenance work of YSM10 main unit options (sATS15, ionizer, UPS and nozzle station). Chapter 5 Lubrication Points & Schedule Provides information regarding the lubrication points, lubrication tools, and the lubrication schedule for the axes described in section 3 "Periodic Inspections".
Page 41: Maintenance List
2. Maintenance list n Maintenance list The following maintenance procedure codes are used: S: Inspection C: Cleaning L: Lubrication E: Replacement ( ): Procedure required only when a problem exists NOTE Example) "C(E)" is indicated in the "3 Mon." field of [All heads] - [Valve] - [Filter] in the list shown below. This means that the filter needs to be cleaned at intervals of 3 months.
Page 42 n Option : Maintenance list S: Inspection C: Cleaning L: Lubrication E: Replacement ( ): Procedure required only when a problem exists Section Unit name Check item Daily Weekly Monthly 3 Mon. 6 Mon. 1 Year 2 Years 3 Years Ionizer Discharge needle Main unit...
Page 43: Maintenance
Chapter 1 Maintenance Contents 1. Maintaining machine per formance Essential conditions and working environment Importance of periodic inspections and cleaning Importance of appropriate humidity management 2. Preparing for maintenance tasks Consumable parts 2.1.1 Head unit 2.1.2 Nozzles 2.1.3 Main unit / base Replaceable parts 2.2.1 Head unit...
Page 44: Maintaining Machine Performance
Air hose with inner diameter of 8mm or more should be used. Use conditions Clean air passed through air dryer and air filter should be used. n Power Item YSM10 Power supply 200/208/220/240/380/400/416VAC (±10%), 3-phase AC line Frequency 50 Hz or 60 Hz Power supply capacity 7.0 kVA...
Page 45: Importance Of Periodic Inspections And Cleaning
Importance of periodic inspections and cleaning Periodic inspections and cleaning are extremely important maintenance tasks. Failure to perform inspections and cleaning will prevent the machine from delivering full performance and may lead to component mounting problems or equipment breakdowns. Examples: •...
Page 46: Preparing For Maintenance Tasks
2. Preparing for maintenance tasks Tasks described in this section focus mainly on replacing parts (consumable parts) that might cause a gradual loss of machine functions during use. This section also describes how the user can easily replace parts (replaceable parts) when a breakdown occurs. Consumable parts The followings are prepared as consumable parts of this machine and should be replaced as needed during maintenance work.
Page 47 Consumable part (optional part) Consumable part (Example: HM head) Optional part Ejector bit 53108-KMG-00 Name Part name Part No. Note Recommended replacement intervals: Approx. 2 years Ejector bit KLW-M7154-00X It is not allowed to reuse the bit. NOTE figure above shows the example of HM head. However, HM5 head also uses the same consumable part. CAUTION The part Nos.
Page 48: Nozzles
2.1.2 Nozzles n Consumable parts (optional parts) Name Part name Part No. Note NOZZLE 301A ASSY. KHN-M7710-A4X 0603 to 1005 size components Standard 30X Group nozzles NOZZLE 302A ASSY. KHN-M7720-A3X 1608 to 3216 size components NOZZLE 311A ASSY. KHY-M7710-A4X 0603 dedicated Narrow-pitch NOZZLE 312A ASSY.
Page 49 Name Part name Part No. Note BODY, NOZZLE 310 KHY-M77A1-00X For 310A/3010A/3110A Nozzle tip only BODY, NOZZLE 311 KHY-M7711-03X For 311A Nozzle tip only BODY, NOZZLE 312 KHY-M7721-02X For 312A Nozzle tip only BODY, NOZZLE 313 KHY-M7731-02X For 313A Nozzle tip only BODY, NOZZLE 301 KHN-M7711-05X For 301A...
Page 50: Main Unit / Base
2.1.3 Main unit / base n Main unit/base consumable parts (Optional purchase parts) Name Part name Part No. Note Conveyor belt (Standard type) BELT, CONV. (2670) KMG-M91A3-00X Length: 2670 mm Conveyor belt BELT, CONV. (3090) KMG-M91A4-00X Length: 3090 mm (Extention conveyor belt type) Filter element FILTER ELEMENT KLF-M8502-50X...
Page 51 Consumable parts (main unit/base) Optional purchase parts Conveyor belt Conveyor belt Air/mist filter Air filter Oil mist filter Filter element Element assembly Air intake filter Air intake filter (Control box) Air intake filter (Machine rear side) Air intake filter (Machine front side) * 2 each for front 53102-KMG-00...
Page 52: Replaceable Parts
Replaceable parts The replacement parts shown in this manual are for parts which could cause machine stops due to the breakdown or the life expiration. No machine adjustments are required after replacing these parts. 2.2.1 Head unit Replaceable parts HM head (figure shows the cover, connector, and air hose detached) Bit cap Blow valve Shaft blow valve...
