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UIC GSM FlexJet, Manual

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T47541109 Rev. J

FlexJet Head Assembly

TECHNICAL

 

PUBLICATIONS

This Document Supports Assembly 47541109 Rev. F

Replace the Spindle Assembly ..................................................................................................... 106
Connect the Spindle to the Platform Assembly ............................................................................ 106
Perform Final Installations and Adjustments ............................................................................... 108

Final Steps .............................................................................................................................................. 108

Changes To This Revision ........................................................................................................................................ 109

Summary of Contents for GSM FlexJet

Page 1: ...et Head Assembly FlexJet Head Assembly FlexJet Head Assembly FlexJet Head Assembly FlexJet Head Assembly FlexJet Head Assembly T47541109 Rev J 01 01djh fg djh This document supports assembly 47541109...

Page 2: ...ial Steps 19 Mount the FlexJet Head 19 Attach Pneumatics and Electrical Cables 19 Final Steps 21 Removing the FlexJet Head 22 Initial Steps 22 Disconnect the Electrical and Pneumatic Cables 22 Remove...

Page 3: ...Belts 51 Inspect Theta and Z Motor Belts 51 General Inspection 51 Clean the Camera Mirrors 52 Install the FlexJet Head 54 Final Steps 54 Zeroing the Theta Encoder 55 Prerequisites 55 Install the Thet...

Page 4: ...Steps 81 Procedure 82 Final Steps 84 Replacing a Clutch 85 Prerequisites 85 Initial Steps 85 Disassemble the Head 86 Install the New Clutch 89 Final Steps 91 Replacing a Manifold Tubing 92 Prerequisi...

Page 5: ...CHNICAL PUBLICATIONS This Document Supports Assembly 47541109 Rev F Replace the Spindle Assembly 106 Connect the Spindle to the Platform Assembly 106 Perform Final Installations and Adjustments 108 Fi...

Page 6: ...Page 1 FlexJet Head Assembly T47541109 Rev J TECHNICAL PUBLICATIONS This Document Supports Assembly 47541109 Rev F...

Page 7: ...exJet Head Assembly TECHNICAL PUBLICATIONS This Document Supports Assembly 47541109 Rev F Ref 80026907 2 Ref 80026810 2 4 6 15 5 2 22 9 10 7 47813303 Ref Ref 47814003 86 80 IN OZ 56 NM 6 16 86 20 IN L...

Page 8: ...et Head Assembly T47541109 Rev J TECHNICAL PUBLICATIONS This Document Supports Assembly 47541109 Rev F Detail A Page 4 Detail B Page 4 4 18 8 17 2 19 11 4 22 24 25 26 Ref 5 27 28 4 30 23 29 4 29 4 17...

Page 9: ...41109 Rev J FlexJet Head Assembly TECHNICAL PUBLICATIONS This Document Supports Assembly 47541109 Rev F Detail A Detail B Ref 47749501 Clearflo Tubing 7 x 4in Ref 80031302 Ref 80031705 Ref 80055601 40...

Page 10: ...Page 5 FlexJet Head Assembly T47541109 Rev J TECHNICAL PUBLICATIONS This Document Supports Assembly 47541109 Rev F 14 20 2 21...

Page 11: ...Page 6 T47541109 Rev J FlexJet Head Assembly TECHNICAL PUBLICATIONS This Document Supports Assembly 47541109 Rev F 1 3 3 12 4 13 7 6 7 17 2 2 86...

Page 12: ...Page 7 FlexJet Head Assembly T47541109 Rev J TECHNICAL PUBLICATIONS This Document Supports Assembly 47541109 Rev F...

Page 13: ...n Range Sensor is not on or is not functioning correctly Out of adjustment or failure LT8 Head Enable See Note 7 The FlexJet Head has power and the machine recognizes the head configuration Machine po...

Page 14: ...09 Rev J TECHNICAL PUBLICATIONS This Document Supports Assembly 47541109 Rev F Notes 2 Adjust belt tension until 200 inch 0 508 cm 5 08mm of deflection is achieved with 2 oz of force Lubricants and Ad...

