Table of contents
Chapter 1 introduction
Safety precautions for repair operation 1
Precautions for machine operations 10
Important precautions to prevent machine down time 12
List of special jigs and tools 13
List of recommended lubricants 14
Chapter 2 general information
Overall drawing(mechanical units) 1
Overall drawing(controllers) 2
Overall drawing(optical module)4
Optical module arrangement diagram 6
Sensor layout 18
Control composition drawing 28
Cycle timer timing chart 29
Cam timing chart 30
Pneumatic machinery allocation 31
Pneumatic circuit diagram 33
Chapter 3 inspection
Routine inspection 1
Chapter 4 trouble shooting
Trouble shooting 1
Chapter 5 maintenance guide
1 replacement of the x axis/y axis minasu motor of the x-y table 1
2 check and adjustment of x-y table unit rail parallelism 3
3 check and adjustment of reference pin parallelism 5
4 adjustment of the x-y table automatic width adjustment unit 7
5 adjustment of the halogen lamp iiiumination plsition 8
6 adjustment of the line sensor height and allocation 9
7 line sensor offset adjustment 11
8 nozzle unit replacement 12
9 adjustment of the recognition shutter 13
10 check and adjustment of the nozzle select unit 15
11 check and adjustment of the nozzle select check sensor 18
12 nozzle inner shaft replacement 20
13 check and adjustment of the θ1,θ2,θ3 unit flange and cam follower clearance 22
14 adjustment of obtaining theθ1,θ2,θ3 unit tooth parallelism 24
15 adjustment of end cutter interlook 26
16 adjustment of end cutter stroke 27
17 registration of the component camera scale 28
18 nozzle center measurement 30
19 pcb board camera unit exchange 31
20 registration of the pcb board camera scale 33
21 registration of head position correction data and pcb board camera offset 34
22 check and adjustment of the mechanical stopper clearance(thrust up) 35
23 check and adjustment of the mechanical stopper clearance(shutter) 36
24 check and adjustment of the mechanical stopper clearance (feed) 37
25check and adjustment of the nozzle No. detection sensor 38
26 check and adjustment of theθ3 unit origin check sensor 40
27 check and adjustment of shutter seating detection sensor 442
28 check and adjustment of parts cassette loose shutter seating detection 43
29 check and adjustment of pcb board detection 44
30 check and adjustment of reference pin vertical detection 45
31 large component detection adjustment 46
32 p-922MⅡ(sensor amplifier) adjustment procedure 48
33 sc program sheet symbol list 49
34 check and the reference data setting for the mounting nozzle stroke 50
35 check and the reference data setting for the picking up nozzle stroke 52
Chapter 5 MAINTENANCE GUIDE
Tish chapter includes explanations of how to check, adjust and repair when performing installation,
inspection and trouble shooting.
● .to avoid personal injury, correct procedure for performing maintenance must be observed.
.be sure to read”safety precautions” in chapter 1 carefully.
.each section in this chapter has the procedure for performing maintenance as described below.
The maintenance of the current page is represented by bold frame. the left frame shows the maintenance must be
done before performing this maintenance and the right frame shows the mext maintenance to be done .
Always follow the sequence when performing maintenance.
1.X axis motor replacement and origin adjustment
1. Turn the power [OFF] and remove the 100V wire connector and the encoder wire connector.
2. Remove the coupling cover and X axis cover.
3. Loosen the coupling nut on the motor side.
4. Remove the bolts and remove the motor from the motor bracket.
5. Replace the motor.
6. Move the X axis ball screw manually and match the sensor dog with the X axis origin sensor.
7. Turn the power [ON] and return to origin.
8. Temporarily tighten the coupling nut on the motor side at the position in which the X axis sensor dog and
origin sensor match.
9. Select the PCB camera so XY table displays on the camera monitor.
10. Select [F1] NC AXIS JOG CHECK of MACHINE CHECK screen on the control monitor and move XY table
to the chart position in order to verify the machine.
M
XL
X Axis
(160mm)-(Board camera offset)=Input value.
(220mm)-(Board camera offset)=Input value.
Y Axis
(-365mm)- (Board camera offset)=Input value.
(-505mm)- (Board camera offset)=Input value.
11. Loosen the coupling nut on the motor side, manually rotate the X axis ball screw so the reference positioning
pin moves to the center of camera monitor, then tighten the coupling nut. (Note) The Y direction of
positioning pin is basically in the proper position.
12. Return to the origin, move XY table to the chart position again and check that the center of reference
positioning pin moves to the center of camera monitor. (Note) Readjust if mis-positioned.
13. Attach the X axis cover and the X axis ball screw cover.
14. Attach the 100V wire connector and the encode wire connector. (Note) Since the PCB mount position has
been moved, change the NC program offset, move the origin position of MACHINE INITIAL SETTINGS, or
adjust the origin again.
Y axis motor replacement and origin adjustment
1. Identical procedure ad in above but instead for Y axis motor replacement and origin adjustment.
2.Check and adjustment of X-Y table unit rail parallelism
Fixed rail parallelism adjustment
1. Remove the plates on fixed and movable rails.
2. Turn the power [ON] and return to origin.
3. Set the magnet stand to the upper frame and touch the dial gauge against the fixed rail.
4. Select [F1] NC JOG CHECK of screen on the control monitor and move the X axis.
5. Check the rail parallelism. (speclfication) parallelism:within 0.1mm
6. If the parallelism is not within the specification, move XY table to the end of X direction (+) limit and loosen
the bolts of X axis (+) side with SERVO MOTOR [OFF].