Page 53: Maintenance Tools
Maintenance tools 2.3.1 Cleaning tools Cleaning tools Parts supplied with machine Nozzle tip cleaning tape Nozzle cleaning wire Feeder plate cleaning brush 53104-KMG-00 n Cleaning tools Parts supplied with machine Name Part name Part No. Note Nozzle cleaning wire NEEDLE ASSY KV8-M8883-A0X Nozzle tip cleaning tape TAPE, CLEANER...
Page 54 Cleaning tools Optional purchase parts CLEANER, VISION SET Nozzle cleaning wire handle Blower brush Lens cleaner Air blow tool Cotton swab sticks (15 cm) Vacuum assembly Cleaning wiper Spline shaft cleaning kit 53105-KMG-00 n Cleaning tools (Optional purchase parts) Name Part name Part No.
Page 55: Lubricating Tools And Grease
2.3.2 Lubricating tools and grease Lubricating and greasing tools Parts supplied with machine / Optional Parts Nozzle buffing lube supply syringe Lithium-based grease NSL GREASE GUN SET Bent type nozzle Standard nozzle Flexible type nozzle Grease gun 53106-KMG-00 n Lubricating and greasing tools (Parts supplied with machine) Name Part name Part No.
Page 56 n Precautions when handling grease WARNING INFLAMMATION MAY OCCUR IF GREASE OR LUBRICANT GETS INTO THE EYES. BEFORE HANDLING THE GREASE OR LUBRI- CANT, WEAR SAFETY GOGGLES TO ENSURE THE GREASE OR LUBRICANT DOES NOT GET INTO THE EYES. WARNING INFLAMMATION MAY OCCUR IF GREASE OR LUBRICANT COMES INTO CONTACT WITH SKIN.
Page 57: Special Tools
Because these part Nos. may be changed without prior notice, be sure to verify the latest part Nos. before ordering parts. NOTE The leaf spring installation tool is also available for other YAMAHA machines such as Z:LEX (YSM20/YSM20W: HM head type) and YS series (excluding YS88). 1-14...
Page 58: Required Tools
Required tools Prepare the following tools and items necessary for maintenance. n Tool list : Supplied with machine, : Options Name Description Remarks Phillips screwdriver Large, small Slotted (flat-blade) screwdriver Large, small #0, #1 (Used to replace nozzle leaf springs and Phillips precision screwdriver air valves.) Hex wrench set...
Page 59 Chapter 2 Daily maintenance items Contents Before beginning work 1. Checking the nozzle Checking with software 1.1.1 Vacuum level when nozzle is open Checking the nozzles visually 2. Cleaning the feeder plate...
Page 60: Before Beginning Work
Before beginning work In most cases, maintenance should be performed with the main power turned off. However, some maintenance tasks are performed under emergency stop conditions with the power turned on. In such cases, ensure adequate safety and press the emergency stop before beginning the maintenance. The power is turned on during maintenance where any servo-axis must be operated or machine operation checked.
Page 61: Checking The Nozzle
1. Checking the nozzle Solder sticking to the nozzle tip or a clogged nozzle hole can cause component pickup errors and recognition errors. Poor nozzle spring action can also cause pickup and mounting errors. To prevent such problems, inspect each nozzle daily. Checking with software n How to check for a dirty nozzle (with the [Tip Dirt Check] button) The term "dirty nozzle"...
Page 62 n How to check for clogged nozzles (on the [Unit] - [Head] tab screen) The term "clogged nozzle" used here indicates that material such as solder is adhering to the nozzle hole, causing a rise in negative pressure even if no component is being picked up by the nozzle. This state might cause problems such as component mounting errors.
Page 63: Vacuum Level When Nozzle Is Open
1.1.1 Vacuum level when nozzle is open The table below shows the vacuum level measured when each nozzle is open. The values might differ slightly depending on the air source and operating conditions. Use these values for reference during maintenance. n Standard vacuum level when nozzle is open Head Type Nozzle...
Page 64: Checking The Nozzles Visually
Checking the nozzles visually To visually check nozzles, remove each nozzle from the head or from the nozzle station. NOTE As for a simple method, check the nozzle attached to the head with a mirror or similar tool. n Points to check the removed nozzles Check the removed nozzles with a magnifying glass or similar tool.
Page 65: Cleaning The Feeder Plate
2. Cleaning the feeder plate If any chip or foreign object falls onto the feeder plate, it may be caught in when setting the feeder, causing the pickup position to deviate. Therefore it is recommended to inspect and clean portions around the feeder plate periodically.
