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JUKI KE-2050, Maintenance Manual

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KE-2050/2060 Maintenance

 

Manual 

 

16-1 

 

 

DANGER

 

To prevent any trouble caused by accidental machine start, always 
shut-down the power before starting the maintenance and 
adjustment work. 

 

[16] FEEDER POSITION INDICATOR 

16-1. Detaching the FPI (Front) from the Machine Main Unit 

As shown in the figure below, the FPI is hanged on the hook of the FPI side bracket fixed to the 
Y-axis frame (both sides), and fixed with the SEMS cap bolts (M6 

×

 12). 

To detach the FPI, remove two bolts and slide it upward. 
 
 

 

FPI side bracket F

 

FPI assembly F 

SEMS cap bolt 

Rev. 2.00 

Summary of Contents for KE-2050

Page 1: ...KE 2050 KE 2060 KE 2050R 2055R KE 2060R High Speed Modular Mounter MAINTENANCE GUIDE ELECTRONIC ASSEMBLY TEST SYSTEMS DIVISION SMT TRAINING CENTER...

Page 2: ...you have any question or find any error or omission in writing contact our dealer or JUKI Corporation 4 JUKI Corporation shall disclaim all the responsibility for any trouble resulting from the user...

Page 3: ...ing the Limit Sensor and the X Axis Home Position Sensor 1 16 1 5 1 Replacing the X Axis Limit Sensor and the X Axis Home Position Sensor 1 16 1 5 2 Replacing the Y Axis Limit Sensor 1 17 1 6 Replacin...

Page 4: ...placing the Nozzle Outer Shaft Assembly 2 23 2 9 List of Readjustment Items After Replacement 2 24 3 PARTS AROUND THE HEAD 3 1 3 1 Replacing the Ejector Unit 3 1 3 2 Replacing the Bad Mark Sensor 3 2...

Page 5: ...Fiber 5 7 5 6 2 Replacing the Amplifier Unit 5 8 5 7 Replacing the STOP and C OUT Sensors 5 9 5 8 Replacing the Stopper Cylinder 5 10 5 9 Replacing the Support Table Home Position Sensor BU Home Posit...

Page 6: ...placing the Feeder Bank Board and Feeder I F Board 9 5 9 5 Replacing the Bank Up Cylinder 9 6 9 6 Adjusting the Speed Controller of the Bank Up Cylinder Optional Replacement Table 9 7 9 7 Replacing th...

Page 7: ...t of Electrical Components 14 1 14 2 Layout of Top of Base Frame 14 2 14 3 Power Supply Unit 14 3 14 4 Control Unit 14 11 14 4 1 Structure of Control Unit 14 11 14 4 2 CPU Board 14 13 14 4 3 XMP Board...

Page 8: ...the UPS Battery E9659729A000 Voltage 14 64 14 10 2 Replacing the UPS Battery 14 65 14 11 Replacing the Fuse of the AC Input Unit 14 68 15 AUTO BOARD WIDTH ADJUSTMENT 15 1 15 1 Assembling the AWC Brack...

Page 9: ...r the criteria value see Readjustment on market of Specification values on page 1 4 1 1 1 Timing Belt XM To carry out the work efficiently detach the side cover Remove the cover fixing screws and slid...

Page 10: ...to detach the XA pulley bracket assembly 5 Remove the SL6062092TN fixing the motor assembly to detach the X motor assembly 6 Replace the timing belt XM 7 Reassemble the components in the reverse order...

Page 11: ...he X belt support R 3 Remove the SL6042092TN sandwiching the timing belt to replace the belt 4 Sandwich the timing belt XB by the X belt support 2 and X belt support L or X belt support R and secure t...

Page 12: ...s within the specification value range Tension meter input values Belt type Model Belt unit weight g m mm Belt width mm Belt span mm Timing belt XM All models 2 5 20 119 Timing belt XB All models 3 8...

Page 13: ...t the tension using the SM8053002TN e Tighten the SL6051692TN firmly Tightening torque 15 N m f Lock the NM6050001TN X frame end L assembly Timing belt XB c Loosen the SL6052592TN fixing the X belt su...

Page 14: ...bracket assembly 6 Loosen the SL6063592TN to replace the YA pulley bracket assembly Replacement of only the timing belt YM is not allowed Always replace the YA pulley bracket assembly as a set 7 Reas...

Page 15: ...TN fixing the YB pulley bracket assembly 3 Loosen the SM6084002TN to detach the YB pulley bracket assembly 4 Remove the SL6041292TN sandwiching the timing belt YB Replace the timing belt YB 5 Reassemb...

Page 16: ...specification value range Tension meter input values Belt type Model Belt unit weight g m mm Belt width mm Belt span mm Timing belt YM All models 2 5 40 93 50M 60M 3 8 70 1115 50L 60L 3 8 70 1221 Timi...

Page 17: ...fixing the Y motor d Adjust the tension using the SM6041602TN e Tighten the SL6061492TN firmly Tightening torque 10 N m Y axis frame Timing belt YB c Loosen the SL6062592TN fixing the YB pulley brack...

Page 18: ...sembly Carry out the replacement work in the same manner as for the timing belt XM in 1 1 1 1 2 3 Replacing the Pulley YA Carry out the replacement work in the same manner as for the timing belt YM in...

Page 19: ...Rev 2 00 1 3 Replacing the Servomotors 1 3 1 Replacing the X Motor Carry out the replacement work in the same manner as for the timing belt XM in 1 1 1 1 3 2 Replacing the Y Motor Carry out the replac...

Page 20: ...g surface and magnescale completely It is recommended to use Mechafine Mate for the degreasing agent 1 4 1 Magnescale Affixing Position X axis magnescale affixing procedure c With the X axis affixing...

Page 21: ...No 40008105 made in contact with the side of the Linear way Y and the top of the Y axis make the magnescale in contact with the Y axis affixing jig to affix the magnescale Y axis Magnescale Linear way...

Page 22: ...s under 1 5V loosen the screw fixing the sensor screw c for X axis and screw e for Y axis shown in the following Fig f Put the MSC clearance jig part No 40008106 with a thickness of 0 35 mm in the cle...

Page 23: ...he clearance gauge is inserted smoothly d If the clearance is not 0 5 mm in the check in c above loosen the screw fixing the sensor bracket screw d shown in the figure below e Put a 0 5 mm clearance g...

Page 24: ...o and fro direction make the adjustment so that the clearance between the X MSC bracket mounted on the rear of the head plate and sensor surface is 0 8 to 1 5 mm target 1 0 mm and then tighten the scr...

Page 25: ...d For adjustment in the vertical direction make the adjustment so that the clearance between the Y MSW bracket mounted on the X frame end L and sensor surface is 0 8 to 1 5 mm target 1 0 mm and then t...

Page 26: ...een replaced is turned ON 3 Move the newly mounted Y axis home position sensor from the front side toward the far side and secure it temporarily at a position where the sensor is turned ON 4 Select th...

Page 27: ...detach the cable clamp X 3 Open the flap of the X axis plastic rail to remove the cables and replace the X axis plastic rail 4 Reassemble the components in the reverse order of disassembly At this ti...

Page 28: ...2 Loosen the SL6061092TN and detach the cable clamps YU and UB 3 Open the flap of the Y axis plastic rail to remove the cables and replace the X axis plastic rail 4 Reassemble the components in the re...

Page 29: ...050R 2055R KE 2060R Maintenance Manual 1 21 1 8 Replacing the Cables in the X Y Cable Bearers 1 8 1 Removing the X Cable 1 Detach the head cover Then cut and remove the tie up band Figure 1 8 1 1 Figu...

Page 30: ...e the tie up band FC case cover Figure 1 8 1 3 3 Cut and remove the X axis frame side plastic rail bracket A of X axis plastic rail the cable clamp X and the tie up band Plastic rail bracket A Cable c...

Page 31: ...e side 750mm from the end of CN218 of the 40002233 cables d Place white marks at a position on the side and the horizontal direction 945 5 0mm from the position marked in Step c e Place a white mark a...

Page 32: ...ce the cables in the X axis cable bearer as shown in the figure below a figure viewed from A Rev 2 00 Figure 1 8 3 1 Check the connector orientation and take care so that the air tubes do not become w...