Page 15: ...04 ASSY MANIFOLD 1 EA 12 47586101 BELT TIMING ALTERED 3 EA 13 47586201 BELT TIMING ALTERED 4 EA 14 47804001 GSM FLEXJET COVER 1 EA 15 80008407 PHMS 4 40 X 1 2 6 EA 16 80019002 ITLW 4 6 EA 17 80026803...

Page 16: ...IONS This Document Supports Assembly 47541109 Rev F 32 30885705 TUBING POLY 1 4 OD BLUE 2 FT 33 47571101 LABEL FLEXJET HD 1 EA 34 47612101 AIRKISS HD CABLE ASSY 1 EA 35 47612201 VACUUM HD CABLE ASSY 1...

Page 17: ...chnicians The following procedures require a minimum skill level of Maintenance Technician and should be performed only as required to ensure proper functioning of the FlexJet Head Maintenance Procedu...

Page 18: ...ruments Field Service Engineers The following procedures are intended for Universal Instruments Field Service Engineers only These procedures should be performed as required to ensure proper functioni...

Page 19: ...E for a new head installation Perform CPE for an installation to the previous location of the head Replacing Aligning a Coupler Body CPE Adjusting the Spindle Drive Belt Tension Spindle Height Calibra...

Page 20: ...harge ESD precautionary measures when maintaining adjusting or repairing the platform machine and the FlexJet Head Acronyms The following acronyms are used frequently in this module GSM General Surfac...

Page 21: ...tor Replacing the Theta Motor Timing Belt Calibrating the Z Motor Tension Tools Z Axis Index Housing Assembly Various Various Installing an OTH Camera Assembly Adjusting the Z Axis Timing Belt Tension...

Page 22: ...cedure executed during this procedure to ensure personal safety 4 Open the hinged cover and lock it in the upper position 5 Remove the safety cover below the hinged cover Use Electro Static Discharge...

Page 23: ...Log document that the procedure was performed and include the date Installing the FlexJet Head Install a FlexJet Head using the following procedure If a FlexJet Head has not previously been installed...

Page 24: ...is available for FlexJet Heads with serial numbers that begin with FJ09 2 Carefully place the FlexJet Head on the head mounting plate so the mounting plate dowel pins align with and enter the alignmen...

Page 25: ...able Assembly 3 Connect the HD INTF1 Cable Assembly and CAM INTF Cable Assembly 4 If the video connections for the PEC are already connected to the CAM INTF Cable Assembly continue with the Final Step...

Page 26: ...DRIVE HD GEN LOCK Final Steps The FlexJet Head requires calibration prior to production 1 Complete the steps in the Prepare the Machine for Production section of this document to ensure that the machi...

Page 27: ...powered down and the site s Lockout Tagout procedure executed during this procedure to ensure personal safety Disconnect the Electrical and Pneumatic Cables It is important to disconnect the HD INTF2...

Page 28: ...ate 4 While firmly supporting the FlexJet Head pull the head straight back from the mounting plate If possible use an ESD dissipative foam pad between the head and the work surface Removing the Plate...

Page 29: ...ic Panel 1 Remove the Center Rear Cover Assembly of the machine by pulling on the handle 2 Remove the 2 top screws from the rear panel containing the cooling fans 3 Release the panel locking lever fro...

Page 30: ...assembly 2 Check for damaged or crimped wires and pneumatic lines Make any changes to the orientation of the wires or pneumatic lines to maintain proper operation of the Pneumatic Panel Assembly 3 At...

Page 31: ...the FlexJet Head 5 Remove the FlexJet Head Cover Install the Vacuum Gauge 1 Remove the nozzle from Spindle 1 2 If the vacuum gauge has an adapter designed to fit inside the Coupler Body push the adapt...

Page 32: ...pending on the Theta angle 4 Observe the vacuum gauge reading while manually rotating the Theta pulley 360 degrees If the vacuum level is at least 20 inches Hg for a complete revolution proceed to ste...

Page 33: ...and install the previously removed nozzle If the vacuum gauge installs into a 10MPF nozzle remove the gauge and 10MPF nozzle and install the previously removed nozzle 7 Attach the gauge and 10MPF nozz...

Page 34: ...e Maintenance Log document that this procedure was performed and include the date Verifying Air Kiss Verify the FlexJet Head Assembly air kiss using the following procedure Initial Steps 1 Zero the ma...

