Page 1 Preventive Maintenance Manual AX-201...
Page 2: Feedback On This Manual
DOCUMENT DATA Document ....Preventive Maintenance Manual AX-201 Based on ....Service Manual AX-201 4022 593 50293 08.03 Order number .
Page 3 CONTENTS Preventive Maintenance Manual This manual is a summary of all maintenance instructions from: Service Manual AX-201 4022 593 50293 08.03 This manual can be used to maintain the machine. More detailed information can be found in the service manual mentioned above. Use of this manual for qualified and trained personel only.
Page 4 SYSTEM Chapter A7 CHAPTER A7 Maintenance schedules This chapter lists all preventive maintenance aspects of the machine, completed with recommended intervals and references to the actual procedure. A7.1 Recommended maintenance tools and materials Recommended maintenance tools and materials can be found in: •...
Page 5 SYSTEM Chapter A7 A7.3 Preventive maintenance schedule Item Operator Engineer Base ✸ ✸ ✸ ✸ B7.1 Touch screen and keyboard, cleaning ✸ ✸ ✸ ✸ B7.2 Protection hoods, cleaning ✸ ✸ ✸ ✸ B7.3 Safety contacts on front and rear cover, checking ✸...
Page 6 Integrated electronics manufacturing solutions MODULE 1. MAINTENANCE INSTRUCTIONS Table of Contents CHAPTER A2 Safety A2.1 General A2.2 Personnel qualification A2.3 Basic safety rules A2.4 Safety compliance A2.5 Danger, warning and caution A2.6 Safety stickers A2.7 Safety devices A2.7.1 Enabling switch front/rear, usage A2.8 Noise levels A2.9 Emergency contact A2.10Liability...
Page 7 MAINTENANCE SCHEDULE Chapter 11 MM-00001.fm D7.3 Nozzles interface, checking cleaning D7.4 Placement head DV, cleaning the air channel D7.5 Placement head HA, replacing the dust catch filter in flip chip nozzle D7.6 Placement head HA, replacing the dust catch filter in nozzle D7.7 Placement head HA, replacing the carbon brushes from Z and RZ motor...
Page 8 BASE Chapter B7 CHAPTER B7 Maintenance instructions NOTE: Operation, adjustment, maintenance and repair of this machine shall be carried out by qualified and trained personnel only. This chapter contains detailed (corrective and preventive) maintenance instructions. The preventive maintenance intervals are defined in A7.3 Preventive maintenance schedule For Material Safety Data Sheets, see...
Page 9 BASE Chapter B7 B7.1 Touch screen and keyboard, cleaning Estimated time te complete [min.]: Required special tools..Fibre free tissue, household glass cleaner Required part(s) ... . . - 1.
Page 10 BASE Chapter B7 B7.2 Protection hoods, cleaning Estimated time te complete [min.]: Required special tools..Vacuum cleaner, fibre free tissues, household glass cleaner Required part(s) ... . . - 1.
Page 11 BASE Chapter B7 B7.3 Safety contacts on front and rear cover, checking Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . 1.
Page 12 BASE Chapter B7 B7.4 Air supply unit, draining Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . - DANGER OF STRONG MAGNETIC FIELD WARNING WARNING...
Page 13 BASE Chapter B7 B7.5 Filter in controllers, replacement Estimated time te complete [min.]: Required special tools..Vacuum cleaner Required part(s) ... . . Filters, see A8.4.1 Controllers, spares 1.
Page 14 BASE Chapter B7 B7.6 Filter in air supply unit, replacement Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . Filter, see A8.4.5 Air supply unit, spares DANGER OF STRONG MAGNETIC FIELD WARNING...
Page 15 BASE Chapter B7 B7.7 Gauges on air supply unit, checking Estimated time te complete [min.]: Required special tools..Required part(s) ... . . 1.
Page 16 BOARD TRANSPORT Chapter C7 CHAPTER C7 Maintenance instructions NOTE: Operation, adjustment, maintenance and repair of this machine shall be carried out by qualified and trained personnel only. This chapter contains detailed (corrective and preventive) maintenance instructions. The preventive maintenance intervals are defined in A7.3 Preventive maintenance schedule For Material Safety Data Sheets, see...
Page 17 BOARD TRANSPORT Chapter C7 C7.1 Board sensors, cleaning Estimated time te complete [min.]: Required special tools..Ethanol, lense tissues Required part(s) ... . . - 1.
Page 18 BOARD TRANSPORT Chapter C7 C7.2 Transport area, cleaning Estimated time te complete [min.]: Required special tools..Vacuum cleaner, fibre free tissues, ethanol Required part(s) ... . . - 1.
Page 19 BOARD TRANSPORT Chapter C7 C7.3 Transport spindles and bearings, checking and lubricating Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . Grease, A8.5.3 Maintenance kit (PA 2440/00) 1.