7. Move XY table to the end of X direction (+) limit, loosen the bolts of X axis (+) side, move the rail, and
adjust within the specification.
8. Tighten both bolts on the (+) and (-) limit sides.
9. Turn SERVO MOTOR [ON].
Movable rail parallelism adjustment
1. Turn SERVO MOTOR [OFF].
2. Check the rail parallelism of entrance, center and exit between the fixed and movable rails with caliper to
150mm rail width. (specification) Parallelism:within0.2mm
3. If not within the specification, loosen the bolt and set screws on the right or left timing pulley, rotate the ball
screw on the right side and adjust the parallelism.
4. Tighten the bolt and set screws. (Note) check the auto width control positions for changes. Refer to “4
Adjustment of the X-Y Table Automatic Width Adjustment Unit”
5. Turn SERVO MOTOR [ON].
3.Check and Adjustment of Reference Pin Parallelism
Positioning pin parallelism adjustment
1. Turn the power [ON] and return to origin.
2. Turn [POSING PIN] of sub control panel [ON] to raise the positioning pins.
3. Set the magnet stand to the upper frame and touch the dial gauge to the reference positioning pin.
4. Select [F1] NC JOG CHECK of MACHINE CHECK screen on control monitor and move the X axis.
5. Touch the dial gauge to the other adjustable positioning pin.
6. Check the parallelism of adjustable positioning pin. (Specification) parallelism : within 0.05mm (Note)
check positions for the adjustable positioning pin from the reference positioning pin : 50,
100,150mm(M size) 100,200,300mm(XL size)
7. If the parallelism is not within the specification, loosen the bolts, move the adjustable positioning pin bracket
and adjust the parallelism.
8. Tighten the bolts.
Positioning pin clearance adjustment
1. Remove the plate on the fixed rail.
2. Turn the power [ON] and return to origin.
3. Turn [posing pin] of sub control panel [ON] to lower the positioning pin and set a PCB onto XY table. .
4. Check the clearance between the fixed rail and PCB with the thickness gauge. (specification) clearance:
0.1-0.2 mm (Note) component clearance is related to the adjustment above, making reference
positioning pin adjustment is almost impossible. only adjustable positioning pin adjustment is possible.
5. If the clearance is not within the specification, loosen bolts, move the adjustable positioning pin bracket and
adjust the clearance.
6. Tighten bolts.
4.Adjustment of the X-Y Table Automatic Width Adjustment Unit
1. Remove the top plate of the fixed and movable rails.
2. Turn the power ON to return to the origin.
3. Rotate the movable rail with the manual wheel, and set the M/C size M maximum PC board (250mm) onto
the X-Y table.
4. Rotate the movable rail with the manual wheel, or the timing belt and adjust so the space between the side of
the movable rail and the PC board is 0.8±0.2. Specification: [Rail width origin position] Size M 250.8±0.2
Size XL 460.8+-0.2
5. Tighten the bolt of the origin detection dog on the right side of the movable rail, match it with the automatic
width adjustment origin sensor on the X-Y table, and replace the bolt. (check that the origin sensor LED is
ON)
6. Loosen the two set screws fastening the origin detection disk of the automatic width adjustment pulsemotor
attached to the left side of the X-Y table, and match the slit of the origin detection disk with the origin sensor.
(check that the origin sensor LED is ON)
7. Fasten the fixed and movable rail plates. (Note) Do the same for pulsemotor exchange.
5.Adjustment of the Halogen Lamp Illumination position
Halogen lamp adjustment
1. Turn the power [ON] and return to origin.
2. Turn [HEAD ENABLE] of sub control panel [ON].
3. Turn HEAD SERVO [OFF] and rotate the manual wheel to cycle timer of 0゜ at station 4.
4. Loosen set screw and bolt, and rotate the unit that the halogen lamp illuminates at a position above the
stepped section of nozzle 1.
5. Tighten the set screw and bolt.
6. Set the volume of halogen lamp controller to 85% of maximum.
7. Turn HEAD SERVO [ON].
Line sensor height and angle adjustment
1. Turn the power [ON] and return to origin.
2. Set the dip switch of line sensor controller to [MANU-DIPS] and [MEASURE] mode.
3. Turn HEAD SERVO [OFF] and rotate the manual wheel to cycle timer of 145゜±2゜
4. Turn HEAD SERVO [ON]
5. Check the line sensor height with the line sensor controller. (specification) height: 2.75mm
6. If not within the specification, loosen the clamp block bolt, move the clamp block and adjust the line sensor
height.
7. Tighten the clamp block bolt.
8. Turn [O.ADJ] if the line sensor controller [ON].
Line Sensor Allocation Adjustment
1. Turn HEAD SERVO [OFF] and rotate the manual wheel slowly in the (+) and (-) direction 1 degree at a
time.
2. Check the angle where the line sensor height becomes 0 on the line sensor controller. (specification)
angle(origin): 145゜±2゜
3. If the angle is not within the specification, loosen the clamp block bolt and adjust the angle.
4. Tighten the clamp block bolt and repeat over the check when the angle is not within the specification.
5. Set the dip switch of line sensor controller to [AUTO] mode again.
6.Line Sensor Offset Adjustment
Line sensor offset adjustment
1. Turn the power [ON] and return to origin.
2. Set the dip switch of the line sensor sensor controller [MANU-DIPS] and [MEASURE].
3. Turn HEAD SERVO [OFF] and rotate the manual wheel to cycle timer of 145゜.
4. Turn HEAD SERVO [ON] again.
5. .Measure the line sensor height of all nozzles on the line sensor controller.
