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Table of Contents 2 MEC-CP842-1.0E 4.5 Changing Pallets (CP-842M E option) ................. .............. ........ 4-9 5. Maintenance .................. .......................................... .............. .......…

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Table of Contents
MEC-CP842-1.0E 1
1. About This Manual ..........................................................................1-1
1.1 Manual Structure ...................................................................... 1-1
1.2 Page Layout .............................................................................1-2
1.3 Notation Conventions Used in this Manual...............................1-3
2. Safety ...............................................................................................2-1
2.1 About Symbols .........................................................................2-1
2.2 Safety Rules for All Machine Types..........................................2-2
2.3 Safety Rules for Individual Machine Types...............................2-7
2.3.1 CP-842E/842ME Machines ....................................................2-7
2.4 Safety Labels............................................................................2-8
2.5 The EMERGENCY STOP Buttons .........................................2-11
3. The Machine ....................................................................................3-1
3.1 Machine Components...............................................................3-1
3.1.1 General View ......................................................................3-1
3.1.2 Servo Control Axes.............................................................3-5
3.1.3 Rotary Head........................................................................3-5
3.1.4 Placing Head ......................................................................3-6
3.1.5 PCU (Pallet Change Unit)...................................................3-6
3.2 Functions of Each Part .............................................................3-7
3.2.1 Parts Mounting System.......................................................3-7
3.2.2 Parts Supply System .........................................................3-8
3.2.3 Vision System .....................................................................3-9
3.2.4 Panel Conveyance System.................................................3-9
3.2.5 Electrical Control System....................................................3-9
3.3 Sensor Positions.....................................................................3-11
3.3.1 XY-table ............................................................................3-11
3.3.2 In-conveyor .......................................................................3-13
3.3.3 Out-conveyor ....................................................................3-14
3.3.4 Main Conveyor..................................................................3-15
3.3.5 In-carrier ...........................................................................3-16
3.3.6 Out-carrier.........................................................................3-17
3.3.7 Panel Clamp .....................................................................3-18
3.3.8 Cam Box ...........................................................................3-19
3.3.9 Tape Feeder Unit (ST1, 2)................................................3-20
3.3.10 Tape Cutter (ST1).............................................................3-21
3.3.11 Nozzle Clutch (ST10)........................................................3-22
3.3.12 Nozzle Changer (ST15) ....................................................3-23
3.3.13 Feeder Check ...................................................................3-24
3.3.14 Device Table.....................................................................3-26
4. Basic Operation...............................................................................4-1
4.1 Changing the Conveyor Width..................................................4-1
4.2 Changing the Panel Back-up Pin Positions ..............................4-3
4.3 Setting the Feeders .................................................................. 4-5
4.4 Removal and Installation of Rotary Holders .............................4-7
Table of Contents
2 MEC-CP842-1.0E
4.5 Changing Pallets (CP-842ME option) .......................................4-9
5. Maintenance.....................................................................................5-1
5.1 Cleaning....................................................................................5-1
5.1.1 Waste Tape Box and Filter (Every 8 Hours) .......................5-1
5.1.2 Waste Tape Duct (Every 8 Hours) ......................................5-2
5.1.3 Reject Parts Box (Every 8 Hours) .......................................5-3
5.1.4 Removing Parts from the Camera Glass (Every 8 Hours) ..5-4
5.1.5 Nozzle Interior (Weekly)......................................................5-6
5.1.6 Camera Glass (Weekly)......................................................5-7
5.1.7 Filter Regulator (Weekly) ....................................................5-8
5.1.8 Machine Interior (Weekly) .................................................5-10
5.1.9 Part Height Check Sensor Lens (Weekly) ........................5-11
5.1.10 Fluorescent Nozzle Stickers (Monthly) .............................5-12
5.1.11 Tapered Clutch on the Nozzle Indexing Shaft (Monthly) ..5-13
5.1.12 Air Filter (Monthly).............................................................5-14
5.1.13 Oil Cooler Air Filter (Monthly)............................................5-15
5.1.14 Carrier Rodless Cylinder (Monthly)...................................5-16
5.1.15 Nozzle Filter (Every 3 Months)..........................................5-17
5.1.16 Cleaning Checklist ............................................................5-18