Page 66 Chapter 3 Periodic maintenance items Contents 1. Weekly inspection Nozzle inspection 1.1.1 Nozzle buffing area inspection 1.1.2 Checking the nozzle leaf spring Nozzle cleaning 1.2.1 Cleaning and lubricating the nozzle buffing area 1.2.2 Cleaning the nozzle air path 1.2.3 Cleaning the nozzle tip 1.2.4 ANC nozzle attaching / detaching tool Recognition unit...
Page 67 5. One-year inspection 3-29 5.1. Head unit 3-29 5.1.1 Cleaning the spline shaft 3-29 Conveyor 3-31 5.2.1 Inspecting conveyor belt and cleaning guides and pulleys 3-31 W-axis 3-35 5.3.1 Cleaning and lubricating W-axis ball screw and hexagon spline 3-35 5.3.2 Cleaning and lubricating the W-axis guide 3-37 Base...
Page 68: Weekly Inspection
1. Weekly inspection This section mainly describes weekly inspection and cleaning. Nozzle inspection A faulty buffing operation (spring action) or defective nozzle leaf spring may cause pickup errors. To prevent this, inspect each nozzle. 1.1.1 Nozzle buffing area inspection Check the spring action of the nozzles. Press on a nozzle and if it returns normally there is no problem. However, if the return action is poor (sluggish) then pickup errors and recognition errors will occur.
Page 69: Checking The Nozzle Leaf Spring
1.1.2 Checking the nozzle leaf spring Inspect the nozzle holding status of the head periodically. • An unstable holding force at the nozzle leaf spring (hereafter "leaf spring") can adversely affect pickup, recognition, and mounting operations. n Leaf spring inspection points Check the following points by removing the nozzle and reattaching it to the nozzle holder.
Page 70: Nozzle Cleaning
Nozzle cleaning The following describes how to clean and lubricate the Type 30X Group nozzles. Also, clean and lubricate the Type31X Group nozzles in the same manner. 1.2.1 Cleaning and lubricating the nozzle buffing area Remove the nozzle from the head. 1.
Page 71: Cleaning The Nozzle Air Path
1.2.2 Cleaning the nozzle air path Remove the nozzle from the head. Step 2 Air blow 1. Press the emergency stop button to open ■ Attaching/detaching the nozzle tip the machine safety cover. 2. Remove the nozzle from the head. If the Remove the clip.
Page 72: Anc Nozzle Attaching / Detaching Tool
1.2.4 ANC nozzle attaching / detaching tool Regarding the machine equipped with a nozzle station (option / hereafter "ANC"), nozzles are detached manually from the nozzle station for maintenance. In this case, if using the "ANC nozzle attaching / detaching tool"...
Page 73 n How to use ANC nozzle attaching / detaching tool (detaching nozzles) Step1 Open the nozzle station shutter. Nozzle station - Opening the shutter Open the [Unit] - [Head] screen and press the [Nozzle. Stn Shutter] button to open the nozzle station shutter.
Page 74 n How to use ANC nozzle attaching / detaching tool (attaching nozzles) Attach nozzles at the nozzle station in the reverse order of detaching. Check the nozzle setting position. Check that other nozzles are not set to the nozzle storage position and the setting position is correct. NOTE Regarding the nozzle setting position, check the nozzle placement position label attached in the machine or the machine setting.
Page 75: Recognition Unit
Recognition unit 1.3.1 Cleaning the multi-camera lighting's protective glass Adhered dust, etc., on the multi-camera lighting's protective glass can cause component recognition errors. To prevent this, it is recommended to inspect and clean the cover in a periodic manner. Blow off dust on the lighting's Step 1 Blowing off dust with blower brush protective glass.
Page 76: Monthly Inspection
2. Apply grease while referring “Cleaning and lubrication” described later on. 3. Consult your YAMAHA sales office or representative when abnormal sounds occur even after trying the countermeasures in the above steps 1 and 2.
Page 77: X-Axis
X-axis This section explains the X-axis inspection, cleaning, and lubrication procedures. For details regarding lubrication points and the lubrication condition, see "Chapter 5 Lubrication points and schedule". The user must provide the grease gun (standard nozzle) and the prescribed grease (NSL). NOTE The procedure and the lubrication points of HM head unit are described as example.
Page 78 Inject the grease. Step 4 Applying grease 1. As shown in the figure on the right, move the head unit to the right to see the Grease nipple (center) grease nipple. 2. The grease nipple at the center of those aligned at 3 locations is the ball screw nipple.
Page 79: Cleaning And Lubricating The X-Axis Guide
2.1.2 Cleaning and lubricating the X-axis guide Prepare for the cleaning and greasing. 1. Press the emergency stop button to open the machine safety cover. 2. Grasp the carrying handle to move the head unit forward. 3. Place a square cloth under the head unit. Clean the guide.
