IP-3

Level 3 Tutorial Manual

TT3-IP3-2.1E
R
 IP-3
Level 3 Tutorial Manual

TT3-IP3-2.1E

R
Notice
1. All rights regarding this manual are reserved by Fuji Machine Manufacturing Co., Ltd. This
manual may not, in whole or in part, be reproduced by any means (electronic, mechanical or
otherwise), or reused in any way, without the prior written permission of Fuji Machine
Manufacturing Co., Ltd.
2. Fuji Machine Manufacturing Co., Ltd. accepts no responsibility for any situations that may arise as
a result of the use of this manual.
3. Fuji Machine Manufacturing Co., Ltd. reserves the right to change the content of this manual
without notice.
4. Every effort has been made to ensure that this manual is correct in every detail. However, please
contact Fuji in the unlikely event that errors or omissions are detected.
Copyright  2000 by Fuji Machine Manufacturing Co., Ltd. All Rights Reserved.
R
is a trademark of Fuji Machine Manufacturing Co., Ltd., and registered in the
following countries: Austria, Belgium, Denmark, Finland, France, Germany, Greece, Indonesia,
Ireland, Italy, Japan, Korea, Luxembourg, the Netherlands, Portugal, Spain, Sweden, the U.K., and the
U.S.A.

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

Fuji Machine Manufacturing Co., Ltd.

19 Chausuyama Yamamachi, Chiryu, Aichi, 472-8686 Japan
Tel: (0566) 81 - 2111 Fax: (0566) 83 - 1140
Fuji America Corporation
171 Corporate Woods Parkway, Vernon Hills, IL. 60061 USA
Tel: (847) 913-0162 Fax: (847) 913-0186
Fuji Machine Mfg (Europe) GmbH
Peter-Sander-Str. 43, D-55252 Mainz-Kastel Germany
Tel: 06134-202120 Fax: 06134-202200
Fuji do Brasil Maquinas Industriais Ltda.
Rua Joao Cachoeira,
128 Itaim Bibi, Sao Paulo, SP 04535-000 Brazil
Tel: 11-3064-7650 Fax: 11-852-6833
Fuji Machine Philippines, Inc.
Warehouse 888 Don Mariano Lim
Industrial Complex (La Fuerza Compound) Alabang, Zapote Rd.,
Almanza Uno Las Pinas City, Philippines
Tel: (02) 809-4565 Fax: (02) 807-2767
Fuji Singapore Office
C/O Mecomb Singapore Limited
Sime Darby Centre, 896 Dunearn Road #04-03A, Singapore 589472
Tel: 4675952 Fax: 4693758
Fuji Malaysia Office
C/O Mecomb Malaysia Sdn Bhd
2487, Jalan Sultan Azlan Shah, 11700 Penang, Malaysia
Tel: (04) 656-4002 Fax: (04) 656-2941
Fuji Taiwan Office
C/O Ascentex Industry Corp.
3 Fl, No. 396, Sec. 1, Nei Hu Rd., Taipei, Taiwan R.O.C.
Tel: (02) 8797-8716 Fax: (02) 8797-8717
 About this Manual

About This Manual

This manual contains important machine maintenance information for the user.
The manual content is intended for specialized technicians who are familiar with the
systems used in this machine.
Please read this manual carefully in order to ensure safe and efficient machine
maintenance.

Some of the machine names used in this manual are not the formal machine names.

(Formal machine name) (Notation used in this manual)

FUJI IP-III IP-3
FUJI-IP-IIIE IP-3E

Manual Structure
This manual consists of the following fourteen parts.

Safety Guidelines
Chapter 1 Nozzle Changer Unit
Chapter 2 X-Motor
Chapter 3 Y-Motor
Chapter 4 Spline Shaft
Chapter 5 Q-Motor
Chapter 6 Z-Motor
Chapter 7 Fiducial Camera
Chapter 8 Image Camera
Chapter 9 MTU4 SX-Motor
Chapter 10 MTU4 SY-Motor
Chapter 11 MTU4 T-Motor
Chapter 12 MTU4 SZ-Motor
Chapter 13 MTU4 Carrier

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 About this Manual

Page Layout
Each page indicates the chapter number, section title and number, body, manual name,
page number, and the edition number.

Chapter number Section number and title

Chapter 1 1.2 Calibrating Nozzle Changer

1.2 Calibrating Nozzle Changer

Nozzle Changer Coplanarity
Definition: Nozzle Changer Coplanarity is the uniformity in height
Section title between all of the nozzle changer jaws.

Required Tools: 1 (0.01 mm) Dial Indicator

Required Jigs: None

Procedure:

Note: Holder #1 is always used for zero reference.

1. Attach the dial indicator shaft arm to the X1 or X2 head depending on

the nozzle changer unit to be checked.

2. Advance the changer that has been replaced and align a dial gauge on
the bottom edge of the clamper jaw. Zero the indicator.

Body 3. Jog the head to the inside of the machine until the indicator is on the
desired nozzle and measure and record the amount of deflection.

4. Align the head to changer number 1. Measure the deflection and

compare it with what was recorded in Step 3.

5. The total amount of deflection should not exceed “0.5 mm” across each
holder, with holder 1 as the zero reference.

6. If the value exceeds the tolerance, it is most likely due to the following
reasons:

a. Loss of bearings

b. Nozzle changer obstruction /seating

c. Nozzle changer unit level

d. Bent LM rail

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Edition number Page number Manual name

IP3T30001

Chapter number
The chapter number to which each section belongs is shown on the header on each page.
The manual is made up of fourteen chapters as detailed earlier in this section.

Section number and title

The title of each chapter is shown in the header on each page. Each part may contain one
or more sections.

Section title
Each chapter may be divided into several sections. The section number is composed of
the number of the chapter to which the section belongs, followed by a sequential number
for each section.

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 About this Manual

Body
The information needed to understand the workings of the machine and how to perform
operation is explained using text and illustrations.

Page number
A two digit hyphenated number appears in the footer on each page. The first digit of
each page number indicates the chapter number and the second digit is the sequential
page number within that chapter. Page 1-2, for example, indicates that this is the second
page in the first chapter.

Manual name
The name of the manual that appears on the cover is also shown in the footer on each
page.

Edition number
The edition number is updated each time the manual is revised, with the number
reflecting the scale of changes that were made.

Minor revision: Minor changes are reflected in the part of the edition number after
the decimal point, for example, a change from edition 1.0 to 1.1. This
change is made on the revised pages only, and these pages can be
downloaded as required from Fuji's website.
Major revision: If major changes are made, the edition number is increased by one,
for example, a change from edition 1.0 to 2.0. This change is made on
all pages, including the cover.

Notation Conventions Used in this Manual

The notation conventions employed in this manual are described below.

[Production] command The names of the command buttons are enclosed in brackets,
and use the verb “press”.

START button Buttons on the machine are written exactly as they appear,
and use the verb “press”.

“Production” command section The names of commands that have been grouped
together are enclosed in quotation marks.

[TAB] key Keys on the keyboard appear in brackets.

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 About this Manual

Terminology Notice
“Production Program” In this manual the term “production program” is
used to refer to the operating instructions used by
the machine in the production of a board.
In FujiCam, Fuji’s latest host system, this data is
referred to as the “recipe”.
Despite the differences in name, the terms carry the
same meaning, and references to “production
program” may therefore be thought of as “recipe” by
FujiCam users.

“Board”, “Block” In this manual the term “board” is used to refer to

the printed circuit on which parts are placed, and the
term “block” is used for multiple identical circuits
that may exist within a board and which are split
into individual units when production is complete.
In FujiCam, Fuji’s latest host system, these terms are
referred to as “panel” and “board” respectively.
Despite the differences in name, the terms used in
this manual carry the same meaning as the
corresponding FujiCam terminology and can
therefore be freely interchanged by FujiCam users.

