IP3

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Revisions

The IP-III(E) Maintenance Manual (MNT-IP030-5.1E) has been revised asfollows.

As of February 10th, 1999Chapter

Section

1. Cleaning2. Lubrication56

10. Replacing the Air

Regulator Filter (Yearly)4.2 Adjusting the Height of

the Side Plates

Summary

“1.6 Cleaning the Air Regulator Filter”has been removed.

An precautional item has been addedat “2.4 Placing head lubrication”. Newly added.

The dimension has been changed.

Note:Please note that the pages made available on Fuji’swebsite are the pages which have been revised forthis edition of the manual. Users should download thenew pages and replace the equivalent existing pagesin their manual. If the design of any parts of themachine have been changed, former and currentdesign information is given with the model of machinemanufacture indicated. For a copy of the wholemanual, contact your nearest Fuji sales representativeor send a request via e-mail to the following address.smtdocu@fuji.co.jp

IP-III(E)Maintenance ManualMNT-IP030-5.1ENotice

1.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 orotherwise), or reused in any way, without the prior written permission of Fuji MachineManufacturing Co., Ltd.2.Fuji Machine Manufacturing Co., Ltd. accepts no responsibility for any situations that may arise as

a result of the use of this manual.3.Fuji Machine Manufacturing Co., Ltd. reserves the right to change the content of this manual

without notice.4.Every effort has been made to ensure that this manual is correct in every detail. However, please

Fuji Machine Manufacturing Co., Ltd. serves its customers from the following locations:

Fuji Machine Manufacturing Co., Ltd.19 Chausuyama Yamamachi

Chiryu, Aichi Prefecture, 472-8686Japan

Fuji America Corporation

171 Corporate Woods ParkwayVernon Hills, IL. 60061USA

Fuji Machine Mfg (Europe) GmbHPeter-Sander-Str. 43D-55252 Mainz-KastelGermany

Fuji Singapore Office

C/O Mecomb Singapore LimitedSime Darby Centre

896 Dunearn Road #04-03A, Singapore 589472

Fuji Malaysia Office

C/O Mecomb Malaysia Sdn Bhd2487, Jalan Sultan Azlan Shah 11700 Penang, Malaysia

Fuji do Brasil Maquinas Industriais Ltda.Rua Joao Cachoeira, 128Itaim Bibi, Sao Paulo, SP14535-000 Brazil

Tel :0566-81-2111Fax :0566-83-1140

Tel :847-913-0162Fax :847-913-0186

Tel :06134-202120Fax :06134-202200

Tel :4675952Fax :4693758

Tel :604-656-4002Fax :604-656-2941

Tel :11-3064-7650Fax :11-852-6833

Contents – List of Current PagesContents – List of Current Pages

(Current version)

Page

Introduction

1. About This Manual...............................................(Version 5.1).............v

How to Use This Manual.............................................................................................viDANGERS: WARNINGS: CAUTIONS: and NOTES..................................................vii

2. Safety Labels.......................................................................................viii3. Emergency Stop Buttons......................................................................ix4. People Near the Machine......................................................................x5. Tools within the Machine........................................................................x

Chapter 1 Name and Function of Each Part of the Machine

1. Parts of the Machine............................................(Version 5.0)......1-1-1

1.1 Front View.......................................................................................................1-1-11.2 Rear View.......................................................................................................1-1-11.3 Main Parts.......................................................................................................1-1-21.4 Placing Head1................................................................................................1-1-21.5 Placing Head2................................................................................................1-1-31.6 Y-Table...........................................................................................................1-1-3

2. Functions of the Each Parts.................................(Version 5.0)......1-2-1

2.1 Machine Part Categories................................................................................1-2-12.2 Placing............................................................................................................1-2-22.3 Parts Supply System......................................................................................1-2-42.4 Other Units......................................................................................................1-2-52.5 Board Transport..............................................................................................1-2-52.6 Electrical Control System................................................................................1-2-62.7 Air Supply System..........................................................................................1-2-62.8 Main Parts of the Machine..............................................................................1-2-6

Chapter 2 Setup

1. Installation............................................................(Version 5.0)......2-1-12. Leveling................................................................(Version 5.0)......2-2-13. MFU.....................................................................(Version 5.0)......2-3-14. Air Supply.............................................................(Version 5.0)......2-4-15. Checking the Transformer Connections..........(Version 5.0)......2-5-16. Electric Power Supply..........................................(Version 5.0)......2-6-17. Transmission Cable Connection..........................(Version 5.0)......2-7-1