6. Select [F1] (MACHINE INITIAL SETTINGS)→[F7]→[SHIFT]→[M][V][F6] (MACHINE PARAMETER
SETTING) of main control panel.
7. Enter the measured values to the nozzle offset on the line sensor controller.
8. Set the dip switches of the line sensor controller to [AUTO] and [ORG] mode again.
8.Nozzle Unit Replacement
Nozzle unit replacement
1. Turn the power [OFF] and remove dust plate bolt and dust plate.
2. Rotate the manual wheel and move the nozzle unit for removal in between stations 7 and 8.
3. Remove the bolts and clamp plate from the bottom of nozzle unit rear.
4. Raise the bracket with the tip of long wrench to remove nozzle unit from the adapter.
5. Remove the air hose using pylers. (Note) the first air hose is a little difficult to remove.
6. Remove the air hose before nozzle unit removal for other nozzle units.
7. Replace the nozzle unit.
8. Attach the air hose.
9. Insert pin A of bracket into a oval hole. Lower pin B of bracket down into the other oval hole.
10. Attach clamp plate and tighten the bolts(M5*55). (Note) Make sure that the air hose is not touching against
the adjacent air hose during nozzle unit up/down movement. Shorten air hose a little if necessary.
9.Adjustment of the Recognition Shutter
shutter allocation check and adjustment (note) check with nozzle 3 of head NO.1.
1. Turn the power [ON] and return to origin.
2. Turn [SHUTTER OPEN/CLOSE LOCK] of sub control panel [OFF].
3. Select [F1] (INITIAL SETTING)→[F4](RECOGNITION BASIC DATA)→[F1] (AUTOMATIC SETTING)
→[F1] (COMPONENT CAMERA SCALE)→[F2] (SMALL CAMERA) of main control panel.
4. Turn HEAD SERVO [OFF] and rotate manual wheel to cycle timer of 260゜ slowly. (Note) make sure that
the nozzle does not hit the shuter.
5. Adjust turn buckles while watching shutters through camera monitor.
Shutter Height Check (note) check with nozzle 3 of head NO.1.
1. Turn the power [ON] and return to origin.
2. Select [F1] (INITIAL SETTING)→[F4] (RECOGNITION BASIC DATA)→[F1] (AUTOMATIC SETTING)
→[F1] (COMPONENT CAMERA SCALE)→[F2] (SMALL CAMERA) of main control panel.
3. Turn HEAD SERVO [OFF] and rotate manual wheel to cycle timer of 260゜slowly.
4. Turn HEAD SERVO [ON]. (Note) make sure that no error message appears on the control monitor.
With error messages, HEAD SERVO can not be locked in despite of turning HEAD SERVO [ON].
5. Check the clearance between the nozzle reflector and right shutter at cycle timer of 260゜with thickness
gauge. (specification) clearance:0.8–1.0mm
6. If the clearance is not within the speification, loosen the bolts of shutter unit bracket and move the bracket
up/down to adjust the clearance between the nozzle reflector and the right shutter.
10.Check and Adjustment of the Nozzle Select Unit
Nozzle select clearance adjustment
1. Turn the power [ON] and return to origin.
2. Turn HEAD SERVO [OFF] and rotate the manual wheel to cycle timer of 270゜.
3. Turn HEAD SERVO [ON].
4. Check the clearance between the lever and the nozzle select gear. (specification) clearance:0.5±0.1mm
5. If the clearance is not within the specification, loosen the bolt and adjust the clearance.
6. Tighten the bolt.
7. Check the clearance again. (Note) when the engagement is bad, loosen the turn buckle of nozzle select
gear and adjust.
Nozzle select backlash adjustment
1. Turn the power [ON] and return to origin.
2. Turn HEAD SERVO [OFF] and rotate the manual wheel to cycle timer of 270゜.
3. Touch dial gauge to nozzle unit gear.
4. Check the backlash when making a nudge the nozzle unit gear.
5. Check all nozzle units similarly. (specification) backlash:0.1–0.2mm
6. If the backlash is not within the specification, touch the dial gauge to nozzle unit gear of head 1at station.
7. Rotate the nozzle unit gear slowly in the opposite direction to the head axis center and find the farthest outer
position of nozzle head gear.
8. Set the dial gauge to 0 as reference.
9. Check all other nozzle units similarly and find the farthest outer position.
10. Move the farthest outer nozzle unit to nozzle select unit (station 10) and rotate the manual wheel to cycle
timer of 270゜.
11. Turn HEAD SERVO [ON].
12. Loosen the lock nut and rotate the turn buckle. Engage the nozzle select gear and nozzle unit gear until the
backlash is 0.
13. Touch dial gauge to nozzle unit gear. At this time, disengage the nozzle select gear from the nozzle unit gear
gradually while rotating the turn buckle so that the backlash will increase.
14. Tighten the turn buckle, when the backlash is 0.1±0.2mm.
15. Check backlash for all nozzle units.
11.Check and Adjustment of the Nozzle Select Check Sensor
Nozzle select confirmation adjustment
1. Turn the power [ON] and return to origin.
2. Turn HEAD SERVO [OFF] and rotate the manual wheel to cycle timer of 0゜.
3. Turn HEAD SERVO [ON].
4. check if the nozzle select confirmation sensor 1 detects correctly by the sensor amplifier (DARK ON)
located on the rear side of machine or on the control monitor. (Select [REQUEST]→[F1] (MACHINE
INITIAL SETTINGS)→[F2] (MONITORING)→[F1] (SC)→[F2] (IN) of main control panel and enter
the address number 0043).