Page 80: Y-Axis
Y-axis This section explains the Y-axis inspection, cleaning, and lubricating procedures. For details regarding lubrication points and the lubrication condition, see "Chapter 5 Lubrication points and schedule". The user must provide the grease gun (standard nozzle and bent nozzle) and the prescribed grease (NSL). 2.2.1 Cleaning and lubricating the Y-axis ball screw Prepare for the cleaning and greasing.
Page 81 Inject the grease. Step 4 Injecting grease Using a grease gun (standard type), inject the prescribed grease (NSL) at the 2 grease nipples (1 each nipple for the left and right) Grease nipple for the Y-axis guide. 53320-KMG-00 NOTE Inject until the grease begins to seep out from the gap. Wipe off the excess grease.
Page 82: Cleaning And Lubricating The Y-Axis Guide
2.2.2 Cleaning and lubricating the Y-axis guide Prepare for the cleaning and greasing. 1. Press the emergency stop button to open the machine safety cover. 2. Place a square cloth under the head unit. Step 2 Cleaning the guide Clean the guide. 1.
Page 83: Conveyor
Conveyor 2.3.1 Checking the conveyor sensor condition and operation This machine uses a transmission type fiber sensor as the conveyor sensor. As the conveyor width changes, the distance between the light emitting and light receiving sensors also changes. Accordingly, the light receiving status of the sensor may change. Therefore, a conveyor sensor tuning function is provided on this machine that stores the sensor light receiving status after the conveyor rail width has been changed and automatically rewrites the sensor threshold value.
Page 84 Perform the conveyor sensor Step 4 Conveyor sensor tuning tuning. [Sensor tuning] button 1. If an error occurred, press the [Sensor Tune] button on the right of the [Unit] - [Conveyor] tab screen. 2. If pressing the [OK] button on the confirmation screen, the threshold value is calculated as the current sensor status is no board.
Page 85: Three-Month Inspection
3. Three-month inspection This section describes the maintenance work performed once every 3 months. Head unit 3.1.1 Cleaning and replacing the air filter As a general guideline, the filter should be inspected once every 3 months, although this may vary somewhat depending on the air supply conditions and the operating time.
Page 86: Pu-Axis
PU-axis The PU (push-up) axis is designed to prevent flexing or warping of the board during clamping and is important because it prevents depressing of the board during component mounting. The PU-axis also prevents deviations in the component mounting accuracy due to the board depressing during component mounting, so it is important to regularly clean and inspect the PU-axis to ensure it operates correctly.
Page 87 Apply the new grease. Step 4 Applying the grease Apply as much as 2 cm of new grease to Grease your finger. Apply it equally on the surface of the ball screws and the ball guides and also into its grooves. 53329-KMG-00 Spread the grease.
Page 88: Base
Base This machine is equipped with the air intake fan filters (2 in total: 1 each for left and right on the front of the machine) to prevent the heat generated while moving axes. If the filters are not cleaned properly, the temperature inside the machine may rise due to filter clogging. Clean the filters to prevent lowering of the machine function or shortening of the service life.
Page 89 n Simple cleaning of air intake filter The periodic filter cleaning procedure is described on the previous pages. The simple cleaning of air intake filter is also available with a household vacuum cleaner. Remove dust over the filter cover. CAUTION Do not clean the air intake filter during the automatic operation.
Page 90: Cleaning The Machine Rear Side Filter
3.3.2 Cleaning the Machine rear side filter The air intake filter for protecting the control unit is installed on the right of machine rear side. Open the cover. Step 1 Opening the cover Use a Phillips screwdriver to remove the 4 screws that mount the cover.
Page 91: Six-Month Inspection
The lighting unit may become dirty with dust due to the long-term use of the machine. Periodic cleaning is recommended. CAUTION If trouble occurs with the lighting unit that was not improved by cleaning, contact YAMAHA or YAMAHA sales representatives. Disassembly and cleaning of the lighting unit by the user will be excluded from the warranty. 4.1.1 Cleaning the fiducial camera The fiducial camera is mounted on the head unit.
Page 92: Cleaning The Multi-Camera Lighting Unit
4.1.2 Cleaning the multi-camera lighting unit The following describes the cleaning procedure for the multi-camera lighting unit. CAUTION Do not apply strong force or shock to the camera unit and lighting unit during cleaning. Doing so may damage the glass components used in the camera unit. Detach the protective glass.
Page 93: Cleaning The Scan Camera
4.1.3 Cleaning the scan camera The light diffuser plate and prism for the scan camera are attached to the opening at the left end of the camera. These diffuser plate and prism may become dirty due to dust and dirt. Periodic cleaning is recommended. CAUTION Do not apply strong force to the camera parts during cleaning.
Page 94: Base
Base 4.2.1 Cleaning the Control box filter The air intake fan and the filter are in the control box that controls the machine. The filter should be cleaned once a 6-month, although this may vary depending on the machine condition. Power off the machine.