Page 20 BOARD TRANSPORT Chapter C7 5. Grease the board width adjustment • Grease the spindles (8) left and right, use NSK no.1 • Grease the guides (9) left and right, use Isoflex Topas NCA52. Service Manual 4022 593 50293 C.46 AX-201 08.03...
Page 21: Checking The Belts
BOARD TRANSPORT Chapter C7 C7.4 Transport belts, checking Estimated time te complete [min.]: Required special tools..Belt tension indicator, A8.6.6 Recommended Assembléon tools Required part(s) ... . . - 1.
Page 22 PICK AND PLACE Chapter D7 CHAPTER D7 Maintenance instructions NOTE: Operation, adjustment, maintenance and repair of this machine shall be carried out by qualified and trained personnel only. This chapter contains detailed (corrective and preventive) maintenance instructions. The preventive maintenance intervals are defined in A7.3 Preventive maintenance schedule For Material Safety Data Sheets, see...
Page 23 PICK AND PLACE Chapter D7 D7.1 Toolbit exchange unit, cleaning Estimated time te complete [min.]: Required special tools..Vacuum cleaner, fibre free tissues Required part(s) ... . . - 1.
Page 24 PICK AND PLACE Chapter D7 D7.2 Component reject module, cleaning Estimated time te complete [min.]: Required special tools..Vacuum cleaner, fibre free tissues Required part(s) ... . . 1.
Page 25 PICK AND PLACE Chapter D7 D7.3 Nozzles interface, checking cleaning Estimated time te complete [min.]: Required special tools..Ethanol, petroleum jelly Required part(s) ... . . - 1.
Page 26 PICK AND PLACE Chapter D7 D7.4 Placement head DV, cleaning the air channel Estimated time te complete [min.]: Required special tools..Set nozzle punches, see A8.6.4 Placement head cleaning tool, see A8.6.4.
Page 27 PICK AND PLACE Chapter D7 D7.5 Placement head HA, replacing the dust catch filter in flip chip nozzle Estimated time te complete [min.]: 3 per nozzle Required special tools..- Required part(s) ... . . - 1.
Page 28 PICK AND PLACE Chapter D7 D7.6 Placement head HA, replacing the dust catch filter in nozzle Estimated time te complete [min.]: 5 per nozzle Required special tools..Ethanol Filter replacement tool A8.5.3 Maintenance kit (PA 2440/00) Required part(s) .
Page 29 PICK AND PLACE Chapter D7 D7.7 Placement head HA, replacing the carbon brushes from Z and RZ motor Estimated time te complete [min.]: Required special tools..Vacuum cleaner Required part(s) ... . . Brushes, A8.4.8 Placement head HA, spares This procedure is meant for preventive maintenance.
Page 30 PICK AND PLACE Chapter D7 D7.8 Placement head DV and Z-lift, checking, cleaning and lubricating Estimated time te complete [min.]: Required special tools..Lubrication tool with bended needles A8.5.3 Maintenance kit (PA 2440/00) Required part(s) .
Page 31 PICK AND PLACE Chapter D7 3. Loading the lubrication tool • Remove the needle from the syringe. • Fill the lubrication tool container for ¾ with grease (6). Note: Make sure no air bubbles are formed • Put the plunger through the flange screw (7) and put the plunger in the container.
Page 32 PICK AND PLACE Chapter D7 6. Lubricate the placement head • Press the button once (13) to lubricate the placement head. Do not move the guidance in Z-direction when the needle is inserted, this will bend the needle. 7. Finalize •...
Page 33 PICK AND PLACE Chapter D7 D7.9 Placement head HA, checking, cleaning and lubricating Estimated time te complete [min.]: Required special tools..Ethanol Required part(s) ... . . Grease, A8.5.3 Maintenance kit (PA 2440/00) 1.
Page 34 VISION Chapter F7 CHAPTER F7 Maintenance instructions NOTE: Operation, adjustment, maintenance and repair of this machine shall be carried out by qualified and trained personnel only. This chapter contains detailed (corrective and preventive) maintenance instructions. The preventive maintenance intervals are defined in A7.3 Preventive maintenance schedule For Material Safety Data Sheets, see...
Page 35 VISION Chapter F7 F7.1 CV camera, cleaning the external waste bin Estimated time te complete [min.]: Required special tools..Vacuum cleaner Required part(s) ... . . - 1.
Page 36 VISION Chapter F7 F7.2 Vision markers on CV camera, cleaning Estimated time te complete [min.]: Required special tools..Ethanol, fibre free tissues Required part(s) ... . . - 1.
Page 37 VISION Chapter F7 F7.3 BA camera, cleaning Estimated time te complete [min.]: Required special tools..Clean air spray, lens tissue Required part(s) ... . . IRRITATING SUBSTANCE CAUTION CAUTION...
Page 38 VISION Chapter F7 F7.4 CV camera, cleaning the glass plate Estimated time te complete [min.]: Required special tools..Fibre free tissue, ethanol, small soft brush Required part(s) ... . . - IRRITATING SUBSTANCE CAUTION CAUTION...
