J-CAT SLV. Operation Manual

Transcription

1 J-CAT SLV Operation Manual Thank you for purchasing the J-CAT SLV. Read these instructions thoroughly for proper use of this machine. Make sure to read "Safety Notes" before you use machine. This information protects you from possible dangers during use. Apollo Seiko Ltd. Rev

2 Page 2 of 48 Safety Notes This manual includes the important information to use this machine safely. This also includes useful information to prevent injury or damage to property. Please read this manual carefully prior to connecting or operating the J-CAT SLV. Keep this manual near the machine at all times. Supply only specified voltage Do not connect to a power supply greater than the specified voltage. If voltage is exceeded, electrical shock and /or damage to the unit may occur. Make sure that the electrical outlet is properly grounded. If the outlet is not properly grounded, electrical shock and/or damage to the unit may occur. Working ambient temperature and relative humidity This machine has been designed for use between 20~30 degrees,10%~85%. Do not use this machine exceeding these conditions. Handle with care This machine is designed to use a solder feeder and hot ceramic sleeve for soldering. Touching a heated soldering sleeve will cause severe burns. Make sure the sleeve has cooled down before you are touching it for replacing the sleeve. Please handle this machine with care. If the machine is dropped or sustains great impact / vibration, it may cause malfunction. If you do not use the machine for a long time Please turn off the power, remove the power cable and keep it in a dry and cool place. If you note malfunction on machine If the machine malfunctions, turn off the power immediately and contact the dealer you purchased the machine from. Immunity from responsibility We do not take responsibility for damage caused by misuse, mistakes, accidents, use in abnormal conditions or natural disasters, such as in an earthquake, a fire etc. We do not take responsibility on contingency loss,(business loss, Business stop) caused by machine stop. We do not take responsibility for losses or damages caused by operating with other means not mentionined in this manual. We do not take responsibility for losses or damages caused by a wrong connection with other equipment. If for any reason the internal circuitry is tampered with altered or repaired without written consent of Apollo Seiko, the warranty is null and void. The customer is allowed to make necessary tooling adjustments, replace ceramic sleeve and make any necessary adjustments to the temperature controller.

3 Page 3 of 48 INDEX Safety Notes... 2 INDEX Summary of J-CAT SLV Specification Dimensions Descriptions Preparation Operation process Start-up preparation Program number selection Teaching pendant useful function Select Point Type: Point Soldering Select Point Type: Cleaning Select Point Type: PTP Point Select Point Type: PTP Evasion Point Select Point Type: PTP Evasion Point Soldering System Settings I/O Function Assignment Error Sign Maintenance... 43

4 Page 4 of Summary of J-CAT SLV This point soldering robot meters, cuts and melts a programmed length of solder wire in the ceramic sleeve. By equipping the nitrogen gas generator, the oxidation of soldered face does not occur. Also, the fine setting of solder feeding amount, heating time, temperature is possible. 2. Specification Weight Operation Range Portable Weight Repeatability Program Capacity Memory Capacity Soldering Conditions Setting Temperature Solder Feeding Amount Solder Feeding Speed Solder Diameter Apparent Power Heater Power Consumption Power-Supply Voltage Supply Air Usage Environment Storage Environment Interface J-CAT200 SLV J-CAT300 SLV J-CAT400 SLV ROBOT:35kg ROBOT:42kg Head: 3.5kg Head: 3.5kg Attachment Units Attachment Units (AC-HC, APN05):2kg (AC-HC, APN05):2kg ROBOT: 18kg Head: 3.5kg Attachment Units (AC-HC, APN05):2kg X, Y: 200 x 200 mm Z: 50 mm X, Y: 300 x 320 mm Z: 100 mm 11kg (X table stage) X,Y,Z ±0.007mm 255 programs Max. 30,000 points 500 conditions 0 ~ 550 (1 increments) 0.1 ~ 200mm (0.1mm increments) 1.0 ~ 50.0mm/sec (0.1mm/sec increments) φ0.8~1.2 <400VA 160W X, Y: 400 x 400 mm Z: 100 mm Heater for AC100V: AC100V, Single Phase AC 50/60Hz Heater for AC200V: AC200V, Single Phase AC 50/60Hz 0.5Mpa Temperature range: 20 ~30 (This temperature is not keeping the yield rate of the product) Humidity range: less than 85% (Non-condensing) Indoor use only 1 ~ 60 (Non-condensing) For external operation command D-SUB25 female pin (Harness side: male) *Refer to I/O Function Assignment page.

5 Page 5 of Dimensions J-CAT200 SLV

6 J-CAT300 SLV Page 6 of 48

7 J-CAT400 SLV Page 7 of 48

8 Page 8 of Descriptions Over view Heater Controller (AC-HC) - Y Axis + Head Cover Z Axis - Ceramic Sleeve + + Start Button Nitrogen Gas Generator (APN-05) X Axis - Program Selection Key Emergency Stop Switch Connector for Teaching Pendant *The above picture is J-CAT300 SLV.

9 Internal Head Page 9 of 48 Solder Wire Encoder Roller (Solder Shortage Sensor) Floating Amount Adjusting Screw Feeding Roller Guide Tube Push Pin Upper Blade Lower Blade Nitrogen Cooling Air Chute Pipe Sleeve Holder Heater Thermocouple Sleeve

10 Heater Controller (AC-HC) Page 10 of 48 <FRONT> PV SV Temperature Controller Refer to 5-4. How to set Temperature controller MODE FUNC Power Switch for Heater Controller Temperature will be displayed on the temperature controller when the power turned on after a while. Data Download Connector Temperature data can be downloaded. <BACK> Heater Connector Connect the heater cable. HEATER I/O FUSE 2A I/O Connector Connect the I/O cable. MADE IN JANAPN AC IN AZ100V~240 Power-supply connector Connect the power cable. Nitrogen Gas Generator (APN-05) *Refer to APN-05 operation manual for more details.. Digital Flow Meter PV Nitrogen flow rate is displayed. Flow Adjusting Knob Adjust nitrogen flow.