Page 33: ...stic rail Press in the cables by hand and check that they yield Figure 1 8 3 4 c For the upper head side align the marking positions of 40002233 and 40002234 cables with the end on the head side of th...

Page 34: ...es 1 Separate the fusion bonded parts of the cables with a cutter so that the 40002233 and 40002234 cables can be bent to the Y axis bear cables at an angle of 90 degrees Incise with a cutter At this...

Page 35: ...s cable bearer and the relay connector Figure 1 8 5 1 2 Detach the cover of the Y cable bearer and remove the cable to be replaced Figure 1 8 5 2 1 8 6 Placing Marks on the Y Cable Bearer 1 Place mark...

Page 36: ...1 Equate the lengths of the swing part relay connectors for 40002234 and 40002232 Figure 18 8 2 Then fix them with the cable clamp YB Fix with the cable clamp YB so that the cables do not stand out C...

Page 37: ...ks on the sides of 40002234 and 40002233 cables aligning with the marking of 40002232 cables Rev 2 00 40002232 535mm Fix at the marking position Align with the marking of 40002232 and place a mark on...

Page 38: ...ce Manual 1 30 5 Assemble the Y axis cable bearer At this time grease the portion of cables which is included in the cable bearer Figure 1 8 7 5 6 Bind the lower part of the X axis as shown in the fig...

Page 39: ...KE 2060 KE 2050R 2055R KE 2060R Maintenance Manual 1 31 7 Wiring of the XL motor Figure 1 8 7 8 8 Wiring of the XL motor relay line limit sensor relay line and YL magnescale relay line Figure 1 8 7 9...

Page 40: ...f 40002232 cables Pull the 40002232 cables in the direction of c once and check that the marking is located about 10mm outside the CB angle end surface Then press in the cables up to the position of e...

Page 41: ...Z and connectors of the motor starting from the left in the order of CN209 CN210 CN216 Plug into the connector bracket 50 from bottom to top Clamp the cables on the board in a bundle within 50mm of t...

Page 42: ...m to top To FMLA Z sensor To MNLA Z sensor See the figure below See the figure below To the OCC relay board Clamp the cables on the board in a bundle within 50mm of the connector Clamp the cables on t...

Page 43: ...oute the cable connected to the head main board so that it does not stand out OCC relay power cable for KE2060 2060R only BAD MARK sensor optional Route the cable so that it does not stand out Figure...

Page 44: ...Figure 2 1 3 c d f e 5 Keep all the d e and f on the left side of the head See Figure 2 1 4 6 Remove the air tube from the half union See Figure 2 1 5 7 Disconnect the connector of the Z sensor cable...

Page 45: ...These shims are used to adjust the deviation in position between the left and right heads in the Y direction Even if you remount the head which has been detached or mount another new head use the sam...

Page 46: ...ot fall down remove the SEMS cap bolts 4 pcs See Figure 2 1 10 5 Pull out the parallel pin at the top of the head from the head plate Then raise the head to detach it so that it is not in contact with...

Page 47: ...attach the jig nozzle to the L1 head and operate the Z axis with the HOD to set it to the DOWN height g Set the dial gauge on the bank and operate the XY axis of the head with the HOD to make it in c...

Page 48: ...xis is operated using the HOD with the rotation center Y kept to rotate the jig nozzle a position where the needle on the dial gauge shows the center of the deflection is determined to the rotation ce...

Page 49: ...ction 2 1 1 and keep d and e on the left side of the head 2 Detach the motor cover l Four mounting screws Cut four tie up bands 3 Remove the Z motor mounting screws 11 4 pcs and slide the motor in the...

Page 50: ...d tighten them with a tightening torque of 2 3 Nm When tightening the setscrew of the Z motor pulley make sure to align the orientation of the flat part of the Z motor shaft and the setscrew of the pu...

Page 51: ...1 and keep d and e on the left side of the head 2 Carry out the step 2 in section 2 2 1 and detach the motor cover Rev 2 00 12 3 Remove the motor mounting screws l 4 pcs and slide the motor to loosen...

Page 52: ...is within the proper tension range 8 1 N e After the tension has been adjusted remove the adjustment screw Apply Loctite 242 to the motor mounting screws 12 4 pcs and tighten them with a tightening to...

Page 53: ...the steps 1 through 3 in section 2 1 1 and keep d and e on the left side of the head 2 Remove the ICZ motor mounting screws 13 4 pcs and slide the motor to loosen the belt 3 Cut the tie up band fixin...

Page 54: ...otor should be located on the left side when viewed from the front Distance between the axes 45 When tightening the setscrew of the ICZ motor pulley make sure to align the orientation of the flat part...

Page 55: ...s 3 Remove the mounting screws 14 4 pcs of the ball screw 4 Remove the mounting screws 15 4 pcs of the IC motor 5 Remove the Z sensor dog IC 16 half union 17 and the nozzle outer shaft IC from the det...

Page 56: ...sensor e With the ICZ motor and head up SPIC not mounted check using a spring scale that the Z sensor dog slides at 0 75kg Apply Loctite 242 to the IC motor mounting screws After tighten the half uni...

Page 57: ...ase downward 3 Cut the tie up band to replace the Z sensor 4 Reassemble the components in the reverse order of disassembly Figure 2 3 1 5 Check following the procedure below and make adjustments if ne...

Page 58: ...2 4 and 7 in the section 2 1 2 2 Remove the Z sensor base IC mounting screws 19 2 pcs and detach the Z sensor base IC downward 3 Cut the tie up band to replace the Z sensor 4 Reassemble the component...

Page 59: ...ctor and the mounting screws 20 3 locations to detach the MNLA 2 Before mounting the components remove Loctite sticking to the sensor bracket as much as possible Reassemble the components in the rever...

Page 60: ...e 3 pcs from the sensor 2 Remove the sensor mounting screws f 4 pcs to detach the sensor 3 Reassemble the components in the reverse order of disassembly Rev 2 00 4 When attaching the diffuser base mak...

Page 61: ...lace the head up SP g Replacing the head up SP2 Note This replacement is applicable only to the machines shipped in the first term 1 Loosen the set collar mounting screws h 2 pcs to detach the set col...

Page 62: ...KE 2050 KE 2060 KE 2050R 2055R KE 2060R Maintenance Manual 2 19 2 5 2 FMLA Head Remove the head up SPIC j from the Z sensor dog to replace it Figure 2 5 3 Rev 2 00...

Page 63: ...orque of 2 3 Nm Adjust the belt tension following section 2 2 1 Z motor on page 2 7 Replacing the timing belt After the timing belt has been replaced it is absolutely necessary to re input the MS para...

Page 64: ...d to the Z axis home position adjustment Z axis height and laser For details of input items see section 2 9 1 Loosen the timing belt ICZ 11 following the steps 1 and 2 in section 2 2 3 Rev 2 00 2 Appl...

Page 65: ...0 Remove the bearing plate 14 and pull out the spline housing downward 11 Reassemble the components in the reverse order of disassembly 12 While replacing check that the thrust rubber protrudes 50 m f...

Page 66: ...Attach the jig nozzle to the head d Place a dial gauge over the jig nozzle and check that the run out of the nozzle outer shaft is within 0 02 mm If the run out is 0 02 mm or more move the screw posit...

Page 67: ...bly Note 1 Note 1 Note 2 Note 2 Z motor motor Note 1 Note 1 Note 1 Note 1 Note 2 Note 2 Z sensor Laser sensor Note 1 Head up SP2 Timing belt Z Timing belt S housing assembly Nozzle outer shaft Note 1...

Page 68: ...ctions After the ejector unit has been replaced turn on and off the manual control head vacuum blow to check that the ejector unit functions correctly Note Carefully disassemble the unit so that oil s...

Page 69: ...the distance between the surface of the bad mark sensor and the top surface of the calibration block becomes 28 mm When the specified distance is reached secure the bad mark sensor with SEMS cap bolts...

Page 70: ...er Unit to the Amplifier Make the projection on the fiber unit facing toward a position where the LED does not exist on the amplifier and insert it completely until it is in contact with the far side...

