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CP-842E - Tekmart International

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1. Note Cover the machine carefully to prevent oil spilling on the machine when draining the oil cooler 7 Remove the oil from the nozzle index unit drain plug Cover the corrugated cardboard with a plastic sheet create a slope and drain the contents of the nozzle index unit into a collecting bucket 7 Remove the oil from the nozzle index unit drain plug Drain plu Slope did mms Note The oil removed from the machine should be discarded in accordance with local ordi nances from handling waste matter 8 Replace and properly tighten the drain plug once the oil has been fully removed CP 842 Preliminary 5 39 Maintenance gt gt Lubrication 9 Open the front doors 10 Removethe oil from the theta q index unit drain plug Use a plastic sheet as shown in the diagram below remove the drain plug and drain the old oil into the collecting bucket 10 Remove the oil from the theta q index unit drain plug Drain plug Plastic sheet
2. C746M5003 CP 842 Preliminary 8 13 Troubleshooting gt gt Servo System Troubleshooting X D1 D2 Cam and NY Axes Servo Amp Alarm Display 1 D1 axis 2 D2 axis 3 X axis 4 Cam axis 88188 81886 2 nag 2 A O 5 NY axis connector LED panel LED panel connector C746M5004 8 14 CP 842 Preliminary Troubleshooting gt gt Servo System Troubleshooting 8 2 2 Alarm Codes and Troubleshooting Check List Alarm status cause and remedy are listed in the following table to facilitate trouble shooting of alarm codes Note Some of the repairs such as replacement of a servo motor or servo pack require special training and expertise Contact a Fuji agent before attempting to perform any of these proce dures Please have the Check List for Troubleshooting available for reference when con tacting a Fuji agent for assistance CP 842 Preliminary 8 15 Troubleshootin
3. connector Z axis Y axis lt CP 842E gt BIB BIB LED panel Connector CN3 LED panel R0 axis NC axis NZ axis Connector CN3 D1 axis LED panel D2 axis X axis Cam axis A E 0000210 1 2 3 4 Connector CN3 7 49 CP 842 Preliminary Adjustments gt gt Servo Amplifier Adjustments lt CP 842ME gt Z axis Y axis 21811818 HARRE LED panel Connector CN3 LED panel R0 axis NC axis F0 axis P0 axis NZ axis Connector CN3 LED panel D1 axis D2 axis X axis Cam axis Glee EHE P j B 1 2 3 4 Connector CN3 C7SM4070 7 50 CP 842 Preliminary Adjustments gt gt Servo Amplifier
4. Ajddns oy 18S peunooo jou sey Jewod e YO9UD A 5 J p yoedonas Ajddns o lt samod eui 72940 p onp 1 si Ajddns ews Ajaalsseoxe oDJe si Ajddns A 5 J p yoedonsas s Ajddns uoneJedo sl JO OW JO NO 4e od sinooO 409940 20 3517 yOoUD 571816 OV y yoedonsas NO Jamod 11950 au oedoAJes eAnoejep eBuei y e oj S eBejo uoneJedo ul SI Jo OW JO Ajddns Jamod oy eui 39S samod oy 10992 Ajddns eAisseox3 NO sinooO au yoedonsas NO 4 41950
5. Piston packing 14755 16 Cylinder tube C7SM3119 8 Cleantherod cover piston rod and cylinder tube 9 Apply Daphne E ponex No 2 grease uniformly to the rod and piston packings and then mounting them in the rod cover and on the piston rod Note Do not damage or twist the packings when mounting them Also the packings are directional so be sure to mount them in the correct orientation CP 842 Preliminary 6 25 Replacing Consumable Parts gt gt Replacing the Carrier Clamp Unclamp Air Cylinder Packings 10 Apply athin layer of Daphne E ponex No 2 grease to the piston rod and inside of the cylinder tube Cylinder tube Piston rod 8 C7SM3120 11 Assemble the rod cover on the piston rod and then insert the piston rod in the cylinder tube 12 Useasnap ring pliers to assemble the snap ring in the air cylinder Note The side of the snap ring with beveled edges faces the air cylinder Snap ring A Cross section of snap ring Air cylinder X Beveled edge Snap ring C7SM3121 13 TypeA carrier damp unclamp air cylinder Adjust the distance from the end of the piston rod to the head of the bolt and lock the locknut Type carrier clamp unclamp air cylinder Fasten the link bracket on the end of the piston rod Type A Type B Piston rod Piston rod mm A
6. Jo uonoeuuoosip 10 uonoeuuoo 1 poou se p sn ueuM 0 2 Z00Ud NO Jamod 10 113 Jepooug ejiosqv 8 4oedoAJes ay Ajuanbe y sinooo 99 Jojoul eoe des Jepooue 99 dn 195 eAlejep uoneJedo ul 1 UBYM 10 NO sinooO 103 Jepoou3 Zev 4oedoAJes y Jepooue se pesn xoedoaes 1 00 NO Jamod sinooO 4oedoAJes ay Jepooue y oye Buioel d i Aq jepooue o jddns y Buliols i Jaye Jepooue y dn jas Jepooue y dn jeg 49euo e oqe y yoedonas ejnjosqe y dn Bunjes Aq eoueJnooo eAnoejep Jepoou3 epis Jepooue perddns si samod y yey yOOYD dn jas u q sey Jepooue ejnjosqe y yeu 0940 anjoajep yoedoAd8S eAnoejep 1epooue ejnjosqy pejej samod eu pue oedoAJeg y Ajddns 9d ulog euin 3510 OY 10 Jepooue ejnjo
7. LED panel BIBIBIEIG AISI i CNS connector C746M4038 D1 D2 X Cam and NY Axis Servo amplifier lt CP 842E gt lt CP 842ME gt 1 D1 axis 2 D2 axis 3 X axis 4 Cam axis 2 3 0 2 BlBB 5 2 000000 200000 000000 000080 5 NY axis 746 4039 6 22 CP 842 Preliminary Replacing Consumable Parts gt gt Servo Amp Battery Procedure Replace the servo amplifier battery with the machine power on 1 Verify that the machine s SYSTEM lamp is 2 Press the machine s EMERGENCY STOP button N WARNING Be sure to switch off the 200V power supply before beginning this procedure 3 Identif
8. y x oedo es Jewod sinooO CP 842 Preliminary 8 18 Troubleshooting gt gt Servo System Troubleshooting 9115 97 95 4oedoAJes y Apuenbej sinooo ay J JO OW eu Jepooue y punoJe BuisseooJd Apuenbej sinooo y J 10jouu eoejdes ureBe Ajddns Jepooue eui NO UNL BU 12909 Jepooue y u Josueg uoneJedo ul SI JO NO Jog geq 4oedoAJes Jepooue jejueujeJoui se pesn xoedoAies 1 lt 00 NO 41590 4oedoAJes ay Ajddns jepooue NO pue y ay 1290105 e oqe y SI J ss JO A Z 0 peonpai jou Si y yey 72942 pejoeuuoo 42942 yoedonsas ss 10 A 2 2 payloads peonpei si
9. 3 7 3 2 2 Parts Supply I Een 3 8 3 23 VISION OS VSIOITIu 5 roto on s too dcin boda 3 9 3 2 4 Panel Conveyance 3 9 3 2 5 Electrical Control System 3 9 3 3 Sensor POoSILHODS us orent rper tet rure een eee 3 11 cR Masi M E 3 11 3 9 2 II COR NOVDE au gece E UR Da acte de sett p dede EQ rms 3 13 3 3 3 Out conveyor 3 14 3 3 4 Main 3 15 22222 3 16 3 9 5 3 17 3 3 7 Panel Clamp bold 3 18 22220 3 19 3 3 9 Tape Feeder Unit 511 2 3 20 3 3 10 Tape Cutter ST 1 3 21 3 3 11 Nozzle Clutch ST 10 ac aiti aries cbe este fro koh 3 22 3 3 12 Nozzle Changer 3 23 3 213 Feeder CNECK Eh Erb Red 3 24 3 3 14 Device Table 3 26 CP 842 preliminary i Table of Contents 4 Basic ODeratiOD ipn de v a cr 4 1 4 1 Changing the Conveyor Widlh 4 1 4 2 Changing the Panel Back up Pin Posit
10. EN N 1 Camera glass P C746M3005 CP 842 Preliminary 5 5 Maintenance gt gt Cleaning 5 1 6 Filter Regulator Weekly Point The air that flows through the system s air lines must always be clean A soiled filter regulator makes it impossible to supply clean air and can cause equipment failure Procedure N CAUTION Be sure to turn the main power off before performing this proce dure Besuretoturn the air supply off and torelease the air pressure in advance 1 Close the air inlet valve lever and cut the external air supply Valve lever C746M3006 2 Reduce the pressure in the air hose After disconnecting the air hose return the valve lever slowly to the position indicated in the illustration below to expel the air from the air inlet Reduce the pressure in the air hose Air hose J Valve lever Air C746M3007 3 Close the valve lever again when the air has been fully expelled 5 6 CP 842 Preliminary Maintenance gt gt Cleaning Next remove the filter case and clean the filter element AN Pise gt B Filter regulator Mist separator AW3000 02 BD AFM3000 02 D A B O ring lt gt 5 lt Filter element Model 111
11. A Digital pressure gauge Digital pressure ga Handle 7 Knob 20PM Plug LL 20SH for 1 4 hose 305 for 3 8 hose Socket E Hose 40SH for 1 2 hose za 0 5MPa 5kgf cm C746M6003 Note The air hose is not supplied with the machine CP 842 Preliminary 9 3 Setup gt gt Electrical Power Supply amp Transformer Wiring 9 3 Electrical Power Supply amp Transformer Wiring Point Wire the transformer so that its voltage matches the power supply voltage Procedure N DANGER Verify that the external power supply is off before performing this procedure Connecting the Power Supply The power capacities are indicated below Be sure to connect the machine to a power supply which exceeds this capacity 842 9 5KVA CP 842ME 9 0KVA 1 Open the main breaker box then remove the transparent terminal cover Feed the power cable into the main breaker box from the power cable inlet located at the top of the main breaker box 3 Connect the ground cable to the dedicated ground terminal 4 Connect the 3 phase cable to the main breaker and tighten to the prescribed torque Terminal screw tightening torque 5 8 N m 58 kgf cm Note Terminal screws should be tightened periodically 5 After connecting the cable secure it with the cable lock nut located at the power cable inlet Cable lock nut tightening torque 7 5 N m 75 kgf cm Cable lock nut Power cable 20
12. C7SM4051a CP 842 Preliminary 7 17 Adjustments gt gt Station Adjustments D1 D2 Retract Area Lower direction check Inner sensor Block DCPJ0060 Sensor bracket C7SM4052a Outer sensor Block DCPJ0070 Oo Sensor bracket C7SM4053a 7 18 CP 842 Preliminary Adjustments gt gt Station Adjustments Sensor Amp Adjustment Open the front cover and follow the procedures bel ow D Feeder sensor amp Open the cover D Power mode Timer mode SET button MODE button A 7 button Output dip switch C7SM4023a 1 Check that the output dip switch is set to L ON Set the power modes and timer modes as detailed below 2 1 Press and hold down the MODE button for three seconds or more to change the display to turb Use the up and down arrow buttons to set the power mode to SU PE R 2 2 Press the MODE button to change the display to dLy Usethe up and down arrow buttons to set thetimer mode to OFF 2 3 Press theM ODE button again toreturn thedisplay totheoriginal state 3 Press the MODE button to toggle the display from the light value to the per centage value value P and then back to the light value Ensurethat thefigures for all the sensors are abovethe minimum values shown below CP 842E Pickup area 1000 digit target 2000 digit Retract area 30 digit tar
13. C7SM4063 Note Do not turn cam with the jig attached to the placing heads otherwise the heads might be damaged 7 Loosen the fixing bolts and adjust the clutch position so that it can be smoothly inserted to the cavity of the jig block Adjustment jig Fixing bolt Bracket Bracket C7SM4065 7 42 CP 842 Preliminary Adjustments gt gt Station Adjustments Nozzle Change Stroke Adjustment 1 Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Position the cam at an angle of 0 and turn the ST14 solenoid toON Y037 ST14 NOZZLE CHANGE SOL ENGAGED to activate the cam lever 3 Usethe cam handle to rotate the cam to 141 4 Verify that the nozzle change clutch is engaged with the holder clutch and that the rotary holder is pushed 0 01 to 0 05 mm as shown in the figure below 5 If the push amount is outside this range adjust by turning the adjusting rod ST14 Adjustment rod Rotary holder Nozzle change clutch Holder clutch C7SM4048 CP 842 Preliminary 7 43 Adjustments gt gt Station Adjustments 7 1 14 Nozzle Detection Sensor ST15 Point Station 15 uses three nozzle detection sensors to detect
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15. 7 1 7 1 2 Waste Tape Cutter ST1 7 4 7 1 3 Nozzle Vertical Movement During Pickup 571 7 6 7 1 4 Mechanical Valve Switching 1 7 12 7 1 5 Feeder Height Error Detection 571 7 15 7 1 6 Large Parts Check Sensor 572 7 21 7 1 7 Pre theta Movement ST2 7 23 7 1 8 Fine theta Movement S T8 7 24 7 1 9 Nozzle Vertical Movement During Placement ST9 7 25 7 1 10 Mechanical Valve Switching ST9 7 32 7 1 11 Reverse theta Mechanism 10 7 35 7 1 12 Mechanical Valve Switching ST13 7 38 7 1 13 Nozzle Change Function ST14 7 41 7 1 14 Nozzle Detection Sensor ST15 7 44 7 2 Servo Amplifier Adjustments 7 49 7 2 1 Servo amplifier 7 49 7 2 2 Resetting servo errors 7 52 8 Troubleshooting rire 8 1 8 1 Troubleshooting Table 8 1 8 1 1 Poo
16. The X and Y values which appear in the remedy column correspond to the I O map assignment numbers C746M5TO6 8 7 Troubleshooting gt gt Troubleshooting Table No Cause Remedy Remarks Ref Page 1 Check the following sensors for problems In lifter UP DOWN limit sensor fails to M Sect 3 3 3 6 see above switch on and off In lifter UP limit check X0B5 In lifter DOWN limit check X0B6 4 10 cycle 2 Check the in lifter UP DOWN cylinder for Lifter may not be moving all the way to S Sect 3 1 emor problem 7 see above its motion limit position Execute the following commands to see if the lifter can be moved to its motion limit position Panel Loader Loader Maintenance In side Lifter Up Lifter Down START In lift 1 Check the following sensors for problems Panel loading from the in lifter to the in M Sect 3 3 neer pane 1 6 described above carrier began but the panel arrival 4 11 conveyance ineconvevor panalamvali check Sensor switched off before the in carrier elton yore was advanced 1 Check the following sensor for problems A panel which should have been M Sect 3 3 1 6 described above unloaded has not been conveyed to Out conveyor unloader panel arrival check the XOCB sensor position Look for a failed tuck Panel unloading 2 Check the out conveyor motor for problem 3 er SCS panei ora S Se
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19. 49 2 T9 2 Note Apply AFC grease to the outside surface of the thrust bearing and rotate it to work the grease into the bearing Disassembly is not required Lightly remove the applied grease leaving behind a thin film CP 842 Preliminary Monthly C746M3T15 C746M3028 5 35 Maintenance gt gt Lubrication 5 2 18 Lubricating the Rear Cover Lubrication points Types of lubricant Schedule Slide rail Daphne Exponex No 2 Every 3 months C746M3T16 Arrow marks in the illustration indicate lubrication points C746M3029 Note The above drawing represents the CP 842ME Please conduct lubrication for the CP 842E in the same fashion 5 36 CP 842 Preliminary Maintenance gt gt Lubrication 5 2 19 Lubricating the Index Unit Point The lubricant for the index unit in the cam box is contained within the oil cooler on the left side of the box Replace the oil in the oil cooler once every three years or after 12 000 hours of operation Lubrication points Types of lubricant Schedule Every 3 years or 12 000 hours C746M3T17 Oil cooler SHC 630 Procedure The oil in the oil cooler can be drained at three locations Refer to the diagram below for guidelines on how much oil should be removed from each drain plug Prepare in advance a bucket for collecting the old oil a plastic sheet with which to cover the machine and some corrugated cardboard
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21. 8 20 Troubleshooting gt gt Servo System Troubleshooting 8115 197 5 By yoedonies Ano J p Jepoou3 Buunp sinooo y soejday 49940 Bunoousej qnoJ 1041611 X29949 sme1s OV By An5 J p Jepoou3 Jamod 4 Jepoou3 ay eAnoejep yOedoas u 9 eAnoejep Jepoou3 Ano J p 1epoou3 epis Jepooue BUHIA y Buunp Jepooue Jo 2942 100d 10 Bum Jepoou3 JO Je od 69 ay eAnojep 1950 1043 Bunias Jepoou3 SINDIO WN INV eAnoejep yoedonas pue 10113 e31
22. Placing heads Stations 1 16 Part supply system Feeders Tape cutter Pallet supply device PCU Pallet Change Unit CP 842ME Option 842 842 Vision system Parts camera Mark camera Panel conveyance _ Carrier loader system Electrical control Operation panel system Control box Servo box Servo UPS Uninterrupted Power Supply Pneumatic control Unit system Machine functions C746M1007 3 2 1 Parts Mounting System Cam box The cam box system comprises a cam axis motor index units cam axes cam levers and air cylinders Index units Two index units are housed in the cam box One is used to index the nozzle shaft dutch and the other is used to index the nozzle holder Placing heads There are a total of 16 placing heads mounted around a single rotary head The plac ing heads comprise nozzles shafts and holders Each placing head is fitted with six nozzletypes with the appropriate nozzle being selected in accordance with the size of the part which is to be placed Placing heads pick up parts from the feeder hold the parts during vision processing and then place the parts on a panel CP 842 Preliminary 3 7 The Machine gt gt Functions of Each Part 3 8 Stations 1 16 Stations 1 16 represent the positions of the 16 placing heads In this manual Sta tion is abbreviated as
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24. 049 048 746 1021 Sensor SIGNAL 048 049 X04A 5715 NOZZLE TYPE CHECK 1 ST15 NOZZLE TYPE CHECK 2 5715 NOZZLE TYPE CHECK CP 842 Preliminary C746M1T13 3 23 The Machine gt gt Sensor Positions 3 3 13 Feeder Check lt CP 842E gt X043 C746M1029 Sensor No SIGNAL NAME x042 ST1 FEEDER CHECK X043 D1 FEEDER CHECK UP X044 D1 FEEDER CHECK DOWN X054 D2 FEEDER CHECK UP X055 D2 FEEDER CHECK DOWN 746 1 14 3 24 CP 842 Preliminary lt 842 gt The Machine gt gt Sensor Positions FQ SL X055 C746M1022 Sensor No SIGNAL NAME X042 X043 X044 X054 X055 ST1 FEEDER CHECK D1 FEEDER CHECK UP D1 FEEDER CHECK DOWN D2 FEEDER CHECK UP D2 FEEDER CHECK DOWN CP 842 Preliminary C746M1T14 3 25 The Machine gt gt Sensor Positions 3 3 14 Device Table D Servo Axis 1 SX04A C746M1023 Note CP 842ME sensors are indicated by 1 and CP 842E sensors by 2 Sensor No SIGNAL NAME 5 041 D1 AXIS OT SX042 D1 AXIS OT SX04A D2 AXIS OT C746M1T15 3 26 CP 842 Preliminary The Machine gt gt Sensor Positions D1 Table CP 842ME option CP 842 Preliminary C746M1024 Sensor No SIGNAL NAME 01 CAM CYLINDER UPPER LIMIT CHECK X080 D1 TABLE STOPPER LOCK CHECK X081 D1 TABLE STOPPER UNLOCK CHECK X082 D1 PCU CLAMP CHECK 1 X083 D1 PCU UNCLAMP CHE
25. 51 Oil cooler drain plug approx 2 000 3 000cc Nozzle index drain plug approx 1 000cc C746M3030 CP 842 Preliminary 5 37 Maintenance gt gt Lubrication 1 Remove the acrylic cover from the top of the machine and remove the cap from the oil cooler lt 842 gt gt Clear acrylic cover lt 842 gt Clear acrylic cover Oil cooler C746M3031 2 Open the cover on the rear left of the machine 3 Removethe old cooler oil using the drain plugs Protect the area surrounding the drain plugs using a plastic sheet remove the drain plug and drain the oil into a collecting bucket Drain plug Plastic sheet C 746M3032 Note 1 Cover the machine carefully to prevent oil spilling on the machine when draining the oil cooler 2 The oil removed from the machine should be discarded in accordance with local ordi nances for handling waste matter 4 Replace and properly tighten the drain plugs once the oil has been fully removed 5 38 CP 842 Preliminary Maintenance gt gt Lubrication 5 Open the doors at the rear of the machine 6 Cover the cameras prism box and surrounding areas with a plastic sheet EXIT Plastic sheet
26. SET DON RUN LON TUNING SET DON HB RUN LON Sensor ON DeLay SET DON LON RUN Sensor OFF DELAY TUNING SET DON RUN LON C7SM4040 7 37 Adjustments gt gt Station Adjustments 7 1 12 Mechanical Valve Switching ST13 Point The station 13 mechanical valve is used to switch the vacuum off inside the nozzle This releases the negative pressure the nozzle and the nozzle can no longer hold part Verify that parts which fail vision processing are discarded at station 13 C7SM4041a Valve Switching Unit Position Adjustment This adjustment should be performed on the high valve head after completing adjust ments to the vertical movement of the nozzle during the placement Refer to 7 1 9 Nozzle Vertical Movement During Placement for details The high valve head can be identified by its height The heights of the spool lower surface are measured for all placing heads with spools lifted and the highest one is referred to as the high valve head C7SM4055 7 38 CP 842 Preliminary CP 842 Preliminary Adjustments gt gt Station Adjustments Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off
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28. C746M3T07 Black arrows indicate Note Lubrication of 22 requires a special grease Caution 2 is lubricate the shaft on the air cylinder CP 842 Preliminary nozzle Refer to the next page for details C746M3021 5 25 Maintenance gt gt Lubrication SR Special grease nozzle for the NZ axis LM block ADGPJ818 NZ axis LM block Connect the hose to the special grease nozzle and inject grease into the NZ axis LM block C746M3040 5 26 CP 842 Preliminary Maintenance gt gt Lubrication 5 2 9 Lubricating the Waste Tape Disposal Unit Lubrication points Types of lubricant Schedule Movable cutter Daphne Exponex No 2 Weekly Cam follower Daphne Exponex No 2 Weekly Thrust bearing AFC grease Monthly C746M3T08 Arrow marks in the illustration indicate lubrication points CP 842 Preliminary Note Apply AFC grease to the outside surface of the thrust bearing Disassembly is not required C746M3022 5 27 Maintenance gt gt Lubrication 5 2 10 Lubricating the NY Axis Pickup Offset Mecha nism Lubrication points Types of lubricant Schedule LM block AFC grease Monthly Roller Multemp LRL3 Monthly C746M3T21 Arrow marks in the illustration indicate lubrication points Black arrows indicate points where a
29. C7SM4022a Note This diagram shows the CP 842ME D1 arrangement but the D2 arrangement is the same The jig used to adjust the sensor positions is shown below Block DCPJ0040 Z Block DCPJ0050 lt For CP 842ME gt Block DGPJ5070 lt For CP 842E gt X Block E DCPJ0060 ME Block ositioning jig body DCPJ0070 ADCPJ8020 C7SM4049b CP 842 Preliminary 7 15 Adjustments gt gt Station Adjustments Feeder Check Sensor Position Adjustment 1 Press the EMERGENCY STOP button to turn off the 200V power leaving only the 100V power on N WARNING Always be sure to cut off the 200V power before carrying out any work 2 Set the positioning jig body on a feeder pallet 3 Usethe inching keys to position the feeder pallet and bring the positioning jig body within the vicinity of the sensor in question 4 Attach a block appropriate for each sensor within the jig and then adjust the sensor position Pick up Area Sensor bracket Pa Block DCPJ0040 C7SM4050a 7 16 CP 842 Preliminary Adjustments gt gt Station Adjustments D1 D2 Retract Area Upper direction check Inner sensor Sensor bracket 2 Block DCPJ0040 C78MAn na Outer sensor lt 842 gt Block DGPJ5070 Sensor bracket C7SM4057a lt CP 842ME gt Sensor bracket Block DCPJ0050
30. Cleaning 5 1 12 Oil Cooler Air Filter Monthly Point A filter is attached to the oil cooler unit The air filter should be cleaned periodically to prevent damage to the machine as a result of blockage Procedure N WARNING Be sure to turn the main power off before performing this proce dure 1 Remove the acrylic cover from the top of the machine Hold the tab and lift the filter upwards to remove 3 Clean the filter with a vacuum cleaner lt CP 842E gt lt CP 842ME gt Acrylic cover Acrylic cover Tab C746M3012 CP 842 Preliminary 5 13 Maintenance gt gt Cleaning 5 1 13 Carrier Rodless Cylinder Monthly Point There is a tendency for scattered parts and fine fibers etc to adhere to the slide sur face of the rodless cylinder used to drive the carrier As a result it is necessary to per form periodic cleaning Procedure WARNING Be sure to turn the main power off before performing this proce dure 1 Lightly wipe the slide surface of the rodless cylinder using a fine cloth Further more ensure to remove any dirt etc that has accumulated between the ends of the slider surface and the absorber holder 2 Apply some grease to a fine cloth and wipe along the slider surface Note Ensure to use Daphne Eponex No 2 by Idemitsu Carrier cylinder Absorber holder Slider gt C746M3013 Absorber holder 5 14 CP 842 Preliminary Maintenance gt