Chapter 3 Changeover

1. Adjusting the Conveyor Width..............................(Version 5.0)......3-1-12. Removing/Attaching the MFU (Changeover with an MFU)

.............................................................................(Version 5.0)......3-2-13. Attaching the Back-up Pins..................................(Version 5.0)......3-3-14. Setting the Board Positioning Pin.........................(Version 5.0)......3-4-15. Changing Pins (Reference, Follow-up Pin)..........(Version 5.0)......3-5-1

Version 5.1iIP-III(E) Maintenance

Contents – List of Current Pages(Current version)

Page

Chapter 4 Cleaning and Lubrication

1. Cleaning...............................................................(Version 5.1)......4-1-1

1.1 Cleaning the Nozzles (Weekly).......................................................................4-1-11.2 Cleaning Out the Waste Tape Box (Every 8 Hours).......................................4-1-21.3 Cleaning the Surface of the Camera (Weekly)...............................................4-1-21.4 Cleaning the Reject Parts Box (Every 8 Hours)...............................................4-1-21.5 Cleaning the Rotary Joint Guide Area (Weekly)..............................................4-1-31.6 Discharge the Air Regulator Drain (Every 3 Months)......................................4-1-41.7 Cleaning the Y-table Vacuum Generator Filter (Every 3 Months)..................4-1-51.8 Cleaning the Control Box Cooling Fan Air Filter (Every Month).....................4-1-6

2. Lubrication............................................................(Version 5.1)......4-2-1

Precautions During Lubrication..............................................................................4-2-1Types of Lubricants...............................................................................................4-2-1Essential Point Regarding Lubrication...................................................................4-2-12.1 X1-, X2-axis lubrication....................................................................................4-2-32.2 Y-table lubrication............................................................................................4-2-42.3 Linearscale (rubber shield) lubrication.............................................................4-2-52.4 Placing head lubrication...................................................................................4-2-62.5 Nozzle change lubrication................................................................................4-2-72.6 Conveyor lubrication........................................................................................4-2-82.7 Feeder lubrication............................................................................................4-2-9Lubrication Check Points.....................................................................................4-2-10

Chapter 5 Replacing Consumable Parts

1. Replacing the Vision Processing Lamp................(Version 5.0)......5-1-12. Replacing the Frontlight Lamp Power Fuse (Option)

.............................................................................(Version 5.0)......5-2-13. Replacing the Vision Processing Frontlight Lamp

.............................................................................(Version 5.0)......5-3-14. Changing the Mark Camera Bulbs.......................(Version 5.0)......5-4-15. Replacing the Conveyor Belt................................(Version 5.0)......5-5-1

5.1 Replacing the In- and Out-Conveyor Belts.....................................................5-5-15.2 Replacing the Y-Table Belt.............................................................................5-5-2

6. Loader Sequencer Battery Replacement(About Every 4 Years)

.............................................................................(Version 5.0)......5-6-17. SCSI Board Battery Replacement (About Every 6 Years).............................................................................(Version 5.0)......5-7-18. MP Board Battery Replacement (About Every 3 Years)

.............................................................................(Version 5.0)......5-8-19. Filter Replacement for Part Pickup Vacuum Generator (Every 6 Months).............................................................................(Version 5.0)......5-9-110. Replacing the Air Regulator Filter (Yearly).........(Version 5.1)....5-10-1

Version 5.1iiIP-III(E) Maintenance

Contents – List of Current Pages(Current version)

Page

Chapter 6 Adjustments

1. Placing Head........................................................(Version 5.0)......6-1-1

1.1 Z1-Axis Switch Adjustment.............................................................................6-1-21.2 Q1-Axis Adjustment........................................................................................6-1-31.3 Placing Pressure Control Mechanism (Option)...............................................6-1-4

2. Nozzle Change Unit.............................................(Version 5.0)......6-2-1

2.1 Adjusting the Advance Limit of the Nozzle Change Unit................................6-2-12.2 Adjusting the Nozzle Changer Advance and Retract Limit SW......................6-2-22.3 Adjusting the Nozzle Change Unit Forward/Retract Speed............................6-2-32.4 Adjusting the Nozzle Confirmation SW...........................................................6-2-3

3. Reject Parts Conveyor.........................................(Version 5.0)......6-3-14. Y-Table.................................................................(Version 5.1)......6-4-1