Page 71: ...itches on the Bad Mark Sensor Assembly Use the bad mark sensor assembly with the settings made before shipment from the factory default settings Output timer selector switch NORMAL Operation mode sele...

Page 72: ...m top to bottom For the machine with the component height of 06 mm For the machine with the component height of 12 mm For the machine with the component height of 20 mm Figure 3 3 1 Replacing the HMS...

Page 73: ...3 3 3 Replacing the Amplifier Left label right label stuck 3 3 4 Mounting the Board To mount the height sensor board 2 assembly insert the connector into the head main board completely and press the H...

Page 74: ...ark sensor with SEMS cap bolts CAL FAR NEAR Rev 2 00 After the sensor height has been adjusted input the MS parameters related to the bad mark sensor offset For details about how to input MS parameter...

Page 75: ...t voltages c Attach the 503 nozzle to the axis to be adjusted and turn the vacuum on d Measure the voltage Vvac between the TP 1 GND and external input check terminals with a voltmeter and then record...

Page 76: ...board Rev 2 00 Figure 3 4 2 Replacing the OCC Relay Board Assembly 3 4 3 Replacing the Sensor Relay Board Assembly Figure 3 4 3 Replacing the Head Sensor Board Assembly Top KE 2050 50R 55R bottom KE...

Page 77: ...head cap bolts e Disconnect the connectors and remove relevant bolts to detach the camera and light assemblies 3 Reassemble the components in the reverse order of disassembly 4 After the camera assemb...

Page 78: ...from the shims A to D so that no load is applied to the lens 4 After the CCD camera and lens have been replaced adjust the focus and input the MS parameters See 4 8 List of Readjustment Items After R...

Page 79: ...bly 3 Remove the washer assembled hexagon socket head cap bolt d to detach the OCC angle light board assembly 4 Reassemble the components in the reverse order of disassembly 5 After replacement it is...

Page 80: ...support lens filter and guide plate 3 Remove the countersunk head screws to detach the lens filter 4 Reassemble the components in the reverse order of disassembly 5 After the filter has been replaced...

Page 81: ...hen the screen is at the brightest level 3 In the brightest status re stick the OCC light label as shown in the figure below Slit Figure 4 4 2 Filter Adjusting Position and Sticking the Light Label No...

Page 82: ...rly visible see the figure below secure the camera in position When the polarizing filter is adjusted to the scale 0 dark position the line can be seen easily After the adjustment has been completed r...

Page 83: ...0 4 6 Adjusting the OCC Light Quantity Procedure c Check that the OCC light goes on with manual control d Carry out Adjustment of OCC Light in the MS parameters See the section related to OCC light qu...

Page 84: ...djust both the Offset Placement After Solder Screen Printing light and the OCC light See 4 8 List of Readjustment Items After Replacement Prism base Board spacer x 4 Low head cap screw M3 x 10 x 4 Boa...

Page 85: ...rd assembly Lens filter Focus adjustment Filter adjustment Adjustment of OCC Light Note OCC offset Note Origin rough adjustment Note Head offset Note BMR offset Note HMS offset Note Overall mounting o...

Page 86: ...on exerted and adjust the position of the transport pulley along the slot so that the belt length increases by 0 5 To carry out the adjustment use a pencil or similar tool to put two marks on the belt...

Page 87: ...tation or incorrect alignment of the transport belt resulting in wear on the belt Always refer to relevant mounting procedure when mounting the transport pulley 5 2 1 Transport Pulley A Assembly E2111...

Page 88: ...ay cable 2 Loosen the screws fixing the motor bracket A to detach the drive belt from the motor pulley A 3 Detach the motor and gear head 4 If you have detached the motor pulley A from the gear head i...

Page 89: ...e motors to the rail stand Note Belt tension is stretched excessively Torque of the drive shaft increases Note Belt tension is loosened excessively Teeth on the timing pulley are skipped Noise is prod...

Page 90: ...ure Loosen the screw of the motor bracket C and move the motor bracket to the left and right Loosen the motor fixing screw and move the CENTER motor up and down Adjust the belt tension as described at...

Page 91: ...4031291SC SCREW EA9500B0000 CABLE_BAND Adjusting the sensitivity Make an adjustment so that a matte black glass epoxy PWB placed on the transport path can be detected Place a matte black glass epoxy P...

Page 92: ...order of step 3 to 1 5 Adjust so that the fiber extrudes beyond the WAIT sensor block as follows Dimension A M size A 10 mm L size A 9 mm In addition in the case of L size specification adjustment mu...

Page 93: ...unit insert a screwdriver into the groove of the part C and raise the amplifier unit while pulling it backward 5 6 2 3 How to adjust the gain of the amplifier unit After the WAIT sensor has been repl...

Page 94: ...ase of L size For your reference the distance from STOP sensor ON to the stopper end will be 28 8 mm when the solenoid valve is turned ON manually and a PCB is placed in the transport path 3 Carefully...

Page 95: ...he stopper frame and moves smoothly Also make sure that the distance from the end of the cylinder to the end of the stopper connector is as shown in the figure below 5 Adjust the opening of the speed...

Page 96: ...port Table Home Position Sensor BU Home Position Sensor 1 Detach the sensor from the sensor bracket 2 Adjust the distance between the sensor and sensor dog to 1 mm Figure 5 9 1 BU sensor bracket E4115...

Page 97: ...reassembling the components adjust the position of the sensor bracket by loosening the adjustment screw and moving the sensor bracket up and down so that the T PIN sensor is turned ON when the center...

Page 98: ...0 1mm when the Y pusher is ON extruded and distance A is 0 5 mm 0 1mm when the Y pusher is OFF not extruded See Figure 5 11 2 Adjust so that the gap C between the Y pusher and transport belt is 0 2 mm...

Page 99: ...ion where the pusher X 30 moves vertically with the air supplied to the cylinder 4 After the components have been reassembled supply the air 0 37 MPa to check that the pusher Y cylinder functions corr...

Page 100: ...the components in the reverse order The E rings must also be replaced with new ones After the components have been reassembled adjust the sensor position in the same manner as described in 5 10 Replac...

Page 101: ...ble motor assembly together with the torque supporter assembly 3 Loosen the screw to detach the torque supporter assembly from the support table motor assembly 4 When installing a new BU motor reassem...

Page 102: ...rter assembly and move the assembly in the arrow direction input the said values to the sonic belt tension meter manufactured by UNITTA measure the tension at the locations shown below and then adjust...

Page 103: ...2 Determine the lowest measurement point of four measurement points to the reference point Based on this reference point turn the adjustment screw in the down direction screw tightening direction to...

Page 104: ...he timing belt 3 Loosen the screw to detach the encoder bracket assembly 4 Loosen the SEMS cap bolt SL6030692TN 5 Loosen the encoder s screw the setscrew supplied with the encoder and fixing screw to...

Page 105: ...back from the fully closed position and secure it Adjustment Method 1 With air ON loosen the screw on the BU stopper bracket Loosen the air cylinder fixing screw and adjust the position of the air cy...

Page 106: ...anual 5 21 Rev 2 00 In the case of EN type a solenoid valve PV150209000 is provided in addition to those provided as the standard specifications VCS VCS SHAPE X SHAPE Y Standard type EN type Standard...

Page 107: ...o bounded cables c from the board 2 Disconnect the air tube d from the elbow union 3 Remove the four M3 SEMS bolts e pull the board downward from the CAL side cover and remove it from the 4 air tube T...

Page 108: ...Ejector 1 Remove the two SEMS bolts c 2 Disconnect the cable d 3 Disconnect the air tube e 4 Remove the screws and replace the ejector f with a new one 5 Reassemble the components in the reverse order...

Page 109: ...obtain ATC Offset of the MS parameters See also section 4 7 in the MS parameters 7 1 Replacing the Air Cylinder 1 Close the hand valve at the lower left portion of the main unit 2 Remove the ATC join...

Page 110: ...n visually adjust the position so that the hole on the ATC base matches the center of the arc of the slide plate then fit the nut supplied with the ATC cylinder to the ATC joint At this time apply Loc...