Purpose of This Technical Training

- Provide knowledge and practical training for recovering the machine by
troubleshooting including measurement of Proper data.
- Carry out practical training for changing the sliding parts (such as IP-III
spline shaft)
- Give practical exerciseon how to locate troubles and recover the machine
when the machine cannot be recovered by simple replacement of a camera,
a servo amplifier or a motor.

Person Qualified for This Training

Manufacturing line manager, factory manager or a person in equivalent position who
has already completed the Level 2 training.

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 Contents – List of Current Pages

Contents – List of Current Pages

Safety Guidelines ......................................................(Edition 2.0)

1. About Symbols.......................................................................................1
2. Safety Rules for All Machine Types .......................................................2
3. Safety Rules for Individual Machine Types............................................7
IP-series Machines....................................................................................................7
4. Safety Labels .........................................................................................8
5. The EMERGENCY STOP Buttons ........................................................9
6. Before Operation .................................................................................10
7. Do not Leave Tools in or on the Machine ............................................10

Chapter 1 Nozzle Changer Unit

1.1 Replacing Nozzle Changer ................................(Edition 2.0)..........1-1
1.2 Calibrating Nozzle Changer ...............................(Edition 2.0)..........1-4
Nozzle Changer Coplanarity .....................................................................................1-4
Nozzle Change Position X and Y..............................................................................1-5
Nozzle Change Speed Control .................................................................................1-8
1.3 Training Evaluation.............................................(Edition 2.0)..........1-9

Chapter 2 X-Motor
2.1 Replacing X-Motor .............................................(Edition 2.0)..........2-1
2.2 Calibrating X-Motor ............................................(Edition 2.0)..........2-3
X Flag Set-Up (Head Interlock).................................................................................2-3
2.3 Measuring X-Motor Proper Data ........................(Edition 2.0)..........2-4
Limit Positions for X1 or X2.......................................................................................2-4
X Max........................................................................................................................2-5
Nozzle Change Position X ........................................................................................2-5
Error_Box1_Pos._X1, Error_Box2_Pos._X2 ............................................................2-6
Error_Conveyor_Pos._X1, Error_Conveyor_Pos._X2 ..............................................2-7
Carrier Position X......................................................................................................2-8
ESC_Position_X1 .....................................................................................................2-9
ESC_Position_X2 .....................................................................................................2-9
MFU1_Position_X1, MFU2_Position_X2 ................................................................2-10

Chapter 3 Y-Motor
3.1 Replacing Y-Motor..............................................(Edition 2.0)..........3-1
3.2 Measuring Y-Axis Proper Data...........................(Edition 2.0)..........3-4
Max Limit Position Y, Min Limit Position Y................................................................3-4
Loading Position Y ....................................................................................................3-5
3.3 Training Evaluation.............................................(Edition 2.0)..........3-6

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 Contents – List of Current Pages

Chapter 4 Spline Shaft

4.1 Removing Spline Shaft.......................................(Edition 2.0)..........4-1
4.2 Installing Spline Shaft.........................................(Edition 2.0)..........4-3
4.3 Training Evaluation.............................................(Edition 2.0)..........4-6

Chapter 5 Q-Motor
5.1 Replacing Q-Motor .............................................(Edition 2.1)..........5-1
5.2 Measuring Q-Axis Proper Data ..........................(Edition 2.1)..........5-7
Min Limit Position Q ..................................................................................................5-7
Max Limit Position Q ................................................................................................5-8
Q Origin Position.......................................................................................................5-9
5.3 Training Evaluation.............................................(Edition 2.0) ........5-11

Chapter 6 Z-Motor
6.1 Replacing Z-Motor..............................................(Edition 2.1)..........6-1
6.2 Measuring Z-Axis Proper Data...........................(Edition 2.0)..........6-6
Max Limit Position Z..................................................................................................6-6
Min Limit Position Z...................................................................................................6-7
Origin Position Z .......................................................................................................6-8
Verify the Z Interlock Sensor Position.....................................................................6-10
Carrier Position Z1 and Z2......................................................................................6-11
MFU Position Z .......................................................................................................6-12
Nozzle Change Position Z ......................................................................................6-13
6.3 Training Evaluation.............................................(Edition 2.0)........6-15

Chapter 7 Fiducial Camera

7.1 Replacing Fiducial Camera ................................(Edition 2.0)..........7-1
7.2 Calibrating Fiducial Camera...............................(Edition 2.0)..........7-2
Focus ........................................................................................................................7-5
Resolution and Delta.................................................................................................7-6
7.3 Training Evaluation.............................................(Edition 2.0)..........7-8

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 Contents – List of Current Pages

Chapter 8 Image Camera

8.1 Replacing Parts Camera ....................................(Edition 2.0)..........8-1
8.2 Calibrating Parts Camera...................................(Edition 2.0)..........8-4
Image Camera Y Adjustment....................................................................................8-4
Camera Focus ..........................................................................................................8-6
Image Camera Resolution ........................................................................................8-8
8.3 Measuring Parts Camera Proper Data...............(Edition 2.1) ........8-11
Origin Position X, Y.................................................................................................8-11
Camera Scan Position ............................................................................................8-12
Nozzle Position .......................................................................................................8-13
8.4 Measuring Placing Accuracy..............................(Edition 2.0)........8-14
Component Theta Skew .........................................................................................8-15
Camera Offset X, Y and Nozzle Position X, Y Calculations....................................8-17
8.5 Training Evaluation.............................................(Edition 2.0)........8-21

Chapter 9 MTU4 SX-Motor

9.1 Replacing MTU4 SX-Motor ................................(Edition 2.0)..........9-1
9.2 Measuring MTU4 SX-Axis Proper Data .............(Edition 2.0)..........9-3
Max Limit Position SX ...............................................................................................9-3
Min Limit Position SX ................................................................................................9-4
Origin Position SX.....................................................................................................9-5
Carrier Position SX ...................................................................................................9-6
Tray Out SX ..............................................................................................................9-7

Chapter 10 MTU4 SY-Motor

10.1 Replacing MTU4 SY-Motor ..............................(Edition 2.0)........10-1
10.2 Measuring MTU4 SY-Axis Proper Data............(Edition 2.0)........10-3
Max Limit Position SY .............................................................................................10-3
Min Limit Position SY ..............................................................................................10-4
Origin Position SY...................................................................................................10-5
Carrier Position SY .................................................................................................10-6
Tray Out SY ............................................................................................................10-7
10.3 Training Evaluation...........................................(Edition 2.0)........10-8

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 Contents – List of Current Pages

Chapter 11 MTU4 T-Motor

11.1 Replacing MTU4 T-Motor .................................(Edition 2.0) ........11-1
11.2 Adjusting MTU4 T-Axis Sensor Positions .........(Edition 2.0) ........11-5
Tray Eject Check Sensor ........................................................................................11-6
Positive (+) and Negative (-) Overtravel Sensors ...................................................11-6
Speed Reduction Sensor ........................................................................................11-6
Sub-Robot Interlock ................................................................................................11-6
Tray Set OK Sensor................................................................................................11-7
Tray Out OK Sensor ...............................................................................................11-7
Tray Position Set Sensors 1 ~ 4 .............................................................................11-7
Tray Add Confirmation Sensors 1 ~ 4.....................................................................11-8
11.3 Measuring MTU4 T-Axis Proper Data...............(Edition 2.0) ........11-9
Max Limit Position T................................................................................................11-9
Min Limit Position T...............................................................................................11-10
Origin Position T0 .................................................................................................11-11
11.4 Training Evaluation...........................................(Edition 2.0) ......11-12