5.2 Lubrication ..............................................................................5-19
5.2.1 Precautions During Lubrication.........................................5-19
5.2.2 Types of Lubricant ............................................................5-19
5.2.3 Lubrication Instructions .....................................................5-21
5.2.4 Lubricating the XY-table....................................................5-23
5.2.5 Lubricating the Conveyors ................................................5-24
5.2.6 Lubricating the Carriers.....................................................5-25
5.2.7 Lubricating the Tape Advance Link...................................5-26
5.2.8 Lubricating the Cam Box...................................................5-27
5.2.9 Lubricating the Waste Tape Disposal Unit........................5-29
5.2.10 Lubricating the NY-Axis Pickup Offset Mechanism...........5-30
5.2.11 Lubricating the Rod Ends..................................................5-31
5.2.12 Lubricating the D-axis Carriers .........................................5-32
5.2.13 Lubricating the Rotary Head .............................................5-33
5.2.14 Lubricating the ST9 Air Valve Push Pin ............................5-34
5.2.15 Lubricating the Parts Reject Unit ......................................5-35
5.2.16 Lubricating the Pallet Table ..............................................5-36
5.2.17 Lubricating the Nozzle Changer........................................5-37
5.2.18 Lubricating the Rear Cover ...............................................5-38
5.2.19 Lubricating the Index Unit .................................................5-39
5.2.20 Lubricating the Cam Lever Air Cylinder ...........................5-44
5.2.21 Lubricating the Rotary Holder Positioning Pins.................5-45
5.2.22 Lubrication Checklist.........................................................5-46
6. Replacing Consumable Parts.........................................................6-1
6.1 Nozzles .....................................................................................6-1
6.2 Fluorescent Nozzle Stickers .....................................................6-2
Table of Contents
MEC-CP842-1.0E 3
6.3 Waste Tape Cutter....................................................................6-4
6.4 Conveyor Belts .........................................................................6-5
6.5 Vacuum Pump Filter Element...................................................6-7
6.6 Vacuum Pump Belt...................................................................6-8
6.7 Vacuum Pump Internal Vanes and Bearings..........................6-10
6.8 Vacuum Pump Motor..............................................................6-17
6.9 Vacuum Hoses .......................................................................6-20
6.10Servo Amp Battery .................................................................6-21
6.11Replacing the Carrier Clamp/Unclamp Air Cylinder Packings 6-24
7. Adjustments ....................................................................................7-1
7.1 Station Adjustments..................................................................7-1
7.1.1 Tape Feed Lever (ST1) ......................................................7-1
7.1.2 Waste Tape Cutter (ST1)....................................................7-4
7.1.3 Nozzle Vertical Movement During Pickup (ST1).................7-6
7.1.4 Mechanical Valve Switching (ST1) ...................................7-12
7.1.5 Feeder Height Error Detection (ST1)................................7-16
7.1.6 Large Parts Check Sensor (ST2)......................................7-22
7.1.7 Pre-theta Movement (ST2) ...............................................7-24
7.1.8 Fine-theta Movement (ST8)..............................................7-25
7.1.9 Nozzle Vertical Movement During Placement (ST9) ........7-26
7.1.10 Mechanical Valve Switching (ST9) ...................................7-33
7.1.11 Reverse-theta Mechanism (ST10)....................................7-37
7.1.12 Mechanical Valve Switching (ST13) .................................7-40
7.1.13 Nozzle Change Function (ST14) ......................................7-43
7.1.14 Nozzle Detection Sensor (ST15) ......................................7-46
7.2 Servo Amplifier Adjustments...................................................7-51
7.2.1 Servo amplifier parameters...............................................7-51
7.2.2 Resetting servo errors ......................................................7-54
8. Troubleshooting..............................................................................8-1
8.1 Troubleshooting Table..............................................................8-1
8.1.1 Poor Placing Accuracy........................................................8-2
8.1.2 Pickup Errors ......................................................................8-3
8.1.3 Vision Processing Errors ....................................................8-5
8.1.4 Panel Conveyance Related Errors .....................................8-6
8.1.5 Missing Parts ....................................................................8-10
8.1.6 Part Height Sensor Errors.................................................8-11
8.2 Servo System Troubleshooting ..............................................8-12
8.2.1 Alarm Code Display ..........................................................8-12
8.2.2 Alarm Codes and Troubleshooting Check List .................8-15
9. Setup ................................................................................................9-1
9.1 Leveling the Machine................................................................9-1
9.2 Connecting the Air Supply ........................................................9-3
9.3 Electrical Power Supply & Transformer Wiring.........................9-4
9.4 Connecting the Data Transmission Cable ................................9-8