Page 111: ...OSE sensor is turned ON Note 1 After the position has been adjusted tighten the hexagon socket head bolt with a nut Note 2 The nut must be tightened with a torque of 1 3N m Rev 2 00 Hexagon socket hea...

Page 112: ...ing band OPEN sensor CLOSE sensor Figure 7 2 1 OPEN and CLOSE Sensors 7 3 Adjusting the Speed Controller 1 Rotate the knob of the speed controller to adjust the opening closing time of the slide plate...

Page 113: ...V before and after the cover 2 Detach the cable clamp d on the rear and disconnect the power cable of the light unit Additionally if the machine is equipped with the optional VCS disconnect the pipin...

Page 114: ...order of steps described above return the camera and light unit to their previous positions and then adjust the focus For focus adjustment refer to Camera focus offset of the MS parameters CCD camera...

Page 115: ...the distance between the left 2 falls at the position of 7 mm when the cylinder is 1 Assemble the VCS sensor or the o end surface of the air cylinder and the front end surface of the sensor is 17 5 m...

Page 116: ...t Board 1 In the case of the coaxial light board detach the cylinder remove the bolts c and then replace the board 2 In the case of the transmission light board remove the SEMS bolts d and then replac...

Page 117: ...he board has been replaced make sure the cables are reconnected 1 In the case of the side light board remove the SEMS bolts 2 In the case of the downward light board remove the side light board first...

Page 118: ...ACEMENT TABLE OPTIONAL 9 1 Overall Drawing 4 R 0000576 Rev 2 00 R 40000590 d c d c E2506729000 L 40000588 L 40000575 Drive cylinder L 40000575 Driver bracket E2506729000 Bank lifter L 40000588 Drive c...

Page 119: ...levers to move the lifter up When the lifter is moved up shut down the main compressed air 3 Disconnect the left and right air tubes c and connectors d 4 Remove the driver bracket support mounting scr...

Page 120: ...o gap between them See Figure 9 2 3 Carefully mount the drive cylinders in the vertical direction by placing the driver support against the rib of the main unit so that there is no gap between the top...

Page 121: ...and turn on the power 4 Using the IO manual control operate all drive cylinders continuously the speed controller of which needs to be adjusted 5 Adjust the speed controller of the cylinder to be adju...

Page 122: ...Disconnect the connectors from the feeder bank board and feeder I F board 4 To detach the feeder bank board remove eight round head screws To detach the feeder I F board remove four nuts After releva...

Page 123: ...ive cylinder assembly mounting screws 6 Pull out the bank lifter upward Bank lifter to be replaced 7 Remove four bank up cylinder mounting screws to detach the cylinder 8 Mount the speed controller on...

Page 124: ...oo fast turn the speed controller adjustment screw clockwise DOWN speed To be adjusted by the lower speed controller If the down speed of the left cylinder is too fast turn the speed controller adjust...

Page 125: ...he power to the main unit 2 Lower the lifter 3 Loosen the fixing screws remove the sensor and replace it with a new one 4 Reassemble the components in the reverse order of disassembly Adjustment c Tur...

Page 126: ...rclockwise to detach the selector switch from the cover 3 Mount the half union and silencer on a new selector switch and secure the selector switch to the cover with the cap 4 Supply the main compress...

Page 127: ...efore replacing the roller lever always shut down the main compressed air Bank valve R assembly Bank valve bracket E2631729000 Valve nut plate E2811729000 Silencer PX050501000 Elbow union PJ304040505...

Page 128: ...Assembly 1 Detach the pressure gauge from the cover FB 2 Disconnect the connector 3 Reassemble the components in the reverse order of disassembly CAUTION Before replacing the pressure detection cable...

Page 129: ...to detach it 3 When replacing the filter element A on the mist separator side turn the filter element A counterclockwise to detach it 4 Reassemble the components in the reverse order of disassembly C...

Page 130: ...tart switch e On line switch f Origin switch g Stop switch h Single cycle switch i Feeder switch j Keyboard setting switch 1 Detach the PWB cover on the front of the machine 2 Detach the operation boa...

Page 131: ...g the EMERGENCY STOP Switch 1 Remove the knobs c and d to detach the EMERGENCY STOP switch from the back of the cover 1 2 Rev 1 00 2 Disconnect the cables from the rear of the switch with a screwdrive...

Page 132: ...nts in the reverse order of disassembly Rev 1 00 Right side view Front view Left side view Front view No Part No Part name Qty c 40001402 Cover FUR 1 d 40001453 Safety switch bracket 1 e NM3040520SF F...

Page 133: ...ce Manual 11 4 11 3 2 Operation Key 1 Remove two mounting screws to replace the operation key Note The operation key must be mounted in the specified orientation Mount to face inside the machine Mount...

Page 134: ...o be replaced from the operation switch board 3 To detach the switch remove the root part mounting nut of the switch from the back of the cover and pull out the case from the cover surface 4 Reassembl...

Page 135: ...FEEDER FLOAT SENSOR 1 Check the position of a sensor to be replaced in the machine while referring to the figure below and detach the sensor together with the bracket c Left side FSD bracket assembly...

Page 136: ...side M size machine FSD bracket assembly Rear right portion FSD bracket assembly Front right portion FS bracket assembly Right L size machine FSD bracket assembly Front right portion FSD bracket asse...

Page 137: ...SD bracket Confirmation LED side Confirmation LED side Feeder float sensor FF light emission assembly Feeder float sensor FR light receiving assembly Figure 12 3 d FSD bracket assembly front right por...

Page 138: ...nfirmation LED side Figure 12 5 Rev 2 00 f FSD bracket assembly rear right portion Feeder float sensor RF light emission assembly Feeder float sensor RR light receiving assembly FSD bracket Confirmati...

Page 139: ...of the top surface of the FSD bracket to 127 5 mm from the top surface of the feeder bank and secure it 0 3 0 0 However adjust the height of the FSD bracket with a set of left and right sensors light...

Page 140: ...0 1 mm or less Rev 2 00 FS bracket Top surface of bank 4 Adjust the light axis c Connect the connectors of the sensors to their specified positions and turn on the power to the main unit d Move the li...

Page 141: ...units are used for adjustment of the feeder float sensor on the transport side NF16 NF12 NF24 NF12N NF16N or NF24N is also accepted NF32 feeder NF323S NF324S or NF32FS is also accepted Bulk feeder BF...

Page 142: ...de Light receiving Light emission Move the sensor back and forth 4 If the sensor mounting position is changed in work step 3 adjust the light axis and perform the adjustment again from step 1 The abov...

Page 143: ...lamp does not light up correctly turn the volume to make the green lamp lit 4 Set the NF32 feeder at the same positions as described in step 3 and open the top cover by hand to check that the sensor...

Page 144: ...e CRT Vision Monitor 1 Disconnect the monitor power cable and detach the vision monitor Vision monitor 2 Disconnect the image monitor cable from the rear of the monitor head 3 Lower the hook on the ba...

Page 145: ...rom the FDD 3 Remove four screws at the lower portion of the FDD to detach the FDD from the FDD support 4 Remove two screws on both sides of the FDD to detach the FDD face plate from the FDD 5 Reassem...

Page 146: ...frame 2 Remove the screws of the flat cable clamp to detach it from the CD ROM bracket 3 Remove the screws of the CD ROM drive to detach the drive from the CD ROM bracket 4 Reassemble the components i...

Page 147: ...and thumbscrews and to detach the LCD bracket F from the LCD bracket R 2 Remove the SEMS cap bolts to detach the LCD bracket F from the LCD monitor 3 Reassemble the components in the reverse order of...

Page 148: ...able Handling of the LCD Since the set especially the LCD module in it uses glass and fine wiring components it may crack or chip or the inside wires may break if you drop it hit it against a solid ob...

Page 149: ...f the KE 2050R 2055R 2060R 1 Disconnect the connecting cables Disconnect the cables for signals power supply and RS 232C connected to the set 2 Detach the rear panel and the rear cover Remove the nine...

Page 150: ...Only for the front monitor of a machine with coplanarity option Remove the four screws 2 fixing the front bracket and the LCD module Disconnect the cable for LCD from the connector CN302 on the main b...