Page 35: ...hat are obstructing the work The machine cover must remain open during this procedure to place the Interlock circuit in the violated state disabling machine servo axes Failure to comply could result i...

Page 36: ...that the head nozzle configuration is correct by selecting Machine Configuration Then select the head icon to access the configuration window 3 Close the hinged cover 4 Palm down to automatically rais...

Page 37: ...rotate the Theta Motor pulley and inspect all Theta Motor Belt teeth for damage If the belt is damaged replace the Theta Motor Belt while referring to the Replacing the Theta Motor Timing Belt sectio...

Page 38: ...e was performed and include the date Verifying the Touch Down Sensors Verify the touch down sensor setup for all 7 spindles using the following procedure Move the Head 1 Select Production Control Manu...

Page 39: ...p for a spindle is not necessary under the following circumstances If all LEDs for a spindle are illuminated If all but 1 of the LEDs for a spindle are illuminated 2 Select Increment 1 0 3 Move the sp...

Page 40: ...ensor Setup Tool Isopropyl alcohol or a solution approved for use on sensitive optical surfaces A flashlight is recommended A Calibration Kit for FlexJet for spindle height calibration Position the Fl...

Page 41: ...to comply could result in serious personal injury 6 Palm down and open the hinged cover Then remove the safety cover below the hinged cover and remove feeders if necessary 7 Rotate a Z Driven Pulley...

Page 42: ...ach side of the head For example it may be preferable to clean 8 Pin Mirrors on 4 spindles from one side of the head and clean the 6 Pin Mirrors on the 3 remaining spindles from the other side of the...

Page 43: ...in this document 3 Perform Spindle Height Calibration Refer to the Calibration CPE and Measurement manual 4 Install the safety cover below the hinged cover and install any feeders removed for mainten...

Page 44: ...the feeders from the feeder bank where the head is located 5 Remove the FlexJet Head Cover Sensor Setup Perform the following procedure to setup touch down sensors which are not adjusted correctly In...

Page 45: ...68601 Coupler Nozzle Tip Camera Housing FlexJet Head Mounting Platform Visually Align with Shelf Shown If visually aligning the Impact Sensor Setup Tool after it is installed on the FlexJet Head is un...

Page 46: ...Select SPINDLE_CLUTCH in the Select Outputs field 5 Select Set Outputs to engage the clutch 6 Select Yes when the Discrete I O message box displays Use extreme caution when driving the Z Axis down unt...

Page 47: ...m the shelf on the setup fixture Use new style fixture Fixture 47768601 Coupler Nozzle Tip Visually Align with Shelf Shown e While holding the Z Axis pulley in position select the Set Outputs button A...

Page 48: ...e nozzle tip 0 02 inches 0 50 mm e Push and release the Set Button The red Incident Level Indicator LEDs should extinguish If the lights flash red repeat from step 1 of this section driving the vernie...

Page 49: ...removed from the Coupler Body Assemblies before head use to prevent head damage 1 Palm up and zero the machine Refer to the Machine Operation document for information on zeroing 2 Perform the Verifyi...

Page 50: ...d accuracy after performing this procedure For a GSM2 platform it is recommended to perform the entire procedure on one FlexJet Head before removing the second head Use Electro Static Discharge ESD pr...

Page 51: ...Head section of this module before performing the Comprehensive Head Maintenance procedures Use an ESD dissipative foam pad for cushioning between the head and the work surface if one is available Cl...

Page 52: ...iffener 7 CCD Camera Assembly 7 CCD Camera Assembly Screws and Washers 4 ea Use Electro Static Discharge ESD precautionary measures when disconnecting cabling from the PCA Flex Jet Control a Disconnec...

Page 53: ...wab tips frequently and discard a swab when contamination is evident 4 Moisten a lint free swab ESD Swab with Isopropyl alcohol or a solution approved for use on sensitive optical surfaces and roll th...

Page 54: ...th the next procedure Verify Adjust the Camera Mirror Cable Use the following procedure to verify the camera cable adjustment After the cable is adjusted proceed to the next section 1 Use feeler gauge...

Page 55: ...g the PCA Flex Jet Control and associated cabling c Disconnect the 15PL connector from the PCA Flex Jet Control d Connect 15PL to the P15 connector on the FlexJet Prism Setup Fixture shown in the diag...