11 Page 11 of Preparation 5-1.How to set ceramic sleeve Caution Please make sure the ceramic sleeve is cool down for exchange. Caution Move the lock pin quietly. If the lock pin is rapidly moved (is returned back by the repulsion of the spring), the fixing part may be dropped off. 1 Pull the sleeve rock pin. 2 Insert the sleeve with adjusting the sleeve groove to the position of the lock pin. 3 Fix the sleeve groove with the sleeve lock pin. Make sure the lock pin firmly inserts to the sleeve groove.

12 5-2.How to set solder wire Page 12 of 48 1 Insert the shaft in to the solder wire bobbin, then screw the both side of knob. 2 Hook the shaft to the groove of the hook plate. 3 Open the encoder ( 1), then insert the solder wire A into the guide piece. ( 2) 4 Open the solder roller ( 3), insert further the solder wire. 5 For check the solder wire cut and initialization after replacing solder wire, press the teaching pendant keys in order of [9] [8] [7] [4] [5] [6]. *9. Teaching Pendant Useful Function *In case of the setting solder feed amount, refer to One Touch Feed Length. Caution After setting solder wire, please make sure to put the head cover back for soldering. If not, it may cause the difference of soldering quality.

13 5-3.Power-on Page 13 of Connect the teaching pendant to the robot. 2. Connect the power cable to the back of the robot. <ROBOT BACK> 3. Connect the air supply pipe to a regulator. 4. Adjust nitrogen flow amount in 0.4~0.5 MPa by the white knob.. 5. Turn on the power switch of the heater controller. P V S V MODE FUNC 6. Turn on the power switch on the back of the robot.

14 5-4.How to set temperature controller Page 14 of 48 PV PV (Present Temperature) Parameter Change SV SV (Set Temperature) Digit Change MODE FUNC SV can be changed by pushing Keys. Operation flow chart Power-on Initial screen Press for 4 sec. Operation mode Press for 4 sec. Press for 2 sec. Setting Item Selection screen (SET01) (SET04) (SET06) (PVS1) (AT) (E2H) (E2L) Setting item selection screen or SET xx screen is changed back to operation mode screen after 2 minutes if no operation is done. <Auto tuning AT> After setting the proper soldering condition, the start-up time or over-shooting may be improved by auto tuning at the setting temperature. MODE FUNC MODE FUNC MODE FUNC MODE FUNC Press for 4 sec. Press until Press once. Press once. Press above screen appears. for 2 sec to return.

15 Page 15 of 48 <Temperature calibration PVS1> MODE FUNC MODE FUNC MODE FUNC MODE FUNC Press for 4 sec. Press once. <Temperature alarm upper limit E2H> Change value by Press for 2 sec to return. *For higher accuracy, leave the soldering unit for 30 minutes, then do calibration. MODE FUNC MODE FUNC MODE FUNC MODE FUNC MODE FUNC Press for 4 sec. Press until above screen appears. <Temperature alarm lower limit E2H> Press once. Change value Press by for 2 sec to return. MODE FUNC MODE FUNC MODE FUNC MODE FUNC MODE FUNC Press for 4 sec. Press until above screen appears. <Digit change function> Press twice. Change value Press by for 2 sec to return. Press or leave for 4 sec to return. MODE MODE FUNCF UNC MODE FUNC MODE FUNC Push FUNC once Push FUNC twice Push FUNC three times to change 1st digit. to change 2nd digit. to change 3rd digit. <Temperature lock function> MODE FUNC MODE FUNC MODE FUNC MODE FUNC Press for 4 sec. Press until above screen appears. Press once. Press 0:off 1:All lock for 2 sec to return. 2:Lock in operation mode 3:Lock except operation mode

16 Page 16 of Operation process This robot variously operates by program operation. To operate the robot, creating program is firstly necessary. Operating process is as follows: Start up preparation Refer to 7. Start-up preparation for more detail. Program number selection Refer to 8. Program number selection for more detail. Point teaching Point coordinates input Point type selection Soldering condition number input Soldering condition input Repeat as many as the number of point Refer to 10~13. Program setting for more detail. Test Refer to JANOME operation manual, Quick start for more detail. Running Refer to JANOME operation manual, Quick start for more detail. Teaching means creating program and inputting any setting to the robot. Teaching mode is the mode for program creating and various setting. It is called Teaching data that is registered to the robot by Teaching.

17 Page 17 of Start-up preparation 7-1. Home position returning (Mechanical Initializing) After turning on the power switches of the heater controller and the robot, do the home position returning (initializing) according to the display of the teaching pendant. Teaching Mode: Initializing by F4 key on the teaching pendant Teaching Mode Press F4 Key For Mechanical Initializing LANG INIT Switch Run Mode: Initializing by the start button on the robot Teaching Mode Press Start Button For Mechanical Initializing LANG INIT External Run Mode: Outputting start signal to I/O SYS (*Refer to I/O Function Assignment, Start signal) Teaching Mode Input START Signal On for Mechanical Initializing LANG INIT Caution The arms return to the home position. The temperature controller of AC-HC simultaneously starts operating.