Page 151: ...re backlight unit in a position where the seven locking lugs are properly aligned i e a position reached by sliding in the direction indicated by the arrow A Tightening torque for the lamp replacement...

Page 152: ...break it Applying the power to a broken cable may cause smoke or fire Step Press down the lug for fixing the backlight tube in the direction indicated by the arrow Step While executing Step pull out t...

Page 153: ...ications are different It is 40025669 standard LCD 40028131 an analog LCD for coplanarity This section describes the connection in two cases one with the optional coplanarity used together and the oth...

Page 154: ...2 R VIDEO R LCD RS 232C F VIDEO F LCD RS 232C RS 2 EXT 1 RS 1 CN720 CHG 4P CHG 4P A CHG 4P B KB MOUSE RS PC EX RS1 RS2 MS2 KB2 KB1 MS1 KB MS 40003296 40003308 40002263 40002260 40002302 40002301 40002...

Page 155: ...232C RS 2 EXT1 RS 1 CN720 CHG 4P CHG 4P A CHG 4P B KB MOUSE RS PC EX RS1 RS2 MS2 KB2 KB1 MS1 KB MS 400032 40002263 40002302 40002301 40002303 40002304 40027815 RS CN2 RS A RS B 40026196 40026414 CN2...

Page 156: ...13 5 1 1 HDD Part No Machine model Language OS Part name Par No Japanese WindowsNT KE2050 60 HD assembly ST 40002933 English WindowsNT KE2050 60 HD assembly JE 40002937 WindowsNT KE2050 60 HD assembly...

Page 157: ...he HDD studs 12 3 Remove the screws to 11 to detach the HDD from the HDD support 4 Detach the rubber caps from the HDD 5 Reassemble the components in the reverse order of disassembly HDD cover 1 Screw...

Page 158: ...the CPU board 13 5 3 1 Checking the Recognition of the HDD You may check whether or not the BIOS recognizes the HDD correctly If no startable HDD or FDD is found after memory check a message like the...

Page 159: ...are to be searched The screen shows the default settings Switch the setting to the following Boot 1st Drive A Boot 1ST Drive C Boot 2nd Drive C Boot 2nd Drive A 4 Changing Memory Test Tick setting By...

Page 160: ...owing screen The screen shows the default settings 7 Changing IDE 1 MOTOR OFF TIME setting Locate the cursor to IDE 1 MOTOR OFF TIME using arrow keys and switch Disable to 30 min using the PgUp PgDn a...

Page 161: ...e network to perform the communication between the KE2000 series and HLC You must always set up the network to use the HLC in the on line mode Setting procedures Setting up the TCP IP Setting up a sha...

Page 162: ...KE 2050 KE 2060 KE 2050R 2055R KE 2060R Maintenance Manual 13 19 3 Select the Protocol tag and click the Add button 4 Select TCP IP Protocol and click the OK button Rev 2 00...

Page 163: ...ance Manual 13 20 5 The following message will appear Select the No button 6 The Windows NT Setup screen will appear Input C WinNT Options Cab i386 and select the Continue button 7 The TCP IP protocol...

Page 164: ...p you must follow the instructions given by the network administrator of your company If no rules are specified set an IP address which has not been set in other KE2000 connected to the HLC In this de...

Page 165: ...KE 2050 KE 2060 KE 2050R 2055R KE 2060R Maintenance Manual 13 22 10 The message prompting you to restart the computer will appear Select the No button to continue the process Rev 2 00...

Page 166: ...KE 2050 KE 2060 KE 2050R 2055R KE 2060R Maintenance Manual 13 23 For Windows XP 2 Select the Network icon from the control panel 3 The Network connection dialog box appears on the screen Rev 2 00...

Page 167: ...l Area Connection icon on the dialog box and then click the Properties command with the right button to select it 5 The LOCAL Area Connection Properties dialog box appears on the screen Select the Int...

Page 168: ...about IP address setup you must follow the instructions given by the network administrator of your company If no rules are specified set an IP address which has not been set in other KE2000 connected...

Page 169: ...a folder named C machine Prg under the C drive and make this Prg folder shared For Windows NT 1 Start up Explorer Rev 2 00 2 Select the C drive From the File menu select New and then Folder 3 Input m...

Page 170: ...select Sharing 6 Select the Sharing tag check on Shared As and input Prg to the Share Name field Note Set up a shared folder so that the shared folder name prg is not duplicated in the computer If a s...

Page 171: ...3 28 7 Select the Permissions button The Access Through Share Permissions screen will appear Check that Everyone is set at Full Control If this setting is not made press the Add button and set Everyon...

Page 172: ...p Explorer 2 Select the drive C and select the commands from the menu bar File New and Folder commands 3 Enter Machine as the folder name 4 The folder named machine is then created under the C drive I...

Page 173: ...ect the Share this folder radio button to check to see if Prg is entered as the Share Name If Prg is not entered in the Shared Name field change the entered name to Prg If any name is not entered sele...

Page 174: ...e Permissions for prg dialog box Check to see if Everyone is set to Full Control by checking its check box Note Full Control is allowed for the access privilege described above by default when the net...

Page 175: ...and then select Programs Administrative Tools Common and User Manager in that order 3 The User Manager screen will appear Select New User from the User menu 4 The New User setup screen will appear In...

Page 176: ...2050R 2055R KE 2060R Maintenance Manual 13 33 For Windows XP 2 Select the User accounts icon form the control panel 3 The User accounts dialog box appears on the screen Select Create a new account fro...

Page 177: ...a new account the screen that allows you to set a user name appears on the screen Enter a user name and click the Next button 5 The screen that allows you to set the user type appears on the screen Se...

Page 178: ...060 KE 2050R 2055R KE 2060R Maintenance Manual 13 35 6 Select the user account you set 7 The screen that allows you to change the account settings appears on the screen Select the item Create a passwo...

Page 179: ...8 The password creating screen appears Be sure to enter the same password in both Type a new Password and Type the new Password again to confirm fields and click the Create password button After you f...

Page 180: ...system disks and FlexlineDB system disks You must always install the KE2000 main unit system disks and FlexlineDB system disks in that order 13 5 5 1 Installing the KE2000 Main Unit System Disks 1 Po...

Page 181: ...000 Series upgrade only all models Select this item when upgrading the version KE20X0 Full installation Select this item when installing the KE20X0 system newly Therefore select KE20X0 Full installati...

Page 182: ...d select the Next button to complete the tup W ap se The necessary FD may vary depending on the machine model Therefore all FDs may not be used during installation 13 5 5 2 Installing the FlexlineDB S...

Page 183: ...completely the following message Setup Needs the Next Disk will appear Insert the 2nd FD into the FDD and click the OK button 5 When each FD has been installed the same message will appear Follow the...

Page 184: ...ile and Control Date Management to restore the control data in the HDD For the detailed procedure of restoration see Section 13 3 Control Data Management in the Instruction Manual If there is no backu...

Page 185: ...feeder board IO control board and laser board 13 5 6 hanging the Windows NT Product ID C If this process is not performed the customer using the KE2000 series may infringe the copyright law To avoid...

Page 186: ...t ID of Windows NT is described on the paper shown in the figure above or around the non fuse breaker on the right side of the main unit 4 Select the OK button The following Save confirmation screen w...

Page 187: ...replaced it is required to set up the touch panel 1 For KE 2050 60 Win NT 1 Run apci 8302 6J COM in the Control Panel window 2 Set up the COM device for each apci 8302 6J COM channel and the line con...

Page 188: ...ngs are correct z Device Name COM Device No 3 Device Name COM3 z Communication Line Controls Baud Rate 9600 Character bits 8 Stop Bits 1 Parity NONE Rx Fifo Trigger 1 5 Run Device in the Control Panel...

Page 189: ...Manual 13 46 7 Check on System in the Startup Type area and click the OK button 8 Select acpi8302c in the Device area and click the HW Profiles button 9 Click the Enable button to make the device sta...

Page 190: ...enance Manual 13 47 10 Click the Close button to close the Devices window After that close also the Control Panel window 11 Create a shortcut of TP_R_Driver 12 Change the name of TP_R_Driver located u...