Page 39 VISION Chapter F7 F7.5 CV camera, cleaning the internal waste bin Estimated time te complete [min.]: 2 or 20 Required special tools..- Required part(s) ... . . - 1.
Page 40 XY-ROBOT Chapter G7 CHAPTER G7 Maintenance instructions NOTE: Operation, adjustment, maintenance and repair of this machine shall be carried out by qualified and trained personnel only. This chapter contains detailed (corrective and preventive) maintenance instructions. The preventive maintenance intervals are defined in A7.3 Preventive maintenance schedule For Material Safety Data Sheets, see...
Page 41 XY-ROBOT Chapter G7 G7.1 Linear scales on XY robot, cleaning Estimated time te complete [min.]: Required special tools..Ethanol Required part(s) ... . . - 1.
Page 42 XY-ROBOT Chapter G7 G7.2 Linear guides on XY robot, cleaning and lubricating Estimated time te complete [min.]: Required special tools ..Grease gun with Kluber Isoflex Topas NCA52, A8.5.3 Maintenance kit (PA 2440/00) , vacuum cleaner (with plastic attachments) fibre free tissues.
Page 43 XY-ROBOT Chapter G7 2. Cleaning the linear guide rails • Move all carriages by hand and clean the newly exposed surface of each linear guide rail with fibre free tissues. • Remove old grease and contaminations. 3. Lubricating the linear guides •...
Page 44 XY-ROBOT Chapter G7 G7.3 Fans on X axis, cleaning Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . - 1.
Page 45 XY-ROBOT Chapter G7 G7.4 Fans on Y axis, cleaning Estimated time te complete [min.]: Required special tools..Vacuum cleaner Required part(s) ... . . - 1.
Page 46 Integrated electronics manufacturing solutions MODULE 2. ADDITIONAL INSTRUCTIONS Table of Contents A5.1.3 TIP tools A5.1.3.1 TIP tools, start up procedure A5.1.3.2 TIP tools, logoff procedure A5.1.3.3 Board transport, testing via TIP tools A5.1.3.4 Placement head HA, testing via TIP tools A5.1.3.5 Tray trolley, testing via TIP tools A5.1.3.6 Process controller, software and hardware check via TIP tools...
Page 47 MM-00002.fm setting procedure C6.1 Transport, release width or lift brake manually C6.2 Transport width belt, check/adjust tension C6.3 Transport drive belt, check/adjust tension C6.4 Transport lift belt, check/adjust tension C6.6 Transport lift table, levelling C6.7 Board clamps, adjustment C6.8 Transport belts, check/adjust adjustment C6.9 Transport rails, parallelism adjustment C6.12 Transport width, parallelism adjustment C8.2 Transport drive belts, replacement...
Page 48 SYSTEM Chapter A5 A5.1.3 TIP tools A5.1.3.1 TIP tools, start up procedure NOTE: Make sure that the correct logoff procedure is performed whenever you have been logged on to the system. 1. Start up TIP tools • Power up he machine. •...
Page 49 SYSTEM Chapter A5 A5.1.3.3 Board transport, testing via TIP tools • Start up TIP tools, see A5.1.3.1 TIP tools, start up procedure 4022 593 50293 Service Manual 08.03 AX-201 A.85...
Page 50 SYSTEM Chapter A5 • Log off TIP tools, see A5.1.3.2 TIP tools, logoff procedure A5.1.3.4 Placement head HA, testing via TIP tools • Start up TIP tools, see A5.1.3.1 TIP tools, start up procedure Service Manual 4022 593 50293 A.86 AX-201 08.03...
Page 51 SYSTEM Chapter A5 • Log off TIP tools, see A5.1.3.2 TIP tools, logoff procedure 4022 593 50293 Service Manual 08.03 AX-201 A.87...
Page 52 SYSTEM Chapter A5 A5.1.3.5 Tray trolley, testing via TIP tools • Start up TIP tools, see A5.1.3.1 TIP tools, start up procedure C - FDR Test Program. T - Tray trolley commands Select section N - New controller A - Purge flashprom B - Read all parameters from flashprom C - Reset all parameters in flashprom D - PID parameters lift to flashprom...
Page 53 SYSTEM Chapter A5 A5.1.3.6 Process controller, software and hardware check via TIP tools For basic checks on the software and hardware of the process controller, a tipscript (aitcheck.tip) has been made. 1. Start-up TIP tools • Logon to the system as ‘Administrator’ . •...
Page 54 SYSTEM Chapter A6 A6.1.1 Exchange calibration procedure Estimated time te complete [min.]: Required special tools..Calibration nozzle for CV and placement heads Required part(s) ... . . 1.
Page 55 SYSTEM Chapter A6 4. FEED SECTION 1 and/or 2 • XY position, • Z level. 5. TOOLBIT EXCHANGE UNIT • XY position. 6. FRONT CV • Calibration nozzle • Head marker, • XY robot is homing, • CV Left/Right, • Head 1 and 2 Z=0, •...