18 7-2. Changing modes Page 18 of 48 By pressing MODE key, Change Mode display is shown on the teaching pendant. Change Mode External Run Mode Switch Run Mode Teaching Mode Select Switch Run Mode or External Run Mode for running program. Select Teaching Mode for Teaching. Then press ENTER. * In order to run program, make sure that LED of Start button is flashing. Then press Start button. External Run Mode To start running programs using a signal from the I/O SYS or COM1 Switch Run Mode To start running programs by pressing Start button on the robot Teaching Mode To create programs LED lights on the teaching pendant indicate the current mode. E.RUN RUN TEACH CUSTOM ADMIN E.RUN External Run Mode RUN..Switch Run Mode TEACH..Teaching Mode 7-3. Emergency Stop Use the emergency stop switch to stop the robot if any accident has occurred during operation. The motor s power (power to the motor) will be turned off and the robot will stop running by pressing this button. Also during soldering, the soldering will be stopped. How to release the emergency stop: Turn the depressed emergency stop switch clockwise. Then press the start button at Switch Run Mode or press F4 key at Teaching Mode for the mechanical initialization. Emergency stop switch Release

19 Page 19 of Program number selection When you press PRO. NO key on the teaching pendant at Teaching mode, the following display is shown. If there is no registered program, the following display simply appears by starting Teaching mode. Enter a number Program Number 1 DEL COPY NEW LIST GLIST F0 F1 F2 F3 F4 DEL: to delete program number COPY: to copy program number NEW: to display the list of unset program number LIST: to display the list of set program number GLIST: to check the teaching point on the sreen F0 F1 F2 F3 F4 For setting the new program number, press list. F2 in order to display the unset program number Select Itme Select the setting program number by CURSOR key, then press ENTER to register. Program 1 X Y Z P1 0mm 0mm 0mm Point 1 (P1) screen of the selected program number appears. FUNC JOG MDI INIT

20 Page 20 of Teaching pendant useful function At Teaching mode Heater Off Heater On E.RUN RUN TEACH CUSTOM ADMIN MODE SAVE GO PRG.NO R R X Z X Z JOG key *1 To move each arm at JOG mode. Pin Up J.ENTR T.ENV EDIT Y Y Cutter Off Pin Down Cutter On /- 0. SHIFT CTRL CURSOR JOG SPEED MENU DEL CURSOR CURSOR MONITOR ESC CLEAR ENTR CURSOR One Touch Solder Reverse One Touch Solder Feed *Refer to Soldering System Settings At the screen where the coordinates is registered (Setting Screen) CURSOR GO F4 SHIFT *For checking solder cut or initializing after the solder wire exchange, press the numeric key in the order of [9] [8] [7] [4] [5] [6]. CURSOR The setting screen is switched to previous / next screen by this key....the Arm of robot moves to the displayed point...the Arm of robot moves to the displayed position and operates the registered condition. + GO...The Arm of robot returns to home position. JOG Mode For inputting the position by moving arms with JOF keys. MDI Mode For inputting the coordinate value by numeric keys. The arms do not move in MDI Mode. Program 1 X Y Z P1 122mm 151.2mm 59.1mm Program 1 P1 >X 122mm Y 151.2mm Z 59.1mm FUNC JOG MDI INIT FUNC JOG MDI INIT F0 F1 F2 F3 F4 F0 F1 F2 F3 F4 Press [F2] or [F3] for switching JOG/ MDI Mode.

21 Page 21 of Select Point Type: Point Soldering 10-1.Point Soldering Flow Soldering Process: 1 Solder Feed & Preheating 2 Solder Cutting 3 Soldering 4 Heating 5 Evasion *1 *1 Robot Height: Pre-Heat Height Cut Height Teaching Position Heating Height Evasion Height Robot Speed: Z Down Speed Z Down Speed Z Down Speed Heating Height Moving Speed Z Up Speed Timer: Pre-Heat Time Solder Time Heating Time Soldering Condition: Solder Length Solder Rev. Amount Solder Feed Speed Solder Rev. Speed *1 When the time is 0, the arms jump to the next step height. Set in Point Teaching. (Refer to JANOME instruction manual: Quick Start 2.2 Teaching.) Set in Soldering condition. (Refer to Soldering Condition List) Set in Soldering System Settings. (Refer to 15. Soldering System Settings.)

22 10-2.Point Soldering Program 1 X Y Z P1 122mm 151.2mm 59.1mm Page 22 of 48 Using JOG key to move sleeve until Point Soldering point. Press ENTER. FUNC JOG MDI INIT Select Point Type Point Soldering Cleaning PTP Point CP Start Point CP Passing Point PTP Evasion Point CP Stop Point CP Arc Point CP End Point Circle Start Point Circle Center Point Select the type Point Soldering by CURSOR key. Press ENTER. Enter condition number Enter a number Condition Number 1 DEL COPY NEW LIST VIEW F0 F1 F2 F3 F4 F0 F1 F2 F3 F4 DEL: to delete condition number COPY: to copy condition number NEW: to display the list of unset condition LIST: to display the list of set condition number VIEW: to check the soldering condition of the displayed number *Refer to the next page *If the solderting condition is not set, initial value is displayed. * The set solderting condition number can be used in the other point soldering program.