Chapter 12 MTU4 SZ-Motor

12.1 Replacing MTU4 SZ-Motor ..............................(Edition 2.0)........12-1
12.2 Measuring MTU4 SZ-Axis Proper Data............(Edition 2.0)........12-4
Max Limit Position SZ .............................................................................................12-4
Min Limit Position SZ ..............................................................................................12-5
Part Position ZC0....................................................................................................12-6
Part Position ZT0 ....................................................................................................12-7
12.3 Calibrating MTU4 SZ-Motor .............................(Edition 2.0)........12-8
SZ Interlock Sensor ................................................................................................12-8
12.4 Training Evaluation...........................................(Edition 2.0)........12-9

Chapter 13 MTU4 Carrier

13.1 Calibrating MTU4 Carrier .................................(Edition 2.0)........13-1
Advance Limit Adjustment ......................................................................................13-2
Retract Limit Adjustment.........................................................................................13-4
13.2 Adjusting MTU4 Carrier Sensors .....................(Edition 2.0)........13-5
Forward Limit Sensor and Forward Speed Reduction Sensor................................13-5
Retract Limit Sensor and Retract Speed Reduction Sensor...................................13-6
Part Detect Sensor..................................................................................................13-7
13.3 Replacing MTU4 Carrier Pad and
Adjusting Its Height .........................................(Edition 2.0)........13-8
Carrier Pad Replacement .......................................................................................13-8
Carrier Nozzle .........................................................................................................13-8
Carrier Height Adjustment.......................................................................................13-8
Carrier Filter Element Replacement........................................................................13-9
13.4 Training Evaluation...........................................(Edition 2.0)......13-10

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Safety Guidelines

Fuji machines are designed and produced with safety as

one of our main considerations. However, even a
perfectly designed machine can be damaged, or someone
can still be injured if the user does not follow the safety
rules. It is the responsibility of the user to make sure all
safety rules are followed during operation and
maintenance.
Be sure to read these safety rules before operating the
machine. Keep this manual close to hand when
operating the machine.
 Safety Guidelines

1. About Symbols
To avoid injury to persons and damage to the machine, Fuji employs a number of messages
and symbols that are used in manuals and on the machines. Be sure you understand the
meanings of these symbols before reading the manual.

Hazard warnings are divided into the following three classes:

The hazard or unsafe practice will cause severe injury or

DANGER death.

The hazard or unsafe practice may cause severe injury or

WARNING death.

The hazard or unsafe practice may lead to personal injury

CAUTION or damage to the machine.

To distinguish the type of hazard, the following symbols are used in combination with the
ones above.

Hazard Alert
A triangle is used to draw your attention to a hazard. The symbol inside the
triangle indicates the nature of the hazard (in this case electrical shock).

Prohibition
A circle with a diagonal line inside is used to draw your attention to an
operation that is prohibited. The symbol inside the circle indicates the nature
of the operation (in this case disassembly).

A circle with an exclamation mark is used to draw your attention to a

mandatory action. In other words, you are required to carefully carry out the
given instructions.

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 Safety Guidelines

2. Safety Rules for All Machine Types

DANGER

Do not approach moving parts during automatic or

manual operation.
● Do not place hands or other body parts inside the machine during
automatic operation or positioning.
Body parts or clothing may be caught in the machine causing
personal injury.

Do not operate the machine with the safety covers or

doors open.
● Do not leave covers or safety doors open, except during
adjustment.
● When adjustments are completed, return the covers and doors to
their original (closed) position.
● When safety covers or doors are removed, body parts or clothing
may be caught in the machine causing personal injury. Always be
sure to replace the safety covers or doors.

WARNING

Always verify the position of the EMERGENCY STOP

buttons before operating the machine.
● Always be aware of the positions of the EMERGENCY STOP
buttons so that they can be pressed quickly in case of an
emergency.
● To reduce accidents and injury to a minimum, it is essential to know
the positions and understand the use of the EMERGENCY STOP
buttons.

Check the safety functions before starting operation.

● Before starting the machine check the operation of the
EMERGENCY STOP button, the safety switches on the acrylic
covers, the safety switch on the rear fence gate, the optical sensors
on the rear fence and all other machine safety features.
● Contact a Fuji serviceman immediately if any of the safety functions
fails.

Do not remove safety switches.

● Do not remove safety switches or disarm the safety functions.
● Disarming the safety switches may result in injury when others
unknowingly press the START button.
● Fuji does not take any responsibility when a machine is
disassembled without Fuji's permission, even if this results in
accidents or trouble.

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 Safety Guidelines

WARNING

Check that there is nobody inside the machine when

working on the machine with two persons or more.
● Verify that nobody is within or near the machine before operating
the machine. Operating the machine may cause injury to the
person who is carrying out maintenance.
[Example]
If one person moves the device table while another person is
exchanging a feeder, the latter may be injured.

Do not close the fence when someone is inside the

fence.
● When the fence is opened, it is safe to approach the machine.
Closing the fence, however, will put anybody working inside the
fence in immediate danger when the RESET or START button is
pressed. Be sure to leave the fence open when anyone is inside
the fence.

Do not approach a machine that has stopped moving.

● There are times during automatic operation when the machine may
appear to have stopped while it is waiting for a board, waiting for the
next machine, reading marks, transmitting data, etc. In such cases,
once certain conditions are fulfiled, the machine will begin moving
again automatically, so care should be taken. Only approach the
machine after the EMERGENCY STOP button has been pressed.
When the message "Ready" displays at the machine display, the
machine will begin to move once certain conditions are fulfiled.
● Keep in mind that the machine will begin to move regardless of
whether these conditions are fulfiled intentionally or inadvertently.

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 Safety Guidelines

WARNING

Resupply solder paste, glue and parts while the

machine is in manual mode.
● Never resupply solder, glue or parts during automatic operation
unless instructed otherwise. Body parts or clothing may be caught
in the machine causing personal injury.

Do not place hands near the main conveyor.

● Hands or other body parts may be caught in the machine.

Always turn the 200 V power supply off when cleaning

or lubricating the machine.
● When the 200 V power supply to the machine is turned on, the
servo amps will be activated. In this condition the machine may
unexpectedly begin to move.

Do not insert or remove connectors while power is

being supplied to the machine.
● Removing or inserting connectors while power is supplied to the
machine may not only cause damage to the machine, but may also
cause electrical shock.
● Be sure to cut the power to the machine before inserting or
removing connectors.

Do not touch the high voltage section within the

machine's control box.
● The Brown tube section within the machine's control box contains
high voltage wiring. Do not insert your hand or any metal object into
this part as it may cause electrical shock.

Stay clear from the machine when it is being lifted.

● Never put hands or feet under the machine when the machine is
being raised by means of a jack or other device for leveling or
transport.

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 Safety Guidelines

WARNING

Do not look into the conveyor inlet or outlet and do not

open the cover. (Reflow oven)
● Do not look into the conveyor inlet or outlet and do not open the
cover.
[Example]
The UV light on the reflow oven may damage eyesight or result in
burns.

Exchange the halogen lamp only after it has cooled

down.
● When turned on, halogen lamps will reach high temperatures,
resulting in skin burns when touched. To exchange a halogen
lamp, turn off the power and allow the lamp to cool off sufficiently.

Do not wear gloves made of cloth when operating the

machine.
● Rubber gloves will tear when caught by the machine and prevent
hands from being drawn into the machine. Gloves made of cotton
or similarly strong material may cause hands to be drawn into the
machine.

Long hair should be tied back.

● Long hair may get caught in running machines.
Hair should be kept short or tied back so that it does not get caught
in the machine.

Turn off the air supply when carrying out maintenance

on cylinders, valves, and filters.
● Removing cylinders, valves, or filters without turning the air supply
off, may cause parts or particles to be propelled into the eyes.
● Be sure to turn off the air supply when carrying out maintenance on
cylinders, valves, and filters.

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 Safety Guidelines

WARNING

Be sure to wear protective glasses.