4.1 Adjusting the Width of the Y-Table.................................................................6-4-14.2 Adjusting the Height of the Side Plates..........................................................6-4-24.3 Adjusting the Height of the Back-up Pins.......................................................6-4-34.4 Adjusting the Board Liffter Upper/Lower Limit Sensors..................................6-4-44.5 Adjusting the Board Lifter Speed....................................................................6-4-54.6 Adjusting the Board Stopper...........................................................................6-4-64.7 Adjusting the Height of the Reference Pin Detection Sensors.......................6-4-7

5. Board Conveyor...................................................(Version 5.0)......6-5-1

5.1 Conveyor Sensors..........................................................................................6-5-15.2 Conveyor Width Change Notch Cylinder Adjustment.....................................6-5-2

6. Electrical Control..................................................(Version 5.0)......6-6-1

6.1 Servo Amps....................................................................................................6-6-16.2 VME Boards....................................................................................................6-6-36.3 Checking Input/Output Using the Direct I/O (MX 250)....................................6-6-6

Supplementary Information

1. Upgrading the Software.......................................(Version 5.0)......A-1-1

1.1 Static Electricity Countermeasures................................................................A-1-11.2 Upgrading the Control Program Software......................................................A-1-11.3 Upgrading the Vision Processing Software....................................................A-1-11.4 Upgrading the VME Board (IS70B): Servo Board ROM.................................A-1-21.5 Loader Sequencer EP-ROM Replacement....................................................A-1-3

2. Camera Proper Data Backup Procedure

.............................................................................(Version 5.0)......A-2-1

2.1 Camera Proper Data Save Method................................................................A-2-22.2 Camera Proper Data Load Method................................................................A-2-42.3 Troubleshooting..............................................................................................A-2-5

Version 5.1iiiIP-III(E) Maintenance

Contents – List of Current PagesNotes:

Version 5.1ivIP-III(E) Maintenance

IntroductionIntroduction1. About This Manual

This manual contains important machine maintenance information for the operator.

The manual content is intended for specialized technicians who are familiar with SurfaceMount Technology (SMT).

Please read this manual carefully in order to ensure safe and efficient machinemaintenance.

Some of the machine names used in this manual are not the formal machine names. (Formal machine name)FUJI IP-IIIFUJI IP-III E

(Notation used in this manual): IP-III: IP-III E

Version 5.1vIP-III(E) Maintenance

IntroductionHow to Use This Manual

Each page indicates the chapter title, section title , manual name, page number,and the version number.

Section titleChapter 2 SetupChapter titleMain body1. InstallationPointSet leveling sheets in the prescribed positions and ensure that the GP-551E is level. Besure to use leveling sheets that conform to the board transport height. (mm)Board transport heightLeveling sheet height900169506096575Table01Procedure1.2.Position the leveling sheets referring to the figure below.Position the sprit levels in the base of the machine. (Vertical and horizontal direc-tions)Turn to adjust each of the leveling bolts.Verify that the board transport height and horizontal level of the machine are cor-rect and then tighten each of the lock nuts.37.5450146037.52015(mm)15003.4.Lock nutLeveling boltLeveling sheetGP5MS001Version 1.02-1-1GP-551E MaintenanceVersion numberPage numberManual nameGP5MF001EMain Body:

The information needed for conducting maintenance work isexplained using text and figures (illustrations) below the title.The chapter name attached to that page is indicated.The section name attached to that page is indicated.The relevant machine type and type of manual is indicated.Hyphenated page numbers indicate the chapter-section-pagenumber.

The version number of a manual will be updated each time a revisionis carried out once the manual has been published. For example ifmajor changes are associated with a revision then the revision

number would be updated from version 1.0 to 2.0. (In such a case themanual number on the cover page would be updated at the sametime and thus all of the pages in the manual would need to be

substituted.) In addition if minor changes are made to a portion ofthe pages then the version number would be updated from version1.0 to 1.1. (In this case only the revised pages would need to besubstituted.)

Chapter Title:Section Title:Manual Name:Page Number:

Version Number:

Version 5.1viIP-III(E) Maintenance

Introduction2.

To enable the user to insert and/or replace updated pages, this manual ispublished in loose leaf form.

The “List of Current Pages” provides a summary of the most recent release for allpages. Refer to this list when updating a manual.

Any additional or updated sections of this manual can be downloaded as requiredfrom Fuji’s web site.

DANGERS: WARNINGS: CAUTIONS: and NOTES

The Safety Alert Messages and how they will appear in this manual are defined below.

DANGERFailure to follow the instructions will result in serious injury or death.

WARNINGFailure to follow the instructions could result in serious injury or death.

CAUTIONFailure to follow the instructions could result in equipment damage, or may result inminor or moderate injury.