23 Page 23 of 48 Point solderting condition input screen When you press F4 VIEW at inputting Soldering condition number, the following Soldering condition input display appears. Select the each condition that is necessary to the point where you did Teaching by CURSOR key, then press ENTER Input value ENTER for register. Soldering Condition 1 Solder Length Solder Feed Speed Pre-Heat Height Pre-Heat Time Cut Height Solder Time Heating Height Heating Height Moving Speed Heating Time Evasion Height 1.3mm 15mm/s 1.5mm 0sec 1mm 1sec 0.5mm 3mm/s 2sec 40mm After inputting necessary value, the screen returns to Soldering condition number input screen by ESC key. Press ENTER. Enter a number Condition Number 1 DEL COPY NEW LIST VIEW Program 1 X Y Z P2 122mm 151.2mm 59.1mm Soldering Point has been registered and the next point screen is displayed. FUNC JOG MDI INIT *Soldering condition can be also input in Soldering condition by pressing MENU key at Teaching mode.

24 10-3.Soldering Condition List Page 24 of 48 Solder Length Items Setting range Description Remark Solder Feed Speed Pre-Heat Height * Pre-Heat Time Cut Height * Solder Time Heating Height * Heating Height Moving Speed 0.1~200mm (0.1 increments) 1~50mm/sec (0.1 increments) -5~50mm (0.1 increments) 0~60sec (0.1 increments) -5~50mm (0.1 increments) 0~60sec (0.1 increments) -5~60mm (0.1 increments) -5~100mm/sec (1 increments) Solder feeding length Solder feeding speed Preheating height Preheating time The solder cutting height (The height is from the teaching position.) Time to move from the teaching position to the heating height Heating height form the teaching position Speed to move from the teaching position to the heating height Stand-by time at the heating height. In case the preheating time is set in 0, sleeve does not move to this height. In case the heating time is set in 0, sleeve does not move to this height. Heating Time 0~60sec (0.1 increments) Evasion Height * 0.1~9.9mm Sleeve evasion height (0.1 increments) after heating * The Height means the height from the teaching position of Z-axis minus up direction. Caution After setting solder wire, please make sure to put the head cover back for soldering. If not, it may cause the difference of soldering quality. Caution Either the longer time of Pre-Heat Time or Feeding Time (Solder amount Feeding Speed) is given priority. If the sleeve is pushed to the application, the cutter is also moved together. Therefore the solder amount gets longer by the amount that the sleeve is pushed. In this case, make correction to adjust Cut Height. Sleeve has two holes that the gas fume comes out. If the solder wire length is longer than the height to those holes, the melting solder might come out from the holes. It is necessary to adjust the solder wire length shorter than the height to the holes or feed the solder wire twice or more.

25 Page 25 of Select Point Type: Cleaning 11-1.Cleaning Flow Cleaning Process: 1 Cleaning Start 2 Sleeve Down 3 Shift Right 4 Sleeve Up 5 Down Up Repeat 6 Sleeve Rising Robot Height: Robot Speed: Timer: Cleaning Height Cleaning Speed (Z) Teaching Position Stopping Cleaning Time Teaching Position Cleaning Height Cleaning Speed (Z) Repeat 2 4. Cleaning Height Cleaning Speed (Z) Operation: Cleaner Motor rotating Right Offset Times of the Repeat Return from the right offset position Set in Point Teaching. (Refer to JANOME instruction manual: Quick Start 2.2 Teaching.) Motor stops before sleeve rising Set in Soldering System Settings. (Refer to 15. Soldering System Settings.) Set in Point Setting Variable (Refer to 11-2.) 11-2.Point Setting Variable List Items Input Range Description Remark Call Interval Times of the Repeat Right Offset Caution: 1~999 (1 increments) 1~30 (1 increments) 0~0.3mm (1 increments) The interval to operate the cleaning Times of repeat of sleeve up&down The distance to shift to the right after sleeve down Enable in Teaching Mode If setting the Right Offset, the Cleaning Height should be set in the state that the sleeve inserts to the drill. When moving to the cleaning point and shifting back from the cleaning point, Z-axis moves to Z=0mm position once.

26 11-3. Cleaning Position Teaching Page 26 of 48 Make sure to attach the position holding plate for cleaning position teaching. Fix the plate by M6 screws. After the teaching, remove the plate. Sleeve Cleaner DRC-1300 Program 1 X Y Z P1 20mm 10mm 50mm Using JOG key to move sleeve until the top of the sleeve cleaner s drill.. Press ENTER. FUNC JOG MDI INIT Change to MDI mode, then enter the Z value that is added the length of the sleeve. * Adjust the Z coordinate that the sleeve bottom reaches to the drill holder. Select Point Type Point Soldering Cleaning PTP Point CP Start Point CP Passing Point PTP Evasion Point CP Stop Point CP Arc Point CP End Point Circle Start Point Circle Center Point Select the type Cleaing by CURSOR key. Press ENTER. Program 1 P1 X+20 Y+10 Z+50 Type: Cleaning Call Interval 5 Times of the Repeat 2 Right Offset 0.1mm Enter the each Setting Point Variables. FUNC JOG MDI INIT

27 Page 27 of Select Point Type: PTP Point PTP stands for Point to Point. The robot axis shifts in the X or Y direction and moves to the next point. At this PTP point, I/O input & output signal and the jump pf the program based on I/O signal is possible. Set the necessary settings, such as the PTP speed or maximum height of arc motion, in the program data parameter PTP Condition. Any changes in the program data parameter PTP Condition will affect all the PTP drive points in a program, excluding points which the additional function data PTP Condition is set to. For I/O input & output, set in the additional function data Point Job Job Before Moving Job While Moving. Program 1 X Y Z P1 122mm 151.2mm 59.1mm Using JOG key to move sleeve until PTP Point point. Press ENTER. FUNC JOG MDI INIT Select Point Type Point Soldering Cleaning PTP Point CP Start Point CP Passing Point PTP Evasion Point CP Stop Point CP Arc Point CP End Point Circle Start Point Circle Center Point Select the type PTP Point by CURSOR key. Press ENTER. Program 1 X Y Z P2 122mm 151.2mm 59.1mm PTP Point point has been registered and the next point screen is displayed. FUNC JOG MDI INIT