● Be sure to wear protective glasses.
[Example]
CP-6 nozzles use springs which may be propelled during
disassembly. Be sure to handle the nozzles carefully to prevent eye
injuries.

Check the machine monitor and the target axes

while manually operating the machine.
● When operating the machine, carefully follow the instructions that
are displayed at the machine display.
● Operating the machine without looking at the machine display may
lead to operating errors or result in damage to the machine or
products.

CAUTION

Do not operate the machine after removing or disabling

sensors.
● Removing or disabling sensors will disarm the interlock, leading to
collisions and damage to the machine.

Check the machine display to determine whether

HELPS compatible machines are in the middle of
performing changeover.
● During operation in automatic mode on machines equipped with
automatic changeover equipment, it may be difficult to actually see
automatic changeover taking place from the front of the machine.
When a message appears at the machine display, follow the
instructions that are given.

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 Safety Guidelines

3. Safety Rules for Individual Machine Types

IP-series Machines

WARNING

Do not press the START button while the control box is

turned towards the back of the machine.
● When two or more people are working on the machine, the machine
from the rear may put the person(s) in front of the machine in
danger. Be sure to turn the control box to the front and only operate
the machine after verifying that nobody is near the machine.

Do not operate the machine with the Y-axis rear side

cover removed.
● Body parts or clothing may be caught in the machine causing
personal injury.

Do not disarm the safety switch on the MTU's front

acrylic cover and leave the cover open.
● Do not operate the machine with the MTU's front acrylic cover open
or removed and the wiring to the safety switch short circuited. Body
parts or clothing may be caught in the machine causing personal
injury.
● Do not short circuit or remove the safety switch or disarm the safety
function.

Do not move the MFU without first checking that

nothing lies in the direction of movement.
● Hitting someone with the MFU may cause injury or damage the
equipment.

Do not move the MFU by applying a sharp push to it and

then releasing the handle.
● Hitting someone with the MFU may cause injury or damage the
equipment.

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 Safety Guidelines

4. Safety Labels
To warn the operator of hazards, safety labels are attached to the machine at the
positions indicated in the figure below.
Familiarize yourself with each label and its message before operating the machine.

Placing pressure control (option) 1

1
,,
1
2

,, ,,
A 2 High Voltage
,, ,,
,,
,
,,,, ,,,, 2

, ,,,,,,,, A

1 Keep hands and

clothing well clear
of the moving conveyor
A

,,,,,,
, MFU DANGER
Never insert your hand
inside an operating machine.
1 Moving parts may cause injury.

IP3-m051

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 Safety Guidelines

5. The EMERGENCY STOP Buttons

In the event of an emergency, press any of the four red EMERGENCY STOP buttons
located on the machine at the positions indicated in the figures below.

EMERGENCY STOP buttons on the front of the machine

EMERGENCY STOP button on the rear of the machine

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 Safety Guidelines

6. Before Operation
Prior to operating the machine, make sure that no one is inside the machine or inside the
safety fence, or that anyone other than yourself is touching the machine.

7. Do not Leave Tools in or on the Machine

Following maintenance on a machine, make sure that no tools have been left in or on the
machine. Tools that get caught in the machine's moving parts may cause severe damage
to the machine.

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 Chapter 1
Nozzle
Changer Unit

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the
Nozzle Changer Unit to FUJI
specifications.
Chapter 1 1.1 Replacing Nozzle Changer

1.1 Replacing Nozzle Changer

Required Tools: 1 Metric Allen Wrench Set

Required Jigs: None

The nozzle change unit consists of the nozzle rests and the cylinder units (see the
figure below). Each nozzle change unit (left and right) can hold six standard
nozzle types or twelve optional nozzle types.

IP3T31001

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Chapter 1 1.1 Replacing Nozzle Changer

Arm Removal

1. Release the air pressure in the machine by turning off the air valve and
flushing out the residual air pressure within the system.

2. Remove the advancing physical stopper and cover plate by removing the
two (2) bolts that mount it to the nozzle changer.

3. Disconnect the four (4) pin electrical connector.

Warning
Do not remove the LM blocks from the LM guide. Doing so can result in
a loss of bearings and change the nozzle changers arm coplanarity
position. WN005

4. Remove the nut fixing the nozzle changer arm to the air piston.

5. Remove the eight (8) bolts securing the nozzle changer arm to the LM
blocks.

6. Remove the nozzle changer arm from the machine by pulling toward the
rear of the machine.

Note: Ensure that the LM blocks remain on the LM guide.

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Chapter 1 1.1 Replacing Nozzle Changer

Installation

1. Remove the nozzle changer hardware from the old nozzle changer arm
and reinstall the hardware onto the new nozzle changer arm.

Warning
Do not remove the LM blocks from the LM guide. Doing so can result in
a loss of bearings and change the nozzle changers arm coplanarity
position. WN005

2. Attach the new nozzle changer arm to the LM bearings by inserting the
changer into position from the MFU side of the machine.

3. Align the holes on the LM block with the holes in the nozzle change arm
and install the eight (8) mounting bolts to secure the changer to the LM
block.

4. Reconnect the electrical connector and then put the cover on.

5. Slide the cover into the groove on the nozzle changer arm.

6. Attach the nozzle changer arm to the air cylinder piston with a nut.

7. Install the two (2) bolts which secure the front of the cover to the nozzle
changer arm.

After replacing the nozzle change arm, the following calibrations must be be
completed:

Jaw Spacing
Nozzle Changer Coplanarity
Nozzle Change Position X
Nozzle Change Y
Nozzle Changer Speed Control

Note: After all the nozzle changer Proper calibrations are completed, change the nozzles using
the nozzle change function on all the calibrated nozzle changer arms.

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Chapter 1 1.2 Calibrating Nozzle Changer

1.2 Calibrating Nozzle Changer

Nozzle Changer Coplanarity
Definition: Nozzle Changer Coplanarity is the uniformity in height
between all of the nozzle changer jaws.

Required Tools: 1 (0.01 mm) Dial Indicator

Required Jigs: None

Procedure:

Note: Holder #1 is always used for zero reference.

1. Attach the dial indicator shaft arm to the X1 or X2 head depending on

the nozzle changer unit to be checked.

2. Advance the changer that has been replaced and align a dial gauge on
the bottom edge of the clamper jaw. Zero the indicator.

3. Jog the head to the inside of the machine until the indicator is on the
desired nozzle and measure and record the amount of deflection.

4. Align the head to changer number 1. Measure the deflection and

compare it with what was recorded in Step 3.

5. The total amount of deflection should not exceed “0.5 mm” across each
holder, with holder 1 as the zero reference.

6. If the value exceeds the tolerance, it is most likely due to the following
reasons:

a. Loss of bearings

b. Nozzle changer obstruction /seating

c. Nozzle changer unit level

d. Bent LM rail

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Chapter 1 1.2 Calibrating Nozzle Changer

Nozzle Change Position X and Y

Definition: Nozzle Change Position X and Y is the position where the
machine will position the head to change a nozzle.
The X and Y positions must be calibrated for each nozzle
changer arm that is changed or repaired.

Required Tools: 1 Dial Indicator (0.01 mm) 1 Magnetic Base

Required Jigs: 1 Nozzle Change Jig; Part Number: QPJ-1050

Warning
Failure to follow this procedure in the correct order can cause severe
damage to the machine. Take notice of all servo speeds, as they must
not exceed 0.5%. WN006

Procedure:

Receive the machine Proper to the host computer before beginning this
procedure.

1. Press [SET] → [PROPER] enter the password and press CR. In the “CHG
UNIT” screen, press [HEAD 1] and press the arrows keys to move up or
down to select the changer to be calibrated. Record the pulse count of
the changer and press [SELECT].

2. Press [POSITION] and note the “Servo Counter” column. The counter
column must read “Mode 1”. If the column does not read “Mode 1”,
press [MODE] several times to change the counter mode to “Mode 1”.