Page 191: ...R KE 2060R Maintenance Manual 13 48 13 Cut the shortcut of the touch panel and paste it in C Winnt Profiles All Users Start Menu Programs Startup 14 To check that the setup has been performed correctl...

Page 192: ...Double click UPSilon_2000 to check that UPSilon_2000 monitors the power supply correctly If the UPS is not connected correctly it is thought that the setup is incorrect In this case read Actions to b...

Page 193: ...17 Check that the settings of COM3 are those shown below Additionally check that the Advanced button is disabled If the following settings are not set the setup may be incorrect In this case read Act...

Page 194: ...y Touch 20 Touch the Setup button 21 Check that the settings are those shown below If the settings are incorrect change the settings to those shown below and touch the Exit OK button After the window...

Page 195: ...K button to return to the Touch Panel Drivers window Touch the Calibration button 23 When touching the Start button the FirstPoint mark will appear Touch the center of the mark precisely 24 Subsequent...

Page 196: ...ellow mark will appear at the position you have touched Check whether or not the position is correct If the position is incorrect touch the Start button again to restart the calibration After the setu...

Page 197: ...the touch panel does not function Shut down the system and restart it 3 Is the Startup setting of the control panel set at System If any setting other than System is specified the COM port assignment...

Page 198: ...the Device window Click the Disable button and change Status to Disable When the status has been changed click the OK button to close the Device window Click the Close button to close the Devices wind...

Page 199: ...ofiles All User Start Menu Programs Startup delete only the shortcut of the touch panel Never delete other shortcuts 5 1 Right click Start to select Find Set C Drive in the Find location to find the f...

Page 200: ...ese KE2050 60 XP specifications 1 Click the system tray icon at the lower right portion of the desktop and select Adjust settings to start it up Figure 13 3 1 1 System Tray 2 When started up the windo...

Page 201: ...row mark will appear at other location In the same manner touch the top end of this arrow mark by your finger Touch the top end of this arrow mark by your finger Figure 13 3 1 3 Calibration Screen 4 A...

Page 202: ...1 axis SAFETY board Base Feeder board I O control board LIGHT CTRL board IP X3 board c PCI Board VME Back Board CTRL PWR board Optional boards Verify board RS 232C expansion board Circuit breaker 13...

Page 203: ...2 1 Part Names c ATC unit sensor relay board d CAL block board e XL axis motor f XR axis motor g Backup motor h Center motor i IN OUT motor j IN OUT motor k YL motor l YR motor 11 CARRY board 12 BANK...

Page 204: ...ng of feeder stacking 32mm paper tape and changing of rear monitor 14 3 1 1 Adjusting Method of DC Power Source Voltage Level No Power specification Power symbol Measuring terminal of CN019 of power s...

Page 205: ...KE 2050 KE 2060 KE 2050R 2055R KE 2060R Maintenance Manual 14 4 14 3 1 2 Block Diagram of the DC Power Supply Unit Figure 14 3 1 1 Block Diagram of the DC Power Supply Unit Rev 2 00...

Page 206: ...V 50 W 1 PS4 12V 14 HX00494000A Power supply 3 3 V 50 W 1 PS5 15 KX000000150 Power supply 6 V 75 W 1 PS6 16 HX005420000 Power supply 12 V 100 W 1 PS7 12V 17 HB001100000 Power relay 1 RL1 ST specificat...

Page 207: ...1 C ACL1 C CP 40A CP3 15A 1 2 CP1 30A FAN 4 3 2 1 10A CP4 TF1 SAFETY UNIT TF1 34 RL1 POWER UNIT INSIDE A1 A2 RL2 43 44 TB1 4 3 2 1 4 1 8 0 2 6 48UNRTN A 9 3 4 SVON11 24VRTN 1 2 SVON 24VRTN 48UNR B 48U...

Page 208: ...PS7 12V 8 4A PS5 3 3V 10A AC N AC L 4 GND A 3 2 GND A GND A TB3 3 4 5 5V 5VR 5VR V V V OUT IN 30A CP6 PS2 5V 30A V 1 GND B 3 3V 1 24VSRTN 4 2 24VS POWER PCB 2 2 TB2 3 3 CN034 1 7 8 24V 3 CP9 8A IN OU...

Page 209: ...KE 2050 KE 2060 KE 2050R 2055R KE 2060R Maintenance Manual 14 8 Figure 14 3 1 4 Connection Diagram for the Z Power Supply Board Rev 2 00...

Page 210: ...EXCHANGE TROLLEY OLD OVERALL EXCHANGE TROLLEY SPARE YELLOW Z DRIVER 1 2 CONTROL UNIT FRONT COPLA SENSOR TRANSPORT CENTER MOTOR BOARD REAR MONITOR CONTROL UNIT OVERALL EXCHANGE TROLLEY OLD OVERALL EXC...

Page 211: ...anual 14 10 BLUE CONTROL UNIT BLUE SAFETY UNIT 24 V POWER SUPPLY OUTPUT CONTROL Z POWER SUPPLY CONTROL SAFETY UNIT YELLOW XY TRANSPORT POWER SUPPLY CONTROL BLUE FROM CONTROL UNIT Figure 14 3 1 6 Conne...

Page 212: ...8 SAFETY BOARD ASSY 40001924 LIGHT CTRL BOARD ASSY 50 40001918 Note1 BASE FEEDER BOARD ASSY 40001941 II O CTRL BOARD ASSY 40001943 IIP X3 BOARD ASSY 40001920 Note1 MCM MNLA E9609729000 VERIFY B E86717...

Page 213: ...920 Note 1 MCM MNLA E9609729000 MCM FMLA E9610729000 VERIFY B E86717290B0 CVS 40003313 XMP CPCI 40003259 CPU 40003280 40003281 CVS E9701705000 RS232C CHANGE PCB ASM 40026382 MCM BOARD FOR MNLA E960972...

Page 214: ...D in addition to replacement of the CPU board Follow the steps stated in the Instruction Manual for Replacement of CPU Board ACP 125J ACP 128J to replace the CPU board Functions This is a circuit boar...

Page 215: ...259 SYNQNET CABLE 20 40003263 JGRMB 40003260 JHRMB 40003261 IN OUT IN OUT 1 KE 2050 2050R 2055R XMP CPCI 40003259 SYNQNET CABLE 120 40003262 SYNQNET CABLE 20 40003263 SYNQNET CABLE 120 40003262 JGRMB...

Page 216: ...exchanges the signals among the JGRMB board SAFETY board CARRY board motor drivers magnescales and limit sensors Jumper switch settings The jumper switches are as shown below Check them when you set...

Page 217: ...en setting a board in the control unit set up the dip switches as shown below 1 2 3 4 5 6 7 8 1 2 3 4 1 2 3 4 ON ON ON DS1 DS2 DS3 Meaning of LED SCON Lights up when this board is set as VMEbus contro...

Page 218: ...are provided 4 axis board for MNLA E9609729000 and 1 axis board for FMLA E9610729000 The board for MNLA can be substituted for that for FMLA Dip switch settings MCM board c for L MCM board d for R Adj...

Page 219: ...ges the signals among the sensors and solenoid valves of the board transport and the sensors and solenoid valves of the ATC g SMEMA I F circuit is mounted on this board h This board is equipped with a...

Page 220: ...P 1 5 3 W12 ALM 1 5 3 W14 SG FG 1 2 1 4 W8 3 6 2 5 1 3 2 W9 25 1 2 W3 IRQATC 13 14 1 2 W4 IRQCNV 13 14 1 3 2 W10 10 12 11 KE 2050 ST JE CH 1 2 W6 IDSEL 13 14 W5 1 3 7 9 2 indicates that a receptacle c...

Page 221: ...XMP 1 5 3 W12 ALM 1 5 3 W14 SG FG 1 2 1 4 W8 3 6 2 5 1 3 2 W9 25 1 2 W3 IRQATC 13 14 1 2 W4 IRQCNV 13 14 1 3 2 W10 10 12 11 KE 2060 ST JE CH 1 2 W6 IDSEL 13 14 W5 1 3 7 9 2 KE 2060 2060R ST JE CH ind...