“Notes” are shown in italics. An example follows;

Note: Important information related to equipment or procedures.Version 5.1viiIP-III(E) Maintenance

Introduction2. Safety Labels

The safety labels that indicate cautions which must be observed during machineoperation, and / or maintenance are affixed to the machine as shown below.Be sure to read these labels carefully and use the machine in a safe manner.

Placing pressuer control (option)1112A2High Voltage2A1Keep hands andclothing well clearof the moving conveyorAMFUDANGERNever insert your handinside an operating machine.Moving parts may cause injury.IP3-m0511Version 5.1viiiIP-III(E) Maintenance

Introduction3. Emergency Stop Buttons

To stop machine operation immediately in an emergency situation, press one of the threered round emergency stop buttons on the machine. The positions of the emergency stopbuttons on the front and rear of the machine are shown in figures 1-3 and 1-4.

Emergency Stop Buttons on Front of Machine

Emergency Stop Button on Back of Machine

Version 5.1ixIP-III(E) Maintenance

Introduction4. People Near the Machine

Before operating the machine, make sure that an operator is not working in the machineand that non-operators are a safe distance from the machine.

5. Tools within the Machine

After performing routine maintenance, check for tools or other articles left in the

machine. Tools or other articles left in the machine can result in costly machine damage.

Version 5.1xIP-III(E) Maintenance

Chapter 4 Cleaning and Lubrication1. Cleaning

1.1 Cleaning the Nozzles (Weekly)

Point

The vacuum nozzles draw in air. Nozzle blockage occurs when particles of dust, glue, orsolder paste are drawn in and solidify. If this blockage is not corrected pickup errors willoccur and placing performance will drop.

The nozzle slides out of the ball screw spline axis. When blockage occurs this slidingaction can also be affected; increasing the time it takes to place the part, and making itincreasingly harder to change the nozzle with the buildup.

Procedure

If a certain nozzle consistently causes pickup errors, clean it out using an air gun.

Accordingly, the nozzles should be cleaned on a regular basis (once a week) a smallamount of Biral T&D applied. Use a cotton swab to spread a small amount of Biral T&Don the inside of the nozzle. Apply a small amount of grease to the nozzle hook as well.

Version 5.14-1-1IP-III(E) Maintenance

Chapter 4 Cleaning and Lubrication1.2 Cleaning Out the Waste Tape Box

(Every 8 Hours)

WARNINGAlways be sure to cut the 200V power before carrying out any work.The waste tape from the feeders is collected in the MFU waste tape box. This waste tapebox should be emptied every eight hours.1.3 Cleaning the Surface of the Camera (Weekly)WARNINGAlways be sure to cut the 200V power before carrying out any work.If the surface of the image sensor camera becomes dirty with oil, dirt, etc. the changes inlight can distort the image that is read by the camera and resulting in a vision processingerror which causes the placement rate to fall. The surface of the camera should be wipedwith gauze once a week. 1.4 Cleaning the Reject Parts Box (Every 8 Hours)WARNINGAlways be sure to cut the 200V power before carrying out any work.Small parts deemed as NG by vision processing or unplaced parts are rejected and

placed in the reject parts box. Inspect this box and remove the rejected parts every eighthours.

Version 5.14-1-2IP-III(E) Maintenance

Chapter 4 Cleaning and Lubrication1.5 Cleaning the Rotary Joint Guide Area (Weekly)

Point

The dog and the cover guide, inside the rotary joint, also act together as a seal to preventair leaks. However, this results in the rotary joint drawing foreign particles to this area.This often results in the dog’s movement becoming restrained causing errors duringoperation. (The nozzle sensor remains in the on position.)

Procedure

WARNINGAlways be sure to cut the 200V power before carrying out any work.Therefore, clean the dog and the cover guide thoroughly with a dry cloth every week.Furthermore, on a monthly basis, wipe the area with a cloth dampened with a smallamount of Biral T&D.

By pressing the tip of the dog up, the guide area of the rotary joint becomes accessible.This should allow you to easily access the area for cleaning during periodic maintenancework.

Version 5.14-1-3IP-III(E) Maintenance

Chapter 4 Cleaning and Lubrication1.6 Discharge the Air Regulator Drain

(Every 3 Months)

Point

Unwanted water droplets included in the air supply are collected inside the regulatorthereby necessitating the discharge of the drain.

Procedure

Cut the power to the machine.

WARNINGAlways be sure to cut the 200V power before carrying out any work.2.3.4.

Remove the air hose (coupler).

Place a receptacle for holding the unwanted water underneath the air regulator.Press the drain discharge button.