3. Note the “Servo Counter” Z pulse count. It must read “Ø.”

a. If the pulse count for the Z-axis is not Ø, use the arrow keys and
highlight the Z-axis under the position column. Press the “Ø” key
and then CR.

b. Press [MOVE] and then the START button. This procedure raises
the Z-axis high enough to clear all nozzle changers.

4. Highlight the corresponding X-axis under the “POSITION” column and

enter the X position that was recorded in Step 1, noting whether it’s a
positive or negative pulse count (e.g., CHG 3 on Head 1~ -7316).

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Chapter 1 1.2 Calibrating Nozzle Changer

5. Press [MOVE] and then the START button. This moves the
corresponding head to the nozzle changer arm to be calibrated (e.g.,
head 1 to -7316).

Note: If the head does not move after pressing the START button, check the servo counter
mode. It must read “Mode 1”. If it does not, see Step 2.

6. If there is a nozzle in the head or nozzle changer, remove it at this time.

Note: When installing the hardware, adjust the jaw spacing to 2.5 mm. This must be done
without a nozzle in the jaw.

2.5 mm

IP3T31002

7. Press [RETURN] → [CHANGE ORIGIN] and press START.

8. Place the nozzle jig QPJ-1050 into the changer, ensuring it is correctly
orientated.

9. Position a dial indicator on the bottom of the jig. Preload the indicator.

Note: 2 dial gauges can be used to measure deflection in both the X and Y directions.

IP3T31003

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Chapter 1 1.2 Calibrating Nozzle Changer

Warning
Care should be taken when performing the next step. Failure to do so
may result in machine damage. WN007

10. For the X adjustment, inch the Z-axis downward and use the X-axis jog
key to align the nozzle change jig to the spline shaft with a maximum of
+/-0.02 mm of deflection.

Note: DO NOT jog the X-axis with the spline shaft inside the jig.

11. After the Z-axis spline shaft fits into the nozzle change jig with no more
than +/- 0.02 mm of deflection, press [RETURN] → [SET] → [X] → [YES]
to set the current X position in the Proper for the X position for that
nozzle changer.

12. For the Y position, jog the Z-axis spline shaft into the jig. Make
adjustments with the Y adjust bolt and lock nut so the amount of
deflection in the Y direction is no more than +/- 0.02 mm.

13. When finished adjusting the Y direction, tighten the lock nut on the
adjusting bolt and adjust the shock absorber so that when the nozzle
changer arm is extended, there is only 0.5 mm gap between the main
body of the shock absorber and the physical stopper.

14. Return the axes to their zero positions and change the nozzles on the
head using the adjusted nozzle changer arms. Check for smooth
transitions. If further adjustments are necessary, repeat this procedure.

Warning
If this calibration was done at the machine, you must receive the Proper
to the host computer. Failure to do so may result in loss of recent
information. WN008

15. Receive the new Proper to the host computer.

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Chapter 1 1.2 Calibrating Nozzle Changer

Nozzle Changer Speed Control

Definition: The nozzle changer air cylinder is the air cylinder which drives the
nozzle changer arms to extend or retract.

Required Tools: None

Required Jigs: None

Speed Controller
Advance Limit Sensor

Retract Limit Sensor

Lock Nut

Speed Controller

Air Cushion
IP3T31004

Procedure:

1. Adjust the nozzle change air cylinder speed controller valves by fully
closing and then opening them 3 to 4 turns for each changer (See the
figure above).

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Chapter 1 1.3 Training Evaluation

1.3 Training Evaluation

Circle the most appropriate answer from the choices given below.

(1) To extend the nozzle changer 1-2 by using the I/O:

a. Turn on both “Y030 CHANGE BWD” and “Y032 CHANGE 1-2
FWD”.
b. Turn off “Y030 CHANGE BWD” and turn on “Y032 CHANGE 1-2
FWD”.

(2) After removing the fixing bolts and while detaching a nozzle changer
arm from its LM block:
a. To prevent the linear rail ball bearings from dropping, put a piece
opf tape at the rear end of the rail and use your fingers on the side
of the rail.
b. Detach the changer together with the LM guide.

(3) Nozzle changer position X is measured only on position 1-1 (head 1) and
2-1 (head 2).
a. True
b. False

(4) When the tip of the nozzle change arm 2-5 is lower than the other arms,
what countermeasures should be taken?
a. Change nozzle position Z (Proper data).
b. Replace the LM rail and blocks, etc.

(5) When a changer does not move smoothly, the linear rail should first be
replaced.
a. True
b. False

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Notes:

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 Chapter 2
X-Motor

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the X-
motor to FUJI specifications.
Chapter 2 2.1 Replacing X-Motor

2.1 Replacing X-Motor

Required Tools: 1 Metric Allen Wrench Set

Required Jigs: None

Removal

Procedure:

Receive the machine Proper to the host computer before beginning this procedure.

1. Turn off the machine and disconnect the two (2) electrical connectors to
the X-axis motor.

2. Loosen the coupler set screw located on the motor shaft side.

3. Remove the four (4) mounting bolts holding the motor in place.

4. Remove the old motor from the machine.

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Chapter 2 2.1 Replacing X-Motor

Installation

1. Connect the two (2) electrical connectors to the new motor, attach the
motor mechanically to the machine with the four (4) bolts and tighten the
coupling.

2. Turn on the machine and zero set.

3. Verify that the appropriate X-axis sensor locations are correct.

(The speed reduction, plus and minus overtravel sensors locations are
shown in the figure below).

X1 and X2 Sensor Positions

1 pls = 0.0028125 mm
Speed Reduction OT Sensor
Sensor
OT Sensor 0 pos

800 pls 100 pls 100 pls 800 pls

Min limit Max limit

Mechanical Stopper
3556 pls +/- 100
(10 mm)

~15556 pls
This diagram is for
the right X-axis Mechanical Stopper
IP3T32001

To check the sensor locations:

a. Press [SET] → [SERVO] to display the servo counters and press an

EMERGENCY STOP button to release the servo lock.

b. Manually move the X-axis into a physical stop and adjust the flag
to just break the sensor beam at the servo pulse counts as shown in
the figure above.

4. Due to the use of the linear encoder, no Proper calibrations need to be

performed when the X-motor is replaced. However, verification of the X
calibrations is recommended.

The following is a listing of the physical calibrations and Proper values

associated with the X-axis:
X Flag Set Up
Max and Min Limit Position X1 or X2
X Max
Nozzle Change Position X
Error Box Position X1 or X2
Error Conveyor Position X1 or X2
Carrier Position X
Escape Position X1, X2
MFU 1 and 2 Position X1 or X2

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Chapter 2 2.2 Calibrating X-Motor

2.2 Calibrating X-Motor

X Flag Set-Up (Head Interlock)
Definition: X Flag Set-Up is the position where the X1 - X2 interlock sensor trips,
preventing the heads from colliding.

Required Tools: 1 Metric Allen Wrench Set

1 Scale

Required Jigs: None

Procedure:

1. Zero set the machine.

2. Press [SET] → [SERVO] → [POSITION] and ensure that the servo pulse
count mode is “Mode 1 World 0”. Press an EMERGENCY STOP button
to release the servo lock.

3. Manually move the two X heads together until contact is made.

4. Using a scale, separate the two heads by 100 mm (as measured from the
urethane stopper located on head 2).

5. At this position, the flag on head 2 should just trip the sensor on head 1.

6. If the sensor is not tripped, loosen the two (2) allen bolts which secure
the flag and move the flag to the position where it just trips the sensor.

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Chapter 2 2.3 Measuring X-Motor Proper Data

2.3 Measuring X-Motor Proper Data

Limit Positions for X1 or X2
Definition: The limit positions are the software travel limits which prevent the X-
axes from driving into the mechanical stopper.