28 Page 28 of 48 For setting PTP Condition, press CURSOR key at the setting screen, then the screen as follows is displayed. Program 1 P1 1/2 X+0 Y+0 Z+0 Type PTP Point Condition Number Job Before Moving Job while moving Point Job Number PTP Condition Number Tool Number Pallet Routine Number Work Adjustment Number Execute Condition Number S.MARK E.MARK J.EXEC P.EXEC Select PTP Condition Number, then set the PTP conditions.

29 Page 29 of Select Point Type: PTP Evasion Point It can be used in order to evade such as obstacle on the moving line of sleeve. Sleeve always moves the shortest distance between the coordinates. Set more than one PTP evasion point, if necessary. Program 1 X Y Z P1 122mm 151.2mm 59.1mm Using JOG key to move sleeve until PTP Evasion Point. Press ENTER. FUNC JOG MDI INIT Select Point Type Point Soldering Cleaning PTP Point CP Start Point CP Passing Point PTP Evasion Point CP Stop Point CP Arc Point CP End Point Circle Start Point Circle Center Point Select the type PTP Evasion Point by CURSOR key. Press ENTER.

30 Page 30 of Select Point Type: PTP Evasion Point When pressing EDIT key at the setting screen that displays the coordinates, the point can be inserted or deleted. Also the specified range of the points can be edited by the Block Editing. Editing Points Menu Insert a Point Delete a point Block Editing Block Setting Same Value Transform into Relative Insert a Point New point can be inserted. Display the setting screen for the point that the new point is inserted. Press EDIT and select Insert a Point. New point is created before the point that was shown on the screen. Enter the point positon and select the point type. Each point that comes after the inserted point shifts down by one number. Insert Displayed Point (Before Insertion) P1 P2 P3 P4 (After Insertion) P1 P2 P3 P4 P Delete a Point The created point can be deleted. Display the setting screen for the point to be deleted. Press EDIT and select Delete a Point. The displayed point is deleted, the next point setting screen is shown. Each point that comes after the deleted point shifts up by one number. Displayed Point (Before Deletion) P1 P2 P3 P4 P5 (After Deletion) P1 P2 P3 P4 Delete

31 Page 31 of Block Editing The specified points range in the program can be edited (moved/ deleted/ copied/ mirror copied/ offset/ rotated) by block unit. (*Please refer to JANOME Teaching Pendant operation manual for more details.) Editing Points Menu Insert a Point Delete a point Block Editing Block Setting Same Value Transform into Relative Press EDIT at the point setting screen. Select Block Editing. number Block Editing Enter a number. Block Start Number 1 Enter the Block start (point) number. *If pressing F4 (ALL), all the programmed points are selected. (In this case, the screen of Block End does not appear.) ALL Block Editing Enter a number. Block End Number 15 LAST Enter the Block end (point) number. *If pressing F4 (LAST), the last point in the program is entered. Also the Block start/ end point number can be set in advance. At the point setting screen: Press F0 (S.MARK) to set the Block start point number. Press F1 (E.MARK) to set the Block end point number. *The displayed point is set the Block start / end point number. Block Editing Delete Block Points Move Block Points Copy Block Points XYZR Offset Mirror Copy (Right-Left) Mirror Copy (Front-Back) Block Rotation Copy Block Rotation JOG Offset Select the Block Editing menu.

32 Page 32 of Delete Block Points The specified points range in the program can be deleted by block unit. Select Delete Block Points from the Block Editing Menu. The screen to confirm the delete block points appears. Then select Yes. (Before Deletion) P1 P2 P3 P4 P5 P6 (After Deletion) P1 Block Points P2 (Before P5) P3 (Before P6) Each point that comes after the deleted block shifts forward Move Block Points The specified points range in the program can be moved by block unit. However the points cannot be moved to the other programs. Select Move Block Points form the Block Editing Menu. The screen on the right is shown. Enter the Destination (Point) Number. The specified block moves forward to the Destination Point number. Enter a number. Destination Number 3 *The Block points move to P1 by pressing F3 (TOP). The Block points move to the last point number + 1 by pressing F4 (LAST). TOP LAST Destination Number Block Points (Before Moving) P1 P2 P3 P4 P5 P6 P7 P8 (After Moving) P1 P2 P5 P6 P7 P3 P4 P8 *It is invalid, if the Destination Point Number is selected from the block points.