Page 56: ...oil is visible absorb the oil with a dry lint free cloth or an ESD Swab Linear Bearing For Reference Only Verify Adjust Tension of Spindle Drive Belts Refer to the Adjusting the Spindle Drive Belt Te...

Page 57: ...the head If the movable mirror is damaged the entire Slide Mirror assembly must be replaced In addition if the stationary image path mirror is damaged it must be replaced However the side plate mirror...

Page 58: ...uch substances are not visible use clean compressed air only in an area away from the head Also do not dry wipe the glass plates 5 Install the 7 CCD Camera Assembly and the Stiffener using the followi...

Page 59: ...eps in the Prepare the Machine for Production section of this document to ensure that the machine is in a safe operational state Verify that all covers removed for maintenance are installed including...

Page 60: ...e spindles and remove the nozzles from the FlexJet Head Refer to the Installing Removing Nozzles section of the Spindle Assembly document The machine cover must remain open during this procedure to pl...

Page 61: ...ng Belt theta pulley is rotated Theta Alignment Tool Inserted into Coupler Bodies Adjust the Encoder Counts Value There is only one pulse per revolution of the Theta Encoder 1 Loosen the top set screw...

Page 62: ...2_READONLY_ AXIS_LOC_AREA window displays 4 Choose one of the following options to enter a number in the Axis field Front Head Beam 1 enter 11 Rear Head Beam 1 enter 13 Rear Head Beam 2 enter 15 5 Cli...

Page 63: ...om the Counts field Refer to the following diagram Theta Timing Belt Pulley 2 With the tool firmly in place gently rotate the theta Timing Belt Pulley to the other extreme and hold it in position Then...

Page 64: ...Z Safe sensor Z Safe is to be adjusted to 0 030 inches 0 762 mm from the Z Home position The Z Safe Optics should not be moved unless the Z Safe Optics were replaced or the alignment of the emitter an...

Page 65: ...d in the Select Outputs field Select the Reset Outputs button If a message box displays asking to place machine in Diagnostic Mode select Yes 5 Deselect STOP_BRAKE located in the Select Outputs field...

Page 66: ...tate Z Driven Pulleys Stop Bracket Head MNT Platform 8 Highlight STOP_CLUTCH located in the Select Outputs field Select the Reset Outputs button 9 Select Exit Verify the Z Safe Sensor Signal Use the f...

Page 67: ...together Example If the measured gap is 0 025 inches 0 635 mm shim the bracket to 0 025 0 03 0 055 inches 1 4 mm 4 Verify that the digital readout is greater than 100 and the orange indicator LED is...

Page 68: ...e nuts Refer to the following diagram Correct Emitter Slot Orientation Correct Receiver Slot Orientation Digital Z Safe Sensor 5 Remove the extra 0 01 inches 0 254 mm from the gap and verify that ther...

Page 69: ...Maintenance section of this document to ensure that the machine is in a safe state for maintenance It is not necessary to remove the FlexJet Head Cover The machine must be powered down and the site s...

Page 70: ...djust the selected Timing Altered Belt tension using the following steps a Loosen the set screw at the bottom of the Platform Assembly corresponding to the selected spindle as seen in the diagram abov...

Page 71: ...ed including the safety covers below the hinged covers 4 Perform Calibration Placement Enhancement CPE Refer to the Calibration CPE and Measurement manual Adjusting the Stop Brake Belt Tension Set the...

Page 72: ...ration 5 Record on the appropriate copied sheet from the Maintenance Log document that this procedure was performed and include the date Adjusting the Stop Bracket Belt Tension The Stop Bracket Belt r...

Page 73: ...he machine must be powered down and the site s Lockout Tagout procedure executed during this procedure to ensure personal safety 2 Remove the FlexJet Head Refer to the Removing the FlexJet Head proced...

Page 74: ...rformed without removing the 2 6 OTH Camera damage to the camera mirrors may result 1 Remove the damaged Coupler Body Assembly from the Bearing Cap by removing the 2 mounting screws and disconnecting...

Page 75: ...ool must be removed from the Coupler Body Assemblies before head use to prevent machine damage Final Steps 1 Install the Camera assembly Refer to the Installing an OTH Camera Assembly procedure in the...