31. do Buunp 41550 11990 y QU Bun s Jepooue y GOZUd 991 99 u q jou seu jiu eu eui lt 151 JejeuueJed y 0 jueujeeJBesiq GOZUd 1281102 1 yooyD BuoJA si sinooO jur 29v oedoAJes eoejdes Jepoou3 eAnoejep Jepoou3 epis Jepooue ay uoniesul uooeuuoo uoneJgedo JOU Jepooue eu 1284100 Jo BuuiM Jepooue BU x99u2 4004 10 Jepoou3 JO NO Je od sino5O 4oeqouo3 Jepoou3 CP 842 Preliminary 8 22 Troubleshooting gt gt Servo System Troubleshooting OZLSW9bLD 41800395 4 SOOH3S suoneoiunuuuuo2 pJeoq 5 4 SOOH3S suoneoiunuiuoo SOOMH3S Jo uonezijeniut way 42049 Bunoous lqno11l 20 517 2842 5 yoedonias ov yoedonies ay eoejdes u sino se yons 1
32. gt Cleaning 5 1 14 Nozzle Filter Every 3 Months Point The filter inside the shaft becomes soiled during the course of machine operation and should be replaced approximately every 3 months If errors occur frequently for a spe cific nozzle it is probable that the flow of air is being impeded by a dirty filter Procedure N WARNING Be sure to turn the main power off before performing this proce dure 1 Squeeze in the levers shown in the figure below and carefully extract the filter Filter Assy C746M3015 Caution Do not apply excess force to the nozzle shaft 2 Ensure that the filter is returned to the nozzle with the levers at the bottom 2 Remove the pin from the filter Assy and replace both the filter and the pin mre 25 Filter Pin C746M3014 CP 842 Preliminary 5 15 Maintenance gt gt Cleaning 5 16 5 1 15 Cleaning Checklist Cleaning points Schedule Check 1 Waste Tape Box and Filter Every 8 Hours 2 Waste Tape Duct Every 8 Hours 3 Reject Parts Box Every 8 Hours 4 Nozzle Interior Weekly 5 Camera Glass Weekly 6 Filter Regulator Weekly 7 Machine Interior Weekly 8 Part Height Check Sensor Lens Weekly 9 Fluorescent Nozzle Stickers Monthly 10 Tapered Clutch on the Nozzle Indexing Shaft Monthly 11 Air Filter Monthly 12 Oil Cooler Air Filter Monthly 13 Carrier Ro
33. working inside the fence in immediate danger when the RESET or START button is pressed Be sure to leave the fence open when anyone is inside the fence Do not approach a machine that has stopped moving There are times during automatic operation when the machine may appear to have stopped while it is waiting for a board waiting for the next machine reading marks transmitting data etc such cases once certain condi tions are fulfiled the machine will begin moving again automatically so care should be taken Only approach the machine after the EMERGENCY STOP button has been pressed When the message Ready displays at the machine display the machine will begin to move once cer tain conditions are satisfied oo e o Keepin mind that the machine will begin to move regard less of whether these conditions are satisfied intentionally or inadvertently Resupply solder paste glue and parts while the machine is in manual mode Never resupply solder glueor parts during automatic operation unless instructed otherwise Body parts or dothing may be caught in the machine causing personal injury e CP 842 Preliminary 2 3 Safety gt gt Safety Rules for All Machine Types 2 4 NWARNING Do not place hands near the main conveyor Hands or other body parts may be caught in the machine Always turn the 200V power supply off when cleaning or lubricat ing the machine Wh
34. 3 Months 5 15 5 1 15 Cleaning Checklist 5 16 AMON n a ira 5 17 5 2 1 Precautions During Lubrication 5 17 5 2 2 Types of Lubricant 5 17 5 2 3 Lubrication Instructions 5 19 5 2 4 Lubricating the XY table 5 21 5 2 5 Lubricating the Conveyors 5 22 5 2 6 Lubricating the Carriers 5 23 5 2 7 Lubricating the Tape Advance Link 5 24 5 2 8 Lubricating the Cam Box 5 25 5 2 9 Lubricating the Waste Tape Disposal Unit 5 27 5 2 10 Lubricating the NY Axis Pickup Offset Mechanism 5 28 5 2 11 Lubricating the Rod Ends 5 29 5 2 12 Lubricating the D axis Carriers 5 30 5 2 13 Lubricating the Rotary Head 5 31 5 2 14 Lubricating the ST9 Air Valve Push Pin 5 32 5 2 15 Lubricating the Parts Reject 5 33
35. 30 746 3024 5 30 CP 842 Preliminary Maintenance gt gt Lubrication 5 2 13 Lubricating the Rotary Head Lubrication points Types of lubricant Schedule Turret groove Daphne Exponex No 2 Monthly Helical gear Daphne Exponex No 2 Monthly LM rail AFC grease Monthly Spline shaft AFC grease Monthly Wave washer Daphne Exponex No 2 Every 3 months Pin Arrow marks in the illustration indicate lubrication points CP 842 Preliminary AFC grease GE C Monthly C746M3T11 C746M3025 5 31 Maintenance gt gt Lubrication 5 2 14 Lubricating the ST9 Air Valve Push Pin Lubrication points Types of lubricant Schedule 38 Valve push pin AFC grease Monthly C746M3T12 Arrow marks in the illustration indicate lubrication points Valve push pin overview lt Apply grease Do not apply grease on the air blow hole 746 3026 5 32 CP 842 Preliminary Maintenance gt gt Lubrication 5 2 15 Lubricating the Parts Reject Unit Lubrication points Types of lubricant Schedule Valve push pin AFC grease Monthly Cam follower LM rail AFC grease AFC g
36. 5 2 16 Lubricating the Pallet Table 5 34 5 2 17 Lubricating the Nozzle Changer 5 35 5 2 18 Lubricating the Rear 5 36 5 2 19 Lubricating the Index Unit 5 37 5 2 20 Lubricating the Cam Lever Air Cylinder 5 42 5 2 21 Lubrication Checklist 5 43 ii CP 842 preliminary Table of Contents 6 Replacing Consumable Parts J J1 6 1 Bal aaa Sus 6 1 6 2 Fluorescent Nozzle Stickers 4 2 4 6 2 6 3 Waste Tape 6 4 6 4 Conveyor Belts sss 6 5 6 5 Vacuum Pump Filter Element 6 7 6 6 Vac u m P ump c 6 8 6 7 Vacuum Pump Internal Vanes and Bearings 6 10 6 8 Vacuum Purp MOILOF re P Uis 6 17 6 9 Vacuum d n un a 6 20 6 10Servo Amp SAA obtu eei ns 6 21 6 11Replacing the Carrier Clamp Unclamp Air Cylinder Packings 6 24 To Spin re 7 1 7 1 Station dear 7 1 7 1 1 Tape Feed Lever ST1
37. 842 Preliminary The Machine gt gt Machine Components 3 1 2 Servo Control Axes D1 axis motor NZ axis motor a PQ axis motor S Cam axis motor px RQ axis motor gt 7 3 02 FQ axis motor ey lt 5 NC axis motor SS Z axis motor IR NY axis motor Y axis motor X axis motor C746M1003 Note The above figure shows the CP 842ME but the position of the servo motors is the same on the CP 842E 3 1 3 Rotary Head ST1 Feeder advance ST1 Mechanical valve switch ST2 STA Large parts check Picking nozzle up down ST1 Pickup position offset Waste tape disposal ST15 Nozzle post change check ST2 Pre theta ST5 Vision processing ST14 Nozzle change ST13 Reject dump parts ST11 2 Head detection gt ST6 Parts height check nozzle length check Option ST8 Fine theta ST9 k Placing nozzle up down ST9 Mechanical valve switch ST10 Nozzle clutch origin position Nozzle clutch engagement check ST10 Reverse theta C746M1004 CP 842 Preliminary 3 5 The Machine gt gt Machine Components 3 1 4 Placing Head C746M1005 C746M1006 Note The PCU is optional on the CP 842ME 3 6 CP 842 Preliminary The Machine gt gt Functions of Each Part 3 2 Functions of Each Part r Part placement system Cam box Index units
38. Adjustments 2 Pressthe DSPL SET button on the Digital Operator until PN 00 is displayed by the LED indicator 3 The parameter type can be changed by pressing the Up or Down arrow key 4 When the desired parameter is displayed press the DATA ENTER button and check the current setting Note Contact Fuji if any of the displayed parameters differ from those indicated in the servo parameter sheet Do not change the parameter settings unless otherwise instructed OOU O O E4144 Servo Pack Digital Operator Reset Jusp 0p02A Alarm DSPL DATA Yaskawa QP3M4008Ea 5 After confirming the parameter setting press the DSPL SET button to return to the PN XX display Repeat steps to 5 to check all the parameters CP 842 Preliminary 7 51 Adjustments gt gt Servo Amplifier Adjustments 7 2 2 Resetting servo errors Servo errors that cannot be reset using commands at the machine can be reset by con necting the digital operator to the applicable servo amplifier and pressing the Alarm Reset button Servo alarm codes When a servo amplifier error occurs you can view the alarm code by connecting the digital operator tothe applicable amplifier For further details regarding alarm codes see Chapter 2 2 2 Alarm Codes and Troubleshooting Check List Servo alarm code history It is possible to view previous alarm codes either by using the digital operator or by using the indicato
39. C746M3035 ds Carefully arrange the plastic sheet to prevent oil spilling on the machine when draining the oil cooler 2 The oil removed from the machine should be discarded in accordance with local ordi nances from handling waste matter 11 Replaceand properly tighten the drain plug once the oil has been fully removed 5 40 CP 842 Preliminary Maintenance gt gt Lubrication 12 Slowly pour the new lubricating oil into the inlet on the top of the oil cooler lt 842 gt lt 842 gt Level indicator Gauge glass Oil cooler C746M3036 13 Ensure that the surface of the oil is the range specified by the level indicator Note Whether the machine is at rest or during operation the oil level does not normally change Immediately after replacing the oil after 3 years or 12 000 hours of operation the oil level will drop when operating the machine Following operation add more oil until the level falls within the recommended range CP 842 Preliminary 5 41 Maintenance gt gt Lubrication 5 2 20 Lubricating the Cam Lever Air Cylinder Lubrication points Types of lubricant Schedule Air cylinder Turbine oil NASKALUBE Every 6 months The lubrication used is a Fuji special blend Turbine oil NASKALUBE Contact Fuji when placing an order C746M3T18 Procedure 1 Open the lid of the lubricator with a Phillips driver 2 Lower the lubricator cover 3 Visually check the oil
40. N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Set the dial gauge to the bottom of the nozzle shaft brake 3 Usethe cam handle to rotate the cam to 200 4 Ensure that the clutches mesh properly and the placing head assembly deflects the dial gauge by 0 30 0 35 mm as illustrated below Measure the amount V of push down Clutch 0 30 0 35 mm Nozzle shaft brake C7SM4026a 7 24 CP 842 Preliminary Adjustments gt gt Station Adjustments 7 1 9 Nozzle Vertical Movement During Placement 579 Slider Adjustment Adjust the height of the slider to ensure that the cam follower can travel smoothly through the slider and along the cam groove 1 Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 In order to remove the nozzle shaft assembly it is first necessary to remove the upper clutch Set the cam angle to zero degrees and use spanner 0450 to loosen the bolt on the nozzle shaft moving from ST9 to ST10 Turn the loos ened bolt by hand and then remove
41. accuracy deviations or defects are An unsuitable XY table speed applya Part 3 Setting error occurring for a specific part decrease force which exceeds the holding capacity of Lesson 2 1 1 in Part data the XY table speed setting in the Part the part s solder resulting in position data where the problem is occurring deviations U Part 2 Solder adhesion decreases when it dries Chapt 4 Therefore the sooner placement occurs after Speed printing the better Check for errors in the part height Missing parts conditions may occur if there T Part 3 information is an error in the part height information or Lesson 2 in the table reference height Proper 211 data U Part 2 Fuji recommends actually measuring the part Chapt 4 height and entering the measured value Appearance Part data 1 Use the nozzle check command to A bent or stuck nozzle will make it impossible M Sect 6 1 check for bent nozzles to place parts properly 2 Verify that the nozzle spring back 1 2 Defective nozzle motion is smooth 3 Verify that the nozzle is not clogged If a problem is found with any of the above replace the nozzle Check the backup pin heights quantity A misalignment between the ST9 nozzle M Sect 4 1 and configuration and verify that the down limit and the panel height can prevent panel is flat the part from being pressed onto the board Improper properly and it may become impossible to 1 8 placement m
42. but leaves the 100V power on N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator Set the cam angle to 0 degrees then turn the first nozzle solenoid valve on to work the cam lever Usethe cam handle to rotate the cam to 170 Use a thickness gauge to ensure a space of 0 65 mm between the tip of the noz zle and the feeder pick up height s Nozzle 34 0 65 mm Feeder ES E C7SM4014 Adjustments gt gt Station Adjustments Adjusting the Nozzle UP Limit Sensor The sensor which detects the height of the nozzle UP DOWN rod is mounted inside the cam box Adjust the sensor s mounting position so that the sensor switches ON when the nozzle 15 at its UP limit 1 Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Set the cam axis at the 0 degree position 3 Activate the ST1 pick up solenoid air cylinder located in the cam box Cam lever 1ST Pick up solenoid air cylinder Nozzle UP DOWN rod Cam lever follows the cam axis Cam axis C7SM401
43. level of the oil tank and slowly pour in the oil to the lubri cator Be sure not to exceed the upper limit while pouring in the oil Note The maximum amount of oil that can be supplied to the lubricator is 75 cc If the oil level does not reach the tip of the pipe inside the case there will be insufficient oil to lubricate the cylinder 4 Replace the lubricator cover and attach the oil inlet cap 5 Check and discard of any accumulated waste oil in the collection bottle Lubricator Upper limit Case Pipe Lower limit Cover C746M3037 5 42 CP 842 Preliminary Maintenance gt gt Lubrication 5 2 21 Lubrication Checklist 1 2 Lubrication points Types of lubricant Schedule Check 1 xy table X axis LM block Daphne Exponex No 2 Every 3 months 2 X axis ball screw Multemp LRL3 Monthly 3 X axis screw cover Daphne Super Multi Oil 32 Every months 4 Y axis LM block Daphne Exponex No 2 Every 3 months 5 Y axis ball screw Multemp LRL3 Monthly 6 Y axis screw cover Daphne No 2 Every months 7 Z axis ball screw Multemp SRL Monthly 8 Conveyors Ball screw Daphne Exponex No 2 Every 6 months 9 Lifter guide bar Daphne Exponex No 2 Every 6 months 10 LM block Daphne Exponex No 2 Every 6 months
44. off Always wait at least five minutes and ensure that the CHARGE lamp is off before under taking any work that may result in contact with the servo amp terminal gt CP 842 Preliminary 2 5 Safety gt gt Safety Rules for All Machine Types CAUTION Do not operate the machine after removing or disabling sensors Removing or disabling sensors will disarm the interlock leading to collisions and damage to the machine Check the machine display to determine whether HELPS com patible machines are in the middle of performing changeover During operation in automatic mode on machines equipped with automatic changeover equipment it may be difficult to actually see automatic changeover taking place from the front of the machine When a message appears at the machine display follow the instructions that are given Ensure to use the handle when opening or closing the safety doors fences or covers Opening or closing the safety doors fences or covers with out using the handle may result in injury to the hand Opening or closing the safety doors fences or covers with force without using the handle may result in damage to the machine CP 842 Preliminary Safety gt gt Safety Rules for Individual Machine Types 2 3 Safety Rules for Individual Machine Types 2 3 1 CP 842E 842ME Machines NWARNING Do not insert hands or other body parts into the conveyor inlet
45. sensor C7SM4003a Retract Sensor Position Adjustment 1 When the dog is at the upper limit at cam angle 0 ensure that the sensor is ON 2 Set a dial gauge to the roller and adjust the sensor to go off 0 5 mm below the upper limit Retract sensor Dog Upper Limit Dog Lower Limit C7SM4004a CP 842 Preliminary 7 3 Adjustments gt gt Station Adjustments 7 1 2 Waste Tape Cutter ST1 Point The waste tape cutter cuts waste tape that protrudes from feeder tips A vacuum takes the cut tape into the waste tape box at the front side of the machine Rotate the adjustment rod to align the movable blade with the fixed blade Adjustment rod Cutter lever C7SM4007a Adjustment Procedure 1 Press the EMERGENCY STOP button This cuts the 200V servo power and leaves on only the 100V power supply N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Use the cam handle to rotate the cam to 0 7 4 CP 842 Preliminary Adjustments gt gt Station Adjustments 3 Ensure that there 15 a gap of 0 0 5 mm between the movable cutter lower sur face and the cutter unit base Movable cutter O OO 6 0 0 5 mm E plate C7SM4009b 4 Usethecam handle to rotate the cam to 194 5 Adjust the ro
46. the hose band CP 842 Preliminary Setup gt gt Connecting the Data Transmission Cable 9 4 Connecting the Data Transmission Cable Point The machine is connected to the host computer by means of an Ethernet twisted pair communication cable class 5 which permits program transmissions and production log compilation Procedure 1 Register the 842 842ME the line descriptor file at the host Note Refer to the host computer manual for details regarding the registration procedure 2 Connect one end of the transmission cable to the Ethernet connector at the host and connect the other end to the connector on the machine C746M6007 CP 842 Preliminary 9 7 Setup gt gt Moving the Machine 9 5 Moving the Machine 9 5 1 Precautions when Moving the Machine When moving a machine be sure to observe the safety measures described bel ow in order to avoid accidents Be sure that the workers who are moving the machine are wearing safety shoes and helmets Prepare the transport path in advance and be sure that those who are not assisting in the machine transport are kept out of the area The machine should be moved only by qualified personnel Before moving the machine attach the machine brackets red which were attached when the machine was delivered Attach the brackets in the pre scribed positions Usea forklift load capacity of 10 t or higher which is suitable for the weight of the machine in que
47. tube causing clogging Such clogging can reduce the nozzle suction and cause problems when picking up parts The nozzle tube should be cleaned out weekly or when clogging occurs Procedure Use an appropriately sized drill bit to remove foreign matter from inside the nozzle tube When cleaning is complete check the drill bit to ensure that dirt from the nozzle has not adhered to the tip JIG No AWPJ8100 Drill bit Fluorescent nozzle sticker C746M3004 Note Jig AWPJ810 cannot be used for 0 4 nozzles Caution 1 Take care to avoid bending the nozzle 2 Take care to avoid dirtying the surface of the fluorescent sticker 5 4 CP 842 Preliminary Maintenance gt gt Cleaning 5 1 5 Camera Glass Weekly Point The camera glass should be cleaned once a week to ensure that a clear image is being acquired This also contributes to stable vision processing and part pick up opera tions Procedure N WARNING Be sure to turn the main power off before performing this proce dure Usea soft brush such as those used to clean camera lenses to clean the camera glass If the glass is badly soiled use commercially available glass cleaner N CAUTION Take care not to bend the nozzle by touching it at the tip Because the camera glass is thin and easy to break do not push hard when wiping it clean 1 A J 54 r V vest N TENE Va
48. which of the six nozzles No 1 6 is pointing straight down The following illustration shows the location of each sensor Sensor 1 Sensor 2 Sensor 3 Sensor C7SM4043b Sensor Position Adjustment 1 Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator Remove the nozzle holders of the reference head and the neighboring heads Use inching operation and move the reference head to ST 13 Use the cam handle to rotate the cam to 200 WN Detach the reject parts brush Reject parts brush AA EN 7 44 CP 842 Preliminary 6 7 CP 842 Preliminary Adjustments gt gt Station Adjustments Attach the adjustment jig for ST15 to the placing heads at ST15 and 16 ST15 ST16 Adjustment jig ADGPJ8050 C7SM4062 Note Do not turn the cam with the jig attached to the placing heads otherwise the heads might be damaged Adjust the sensor bracket position so that it can be smoothly inserted to the cav ity of the jig block Jig block 21 Sensor bracket Jig block C7SM4061 7 45 Adjustments gt gt Station Adjustments Checking the Sensor Reaction 1 Press the EMERGENCY STOP button to take the 200V dow
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51. 0 50 0 60 kg 0 38 0 46 kg Tension meter 28 34 Ib 20 26 Ib Polyflex tension meter manufactured by Gates Co C746M4012 Reassemble the remaining parts in the reverse order of the disassembly proce dure then connect the harness connectors Conectors C746M4031 6 19 Replacing Consumable Parts gt gt Vacuum Hoses 6 9 Vacuum Hoses Procedure WARNING Be sure to switch off the 200V power supply before beginning this procedure spring force may cause the cam axis to rotate if the cam axis is positioned anywhere other than the origin position 0 degrees Always use extreme care when working inside the machine as this is a dangerous area 1 Detach all nozzle holders Move the placing head where a vacuum hose is to be replaced to 579 fix the cam angle at 180 degrees then replace the vacuum hose between the head man ifold and the nozzle shaft assembly 3 Connect the vacuum hose to joint 4 as shown in the figure below Head manifold Vacuum hoses Cam angle 180 Push the hose from the head manifold all the way to the back of the support axis nipple at theposition shown in the M figure at right Nozzle shaft assembly Vacuum hoses Nozzle holder C746M4036 6 20 CP 842 Preliminary Replacing Consumable Parts gt gt Servo Amp Battery 6 10 Servo Amp Battery Point CP 842E 842ME machines use absolute encoder motors with servo am
52. 04535 000 Brazil Tel 11 3064 7650 Fax 11 852 6833 Fuji Machine Philippines Inc Warehouse 888 Don Mariano Lim Industrial Complex La Fuerza Compound Alabang Zapote Almanza Uno Las Pinas City Philippines Tel 02 809 4565 Fax 02 807 2767 Fuji Machine Mfg Singapore Pte Ltd 2 51 Ubi Avenue 1 01 24 Paya Ubi Industrial Park Singapore 408933 Tel 65 67464966 Fax 65 68412326 Fuji Malaysia Office C O Mecomb Malaysia Sdn Bhd 2487 Jalan Sultan Azlan Shah 11700 Penang Malaysia Tel 04 656 4002 Fax 04 656 2941 Fuji Taiwan Office C O Ascentex Industry Corp 3 Fl No 396 Sec 1 Nei Hu Rd Taipei Taiwan R O C Tel 02 8797 8716 Fax 02 8797 8717 Fuji Machine Mfg Co Ltd China Representative Office Room A 26F Zhaofeng World Trade Building No 369 Jiangsu Road Shanghai China Tel 21 5240 0730 Fax 21 5240 0728