5. If the sensor does not detect correctly, loosen the bolts 1 and adjust the sensor 1 position, so that the sersor
matches with the bearing center.
6. Check the clearance between the bearing and sensor 1. (specification) clearance:0.8–1.0mm
7. If not within the specification, loosen the adjustment bolt and adjust the clearance.
8. Tighten the adjustment bolt.
9. Tighten the bolts 1.
10. Turn HEAD SERVO[OFF] and rotate the manual wheel to cycle timer of 66゜(Former Type Machine 64゜).
11. Turn HEAD SERVO [ON].
12. Check if the nozzle select confirmation sensor detects correctly by the sensor amplifier (DARK ON) located
on the rear side of machine or on the control monitor. (Select [REQUEST]→[F1] (MACHINE INITIAL
SETTINGS)→[F2] (MONITORING)→[F1] (SC)→[F2] (IN) of main control panel and enter the address
number 0044).
13. If the sensor does no detect correctly, loosen the bolt 2 and adjust the sensor 2 position, so that the sensor
matches with the bearing center.
14. Check the clearance between the bearing and sensor 2. (specification) clearance:0.8–1.0mm
15. If not within the specification, loosen the adjustment bolt and adjust the clearance.
16. Tighten the adjustment bolt.
17. Tighten the bolt 2.
Specification
Former Type Machine
1.5±0.5mm
Present Type Machine
0.8–1.0mm
12.Nozzle Inner Shaft Replacement
Nozzle inner shaft replacement
1. Turn the power [ON] and return to origin.
2. Turn HEAD SERVO [OFF].
3. Remove nozzle and nozzle reflector.
4. Rotate the nozzle unit so that the cross guide bearing is on upper position at station 8.
5. Loosen the set screw.
6. Set the nozzle inner shaft removal jig into the outer shaft and push against the spring.
7. Remove the pin.
8. Remove the spring.
9. Set a bolt(M5 size) on the upper face of nozzle inner shaft and hit the bolt softly with hammer.
10. Replace nozzle inner shaft.
11. Attach the spring, pin and tighten the set screw.
12. Attach nozzle and nozzle reflector.
13. Turn HEAD SERVO [ON].
13.Check and Adjustment of theθ1,θ2,θ3 Unit Flange and Cam Follower Clearance
θ1,θ2,θ3 flange and cam follower clearance adjustment
1. Turn the power [ON] and return to origin.
2. Turn [HEAD ENABLE] of sub control panel [ON].
3. Touch the dial gauge onto top of outer shaft and find the lowest nozzle point of head NO.1 outer shaft by dial
gauge.
4. Touch the dial gauge to the bottom ofθ2 flange and find the lowest nozzle at cycle timer of 270゜.
5. Match the lowest nozzle with theθ1 andθ2 tooth.
6. Check the clearance between the flange and cam follower ofθandθ2 by thickness gauge. (specification)
clearance θ1:0.05–0.15mm θ2:0.05–0.15mm
7. Touch the dial gauge to the bottom ofθ3 flange and find the lowest nozzle at cycle timer of 270゜.
8. Match the lowest nozzle with theθ3 tooth.
9. Check the clearance between theθ3 flange and cam follower by using thickness gauge. (specification)
clearance θ3:0.05–0.20mm
10. If clearance is not within the specification, loosen the bolt of stopper and adjust the clearance.
11. Tighten the bolt.
12. Loosen the set screws of tooth and put the tooth with the stopper together.
13. Tighten the set screws.
14. Check the clearance between the flange and cam follower with the all nozzles.
14.Adjustment of Obtaining theθ1,θ 2,θ 3 Unit Tooth Parallelism
θ1,θ 2,θ 3 tooth parallelism adjustment
1. Turn the power [ON] and return to origin.
2. Select [REQUEST]→[F8]→[F1] (MACHINE INITIAL SETTINGS)→[F1] (MACHINE DATA) of
main control panel.
3. Enter V NOTCH OFFSET value of 0 initialize.
4. Turn HEAD SERVO [OFF] and rotate the manual wheel to move head NO.1 between stations 6 and 7.
(Note) Adjustθ2 tooth parallelism first as reference.Check adjustment with the dial gauge at station 7
5. Remove the nozzle 1 inner shaft by using nozzle remove jig and set small component camera jig large
component camera jig. (Note) Refer to”12.Nozzle Inner Shaft Replacement.”
6. Turn [FEED LOCK] [PUSH UP LOCK] [REDG.SHUTTER LOCK] of sub control panel [ON].
7. Rotate the manual wheel to cycle timer of 270゜and check if theθ2 tooth engages with the outer shaft.
8. Rotate the manual wheel between cycle timer of 355゜–359゜in the reverse direction.
9. Turn HEAD SERVO [ON].
10. Select [F1] NC JOG CHECK of MACHINE CHECK screen on control monitor.
11. Set the magnet stand on XY table and touch the dial gauge to large component camera jig.
12. Move XY table in the X axis(-) direction and check the parallelism between XY table and the tooth.
(specification) parallelism: within 0.03mm
13. If the tooth parallelism is not within the specification, loosen the set screws and touch the dial gauge to large
component camera jig. Rotate the tooth until the dial gauge reaches the halt amount of parallelism slippage
and tighten the set screws.
14. Check the tooth parallelism again. (specification) parallelism with the V NOTCH OFFSET value:
within 0.03mm (Note) The parallelism should be adjusted to within the specification without entering
the V notch offset value.