33 Page 33 of Copy Block Points The specified points range in the program can be copied by block unit. The number of times to copy and the parallel shifting distance in X/ Y direction can be set. However the points cannot be copied to the other programs. Select Copy Block Points from the Block Editing menu. The screen on the right is shown. Enter the X-direction shifting distance. After the X Distance, the screen moves to Y Distance entry Screen. X Distance Enter a number. 7.5mm Enter the number of times to copy. The block copy is executed and the screen returns to the setting screen. The copied block points are inserted behind the original block points. Enter a number. Copy Times 2 The coordinates after block copy may exceed the operation range. Make sure to execute the Checking Data by pressing MONITOR on the teaching pendant. Example) Block Points: P3-P5, Shifting Distance: X-direction +7.5mm, Copy twice Y Block Points Copy Times: 2 P4 P7 P10 P3 P5 P6 P8 P9 P 11 X: 7.5mm Shifting Distance X

34 Page 34 of XYZR Offset The specified points range in the program can be offset. Select XYZR Offset from the Block Editing menu. The screen to enter the offset value appears in the order of X-Y-Z-R axis. Enter 0 for the unnecessary axis shifting distance. Enter a number. Y Offset 2.54mm The offset value adds to all the points in the block points. Then the screen returns to the point setting screen. 1. The coordinates after offset may exceed the operation range. Make sure to execute the Checking Data by pressing MONITOR on the teaching pendant. Example) Block Points: P3-P5, Y Offset +2.54mm Y P4 Y P4 P5 Y: 2.54mm P3 P5 P3 X X (Before Offset) (After Offset)

35 Page 35 of Soldering System Settings The following is Soldering System Settings list. Press MENU key at teaching mode, and select Soldering System Settings. Item Setting Range Descriptions Remark Rev. Amount Z Down Speed Z Up Speed Cleaning Height Cleaning Speed (Z) Cleaning Time Feeder Com Time Over Air Cylinder Time Over Heater Ready Waiting Time One Touch Feed Length One Touch Feed Speed Cycle Count 1~10mm (1 increments) 2~250mm/sec (1 increments) 2~250mm/sec (1 increments) 0~50mm (1 increments) 3~250mm/sec (1 increments) 0~30sec (1 increments) 1~300sec (1 increments) 1~10sec (1 increments) 0~120sec (1 increments) 0~900mm 1~50mm/sec (0.1 increments) Enable/Disable Solder reverse length after solder cutting Axis speed to move to the evasion height Axis speed to move to the height of preheating, cutting, teaching position Height to start and finish cleaning Sleeve inserting speed into the cleaner Sleeve inserting speed into the cleaner Waiting time of communication operation check signal with motor driver Waiting time of communication operating check signal of air cylinder (Pusher pin, Cutter) Waiting time of heater temperature reaching to setting time after point soldering Solder feed length to operate by [9] key. Feeding speed to set in above. Enable: Displays cycle count value on the teaching pendant Soldering completion height is set in Soldering Condition. In case of no signal,even if the waiting time passes, it s an error. In case of no signal,even if the waiting time passes, it s an error. In case of no signal,even if the waiting time passes, it s an error. Refer to Refer to Cycle Count Reset 0 Reset of cycle count value Refer to Shot Counter SV 10~99999 (1 increments) Setting value as a measure of exchange sleeve The present value reaches the SV, buzzer sounds. Refer to Shot Counter Reset 0 Reset of shot counter value Refer to Shot Counter Test Mode Enable/Disable Enable/Disable Enable: Displays shot count value on the teaching pendant Enable: Ignores solder shortage sensor (encoder) and heater READY signal Refer to For teaching and check the tact time

36 15-1.One Touch Feed Length Solder wire can be fed to the top of solder tube. It is useful function, when solder wire is replaced. Page 36 of 48 Soldering System Settings 1/2 IO Function Assignment Rev. Amount 1mm Z Down Speed 50mm/s Z Up Speed 10mm/s Cleaning Height 10mm Cleaning Speed (Z) 5mm/s Cleaning Time 2sec Feeder Com Time Over 30sec Air Cylinder Time Over 2sec Heater Ready Waiting Time 3sec One Touch Feed Length 10mm One Touch Feed Speed 5mm Press MENU key at teaching mode, and select Soldering System Settings. Then, select One Touch Feed Length and press ENTER. Soldering System Settings Enter the same length of the solder tube. The set range is 0mm~900mm. Enter a number One Touch Feed Length 650mm By pressing 9 on teaching pendant, the solder wire can be fed Cycle count The number of program cycle can be counted. 1 cycle is 1 count. Soldering System Settings 2/2 Cycle Count Disable Cycle Counter Reset 0 Shot Counter SV Shot Counter Reset 0 Shot Counter Disable Test Mode Disable Press MENU key at teaching mode, and select Soldering System Settings. Then, select Cycle Count and press ENTER. *Page 2 is displayed by SHIFT + key. Disable Enable Cycle Count Select Enable.

37 Cycle Count (Display at the operation mode) Page 37 of 48 Shot Counter is displayed in External Run Mode or Switch Run Mode as follows: Switch Run Mode Stopping Top of Cycle Cycle Count 2 Program1 Start Enable The cycle count value is not updated during robot running. Indication is reflected after the end of the program. *It is not counted during continuous operation mode that is set it the program data setting. Cycle count value SHOT COUNTER 102 / The maximum setting number of cycle count is 99999, if it s 10000cysles, it becomes 0. (This is repeated.) Cycle Count Reset Soldering System Settings 2/2 Cycle Count Disable Cycle Counter Reset 0 Shot Counter SV Shot Counter Reset 0 Shot Counter Disable Test Mode Disable Press MENU key at teaching mode, and select Soldering System Settings. Then, select Cycle Count Reset and press ENTER. *Page 2 is displayed by SHIFT + key. Soldering System Settings Press CLEAR key to reset the number. Enter a number Counter Reset 0