Page 76: ...rap New PCA FlexJet Control Initial Steps Complete the steps in the Prepare the Machine for Maintenance section of this document to ensure that the machine is in a safe state for maintenance The machi...

Page 77: ...g the PCA FlexJet Control to the top bracket 5 Remove the 4 screws and washers securing the Bracket to the Platform Assembly and remove the Bracket and PCA FlexJet Control 6 Remove the 4 screws and wa...

Page 78: ...nnecting them in the order presented in the following wiring chart read from top to bottom Make sure to route the Touch Down Sensor cables behind the Theta Motor Cable for Connect from Spindle Touch D...

Page 79: ...ighting 35PL 36PL LED Asm Side Lighting 37PL 38PL PCB On Axis Lighting 39PL 8 Install all cables from the clutches Z Motors and Manifold Assembly to their corresponding location on upper portion of th...

Page 80: ...ary to retain the wiring so that the FlexJet Head Cover can be installed without stressing the wiring 3 Install the FlexJet Head Cover 4 Complete the steps in the Prepare the Machine for Production se...

Page 81: ...the Stop Brake Belt Use the following procedure to replace the Stop Brake Belt Prerequisites Ensure that the following items are available before beginning the procedure New Z Stop Brake Belt Torque...

Page 82: ...er Assembly then push back the Tensioner Assembly and tighten the screw to create belt slack 5 Remove the 4 screws washers and lock washers securing Brake Bracket to the Platform Assembly and remove t...

Page 83: ...Z Stop Clutch cable 10PL to P10 and the Z Stop Brake cable 11PL to P11 on the PCA Flex Jet Control 8 Install cable ties as necessary Final Steps 1 Apply Loctite 222 to the 2 screws and install the Pl...

Page 84: ...the steps in the Prepare the Machine for Maintenance section of this document to ensure that the machine is in a safe state for maintenance The machine must be powered down and the site s Lockout Tag...

Page 85: ...2 set screws securing the Z Stop Brake pressure plate to the shaft Then remove and discard it Install the New Stop Brake Assembly 1 Install the new Z Stop Brake pressure plate on the shaft and tighte...

Page 86: ...Sensor due to damage or wear Replace the Spindle Touch Down Sensor using the following procedure The digital Z Safe Sensor has a different part number than the 7 Touch Down Sensors If the Z Safe Senso...

Page 87: ...Jet Control 2 Disconnect the Spindle Touch Down Sensor Assembly cable from the PCA Flex Jet Control Refer to the following diagram and wiring chart Spindle Touch Down Sensor Assembly 1 Z Safe Sensor A...

Page 88: ...Down Sensor Assemblies in the appropriate location Refer to the following diagram 1 2 3 4 6 7 5 Spindle Touch Down Sensor Assemblies 1 through 7 Digital Z Safe Sensor 6 Slide the stack of Spindle Touc...

Page 89: ...ties securing the Spindle Touch Down Sensor cable to the PCA Flex Jet Control Final Steps 1 Set the Touch Down Sensors so that the light goes off as soon as the nozzle impacts the component or board...

Page 90: ...Housing Assembly document Initial Steps 1 Complete the steps in the Prepare the Machine for Maintenance section of this document to ensure that the machine is in a safe state for maintenance The machi...

Page 91: ...crews Refer to the following diagram Spring Bar EXT Special Spring Screws 3 Retainer Arm Spring 3 Disconnect all 7 EXT Special Springs from the arm springs Disconnect each spring from its retainer the...

Page 92: ...4 Clutch 2 Lower Shaft Clutches Use the following procedure for the lower shaft clutches 2 4 6 and mirror a Remove Z Safe Clutch b Loosen 3 screws securing bottom Z Motor in position Loosen and remov...

Page 93: ...C clips Idler Shaft Idler Shaft Clutch Shaft E Ring Z Encoder Idler Pulley Timing Belt Pulley E Ring Clip Spacer Clutch Assembly Idler Shaft Clutch Standoff Idler Shaft Clutch Shaft Clutch Assy Idler...

Page 94: ...move the cable clamp from Mirror Clutch Remove the screw and hex nut from the pulley on the clutch assembly The pulley cannot be removed from the clutch shoe so a new pulley will be needed for each cl...