Required Tools: None

Required Jigs: None

Proper Data Items: Max Limit Position X (X MAX)

Min Limit Position X (X MIN)

Procedure:

Before beginning this procedure ensure that the current Proper has been sent to the host
computer.

1. Press [SET] → [SERVO] to display the servo pulse counter. Ensure that
the servo pulse count menu reads “Mode 1, World Zero”.

Note: Since the world coordinate system is used, it appears that the overtravel sensors used for
calculating the limit positions for the X axis are backwards, but this is not the case. Take
care not to miscalculate the limit positions.

2. Press an EMERGENCY STOP button to release the servo lock.

3. Manually push the X-axis until it engages an overtravel sensor.

4. Write down the pulse counter value of the axis in this position. Repeat
for the other overtravel sensor.

5. Calculate the values for each axis using the values found in the previous
step. The resulting values are the respective limit positions.

Limit Position Calculation

116. Max. Limit Position X = X-axis (-) overtravel sensor value - 100

121. Min. Limit Position X = X-axis (+) overtravel sensor value + 100

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually
update the limit positions in the Proper. Re-send the Proper to the
machine.

Method 2 Jog the axis to its desired position and press [SET] → [PROPER] and
enter the password and press CR → [X1 or X2] → [MAX] or [MIN]
→ [SET] to change the Proper in the machine to the current axis
position. Receive the Proper to the host computer.

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Chapter 2 2.3 Measuring X-Motor Proper Data

X Max
Definition: X Max is the value that is utilized to regulate the position of the
heads.

Required Tools: None

Required Jigs: None

Procedure:

Receive the machine Proper to the host computer before beginning this procedure.

1. Zero set the machine.

2. Press [SET] → [SERVO] → [POSITION] and ensure that the Servo pulse
count menu reads “Mode 1 World 0”. Press an EMERGENCY STOP
button to release the servo lock.

3. Manually push head 1 and 2 together and record the X1 and X2 servo
pulse counts.

4. Add the X1 and X2 values together as absolute values.

5. Open the Proper in the host computer and enter the value calculated in
Step 4 as “X_MAX”. Transmit the Proper to the machine. Restart the IP-
3.

Nozzle Change Position X

Definition: Nozzle Change Position X is the position where the machine
positions the head in order to change a nozzle.

Required Tools: 1 Dial Indicator (0.01 mm)

1 Magnetic Base

Required Jigs: 1 Nozzle Change Jig, Part Number: AQPJ-1060

Procedure:

Note: For more information, refer to Chapter 1, “Nozzle Change Position X and Y”.

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Chapter 2 2.3 Measuring X-Motor Proper Data

Error_Box 1_Pos._X1
Error_Box 2_Pos._X2
Definition: Error Box 1 or 2 Position X1/X2 is the position where the
corresponding head will go to dispose of components in a reject box.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Ensure that there is a nozzle in the corresponding head.

2. Press [SET] → [SERVO] → [POSITION] and ensure that the servo pulse
count menu reads “Mode 1 World 0”. Press an EMERGENCY STOP
button to release the servo lock.

3. Move the head so that it lies directly above its respective error box.

4. Record the position for the X-axis.

5. Enter this position into the machine Proper.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually enter the
new position in the Proper. Re-send the Proper to the machine.

Method 2 Jog the axis to the proper position and press [SET] → [PROPER] and enter the
password and press CR, [ETC] → [X1 or X2] → [Error Box] → [SET] to set the
current heads position as the position for the error box. Receive the Proper to
the host computer.

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Error_Conveyor_Pos._X1
Error_Conveyor_Pos._X2
Definition: Error Conveyor Position X1/X2 position is where the corresponding
head will go in order to reject a part on the conveyor.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Ensure that there is a nozzle in the corresponding holder.

2. Press [SET] → [SERVO] → [POSITION] and ensure that the servo pulse
count menu reads “Mode 1 World 0”. Press an EMERGENCY STOP
button to release the servo lock.

3. Move the head so that it lies directly above the conveyor.

4. Record the position for the desired X-axis.

5. Enter the new value in the machine Proper.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually enter the
new positions into the Proper. Re-send the Proper to the machine.

Method 2 Jog the axis to the proper position and press [SET] → [PROPER] and enter the
password and press CR, [ETC] → [X1 or X2] → [ERR CONVEYOR] → [SET]
to set the current heads position as the position for the error conveyor.
Receive the Proper to the host computer.

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Chapter 2 2.3 Measuring X-Motor Proper Data

Carrier Position X
Definition: Carrier Position X is the position in which the X-axis will go to pick a
part from the MTU4 parts carrier.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Zero set the machine.

2. Press [SET] → [POSITION] → [NOZZLE CHANGE] → [HEAD 1 or

HEAD 2] and select a 1.3 or 2.5 mm nozzle.

3. Advance the carrier from the MTU4 by pressing [MANUAL]

→[MANUAL 1] → [CARRIER] → [FORWARD]. Return to the MTU4
main menu after advancing the carrier.

4. Press an EMERGENCY STOP button and manually move the X-axis

close to the MTU4 vacuum cup. Manually lower the Z-axis and align the
tip of the nozzle as close to the center of the cup as possible by eye.
Release the Emergency Stop and press RESET.

5. Press [SET] → [SERVO] → [POSITION] and ensure that the servo pulse
count menu reads “Mode 1 World 0”.

6. Record the position of the appropriate X-axis and enter this into the
machines Proper.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually
enter the new position into the Proper. Re-send the Proper to the
machine.

Method 2 Jog the axis to the proper position and press [SET] → [PROPER]
and enter the password and press CR, [ETC] → [DEVICE] →
[carrier 1 or 2] → [X] → [SET] to set the current heads position as
the position for the error conveyor. Receive the Proper to the host
computer.

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ESC_Position _X1
Definition: Escape Position X1 is the servo pulse counter value in which the X1
head will go when waiting to place a part while head X2 is placing a
component.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. The value for this position is a fixed value of -170000 pulses. Ensure that
this value is entered in the machines Proper data under
“ESC_Position_X1.” Since this is a fixed value, no calibrations are
necessary.

ESC_Position _X2
Definition: Escape Position X2 is the servo pulse counter value in which the X2
head will go when waiting to place a part while head X1 is placing a
component.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. The value for this is a fixed value of 170000 pulses. Ensure that this
value is entered in the machines Proper data under “ESC_Position_X2”.
Since this is a fixed value, no calibrations are necessary.

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MFU1_Position_X1
MFU2_Position_X2
Definition: The MFU Position X is the position at which the center of the nozzle
of the respective head is aligned to the center of device location #1.

Required Tools: None

Required Jigs: IPJ-1011

QPJ-1040

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Press [SET] → [SERVO] → [POSITION] and ensure that the servo pulse
count menu reads “Mode 1 World 0”.

2. Install the feeder jig into device location number 1 of the corresponding
MFU.

3. Place the nozzle jig onto the shaft of the corresponding head.

4. Press an EMERGENCY STOP button to release the servo lock and move
the head above the feeder jig.

5. Lower the Z-axis into the center of the feeder jig while moving the X axis
until the two jigs fit together.

6. With the jigs in position, record the X-axis position for the desired X-axis
and enter this into the machines Proper data.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually
enter the new position into the Proper. Re-send the Proper to the
machine.

Method 2 Jog the axis to its desired value position as specified and press [SET]
→ [PROPER] and enter the password and press CR, [DEVICE] →
[MFU1 or MFU2] → [X] → [SET] to set the current position as the
new MFU position. Receive the Proper to the host computer.

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 Chapter 3
Y-Motor

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the Y-
motor to FUJI specifications.
Chapter 3 3.1 Replacing Y-Motor

3.1 Replacing Y-Motor

Required Tools: 1 Metric Allen Wrench Set

Required Jigs: None

Removal

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Turn off the machine and disconnect the two (2) electrical connectors to
the motor.