38 Page 38 of Shot Counter When the present value of the counter reaches the set shot counter, the message on teaching pendant appears and a buzzer sounds. This is useful function to exchange sleeve. Soldering System Settings 2/2 Cycle Count Disable Cycle Counter Reset 0 Shot Counter SV Shot Counter Reset 0 Shot Counter Disable Test Mode Disable Press MENU key at teaching mode, and select Soldering System Settings. Then, select Shot Counter and press ENTER. Disable Enable Shot Counter Select Enable and press ENTER. Soldering System Settings 2/2 Cycle Count Disable Cycle Counter Reset 0 Shot Counter SV Shot Counter Reset 0 Shot Counter Disable Test Mode Disable Select Shot Counter SV and press ENTER. Soldering System Settings Enter a number Enter the maximum setting value. *The maximum set range is 1~99999 Shot Counter 10000

39 Shot Counter (Display at the operation mode) Page 39 of 48 Shot Counter is displayed in External Run Mode or Switch Run Mode as follows: Switch Run Mode Stopping Top of Cycle Program1 Start Enable During the operation mode, the shot counter is updated in every one shot. SHOT COUNTER 102 / Shot Counter Present value Shot Counter Setting value When the present value of the counter reaches the maximum shot counter point, the message on teaching pendant appears and a buzzer sounds. (The robot operation enables after reaching set value.) Switch Run Mode Stopping Top of Cycle Please change a Bit Cartridge. SHOT COUNTER 102 / Program1 Start Enable To turn off the buzzer, reset the counter current value while the machine is stopping. Because shot counter checking is done at the time of the program end, the current value becomes bigger value than maximum shot number. This message is displayed Shot Counter Reset How to reset Shot Counter Soldering System Settings 2/2 Cycle Count Disable Cycle Counter Reset 0 Shot Counter SV Shot Counter Reset 0 Shot Counter Disable Test Mode Disable Press MENU key at teaching mode, and select Soldering System Settings. Then, select Shot Counter Reset and press ENTER. Soldering System Settings Enter a number Press CLEAR key to clear the number. It should be done everytime after replacing to a new sleeve. Counter Reset 0

40 Page 40 of I/O Function Assignment IN/OUT No Unit Description 1 Robot System Signal Start 2 Robot System Signal Free 3 Robot System Signal Program LOAD 4 Robot System Signal Program BIT0 5 Robot System Signal Program BIT1 6 Robot System Signal Program BIT2 7 Robot System Signal Program BIT3 IN 8 Robot System Signal Program BIT4 (External to 9 Robot System Signal Program BIT5 Robot) 10 Robot System Signal Program BIT6 11 Robot System Signal Error Reset 12 Robot System Signal Temporary Stop 13 Air Supply Signal Air Supply 14 Cleaner Signal Cleaner Overload 15 Robot System Signal Free 16 Heater Unit Signal Heater Ready OUT (Robot tot External) Power supply I/O-SYS Connector Diagram 17 Robot System Signal Start Ready 18 Robot System Signal Robot Stopping 19 Robot System Signal Program Number ACK 20 Robot System Signal Program Number Error 21 Robot System Signal Running 22 Robot System Signal Error 23 Robot System Signal Emergency Stop 24 Robot System Signal Free 25 Robot System Signal Free 26 Heater Unit Signal Heater ON 27 Cleaner Signal Rotating ON 28 Robot System Signal Free 29 Error Code Signal Error Code bit0 30 Error Code Signal Error Code bit1 31 Error Code Signal Error Code bit2 32 Error Code Signal Error Code bit3 33 Unused 34 P24 DC24V Power Supply 35 N24 0V 36 N24 0V 37 N24 0V

41 Page 41 of Error Sign The following list is the error sign on the teaching pendant. Code Error Display Failure reason Solution WARNING AIR SUPPLY & APN05 POWER APN05 FLOW ERROR PUSH EMERGENCY STOP HEATER READY WDT ERROR (WDT: Watchdog Timer) 4 SOLDER ERROR 5 SMART SHOT COMUNICATION ERROR 6 Cleaner Overload 7 8 CUTTER ON LS TIME OVER CUTTER OFF LS TIME OVER Lack of nitrogen flow After the above error occurs, it passed 30 sec. The heater is emergency stops for cooling The signal of the temperature setting range from heater controller turns OFF. In case temperature does not rise, disconnection or damage of heater. In case of error of temperature display, cable disconnection or damage of thermocouple. End of solder wire feeding Breaking of solder wire Misdetection of solder shortage sensor Damage of solder shortage sensor Solder wire is clogged in sleeve/ chute pipe/ guide tube. Communication error of the Feeder PCB Disconnection of communication cable Damage of Feeder driver PCB. Reaction of overload sensor at the time of cleaning In case the cylinder does not operate: In case the cylinder operates: In case the cylinder does not operate: In case the cylinder operates: Damage of solenoid valve operation. The solenoid valve cable is damaged. The sensor position is not proper. The sensor cable is damaged. The sensor is damaged. Damage of solenoid valve operation. The solenoid valve cable is damaged. The sensor position is not proper. The sensor cable is damaged. The sensor is damaged. Check the nitrogen supply source. Adjust the nitrogen flow amount. If supplying within 30 sec, it resets automatically. Turn off the power supply immediately, then check the cooling system. After that, restart the robot. Check if the heater controller turns on. Check the heater cable. Refer to the maintenance page for exchange heater. Check the thermocouple cable. Refer to the maintenance page for exchange thermocouple cable. Replace with a new solder wire. Remove the solder wire in the solder tube (encoder) and reset solder wire. Check the solder wire is set properly. Contact Apollo Seiko or our agency for repair. Remove the clogged solder. Check the COM2 (RS232C) connection on the robot. Motor exchange is necessary. Contac to Apollo Seiko or our agency. Check the teaching position of cleaning. Turn off the air-supply. If there is foreign material, cleaning is required. Check the conduction. Check the sensor position. Check the conduction. Replace the sensor. Turn off the air-supply. If there is foreign material, cleaning is required. Check the conduction. Check the sensor position. Check the conduction. Replace the sensor.