11. Window2. Max. drain level3. Discharge drain 23IP3ML005ENote:Filter A in the figure below is self-draining and thus drain discharge is not necessary.Carry out this procedure for filter B only.Filter BFilter AIP3ML006E5.

Looking through the window on the air regulator, when there is no more waterleft in the filter then discharge is complete.

Version 5.14-1-4IP-III(E) Maintenance

Chapter 4 Cleaning and Lubrication1.7 Cleaning the Y-table Vacuum Generator Filter

(Every 3 Months)

Point

This filter must be cleaned periodically since if it becomes clogged this will cause thevacuum pressure of the back-up pins to be reduced thereby resulting in board holddefects.

Procedure

Cut the power to the machine.

WARNINGAlways be sure to cut the 200V power before carrying out any work.2.

As shown in the figure below, loosen one screw at the top and remove the filtercover.

Y-tableFrontFilter coverName: FilterModel No.: VGFE10Maker: PISCOPackingUMCUAB V3PC - OLT1SIP3ML007E3.4.Wash the filter with kerosene or soapy water and then let it dry naturally (Keep inthe shade).

Reinstall the filter. At this time, be sure not to forget to include the packing.

Version 5.14-1-5IP-III(E) Maintenance

Chapter 4 Cleaning and Lubrication1.8 Cleaning the Control Box Cooling Fan Air Filter

(Every Month)

Point

If the air filter becomes clogged the cooling fan efficiency will drop and the temperatureinside the control box will rise. If operation continues under such conditions the servoamps and VME boards will not work properly and there is a danger of the equipmentrunning out of control.

Procedure

Cut the power to the machine.

WARNINGAlways be sure to cut the main power before carrying out any work.2.

Remove the filter cover as shown in the figure below and clean the filter spongeinside.

Version 5.14-1-6IP-III(E) Maintenance

Chapter 4 Cleaning and Lubrication2. Lubrication

Precautions During Lubrication

1.2.

Prior to beginning any work be sure to turn the main power breaker OFF.

Apply an appropriate amount of lubricant. If too much lubricant is applied thelubricant will splatter and may drop on the boards or inside the machine.

Special care should be taken to keep camera lens clean, as a soiled lens can causevision processing errors. If this happens use a lens cleaner to wipe off the lens.

Types of Lubricants

The lubricants that are used have the following properties.

Types of LubricatnsPropertiesThis is a spray type oil that is used as the lubricamtfor moving parts that travel at a relatively slow speedand upon which a relatively low load is exerted.This is also used for rust prevention. This is a lithium-based grease (Idemitsu) that is usedas a lubricant on moving parts that travel at moderatespeeds.This is a silicon-based grease that offers excellent heat resistance, moisture resistance and electrical insulating properties.Table-lub-IP3Biral T&DDaphne EponexNo. 2G-30LSilicon greaseEssential Point Regarding Lubrication

The essential points concering the lubrication of each of the machine companents areindicated with illustrations and tables.

• Type of lubricants and lubrication schedule

The lubrication tables provide information regarding lubrication points, lubricant types,and lubrication schedules.

The following symbols are used in the table:

: Apply the appropriate amount of lubricant.R: Apply a small amount for rust prevention purposes.N/A: Lubrication is prohibited.

Note:The frequency of lubrication is based on eight hours of operation per day.Version 5.14-2-1IP-III(E) Maintenance

Chapter 4 Cleaning and Lubrication• Lubrication points

Areas requiring lubrication are indicated in the diagrams by arrows and numbers.Locations indicated by white arrows signify that grease or oil should be applied to thesurface of the part being lubricated. Black arrows are used to indicate grease nipples andsignify that grease should be inserted using a grease pump.

LM blockLM railNote:Even in the case of LM blocks that do not have a nipple, by applying arease between theblock and LM rail (bearing mechanism), the grease that adheres to the ball bearings androllers 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:1.2.

Check the lubrication points corresponding to the reference numbers shown in theillustrations.

Tick the \"Check\" box after lubricating each point.

Version 5.14-2-2IP-III(E) Maintenance

Chapter 4 Cleaning and Lubrication2.1 X1-, X2-axis lubrication

Types of LubricantsLubrication PointsLM railLM blockDaphne Eponex No.2N/A Biral T&DRN/AN/ALubricationScheduleEvery weekEvery monthEvery monthT001ELM guideBall screw : Lubricate R : Apply for rust prevention N/A : Do not lubricate1.2.

Arrow marks in the illustrations indicate lubrication points.Black arrows indicate points where a grease gun is required.