15. If not within the specification, enter the offset value of V NOTCH OFFSET in MACHINE DATA. Refer to
the step 2. (Note) As forθ1 tooth parallelism adjustment, hold the nozzle with the camera jig up by
hand at station 6 so thatθ2 tooth does not engage with theθ2 outer shaft.
1. 将治具吸在NOZZLE上
2. 回转HEAD使其在θ2作规正
3. 每回转到打体位置以 Digk Goge Check 时是否水平。（0.03↓）
15.Adjustment of End Cutter Interlook
Cutter gap adjustment
1. Turn the power [OFF] and cut air [OFF].
2. Move the left feeder carriage to the waiting position manually.
3. Loosen the fixed blade bolts and the adjust board bolt.
4. Rotate the adjust bolt so that the blades are of cutting a sheet of paper.
5. Tighten the fixed blade bolts and the adjust board bolt.
6. Loosen the bolts and move the bracket to the movable blade so that the cam followers contacts to the
movable blade.
7. Tighten the bolts.
8. Turn air [ON].
16.Adjustment of End Cutter Stroke
Cutter stroke adjustment
1. Turn the power [ON] and return to origin.
2. Turn HEAD SERVO [OFF] and rotate the manual wheel to cycle timer of 25゜.
3. Check the over stroke of the movable blade to fixed blade. (specification) Overstroke:1mm
4. If not within the specification, loosen the lock nuts, rotate the turn buckle and adjust the overstroke of the
movable blade to within the specification. (Note) Make sure that the movable blade does not interfere
with the casting.
5. Match the sensor dog with the forward limit sensor and return limit sensor. (Note) Check sensor LED
lights
6. Check the clearance between the stopper bolt and the movable blade lever. (specification)
clearance:0.5mm
7. If not within the specification, loosen the lock nut and adjust the clearance.
8. Tighten the lock nut.
9. Turn HEAD SERVO [ON].
17.Registration of the Component Camera Scale
Component camera scale adjustment
1. Turn the power [ON] and return to origin.
2. Turn HEAD SERVO [OFF], rotate the manual wheel and stop between station 7 and 8.
3. Remove the inner shaft of nozzle 1 of head NO.1 by using nozzle remove jig. (Note) Refer to”12.Nozzle
Inner Shaft Replacement.”
4. Attach the small component camera jig to where the inner shaft was removed.
5. Move head NO.1 to station 7. (Note) Make sure to remove the component discharge box before doing
camera scale adjustment. Otherwise, the jig will hit brush of component discharge box.
6. Turn the HEAD SERVO [ON].
7. Select [REQUEST]→[F1] (MACHINE INITIAL SETTINGS)→[F4] (RECOGNITION BASIC DATA)
→[F1] (AUTOMATIC SETTING)→[F1] (COMPONENT CAMERA)→[F1] (S CAMERA SWITCH
OVER)→[F1] (MEASUREMENT START) of main control panel.
8. Set the large component camera jig to the small component camera jig, after completion of small component
camera scale.
9. Select [F3] (L CAMERA SWITCH OVER)→[F1] (MEASUREMENT START) of main control panel. If
there are no abnormalities, scale registration is complete.
10. Remove component camera jig and attach the inner shaft again.
θ1平行度调须再作CAMERA SCALE 如果θ1 平行度已调OK.但CAMERA 之前为倾斜的话，则 CAMERA 照射
出现的影相是歪斜造成θ2须再作打体角度的补正
打体歪斜须将CAMERA的中心再作调整
18.Nozzle Center Measurement
Nozzle center measurement
(Note) Must be done after the following:
1. Line sensor offset adjustment
2. Nozzle select clearance and backlash adjustment
3. Nozzle select confirmation adjustment
4. Nozzle origin confirmation adjustment
5. Component camera scale adjustment
6. Nozzle inner shaft replacement
7. θ1,θ 2,θ 3 tooth parallelism adjustment
8. Nozzle unit replacement
(Note) Must do after replacing the nozzle tip
1. Select [REQUEST]→[F8] (Next menu)→[F1](MACHINE INITIAL SETTINGS) →[F5](Nozzle center
measurement)→[F1](ALL nozzle) of main control panel.
(Note) Check all nozzles for incorrect recognition images taken-in.
Refer to” OPERATING INSTRUCTION” for details.
19.PC Board Camera Unit Exchange
PCB camera unit replacement
1. Turn the power [OFF].
2. Remove the fluorescent lamp cable connector.
3. Remove the PCB camera cable connector.
4. Remove the bolts (M6*4pcs) to remove the unit.
5. Replace PCB camera unit.
6. Temporarily tighten the bolts.
7. Attach the PCB camera cable connector and the fluorescent lamp cable connector.
8. Set square grid board on XY table.
9. Turn the power [ON].
10. Select [F1] NC JOG CHECK screen on control monitor.
11. Move XY table in the X and Y axis direction and check if the camera unit is parallel to the square grid board
lines.
12. If not, rotate the camera to adjust.
13. Tighten the bolts. (Note) Check with 300mm ruler in stead of square grid board if square grid board is
not available.
20.Registration of the PC Board Camera Scale
PCB camera scale adjustment
1. Set the PCB onto XY table raise the support plate.
2. Select [REQUEST]→[F1] (MACHINIE INITIAL SETTINGS)→[F4] (PCB camera scale)→[F1]
(Automatic setting)→[F2] (PCB camera scale) of main control panel.
3. Move XY table to the center of camera monitor so that it shows the 1mm hole on PCB. (Note) Make sure
that the recognition take-in image is not doing incorrect recognition. (Note) Error message appears on
the camera monitor when the recognition in incorrect. In this case, use another PCB and adjust again.