Page 95 Detach the control box filter. Step 6-7 Detaching control box filter The filter mounting screws can be loosen manually. Loosen the filter mounting screws Control box and detach the filter from the control box. 53358-KMG-00 NOTE Multiple cables are connected to the control box. If it is difficult to access to the filter, disconnect the cables from the control box as necessary.
Page 96: One-Year Inspection
5. One-year inspection This section describes the maintenance work performed once every year. 5.1. Head unit 5.1.1 Cleaning the spline shaft As a general guide, clean the spline shaft once ever year, although this may vary depending on the machine condition or surrounding situation.
Page 97: Prepare For Cleaning
Prepare for cleaning. Step 6 Cleaning the spline 1. Place a paper cup or cloth under the head to be cleaned. 2. Fill the cleaning kit with absolute ethanol. Cleaning kit 25 mm Clean the inside of the spline shaft. or more 1.
Page 98: Conveyor
Conveyor 5.2.1 Inspecting conveyor belt and cleaning guides and pulleys As the conveyor belt wears away, slippages may occur that prevent securely conveying the boards. It is therefore necessary to make periodic checks for wear of the conveyor belt. Additionally, if belt wear debris accumulate on the light receiving surface of the conveyor sensor, troubles such as incorrect board detection may occur.
Page 99 Loosen the belt. 1. Before loosening the conveyor belt, mark at the current position of the pulley with a permanent marker. 2. Loosen the pulley mounting screws applying the tension with a hex wrenches (5 and 4) referring to the figure below. 3.
Page 100 Clean the belt guides and pulleys. Step 7 Cleaning the belt guide and pulley 1. Use a vacuum assembly (option) to suction the belt wear debris on the belt Spatula (made of plastic) guides and sensors, etc. Belt wear debris 2.
Page 101 When the difference between the belt upper surface and board clamp top surface is very little, the board Board clamp plate transfer error may occur easily. In this case, contact YAMAHA or YAMAHA sales representatives. Checking conveyor belt rotation Conveyor drive buttons Left...
Page 102: W-Axis
W-axis The following describes the cleaning and lubrication procedures for the W-axis. For details about lubrication points and styles, see "Chapter 5 Lubrication points and schedule". Prepare the grease gun (standard type) and the specified grease (NSL). 5.3.1 Cleaning and lubricating W-axis ball screw and hexagon spline Step 1 Changing the conveyor width Change the conveyor width to its...
Page 103 Apply grease. Step 5 Applying grease 1. Apply the specified grease (NSL) by hand Grease uniformly over the surfaces of the (Apply grease in a uniform manner.) hexagon spline and the ball screw and lead grooves while the conveyor is the minimum width.
Page 104: Cleaning And Lubricating The W-Axis Guide
5.3.2 Cleaning and lubricating the W-axis guide Change the conveyor width to its Step 1 Changing the conveyor width maximum width. 1. Press the [Width] button on the [Unit] - [Conveyor] tab screen to display the "Conveyor Width" screen. 2. Enter the maximum value of the conveyor width in the "Target Width"...
Page 105 Apply grease. Step 5 Applying grease 1. Close the machine safety cover to cancel the emergency stop. Grease nipple 2. Change the conveyor to the maximum width with the procedure of Step 1. 3. Press the emergency stop button to open the machine safety cover.
Page 106: Base
Base 5.4.1 Cleaning the air/mist filter and cup Air filters and oil mist filters are installed to this machine to prevent oil, water, and impurities, etc., from being introduced into the machine from the air compressor. The following describes the procedures for inspecting, cleaning, and replacing these filters.
Page 107 Check the filter media status. Step 5 Detaching and checking filter media Rotate the media to remove it, and check it Oil mist filter for soiling and clogging. If soiled, replace it with a new media indicated in the Consumable Parts List. 53360-KMG-00 Attach the media and cup.
Page 108: Two-Year Inspection
6. Two-year inspection Head unit 6.1.1 Replacing the ejector bit As the ejector bit is used for a long time, its function may lower. Therefore, it is recommended to replace the ejector bit with a new one once every about 2 years so as to maintain its performance even though this service life may vary depending on the operating conditions.
Page 109 Chapter 4 Maintenance of options Contents 1. Ionizer Cleaning the ionizer discharge needle (Monthly) Replacing the ionizer discharge needle (2-year) 2. UPS (Uninterruptible Power Supply) Replacing the UPS battery (3-year) 3. Nozzle station Checking and cleaning nozzle station sensor (1-year) 4.
Page 110: Ionizer
NOTE The performance and capability of the ionizer to remove static electricity depends on the operating environment or the materials and shape of the items that the static electricity is removed. YAMAHA does not guarantee such performance or capability. CAUTION The tip of the ionizer discharge needle is sharp and the voltage is applied.