53. 1 Closethe air inlet valvelever and removethe air hose Next gradually open the valve lever to release the air pressure 2 Remove the 4 bolts to remove the air cylinder from the in or out carrier bracket In carrier clamp unclamp cylinder Out carrier clamp unclamp cylinder Out carrier clamp unclamp cylinder Air hoses C7SM3117 3 Disconnect the air hoses and remove the forward limit sensor Note Make a note of the air hose connections before disconnecting them in order to pre vent reconnecting them in the wrong positions 4 Loosen the locknut at the end of the piston rod for type A cylinders and remove the bolt 6 24 CP 842 Preliminary Replacing Consumable Parts gt gt Replacing the Carrier Clamp Unclamp Air Cylinder Packings 5 Use a snap ring pliers to remove the snap ring from the cylinder Piston rod Bolt Piston rod Rod cover Rod cover Air cylinder Air cylinder TypeA Type B C7SM3118 6 Remove the piston rod and then remove the rod cover from the piston rod Note Do not force the rod cover off if it does not slide off the end of the piston rod smoothly Remove any burrs from the beveled end with a whetstone or sandpaper 7 Remove the packings from the rod cover and piston rod Rod cover Rod packing Rod Rod packing x rd Code No H14753 Cross section Type MYR 8 LA Piston rod l Piston packing Piston rod c Cross section
54. 11 Carriers LM rail Daphne Exponex No 2 Every 3 months 12 Cam follower Daphne Exponex No 2 Every 3 months 13 Tape advance Tape feed lever AFC grease Monthly 14 ii Shaft Daphne Exponex No 2 Monthly 15 Joint AFC grease Monthly 16 Cam box Cam Daphne Exponex No 2 Monthly 17 Cam lever pivot 7 points AFC grease Monthly 18 Cam lever bearing Daphne Exponex No 2 Monthly 19 NZ axis ball screw Daphne Exponex No 2 Monthly 20 NZ axis LM rail Daphne Exponex No 2 Every 3 months 21 NZ axis holder Daphne Exponex No 2 Every 3 months 22 NZ axis LM block AFC grease Every 3 months 23 axis connecting pin Daphne Exponex No 2 Monthly 24 Waste tape Movable cutte Daphne Exponex No 2 Weekly disposal 25 Cam follower Daphne Exponex No 2 Weekly 26 Thrust bearing AFC grease Monthly 27 NY axis pickup LM block AFC grease Monthly 28 i Roller Multemp LRL3 monthly C746M3T19 CP 842 Preliminary 5 43 Maintenance gt gt Lubrication 5 44 2 2 Lubrication points Types of lubricant Schedule Check 29 Rod ends Rod end Daphne Exponex No 2 3 months 30 D axis carriers D axis LM block Daphne Exponex No 2 3 months 31 D axis ball screw Multemp LRL3 Monthly 32 Rotary head groove Daphne Exponex No 2 Monthly 33 Helical gear Daphne Exponex No 2 Monthly 34 LM rail AFC grease Monthly 35 Spline shaft AFC grease Monthly 36 Wave washer Daph
55. 19a Checking the Position of the Pin Bracket 1 Press the EMERGENCY STOP button to turn off the 200V power leaving only the 100V power on N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Ensure that distance as seen in the figure below is 8 9 mm for all heads Use a special jig 295260 0371 to check this distance Pin bracket A Jig 8 9 mm Z9526DCPJ0371 C7SM4054a 7 12 CP 842 Preliminary Adjustments gt gt Station Adjustments Valve Switching Lever Height Adjustment This adjustment should be performed on the reference head after completing adjust ments tothe vertical movement of the nozzle Refer to 1 4 Nozzle Vertical Movement During Pickup for details reference head can be identified by its height All heads are measured with spools lifted and the lowest one is referred to as the reference head C7SM4055 1 Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Adjust the position of the lever bracket so that the distance from the
56. 5 746 3039 5 2 3 Lubrication Instructions Illustrations and tables are used to indicate important information about keeping the machine properly lubricated Type and Schedule for Lubrication Within these illustrations symbols are used to indicate the location type and sched ule for lubrication The lubrication schedules are based on eight hours of operation per day five days per week 40 hours and 20 days per month 160 hours However if the machines are being operated in two or three shifts per day the lubrication schedules should be used as follows Daily Eight hours from when the machine is turned on after every eight hour shift or after one day s operation Weekly After 40 hours of operation whether the machine 15 being used in two or three shifts or after one week s operation Monthly After 160 hours of operation whether the machine is being used in two or three shifts or after one month s operation Every months After 480 hours of operation whether the machine is being used in two or three shifts or after three month s operation Every 6 months After 960 hours of operation whether the machine is being used in two or three shifts or after six month s operation Annually After 1920 hours of operation whether the machine is being used in two or three shifts or after a year of operation CP 842 Preliminary 5 19 Maintenance gt gt Lubrication 5 20 Locations for Lubrication Locations
57. 5 Place dial gauge on the top end of the cam lever and set the gauge reading to 0 In this condition the nozzle UP DOWN rod will be at its DOWN limit posi tion Verify that the nozzle DOWN limit sensor is ON X033 ST9 CYLINDER LOWER LIMIT is ON at the I O screen Dog Nozzle down limit sensor ON S s Set the dial gauge to 5 Nozzle UP DOWN rod C7SM4033 6 While observing the dial gauge rotate the cam axis in the forward direction to raise the nozzle UP DOWN rod Adjust the sensor s mounting position so that the sensor switches OFF X033 ST9 CYLINDER LOWER LIMIT switches OFF when the rod has been raised 0 3 to 0 4 mm Nozzle down limit sensor OFF Dog x Me Rod raised 0 3 to 0 4 mm S N Nozzle UP DOWN rod C7SM4034 Adjust the sensor 5 mounting position by loosening the sensor lock screw and sliding the sensor in the front back directions Screw 2 Nozzle down limit sensor Dog C7SM4035 CP 842 Preliminary 7 31 Adjustments gt gt Station Adjustments 7 1 10 Mechanical Valve Switching ST9 Point The nozzle vacuum goes from ON to OFF with the movement of the mechanical valve at station 9 Vacuum pressure inside the nozzle is released for part placement when the valve closes Ensure the part is placed on the production board lt Spool pushed down gt lt Spool pushed up gt Va
58. 585 Element assemby Manufacturer SMC Model 630617 Manufacturer SMG Lock knob i Lock knob i Filter case MI Filter case 746 3008 4 Disconnect the drain hose from the regulator if there is 5 Remove the filter case While pressing the lock down turn to remove the filter case 6 Remove the drainage collected in the filter case and wash the case with neutral detergent 7 Remove and clean the element Note The element should be replaced every 2 years Assemble the filter regulator after cleaning attach the air hose and open the valve lever fully CP 842 Preliminary 5 7 Maintenance gt gt Cleaning 5 1 7 Machine Interior Weekly Point Chip parts and other foreign objects will accumulate in the machine during the course of operation Such objects should be removed from the machine periodically to keep the machine good working order Procedure WARNING Be sure to turn the main power off before performing this proce dure 1 Use a vacuum cleaner to remove the foreign objects from the machine interior 2 Use dry cloth to wipe grease off of all areas not specified as lubrication points Caution Do not use an air gun within the machine as dust or other small fragments may be blown into other areas of the machine CP 842 Preliminary Maintenance gt gt Cleaning 5 1 8 Part Height Check Sensor Lens Weekly Point
59. 5a 7 10 CP 842 Preliminary Adjustments gt gt Station Adjustments 4 Place a dial gauge on the top end of the cam lever and set the gauge reading to 0 In this condition the cam axis will be at its O degree position and the noz zle UP DOWN rod will beat its UP limit position Verify that the nozzle UP limit sensor is ON X030 ST1 CYLINDER UPPER LIMIT is ON at the I O Screen Nozzle up limit sensor ON Set the dial gauge to 10 Nozzle UP DOWN rod C7SM4016 5 While observing the dial gauge rotate the cam axis in the forward direction to lower the nozzle UP DOWN rod Adjust the sensor s mounting position so that the sensor switches OFF X030 ST1 CYLINDER UPPER LIMIT switches OFF when the rod has been lowered 0 3 to 0 4 mm Nozzle up limit sensor OFF Nozzle UP DOWN rod C7SM4017 6 Adjust the sensor s mounting position by loosening the sensor lock screw and sliding the sensor in the front back directions Screw Nozzle up limit sensor C7SM4018a CP 842 Preliminary 7 11 Adjustments gt gt Station Adjustments 7 1 4 Mechanical Valve Switching 571 Point The nozzle vacuum goes from OFF to ON with the movement of the mechanical valve at station 1 Vacuum pressurefor part pick up forms insidethe nozzle when the valve is open Spool pushed up gt Spool pushed down Vaccum OFF Vaccum ON Vaccum Vaccum 2 Spool Spool C7SM40
60. 842 Preliminary 6 7 Replacing Consumable Parts gt gt Vacuum Pump Belt 6 6 Vacuum Pump Belt Point The vacuum pump belt should be replaced when broken or damaged Procedure N WARNING Be sure to switch off 200V power supply before beginning this procedure Do not touch the vacuum pump immediately after operation as it may be extremely not Allow the pump to cool before performing this procedure 1 Remove the bracket bolts which secure the vacuum pump table then disconnect the harness connectors onnectors 746 4008 2 Pull out the vacuum pump together with the table Vacuum pump qw PAS Qe C746M4009 6 8 CP 842 Preliminary Replacing Consumable Parts gt gt Vacuum Pump Belt 3 Open the belt cover Bm 746 4010 m di 4 _ 5 Adjust the tension of the new belt If the belt tension is outside the prescribed range move the motor position in 0 1 mm increments to adjust the L dimen sion Motor pulley New Belt Belt During Use Amount of slack 1 8 mm 1 8 mm Load 0 50 0 60 kg 0 38 0 46 kg Tension meter 28 34 Ib 20 2616 Polyflex tension meter manufactured by Gates Co c746M4012 CP 842 Preliminary 6 9 Replacing Consumable Parts gt gt Vacuum Pump Internal Vanes and Bearings 6 7 Vacuum Pump Internal Vanes and Bearings Point The vacuum pump blade consists of 6 vanes Broken vanes can cause abnor
61. 9 JO OW e ejdey An5 J p Jepoou3 Je od sinooO 1 pooud eiosqv 80 eoejdes eAnoejep Jepoou3 2 9 Jepooue y Buum y 2942 Jepooue si JO OLU UOIlj2euuoo yoedonlas ay JO Je od 11590 eseud gd vd 90 V y A 5 J p eAnoejep eAnoejep 1 poou3 y Buum Jepooue 72945 j284109U unoJio Ajddns si 10143 uonoejeq y x29u2 0 Ajddns ay y Ajddns Auejog 8 21 CP 842 Preliminary Troubleshooting gt gt Servo System Troubleshooting 61 15 197 5 4 1 YORdOMAS way 40040 104 517 Y29849 5 Wey yoedonias ov
62. CING performing maintenance NEVER Teach into this area unless spring ENSURE THAT THE UPS IS SWITCHED OFF AT tension to the Cam Turret is first relieved and the Cam Turret is at a resting position THE UPS UNIT DURING ALL SERVICING mainan should only be performed by one person at a time ATTENTION La came tourelle est susceptible de bouger sousleffet des ressorts de cames Pour eviter dommage corporel TOUJOURS couper l alimentation E electrique et pneumatique avant toute intervention de maintenance JAMAIS cette zone sans s etre assurre gue 2 q rts de tourell t detendus et tourell 221 44 NRE EBATSE ressor paa came tourelle sont detendus et que la come tourelle fi TUER SAT c SIL NESLTRSL 10 11 HEBRORRAS Past at INTERNAL CONDUCTOR AMPACITY PES Bkt SABE Conductor Size Ampacity CAUTION AWG mm in Enclosure A spe 14 2 1 20 12 BP 25 9 53 40 S yZEXRUCFEU 5 83 80 Caution TREE 60 75 LOMA EH LEAR CELT Jt Use appropriate tap on transformer when s 60 75 AC field installed wiring power supply cable to primary side copper conductors are required z 7 7 on DO NOT PLACE FEET ON OPERATION NE PAS MARCHER SUR LE BOITIER E DE COMMANDE 75 0002 2 10 CP 842 Preliminary Safety gt gt The EMERGENCY STOP Buttons 2 5 The EME
63. CK 1 X084 D1 PCU CLAMP CHECK 2 X085 D1 PCU UNCLAMP CHECK 2 X086 D1 PALLET ARRIVE CHECK X087 D1 PALLET SETTING CHECK 1 X088 D1 PALLET SETTING CHECK 2 X08A D1 PALLET PASS CHECK 1 X08B D1 PCU SET CHECK X08C D1 CAM CYLINDER LOWER LIMIT CHECK C746M1T16 3 27 The Machine gt gt Sensor Positions D2 Table CP 842ME option C746M1025 Sensor No SIGNAL NAME OUT CARRIER FORWARD LIMIT PANEL CHECK OUT CARRIER FORWARD LIMIT CHECK XOCF OUT CARRIER RETRACT LIMIT CHECK X0D2 OUT CARRIER RETRACT LIMIT CLAMP CHECK FIXED RAIL OUT CARRIER RETRACT LIMIT CLAMP CHECK ADJUSTABLE RAIL X0D4 OUT CARRIER FORWARD LIMIT CLAMP CHECK FIXED RAIL X0D5 OUT CARRIER FORWARD LIMIT CLAMP CHECK ADJUSTABLE RAIL XOD6 OUT CARRIER RETRACT LIMIT UNCLAMP CHECK FIXED RAIL X0D7 OUT CARRIER RETRACT LIMIT UNCLAMP CHECK ADJUSTABLE RAIL OUT CARRIER FORWARD LIMIT UNCLAMP CHECK FIXED RAIL X0D9 OUT CARRIER FORWARD LIMIT UNCLAMP CHECK ADJUSTABLE RAIL C746M1T07 3 28 CP 842 Preliminary Basic Operation gt gt Changing the Conveyor Width 4 Basic Operation 4 1 Changing the Conveyor Width Point Conveyor width adjustments must be performed jointly at the in conveyor XY table and out conveyor The conveyors should be adjusted to a width which permits smooth panel clamping and conveyance through the machine Procedure N CAUTION Before performing conveyor width adj
64. CK ADJUSTABLE RAIL IN CARRIER FORWARD LIMIT UNCLAMP CHECK FIXED RAIL IN CARRIER FORWARD LIMIT UNCLAMP CHECK ADJUSTABLE RAIL 3 16 C746M1T06 CP 842 Preliminary The Machine gt gt Sensor Positions 3 3 6 Out carrier X0D5 C746M1015 Sensor No SIGNAL NAME X0CC XOCE X0D2 X0D3 X0D4 X0D5 X0D6 X0D7 8 X0D9 OUT CARRIER FORWARD LIMIT PANEL CHECK OUT CARRIER FORWARD LIMIT CHECK OUT CARRIER RETRACT LIMIT CHECK OUT CARRIER RETRACT LIMIT CLAMP CHECK FIXED RAIL OUT CARRIER RETRACT LIMIT CLAMP CHECK ADJUSTABLE RAIL OUT CARRIER FORWARD LIMIT CLAMP CHECK FIXED RAIL OUT CARRIER FORWARD LIMIT CLAMP CHECK ADJUSTABLE RAIL OUT CARRIER RETRACT LIMIT UNCLAMP CHECK FIXED RAIL OUT CARRIER RETRACT LIMIT UNCLAMP CHECK ADJUSTABLE RAIL OUT CARRIER FORWARD LIMIT UNCLAMP CHECK FIXED RAIL OUT CARRIER FORWARD LIMIT UNCLAMP CHECK ADJUSTABLE RAIL CP 842 Preliminary C746M1T07 3 17 The Machine gt gt Sensor Positions 3 3 7 Panel Clamp X07B X063 X061 C746M1016 Sensor No SIGNAL NAME X05F XY TABLE PANEL CLAMP CHECK FIXED RAIL RIGHT X060 XY TABLE PANEL CLAMP CHECK ADJUSTABLE RAIL RIGHT X061 XY TABLE PANEL UNCLAMP CHECK FIXED RAIL RIGHT X062 XY TABLE PANEL UNCLAMP CHECK ADJUSTABLE RAIL RIGHT X063 XY TABLE PANEL CLAMP CHECK FIXED RAIL LEFT X064 XY TABLE PANEL UNCLAMP CHECK FIXED RAIL LEFT X07B BACKUP PIN CHECK C746M1T08 3 18 CP 842
65. D DECELERATION POINT IN CONVEYOR 1 PANEL ARRIVAL CHECK X0B0 IN CONVEYOR PANEL IN CHECK X0B5 IN LIFTER UPPER LIMIT CHECK X0B6 IN LIFTER LOWER LIMIT CHECK CP 842 Preliminary C746M1T03 3 13 The Machine gt gt Sensor Positions 3 3 3 Out conveyor C746M1012 Sensor No SIGNAL NAME X0C7 OUT CONVEYOR 1 PANEL ARRIVAL CHECK X0CB OUT CONVEYOR UNLOADER PANEL ARRIVAL CHECK X0D0 OUT LIFTER UPPER LIMIT CHECK X0D1 OUT LIFTER LOWER LIMIT CHECK C746M1T04 3 14 CP 842 Preliminary The Machine gt gt Sensor Positions 3 3 4 Main Conveyor C746M1013 Note The figure above represents a left to right panel flow Sensor No SIGNAL NAME X0CO ADJUSTING RAIL ENGAGEMENT CHECK IN ADJUSTING RAIL ENGAGEMENT CHECK OUT X0DC ADJUSTING RAIL ENGAGEMENT CHECK CENTER C746M1T05 CP 842 Preliminary 3 15 The Machine gt gt Sensor Positions 3 3 5 In carrier C746M1014 Sensor No SIGNAL NAME X0B1 X0B3 X0B4 X0B7 X0B8 X0B9 X0BB X0BD IN CARRIER FORWARD LIMIT PANEL CHECK IN CARRIER FORWARD LIMIT CHECK IN CARRIER RETRACT LIMIT CHECK IN CARRIER RETRACT LIMIT CLAMP CHECK FIXED RAIL IN CARRIER RETRACT LIMIT CLAMP CHECK ADJUSTABLE RAIL IN CARRIER FORWARD LIMIT CLAMP CHECK FIXED RAIL IN CARRIER FORWARD LIMIT CLAMP CHECK ADJUSTABLE RAIL IN CARRIER RETRACT LIMIT UNCLAMP CHECK FIXED RAIL IN CARRIER RETRACT LIMIT UNCLAMP CHE
66. High Speed Chip Placer CP 842E CP 842ME Mechanical Reference Preliminary FL Machine Mfg Co Ltd Copyrights All rights regarding this manual are reserved by Fuji Machine Manufacturing Co Ltd This manual may not in whole or in part be reproduced by any means electronic mechanical or otherwise or reused in any way without the prior written permission of Fuji Machine Manufacturing Co Ltd Trademark Rights is a trademark of Fuji Machine Manufacturing Co Ltd and registered in the following countries Austria Belgium Denmark Finland France Germany Greece Indonesia Ireland Italy Japan Korea Luxembourg the Netherlands Portugal Spain Sweden the U K and the U S A WindowsNT is a trademark of Microsoft Corporation USA UNLHA 82 DLL is a freeware product created by Micco Warranty and Liability Fuji Machine Manufacturing Co Ltd accepts no responsibility for situations that may arise due to any of the following The use of third party parts The use of non genuine Fuji parts Incorrect settings made by the customer Improper use of Fuji equipment Notice Fuji Machine Manufacturing Co Ltd reserves the right to change the content of this manual without notice Every effort has been made to ensure that this manual is correct in every detail However please contact Fuji in the unlikely event that errors or omissions are detected Fuji Machine Manufacturing Co Ltd accep
67. KT The servo box contains the servo BKT to which the servo amplifiers and boards are attached Users should not interfere with this box except to perform servo amplifier replacement UPS Uninterrupted Power Supply Unit The UPS unit is positioned in the transformer box at the rear of the machine Under normal circumstances the power supply from the UPS is cut automatically when the machine 15 shut down However if the machine 15 not operating correctly the power from the UPS unit may not always be cut As a safety precaution when performing any kind of electrical maintenance work always set the switch on the UPS unit to off after also cutting the main power supply to the machine UPS Uninterrupted Power Supply Unit Power switch 746 1008 3 10 CP 842 Preliminary 3 3 Sensor Positions 3 3 1 XY table X Y axis The Machine gt gt Sensor Positions Sensor No C746M1009 SIGNAL NAME SX009 SX00A 5 011 5 012 X_AXIS_ OT X AXIS OT Y AXIS OT Y AXIS OT CP 842 Preliminary C746M1T01 3 11 The Machine gt gt Sensor Positions Z axis X05E X05 C746M1010 Sensor No SIGNAL NAME SX019 2 5 SX01A Z AXIS OT X05C XY TABLE LOADING HEIGHT CHECK X05E MAIN LIFTER MIDDLE OT 3 12 C746M1T02 CP 842 Preliminary The Machine gt gt Sensor Positions 3 3 2 In conveyor X0B0 XOB5 XOB6 C746M1011 Sensor No SIGNAL NAME IN CONVEYOR 1 SPEE
68. Pb P e P CP 842 Preliminary Safety gt gt Safety Rules for All Machine Types NWARNING Long hair should be tied back Longhair may get caught in running machines Hair should be kept short or tied back sothat it does not get caught in the machine Turn off the air supply when carrying out maintenance on cylin ders valves and filters Removing cylinders valves or filters without turning the air supply off may cause parts or particles to be propelled into the eyes e Besuretoturn off the air supply when carrying out main tenance on cylinders valves and filters Be sure to wear protective glasses when removing parts from the machine Besureto wear protective glasses when removing or replacing parts Example CP 6 7 8 nozzles use springs which may be propelled during dis assembly Be sure to handle the nozzles carefully to prevent eye injuries Q P Check the machine monitor and the target axes while manually operating the machine When operating the machine carefully follow the instruc tions that are displayed at the machine display Operating the machine without looking at the machine display may lead to operating errors or result in damage to the machine or products Do not touch the servo amp power terminal for at least five min utes after turning off the power Theservo amp retains a high voltage even after the power has been turned
69. Preliminary The Machine gt gt Sensor Positions 3 3 8 Cam Box 10LS 31 ET X030 10LS 12 C746M1017 Sensor No SIGNAL NAME X030 ST1 NOZZLE UPPER LIMIT CHECK X032 ST9 NOZZLE UPPER LIMIT CHECK X033 ST9 NOZZLE LOWER LIMIT CHECK 10LS 9 ST5 IMAGE CHECK 10LS 12 CAM ANGLE CHECK 10LS 34 ACQUIRE PARTS HEIGHT COMMAND 10LS 34 FOREIGN OBJECTS CHECK COMMAND C746M1T09 Note The items in parentheses do not display in the I O map CP 842 Preliminary 3 19 The Machine gt gt Sensor Positions 3 3 9 Tape Feeder Unit ST1 2 X03C X03B X036 C746M1018 Sensor No SIGNAL NAME X036 ST2 LARGE PART CHECK X03B FEEDING FORWARD LIMIT X03C FEEDING RETRACT LIMIT X03D TAPE END CHECK C746M1T10 3 20 CP 842 Preliminary The Machine gt gt Sensor Positions 3 3 10 Tape Cutter ST1 C746M1019 Sensor No SIGNAL NAME X04D X04E TAPE CUTTER UPPER LIMIT TAPE CUTTER LOWER LIMIT CP 842 Preliminary C746M1T11 3 21 The Machine gt gt Sensor Positions 3 3 11 Nozzle Clutch ST10 V C746M1020 7088 Sensor No SIGNAL NAME X039 5710 NOZZLE CLUTCH ORIGIN POSITION X03A 5710 NOZZLE CLUTCH ENGAGEMENT CHECK X04F ST11 HEAD A CHECK C746M1T12 3 22 CP 842 Preliminary The Machine gt gt Sensor Positions 3 3 12 Nozzle Changer ST15 X04A
70. RGENCY STOP Buttons In the event of an emergency press any of the red EMERGENCY STOP buttons located on the machine at the positions indicated in the figure below lt CP 842E gt Front side Rear side CP 842 Preliminary 2 11 lt 842 gt 2 12 The Machine gt gt Machine Components 3 The Machine 3 1 Machine Components 3 1 1 General View Front Side lt CP 842E gt Control box 2 Control box 3 Waste tape box Operation box 1 Conveyor width adjusting handle Placing head Index unit In conveyor In carrier XY table Out conveyor C76M1001 CP 842 Preliminary 3 1 The Machine gt gt Machine Components Rear Side lt CP 842E gt Operation box 2 Servo box 1 Servo BKT 1 Servo box 3 Servo BKT 2 Transformer box Transformer BKT 3 2 CP 842 Preliminary The Machine gt gt Machine Components Front Side lt CP 842ME gt Oil cooler box Control box 1 Control box 2 Control box 3 Operation box 1 Waste tape box Control width adjusting handle Placing head Index unit Mark camera Out conveyor C76M1026 CP 842 Preliminary 3 3 The Machine gt gt Machine Components Rear Side lt CP 842ME gt Rear cover Servo box 2 Servo BKT 1 Servo box 3 Servo BKT 2 Transformer box Transformer BKT Waste tape disposal unit Filter regulator Vacuum pump Device table C746M1027 3 4 CP
71. ST The functions of each of the 16 stations are explained below ST1 Picks up parts from the feeder indexes the feeder and offsets the NY axis pickup position ST2 Checks for the presence of large sized parts Also performs pre rota tion PQ operations The pre rotation function rotates parts in advance to a position near the placement angle specified in the place ment program Pre rotation occurs in 90 degree increments ST5 Two CCD cameras Wide View and Narrow View check the presence and pick up condition of the parts ST6 Measures the height of parts which the nozzle has picked up option Also measures the length of the nozzles option ST8 Performs fine rotation F Q operations Rotates a part to its final placement angle based on the vision processing results at ST5 ST9 Places parts on the panels being produced Parts rejected during vision processing at ST5 are not placed ST10 Performs reverse pre theta PQ and fine theta FQ rotation opera tions Also checks the nozzle s origin position 5111 Verifies that nozzles lowered for part placement have been raised again and checks the nozzle Holder A position for the production log ST13 Rejects parts deemed defective by the vision check at ST5 ST14 Rotates the rotary holder to select among the 6 nozzles ST15 Checks the positions of the 6 nozzles after nozzle changes 3 2 2 Parts Supply System Feeders Thefeeders supply taped parts to ST1 wh