1mm hole may be wrong size or camera is mis-adjusted.
21.Registration of Head Position Correction Data and PC Board Camera Offset
Head position correction data and PCB camera offset registration
(Note) Must do be done after the following:
1. Component camera scale adjustment
2. PCB camera scale adjustment
3. Nozzle center measuring
(Note) Enter 0 for the PCB camera offset
1. Select [REQUEST]→[F1] (MACHINE INITIAL SETTINGS)→[F7]→[SHIFT]→[M] [V]→[F5] (Head
position correction)→[F1] (Automatic registration). Move XY table so that the first mount point shows on the
PCB camera. (Note) Set the first mount point at the bottom left of test PCB.
2. Select [F1] (Teach start) of main control panel to automatically start mount. (Note) The PCB camera
automatically recognizes each component and takes in the head position correction data and
simultaneously enters the PCB camera offset.
22.Check and Adjustment of the Mechanical Stopper Clearance
Mechanical stopper clearance (push-up and peel) adjustment
1. Turn the power [ON] and return to origin.
2. Turn [PUSH UP LOCK] of sub control panel [ON]
3. Check the clearance between the cam and cam follower. (specification) clearance:0.01-0.02m
4. If not within the specification, loosen the lock nut.
5. Set thickness gauge between the cam and cam lever and rotate the stopper bolt so that the clearance is within
the specification.
6. Check the clearance between cam and follower again.
23.Check and Adjustment of the Mechanical stopper clearance
Mechanical stopper clearance adjustment
1. Turn the power [ON] and return to origin. (Note) Make sure that [RECG.SHUTTER LOCK] sub control
panel is [ON].
1. Check the clearance between the cam and cam follower. (specification) clearance:0.01-0.02mm
2. If not within the specification, loosen the lock nut.
3. Set thickness gauge between the cam and cam lever and rotate the pusher so that the clearance is within the
specification.
4. Check the clearance between cam and cam follower again.
24.Check and Adjustment of the Mechanical-Stopper Clearance (feed)
Mechanical stopper clearance (feed) adjustment
1. Turn the power [ON] and return to origin.
2. Turn [FEED LOCK] of sub control panel [ON].
3. Check the clearance between the stopper and cam follower. (specification) clearance:0.01-0.02mm
4. If the clearance is not within the specification , loosen the bolt.
5. Set thickness gauge between the stopper and cam lever and rotate the adjustment bolt so that the clearance is
within the specification.
6. Check the clearance between the stopper and cam follower again.
25.Check and Adjustment of the Nozzle NO. Detection Sensor
Nozzle number detection adjustment
1. Turn the power [ON] and return to origin.
2. Turn HEAD SERVO [OFF] and rotate the manual wheel to cycle timer of 0゜.
3. Turn HEAD SERVO [ON].
4. Check if the detection sensors detect correctly by the sensor amplifier (DARK ON) or on control monitor
(Select [REQUEST]→[F1] (MACHINE INITIAL SETTINGS)→[F2] (MONITORING)→[F1] (SC)→[F2]
(IN) of main control panel and enter the address number).
5. If not, turn SERVO MOTOR [OFF].
6. Check that nozzle number is the same as amplifier number after removing the detection sensor from the
bracket.
7. Attach the nozzle number detection sensors 1,2 and 3 to the bracket in order. (Note) Notches in guide
holder have different openings to indicate nozzle number.
8. Check the clearance between the sensors and nozzles. (specification) clearance:0.8-1.0mm
9. If not within the specification, adjust the clearance.
10. Manually turn nozzle unit gear to check that nozzle number is the right one.
11. Turn SERVO MOTOR [ON].
Nozzle
Number
Nozzle Number detection
sensor 1
Nozzle Number detection
sensor 2
Nozzle Number detection
sensor 3
ADD(SC)0040
ADD(SC)0041
ADD(SC)0042
1
ON
OFF
OFF
2
OFF
ON
OFF
3
ON
ON
OFF
4
OFF
OFF
ON
5
ON
OFF
ON
Specification
Former Type Machine
1.5±0.5mm
Present Type Machine
0.8–1.0mm
26.Check and Adjustment of the θ3 Unit Origin Check Sensor
Nozzle origin confirmation adjustment
1. Turn the power [ON] and return to origin.
2. Turn HEAD SERVO [OFF] and rotate the manual wheel to cycle timer of 0゜.
3. Turn HEAD SERVO [ON].
4. Check if the confirmation sensor detects correctly at the sensor amplifier (DARK ON) located on the chine
front.
5. If not, loosen bolts of bracket and move the bracket so that it comes to the center of pin groove of outer shaft.
6. Check the clearance between the outer shaft and nozzle origin confirmation sensor. (specification)
clearance:1.0-1.5mm
7. If not within the specification, loosen the set screw and adjust the clearance again.
8. Turn HEAD SERVO [OFF] again, rotate the manual wheel back and forth, Check if the amplifier turn [OFF]
approximately at the same back and forth rotation of manual wheel from cycle timer of 0゜.
9. Check if the pin is separated from the tip of pin when pin cylinder is in return limit.
10. If there is no clearance between stopper lever and cylinder, loosen the lock nut and adjust the pin cycle
position.
11. Tighten the lock nut.
12. Turn HEAD SERVO [ON].
Specification
Former Type Machine
1.5±0.5mm
Present Type Machine
1.0–1.5mm
27.Check and Adjustment of Shutter Seating Detection Sensor
Loosen cassette detection sensor adjustment
1. Turn SERVO MOTOR [OFF].
2. Move the feeder carriage manually and feeder cassette to loose cassette detection sensor.
3. Check the clearance between the sensors and feeder. (specification) Sensor must be ON with 1.0mm
block gauge, OFF with 1.5mm block gauge.