Page 111: Cleaning The Ionizer Discharge Needle (Monthly)
Cleaning the ionizer discharge needle (Monthly) Perform this work monthly or if the LED on the ionizer main unit is lit red. Power off the ionizer. Step 3 Cleaning the discharge needle 1. Press the emergency stop button and open the machine safety cover to stop the power supply to the ionizer.
Page 112: Replacing The Ionizer Discharge Needle (2-Year)
Replacing the ionizer discharge needle (2-year) Replace the ionizer discharge needle (KJX-M83P1-00X : NEEDLE SPARE SET/5 pcs) once every 2 years or if an error still occurs even after performed "1.1 Cleaning the ionizer discharge needle (Monthly)" on previous page. An ionizer uses 10 discharge needles.
Page 113 3. Check that the green LED of the "POWER" on the ionizer is turned on. Make sure that no error is found. NOTE If continuing to receive the error even after replacing the discharge needle unit, contact YAMAHA or YAMAHA sales representatives.
Page 114: Ups (Uninterruptible Power Supply)
2. UPS (Uninterruptible Power Supply) Replacing the UPS batter y (3-year) The battery is a consumable item. Even though the service life of the UPS may vary depending on the operating environment, such as ambient temperature, it is recommended to replace the battery with a new one (KGA- M6566-30X) at reference intervals of 3 years.
Page 115: Nozzle Station
3. Nozzle station Checking and cleaning nozzle station sensor (1-year) When the machine is equipped with the nozzle station (option), it is necessary to periodically check the nozzle detection sensor status. CAUTION If the nozzle station sensor cannot detect the nozzle correctly, the nozzle change does not operate correctly or the production cannot continue due to nozzle detection error.
Page 116 Open the ANC Auto screen. Step 5 Opening the ANC Auto screen Click the ANC illustration on the right of the Click the ANC illustration. screen. 54403-KMG-00 Check the ANC sensor operation. 1. Check that the nozzle storage status shown on the screen is same as the actual nozzle storage status referring to the "example of nozzle storage position/ sensor status".
Page 117: Maintenance Of Sats15
Clean and apply grease to the ball guide. AH-axis Guide Clean and apply grease to the guide. Six-month NOTE Use only the greases (grease name: NSL) specified by YAMAHA. NOTE Lubrication points including the machine side are described in "Chapter 5 Lubrication points".
Page 118: Daily Inspection
Daily inspection 4.1.1 Checking the pallet and the setting conditions Check the pallet and the setting when replacing tray components everyday. n Checkpoints • The pallet is not bending. • The drawing of the pallet is not worn out or damaged. •...
Page 119 n [Unit] - [Auto TC] screen If an operation failure of sATS15 occurs, check the displayed error messages and the sensor status on the [Unit] - [Auto TC] screen. [Unit] - [Auto TC] screen Sensor status display area 54405-KMG-00 The status of each unit in the sATS15 is monitored by the each sensor. n Sensor list Sensor display When sensor display is ON (lit up), this indicates:...
Page 120: Monthly Inspection
Monthly inspection 4.2.1 Checking the rack and the guide rail Check the rack and guide rail once a month. n Checkpoints • The pallet guide section of the rack is not worn out. • No backlash of the pallet retainer door is found. •...
Page 121: Cleaning And Lubricating The Az-Axis Ball Screw And Guides
4.2.2 Cleaning and lubricating the AZ-axis ball screw and guides The following describes the procedures for cleaning and lubricating the AZ-axis (ball screw and ball guides). Pull out the pallets. Step 2 Detaching AZ-axis cover Open the rack door to pull out all the pallets. Figure viewed from inside of machine Detach the AZ-axis cover.
Page 122 Spread the grease. Step 5 Spreading grease over AZ-axis 1. Close the machine safety cover to cancel the emergency stop. 2. Press the [Pallet Set] button on the [Unit] - [Auto TC] screen. Enter the pallet number "1" in the box of the "Pallet Set" screen and press the [OK] button.
Page 123: 6-Month Inspection
6-month inspection 4.3.1 Cleaning and lubricating the AH-axis guide The following describes the procedures for cleaning and lubricating the AH-axis guide rail. Glean the guide. Step 1 Cleaning AH-axis 1. Press the emergency stop button to open the safety cover on the rear side of the machine.
Page 124 Chapter 5 Lubrication points and schedule Contents 1. Lubrication preparations Compatible grease Grease gun 2. Lubrication points and schedule (Main machine) 5-2 X-axis Y-axis W-axis PU-axis 3. Lubrication points and schedule (sATS15) AZ-axis AH-axis...
Page 125: Lubrication Preparations
1. Lubrication preparations Compatible grease For greasing procedures, always use the YAMAHA prescribed grease shown below. CAUTION Using unauthorized grease could damage the machine. Lube Point Guide Grease Ball screw X-axis Guide Ball screw Y-axis Guide Main unit Ball screw...