72. The lenses should be cleaned periodically to ensure accuracy during part height and nozzle length measurement Procedure N WARNING Be sure to turn the main power off before performing this proce dure Use a soft brush such as those used to clean camera lenses to clean the sensor lens If the lens is badly soiled use a commercially available lens cleaner jt amp xU Sensor lens C746M3011 CP 842 Preliminary 5 9 Maintenance gt gt Cleaning 5 10 5 1 9 Fluorescent Nozzle Stickers Monthly Point Dust and other particles adhere to the nozzle fluorescent sticker reducing the amount of light reflected to the ST5 parts camera A reduced reflection can prevent the part image from being acquired properly resulting in vision errors Procedure If repeated vision errors are occurring for a particular nozzle use a soft brush such as those used to clean camera lenses to wipe the dust from the sticker Note Do not rub the fluorescent seal with a cloth as this will cause dust to adhere to it If the dust cannot be removed replace the fluorescent seal CP 842 Preliminary Maintenance gt gt Cleaning 5 1 10 Tapered Clutch on the Nozzle Indexing Shaft Monthly Point After extended periods of operation grease may adhere to the tapered clutch area of the nozzleindexing shaft causing the clutch toslip This slippage makes it difficult to rotate the nozzle to its placin
73. aintain accuracy height Check for a problem with the Proper Note Machine adjustments can be performed data ZO 0 3 mm push in only by those with a Level 3 training Check for the reference and followup Note Machine adjustments can be performed rails flatness problem only by those with a Level 3 training Replace mechanical valves where the A malfunctioning vacuum break may affect M Sect 7 1 4 4 4 Vacuum break spool motion is not smooth placing accuracy problem Adjust the vacuum break lever position and the speed controller Verify that the machine base is level Failure to level the machine base after the M Sect 9 1 if not level it machine has been moved etc can affect thg Problem after XY table flatness making the current Prope 1 5 machine status data settings unsuitable change Measure the and camera Note Machine adjustments can be performed resolution only by those with a Level 3 training Perform a calibration using a PAM part Check the solder condition after printing The solder printing condition or dryness can cause part deviations during board Printing conveyance or can affect the self alignment 1 6 conditions at reflow operations problems Solder adhesion weakens when the solder dries Therefore the sooner placement occurs after printing the better Check the reflow temperature profile Improper reflow conditions can cause self alignments and tombstoning Reflow Provide a profile in which the te
74. atch changes of feeder pallets Procedure Pallet unloading 1 Align the height of the PCU forks at the end of the PCU with the fork slots on the machine Turn the handle and raise the upper section of the PCU Note Use the guide seal at the side of the handle as a reference when adjusting the height of the forks Adjust so that the lower surface of the plate falls within plus or minus 10 mm of the standard value Guide seal C746M2010 2 Push the PCU to insert the forks into the machine then clamp it with the Stagel Clamp command Note The following explanation describes the D1 axis stage 1 pallet change 3 Close the rear door and select the Stage1 Start command then press START The D axis pallet moves to the change position and is unclamped 4 Open the rear door and pull the pallet out of the machine and onto the PCU Caution 1 Remove the pallet slowly 2 To avoid damage to the door stoppers the door should be opened and closed with care 5 Select the Stagel Unclamp touch panel command then slowly retract the loaded PCU Caution Exercise extreme care when using the PCU to move a fully loaded pallet A dropped pallet may result in serious injury or damage to the machine CP 842 Preliminary 4 9 Basic Operation gt gt Changing Pallets CP 842ME option 4 10 Pallet Loading 1 Push the fork of the PCU containing the replacement pallet into the machine and clamp it usin
75. blems with sensors which detect the cylinder actuator stroke end etc item 7 shown below should also be checked 7 Sensor detection problem caused by malfunctioning cylinder etc After checking the machine s error display content check the following cylinder for problem 7 see above Execute the following commands to see if the carrier can be moved to its motion limit position Panel Loader Loader Maintenance In side Carrier Extend Carrier Retract S TART opening all the way to its limit position No Cause Remedy Remarks Ref Page 1 Check whether the panel is being clamped XOB1 XOB2 panel sensor fails _ M Sect 3 3 correctly Switch on at carrier advance limit even In carrier panel 2 Check the following sensors for problems though a panel has been loaded from 4 4 conveyance 1 6 described above the in lifter error In carrier advance limit panel check 1 XOB1 Or panel has been conveyed from the in carrier to the XY table but the 1 or XOB2 panel sensor fails to switch off 1 Check the following sensor for problems In carrier was advanced but the in M Sect 3 3 3 6 see above carrier advance limit sensor failed to In carrier advance limit check switch on In carrier 0 Check the in carrier conveyance cylinder for In carrier may not be moving all the S Sect 3 1 4 2 advance limit problem 7 see above way to its motion lim
76. can be pressed quickly in case of an emergency e Check the safety functions before starting operation Beforestarting the machine check the operation of the EMERGENCY STOP button the safety switches on the acrylic covers the safety switch on the rear fence gate the optical sensors on the rear fence and all other machine safety features Contact a Fuji serviceman immediately if any of the safety functions fails e CP 842 Preliminary Safety gt gt Safety Rules for All Machine Types NWARNING Do not remove safety switches Donot remove safety switches or disarm the safety func tions Disarming the safety switches may result in injury when others unknowingly press the START button Fuji does not take any responsibility when a machineis disassembled without F uji s permission even if this results in accidents or trouble Check that there is nobody inside the machine when working on the machine with two persons or more Verify that nobody is within or near the machine before operating the machine Operating the machine may cause injury to the person who is carrying out maintenance Example If one person moves the device table while another person is exchanging a feeder the latter may be injured Do not close the fence when someone is inside the fence e When the fence is opened it is safe to approach the machine Closing the fence however will put anybody
77. ccum ON Vaccum OFF Vaccum Vaccum Spool Spool C7SM4036a Checking the Position of the Pin Bracket 1 Press the EMERGENCY STOP button to turn off the 200V power leaving only the 100V power on N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Ensure that distance A as seen in the figure below is 8 9 mm for all heads Use a special jig Z9526DCPJ 0371 to check this distance Pin bracket A Jig 8 9 mm Z9526DCPJ0371 C7SM4054a 7 32 CP 842 Preliminary Adjustments gt gt Station Adjustments Valve Switching Lever Height Adjustment This adjustment should be performed on the reference head after completing adjust ments to the vertical movement of the nozzle Refer to 7 1 9 Nozzle Vertical Move ment During Placement for details reference head can be identified by its height All heads are measured with spools lifted and the lowest one is referred to as the reference head CP 842 Preliminary C7SM4055 Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger t
78. commands to see if the cylinder can be moved to its motion limit position Panel Loader Clamp Unclamp START The clamping cylinder may not be moving all the way to its motion limit position S Sect 3 1 CP 842 Preliminary The X and Y values which appear the remedy column correspond to the I O map assignment numbers C746M5T08 Troubleshooting gt gt Troubleshooting Table 8 1 5 Missing Parts 8 10 No Cause Remedy Remarks Ref Page Specify the appropriate nozzle size and Unsuitable nozzle size part weight and cam T Part 3 cam speed settings using the Tech speed etc settings can result in an Lesson 2 Report issued by Fuji as a reference insufficient holding force when handling 2 4 3 parts causing nozzle and part slippage U Part 2 The Fuji Tech Report is meant for reference Chapt 4 purposes only Nozzle The recommended cam speed may be Speed different even if the part shape is the same If accuracy deviations or missing parts An unsuitable XY table speed can apply a T Part 3 54 Incorrect Part are occurring for a specific part force which exceeds the holding capacity of Lesson 2 data setting decrease the XY table speed setting in the part s solder resulting in position 2 1 3 the Part data where the problem is deviations Solder adhesion decreases U Part 2 occurring when it dries Therefore the sooner Chapt 4 placement occu
79. ct 4 1 4 12 missing panel error 7 see above Out conveyor motor ON Y02D 3 If the panel is caught at some point along the M Sect 3 3 conveyor change the conveyor width 1 Check the following sensors for problems Out lifter UP DOWN limit sensors fail M Sect 3 3 3 6 see above to switch off and on Out lifter UP limit check Out lifter DOWN limit check X0D1 Out lifter cycle 2 Check the out lifter UP DOWN cylinder for Lifter may not be moving all the way to S Sect 3 1 4 13 orror problem 7 its motion limit position see above Execute the following commands to see if the lifter can be moved to its motion limit position PanelLoader Loader Maintenance Out side Carrier Extend Carrier Retract S TART 1 Check the following sensors for problems Out conveyor panel arrival sensor fails M Sect 3 3 3 6 see above to switch on even though the panel has Outconveyor 4 panel arrival check X0C7 from the out carrier to the Out lifter panel QUIET 4 14 conveyance 2 Check the following sensor for problems The panel spacing sensor between out error 1 6 described above conveyors 1 amp 2 is off it should be on Either the spacing sensor has failed or Out conveyors 1 amp 2 panel spacing check the sensor detection position is improper 1 Check the following sensors for problems Adjustable rail engagement sensor M Sect 3 3 3 6 see above fails to switch on Verify
80. d so that the movable blade and fixed blade engages by 0 5 to 1 0 mm Fixed cutter 0 5 1 0 mm Movable cutter C7SM4008a C7SM4010b CP 842 Preliminary 7 5 Adjustments gt gt Station Adjustments 7 1 3 Nozzle Vertical Movement During Pickup ST1 Slider Adjustment Adjust the height of the slider to ensure that the cam follower can travel smoothly through the slider and along the cam groove 1 Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 In order to remove the nozzle shaft assembly it is first necessary to remove the upper clutch Set the cam angle to zero degrees and use spanner 0450 to loosen the bolt on the nozzle shaft moving from station 9 to station 10 Turn the loosened bolt by hand and then remove the clutch See next page illustra tion Caution Remove the nozzle shaft assembly which bears either a or identifier seal Operations may be complicated if other nozzle shaft assemblies are removed 3 Remove the linear guide clampers and vacuum hose then remove the nozzle shaft assembly Caution When handling the nozzle shaft assembl
81. dless Cylinder Monthly 14 Nozzle Filter Every 3 Months T015 CP 842 Preliminary 5 2 Lubrication Maintenance gt gt Lubrication 5 2 1 Precautions During Lubrication Prior to beginning any lubrication turn the main breaker off Apply an appropriate amount of lubricant If too much lubricant is applied it may splatter and drop on panels inside the machine Special care should be taken to keep the camera lens clean as a soiled lens results in poor part inspec tion results Use a lens cleaner to keep the lens clean 5 2 2 Types of Lubricant Thelubricants which are used havethe following characteristics Characteristics Daphne Eponex No 2 Lithium grease by Idemitsu suited to mid low speed parts Daphne Super Multi Oil 32 High grade synthetic based oil by Idemitsu used as a multi purpose lubricating oil applicable to a wide range of parts that require lubrication Multemp LRL3 Lithium grease by Kyodo Oils suited to mid low speed parts Multemp SRL Lithium grease by Kyodo Oils suited to high mid low speed parts AFC Grease High grade synthetic oil based on grease by THK suited to high speed parts SHC 630 This MOBIL PAO based oil is used on gears and axis components Turbine oil NASKALUBE A Fuji special blend containing additives used for the purpose of enhancing durability C746M3T02 Note Do not mix grease types CP 842 Preliminary 5 17 Maintenance g
82. e NO 16 sinooO JO au eoejdes YORAOAIAS OAJ8S eu Aq ueAup sjueuoduJoo UO AISS82X YOOYD OAJ8S UO uonoeuuoo Buum peo Jopooue y 19 uo2 Jepooue 1284J09U snonun uoo eseud u do ue jou seop uoneJedo Jo ZZY Bum y 129 pue 29 109 uonoeuuoo JO Bum SI UBYM JO 1 Jolouu y 328109 SI y JEU YOOYD BUM 991109U NO sinooO snoeuejuejsu oedoAJes eAnejep oedoAJegs l NO 1 o1juoo SINDIO 10 Jepooue eu 4291109 4epooue 199 109 Buum M pue uoneJedo A seseud 1264109 si ul SI JO OUJ UBYM JO J0jOUJ y 1284109 Jojou 124 YOOYD JOJOW 12eJ402U NO 17550
83. e the feeder from being set in the correct Chapt 7 position Adjust the pickup position Pickup position deviations may occur after DT 651 E Digitizer prolonged feeder use with Image Check the pickup posiiton periodically Processing Lubricate the ratchet area Failure to er 2 lubricate can result in ratchet and stopper Chapt 4 4 9 wear which will cause pickup position FM Part 3 deviations Chapt 4 4 11 Adjust the ST1 pickup height M Sect7 1 3 Measure the part height sensor s nozzle An unsuitable reference value will result in an height reference value automatic offset of the pickup height Note Machine adjustments can be performed only by those with a Level 3 training 1 Use the nozzle check command to bent nozzle will cause pickup position M Sect 6 1 check for bent nozzles deviations and may prevent pickup from 2 Verify that the nozzle spring back occurring properly 2 5 Defecti motion is smooth A stuck nozzle cannot reach the part VICE DOZES 3 Verify that the nozzle is not clogged making pickup impossible clogged nozzle will have a lower vacuum If a problem is found with any of the force and may prevent pickup from above replace the nozzle occurring properly Ensure that the pressure value on the A low vacuum force may prevent parts from M Sect 6 7 vacuum pump displays at most 40 being pick up properly Replace the pump parts if the va
84. e Tape Duct Every 8 Hours Point After being cut by the cutter waste tape is carried through a duct along the route shown in the figure below Should the duct become clogged the clogged waste tape may interfere with tape being fed from the feeder resulting in tape feed problems and part pick up errors If a tape feed problem occurs during automatic operation inspect and clean the duct Procedure WARNING Be sure to turn the main power off before performing this proce dure The duct should be cleaned using a vacuum cleaner do not use an air blower 5 2 CP 842 Preliminary Maintenance gt gt Cleaning 5 1 3 Reject Parts Box Every 8 Hours Point Parts which have been rejected during vision processing are discarded to a reject parts box After every 8 hours of operation this box should be removed from the machine and emptied Procedure WARNING Be sure to turn the main power off before performing this proce dure While pulling the lever to the left slide the reject parts box out towards the front of the machine Cushion seat C746M3003 When returning the reject parts box to its position make sure that the cushion sheet exists at the bottom of the box CP 842 Preliminary 5 3 Maintenance gt gt Cleaning 5 1 4 Nozzle Interior Weekly Point Because the part is held by vacuum through the nozzle minute dust or glue particles etc can build up inside the nozzle
85. ems The waste tape cutter must be replaced at such times Procedure N WARNING e Turn the main power off before performing this procedure Rotation may occur caused by spring action if the cam axis is not at its origin position 0 degrees Use special care when working inside the machine as this is a dangerous area Remove the plate located above the waste tape cutter Remove the two bolts which secure the fixed cutter Remove the two bolts which secure the arm of the moving cutter WN H Remove the fixed and moving cutters and mount the new fixed and moving cut ters Note Apply grease to the contact points before attaching the moving cutter See 5 2 9 Lubricating the Waste tape disposal unit Plate y y Fixed cutter C746M4004 6 4 CP 842 Preliminary Replacing Consumable Parts gt gt Conveyor Belts 6 4 Conveyor Belts Point Broken or damaged conveyor belts must be replaced Procedure U WN CP 842 Preliminary N WARNING Be sure to turn the main power off before performing this proce dure Remove the panel lifter Loosen the bolt which secures the tension pulley and weaken the tension Loosen the belt guide bolts Replace the conveyor belt Insert a 0 3 mm clearance gauge between the belt s top surface and the plate then tighten the belt guide bolts while maintaining this 0 3 mm clearance Tighten the belt by applying 1 to 1 5 kg of force to the tension pu
86. en the 200V power supply to the machine is turned on the servo amps will be activated In this condition the machine may unexpectedly begin to move Do not insert or remove connectors while power is being sup plied to the machine Removing or inserting connectors while power is supplied tothe machine may not only cause damage to the machine but may also cause electrical shock Besuretocut the power tothe machine before inserting or removing connectors Stay clear from the machine when it is being lifted Never put hands or feet under the machine when the machine is being raised by means of a jack or other device for leveling or transport Do not look into the conveyor inlet or outlet and do not open the cover Reflow oven Dono look into the conveyor inlet or outlet and do not open the cover Example The UV light on the reflow oven may damage eyesight or result in burns Exchange the halogen lamp only after it has cooled down When turned on halogen lamps will reach high tempera tures resulting in skin burns when touched To exchange a halogen lamp turn off the power and allow the lamp to cool off sufficiently Do not wear gloves made of cloth when operating the machine Rubber gloves will tear when caught by the machine and prevent hands from being drawn intothe machine Gloves made of cotton or similarly strong material may cause hands to be drawn into the machine gt P
87. erethey are picked up The CP 842E 842ME uses WC feeders for CP machines When using part reels 13 inches or larger feeders with CP 7 CP 8 exclusive reel holders are required Waste tape disposal unit The waste tape disposal unit is located beneath ST1 of the placing head and consists of upper and lower cutters which cut the waste tape fed from the feeder The cut waste tape is then carried through a vacuum duct to the waste tape box at the bottom of the machine Device tables Devicetables hold feeders and also are used for transport Thetwo device tables move on the D axes as instructed in the production program CP 842 Preliminary The Machine gt gt Functions of Each Part CP 842ME has an option for pallet tables that can be used to enable batch setting and removal of feeders PCU Pallet Change Unit The PCU is used as a dolly for setting and removal of pallet tables 3 2 3 Vision System Parts camera This CCD camera checks the size and shape of picked up parts Mark camera A mark camera comprises a CCD camera a light and a mounting bracket After the CCD camera reads the fiducial marks on the panels being produced the coordinates are automatically corrected offset in accordance with internal calculations 3 2 4 Panel Conveyance System Carrier loader The machine s sequencer loader conveys panels between the in conveyor the XY table and the out conveyor by way of panel clamp units carriers Thei
88. erly Correct C746M2006 3 Insert the catch on the base of the feeder into the channel beneath the guide Push the feeder forwards and then press the back of the feeder down to damp it firmly in position Clamper C746M2007 Guide channel CP 842 Preliminary 4 5 Basic Operation gt gt Setting the Feeders 13 and 15 inch parts reels should be positioned using the three rubber stoppers When setting ensure that the feeder base and reel itself are positioned in the same slot Correct parts supply will not be possible if feeders incorrectly set as shown in the figure below View of device table from above Reel holder A Rubber brace Rubber brace Rubber brace n 746 2008 4 When setting a feeder a device table be sure that there is no foreign matter waste tape etc between the feeder and the device table Remove any foreign matter which has adhered to the device table grooves or to the bottom of the feeder Waste tape E C746M2009 Device table 4 6 CP 842 Preliminary Basic Operation gt gt Removal and Installation of Rotary Holders 4 4 Removal and Installation of Rotary Holders Point Remove rotary holders from the placing heads as necessary when performing mainte nance such as cleaning and lubrication Note The rotary holder is exclusive to the CP 842E 842ME Do not atte
89. exceeds the 6 1 warning occurs then easure the nozzle length permissible value a warning displays displays again onscreen Clean the glass surface of the part This error occurs when dust has adhered to M Sect 5 1 5 height sensor the part height sensor s camera lens Automatic operation continues unless the 6 2 dus pads ht quantity of dust is such that it hinders the On partnetg measurements senso Note Clean away the dust using cotton swab etc Check the height of the part where the Error occurs because the Part data setting Part error occurred and enter the correct differs from the height of the part which was Lesson 2 setting value picked up 21 1 U Part 2 Chapt 4 Appearance Check the part height tolerance value Error occurs because an unsuitable part T Part 3 for the part where the error ocurred height tolerance value is specified in Part Lesson 2 and enter the correct setting value data The tolerance value varies according 2 to the part type Verify that the tolerance value is appropriate for the part in question Refer to the tolerance values recommended by Fuji Part Use the nozzle check command to A part may be picked up in a tombstoned M Sect 5 1 4 6 3 tombstoning perform a nozzle length measurement posture if the nozzle length measurement M Sect 6 1 detection error Replace the nozzle if its length is outside result differs from the actual nozzle length the tolerance range When u
90. f the sticker which protrudes beyond the disk Remove any of the adhesive which may have adhered to the nozzle tube Nozzle and fluorescent sticker drawing numbers Nozzle Size 0 4 R08 004 Nozzle Assy Dwg No ADCPH751 Disk Size Fluorescent Seal Dwg No DCPH851 0 4 08 004 Short ADCPH769 DCPH851 0 7 R08 007 ADCPH752 DCPH852 1 0 R08 010 ADCPH753 DCPH853 1 3 R08 013 ADCPH754 DCPH854 1 8 R16 018 ADCPH955 DCPH855 2 5 16 025 ADCPH956 WPH820 3 7 16 037 ADCPH957 WPH821 5 0 R16 050 ADCPH958 DCPH856 1 3 08 013 ADCPH770 DCPH854 2 5 M16 025 ADCPH971 WPH820 1 8 516 018 ADCPH959 DCPH857 2 5 516 025 ADCPH961 DCPH858 3 7 516 037 ADCPH963 DCPH859 5 0 S16 050 ADCPH965 DCPH860 CP 842 Preliminary 1 8 16 018 ADCPH960 DCPH881 2 5 B16 025 ADCPH962 DCPH882 3 7 16 037 ADCPH964 DCPH883 5 0 B16 050 ADCPH966 DCPH884 5 0 B21 050 ADCPH968 DCPH885 C746M4T01 Replacing Consumable Parts gt gt Waste Tape Cutter 6 3 Waste Tape Cutter Point A broken or damaged waste tape cutter will be unable to cut the waste tape properly causing tape clogging and tape feed probl