2. Remove the two (2) Philips screws securing the plate to the coupling
cover and loosen the set screw on the motor side of the coupling.

3. Remove the four (4) mounting bolts holding the motor in place.

4. Remove the old motor from the machine.

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Chapter 3 3.1 Replacing Y-Motor

Installation

1. Connect the two (2) electrical connectors to the new motor, attach the
motor to the machine with the four (4) mounting bolts, tighten the
coupling set screw and re-install the coupling cover with the two (2)
Philips screws.

2. Turn on the machine and zero set.

3. After the Y-axis motor is replaced, verification of the Y-axis sensor

locations is required. (The speed reduction, plus and minus overtravel
sensors locations are shown in the figure below.)

Y-Axis Sensor Setup

1 pulse = 0.0025 mm

Mechanical 800 pls

Stopper + OT
100 pls Sensor

Max
Limit

Speed Reduction
Sensor

~4000
pls

0 Position

~4000 pls
Min
Limit

Mechanical 100 pls - OT

Stopper Sensor
800 pls

Front of machine
IP3T33001

To check the sensor locations;

a. Press [SET] → [SERVO] to display the servo counters and press an

EMERGENCY STOP button to release the servo lock.

b. Manually move the Y-axis into a physical stop and adjust the flag
to just break the sensor beam at the servo pulse counts as shown in
the figure above.

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Chapter 3 3.1 Replacing Y-Motor

4. Use of a linear encoder requires no Proper calibrations. However,

verification of the Y-axis calibrations are recommended.

The following is a listing of the Proper values associated with the Y-axis:

Max Limit Position Y

Min Limit Position Y
Loading Position Y

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Chapter 3 3.2 Measuring Y-Axis Proper Data

3.2 Measuring Y-Axis Proper Data

Max Limit Position Y
Min Limit Position Y
Definition: The Max/Min Limit Y Positions are the software travel limits which
prevent the Y-axis from driving into the mechanical stoppers.

Required Tools: None

Required Jigs: None

Proper Data Items: Max Limit Position Y (Y MAX)

Min Limit Position Y (Y MIN)

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Display the servo pulse counter by pressing [SET] → [SERVO] and

ensure that the servo pulse count mode is “Mode 1 World 0”.

2. Press an EMERGENCY STOP button to release the servo lock. Manually

push the axis until it engages an overtravel sensor.

3. Record the pulse counter value of the axis in this position. Repeat for the
other overtravel sensor.

4. Calculate the values for the Y-axis using the values found in the previous
step. The resulting values are the respective limit positions.

Limit Position Calculation

117. Max. Limit Position Y = Y axis (+) overtravel sensor value - 100

122. Min. Limit Position Y = Y axis (-) overtravel sensor value + 100

5. Enter the recorded values into the machine Proper data.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually
enter the new limit positions into the Proper. Re-send the Proper to
the machine.

Method 2 Jog the axis to its desired position as specified and press [SET] →
[PROPER] and enter the password and press CR, [ETC] → [Y] →
[MAX Y] or [MIN Y] → [SET] to change the Proper in the machine
to the current axis position. Receive the Proper to the host
computer.

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Note: Both the X and Y limit positions will be updated.

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Chapter 3 3.3 Training Evaluation

Loading Position Y
Definition: Loading Position Y is the Y-axis servo position in which the Y-axis
will go when loading or unloading a PCB from the machine.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Zero set the machine.

2. Press the [LOADER] → [POSITION]. This moves the Y-axis to the old
Proper loader position.

3. Display the servo pulse counter by pressing [SET] → [SERVO] and

ensure that the servo pulse count mode is “Mode 1 World 0”.

4. Using a straight edge, measure from the front edge of the fixed rail to the
front edge of the loader. Make sure that there is a smooth transfer
between the two units.

5. Use the jog keys to inch the Y-axis to a position where the rails match.

6. Record the Y-axis position and enter the value into the Proper data for
the machine.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually
enter the loading position into the Proper. Re-send the Proper to
the machine.

Method 2 Jog the axis to desired position and press [SET] → [PROPER], and
enter the password and press CR, [ETC] → [Y] → [LOAD
POSITION] → [SET]. Receive the Proper to the host computer.

Edition 2.0 3-6 IP-3 Level 3 Tutorial

 Chapter 4
Spline Shaft

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the
Spline Shaft to FUJI specifications.
Chapter 4 4.1 Removing Spline Shaft

4.1 Removing Spline Shaft

Required Tools: 1 Metric Allen Wrench Set
2 9 mm Wrenches (one flattened or shaved thin)

Required Jigs: None

Note: The Q and Z Motors must be removed to replace the spline shaft. This will require all the
calibrations for the Q- and Z-axis to be completed anytime a spline shaft is replaced.

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Turn off the machine.

2. Remove the Z-axis motor which lies directly in front of the Q-motor (see
Chapter 6 “Z-Motor” for the Z-motor removal procedure).

3. Remove the fluorescent bulb backlight assembly (4 bolts total).

4. Remove the lower cover plate by removing the two (2) allen bolts
securing it to the head.

5. Remove the Q-axis motor which lies directly behind the Z-motor (see
Chapter 5 “Q-Motor” for the Q-motor removal procedure).

6. Remove the nozzle chuck assembly by loosening the 3 mm allen bolt and
sliding it off the shaft.

Warning
The large backlash gear will be removed in the next step. The rubber
physical stopper as well as the floating dog will then fall off. Note the
orientation of the floating dog. (Bevel Up) WN009

Note: Be careful to not lose the springs that are in the large backlash gear.

7. Remove the large backlash gear by removing the four (4) 2.5 mm allen
bolts from underneath.

8. Remove the three (3) 2.5 mm allen screws from the top of the rotary head
joint (top hat) assembly. Remove the top cover and spring from the top
hat. Slide the vacuum shaft out of the spline shaft.

9. Disconnect the vacuum hose from the top hat.

10. Remove the two (2)blue vacuum hose guide bolts.

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Chapter 4 4.1 Removing Spline Shaft

11. Loosen the two (2) 0.75 mm allen set screws from the black knuckle at
the top of the spline shaft. Using two (2) 9 mm wrenches (one flattened
or shaved thin) remove the black knuckle from the spline shaft. Remove
the top hat.

12. Remove 1 screw from the Z-interlock sensor, and loosen the other screw.
Swivel the sensor out of the way. This will allow room for the bearing
and shaft to slide out of the machine without moving the actual sensor
position.

13. Remove the four (4) 2 mm allen bolts that retain the top bearing in the
machine.

14. Slide the shaft and the top bearing up and out of the machine.

15. Remove the four (4) 2 mm allen bolts that retain the bottom bearing in
the machine and remove the bottom bearing.

Edition 2.0 4-2 IP-3 Level 3 Tutorial

Chapter 4 4.2 Installing Spline Shaft

4.2 Installing Spline Shaft

Required Tools: 1 Metric Allen Wrench Set
2 9 mm Wrenches (one flattened or shaved thin)
1 (0.01 mm) Dial Indicator and Magnetic Base

Required Jigs: None

Warning
The shaft and bearings are a matched set. Do not remove the top
bearing from the new spline shaft. If the top bearing slides too high up
the shaft, the bearings will fall out and ruin the new shaft. WN010

Procedure

1. Mount the new bottom bearing on the machine with the numbers on the
mounting plate facing towards the front of the machine. Tighten the
four (4) 2 mm allen bolts.