4. If not within the specification, loosen the bolts of loose cassette detection sensors and adjust the clearance.
5. Tighten the bolts of loose cassette detection sensors.
6. Turn SERVO MOTOR [ON].
28.Check and Adjustment of Parts Cassette Loose Shutter Seating Detection
Loose cassette detection switch adjustment
1. Turn the power [ON] and return to origin.
2. Turn SERVO MOTOR [OFF].
3. Move the feeder carriage manually until feeder cassettes are in the area of loose cassette detection switch.
4. Check the clearance between spring and feeder cassette. (specification) clearance:1.5-2.0mm
5. If not within the specification, loosen the bolts A and adjust the clearance between spring and feeder cassette.
6. Tighten the bolts A.
7. Check if the spring center matches with the center line of feeder cassette wheel.
8. If not, loosen the bolts B and move the loose cassette detection switch so that spring center aligns the center
line of feeder cassette wheel.
9. Tighten the bolts B.
10. Check the clearance between spring and feeder cassette and the loose cassette detection switch again.
11. Turn SERVO MOTOR [ON].
29.Check and Adjustment of PC Board Detection
PCB detection adjustment
1. Turn the power [ON] and return to origin.
2. Set a 0.5mm thick PCB onto XY table and turn [PCB SUPPORT] of sub control panel [ON] to raise support
plate.
3. Check that both sensor LED are [ON] and there is a PCB detection sensor on the bottom right and left sides of
fixed rail bracket.
4. Lower the support plate by using sub control panel, remove the PCB, raise the support plate and check that
both right and left PCB detection sensor LED are [OFF].
5. If sensor does not detect correctly, loosen the bolts of sensor plate and adjust the sensor plate up/down to
detect PCB.
6. Tighten the bolts of sensor plate. (Note) Check PCB detection in AUTO operation mode.
30.Check and Adjustment of Reference Pin Vertical Detection
Positioning pin up/down detection adjust
1. Turn the power [ON] and return to origin.
2. Select control monitor to SC monitoring screen a 0.5mm thick PCB onto XY table.
3. Turn [POSING PIN] of sub control panel [ON] and check that (ADD 4002) is [ON] on SC monitor screen
and turn [OFF] (down) to check that (ADD 4003) is [ON].
4. Slightly move the PCB on XY table and at a position in which the positioning pin does not go up into
positioning hole, turn [POSING PIN] of sub control panel [ON] and check that (ADD 4002) is [OFF] on SC
monitoring screw.
5. Loosen the sensor set screw and adjust the sensor position up/down. After checking the action, tighten the
sensor set screw. (Note) Check the positioning pin up/down detection in AUTO operation mode.
31.Large Component Detection Adjustment
Large component detection adjustment
(Note) check with nozzle 2
1. Turn the power [ON] and return to origin.
2. Turn SERVO MOTOR [OFF].
3. Turn the volume to the large component detection.
4. Turn [NON WORK] [ON] and make sure that the green lamp becomes it. (Note) Make sure that the
sensor optical axis is not blocked.
5. Block the optical axis by hand turn [WORK] [ON] and make sure the green lamp and red lamp become lit.
6. Turn SERVO MOTOR [ON].
7. Turn HEAD SERVO [OFF] and rotate the manual wheel to cycle timer of 0゜ .
8. Turn the [HEAD SERVO] [ON].
9. Check that the green lamp is lit on the sensor amplifier.
10. Vacuum 1mm thick thickness gauge.
11. Check that the green lamp is lit on the sensor amplifier.
12. Vacuum 1.5mm thick thickness gauge.
13. Check that the green and red lamps are lit on the sensor amplifier.
14. If not, loosen the bolts an move the sensor brackets so that the green and red lamps are lit of sensor amplifier.
32.P-922MⅡ(Sensor Amplifier) Adjustment Procedure
1. Set the mode selection SW to the channel NO. corresponding to the sensor NO. on call for the sensitivity
adjustment.
2. Press [NON WORK] button for the sensitivity adjustment when the work piece is not there.
3. Press [WORK] button for the sensitivity adjustment when the work piece is there.
4. Set the SW to the other channel NO. and repeat the steps NO.2 and 3 for the other sensor adjustment.
5. Set the SW to [RUN] when the adjustment is completed. (Note) Green lamp (stable condition indicator)
must always light on when the sensors are on action.
The indicator
Geen
Stable condition
Orange
on action
Mode selection SW
RUN
Normal operation
SET
sensitivity mode
Sensitivity adjustment button
WORK
Presence of the work piece
NON WORK
Absence of the work piece
Timer V.R
OFF delay
0.1-1sec
Operation mode selection SW
S/ON
ON when sensed.(Light ON)
S/OFF
OFF when sensed.(Dark ON)
33.SC Program Sheet Symbol List
34.Check and the Reference Data Setting for the Mounting Nozzle Stroke
Nozzle Mounting Stroke
1. Program the data to mount a piece of paper tape component onto a printed circuit board.
(Example:2125R)
2. Turn on the [Head Rotation Enable] SW to select NO.1 nozzle of the NO.1 head and bring it to station
NO.9.
3. Place the printed circuit board onto the X-Y table.
4. Mount a piece of component onto the board, taking the following steps: [SEMI-AUTO]→[1 BLCCK]
→[START]→[AUTO]→[EOP]→[START] ※Check and read the display on the panel for the line
sensor controller (P-945A) (Example: 3.30mm)
5. Reverse a manual rotation wheel and set the cycle timer to 270゜after switching to [1 BLOCK] mode
from [MANUAL] mode.