Page 222: ...W11 XMP 1 5 3 W12 ALM 1 5 3 W14 SG FG 1 2 1 4 W8 3 6 2 5 1 3 2 W9 25 1 2 W3 IRQATC 13 14 1 2 W4 IRQCNV 13 14 1 3 2 W10 10 12 11 W5 1 3 7 9 2 KE 2060 EN 1 2 W6 IDSEL 13 14 KE 2050 2050R 2055R EN indica...

Page 223: ...6 W11 XMP 1 5 3 W12 ALM 1 5 3 W14 SG FG 1 2 1 4 W8 3 6 2 5 1 3 2 W9 25 1 2 W3 IRQATC 13 14 1 2 W4 IRQCNV 13 14 1 3 2 W10 10 12 11 W5 1 3 7 9 2 KE 2060 EN 1 2 W6 IDSEL 13 14 indicates that a receptacl...

Page 224: ...op switch XY axis limit sensor X STOP sensor area sensor or cover open switch CE is detected Even if this occurs the servo power supply AC200 AC48V is not turned on LED 2 Lights up if an alarm occurs...

Page 225: ...these jumper switches correctly while referring to the table below Jumper switches W3 2P Short circuit W4 2P Short circuit W6 2P Short circuit W7 2P Open W8 2P Short circuit W9 3P Short circuit 1 and...

Page 226: ...ED 3 Red Lights up if the system enters the FAIL state If the board malfunctions both LED2 and LED3 will light up Adjustment items after replacement If the version of the ROM mounted on the new board...

Page 227: ...02 Set Short circuit when the board Rev is 03 or later SW 1 8 OFF Function Rev and pattern Rev of the board are set on the SW 4 Normally do not change the switch settings The following is a sample se...

Page 228: ...pen W3 4P Open W4 2P Wholly open W5 2P Short circuit Adjustment items after replacement Adjusting the reference voltage for the LightCtrl board Specification 8VREF 8 000 V 0 005 V Adjusting Method c B...

Page 229: ...rol unit DIP SW settings for IP X3 board assembly A DIP SW settings for IP X3 board assembly B indicates the position of the switch Front panel SW RESET SW Resets this board ABORT SW Sends NMI to the...

Page 230: ...s that drive the Y axis and two AC servo drivers that drive the X axis is mounted Additionally the magnescale interpolator for the X Y axes is mounted on the left side of the control unit Capacitor bo...

Page 231: ...the X axis the LED 2 is for the Y axis The alarm description is indicated by how many times the LED blinks in red See Table 14 5 2 1 For example if the LED is blinking in such an order as green red r...

Page 232: ...he MODE switch and the OPTION switch are provided for each axis respectively on the board in the cover It is not needed to change the default settings When you check the settings see the figure below...

Page 233: ...2060R Mount a blank panel in the vacant slot in KE 2050 2050R 2055R Additionally mount a 5 phase step driver for backup HX004200000 or HX005450000 for an EN machine in the same rack Figure 14 6 1 1 s...

Page 234: ...of the front panel of the Z driver board These LEDs show the operating status of each axis as shown below The correspondence among the axes and LEDs are as follows Z1 Z2 Z3 1 Z1 Z3 Z5 2 1 3 5 3 Z2 Z4...

Page 235: ...rection L R FR Front reference transport direction R L RL Rear reference transport direction L R RR Rear reference transport direction R L The connection with the motors is as follows Motor to be conn...

Page 236: ...M EN CARRY board CN633 Add 40002120 AWC ORG SENS ASM CN445 Add 40002121 AWC ORG CABLE ASM CARRY sensor relay R CN409R Add 40002237 BU PIN SENS ASM CN443 Add 40002238 BU PIN CABLE ASM CARRY sensor rela...

Page 237: ...Figure 14 7 1 1 c IN motor induction motor d CENTER motor stepping motor e OUT motor induction motor f IN sensor g WAIT sensor h STOP sensor i C OUT sensor j OUT sensor k Stopper l X pusher 11 Y pushe...

Page 238: ...t reference directions 40002083 OUT MTR CABLE ASM CN602 639 CN3 Be careful of the transport reference directions 40002289 COPLA I F CABLE ASM CN604 CN4 In case of COPLA option CN5 Not used CN6 Not use...

Page 239: ...C option Change in EN specification 40002337 CARRY PWR CABLE ASM CN637 CN37 40002084 IN MTR CABLE ASM CN602 638 CN38 Be careful of the transport reference directions 40002083 OUT MTR CABLE ASM CN602 6...

Page 240: ...me Connector No CARRY sensor relay board connection destination Remarks 40002073 CRY SENS R CABLE ASM CN421 R CN1 40002128 ATC OPEN SENS ASM CN402R R CN2 40002127 ATC CLOSE SENS ASM CN403R R CN3 R CN4...

Page 241: ...4 40002242 BU LOCK CABLE ASM EN CN405L L CN5 In EN specification L CN6 Not Used 40002123 T PIN CABLE SAM CN407L L CN7 40002240 BU PIN RV CABLE ASM CN408L L CN8 In case of AWC option 40002124 BU ORG SE...

Page 242: ...time Open ON Short circuit OFF SW2 Used to adjust a period of time when setting the transport delay time of the WAIT sensor by the hardware The switch settings are the same as those described for SW1...

Page 243: ...STOP L sensor is always turned ON 1 and 2 are short circuited or turned ON only when necessary 2 and 3 are short circuited W10 Used to select whether the power to the C OUT L sensor is always turned O...

Page 244: ...of the Transport Stepping Motor Adjustment Procedure c Before starting the adjustment procedure make sure that the DC power source output voltage has been properly adjusted d Turn the transport stepp...

Page 245: ...justment Procedure c Set the rotary switches to the values in the table below Switch Settings STOP 5 RUN C M2 0 M1 0 Rotate the rotary switch so that the arrow points to the desired value Rev 2 00 d S...

Page 246: ...e 3 Manually move each motor axis to check the count value and polarity Check that almost the same values as those stated in Table 14 7 4 1 are counted Motor axis Polarity Count value Resolution Suppo...

Page 247: ...Five kinds of boards shown below are mounted on the head unit c Head main board assembly 40001926 d Head sensor relay board assembly 40001934 Two boards used e OCC relay 50 board assembly 40001936 Use...

Page 248: ...the DSW1 settings may vary depending on the machine model Set the DSW1 corresponding to the machine model VR7 Make the jumper switch W1 short circuited DSW4 DSW3 DSW2 DSW1 VR1 VR2 VR3 VR4 VR5 DSW1 KE...

Page 249: ...he measured result e Turn the vacuum input voltage adjustment potentiometer to adjust the voltage to Vvac 2 0 01 V while monitoring the voltage between the TP 1 GND and the A D input check terminals w...

Page 250: ...r CE marking machines c 40001954 Operation board assembly EN d 40001957 Operation switch board assembly EN 14 9 2 Jumper Switch Settings on the Operation Board Assembly 40001953 and Operation Board As...

Page 251: ...KE 2050 KE 2060 KE 2050R 2055R KE 2060R Maintenance Manual 14 50 Check that these receptacles are mounted Figure 14 9 2 2 Rev 2 00...

Page 252: ...name Element Switch actuator LED Lens for flat Bezel Rotation stop washer c On line HA005340010 HA005340020 HA00534006A HA005340050 HA005340030 d Home position HA005340010 HA005340020 HA005340060 HA0...

Page 253: ...otation stop washer c Start HA005340010 HA005340020 HA005340050 HA005340030 d Stop HA005340010 HA005340020 HA00534005C HA005340030 e Servo free HA005340010 HA005340020 HA005340060 HA00534005A HA005340...

Page 254: ...340060 HA00534005B HA005340030 d Start HA005340010 HA005340020 HA005340050 HA005340030 e Stop HA005340010 HA005340020 HA00534005C HA005340030 f On line HA005340010 HA005340020 HA00534006A HA00534005B...

Page 255: ...tuator LED Lens for flat Bezel Rotation stop washer c Start HA005340010 HA005340020 HA005340050 HA005340030 d Stop HA005340010 HA005340020 HA00534005C HA005340030 e Cycle HA005340010 HA005340020 HA005...