Page 56 SYSTEM Chapter A8 A8.5 Materials A8.5.1 Materials, definitions • Standard materials ..Tools and materials needed for preventive maintenance, local obtainable • Maintenance kit ..A collection of spare parts and materials that enables the customer to perform preventive maintenance, based on a 2 year period and a maximum machine configuration, and also...
Page 57 SYSTEM Chapter A8 A8.5.3 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...
Page 58 SYSTEM Chapter A8 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...
Page 59 SYSTEM Chapter A8 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 60 SYSTEM Chapter A8 A8.5.4 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...
Page 61 SYSTEM Chapter A8 A8.5.5 Standard materials Description Fibre free tissue Local purchase Keyboard cleaner Local purchase Ethanol Local purchase Clean air spray Local purchase Vacuum cleaner with plastic attachments Local purchase Anti-static spray Local purchase Molykote metal protector Local purchase Loctite 243 Local purchase Protective gloves...
Page 62 SYSTEM Chapter A8 A8.6 Tools A8.6.1 Tools, definitions • Recommended standard tools Tools that are used for general purposes during service and maintenance activities. Local purchase by the customer is expected. • Recommended special tools Tools that are used for specific purposes during service and maintenance activities.
Page 63 SYSTEM Chapter A8 A8.6.3 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...
Page 64 SYSTEM Chapter A8 Service Manual 4022 593 50293 A.194 AX-201 08.03...
Page 65 SYSTEM Chapter A8 A8.6.4 Setup tooling kit (PA 2435/00) Figure 83 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...
Page 66 SYSTEM Chapter A8 A8.6.4.1 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 Service Manual 4022 593 50293...
Page 67 SYSTEM Chapter A8 A8.6.5 Recommended special tools Description Application Picture Power supply Used when the trolley will not (24 Volt, 5A) come down from the base Belt tension gauge Corrective maintenance: (Range 50-250 Hz, accuracy 2Hz). belt tension check after Z-motor, Z-belt, X-motor and X-belt replacement.
Page 68 SYSTEM Chapter A8 A8.6.6 Recommended Assembléon tools Description Ordering Code Application Wrist band ESD 2622-890-98277 Spiral coard 2622-890-98352 Adjustment plate 9498-396-00118 Trolley lift Plastic feeler gauge 5322-395-10673 Trolley extension cable 5322-218-11886 Encoder tester 5322-395-10773 Y-calibration tool, A-series trolley 9498-396-00857 Z-calibration tool, A-series trolley 9498-396-00856 Suspension beam 5322-535-10577...
Page 69 BASE Chapter B6 B6.4 Digital pressure switch, check and adjust settings B6.4.1 Digital pressure switch, check setting Figure 85 Digital pressure switch and clock gauge Open the rear left upper door of the base and check the behaviour of the switch by changing the compressed air pressure using the regulator knob (2 in figure 85).
Page 70 BASE Chapter B6 B6.4.2 Digital pressure switch, adjust settings B6.4.2.1 Digital pressure switch in ‘measure’ mode, unlocking or locking PRESSURE PRESSURE PRESSURE 4 Sec. Figure 86 Digital pressure switch, unlocking or locking • Press 'SET' for more than 4 seconds until the display shows 'UnL' (unlocked) or 'Loc' (locked).
Page 71 BASE Chapter B6 B6.4.2.3 Digital pressure switch in ‘pressure set’ mode, adjustment In this mode the set values for switch points van be changed. Press 'SET' (less than 2 seconds) Display goes from ‘measure’ mode to ‘pressure set’ mode. Alternatively 'P_1' and a value is visible in the display. 1.
Page 72 BASE Chapter B6 B6.4.2.6 Digital pressure switch, reset the pressure registration The digital pressure switch can be reset if there is no system pressure. • Unlock the digital pressure switch, B6.4.2.1. Digital pressure switch in ‘measure’ mode, unlocking or locking Press the ▲...
Page 73 BASE Chapter B6 B6.4.3 Digital vacuum switch (ZSE30-01-65), setting procedure For installing the digital pressure gauge on the system the following setting procedure should be followed. 1. Unlock the system • Press the SET button for more than 4 seconds until UnL (unlock mode) or Loc (lock mode) is visible on the display Press the ▲...
Page 74 BASE Chapter B6 4. Lock the system • Press the Set button for more than 4 seconds until UnL (unlock mode) is visible on the display. • Press the ▲ or ▼ button until LoC (lock mode) is visible on the display •...
Page 75 BOARD TRANSPORT Chapter C6 C6.1 Transport, release width or lift brake manually Estimated time te complete [min.]: Required special tools..Power supply (24 Volt, 5A ), see A8.6.5 Recommended special tools Required part(s) .