42 Page 42 of PIN DOWN LS TIME OVER PIN UP LS TIME OVER CUTTER OFF INTERLOCK ERROR CUTTER ON INTERLOCK ERROR PIN DOWN INTERLOCK ERROR ROBOT PLAYBACK ERROR ROBOT SYSTEM ERROR In case the cylinder does not operate: In case the cylinder operates: In case the cylinder does not operate: In case the cylinder operates: Damage of solenoid valve operation. The solenoid valve cable is damaged. The sensor position is not proper. The sensor cable is damaged. The sensor is damaged. Damage of solenoid valve operation. The solenoid valve cable is damaged. The sensor position is not proper. The sensor cable is damaged. The sensor is damaged. The Cutter Off (open) had commanded while the Push Pin is not raised. The Cutter On (close) had commanded while the Push Pin is not raised. The Pin Down had commanded while the Cutter is not opened. The robot detects the operation error. (Self-Diagnosis) The robot detects the system error. (Self-Diagnosis) Turn off the air-supply. If there is foreign material, cleaning is required. Check the conduction. Check the sensor position. Check the conduction. Replace the sensor. Turn off the air-supply. If there is foreign material, cleaning is required. Check the conduction. Check the sensor position. Check the conduction. Replace the sensor. During teaching, check the Push Pin is raised by pressing [4] key on the teaching pendant. During teaching, check the Push Pin is raised by pressing [4] key on the teaching pendant. During teaching, check the Cutter is opened by pressing [5] key on the teaching pendant. Refer to the Janome Maintenance Manual, Troubleshooting page. Refer to the Janome Maintenance Manual, Troubleshooting page. *If the error code 11, 12, or 13 occurred during teaching, press SHIFT + ESC key on the teaching pendant. Then the error is released.

43 Page 43 of Maintenance Sleeve Maintenance 1) Carbide Residue to the Application The carbide that is adhered to the sleeve tip may peel off and left on soldering work. Especially in case the soldering work are left for 10 minutes, the residue carbide is noticeable. <Cause (a)> Carbide starts burning gradually around 400. If the sleeve is left with the carbide residue around 400, the carbide becomes easy to peel off. <Cause (b)> During soldering, the carbide on the sleeve tip peels off and adheres to the soldering work. <Solution> After the sleeve is left in high temperature, clean the sleeve by the sleeve cleaner or by the wire brush before operation, if necessary.

44 2) Thermal Decomposition Page 44 of 48 In order to remove dross completely, burning dross (carbide) is required. Raise the temperature of the sleeve that is attached to the unit or in the cleaning heater (CCH-700). <Cleaning Heater> Burn the dross periodically with CCH-700. Temperature: Approx. 600 <Automatic Burning> Raise the heater temperature with the sleeve attached to the unit. Keep the sleeve temperature in 500. Cleaning Heater CCH-700 Before heating After heating We recommend you to burn the dross by thermal decomposition <Release Hole Cleaning> Solder balls and dross are adhered to a sleeve and a release hole of sleeve holder. It may disturb the fume exhaust. Clean properly in order to smoothly exhaust fume. <How to clean> Insert the Φ0.9mm drill. Rotate the drill and move it back and forth in order to remove dross.

45 18-2. Chute Pipe Cleaning Page 45 of 48 Flux fume may be adhered to the chute pipe. If necessary, burn the dross on the chute pipe (Approx. 600 for a few minutes). Otherwise wipe off the dross with alcohol. <How to detach the chute pipe> 1) Prepare the chute pipe desorption tool. (This tool is the original accessories for SLV.) 2) Detach the sleeve. Then insert the desorption tool. Pull and pick out the chute pipe with a light force. Because the chute pipe is fixed with the heat-resisting O-ring, the strong is not necessary. You can see the clearance in the heater upper side after pulling out the chute pipe. 3) Clean the dirty pipe (right side) with alcohol or burn out.

46 18-3. Lock Pin Dropping Off Page 46 of 48 Move the lock pin quietly. If the lock pin is rapidly moved (is returned back by the repulsion of the spring), the fixing part may be dropped off Attaching Thermocouple Attach the tip of the thermocouple in the state of being pressed to the bottom of the sleeve hole. Check the tip of the thermocouple are inserted in approx. 8mm. [ Right Fig. (L) ] Tighten the fixing screw with pressing the curved position (A) so as the sheath tip is pressed against the bottom of the sleeve hole Heater Exchange <Pull out the sleeve holder> Hold the sleeve holder by pliers. Pull out the sleeve holder as rotating it in the opposite direction of heater winding In case the heater has been burned, by using a lubricant (e.g. KURE5-56) it s easier to pull out the sleeve holder.

47 18-6. Solder Clogs Page 47 of 48 After cutting solder, reverse the solder wire. [Fig.1] If not, the solder piece cannot be supplied to the tip of the sleeve. <Cause> The solder wire may be deformed to a dogleg [Fig. 2 (b)], if the solder wire is not reversed properly and the head is pressed to the application then the cutter parts are raised [Fig. 2(a)]. The doglegged solder wire may be hung in the pipe. [Fig. 2 (c)] <Solution> After cutting the solder wire, make sure to reverse the solder wire properly. Otherwise adjust the floating amount to 0 with the floating amount screw. [Fig. 1] *Solder reverse amount is programmed. [Fig. 2] Dogleg Hanging

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