91. f the tape feed lever reaches the advance limit and retract limit Tape feed lever on machine Retract sensor Advance sensor Tape feed lever on feeder Feeder C7SM4002a Rod Adjustment 1 Set the positioning jig ADCP 8020 in the D1 position 2 Press Position Position D1 axis enter 1 OK and the START button to move the positioning jig to station 1 3 Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator CP 842 Preliminary 7 1 Adjustments gt gt Station Adjustments 4 Use the cam handle to rotate the cam to 0 Switch the I O TAPE FEED SOL ON setting ON 6 Adjust the rod so that there is 0 5 mm clearance between the top of the position ing jig and the roller Adjustment rod Roller 0 5mm Positioning jig ADCPJ8020 Positioning jig ADCPJ8020 C73M4001b 7 2 CP 842 Preliminary Adjustments gt gt Station Adjustments Advance Sensor Position Adjustment 1 When the dog is at the lower limit at cam angle 200 ensure that the sensor is ON 2 Set a dial gauge to the roller and adjust the sensor to go off 0 5 mm above the lower limit Dog Upper Limit A Dog Lower Limit Advance
92. flective seal Check for dust etc around the If the prism box surface is soiled vision M Sect 5 1 5 Prism box displayed image of the part causing the processing errors will occur for almost all Vision processing error the wipe the parts surface is soiled prism box surface clean with a dry cloth or cotton swab Measure the size of the part where Frequent vision processing errors may be T Part 3 part size is frequent errors are occurring then enter caused by slight differences between the Lesson 2 slightly different this correct size in Part data actual part dimensions and the dimension 24 1 from the Part settings In such cases measure the actual U Part2 data setting part and enter those dimensions as the Pul a settings pearance 3 3 Parts are not Refer to item 2 Pickup Errors being picked up C746M5T03 8 5 Troubleshooting gt gt Troubleshooting Table 8 1 4 Panel Conveyance Related Errors Most panel conveyance errors are caused by sensor problems As a rule these errors occur due to one of the following 6 causes items at the sensor in question 1 Panel detection problem 2 3 b 6 board and terminal board malfunction Sensor beam emitter is aimed at a notched area of the panel Sensor beam emitter is soiled foreign matter is present 4 Sensor has failed Disconnected severed cable etc As a malfunctioning actuator may be responsible for pro
93. for lubrication are indicated in the illustrations using arrows and numbers White arrows are used to indicate surfaces that require greasing or oil Black arrows indicate grease nipples and signify that grease should be inserted using a grease pump 1 LM block LM rail 2 C746M3016 Note Even LM blocks that do not have a nipple can be lubricated by applying grease between the block and the LM rail bearing mechanism The grease that adheres to the ball bearings and rollers will be taken into the LM block and thereby serve to lubricate the LM block Lubrication Checklist A lubrication checklist is provided at the end of this chapter This checklist should be used as follows 1 Check the lubrication points corresponding to the reference numbers shown in the illustrations 2 Mark each check box after lubricating each point CP 842 Preliminary Maintenance gt gt Lubrication 5 2 4 Lubricating the XY table Lubrication points Types of lubricant Schedule X axis LM block Daphne Exponex No 2 Every 3 months X axis ball screw Multemp LRL3 Monthly X axis screw cover Daphne Super Multi Oil 32 Every 3 months Y axis LM block Daphne Exponex No 2 Every 3 months Y axis ball screw Multemp LRL3 Monthly Y axis screw cover Daphne Super Multi Oil 32 Every 3 months Z axis ball screw Multemp SRL Monthly C746M3T03 Caution grease on the Y axis screw cover dries the cover m
94. g gt gt Servo System Troubleshooting ELLSW9PZD 0 BY 7991109 Jo 0 BY 7991109 Jo Bulpunos6 JO 1olsis i 10 pue N seseud 2 0 1 5 e sn 10 seseud 5 punoJ6 pue M pue A N seseud ueewjeq uonoeuuoo 1edouduy woedoues Ul poys 9 q amp 5 JO Hous peo peo Jo JoJOW ui Buipunoio uoneJedo Buunp NO je sunooo jueJinoJeAQ Aejas ayeysiu Aq 499UD Bunoouse qnoa 1041611 2942 snels OV jueunoJe o sj29jep yOedOAIaS NO eAnoejep xoedoAJeg JAMO o3uoo
95. g angle and affects the positioning Use the degreasing agent ThreeBond 2706 supplied with the machine to clean the tapered clutch on a monthly basis Procedure N WARNING Turn the 200V power off before performing this procedure Rotation may occur caused by spring action if the cam axis is not at its origin position 0 degrees Use special care when work ing inside the machine as this is a dangerous area While pulling down the outer shaft which covers the nozzle indexing shaft wipe the tapered clutch all the way around with a cloth on which the degreasing agent has been applied Note Do not spray the degreasing agent directly onto the tapered clutch because spraying is inac curate The agent could land on other components removing the lubricant which they require Tapered clutch Outer shaft OTAGO CP 842 Preliminary 5 11 Maintenance gt gt Cleaning 5 1 11 Air Filter Monthly Point Filters are attached to each of the cooling fans on the machine The air filters should be cleaned periodically to ensure smooth passage of air and thus prevent overheating Procedure N WARNING Be sure to turn the main power off before performing this proce dure Remove the cover and the filter and then use a vacuum deaner to remove any parti des from the filter Air filter Filter cover C746M3010 5 12 CP 842 Preliminary Maintenance gt gt
96. g the Stagel Clamp command Caution Exercise extreme care when using the PCU to move a fully loaded pallet A dropped pallet may result in serious injury or damage to the machine 2 Push a pallet onto the machine s D axis Closetherear door and damp the pallet at the D axis Caution 15 avoid damage to the door stoppers the door should be opened and closed with care 2 If the rear door is closed as the pallet is being changed the clamp will be activated even though the pallet is not present 4 Select the Stagel Set command 5 Select the Stagel Unclamp command then slowly retract the PCU This com pletes the pallet change CP 842 Preliminary Maintenance gt gt Cleaning 5 Maintenance 5 1 Cleaning 5 1 1 Waste Tape Box and Filter Every 8 Hours Point Waste tape which has been cut by the cutter is carried through a duct to the waste tape box This box should be emptied after every 8 hours of operation Procedure Open the door remove the waste tape box and empty the contents When emptying the waste tape box also check the filter immediately above it If the filter is soiled clean it with a vacuum cleaner Waste tape box C746M3001 Note When cleaning is complete ensure that the waste tape box and filter are inserted all the way back to their original positions Furthermore ensure that the door is properly closed CP 842 Preliminary 5 1 Maintenance gt gt Cleaning 5 1 2 Wast
97. get 100 digit CP 842ME Pickup area 1000 digit target 2000 digit Retract area 100 digit target 300 digit Note The sensor should be replaced when the light reading is at approximately 4095 CP 842 Preliminary 7 19 Adjustments gt gt Station Adjustments 7 20 Check the following items if the light reading does not reach the minimum required value a b The position of the sensor bracket Check that the sensor is correctly attached to the sensor bracket The positioning of the fiber and attachment tips Check whether the fiber and amp connections are correctly inserted Check the condition of the fiber wiring Change the display to show the percentage value by pressing the mode button to toggle the display as required Use the up and down arrow buttons to set the value to 200 where no object interrupts the sensor Note The arrow buttons cannot be used if the display reads 999P In this situation press the SET button twice to revert the display to 100P CP 842 Preliminary Adjustments gt gt Station Adjustments 7 1 6 Large Parts Check Sensor ST2 Point The machine has a sensor at station 2 that checks for large parts 1 mm or larger in height The machine stops immediately if no part is detected Sensor Position Adjustment 1 PresstheEMERGENCY STOP button This cuts the 200V servo power and leaves on only the 100V power supply N WARNING Always be sure to cut off the 200V po
98. grease gun is required J Special grease nozzle DGPJ055 N 27 T 28 Special 27 grease nozzle Connect the special grease nozzle DGPJ055 to the grease gun hose and insert into the grease Hose port on the LM block J C746M3041 5 28 CP 842 Preliminary Maintenance gt gt Lubrication 5 2 11 Lubricating the Rod Ends Lubrication points Types of lubricant Schedule Rod end Daphne Exponex No 2 Every 3 months C746M3T09 Arrow marks in the illustration indicate lubrication points Black arrows indicate points where a grease gun is required Inside of the cam box Rod end with a grease nipple C746M3023 CP 842 Preliminary 5 29 Maintenance gt gt Lubrication 5 2 12 Lubricating the D axis Carriers Lubrication points Types of lubricant Schedule 30 D axis LM block Daphne Exponex No 2 Every 3 months 31 D axis ball screw Multemp LRL3 Monthly C746M3T10 Arrow marks in the illustration indicate lubrication points Black arrows indicate points where a grease gun is required lt CP 842E gt 299
99. he operator Set cam angle to 0 then activate the place solenoid 035 ST9 PLACE SOL ENGAGED at station 9 to work the lever Use the cam handle to rotate the to 190 7 33 Adjustments gt gt Station Adjustments Loosen the mounting bolts shown in the figure below then adjust the lever height until there is a 1 9 mm gap use a thickness gauge between the bottom of the mechanical valve and the lever At this stage the spring pusher is pressed down 0 1 mm Mounting bolts Mechanical valve 1 9mm 1 1 9 mm 0 1 mm A C7SM4037a AL Note Do not touch the speed regulator The blow air pressure is set to 15 0 0 5 kPa ST13 7 0 0 5 kPa The user should not change the setting as a manometer is required for the adjustment 7 34 CP 842 Preliminary Adjustments gt gt Station Adjustments 7 1 11 Reverse theta Mechanism ST10 Point This mechanism reverses the nozzle rotation which occurred at the station 9 part placement The nozzle is returned from that part placement angle by the amount of rotation which occurred at stations 2 and 8 Clutch Meshing Check Perform this check on the low pressure nozzle Note The low pressure nozzle refers to the placing head out of the 16 that receives the weakest pushing pressure Use the low pressure nozzle for meshing checks at ST2 8 and 10 at all
100. hods and should be used as a reference for troubleshooting and resolving problems 8 2 1 Alarm Code Display Each servo amp has LED panel to display alarm codes The following illustrations show the location of each servo amplifier s LED panel warning The servo amplifier power terminal is high voltage Absolutely do not touch the servo amplifier power terminal Servo amplifier LED panel Connector CN3 746 6001 Note To display the alarm code on the digital operator connect the digital operator cable to the servo amplifier CN3 connector 8 12 CP 842 Preliminary Troubleshooting gt gt Servo System Troubleshooting X and Y Axes Servo Amplifier Alarm Display LED panel CN3 connector C746M5002 Rq Pq and NZ Axes Servo Amp Alarm Display lt CP 842E gt lt CP 842ME gt 4 R0 axis 5 LED panel ASAE Isis n CN3 connector
101. ight Drawing No Name 900 DCABO0370 Leveling sheet 912 DCAB0380 Leveling sheet 920 BB43880 Leveling sheet Anti vibration pads 930 GGA8060 Leveling sheet not used 935 GGA8060 Leveling sheet 950 GGA8030 Leveling sheet 962 965 8 40 Leveling sheet 980 BB42950 Leveling sheet 900 912 DCAB0390 Leveling sheet 920 GXA2071 Leveling sheet Anti vibration pads 930 DCAB0400 Leveling block used 935 WAB0601 Leveling block 950 GXA2121 Leveling block 962 DCAB0410 Leveling block 965 DCAB0410 Leveling block 980 DCAB0420 Leveling block Includes height of anti vibration pads 12mm C746M6T01 Anti vibration pads H 900 H 912 H 920 H 930 not used x 8 H 935 H 950 H 965 H 980 ln _ LO ru Om Anti vibration pads H 912 H 920 H 930 H 935 used e g N H 950 H 962 H 965 H 980 d f if 124 12 2 12 Board conveyance height Units mm C746M6001 CP 842 Preliminary 9 1 Setup gt gt Leveling the Machine Procedure 1 Position the leveling sheets or the leveling blocks as shown in the figure below Set spirit levels on a base surface
102. ions 4 3 4 3 Setting the Feeders x oreet ti da todas 4 5 4 4 Removal and Installation of Rotary Holders 4 7 4 5 Changing Pallets CP 842ME 4 9 5 Maintenance sn oec Dona dae ao nra Ca Bx 5 1 wer 5 1 5 1 1 Waste Tape Box and Filter Every 8 Hours 5 1 5 1 2 Waste Tape Duct Every 8 5 2 5 1 3 Reject Parts Box Every 8 Hours 5 3 5 1 4 Nozzle Interior 5 4 5 1 5 Camera Glass 5 5 5 1 6 Filter Regulator Weekly 5 6 5 1 7 Machine Interior Weekly 5 8 5 1 8 Part Height Check Sensor Lens Weekly 5 9 5 1 9 Fluorescent Nozzle Stickers Monthly 5 10 5 1 10 Tapered Clutch on the Nozzle Indexing Shaft Monthly 5 11 5 1 11 Air Filter Monthly 5 12 5 1 12 Oil Cooler Air Filter Monthly 5 13 5 1 13 Carrier Rodless Cylinder Monthly 5 14 5 1 14 Nozzle Filter Every
103. ir cylinder Air cylinder Bolt Locknut Bolt C7SM3122 14 Temporarily position the forward limit sensor 6 26 CP 842 Preliminary Replacing Consumable Parts gt gt Replacing the Carrier Clamp Unclamp Air Cylinder Packings 15 Extend the piston rod and slide the sensor until it turns ON 16 Advancethe sensor an additional 0 5 mm in the ON direction and tighten the screw to lock the sensor in place 0 5 mm dde Forward limit sensor a is the position where the sensor will come ON when the piston is extended C7SM3123 17 Connect the air hoses to the air cylinder 18 Mount theair cylinder on the carrier bracket 19 Connect the air hose and open the valve lever fully CP 842 Preliminary 6 27 Replacing Consumable Parts gt gt Replacing the Carrier Clamp Unclamp Air Cylinder Packings MEMO 6 28 CP 842 Preliminary Adjustments gt gt Station Adjustments 7 Adjustments Specialized skills and jigs are required to complete machine adjustments Attempting adjustments without these skills and jigs may result in damage to the machine so adjustments should only be performed by people who have received the appropriate training 7 1 Station Adjustments 7 1 1 Tape Feed Lever ST1 Point The pitch lever is the mechanism that advances the parts tape The vertical movement of this lever moves the part to the pick up position Two sen sors are located in order to check i
104. it position xcd Execute the following commands to see if the carrier can be moved to its motion limit position Panel Loader Loader Maintenance In side Carrier Extend Carrier Retract START 1 Check the following sensor for problems In carrier was conveyed but the in M Sect 3 3 3 6 see above carrier advance limit or retract limit In carrier advance limit check XOB3 failed 0 9n if th In carrier retract limit check XOB4 Ee TO CGU advance limit or retract limit sensor fails to switch on within 8 seconds 4 3 In carrier cycle 5 5 error 2 Check the in carrier conveyance cylinder for In carrier may not be moving all the S Sect 3 1 problem 7 see above way to its motion limit position Execute the following commands to see if the carrier can be moved to its motion limit position Panel Loader Loader Maintenance In side Carrier Extend Carrier Retract START 1 Check the following sensor for problems 3 6 In carrier clamper was M Sect 3 3 see above closed but the clamp sensor In carrier retract limit panel clamp check fixed rail side failed to switch on In carrier retract limit panel clamp check adjustable rail side 8 I Carrier clamper was In carrier advance limit panel clamp check fixed rail side opened but the unclamp In carrier advance limit panel clamp check adjustable rail side Sensor failed to switch on In carrier retract li
105. itivity Adjustment Green LED Red LED Digital display Tuner L ON D ON switch Mode changing switch C7SM4046 Remove the cover of the amp and follow the procedures below to adjust the sensor amp Note Be careful not to drop the cover inside the machine Set the L ON D ON switch to L ON for the nozzle detection sensor 1 2 3 4 4 1 Move the amplifier s mode change switch to the SET position Rotate the nozzle holder until the sensor light beam is adjacent to a dark part of the dog and press TUNING 3 Rotate the nozzle holder until the sensor light beam is adjacent to a metal part of the dog and press TUNING 4 Return the amplifier s mode changing switch to the RUN position At this time the sensitivity of the sensor can be checked on the digital display Digital display 0 1 Stableinterruption range 8 9 Stablelight input range If the display is within the stable range setting is complete 5 If the display is not within the stable range check the items below and make the necessary adjustments Check the connections between the amplifier and the fiber optic cable Check the position of the sensor CP 842 Preliminary Adjustments gt gt Servo Amplifier Adjustments 7 2 Servo Amplifier Adjustments Required Tools Required Tools 1 Digital Operator 7 2 4 Servo amplifier parameters 1 Connect the Digital Operator cable to the servo amplifier to be adjusted CN 3
106. limit sensor Z gt Dog C7SM4032 CP 842 Preliminary 7 29 Adjustments gt gt Station Adjustments Adjusting the Nozzle DOWN Limit Sensors The nozzle DOWN limit sensor which detects the down limit position of the nozzle U P DOWN rod is mounted inside the cam box Adjust the mounting position of this sen sor so that it switches ON when the nozzle is at its DOWN limit position Note When performing the DOWN limit sensor adjustment after the UP limit sensor adjustment remove the dial gauge from the machine to avoid interference between the dial gauge and the cam lever 1 Press the EMERGENCY STOP button to take 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Set the cam axis at the 0 degree position 3 Activate the ST9 placing solenoid air cylinder located in the cam box Execute the following I O commands Maintenance I O Check Standard 1 7035 579 PLACE SOL ENGAGED Output Signal ON The cam lever will then follow the cam axis 9ST Place solenoid air cylinder Nozzle UP DOWN rod Cam lever follows Cam axis the cam axis C7SM4029a 7 30 CP 842 Preliminary Adjustments gt gt Station Adjustments 4 Use the cam handle to rotate the cam to 190
107. lley in the direction indicated by the arrow then tighten the tension pulley bolt Note The belt can also be tightened to the prescribed tension by tightening the tension pul ley bolt while pushing the tension pulley 1 to 2 mm in the direction indicated by the arrow Tension pulley Belt guide bolt Panel lifter C746M4005 6 5 Replacing Consumable Parts gt gt Conveyor Belts The standard conveyor belt tension values are as stated in the diagram below Check the tension using a tension meter at the points indicated by the arrows as shown 298Hz 15 o G sia C746M4006 6 6 CP 842 Preliminary Replacing Consumable Parts gt gt Vacuum Pump Filter Element 6 5 Vacuum Pump Filter Element Point Air which is sucked into the pump must be clean The filter element should therefore be replaced when it becomes excessively soiled Procedure N WARNING Be sure to switch off the 200V power supply before beginning this procedure not touch the vacuum pump immediately after operation as it may be extremely not Allow the pump to cool before performing this procedure Loosen the filter case holder then extract thefilter case by pulling it downward After extracting the filter case replace the filter element Vacuum pump Air filter Filter element J C746M4007 Flter case holder CP
108. lue fails to reach the prescribed range Replace mechanical valves where the Poor spool motion can prevent parts from M Sect 7 1 4 26 Vacu m force is spool motion is not smooth being picked up properly too low Check the connection of the hose Cracks in hoses can prevent parts from M Sect 6 9 between the vacuum pump and the being picked up properly index unit Check the hose between the vacuum pump and the index unit The ST1 feeder s Reset the ST1 feeder s feed lever 2 7 feed lever has been tripped C746M5TO3 CP 842 Preliminary Troubleshooting gt gt Troubleshooting Table 8 1 3 Vision Processing Errors CP 842 Preliminary No Cause Remedy Remarks Ref Page Replace the error part with the correct This error occurs because the part part type information set in Part data is different from the part on the machine Part size is Enter the correct error part s part size Part 3 different from Part height lead pitch etc settings Lesson 2 3 1 Part Data Part data 2 1 21 2 k U Part 2 setting value Chapt 4 Appearance Element window Check production information to see if a If the problem is being caused by a soiled M Sect 5 1 4 specific nozzle is causing the vision nozzle the vision processing error will occur Sect6 1 Nozzle is soiled processing errors If so clean replace only when that soiled nozzle is used Sect 6 2 that nozzle or replace its re
109. m of the mechanical valve and the top surface of the pusher bracket becomes 1 7 mm Speed regulator Mechanical valve Pusher bracket Fixing bolt Adjustment bolt C7SM4042b Note Do not touch the speed regulator The blow air pressure is set to 7 0 0 5 kPa ST9 15 0 0 5 kPa The user should not change the setting as a manometer is required for the adjustment 7 40 CP 842 Preliminary Adjustments gt gt Station Adjustments 7 1 13 Nozzle Change Function ST14 Point The station 14 nozzle changer selects from among nozzle numbers 1 6 based the part data Nozzle Change Clutch Position Adjustment 1 CP 842 Preliminary PresstheEMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator Detach the rod end from the nozzle changer Rod end C7SM4064 Removethe nozzle holders of the reference head and the neighboring heads Use an inching operation and move the reference head to ST14 Usethe cam handle to rotate the cam to 200 7 41 Adjustments gt gt Station Adjustments 6 Attach the adjustment jig to the placing heads at ST14 and 15 Adjustment jig ADCPJ8040
110. mal vac uum pump noise and may reduce the vacuum force When replacing the vanes the bearings must also be replaced Procedure WARNING Be sure to switch off 200V power supply before beginning this procedure Do not touch the vacuum pump immediately after operation as it may be extremely not Allow the pump to cool before performing this procedure Disassembly 1 Pull out the vacuum pump For this procedure refer to section 6 6 Vacuum Pump Belt Vacuum pump s KI p PAYN EE 746 4013 U 2 746 4014 6 10 CP 842 Preliminary Replacing Consumable Parts gt gt Vacuum Pump Internal Vanes and Bearings 3 Open the belt cover 4 Remove the pulley and the pulley fan then remove the vacuum pump from the table Vacuum pump C746M4016 Caution The air filter should not be removed from the vacuum pump for the folllowing rea sons 1 There is a possibility of damage to the pump plumbing or air filter bousing 2 Metal fragments other dust from the plumbing may get into the pump 5 Remove the silencer case and the check valve C746M4017 CP 842 Preliminary 6 11 Replacing Consumable Parts gt gt Vacuum Pump Internal Vanes and Bearings 6 Remove the cooling fan cover and the cooling fan Cooling fan C746M4018 7 Liner Bearing retainer Bearing retainer C746M4019 8 Remove the side plate B mounting b