Page 76: Adjust The Belt Tension
BOARD TRANSPORT Chapter C6 C6.2 Transport width belt, check/adjust tension Estimated time te complete [min.]: 5/5 (checking/adjusting) Required special tools..Belt tension indicator, A8.6.6 Recommended Assembléon tools Required part(s) ... . . - 1.
Page 77 BOARD TRANSPORT Chapter C6 C6.3 Transport drive belt, check/adjust tension Estimated time te complete [min.]: 5/5 (checking/adjusting) Required special tools..Belt tension indicator, A8.6.6 Recommended Assembléon tools Required part(s) ... . . - 1.
Page 78: Check Belt Tension
BOARD TRANSPORT Chapter C6 C6.4 Transport lift belt, check/adjust tension Estimated time te complete [min.]: 5/5 (checking/adjusting) Required special tools..Belt tension indicator, A8.6.6 Recommended Assembléon tools Required part(s) ... . . - NOTE: Use TIP tools (A5.1.3 TIP tools...
Page 79 BOARD TRANSPORT Chapter C6 C6.6 Transport lift table, levelling Estimated time te complete [min.]: Required special tools..Height block, dial gauge with support, A8.6.6 Recommended Assembléon tools Required part(s) ... . . - 1.
Page 80 BOARD TRANSPORT Chapter C6 4. Check and adjust levelling of lift table • Check if the eccentric bearing at the rear (3) is in its middle position. • Stroke of the bearing is 0.5 mm • Bring the dial gauge over the height block and note the value (H1).
Page 81 BOARD TRANSPORT Chapter C6 C6.7 Board clamps, adjustment Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . - NOTE: Use TIP tools (A5.1.3 TIP tools...
Page 82 BOARD TRANSPORT Chapter C6 C6.8 Transport belts, check/adjust tension Estimated time te complete [min.]: 5/5 (checking/adjusting) Required special tools..Belt tension indicator, A8.6.6 Recommended Assembléon tools Required part(s) ... . . - 1.
Page 83 BOARD TRANSPORT Chapter C6 C6.9 Transport rails, parallelism adjustment Estimated time te complete [min.]: Required special tools..Gauge board transport, A8.6.6 Recommended Assembléon tools Required part(s) ... . . - 1.
Page 84 BOARD TRANSPORT Chapter C6 C6.12 Transport width, parallelism adjustment Estimated time te complete [min.]: Required special tools..Feeler gauges Required part(s) ... . . 1.
Page 85 BOARD TRANSPORT Chapter C8 C8.2 Transport drive belts, replacement Estimated time te complete [min.]: 30 (sub tasks included) Belt tension gauge, see Required special tools..A8.6.5 Recommended special tools Required part(s) ... . . A8.4.7 Board transport, spares 1.
Page 86 BOARD TRANSPORT Chapter C8 C8.3 Transport belts, replacement Estimated time te complete [min.]: 20 (sub tasks included) Required special tools..Belt tension gauge, see A8.6.5 Recommended special tools Required part(s) ... . . A8.4.7 Board transport, spares 1.
Page 87 BOARD TRANSPORT Chapter C8 C8.7 Transport lift belt, replacement Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . A8.4.7 Board transport, spares 1.
Page 88 BOARD TRANSPORT Chapter C8 C8.17 Transport width belt, replacement Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . A8.4.7 Board transport, spares 1.
Page 89 PICK AND PLACE Chapter D6 D6.1 Placement head HA, measuring friction of the RZ movement Estimated time te complete [min.]: Required special tools..Torque meter 0-5 Nm Required part(s) ... . . - 1.
Page 90 PICK AND PLACE Chapter D6 D6.2 Placement head HA, measuring friction of the Z movement Estimated time te complete [min.]: Required special tools..Torque meter 0-20 Nm Required part(s) ... . . 1.
Page 91 PICK AND PLACE Chapter D8 D8.2 Placement head DV, head replacement Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . A8.4.10 Placement head DV, spares 1.
Page 92 PICK AND PLACE Chapter D8 D8.8 Placement head HA, RZ belt replacement Estimated time te complete [min.]: Required special tools..Feeler gauges Required part(s) ... . . Belt, A8.4.8 Placement head HA, spares 1.
Page 93: Replace The Fan
XY-ROBOT Chapter G8 G8.8 Fans on Y-axis, replacement Estimated time te complete [min.]: Required special tools..- Required part(s) ... . . Loctite 243 A8.4.12 XY robot, spares 1.
Page 94 XY-ROBOT Chapter G8 G8.9 Fans on X-axis, replacement Estimated time te complete [min.]: Required special tools..Loctite 243 Required part(s) ... . . A8.4.12 XY robot, spares 1.
Page 95 Integrated electronics manufacturing solutions MODULE 2. SAFETY Table of Contents A5.1.3 TIP tools A5.1.3.1 TIP tools, start up procedure A5.1.3.2 TIP tools, logoff procedure A5.1.3.3 Board transport, testing via TIP tools A5.1.3.4 Placement head HA, testing via TIP tools A5.1.3.5 Tray trolley, testing via TIP tools A5.1.3.6 Process controller, software and hardware check via TIP tools A6.1.1 Exchange calibration procedure...