Page 95: ...s pulley Apply Loctite 222 to each pulley set screw and install the set screws into their respective pulley assembly 8 While tightening each clutch set screw hold the clutch against the E clip and roc...

Page 96: ...he retainers Refer to the following diagram Spring Bar EXT Special Spring Screws 2 Retainer Arm Spring 15 Move the arm spring up and down below the clutch assembly on all 7 clutch assemblies to ensure...

Page 97: ...ration CPE and Measurement manual Replacing a Manifold Tubing Replace a worn or damaged Manifold Tubing using the following steps Ensure that the new tubing is completely seated on the fittings Prereq...

Page 98: ...ttom of the Manifold Assembly Refer to the following diagram Fittings for Manifold Tubings 2 Use pliers to carefully remove the Manifold Tubing from the Vacuum Cap top portion of spindle 3 Refer to th...

Page 99: ...nal Steps 1 Remove all loose tools and parts from the platform machine 2 Close the hinged cover and install the safety cover below the hinged cover 3 Install the FlexJet Head Cover 4 Install any feede...

Page 100: ...ure executed during this procedure to ensure personal safety 2 Remove the FlexJet Head cover Remove the Current Manifold 1 Remove the cable ties securing the AirKiss HD Cable Assembly 17PL and the Vac...

Page 101: ...e Elbow Fitting 4 Disconnect the Manifold Tubings from the 7 hose fittings underneath the Manifold Assembly Refer to the following diagram Hose Fitting Clearflo Tubing 5 Remove the 3 screws that secur...

Page 102: ...ing lengths per spindle Refer to the following diagram Attach the flaired ends of the tubings to the Manifold Hose Fitting Clearflo Tubing 4 Connect the input pneumatic line to the male elbow fitting...

Page 103: ...ptic Cable due to damage or wear For a dual beam the head can be removed for easier access but calibration time for CPE is also required Prerequisites Ensure that the following items are available bef...

Page 104: ...A Flex Jet Control by removing the 4 side screws and washers and the 2 upper screws and washers Refer to the following diagram but leave the upper PC board Bracket mounted to the head Do not remove th...

Page 105: ...old cable 3 Carefully screw the Lens on the metal fitting on the cable Then thread the cable with Lens attached up from the bottom through the hole in the Fiber Optic Block and carefully screw the Len...

Page 106: ...tall the FlexJet Head cover Final Steps 1 If the head was removed refer to the Installing a FlexJet Head section of this document and install the head 2 Complete the steps in the Prepare the Machine f...

Page 107: ...t for FlexJet Calibration Kit for FlexJet for spindle height calibration and the Calibration CPE and Measurement manual Initial Steps 1 Complete the steps in the Prepare the Machine for Maintenance se...

Page 108: ...tension using the Adjusting the Z Axis Spindle Drive Belt Tension procedure located in this document Final Steps 1 Mount the FlexJet Head on the machine Refer to the Installing a FlexJet Head procedu...

Page 109: ...the Machine for Maintenance section of this document to ensure that the machine is in a safe state for maintenance Make sure to remove the FlexJet Head Cover The machine must be powered down and the...

Page 110: ...sembly but leave the upper bracket on the head 3 Remove the 4 screws securing the PCA Flex Jet Control bracket to the Platform Assembly and remove the PC board with the bracket on the board Do not rem...

Page 111: ...Theta Drive Housing Screws 3 2 Remove the Theta Drive Housing from the Spindle Assembly 3 Install the new spindle Bearing Assembly to Theta Drive Housing with the 3 screws Torque the 3 screws to 46 in...

Page 112: ...keeping the spindle justified to the right Refer to the following diagram Justify to right Linear Slide 3 Install the 2 screws in the Arm Spring Tighten screws to 3 5 in pounds 0 39 Nm EXT special Spr...

Page 113: ...is document 5 Install the FlexJet Head to the machine Refer to the Installing a FlexJet Head procedure located in this document 6 Verify the spindle alignment Refer to the Replacing Aligning a Coupler...

Page 114: ...lexJet Head Assembly T47541109 Rev J TECHNICAL PUBLICATIONS This Document Supports Assembly 47541109 Rev F Changes To This Revision Changed the frequency of belt inspection from 500 to 160 hours of ma...

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