Page 256: ...into the cover FUR panel The bezel has a projection see the figure below to stop rotation and its installation direction varies with the machine type ST JE CH and EN ST JE and CE machines Attach the b...

Page 257: ...a nut to be used to fix the bezel so remove it Fixing nut e Insert the bezel silver from the back of the panel and secure it with the fixing nut f Finally fit the lens for flat into the switch actuato...

Page 258: ...e panel and secure it with the fixing nut 4 Keyboard ON switch feeder switch Parts used Keyboard ON switch cable assembly 40002251 or feeder switch cable 40002252 Bezel white with a lens HA00537001A R...

Page 259: ...W8 CONSOLE SELECT BANK ENABLE EMERGENCY 40002205 40002252 SW4 SW5 SW6 SW7 SW2 SW3 No SW1 Bezel is provided with a cover Actuator Switch name LED Bezel Lens Remarks HA00552001A ORIGI 40002251 HA0055300...

Page 260: ...SW15 CONSOLE SELECT SW13 1 CYCLE HA005520030 HA00534006A HA00552001B HA005520030 HA005520010 HA00534004A BANK ENABLE START HA005340020 STOP HA005340020 SERVOFREE HA005340020 40002252 HA005340020 40002...

Page 261: ...6A OPTION REAR MONITOR HA00534004A HA00552001B CONSOLE SELECT HA00552001B HA005520030 HA00534006A SW4 SW5 ORIGI 1 CYCLE SW2 SW1 START SW3 HA005340020 HA005520030 HA005340020 HA005340020 HA00552001B ST...

Page 262: ...ERGENCY SW14 SW11 SW12 START 1 CYCLE OPTION REAR MONITOR OPTION NON STOP OPERATION SW10 HA005340020 HA005340020 STOP HA005340020 HA00534006A HA005520030 40002252 40002206 HA005530020 HA00553002A HA005...

Page 263: ...es with the machine type ST JE CH and EN ST JE and CE machines Attach the bezel so that the projection faces to the right when viewed from the front i e the EAO mark is at the top position when the ac...

Page 264: ...ssembled at 3 into the black bezel insert the bezel silver from the back of the panel and secure it with the fixing nut 3 CONSOLE SELECT BANK ENABLE SW Parts used Use the OPERATION SW CABLE ASM 400022...

Page 265: ...crew shown in the photo below to demount the UPS from the power unit Screw to fix the UPS and the steel plate UPS Front cover fixing screw f Remove the two screws shown in the photo above to detach th...

Page 266: ...talled in the building and is not the power switch of the machine main unit 14 10 2 1 Detaching the UPS 1 Disconnect the connectors connected to the UPS and the relay connectors of the cable coming fr...

Page 267: ...off all metallic objects such as wrist watch ring and or necklace before starting the work 2 Always use tools with insulated handles 3 Do not put any tools or metallic parts on the battery 1 Remove th...

Page 268: ...0R Maintenance Manual 14 67 4 Draw out the battery 5 Disconnect the two leads connecting the battery and the UPS Connect the leads to the new battery with the red one to the positive pole while the bl...

Page 269: ...5S0 Time lag fuse 250mA Three fuses are supplied with the machine as accessory parts 1 Take out the AC input unit The AC input unit is located at the position shown in Figure 14 11 1 Work Procedure c...

Page 270: ...ence machine AWC R E2152725000 AWC E E2163725000 E94347290A0 SM8040602TP 2 E2153725000 AWC A E2151725000 AWC F cap SL6041092TN 4 For the rear reference machine replace the AWC bracket F E2151725000 wi...

Page 271: ...acket assembly on the front left portion when viewed from the front of the machine Figure 15 2 1 2 Mount the AWC pulley B E2154725000 on the rail stand RR AWC bracket assembly Base bar R Rail stand RL...

Page 272: ...at the belt sags 1 63 mm in the case of M size 1 76 mm in the case of L size when the center A on the belt span is pressed with a force of 1 67N Figure 15 2 2 3 RR R AWC E2160725000 AWC E E2154725000...

Page 273: ...092TN Figure 15 3 1 After the AWC OP dog has been mounted change the rail width between the maximum and minimum levels to check that it does not interfere with other objects such as the air tube SEMS...

Page 274: ...Detection Sensor 15 4 1 Mounting the B U Pin Detection Sensor Part No Part Name c 40001100 SENSOR BRACKET A AWC d SL6031092TN SCREW e 40002237 BU PIN SENS ASM f 40002239 BU PIN RECEIVE SENS ASM g SL6...

Page 275: ...d gap of the sensor bracket A using screws g Turn ON the power and adjust the position of the sensors so that their optical axes are aligned The BU pin sensors must be mounted on the movable side rail...

Page 276: ...d Figure 15 5 1 1 As shown above how to run the cable may vary depending on the solenoid valve mounting position Wind the spiral tube HX003140000 0 5 m at the top of the cable fixed by the tie up band...

Page 277: ...Fix the cable with the tie up band put in holes in the rail plates RR and RL Wind the spiral tube HX003140000 at the top of the cable fixed by the tie up band Figure 15 5 2 1 For part where the soleno...

Page 278: ...KE 2050 KE 2060 KE 2050R 2055R KE 2060R Maintenance Manual 15 9 15 6 Adjusting the Sensor Proximity sensor E40002120 AWC ORG SENS ASM 1 mm Figure 15 6 1 Rev 2 00...

Page 279: ...00 AWC HX004200000 HX005450000 5 SL4041091SC 2 SL4041091SC 2 SL4041091SC SEMS bolt 2 E1616729000 AWC driver bracket SL4041091SC SEMS bolt 2 HX004200000 or HX005450000 5 phase stepping motor driver Not...

Page 280: ...et the rotary switches to the values in the table below Switch Settings STOP 5 RUN C Turn the rotary switch so that it points to M2 0 the specified setting M1 0 2 Setting the DIP switches Front ON OP...

Page 281: ...Perform the steps 1 to 3 in this order 1 2 2 Mount the 40019212 BU_pin sensor dog in the hole from which the tie up band has been removed Note that the orientation varies according to the transferrin...

Page 282: ...stment work 16 FEEDER POSITION INDICATOR 16 1 Detaching the FPI Front from the Machine Main Unit As shown in the figure below the FPI is hanged on the hook of the FPI side bracket fixed to the Y axis...

Page 283: ...PI rear is hung on the hook of the FPI side brackets RR RL fixed to the bank supporter both sides and fixed with the SEMS cap bolts M6 12 To detach the FPI remove the two screws and slide it upward M6...

Page 284: ...I cover U 20 sets Fixing screw 8 Plastic slider 8 FPI LED board 4 Spacer 8 FPI bracket F 40002250 FPI LED cable B assembly Harness clamp Plain washer Fixing screw 4 To CN503 board connector FPI LED ca...

Page 285: ...FPI cover U 20 sets Fixing screw 8 Plastic slider 8 FPI LED board 4 FPI bracket R20 Spacer 8 FPI LED cable A assembly Harness clamp Plain washer Fixing screw 4 FPI LED cable B assembly Plain washer 2...

Page 286: ...and KE700 series E2107998000 Ceramic board 2 inch Adjustment of OCC camera illumination Common for KE2010 20 30 40 40008108 ATC offset boss 6 sets ATC offset assembly position For component height 6 m...

Page 287: ...008103 VCS HT jig 3 VCS camera focus offset For machines applicable to component height of 20 mm 40018924 VCS HT jig EC For machines applicable to component height of 25 mm E21329980A0 VCS jig plate A...

Page 288: ...assembly Pickup reference position offset Same part as that used for TF pick position adjustment 40008104 X MSC installation jig X magnet scale affixing jig 40008105 Y MSC installation jig Y magnet sc...

Page 289: ...Revision record Rev Date Revised locations Revision contents Remarks 1 0 Nov 2004 First edition for KE 2000R series 2 0 Mar 2007 2 1 Aug 2007 Chapter 4...

Page 290: ...CENTER 2 11 1 Tsurumaki Tama shi Tokyo 206 8551 JAPAN PHONE 81 42 357 2298 FAX 81 42 357 2297 http www juki co jp Copyright 2010 JUKI CORPORATION All rights reserved throughout the world The specific...

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