Page 96 MM-00003.fm setting procedure C6.1 Transport, release width or lift brake manually C6.2 Transport width belt, check/adjust tension C6.3 Transport drive belt, check/adjust tension C6.4 Transport lift belt, check/adjust tension C6.6 Transport lift table, levelling C6.7 Board clamps, adjustment C6.8 Transport belts, check/adjust adjustment C6.9 Transport rails, parallelism adjustment C6.12 Transport width, parallelism adjustment C8.2 Transport drive belts, replacement...
Page 97 SYSTEM Chapter A2 CHAPTER A2 Safety A2.1 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 98: Hazard Identification
SYSTEM Chapter A2 A2.5 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 99: Danger, High Voltage
SYSTEM Chapter A2 A2.6 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 100 SYSTEM Chapter A2 A2.7 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 101 SYSTEM Chapter A2 Figure 5 Location of safety devices, rear Lock the electrical main switch (7) and the air main switch (8) by a padlock to avoid unauthorized use. A2.7.1 Enabling switch front/rear, usage DANGER OF MOVING PARTS CAUTION CAUTION Serious injury to fingers and body parts.
Page 102 SYSTEM Chapter A2 A2.8 Noise levels Location Noise level ≤ 72 dB(A) Sound pressure at operator’s position ≤ 58 dB(A) Average environmental noise level during measurement Figure 6 Noise levels A2.9 Emergency contact In case assistance is needed during an emergency situation, contact the regional Assembléon organization.
Page 103 08189 GREASE 9498 396 00143 PHILIPS CMD ANTI-SCORING EP LITHIUM GREASE 01583 LUBE 3 5322 390 20159 PHILIPS NSK GREASE NO. 1 (LR3) GREASE 10138 1322 530 68801 PHILIPS ETHANOL ETHANOL, DENATURATED 00397 1322 526 41801 PHILIPS MOLYKOTE METAL PROTECTOR...
Page 104 1. Identification of the substance/preparation MSDS : 01583 Code number : 5322 390 20157 Supplier : PHILIPS CONSUMER SERVICE Tradename : CMD ANTI-SCORING EP LUBE 3 General description : LITHUIM GREASE Emergency phonenumber +31 40 2755555 2. Composition/information on ingredients...
Page 105 SYSTEM Chapter A2 Procedure by spillage : Dependent on quantity spilt paste, one has the choice between: - remove with cleaning rag or paper, or - cover paste with Powersorb, sand, diatomite, vermiculite and suchlike. Shovel the material into plastic bag or other suitable packaging and remove to the central depot for hazardous waste.
Page 106 SYSTEM Chapter A2 11. Toxicological information Symptoms Skin local : With intensive skin contact risk of skin affection. general : No absorbtion worth mentioning under normal working conditions. Ingestion local : The substance is prickling: abdominal pain, nausea. No symptoms under normal working conditions. general : No absorbtion worth mentioning under normal working conditions.
Page 107 SYSTEM Chapter A2 The information provided in this Material Safety Data Sheet is correct to the best of the knowledge, information and belief of Philips Electronics Nederland B.V. at the date of its printing. 4022 593 50293 Service Manual 08.03 AX-201 A.19...
Page 108 1. Identification of the substance/preparation MSDS : 08189 Code number : 5322 390 10151 Supplier : PHILIPS CONSUMER SERVICE Tradename : ISOFLEX TOPAS NCA 52 General description : BALL AND PLAIN BEARING GREASE Emergency phonenumber +31 40 2755555 2. Composition/information on ingredients...
Page 109 SYSTEM Chapter A2 Local exhausting : Under normal circumstances not applicable. Storage conditions : Store product at room temperature. 8. Exposure controls/personal protection Exposure limits (20 Cel. and 1013 mbar) : not determined Remarks exposure limits : none Odeur threshold (20 Cel. and 1013 mbar) : not tracable Advised personal protection skin...
Page 110 Date last update but one : 1994-08-03 The information provided in this Material Safety Data Sheet is correct to the best of the knowledge, information and belief of Philips Electronics Nederland B.V. at the date of its printing. Service Manual 4022 593 50293 A.22...
Page 111 SYSTEM Chapter A2 MATERIAL SAFETY DATA SHEET According EC 91/155 1. Identification of the substance/preparation MSDS : 08273 Code number : 1311 504 84102 Supplier : LOCTITE Tradename : LOCTITE 243, 50 ML General description : SEALING AND LOCKING AGENT Emergency phonenumber +31 40 2755555 2.
Page 112 SYSTEM Chapter A2 Procedure by spillage : Absorb the liquid in appropriate absorbent (e.g. Powersorb, dry sand, diatomite, vermiculite etc.), shovel the mixture into plastic bags and remove to the central depot for hazardous waste. 7. Handling and storage Local exhausting : Under normal circumstances not applicable.