Page 126: Lubrication Points And Schedule (Main Machine)
2. Lubrication points and schedule (Main machine) X-axis X-axis lubrication points (Example of HM head unit) Ball screw and guide Grease gun: Manual lubrication: X-axis ball screw X-axis guide Top-side grease nipple X-axis guide Bottom-side grease nipple X-axis guide Top-side grease nipple X-axis guide Bottom-side grease nipple 53501-KMG-00...
Page 127: Y-Axis
Y-axis Y-axis lubrication points Grease gun: Y-axis guide Grease nipple Manual lubrication: Y-axis ball screw Grease nipple Y-axis ball screw Grease nipple Y-axis guide Grease nipple 53502-KMG-00 Lubrication section Grease Lubrication point Interval Procedure Ball screw Monthly Grease gun: Standard nozzle Guide Monthly Grease gun: Bent type nozzle...
Page 128: W-Axis
W-axis W-axis lubrication points Grease gun: Manual lubrication: W-axis guide W-axis guide Hexagon spline W-axis ball screw W-axis ball screw 53503-KMG-00 Lubrication section Grease Lubrication point Interval Procedure Guide Yearly Grease gun: Standard nozzle Ball screw Yearly Manual lubrication Hexagon splines Yearly Manual lubrication...
Page 129: Pu-Axis
PU-axis PU-axis lubrication points Grease gun: Manual lubrication: PU-axis ball screw PU-axis ball screw PU-axis ball guide PU-axis ball guide 53504-KMG-00 Lubrication section Grease Lubrication point Interval Procedure Ball screw Every 3 months Manual lubrication Ball guide Every 3 months Manual lubrication...
Page 130: Lubrication Points And Schedule (Sats15)
3. Lubrication points and schedule (sATS15) AZ-axis AZ-axis lubrication points Figure without machine inner cover Grease gun: Manual lubrication: AZ-axis ball screw AZ-axis ball screw AZ-axis guide 53505-KMG-00 Lubrication section Grease Lubrication point Interval Procedure Ball screw Monthly Manual lubrication Ball guide Monthly Manual lubrication...
Page 131: Ah-Axis
AH-axis AH-axis lubrication points Figure viewed from inside of machine Grease gun: Manual lubrication: AH-axis guide 53506-KMG-00 Lubrication section Grease Lubrication point Interval Procedure Guide Every 6 months Grease gun: Bent type nozzle...
Page 132 Chapter 6 How to replace consumable parts Contents 1. Nozzle Replacing the nozzle tip and spring Replacing the nozzle O-ring 2. Nozzle leaf springs Replacing nozzle leaf springs 3. Head unit Replacing the valves 4. Conveyor Replacing the conveyor belt...
Page 133: Nozzle
1. Nozzle If the nozzle tip or O-ring is worn out as the nozzle is used for a long time, this may cause the placement or pickup error. Additionally, if the buffing operation is not smooth even after cleaning and lubricating the nozzle, the spring may need to be replaced.
Page 134: Replacing The Nozzle O-Ring
Replacing the nozzle O-ring Remove the nozzle. 1. Press the emergency stop button to open the machine safety cover. Step 2 Replacing the nozzle O-ring 2. Remove the target nozzle manually. Removing the O-ring Replace the nozzle O-ring. Remove the O-ring and replace it with a new one.
Page 135: Nozzle Leaf Springs
2. Nozzle leaf springs If an error is found after performing the work steps in "1.1.2 Checking the nozzle leaf spring" in Chapter 3, it is necessary to replace the nozzle leaf springs. CAUTION As a rule, be sure to replace a pair of components even when only the nozzle leaf spring on one side deteriorates. Replacing nozzle leaf springs The nozzle leaf spring (hereafter referred to simply as "leaf spring") replacement procedure is given below.
Page 136 n About leaf spring installation tool When installing the nozzle leaf springs, use of the optional purchase part "leaf spring installation tool (P/ N:KGS-M8810-00X)" makes it possible to install the leaf springs more uniformly. NOTE If having this tool, it is recommended to install the leaf springs with this tool. How to use the leaf spring installation tool The following describes steps continued from Step 2 of "2.1 Replacing nozzle leaf...
Page 137: Head Unit
3. Head unit If an operation failure occurs in the operation valve, blow valve, or shaft blow valve of the head unit, follow the steps below to replace the defective valve. NOTE Before replacing the valve, it is required to turn off the air supply and power off the machine. Replacing the valves Turn off the air supply and power Step 2...
Page 138 Disconnect the connector. Step5 Replacing the head valve Disconnect the connector of the valve you want to replace. HM head unit Mounting screw (2 locations) Blow valve Replace the valve. Remove the mounting screws (2 pcs.) of the valve you want to replace with a precision Phillips screwdriver, and then replace the valve.