111. manual contains important machine system information for the user The manual content is intended for specialized technicians who are familiar with Surface Mount Technology SMT Please read this manual carefully in order to ensure safe and efficient machine operation This manual has been written specifically for the CP842E and CP 842ME Unless otherwise stated all explanations apply equally to all machines 11 Manual Structure This manual consists of the following ten parts 1 About This Manual Safety The Machine Basic Operation Maintenance Replacing Consumable Parts Adjustments Troubleshooting O O C Setup 10 Supplement CP 842 Preliminary 1 1 About This Manual gt gt Page Layout 1 2 Page Layout In addition to the main body of the manual each page includes chapter title section title page number and the manual title Chapter title Section title Chapter title Replacing Consumable Parts gt gt Nozzles 6 Replacing Consumable Parts 6 1 Nozzles Point j A nozzle which be bent deformed or clogged ick d Section title must be replaced When replacing a nozzle use cto to avo losing s intemal spring Procedure WARNING Be sure to turn the main power off before performing this proce lure 1 Remove the nozzle and spring as shown in the figure below Body Nozzle Spring Press and turn Remove slowly Caution 1 When removi
112. message before operating the machine lt CP 842E gt Front side T SN 4 4 AN N PAN 75 0001 2 8 CP 842 Preliminary lt 842 gt Safety gt gt Safety Labels 1 13 BRE 2 14 RISQUE DE BRULURES ER 8 lt SRL AWN 876 MEMES OEE LCE 02 6 OX OSA EBmiimAEE ASAUCR O UI Lc BBO HOST S fe CY CM c CAUTION AN EXPLOSION MAY OCCUR IF THE BATTERY IS NOT REPLACED PROPERLY USE THE BATTERY TYPE SPECIFIED BY FUJI OR Neverinsertyourhand _ EQUIVALENT BATTERY TYPE USED BATTERIES MUST BE inside an operating machine DISCARDED FOLLOWING THE MANUFACTURER S INSTRUCTIONS Moving parts may cause injury 4 9 lt B gt E Var F ALBUS Vy Nose ot xus Xv73 VIRREI EE RT RISRM ER ERC LTP OTS TEEN JUS ADISESCIBIEU CL Way Bella HAH RSHERIRIEUPSTT y SEATBELT HIS HALTI ESN ALBUS Vy CHUA lt WARNING gt WARNING The Cam Turret will move if the cam spring THE MACHINE MAIN CIRCUIT BREAKER 4 not T avoid ersonal injury ouUtag ou IS machine before MUST BE SWITCHED OFF DURING ALL SERVI
113. mit panel unclamp check fixed rail side X0BB Inscarrier In carrier retract limit panel unclamp check adjustable rail side 4 4 clampiria amor In carrier advance limit panel unclamp check fixed rail side X0BD ping In carrier advance limit panel unclamp check adjustable rail side X0BA 2 Check the in carrier clamping unclamping The clamper may not be closing S Sect 3 1 X and Y values which appear in the remedy column correspond to the I O map assignment numbers C746M5T05 CP 842 Preliminary Troubleshooting gt gt Troubleshooting Table CP 842 Preliminary No Cause Remedy Remarks Ref Page 1 Verify that the carrier has properly clamped Panel sensor or panel arrival sensor M Sect 3 3 Out conveyor the panel fails to switch on even though a panel panel 2 Check the following sensors for problems has been received from the XY table 45 1 6 described above error Out carrier advance limit panel check 1 0 Out conveyor 1 panel arrival check X0C7 1 Check the following sensor for problems Out carrier advance limit sensor failed M Sect 3 3 3 6 see above to switch on even though the out Out carrier advance limit check XOCE carrier was advanced Out carrier 2 Check the in carrier conveyance cylinder for Carrier may not be moving all the way S Sect 3 1 4 6 advance problem 7 see above to i
114. mm Three phase electric wire Transparent terminal cover Ground wire LUN Recommended driver a 8 0mm le M nl Main breaker 9 4 CP 842 Preliminary Setup gt gt Electrical Power Supply amp Transformer Wiring Wiring the Transformer 1 Open the transformer box cover lt CP 842E gt lt CP 842ME gt yo Transformer box Transformer box C746M6005 2 Wire the transformer 5 primary taps to match the supplied voltage CP 842 Preliminary 9 5 Setup gt gt Electrical Power Supply amp Transformer Wiring Checking the Three phase Connections Perform the following procedure to verify that the three phases are properly con nected 1 Turn the 200V power on 2 Log the machine 3 Press the AUTO button but do not press START Note Do not press the START button The vacuum pump begins operating when AUTO is pressed so disconnect the hose to verify that suction exists If there is suction this indicates that the wiring is correct and the motor is rotating in the correct direction If the air flow is reversed air is blow ing out instead of in then turn the main power off and reverse the three phase power cable s U phase and V phase connections then try again lt CP 842E gt lt CP 842ME gt 746 6006 Caution To avoid leaks the hose should be pushed firmly into position and then secured in position with
115. mperature is 1 7 conditions increased evenly over the entire board If thel problems solder s melting speed differs from point to point parts will be pulled toward the solder which melts first 746 5 1 CP 842 Preliminary Troubleshooting gt gt Troubleshooting Table 8 1 2 Pickup Errors No Cause Remedy Remarks Ref Page Set the top film correctly Take up will be abnormal if the top film is FM Part 2 not set correctly Chapt 1 FM Supplement The top film is not being peeled off at Point The top film is not being peeled off at FM Part 2 the pickup point Peel off the top film the pickup point Peel off the top film Chapt 1 and verify that the and verify that the take up roller and take up roller and reel are set correctly reel are set correctly Clean the tape leaf slit A clogged tape leaf slit can back up the top FM Part 3 Feeder top film film and prevent proper take up Chapt 2 2 2 2 1 does is not Clean the inside of the take up roller Take up resistance increases if the take up FM Part 3 taken up roller fails to rotate smoothly Chapt 2 2 4 correctly If the take up spring is deformed A deformed take up spring reduces the take FM Supplement replace it up force Replacement Check the take up reel s reverse An excessively low reverse direction torque FM Part 3 direction torque will reduce the take up force Chapt 4 4 8 If clearly low re
116. mpt to use on any other machines Likewise do not use rotary holders from other machines on the CP 842E 842ME In particu lar rotary holders from CP 7 series machines will interfere with other mechanisms around the turret and damage the machine Rotary holders can be identified as follows CP 842E 842ME No coloring CP 6 CP 7 machines Colored body anodized Procedure Complete the following 3 items before removal of the rotary holder 1 Move the rotary holder to station 9 2 Move the XY table towards the front of the machine to improve access 3 Turn the machine power OFF N WARNING the main power off before performing this procedure Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator Removal 1 Loosen the rotary holder mounting bolts with L Allen wrench 2 Pull the rotary holder down L Allen wrench Rotary holder C746M2011 CP 842 Preliminary 4 7 Basic Operation gt gt Removal and Installation of Rotary Holders Installation Fasten the rotary holder with the mounting bolts Confirm that the letter on the aluminum drum matches the letter on the rotary holder Letter Rotary holder C746M2012 4 8 CP 842 Preliminary Basic Operation gt gt Changing Pallets 842 option 4 5 Changing Pallets CP 842ME option Point The PCU Pallet Change Unit enables b
117. n Out carrier retract limit panel unclamp check fixed rail side X0D6 4 8 Out carrier Out carrier retract limit panel unclamp che clamp error 2 Check the out carrier s panel clamping Clamper may not be moving all the S Sect 3 1 unclamping cylinder for problem 7 see way to its motion limit position above Execute the following commands to see if the carrier can be moved to its motion limit position Panel Loader Loader Maintenance Out side Carrier Extend Carrier Retract START 1 Check the following sensor for problems Panel request occurred but the panel Sect 3 3 1 6 described above loading sensor failed to switch on In conveyor panel loading check X0B0 2 Check the following sensors for problems In conveyor panel deceleration sensor 1 6 described above failed to switch on even though the In conveyor 1 panel deceleration start point X0AB panel passed the panel In conveyor loading sensor position 4 9 panel 3 Check the following sensors for problems In conveyor panel sensor failed to conveyance 1 6 described above switch on even though the panel error passed the in conveyor panel In conveyor 1 panel arrival check X0AC deceleration sensor 4 Check the in conveyor motor for problem 7 The in conveyor motor may not be S Sect 3 1 see above operating In conveyor motor ON Y029 5 If the panel is caught at some point along the M Sect 4 1 conveyor change the conveyor width
118. n and out carriers are both operated by air cylinders in accordance with the placing program In conveyor Conveys the panel into the machine and transfers it to the in carrier by means of the in lifter In carrier Transfers the panel from the in conveyor to the XY table XY table Clamps the panel in position and moves it to and from the position for placement Out carrier Transfers the panel from the XY table to the out conveyor Out conveyor Conveys the panel to the next machine the line 3 2 5 Electrical Control System Notes Regarding CP 842E 842ME Machines Operation Absolute encoders are used on all servo motors on the machine The harness connectors on the servo motors should not be removed If a harness con nector is removed it will be necessary to recalibrate Proper data Proper data measurement is also required at the following times After replacing the motor After removing the cable connector from between the motor and servo amp f the backup battery within the servo amp is dead Zero setting is not required on the machine CP 842 Preliminary 3 9 The Machine gt gt Functions of Each Part Operation panel The operation panel comprises switches and a touch screen monitor which are used to operate the machine Control box The control box contains electrical circuit boards used to control the machine It is also equipped with a CD ROM drive which is required to install software Servo box Servo B
119. n to 100 N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Manually rotate the rotary holder to select nozzle No 6 At this time the sensor reactions should be the same as shown below Rotary holder Digital display 0 1 Sensor OFF 8 9 Sensor ON Sensor 3 ON TT Sensoria Sensor 2 Sensor No ON OFF Amp front view C7SM4044a Rotate the rotary holder to select nozzle No 2 At this time the sensor reactions should be the same as shown below gt Rotary holder SS Digital display 0 1 Sensor OFF 8 9 Sensor ON Sensor 3 5 x OFF 2 Sensor No Nozzle Sensor 177 Sensor 2 OFF ON Amp front view 7 46 CP 842 Preliminary 4 CP 842 Preliminary Adjustments gt gt Station Adjustments Ensure that the sensors display for the other nozzles as shown below Sensor 1 Sensor 2 Sensor 3 Nozzle 1 ON OFF OFF Nozzle 2 OFF ON OFF Nozzle 3 OFF OFF ON Nozzle 4 ON ON OFF Nozzle 5 OFF ON ON Nozzle 6 ON OFF ON Digital display 0 1 Sensor OFF 8 9 Sensor ON T001 7 47 Adjustments gt gt Station Adjustments 7 48 Sensor Sens
120. n to our customers in the most efficient manner This site makes a range of services available from manual updates and virtual training to online technical reports Fuji hopes that this site will be used as a source of information in addition to the services provided by your agent Fuji Internet is located at http www fuji co jp Fuji Internet membership is required to access the Technical Information section of the site Please contact your agent for membership details Any comments or opinions regarding this document can be sent to intnetqst fuji co jp CP 842E CP 842ME Mechanical Reference Edition No Preliminary Date of Issue Note March 26 2004 Fuji Machine Manufacturing Co Ltd SMT Equipment 19 Chausuyama Yamamachi Chiryu Aichi Prefecture 472 8686 Japan Copyright 2004 by Fuji Machine Manufacturing Co Ltd Printed J n Fuji Machine Manufacturing Co Ltd serves its customers from the following locations Fuji Machine Manufacturing Co Ltd 19 Chausuyama Yamamachi Chiryu Aichi 472 8686 Japan Tel 0566 81 2111 Fax 0566 83 1140 Fuji America Corporation 171 Corporate Woods Parkway Vernon Hills IL 60061 USA Tel 847 913 0162 Fax 847 913 0186 Fuji Machine Mfg Europe GmbH Peter Sander Str 43 D 55252 Mainz Kastel Germany Tel 06134 202120 Fax 06134 202200 Fuji do Brasil Maquinas Industriais Ltda Rua Joao Cachoeira 128 Itaim Bibi Sao Paulo SP
121. ne Exponex No 2 Every 3 months Cam follower Daphne Exponex No 2 Every 3 months C746M3T05 Arrow marks in the illustration indicate lubrication points Q CCS S 11 BSS C746M3019 Note The out carrier should also be lubricated in the same manner as the in carrier shown in the figure above CP 842 Preliminary 5 23 Maintenance gt gt Lubrication 5 2 7 Lubricating the Tape Advance Link Lubrication points Types of lubricant Schedule Tape feed lever AFC grease Monthly Shaft Daphne Exponex No 2 Monthly Joint AFC grease Monthly C746M3T06 Arrow marks in the illustration indicate lubrication points STI C746M3020 5 24 CP 842 Preliminary Maintenance gt gt Lubrication 5 2 8 Lubricating the Cam Box Lubrication points Types of lubricant Schedule Cam Cam lever pivot 7 points Daphne Exponex No AFC grease Monthly Monthly Cam lever bearing Daphne Exponex No Monthly NZ axis ball screw Daphne Exponex No Monthly NZ axis LM rail Daphne Exponex No Every 3 months NZ axis holder Daphne Exponex No Every 3 months NZ axis LM block AFC grease Every 3 months 0 axis connecting pin Daphne Exponex No Arrow marks in the illustration indicate lubrication points points where a grease gun is required ST2 8 9 10 rod 23 Monthly
122. ne Exponex No 2 Every 3 months 37 Pin AFC grease Monthly 38 Valve push pin AFC grease Monthly 39 Parts reject Valve push AFC grease Monthly 4o M Cam follower AFC grease Every 3 months 41 LM rail AFC grease Every 3 months 42 pallet table Pallet clamp surface AFC grease Every 3 months 43 Clamp pin AFC grease Every 3 months Cam follower Daphne Exponex 2 Every 3 months 45 Nozzle Spline shaft AFC grease Monthly changer 46 Beveled gear Daphne Exponex No 2 Monthly 47 Moveable sections on the lever Daphne Exponex No 2 3 months 48 Clutch engagement surface Daphne Exponex No 2 Monthly 49 Thrust bearing AFC grease Monthly 50 Rear cove Slide rail Daphne No 2 3 months 51 Index unit Oil cooler SHC630 Every 3 yrs or 12 000 hrs 52 Cam lever Air cylinder Turbine oil NASKALUBE Every 6 months C746M3T20 Fuji special blend CP 842 Preliminary Replacing Consumable Parts gt gt Nozzles 6 Replacing Consumable Parts 6 1 Nozzles Point A nozzle which becomes bent deformed or clogged can cause part pick up errors and must be replaced When replacing a nozzle use care to avoid losing its internal spring Procedure N WARNING Be sure to turn the main power off before performing this proce dure 1 Remove the nozzle and spring as shown in the figure below Nozzle Press and turn Spring a 22 yw OY Remove slowly G3 C746M4001 Ca
123. nel shape and size with consideration given to pre mounted parts on the lower side of the panel For panels where upward warping is a problem back up pins with vacuum pads should be used to keep the panel flat Procedure 1 Execute the necessary commands to move the XY table to the loading position 2 Raise the XY table 3 PresstheEMERGENCY STOP button N WARNING Turn the main power off before performing this procedure 4 Change the positions of the back up pins or rubber blocks as required CP 842 Preliminary When using back up pins Loosen the pin mounting bolts and reconfigure the pins as necessary C746M2004 4 3 Basic Operation gt gt Changing the Panel Back up Pin Positions lt When using rubber blocks gt Snap the blocks into suitable lengths and use double faced tape to stick them to the panel lifter s back up plate Rubber block C746M2005 4 4 CP 842 Preliminary Basic Operation gt gt Setting the Feeders 4 3 Setting the Feeders Point Feeders must be set on the pallets in the correct manner in order for the nozzles to pick up parts Refer to the CP Feeders Mechanical Reference MEC CPF DR x xE for details Procedure N WARNING Turn the main power off before performing this procedure 1 Verify that the tape guide is not deformed Place the various part tapes in their dedicated feeders If a part tape is placed in the wrong feeder the tape guide may not close prop
124. nes and Bearings 7 Place the liners and bearing retainers on side plates B Liner Bearing retainer C746M4019 Note Even if the number of liners and their combinations are assembled in the same man ner as when disassembled there may be some looseness when the shaft rotates The number of liners and the liner thickness should therefore be adjusted as neces sary to eliminate this looseness 0 20 mm No color C746M4T02 0 03 mm 0 05 mm 0 10 mm Red Yellow Black Liner Thickness Color Coded 8 Verify that there is no contact between the rotor and the side plates when the rotor is rotated while pushing and pulling the rotor shaft C746M4030 9 Complete the vacuum pump reassembly by reversing steps 1 to 6 of the disas sembly procedure then reconnect the harness connectors C746M4031 6 16 CP 842 Preliminary Replacing Consumable Parts gt gt Vacuum Pump Motor 6 8 Vacuum Pump Motor Procedure 1 2 CP 842 Preliminary N WARNING Be sure to switch off the 200V power supply before beginning this procedure not touch the vacuum pump immediately after operation as it may be extremely not Allow the pump to cool before performing this procedure Pull out the vacuum pump For this procedure refer to section 6 6 Vacuum Pump Belt Vacuum pump 746 4013 Use calipers to measure the distance between the vacuum p
125. ng the nozzle take care not to lose the internal spring Also check that the spring is not left within the nozzle holder a To avoid nozzle bend do not hold the nozzle at the tip during removal 2 Reverse the removal procedure to attach a new nozzle CP 842E Mechanical Reference 1 0E 6 7 Manual title Page number C842M1000 Body Text and illustrations are used to explain procedures Chapter Title The chapter number and title are shown on the header of each page Section Title Section number and title A chapter consists of multiple sections and the section is also shown on the header Manual Title This identifies the machine and type of manual PageNumber This numbers consists of the chapter number and the page number within that chapter 1 1 indicates chapter 1 page 1 Note The reference numbers at the bottom right of the illustrations are for administrative purposes only and are in no way connected to the content of the manual 1 2 CP 842 Preliminary About This Manual gt gt Notation Conventions Used in this Manual 1 3 Notation Conventions Used in this Manual The names of operation buttons touch screen titles and commands and keyboard keys are enclosed in brackets CP 842 Preliminary 1 3 About This Manual gt gt Notation Conventions Used in this Manual MEMO 1 4 CP 842 Preliminary Safety gt gt About Symbols 2 Safety Fuji machines are designed and produced with safety as one of our main conside
126. nozzles to determine the lowest value Measure the pushing pressure C7SM4058 1 Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Set the cam angle to 0 degrees then turn the ST 10 solenoid valve on to work the cam lever 3 Set the dial gauge to the bottom of the nozzle shaft brake 4 Use the cam handle to rotate the cam to 200 5 Ensure that the clutches mesh properly and the placing head assembly deflects the dial gauge by 0 30 0 35 mm as illustrated below a L1 10st Measure the amount 1 Vor push down 0 30 0 35 mm Nozzle shaft brake C7SM4038a CP 842 Preliminary 7 35 Adjustments gt gt Station Adjustments Clutch Meshing Check Sensor Position Adjustment I Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Use the cam handle to rotate the cam to 200 Execute inching to align the RQ axis with the RQ data position 4 Make sure the clutche
127. of the machine laterally and vertically Use the leveling bolts to adjust the height N After verifying that the panel conveyance height and the leveling accuracy are correct tighten the lock nuts on the leveling bolts Changes be made by tightening the lock nuts although the levelness should always be checked again after adjustments have been made Note If the lock nuts are not tightened sufficiently vibration may result in a drop in place ment accuracy 125 730 518 778 696 538 730 125 lt 842 gt 5 1 l 10 y Y e e 125 518 778 696 538 125 100 921 lt CP 842ME gt y S 125 518 778 696 538 1258 mm Lock nut Leveling bolt Leveling sheet Anti vibration pad C746M6002 9 2 CP 842 Preliminary Setup gt gt Connecting the Air Supply 9 2 Connecting the Air Supply Point Connect the air hose to the machine and adjust the regulator to the prescribed air pressure Procedure 1 Connect the air hose to the machine s air inlet located on the front of the machine 2 Raise the filter regulator knob to release the lock 3 Turn the handle to adjust the air pressure until the gauge reads 0 5 MPa 5kgf cm2 Note A digital pressure gauge is attached to the rear cover 4 Press the filter regulator knob down to engage the lock lt CP 842E gt lt CP 842ME gt
128. olts then usethese bolts to secure the special tool to side plate B Special tool C746M4020 9 Pull on the special tool to remove side plate B Remove the special tool from side plate B then install the bearing retainer and liner removed at step 7 above on side plate B Do not tighten the bolts fully at this time back off 1 mm from fully tightened condition Bolt Bearing retainer C746M4021 Note Use care to avoid scratching side plate B and the inner surface of the cylinder 6 12 CP 842 Preliminary Replacing Consumable Parts gt gt Vacuum Pump Internal Vanes and Bearings 10 Removethe vanes OY 27 C746M4022 Note Lh Be sure to note the orientation and positions of the vanes as the new vanes must be installed in the same manner 2 If a broken vane exists air blow the pump interior to remove any fragments 11 Mountthe special tool on side plate A then push out therotor Support the shaft area with your hand to avoid dropping the rotor After removing the rotor remove the special tool C746M4023 Side plate A NoteWhen pushing out the rotor use care to avoid scratching the rotor shaft and the cylinder 12 Removethe side plate A mounting bolts and use a plastic hammer to knock the pin off then remove side plate A C746M4024 Side plate A 13 After disassembling to this point clean each component using a soft cloth soaked in an organic solvent chlorine or flu
129. orine based solvent such as Kurorosen or Daifuron S3 CP 842 Preliminary 6 13 Replacing Consumable Parts gt gt Vacuum Pump Internal Vanes and Bearings Assembly 1 Insert the rotor into side plate A Rotor Side plate A 746 4025 2 Place the spacer and bearing in side plate A then use a bearing punch and hammer to pound the bearing in Hammer am j 1 Spacer C746M4026 Note Place a wood block beneath the shaft to prevent it from being scratched 3 Mount side plate A on the cylinder After using the knock pin to position side plate A secure it with the bolts Knock pin Side plate A C746M4027 6 14 CP 842 Preliminary Replacing Consumable Parts gt gt Vacuum Pump Internal Vanes and Bearings 4 Mount the vanes on the rotor Be sure the vane positions and orientations are the same as when disassembled Vane 2224235 1 LE 746 4028 5 Mount side the cylinder After using the knock pin to position side plate B place the spacer and bearing in position then use hammer and bearing punch to pound the bearing in After the bearing is in securethe side plate B mounting bolts Side plate B pl Bearing punch Mounting bolt Bearing Hammer C746M4029 6 Usethe bearing punch and hammer again to pound in the bearings at side plates A and B CP 842 Preliminary 6 15 Replacing Consumable Parts gt gt Vacuum Pump Internal Va