Page 113 Date last update but one : 1997-08-01 The information provided in this Material Safety Data Sheet is correct to the best of the knowledge, information and belief of Philips Electronics Nederland B.V. at the date of its printing. 4022 593 50293 Service Manual 08.03...
Page 114 According EC 91/155 1. Identification of the substance/preparation MSDS : 10138 Code number : 5322 390 20159 Supplier : PHILIPS CONSUMER SERVICE Tradename : NSK GREASE NO.1 General description : GREASE Emergency phonenumber +31 40 2755555 2. Composition/information on ingredients Component...
Page 115 SYSTEM Chapter A2 7. Handling and storage Local exhausting : Under normal circumstances not applicable. Storage conditions : Do not store product close to ignition sources. 8. Exposure controls/personal protection Exposure limits (20 Cel. and 1013 mbar) : TLV:5 mg/m3 SYNTHETIC OIL (as oil aerosol) Remarks exposure limits : none...
Page 116 Date last update but one : 1997-03-25 The information provided in this Material Safety Data Sheet is correct to the best of the knowledge, information and belief of Philips Electronics Nederland B.V. at the date of its printing. Service Manual 4022 593 50293 A.28...
Page 117 SYSTEM Chapter A2 MATERIAL SAFETY DATA SHEET According EC 91/155 1. Identification of the substance/preparation MSDS : 00397 Product code 12nc : 1322 530 68801 Supplier : CHEMPROHA CHEMIEPARTNER B.V. POSTBUS 872 3300 AW ZWIJNDRECHT Netherlands Tel: 078-6544944 Fax: 078-6191399 Tradename : ETHANOL 99,8%, DENATURATED WITH 5% METHANOL 1-24009 General description...
Page 118 SYSTEM Chapter A2 8. Exposure controls/personal protection Exposure limits : TLV: 1000 mg/m3 ETHANOL applicable to: Netherlands (20 ºC; 1013 mbar) TLV: 1907 mg/m3 ETHANOL applicable to: Belgium (20 ºC; 1013 mbar) TLV: 1900 mg/m3 ETHANOL applicable to: Germany (20 ºC; 1013 mbar) TLV: 1880 mg/m3 ETHANOL...
Page 119 SYSTEM Chapter A2 Toxicity : LD-50: 7.06 g/kg (ORL-RAT), ETHANOL Source IUCLID LD-50: >20 g/kg (SKN-RBT), ETHANOL Source ChemDat (Merck) LC-50: 124.7 mg/l/4H (IHL-RAT), ETHANOL Source IUCLID LD-50: 5.628 g/kg (ORL-RAT), METHANOL Source IUCLID LC-50: 83.8 mg/l/4H (IHL-RAT), METHANOL Source IUCLID LD-50: 15.8 g/kg (SKN-RBT), METHANOL Source...
Page 120 * Point to alterations with regard to the previous version. The information provided in this Material Safety Data Sheet is correct to the best of the knowledge, information and belief of Philips Electronics Nederland B.V. at the date of its printing.
Page 121 SYSTEM Chapter A2 MATERIAL SAFETY DATA SHEET According EC 91/155 1. Identification of the substance/preparation MSDS : 12803 Product code 12nc : 1322 526 41801 Supplier : DOW CORNING 62, RUE GENERAL DE GAULLE 1310 TERHULPEN Belgium Tel: +32-2-655-2523 Fax: +32-2-655-2002 Tradename : MOLYKOTE METAL PROTECTOR PLUS General description...
Page 122 SYSTEM Chapter A2 Physical state liquid Colour yellow Odour like solvents Vapor rate/range not traceable Boiling point/range The product decomposes before it boils. Melting point/range not traceable Flash point/range 28 ºC Explosive limits not traceable Dust explosions possible in air not applicable Relative density 0,81000 (water=1) (20 ºC)
Page 123 SYSTEM Chapter A2 Hazard symbol none R-phrases Flammable. S-phrases 23.2 Do not breath vapour. Avoid contact with skin. 43.13 In case of fire, use carbon dioxide, powder extinguisher, foam or water spray. If swallowed, do not induce vomiting: seek medical advice immediately and show this container or label. Hazardous component(s) not applicable Remarks on EC-labeling...
Page 124 : MOLYKOTE DX General description : LUBRICATING PASTE : Various Publicationdate : 2001-01-05 General information : dangerous.goods@philips.com Emergency phonenumber : +31 (0)497-598315 2. Hazard identification * R-phrases • Harmful to aquatic organisms, may cause long-term adverse effects in the aquatic environment.