Page 139: Conveyor
4. Conveyor Replacing the conveyor belt If significant looseness, contamination, or scuffing is found in the conveyor belt when performing the work steps in "5.2.1 Inspecting conveyor belt and cleaning guides and pulleys" of Chapter 3, the conveyor belt needs to be replaced. Change the conveyor width to a Step 1 Changing the conveyor width...
Page 140 Loosen the belt. 1. Before loosening the conveyor belt, mark at the current position of pulley with a permanent marker. 2. Loosen the pulley mounting screws applying the tension with a hex wrenches (5 and 4) referring to the figure below. 3.
Page 141: Replace The Conveyor Belt
Remove the belt from the conveyor. Step 6 Detaching the conveyor belt Detach the conveyor belt through the clearance between the spline shaft and drive pulley. 53612-KMG-00 Clean the belt guides and pulleys. 1. Use a vacuum assembly (option) to suction the belt wear debris on the belt guides and sensors, etc.
Page 142 When the difference between the belt upper surface and board clamp top surface is very little, the board transfer error may occur easily. In this case, contact YAMAHA or YAMAHA sales representatives. 0.5 mm Belt upper surface Board clamp plate...
Page 143 Appendix Appendix Contents 1. Specifications Air regulator unit Power connection terminals Connection between machines 1.3.1 PREVIOUS INTERFACE connector 1.3.2 NEXT INTERFACE connector 2. Maintenance parts YSM10 main unit maintenance parts list sATS15 maintenance parts list...
Page 144: Appendix 1. Specifications
This is the pressure of the source air supplied to the machine. Before setting the air pressure with the air regulator, make sure that this supply air pressure is in the following optimal range. YSM10 : 0.45MPa to 0.70MPa n Digital pressure gauge When within the normal range, the air pressure displays in green.
Page 145: Power Connection Terminals
L1, L2, L3 and ground terminal (PE) on the power terminal block. n Power supply specifications Model name Power Frequency Power capacity YSM10 3-phase AC 200/208/220/240/380/400/416V (+/-10%) 50/60Hz 7.0kVA Power input terminals Power input terminals (L1, L2, L3)
Page 146: Connection Between Machines
Connection between machines To exchange signals such as board request and operation status with the downstream or upstream machine, the "NEXT INTERFACE" and "PREVIOUS INTERFACE" connectors located on the rear of the machine are used. The "NEXT INTERFACE" connector connects to the downstream machine, and the "PREVIOUS INTERFACE" connector connects to the upstream machine such as a loader.
Page 147: Next Interface Connector
1.3.2 NEXT INTERFACE connector When the following three conditions are met, the NEXT INTERFACE circuit in the machine allows the board to be carried out. 1. Machine is ready for carrying in a board (BA OUT : ON) 2. Board carry-in signal is input from the upstream machine. (BUSY IN [N0100420] : ON) 3.
Page 148: Maintenance Parts
2. Maintenance par ts YSM10 main unit maintenance parts list CAUTION The parts (part Nos.) in this manual were described at the time of manual issue. The part Nos. are subject to change without notice. Make sure to obtain the latest information on part names and part Nos. when purchasing.
Page 149 Maintenance parts list Position of use Name Part name Part No. Note Blow valve VALVE KLF-M7152-00X HM head unit For ejector vacuum Operation valve VALVE KLF-M7153-00X generation Shaft blow valve VALVE KLW-M7158-00X Muffler MUFFLER KLW-M715A-00X Muffler inside the bit cap Filer cap FILTER CAP KLW-M7155-00X...
Page 150 CAUTION The parts (part Nos.) in this manual were described at the time of manual issue. The part Nos. are subject to change without notice. Make sure to obtain the latest information on part names and part Nos. when purchasing. Position of use Name Part name...
Page 151 Position of use Name Part name Part No. Note Y-axis cable duct DUCT,CABLE KMG-M2678-00X Y-axis Intermediate tape of inner TAPE 1,Y DUCT KMG-M260B-00X Cable protection tape cable duct Periphery tape of inner cable TAPE 2,Y DUCT KMG-M260C-00X Cable protection tape duct Inner periphery tape of inner TAPE 3,Y DUCT...
Page 152: Sats15 Maintenance Parts List
sATS15 maintenance parts list Position of use Name Part name Part No. Note Pallet drawing guide rail L1 GUIDE, PALETTE L1 KMF-M1809-00X Guide rail Pallet drawing guide rail L2 GUIDE, PALETTE L2 KMF-M1810-00X Pallet drawing guide rail R GUIDE, PALETTE R KMF-M1811-00X Pallet drawing guide rail L3 GUIDE, PALETTE L3...
Page 153 November 2021 Maintenance Manual Version 1.10...

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