130. ove Check that the distance between the cam channel on the slider and the fixed cam channel is 0 to 0 02 mm If this range is exceeded loosen the bolt on the rod bracket and make the required adjustments to the height of the slider Tighten the bolt whilst maintaining the height of the slider Check the distance between the cam channels again Note If the distance between the channels still does not fall within the range then it may be necessary to adjust the unit that controls the vertical movement of the nozzle Reattach the placing head assembly in the original location Use the clutch alignment jig and reverse the removal procedures to attach the placing head Caution The nozzle shaft assembly is exclusive to the CP 842E 842ME and cannot be used on 7 8 other machine types such as CP 733E CP 743ME or CP 743E CP 842 Preliminary Adjustments gt gt Station Adjustments Confirming the Pick up Height Ensure that the nozzle descends low enough to pick up a part set in the feeder Con firm that the mechanical valve movement creates a vacuum for part pick up 1 2 CP 842 Preliminary Set a W8 x P4 mm feeder with tape leaf removed at the D1 position Move the feeder to ST1 by pressing Position Position D1 axis enter 1 OK START Check that the NZ axis is stopping at the position specified at the PICK UP POS NZ item in Proper data Push the EMERGENCY STOP button which disables the 200V power
131. peration or if the Note If a problem is found contact your Fuji nozzle DOWN limit position is incorrect agent Check for a problem with the Proper Note Machine adjustments can be performed data ZO 0 3mm push in only by those with a Level 3 training Replace mechanical valves where the Vacuum break problems can result in parts M Sect 7 1 4 T Vacuum break spool motion is not smooth being returned problem Adjust the vacuum break lever position and the speed controller Check the solder condition after printing The solder printing condition or dryness can cause part deviations during board Printing conveyance or can affect the self alignment 5 5 conditions at reflow operations problem Solder adhesion weakens when the solder dries Therefore the sooner placement occurs after printing the better Check the reflow temperature profile Improper reflow conditions can cause self alignments and tombstoning Reflow Provide a profile in which the temperature is 5 6 conditions increased evenly over the entire board If the problems solder s melting speed differs from point to point parts will be pulled toward the solder that melts first C746M5T09 CP 842 Preliminary Troubleshooting gt gt Troubleshooting Table 8 1 6 Part Height Sensor Errors CP 842 Preliminary No Cause Remedy Remarks Ref Page Nozzle length Replace the nozzle where this warning If the measured nozzle length
132. pin bracket is 12 mm Lever bracket C7SM4056 3 With the YO30 ST1 PICKUP SOL DISENGAGED ON use the cam handle to rotate the cam to 170 CP 842 Preliminary 7 13 Adjustments gt gt Station Adjustments 4 Adjust the height of the bracket so that the distance between the lever and the pin is 0 6 mm Lever bracket Lever 75 4020 5 Return the cam angle to 0 degrees Switch on the 1st nozzle UP DOWN sole noid valve in order to work the cam lever Check the servo counter to verify that the Proper data PICK UP POS NZ is at the pick up height approx 4000 pulse position 6 Use the cam handle rotate the cam to 170 degrees 7 Ensure that the clearance of the pin from the bracket is within the range of 0 5 to 1 0 mm after the pin has been raised by the lever C7SM4021a 7 14 CP 842 Preliminary Adjustments gt gt Station Adjustments 7 1 5 Feeder Height Error Detection ST1 Point To detect the positions of the feeders two sets of sensors are used at each of the retract areas A further pair of sensors are also used at the pickup position bringing the total number to five A dedicated jig is used to position these sensors The sensitivity of the sensors must also be adjusted Feeder check sensor D1 retract area upper direction check Feeder check sensor P Pickup area upper direction check Feeder check sensor D1 retract area lower direction check
133. place the take up reel If the take up reel or aluminum bracket Damage may occur or take up may not be FM Part 3 is deformed replace it correct if the take up reel or aluminum Chapt 5 bracket is bent This may also interfere with 15 57 75 7 surrounding feeders 1 Check the tape and feeder feed 1 An incorrect tape and feeder width or feed FM Part 2 pitches and set the tape on the pitch will prevent parts from being fed to Chapt 2 correct feeder the proper position 2 Use a tape leaf which is suitable for 2 A tape leaf which is unsuitable for the the nozzle nozzle size will cause parts to spring off the tape Set the tape leaf lock securely An incorrectly set tape leaf lock will cause FM Part 2 Feeder set the tape leaf to lift resulting in part Chapt 5 5 2 improperly tombstoning and parts springing off the tape Clean away parts and dust etc which Parts and dust etc adhering to the inside FM Part 3 have adhered to the tape leaf of the tape leaf will prevent the tape from Chapt 2 2 2 being pressed properly Air blow the tape leaf before setting a tape Replace the tape leaf if it is deformed A deformed tape leaf will cause part FM Part 3 if it is not flat tombstoning and parts springing off the tape Chapt 5 5 1 Set the tape correctly Tape feed resistance increases if the tape is FM Part 2 not set properly in the feeder Chapt 1 Clean away parts which are embedded Parts which are embedded in the sprocke
134. plifiers that are equipped with back up batteries for saving the absolute encoder data even when the control power is off The servo amplifier battery should be replaced when a Servo amp error message displays on the machine operation screen together with an A 83 display at the servo amplifiers LED indicator Caution 1 Following a servo amplifier error the absolute data is saved for approximately 1 week after the machine power is turned off Failure to replace the battery during this period will result in the loss of the absolute encoder data and will require another absolute encoder setup and Proper data measurement The battery should therefore be replaced quickly All the absolute encoder data will be lost If the old battery is removed while the servo fier s POWER LED is off and another absolute encoder setup and Proper data measurement will then be required To avoid this ensure that the machine power is ON and that the POWER LED is lit when removing the old battery Y and Z Axis Servo amplifier ___ LED panel connector 746 4037 CP 842 Preliminary 6 21 Replacing Consumable Parts gt gt Servo Amp Battery Rq Pq NZ Axis Servo amplifier lt CP 842E gt lt CP 842ME gt Rq axis Fq axis Pq axis NZ axis
135. q eui 7096 41 SOONAS eui pue 1 uoenee pJeoq eseq au 10 SOOHSS Al SOOS 94 pue HADS pue HADS uonoeuuoS 4O JOBUUOD y 124 YOOYD JI 6500835 Ajuo Jejeedei seop 4 SOONTS jou s op 25 u 16 031 LS 10 S smes dwe 4 SOOM3S uonejedouou uo 19800 y UO O 99 195 01198 S Al 6008436 9 01 1e sinooO 315090495 8 23 CP 842 Preliminary Troubleshooting gt gt Servo System Troubleshooting 1215 9715 s uoissiusueJ SI ejep eu Jl yoedoAJeg y oesui 001 xoidde 1ues Jey y Jo epoo ejep eui Aq peuiuuejep peusi qejse SI UOISSIUUsUEJ JeujeuM 40940 Bunoouse qnoJ 111 X29949 5035 2v JojeJedo eAnoejep Ionuoo eAnoejep
136. r ations However even a perfectly designed machine can be damaged or someone can still be injured if the user does not follow the safety rules It is the responsibility of the user to make sure all safety rules are followed during operation and maintenance Be sure to read these safety rules before operating the machine Keep this manual close at hand when operating the machine 2 1 About Symbols This section provides an explanation of the relevant safety precautions to be adhered to by both operators and those responsible for maintaining the machine An explana tion of the warning labels attached to the machine is also provided This manual employs the use of descriptive symbols and provides details of the level of danger involved in certain operations to accompany the explanations of machine warn ing labels and safety related items sure you understand the meanings of these sym bols before reading the manual Hazard Definitions Symbol Definition A Failure to observe this hazard warning will lead to severe DANGER injury or death A Failure to observe this hazard warning may lead to severe WARNING injury or death Failure to observe this hazard warning may lead to per A CAUTION sonal injury or damage to the machine Examples of Symbols Used Symbol Explanation Hazard A triangle is used to draw your attention to a hazard The symbol inside the triangle indicates the nature of the hazard in thi
137. r Placing 8 2 9 1 2 PIGKUD EITOLS ena oin TUB Coo led et eile a ea 8 3 8 1 3 Vision Processing Errors 8 5 8 1 4 Panel Conveyance Related Errors 8 6 8 1 5 Missing PANS 8 10 8 1 6 Part Height Sensor 8 11 8 2 Servo System Troubleshooting 8 12 8 2 1 Alarm Code Display 8 12 8 2 2 Alarm Codes and Troubleshooting Check List 8 15 CP 842 preliminary iii Table of Contents Setup auc uae 9 1 9 1 Leveling the Machine 9 1 9 2 Connecting the Air Supply 9 3 9 3 Electrical Power Supply amp Transformer Wiring 9 4 9 4 Connecting the Data Transmission Cable 9 7 9 5 Moving the Machine neret rrt 9 8 9 5 1 Precautions when Moving the Machine 9 8 10 Supplementary Information 10 1 10 30156 45 ia a S uu 10 1 iv CP 842 preliminary About This Manual gt gt Manual Structure 1 About This Manual This
138. r panel on the servo amplifier as follows Using the digital operator 1 Connect the Digital Operator cable to the applicable servo amplifier CN 3 con nector 2 Press DSPL SET DATA ENTER to display the alarm code at the LED indi cator 2 24 _ ci Alarm sequence number Alarm code The alarm sequence number is displayed in ascending order starting with the most recent alarm code QP3M4022E 3 It is possible to scroll through the alarm sequences by pressing the Up or Down arrow key Using the indicator panel on the servo amplifier 1 Press the MODE SET button and then press and hold the DATA SHIFT but ton for at least one second to display previous alarm codes 2 It is possible to scroll through the alarm sequences by pressing the Up or Down arrow key The alarm sequence number at the left side of the code is displayed in ascending order starting with the most recent alarm code 7 52 CP 842 Preliminary Troubleshooting gt gt Troubleshooting Table 8 Troubleshooting 8 1 Troubleshooting Table Point This chapter describes troubleshooting measures for problems which may occur during production Separate troubleshooting tables are provided for each type of problem When a problem occurs begin by identifying the appropriate table for the problem in question then refer to the Cause column of that table to find the problem cause After locating the cause refer to the Remedy and Remarks columns
139. rease Every 3 months Every 3 months C746M3T13 Arrow marks in the illustration indicate lubrication points Black arrows indicate points where a grease gun is required Hose Special grease nozzle 41 Connect the hose to the special grease nozzle DGPJ055 and then insert the nozzle tip into the LM guide grease port Valve push pin overview 40 er Do not apply grease on the air blow hole Apply grease A C746M3038 CP 842 Preliminary 5 33 Maintenance gt gt Lubrication 5 2 16 Lubricating the Pallet Table Lubrication points Types of lubricant Schedule Pallet clamp surface AFC grease Every 3 months Clamp pin AFC grease Every 3 months Cam follower Daphne Eponex No 2 Monthly C746M3T14 Arrow marks in the illustration indicate lubrication points lt CP 842ME gt Option C746M3027 5 34 CP 842 Preliminary 5 2 17 Lubricating the Nozzle Changer Lubrication points Maintenance gt gt Lubrication Types of lubricant Schedule Spline shaft AFC grease Monthly Beveled gear Daphne Exponex No 2 Monthly Moveable sections on the lever Daphne Exponex No 2 Every 3 months Clutch engagement surface Daphne Exponex No 2 Monthly Thrust bearing AFC grease Arrow marks in the illustration indicate lubrication points 4 6
140. rs after printing the better Speed Check for errors in the part height Errors in the part height information or in the T Part 3 information table reference height Proper data Lesson 2 information can cause missing parts 2 1 1 Fuji recommends that the actual part be U Part 2 measured with the measured value being Chapt 4 entered as the part height setting in Part data Appearance 1 Press the reflective disk to verify A stuck nozzle will prevent the parts from M Sect 5 1 that the nozzle spring back motion being pushed in far enough when being M Sect 6 1 is smooth mounted and may result in the parts being Defective 2 Check to see if the nozzle is clogged returned 5 2 nozzle 3 Check to see if foreign matter has j adhered to the nozzle tip Parts may be returned if solder etc is Replace the nozzle if any of the above adhering to the nozzle tip problems are found Check the backup pin height quantity misalignment between the ST9 nozzle M Sect 4 2 and configuration and check the board s DOWN limit and the board height can flatness prevent parts from being pushed in far enough when being placed and may affect placing accuracy Check to see if the XY table is level Note If a problem is found contact your Fuji 5 3 Placement agent height problem Replace the cylinder unit if abnormal Improper ST9 cylinder operation may noise is emitted from the cam box prevent parts from being placed correctly uring automatic o
141. s Body parts may get caught in the machine resulting in injury Do not operate the machine when the front rear cover has been removed Body parts may get caught in the machine resulting in injury Do not perform cam box maintenance with power to the machine on e Injury may result from electric shock if maintenance on the cam box is carried out with the power tothe machine on Caution required if cam is not at its origin 0 Operators must ensurethe 15 at its origin 0 prior to car rying out any operations on the machine If the camis not at its origin recoil from springs used to drive the placing heads may cause unexpected movement which is potentially dangerous for the operator If an emergency stop occurs the machine stops immediately In this casethere is a strong possibility that the cam will not be at its origin gt 00 e fthecam is not at its origin when the machine stops use the cam handle to return it to its origin Do not stare into the laser beam On machine fittied with laser type fiber sensors class 2 Exercise extreme caution when working in areas where there is a risk of eye damage from the laser beams gt CP 842 Preliminary 2 7 Safety gt gt Safety Labels 2 4 Safety Labels To warn the operator of hazards safety labels are attached to the machine at the positions indicated in the figure below Familiarize yourself with each label and its
142. s case electrical shock Prohibition circle with a diagonal line is used to draw your attention to an operation that is prohibited The symbol inside the circle indicates the nature of the operation in this case disassembly A circle with an exclamation mark is used to draw your attention to Qo to a mandatory action In other words you are required to carefully carry out the given instructions CP 842 Preliminary 2 1 Safety gt gt Safety Rules for All Machine Types 2 2 Safety Rules for All Machine Types 2 2 DANGER Do not approach moving parts during automatic or manual oper ation Dono place hands or other body parts inside the machine during automatic operation or positioning Body parts or clothing may be caught in the machine causing personal injury NWARNING Do not operate the machine with the safety covers or doors open Dono leave covers or safety doors open except during adjustment hen adjustments are completed return the covers and doors to their original dosed position When safety covers or doors are removed body parts or dothing may be caught in the machine causing personal injury Always be sure to replace the safety covers or doors Always verify the position of the EMERGENCY STOP buttons before operating the machine Always beaware of the positions of the EMERGENCY STOP buttons so that they
143. s engage properly Adjust the height of Bracket A so that Gap C in the figure is 0 2 mm 5 At this position adjust the position of Bracket sothat the sensor beam hits the hole on the dog Bracket B Dog Bracket A C7SM4039a 7 36 CP 842 Preliminary Adjustments gt gt Station Adjustments Clutch Meshing Check Sensor Amp Adjustment Adjust the sensor amp so that it goes off when the clutches mesh properly and it goes on when the clutches do not mesh properly and the dog is pushed down Remove the cover of the amp and follow the procedures below Note Be careful not to drop the cover inside the machine 1 CP 842 Preliminary Set the setting switch to D ON Set the mode selector switch to SET The digital display will then indicate 1 With the dutch engagement sensor on sensor is detecting the hole in the dog press the TUNING button The digital display will then indicate 2 With the dutch engagement sensor off sensor is not detecting the holein the dog press the TUNING button The digital display will then indicate 9 Set the mode selector switch to RUN After completing the amplifier setting procedure verify that the digital display indicates 0 1 when the sensor is on and 8 9 at all other times TUNING SET DON RUN LON 2 ____ ee H DELAY E TUNING
144. s possible DANGER Do not attempt to perform any tasks beneath the lifted machine Note The forklift should be operated in accordance with the manual provided by the forklift manufacturer lt CP 842E gt C746M6010 Using the forklift lift the machine to a height of 30 cm Transport the machine by forklift to its new location then lower the machine slowly onto the leveling sheets or leveling blocks For details concerning level ing sheet or leveling block configurations refer to 9 1 Leveling The Machine Setup gt gt Moving the Machine MEMO 9 10 CP 842 Preliminary Supplementary Information gt gt Noise Levels 10 Supplementary Information 10 1 Noise Levels The following table shows the measured noise levels for CP 842E during operation N WARNING Operators should wear ear plugs in operating environments where noise levels are high enough 80 dBA or more to cause hearing damage Machine Model Noise Level dBA Measurement points m Remarks Background noise 63 dB CP 842E Rear side 1 76 Height from floor 1 2 Front side 2 74 Distance from machine sides 1 0 2 Front side Note noise level of both the CP 842ME is lower than that of the CP 842E CP746 Preliminary 10 1 Supplementary Information gt gt Noise Levels MEMO 10 2 CP746 Preliminary FUJI Internet Fuji Internet aims at providing up to date informatio
145. sing part height information measure the nozzle length before production begins 1 Use the nozzle check command to A bent nozzle will cause a deviation in the check for a bent nozzle part pickup position and may result in the 2 Press the reflective disk with your part being picked up in a tombstoned finger to verify that the nozzle spring posture 3 awa s i 2 stuck nozzle cannot adequately reach the 3 Check for a clogged nozzle part and may result in the part being picked in a tombstoned posture Replace the nozzle if any of the above T pm problems are found A clogged nozzle will have less vacuum force and may result in the part being picked up in a tombstoned posture Turn the cam handle and check the LED A malfunctioning acquisition timing sensor lamp status on the sensor for can cause the 7 segment display to always 6d Mia acquisition timing inside the cam box show the same value or to show the wrong i h If there is a problem with the sensor value value or SNOWS space it Note If sensor replacement is required the wrong value contact your Fuji agent for assistance C746M5T10 8 11 Troubleshooting gt gt Servo System Troubleshooting 8 2 Servo System Troubleshooting servo system controls all servo axes in the machine If there 15 a problem with the servo system the machine displays an alarm code to notify the operator This section describes alarm codes and inspection met
146. sqe Ajddns NO UNL Bunoouse qno J 104 1571 2942 se pesn ueuM 0 2200 NO Jamod sinooO snies 10113 dnyoeg Jepoou3 eiosqv 8 uuejv yoedonlas ov 8 19 CP 842 Preliminary Troubleshooting gt gt Servo System Troubleshooting 111397295 Jepooue 1281100 JOJOW ay epis Jepooue ay snjejs ay pue Jepooue y 40418 Josuas Ajuejod uonezi eniu eAlejep Jepoou3 UoneJedo ul S 40 0 U UA way 49849 yoedonsas OV snigls 2v y yoedoAJ S JO NO 1 11990 2019 sixeninuu e SI 1 Ji g pue v oedoAJes y pue OU YOOUD JOJOW By eAnpejep epis Jepooue eu je snjejs Jepooue 1284100
147. ssure Use the low pressure nozzle for meshing checks at ST2 8 and 10 Measure the pushing pressure at all nozzles to determine the lowest value C7SM4058 1 Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Set the dial gauge to the bottom of the nozzle shaft brake 3 Use the cam handle to rotate the cam to 200 4 Ensure that the clutches mesh properly and the placing head assembly deflects the dial gauge by 0 30 0 35 mm as illustrated below Measure the amount of push down Clutch Ky 0 30 0 35 mm C7SM4027a CP 842 Preliminary 7 23 Adjustments gt gt Station Adjustments 7 1 8 Fine theta Movement ST8 Point Station 8 refers to the vision processing data at station 5 and rotates a part the remaining angle for placement Clutch Meshing Check Perform this check on the low pressure nozzle Note The low pressure nozzle refers to the placing head out of the 16 that receives the weakest pushing pressure Use the low pressure nozzle for meshing checks at ST2 8 and 10 Measure the pushing pressure at all nozzles to determine the lowest value C7SM4058 1 Press the EMERGENCY STOP button to take the 200V down to 100V
148. stem Troubleshooting 9115 9715 OAJ8S y ueAup sjueuoduJoo UO 10 429u2 ss 10 O GE 0 YOedOAIaS eui Jo eui jeg OAJ8S UO 22 GE speeoxe JO eJnjejeduie jueiquue y 2942 si 2 68 speeoxe xoedoues eu JO 42040 Bunoous lqno11l 20 517 2642 5 3v JO BY jeui 2942 ul SI USUM JO yoedonias ay SI 3oedoAJes 99 JEU 2942 YORdOAIAS sinooO x ulsjeeH oedoAles ay eAnejep oedoAJegs pepeeoxe uiu seuun G SI utu seuun 6 10 615 1 pepeeoxe 44O NO 1 Aouenbayu 44O NO f jddns jueJuno usnj ui jo JO SISOJ usnyj ui 33O NO lddns 40 5 59 Jewod 99 124 YOOYD Jo ajqemoyye au SINDIO yuan Ysn ul Xoedoues y vejd y