6. Check the clearance between the board and the nozzle using the thickness gauge. (Example) Panel
display Nozzle length Part thickness on P-945A 3.30mm-2.75mm=0.55mm (The measurement
after adjustment of the line sensor)
7. Nozzle thrusting depth is about 0.2mm if the thickness of the mounted component is 0.55mm with the
gap of 0.35mm between the board and nozzle. (Example) Part Thickness Nozzle Thrusting
Clearance Amount 0.55mm-About 0.2mm=About 0.35mm
8. In the case that 0.2mm is not made out for the nozzle thrusting amounts as indicated at the step NO.7,
call up the《MACHINE CHECK》screen and change the data of the mounting nozzle height by proceeding
the following steps: [REPUEST]→[F8](NEXT MENU)→[F1](MACHINE INITIAL DATA SETTING)
→[F1](MACHINE DATA)
35.Check and the Reference Data Setting for the Picking Up Nozzle Stroke
Nozzle Picking Stroke
1. Program the data for the embossed tape component to be picked with NO.1 nozzle (Reflective SS nozzle)
2. Remove the feeders from the Z axis and return the machine to the origin point.
3. Turn on the [Head Rotation Enable] SW using sub control panel to select NO.1 nozzle and bring it to station
NO.9.
4. Place the Pc board to the loader rall while switching to [1 BLOCK] mode from [AUTO] mode.
5. Looking at screen, press [START] button display <1 step> at <Pick up side>. Then switch to [1BLOCK]
mode from [MANUAL] mode.
6. Turn a crank handle backward till cycle time read 250゜.
7. Place the Z axis jig onto the Z axis plate confirm that The clearance between the nozzle and jig is 0.6mm.
8. If 0.6mm clearance is not set ad the (side view shows), take the following steps to satisfy the specification.
《MACHINE CHECK》screen→[REQUEST]→[F8] (NEXT MENU)→[F1] (MACHINE INITIAL DATA
SETTING)→[F1] (MACHINE DATA) change the data of the nozzle pick up height on the screen displayed
when [F1] is press. ※The data entry individually to the both of ZL and ZR is possible for the nozzle
pick up.
Panadac 783
MMC Main machine control
MM1 Main machine interface
NC Servo Driver Servo Motor
PMC Plus Dirver Plus Motor
REC Camera
SC 控制 sensor value
XY 轴 Servo Motor
HEAD 介绍
1. pick up 大部品吸着检测，吸着高度切换 cmt
2. θ1 装着方向选择 4个方向
3. 部品厚度检测
4. camera 零件部品辨视
5. 空
6. 打体角度补正θ2。
7. 打体，打体高度控制MT
8. MC ORG （64゜-74゜）
9. 不良部品排除
10. Nozzle select
11. Nozzle NO.确认
12. Nozzle 原点及 Nozzle 原点确认
S/C 表找出故障原因
Example: Tranfer org error
4006 0 0 不符 被 pcb stopper up limit sensor 不在定位
1132 0 1
1142 0 1
4303 Ｘ 0
1210 结果须1但为0则表示其必要条件有一不具备
保养（各部加油，调滑）
1. 加油工具
2. 油品
3. Head 每日加一次 （加时p. nozzle stroke 下降 15.01mm）
4. 一般油枪后两次，若有溢出时则须特溢出油擦掉
5. 加油须以半自动模试运转5分钟左右设再检查是否有溢出的，油脂若有则须将其擦去
6. camera line sensor 须每日以干净软不清洁
camera 若角度更改 则小---大
只有 camera角度更改 则小---小
PCB camera scale 角度改变， 对打体无影响
Camera offset
Part camera x offset 大会偏移，小不会有偏移现象
PCB Camera x offset 0.5—8mm----无视 mark 0.05mm—1mm
原点补正 0---0.5 则打体全部偏移0.5mm
Z轴原点补正 0---0.5 吸料位置改变，吸料不正确但对打体无影响
V轴θ2补正---大小零件皆便
吸着高度 无法 pick up or pick up 站立
1. θ2 unit tooth parallelism adjustment 练习调整：将治具装在H1Z1 用手回转在270゜时与θ2 tool 结合
再转到356゜量表测量其水平度（0.03以下）若超出则在270゜时调整tool之误差值
2. Comp camera scale
H1 camera 之scale 在15-16左右 作θ1平行度调整后必须再作 camera scale测量治具须放在H1上
MACHINE INTIAL SETTING→RECOGNITION BASIC DATA→AUTOMATIC SETTING→COMPONENT
CAMERA→S（L）CAMERA MEASURE
3. Pick up Hight
测量以基准高度 nozzle在全自动模式下进行测量，测量高度重要值(29.55)
4. 打体高度的测定
Line sensor controller nozzle 下降为0.2-0.3
5. PCB camera adjustment scale teaching
1. 调整焦距 2.调整水平 3.作 scale teaching 4.修该camera offset 同 Head offset 补正作法一样
用2125C 零件200PCS 用黑色(不可反光)基板打上200pcs
6. Part camera offset
大camera 与小 camera offset以小相机为基准
7. Nozzle select adjust
调整 cam flolwer之位置使 lever在 select nozzle时距gear外围 0.5-0.6
time cycle 270゜
Nozzle select sensor
其2组手动下用sensor1(0゜)全自动下用 sensor(60゜)
位址sensor1:0043 sensor2:0044
8.Nozzle NO. Detection sensor
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