Page 125 SYSTEM Chapter A2 Exposure limits : applicable to: The Netherlands (20 ºC; 1013 mbar) TWA(8 hours): 5 mg/m3 DISTILLATES (PETROLEUM), HYDROTREATED HEAVY NAPHTHENIC (DMSO <3%)(as oil aerosol) (Statutory threshold limit value) TWA(8 hours): 5 mg/m3 DISTILLATES (PETROLEUM), SOLVENT-REFINED HEAVY NAPHTHENIC (DMSO <3%)(as oil aerosol) (Statutory threshold limit value) TWA(8 hours): 5 mg/m3 DISTILLATES (PETROLEUM),...
Page 126 SYSTEM Chapter A2 HYDROTREATED HEAVY NAPHTHENIC (DMSO <3%)(as mineral oil, inhalable dust) TWA(8 hours): 0.2 mg/m3 DISTILLATES (PETROLEUM), SOLVENT-REFINED HEAVY NAPHTHENIC (DMSO <3%)(as mineral oil, inhalable dust) TWA(8 hours): 0.2 mg/m3 DISTILLATES (PETROLEUM), HYDROTREATED HEAVY PARAFFINIC (DMSO <3%)(as mineral oil, inhalable dust) TWA(8 hours): 0.2 mg/m3 DISTILLATES (PETROLEUM),...
Page 127 SYSTEM Chapter A2 LD-50: >2 g/kg (ORL-RAT), DISTILLATES (PETROLEUM), SOLVENT-REFINED HEAVY Source CONCAWE NAPHTHENIC (DMSO <3%) LD-50: >2 g/kg (SKN-RBT), DISTILLATES (PETROLEUM), SOLVENT-REFINED HEAVY Source CONCAWE NAPHTHENIC (DMSO <3%) LD-50: >2 g/kg (ORL-RAT), DISTILLATES (PETROLEUM), HYDROTREATED HEAVY PARAFFINIC Source CONCAWE (DMSO <3%) LD-50: >2 g/kg (SKN-RBT), DISTILLATES (PETROLEUM), HYDROTREATED HEAVY PARAFFINIC Source...
Page 128 * Point to alterations with regard to the previous version. The information provided in this Material Safety Data Sheet is correct to the best of the knowledge, information and belief of Philips Electronics Nederland B.V. at the date of its printing.
Page 129: First Aid
* Point to alterations with regard to the previous version. The information provided in this Instructioncard is correct to the best of the knowledge, information and belief of Philips Electronics Nederland B.V. at the date of its printing. 4022 593 50293 Service Manual 08.03...
Page 130 FAX:+ 49(0)2161-5869-93 Tradename : RHENUS NORLITH STM 2 General description : BALL BEARING GREASE : Various Publicationdate : 2008-01-15 General information : dangerous.goods@philips.com Emergency phonenumber : +31 (0)497-598315 2. Hazard identification 3. Composition/information on ingredients Component CAS-no EC-no Catalogue-no Percentage(%) EC-label...
Page 131 SYSTEM Chapter A2 TWA(15 minutes): 10 mg/m3 MINERAL OIL(as oil aerosol) applicable to: Germany (20 ºC; 1013 mbar) TWA(8 hours): 200 mg/m3 MINERAL OIL(carbonhydrogen mix, group applicable to: United States of America (25 ºC; 1013 mbar) TWA(8 hours): 0.2 mg/m3 MINERAL OIL(as mineral oil, inhalable dust) C=Ceiling;...
Page 132 * Point to alterations with regard to the previous version. The information provided in this Material Safety Data Sheet is correct to the best of the knowledge, information and belief of Philips Electronics Nederland B.V. at the date of its printing.
Page 133 * Point to alterations with regard to the previous version. The information provided in this Instructioncard is correct to the best of the knowledge, information and belief of Philips Electronics Nederland B.V. at the date of its printing. 4022 593 50293 Service Manual 08.03...
Page 134 Supplier : NSK Tradename : NSK GREASE NO.2 General description : GREASE : Various Publicationdate General information : dangerous.goods@philips.com Emergency phonenumber : +31 (0)497-598315 2. Hazard identification 3. Composition/information on ingredients Component CAS-no EC-no Catalogue-no Percentage(%) EC-label 649-454-00-7 ≥23.0 - ≤25.0...
Page 135 SYSTEM Chapter A2 TWA(15 minutes): 10 mg/m3 DISTILLATES (PETROLEUM), SOLVENT-REFINED HEAVY PARAFFINIC (DMSO <3%)(as oil aerosol) applicable to: Germany (20 ºC; 1013 mbar) TWA(8 hours): 1000 mg/m3 DISTILLATES (PETROLEUM), SOLVENT-REFINED HEAVY PARAFFINIC (DMSO <3%)(carbonhydrogen mix, group applicable to: United States of America (25 ºC; 1013 mbar) TWA(8 hours): 0.2 mg/m3 DISTILLATES (PETROLEUM),...
Page 136 * Point to alterations with regard to the previous version. The information provided in this Material Safety Data Sheet is correct to the best of the knowledge, information and belief of Philips Electronics Nederland B.V. at the date of its printing.

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