149. stion Machine weights CP 842E Approx 5 850 kg CP 842ME Approx 4 880 kg Be sure to insert the forklift forks at the prescribed position Use care to avoid bending the leveling bolts If the balance of a lifted machine is unstable lower the machine immediately Raise and lower the machine slowly to avoid subjecting the machine to shocks Transport Procedure 1 2 9 8 Remove all tape feeders air hoses and electrical wiring from the machine Use the machine brackets red to secure the XY table the in and out carriers and the D axes Note If there are no machine brackets available use rope etc to secure the various parts of the machine to avoid damaging them Ae Y axis bracket X axis bracket oF 315 R Carrier brackets C746M6008 CP 842 Preliminary CP 842 Preliminary Setup gt gt Moving the Machine C746M6009 Insert the forklift so that its left and right forks are the same distance from the machine center Moreover the space between the left and right forks should be set as wide a
150. t FM Part 3 in the sprocket and stopper and stopper can prevent tape feed Chapt 2 2 1 Improper feeder 1 Check the feed lever height and the An incorrect feed lever height will prevent a FM Part 3 tape feed feed movement proper tapefeed stroke and may disable Chapt 4 4 9 2 When link assembly is deformed tape feed Chapt 5 5 3 replace any deformed parts Replace the reel holder if it is bent The parts reel will not rotate correctly if the reel holder is bent C746M5TO2 CP 842 Preliminary Troubleshooting gt gt Troubleshooting Table 2 4 No Cause Deviation between the feeder and machine pickup position Remedy Remarks Ref Page Check the pickup offset X Z setting i T Part 3 pickup offset X Z setting in Lesson 2 Part data 2 1 3 U Part 2 Chapt 4 Carryin Clean away parts and dust etc which The presence of parts or foreign matter etc FM Part 3 have adhered to the device table and on the device table or on the feeder s L guide Chapt 2 2 3 feeder tape leaf can prevent the feeder from being set in the correct position Clean away parts and dust etc which Parts which have adhered to the ratchet can FM Part 3 have adhered to the ratchet cause pickup position deviations at regular Chapt 2 2 1 intervals Air blow the ratchet area before etting the tape Use a grinder to flatten the gouges in Gouges in the feeder s L guide can prevent FM Part 3 the feeder s L guid
151. t gt Lubrication 5 18 Grease Gun Kit A grease gun kits with which grease supply for almost all Fuji equipment can be per formed is available from Fuji The grease gun kit comes with all the nozzles required to apply grease to the various grease nipple formats To obtain the grease gun kit please contact your Fuji agent FUJI Grease gun kit contents z Name Code Name Fuji grease gun kit Code AWPJ820 Format Box Sheet PJ EA506J Sheet WPJ1271 PE light Sponge Sheet WPJ1281 Polyurethane Mushroom Nipple WPJ1261 Grease Gun K1153F KH 120 with HSP 1 Syringe S2184A SJ S30S Rubber Hose H5456T SPK 3C 1 2 3 4 5 6 7 8 Air Hose T2063H TU0604B 310 mm Nozzle N5004A L type Nozzle N5005A N type Nozzle N5006A N 1 type Nozzle N5007A P type Nozzle N5008A U type Tube T2061E PTFE tube 2x3 150 mm Connector K5030T PN 1 8 PT1 8 BS Connector Nipple S2176B TS6 01 Sleeve S3084A 40 13 gt gt gt gt gt GRSKITO1E CP 842 Preliminary Maintenance gt gt Lubrication The CP 842E 842ME series requires the following grease nozzles which are not included in the standard grease gun kit Se Nozzle for NG parts disposal unit Nozzle for NZ axis LM blocks NY axis LM block and NY axis LM blocks ADGPJ818 DGPJ05
152. te Press the MODE button to toggle the display from the light value to the per centage value value P and then back to the light value Ensure that the figures for all the sensors are above the minimum values shown below 200 digit target 500 digit Note The sensor should be replaced when the light reading is at approximately 4095 Check the following items if the light reading does not reach the minimum required value a The position of the sensor bracket b Check that the sensor is correctly attached to the sensor bracket C Thepositioning of the fiber and attachment tips d Check whether the fiber and amp connections are correctly inserted e Checkthe condition of the fiber wiring Changethe display to show the percentage value by pressing the mode button to toggle the display as required Usethe up and down arrow buttons to set the value to 200 Note The arrow buttons cannot be used if the display reads 999P In this situation press the SET button twice to revert the display to 100P CP 842 Preliminary Adjustments gt gt Station Adjustments 7 1 7 Pre theta Movement ST2 Point Pre theta rotates the nozzles with parts picked up at station 1 by 90 180 or 90 depending on the settings in the production program Clutch Meshing Check Perform this check on the low pressure nozzle Note The low pressure nozzle refers to the placing head out of the 16 that receives the weakest pushing pre
153. that the Adustable rail engagement check IN conveyor width and the XY table panel Adjustable rail Adjustable rail engagement check OUT XODB conveyence width are properly aligned 4 15 engagement Adjustable rail engagement check CENTER X0DC error 2 Disconnect the machine s air supply and return the adjustable rail to the correct position The X and Y values which appear the remedy column correspond to the I O map assignment numbers 746 5 7 CP 842 Preliminary Troubleshooting gt gt Troubleshooting Table Remedy Remarks Ref Page XY table clamp error 1 Verify that the XY table is clamping panels properly 2 Check the following sensors for problems 3 6 see above XY table panel clamp check fixed rail side right XY table panel clamp check adjustable rail right X060 XY table panel unclamp check fixed rail righ X061 XY table panel unclamp check adjustable rail right X062 XY table panel clamp check fixed rail left X063 XY table panel unclamp check fixed rail left X064 5 Panel was clamped but the clamp sensor failed to switch on and the unclamp sensor failed to switch off Panel was unclamped but the unclamp sensor failed to switch on and the clamp sensor failed to switch off M Sect 3 3 3 Check the panel clamping unclamping cylinder for problem 7 see above Execute the following
154. the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of the cam axis can endanger the operator Use an inching operation and move the high valve head to ST 12 Attach the centering jig to the mechanical valve of the high valve head Centering jig Z9627DGPJ0110 Spacer Mechanical valve t 0 2 mm Bolt C7SM4066 Note Put the 0 2 mm spacer between the fixing bolt and the mechanical valve in order to avoid any scratch to the mechanical valve Move the high valve head to station 13 Use the cam handle to rotate the cam to the following cam angles 190 Make sure that the pusher is inserted smoothly to the hole at the bottom of the centering jig If not loosen the fixing bolts and adjust the position of the valve switching unit Fixing bolt SSS Centering jig L mm Pusher Valve switching unit C7SM4067 Return the cam to 0 and then detach the centering jig from the mechanical valve 7 39 Adjustments gt gt Station Adjustments 7 Usethe cam handle to rotate the cam to the following cam angles 190 Loosen the fixing bolts then adjust the height of the valve switching unit by turning the height adjustment bolt so that the gap between the botto
155. the cam axis can endanger the operator 2 Set the cam axis at the 0 degree position B Activate the ST9 placing solenoid air cylinder located in the cam box Execute the following 1 commands Maintenance I O Check Standard 1 Y 035 579 PLACE SOL ENGAGED Output Signal ON The cam lever will then follow the cam axis 9ST Place solenoid air cylinder Nozzle UP DOWN rod Cam lever follows Cam axis th cam axis C7SM4029a CP 842 Preliminary Adjustments gt gt Station Adjustments 4 Place a dial gauge on the top end of the cam lever and set the gauge reading to 0 In this condition the cam axis will be at its O degree position and the noz zle UP DOWN rod will beat its UP limit position Verify that the nozzle UP limit sensor is ON X032 ST9 CYLINDER UPPER LIMIT is ON Nozzle up limit sensor ON Set the dial gauge to Nozzle UP DOWN rod C7SM4030 5 While observing the dial gauge rotate the cam axis in the forward direction to lower the nozzle UP DOWN rod Adjust the sensor s mounting position so that the sensor switches OFF X032 ST9 CYLINDER UPPER LIMIT switches OFF when the rod has been lowered 0 3 to 0 4 mm Nozzle up limit sensor OFF Nozzle Up Down rod C7SM4031 Adjust the sensor s mounting position by loosening the sensor lock screw sliding the sensor in the front back directions Screw Nozzle up
156. the clutch see next page illustration Caution Remove the nozzle shaft assembly which bears either or identifier seal Operations may be complicated if other nozzle shaft assemblies are removed 3 Remove the linear guide clampers and vacuum hose then remove the nozzle shaft assembly Caution When handling the nozzle shaft assembly exercise caution to ensure that the linear guide and outer shaft do not become separated shaft Linear guide pl C7SM4011a CP 842 Preliminary 7 25 Adjustments gt gt Station Adjustments Bolt Clutch __ Spring amp Outer shaft Spanner DCPJ0450 Clamper Nozzle 3 shaft 4 Le d assembly S the bolt with your A 7 fi 5 um y Clamper al c m Rotate the placing head while holding D Linear guide Vaccum hose Bolt Torque Part T size Nm Kgf cm Caution Washers may jump when the bolt is loosened because of the A M4 2 20 spring under the clutch B M4 2 20 75 4012 Caution Do not disassemble the placing head assembly carelessly Special equipment and skills are required to perform the reassembly of the placing head Such procedures should be attempted only by users who have attended training at Fuji and are equipped with the necessary tools or whilst under the direct guidance of a service man 4 Mo
157. to the right of that item for details regarding appropriate corrective actions The Ref Page column at the far right of the table indicates reference material manuals etc chapter numbers where information is given regarding the procedure in question The following alphabetic codes are used in the Ref Page column to indicate the various reference materials 842 842 Mechanical Reference MEC CP842 Preliminary S CP 842E 842ME System Reference SYS CP842 Preliminary T FujiCam Tutorial Manual 1 U F4G User s Manual ELENO 13 FM CP Feeders Mechanical Reference MEC CPFDR E FJ CP Tape Feeder Jig Instruction Manual INS CPFJG E SG Feeder Setup Guide GDE FEEDER E PG WC Feeder Pickup Position Adjustment Guide GDE PKUPT E CP 842 Preliminary 8 1 Troubleshooting gt gt Troubleshooting Table 8 2 8 1 1 Poor Placing Accuracy No Cause Remedy Remarks Ref Page Specify the appropriate nozzle size and Unsuitable nozzle size part weight and cam T Part 3 cam speed settings using the Tech speed etc settings can result in an Lesson 2 Report issued by Fuji as a reference insufficient holding force when handling parts causing nozzle and part slippage U Part 2 The Fuji Tech Report is meant for reference Chapt 4 purposes only The recommended cam Nozzle speed may be different even if the part shap Speed is the same If
158. ts motion limit position limit error Execute the following commands to see if the carrier can be moved to its motion limit position Panel Loader Loader Maintenance Out side Carrier Extend Carrier Retract S TART 1 Check the following sensors for problems Out carrier was conveyed butthe M Sect 3 3 3 6 see above out carrier advance limit or retract Out carrier advance limit check limit sensor failed to switch on Out carrier retract limit check Out carrier cycle error occurs if the advance limit or retract limit sensor fails to switch on within 8 S seeds y 2 Check the carrier conveyance cylinder for Carrier may not be moving all the way S Sect 3 1 problem 7 see above to its motion limit position Execute the following commands to see if the carrier can be moved to its motion limit position Panel Loader Loader Maintenance Out side Carrier Extend Carrier Retract START 1 Check the following sensors for problems Out carrier clamper was M Sect 3 3 3 6 see above closed but the clamp sensor Out carrier retract limit panel clamp check fixed rail side X0D2 failed to switch on Out carrier retract limit panel clamp check adjustable rail side X0D3 Out carrier clamper was Out carrier advance limit pnale clamp check fixed rail side X0D4 opened but the unclamp Out carrier advance limit panel clamp check adjustable rail side X0D5 sensor failed to switch o
159. ts no responsibility for any situations that may arise as a result of the use of this manual Table of Contents Table of Contents 1 About This Manual ciivscisssicieintssssesdecisieiensteentsacasadcesddaseeesauenscstianiens 1 1 1 1 Manual Structure 1 1 1 2 Page sou bocca peret poca 1 2 1 3 Notation Conventions Used in this Manual 1 3 MERI ID T R 2 1 2 1 2 2 Safety Rules for All Machine Types 2 2 2 3 Safety Rules for Individual Machine 2 7 2 3 1 842 842 Machines 2 7 2 4 2 8 2 5 The EMERGENCY STOP Buttons 2 11 3 The Machine pm 3 1 3 1 Machine CoIipOhebls 3 1 SLT General to al d up 3 1 3 1 2 Servo Control Axes 3 5 3 1 3 Rotary TLC AE 3 5 3 1 4 Placing Head 3 6 3 1 5 PCU Pallet Change Unit 3 6 3 2 FUNCHONS Of Parti uuu uuu t x tie asqa 3 7 3 2 1 Parts Mounting System
160. ump pulley and the motor pulley and make a note of this measured value L Motor pulley Vacuum pump pulley C746M4032 6 17 Replacing Consumable Parts gt gt Vacuum Pump Motor 3 Remove all parts which hinder the motor replacement work These parts include the vacuum pump duct the belt Vacuum pump 746 4033 4 746 4034 5 Mount the pulley on the new motor then set the motor and vacuum pump on the base Bolts which secure the pulley motor and vacuum pump should only be partially tightened at this time Final tightening should be performed after adjusting the pulley deviation and the distance between the vacuum pump pulley and motor pulley distance noted at step 2 The pulley deviation should be 0 3 mm or less 5 Mount the pulley on the new motor then set the motor and vacuum pump on the base Bolts which secure the pulley motor and vacuum pump should only be partially tightened at this time Reference side pulley sns 0 3 mm or less 1 I 0 3 mm or less T C746M4035 6 18 CP 842 Preliminary 6 CP 842 Preliminary Replacing Consumable Parts gt gt Vacuum Pump Motor Adjust the tension of the new belt If the belt tension is outside the prescribed range move the motor position in 0 1 mm increments to adjust the L dimen sion Motor pulley New Belt Belt During Use Amount of slack 1 8mm 1 8mm Load
161. ust be lubricated even if the cover is not due for periodic lubrication Apply a thin layer of grease using a brush Compressing the screw cover by hand may result in injury Furthermore incorrect removal or installation of the screw cover may result in damage to the machine Arrow marks in the illustration indicate lubrication points Black arrows indicate points where a grease gun is required Caution Always lubricate the X axis Y axis ball screws using a grease pump to apply grease to the nipples Applying grease directly to the ball screws or closing the cover by hand may result in injury Furthermore incorrect removal or installation of the screw cover may result in dam age to the machine C746M3017 CP 842 Preliminary 5 21 Maintenance gt gt Lubrication 5 2 5 Lubricating the Conveyors Lubrication points Types of lubricant Schedule Ball screw Daphne Exponex No 2 Every 6 months Lifter guide bar Daphne Exponex No 2 Every 6 months LM block Daphne Exponex No 2 Every 6 months C746M3T04 Arrow marks in the illustration indicate lubrication points Black arrows indicate points where a grease gun is required C746M3018 Note The out conveyor should also be lubricated in the same manner as the in conveyor shown in the figure above 5 22 CP 842 Preliminary Maintenance gt gt Lubrication 5 2 6 Lubricating the Carriers Lubrication points Types of lubricant Schedule LM rail Daph
162. ustment check the back up pin positions on the XY table verifying that there will be no interfer ence between the back up pins and the adjustable rail 1 Execute the necessary commands to link the XY table to the in and out convey ors At the touch panel s main screen select the following commands Con veyor Conveyor Width Change Width then press the START button 2 Turn the handle on the out conveyor to adjust the conveyor width until the panel can be conveyed smoothly First increase the conveyor width then reduce it to between 0 5 1 0 mm wider than the panel width C46M2001 C46M2002 CP 842 Preliminary 4 1 Basic Operation gt gt Changing the Conveyor Width 3 Lower the XY table 4 Run a test panel through the machine verifying that it is conveyed smoothly and that panel clamping is correctly performed 4 2 CP 842 Preliminary Basic Operation gt gt Changing the Panel Back up Pin Positions 4 2 Changing the Panel Back up Pin Positions When the pane clamped on the XY table warps down position back up pins rubber blocks or back up plates under the bottom surface of the panel Back up pin Rubber block C46M2003 Note Producing with the panel in a warped position may negatively impact the product Point The positions and quantity of back up pins or rubber blocks which are required depends on the pa
163. ution f When removing the nozzle take care not to lose the internal spring Also check that the spring is not left within the nozzle holder 2 To avoid nozzle bend do not hold the nozzle at the tip during removal 2 Reverse the removal procedure to attach a new nozzle CP 842 Preliminary 6 1 Replacing Consumable Parts gt gt Fluorescent Nozzle Stickers 6 2 Fluorescent Nozzle Stickers Point Fluorescent nozzle stickers which become soiled and cause vision processing errors must be replaced Procedure 1 WN 6 2 Wash hands before replacing the sticker Use a cutter to peel from outer edge the old sticker off the nozzle disk Use a doth to wipe any residual adhesive off the disk Verify that the new sticker is not soiled or damaged Peel the backing off the new sticker and punch the nozzle tip through from the fluorescent side Note Punching the nozzle tip through from the adhesive side will destroy the fluorescent coating around the hole Align the nozzle and sticker centers and push the sticker into place using the jig Besurethat there 15 gap between the nozzle disk and the sticker Jig DCPJO46 ADCPJ824 Nozzle seal C746M4002 Note Make sure that the sticker is attached firmly to the nozzle Attached neatly without lifting C746M4003 CP 842 Preliminary 7 8 Replacing Consumable Parts gt gt Fluorescent Nozzle Stickers Usea cutter totrim off any o
164. ve the area for the removed placing head to station 9 0 then turn on the solenoid Y035 ST9 PLACE SOL ENGAGED 5 Set the cam angle to 0 and position the dial gauge as shown in the figure bel ow 7 26 CP 842 Preliminary Adjustments gt gt Station Adjustments OO _ 0 02 Cam groove C7SM4028a 6 Adjust the length of the rod using the bolt to ensure that the distance between the base of the slider and the cut out section in the cylindrical cam is within the range of 0 02 mm 7 Reattach the placing head assembly in the original location Using the clutch alignment jig reverse the removal procedures to attach the assembly Caution The nozzle shaft assembly is exclusive to the CP 842E 842ME and cannot be used on other machine types such as CP 733E CP 743ME or CP 743E CP 842 Preliminary 7 27 Adjustments gt gt Station Adjustments 7 28 Adjusting the Nozzle UP Limit Sensors The nozzle UP limit sensor which detects the up limit position of the nozzle UP DOWN rod at station 9 is mounted inside the cam box Adjust the mounting position of this sensor so that it switches ON when the nozzle is at its UP limit position 1 Press the EMERGENCY STOP button to take the 200V down to 100V N WARNING Always be sure to cut off the 200V power before carrying out any work Exercise extreme caution when working on the machine if the cam is not at its origin 0 deg Recoil of
165. wer before carrying out any work Exercise extreme caution when working on the machine if the is not at its origin 0 deg Recoil of the cam axis can endanger the operator 2 Use the handle to rotate the to 200 3 Adjust the sensor bracket positions so that the sensor beam goes through 0 7 0 8 mm below the nozzle tip Use a thickness gauge etc to ensure the sensor reaction while working 4 Actually pick up a large part to check the sensor reaction Adjustment bolt see M Adjustment bolts C7SM4024a CP 842 Preliminary 7 21 Adjustments gt gt Station Adjustments 7 22 Sensor Amp Adjustment Open the front cover and follow the procedures bel ow Large parts check sensor amplifier Open the cover 25 SET button MODE button A v button Output dip switch C7SM4025a Check that the output dip switch is set to L ON Set the power modes and timer modes as detailed below 2 1 Press and hold down the MODE button for three seconds or more to change the display to turb Use the up and down arrow buttons to set the power mode to SU PER 2 2 Press the MODE button to change the display to dL y Usethe up and down arrow buttons to set thetimer mode to OFF 2 3 Pressthe MODE button again to return the display to the original sta
166. y exercise caution to ensure that the linear guide and outer shaft do not become separated Linear guide C7SM4011a 7 6 CP 842 Preliminary Adjustments gt gt Station Adjustments Bolt Clutch o Spring zx Outer shaft nnns F 2 Spanner n DCPJ0450 P Clamper Nozzle 11 Rotate the placing shaft 4 cfe i head while holding assembly e P ES the bolt with your A 7 gt finger JL Clamper P Linear guide d V h accum hose V B 7 Bolt Torque Pals size Nm Caution Washers may jump when the bolt is loosened because of the A M4 2 20 spring under the clutch B M4 2 20 C7SM4012a Caution Do not disassemble the placing head assembly carelessly Special equipment and skills are required to perform the reassembly of the placing head Such procedures should be attempted only by users who have attended training at Fuji and are equipped with the nec essary tools or whilst under the direct guidance of a serviceman CP 842 Preliminary 7 7 Adjustments gt gt Station Adjustments 9 Rod Bracket O O Dial gauge 0 0 02 mm Cam groove C7SM4013b Move the area for the removed placing head to ST1 then turn on the solenoid Y031ST1PICKUP SOL ENGAGED Set the cam angle to 0 and position the dial gauge as shown in the figure ab
167. y the servo amplifier where A 83 is displayed at LED 4 Locate the battery in the case located at the upper front of the servo amplifier and replace it with a new battery CP 842E 842M E machines use the following 2 battery types in servo amplifiers Servo amplifier capacity 30w to 5kw Model JZSP BAO1 Servo amplifier capacity 6kw 7 5kw Model JZSP BAO1 01 Battery Battery C746M4040 Caution All the absolute encoder data will be lost If the old battery is removed while the servo amplifiers POWER LED is off and another absolute encoder setup and Proper data measurement will then be required To avoid this be sure that the POWER LED is on before removing the old battery 5 Turn the machine power off Reboot the machine and verify that the A 83 alarm has cleared 6 Press the READY ON switch toturn on the motor power If machine operation is normal the procedure is complete CP 842 Preliminary 6 23 Replacing Consumable Parts gt gt Replacing the Carrier Clamp Unclamp Air Cylinder Packings 6 11 Replacing the Carrier Clamp Unclamp Air Cylinder Packings Point Replace these packings if a carrier air cylinder is not working properly Procedure N WARNING Press the EMERGENCY STOP bution to turn off the servo power before beginning this procedure

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