2. Mount the Z-axis gear and equipment from the old spline shaft onto the
new spline shaft.

M3 screw
Pulley Pulley shaft
Set screw
Set screw Pulley

IP3T34001

Warning
Be very careful not to let the top bearing slide too high, low, or off the
shaft. The ball bearings may fall out and ruin the shaft. WN011

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Chapter 4 4.2 Installing Spline Shaft

3. Slide the new shaft with the top bearing into the head. Bolt the new top
bearing with the numbers on the mounting plate facing towards the
front of the machine onto the machine.

M3 screw
Ball screw nut
Serial number

Serial number

Head

Serial number
Spline nut
Serial number

IP3T34002

Note: Be careful not to let the shaft slide down too low, or the ball bearings will fall out of the
top bearing. Make sure that the serial numbers on the ball screw spline axis, the ball
screw nut, and the spline nut are facing toward the front of the head when assembling.

4. Place the Z-axis belt on the spline shaft.

5. Replace the top hat assembly by putting the black knuckle on the shaft
and tighten (friction threads may seem tight).

Set screw

IP3T34003

6. Slide the vacuum shaft into the spline shaft.

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Chapter 4 4.2 Installing Spline Shaft

7. Place the top hat cover and spring on the top of the rotary head joint,
secure with the three (3) 2.5 mm allen bolts.

8. Replace the vacuum hose and hose guide (blue).

9. Install the floating Q-axis zero-setting dog. Remember to orientate the

floating dog with the bevel facing up, so that the floating dog’s arm is
flush with the gear.

10. Install the large backlash gear onto the shaft.

Note: Do not tighten the bolts completely yet. In the next step, the concentricity of the gear is
adjusted.

11. Using a dial guage with a long stylus and insert the stylus up into the
center hole (between the shaft and inner gear sleeve), and place it against
the upper gear’s inner sleeve.

Brass rod

IP3T34004

12. Rotate the split gear and adjust the concentricity by tapping on the upper
gear with a brass punch until the dial guage concentricity deviation is
less than ± 0.003 mm. Tighten the bolts diagonally to ensure proper
seating.

Note: This procedure ensures that the large gear is concentric. Otherwise, problems will occur
during normal machine operation.

13. Install the Z-axis rubber stopper. Do not forget this, as Z-axis
calibrations cannot be completed without the stopper on the shaft.

14. Mount the nozzle chuck assembly onto the shaft.

Note: It is sometimes easier to leave the backlash gear cover and fluorescent backlight assembly
off the machine while completing the Q and Z calibrations.

15. Reinstall the Q-motor. Follow the instructions for Q-motor installation in
Chapter 5. All Q-axis calibrations must be completed.

16. Reinstall the Z-motor. Follow the instructions for Z-motor installation in
Chapter 6. All Z-axis calibrations must be completed.

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Chapter 4 4.3 Training Evaluation

4.3 Training Evaluation

Circle the most appropriate answer from the choices given below.

(1) The shaft and bearings are replaced as a single unit.

a. True
b. False

(2) The floating dog should be set with the tapered side:
a. up.
b. down.

(3) A spline shaft should be removed by moving the spline upwards after
detching the bottom bearing.
a. True
b. False

(4) When installing a gear, some play is necessary.

a. True
b. False

(5) When replacing a spline shaft the Q- and Z-motors must be removed.
a. True
b. False

(6) After installing the rotary joint, the (___) sensor ON position should be
adjusted.
a. pressure control
b. nozzle confirmation

Edition 2.0 4-6 IP-3 Level 3 Tutorial

 Chapter 5
Q-Motor

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the Q-
motor to FUJI specifications.
Chapter 5 5.1 Replacing Q-Motor

5.1 Replacing Q-Motor

Required Tools: 1 Metric Allen Wrench Set

Required Jigs: None

Removal

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Turn off the machine.

2. Remove the fluorescent bulb backlight assembly (4 bolts total).

3. Remove the lower gear cover plate by removing the two (2) allen bolts
securing it to the head, as shown in the figure below.

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Chapter 5 5.1 Replacing Q-Motor

4. Remove the two (2) allen bolts securing the Q-motor to the head.

5. Disconnect the two (2) electrical connectors to the motor and remove the
motor from the machine.

Note: Mark the electrical connectors if removing the Z-motor to minimize the possibility of
reconnecting the different motor electrical connectors incorrectly.

6. Remove the Q-motor’s gear by loosening the set screw, remove the nut
and washer securing the gear to the shaft and remove the gear assembly.

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Chapter 5 5.1 Replacing Q-Motor

Installation

1. Place the old gear assembly onto the new motor, install the nut onto the
shaft, tighten the set screw, re-install the motor into the machine with the
two (2) mounting bolts and reconnect the two (2) electrical connector (see
the following note before installing).

Note: When re-installing the new motor, pre-load the split gear to a minimum of 1.5 teeth
before installing the motor.

The Z- and Q-axis motors require a load to be applied to them for servo feedback. Do not
apply servo power without a load applied to the axis. Ensure the Z-axis in the middle of
its range of motion.

Zero-setting the Q-axis is done by using the mecha-check. Failure to follow this
procedure can result in damage to the Servo Amp Motor or to the axes.

2. Boot the machine in mecha-check mode by pressing and holding the jog
“3” key and press Power ON.

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Chapter 5 5.1 Replacing Q-Motor

3. Zero set the Q-axis only. To do this, press [SERVO] and then press [+
PAGE] several times until the desired Q-axis page displays, then press
[SERVO MOVE] → [SERVO ON] and then press the START button.

Note: At this time the Q-axis will zero set.

Warning
Wait for the Q-axis to finish zero setting before proceeding to the next
step. WN012

4. Press an EMERGENCY STOP button and mechanically remove the Q-

motor, leaving the electrical connector plugged in.

5. By hand, turn the Q-motor gear to -4000 pulses.

6. Turn the gear until the zero set flag is against the negative physical
stopper.

7. With the backlash gears pre-loaded to a minimum of 1.5 teeth and the
zero set flag against the negative physical stopper, re-install the Q-motor
while retaining the -4000 pulses (+/- 1000).

8. Re-zero set the Q-axis in mecha-check mode, and press an EMERGENCY

STOP button. Turn the gear until the zero set flag is against the negative
physical stopper to verify that this position is -4000 (+/- 1000) pulse
counts. If it is not, then go to step 4 to reinstall the Q-motor and repeat
the process until -4000 (+/- 1000) is established.

9. Clear the emergency stop and re-zero set the Q-axis.

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Chapter 5 5.1 Replacing Q-Motor

10. Press an EMERGENCY STOP button. Move the Q-axis to its negative
physical stop. Record the pulse count as position A (e.g., A=-4293 ).

11. Back off from the negative physical stop and determine when the flag
just contacts the stabilizer as shown in the figure above. Record the
pulse count as position B (e.g., B= -2448).

12. Find the average between A and B (i.e., (A+B)/2= C). The sum is the
value where the speed reduction sensor should just be activated.

13. Jog the Q-axis to the value C determined in the previous step.

14. Enter the I\O and navigate to the Q-axis zero address:
head 1 (S2X00A) in the Servo 2 I/O
(head 1 servo 1 I/O with 4800 card)
head 2 (S3X00A) in the Servo 3 I/O
(head 2 servo 2 I/O with 4800 card)
At the value of C, the sensor should be active. If it is not active, adjust
the sensor so that it is just activated at that value.

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Chapter 5 5.1 Replacing Q-Motor

15. Perform the Q-axis Proper measurements (Min, Max, Q Origin). The
figure below illustrates the Q-axis and its positions.

A C
100 pls Mechanical Mechanical 100 pls
Stopper Stopper
Min Max
Limit Limit
Speed Reduction
Sensor (A-B)/2+B=

B Stablizer
Q-Axis Calibrations
1 pulse = 0.00375 degrees

Q Origin
(A+C)/2=

IP3T35006

16. After all Q calibrations are completed, go to Chapter 6, “Z-Motor” and

complete the Z-motor installation procedure and the Z-axis calibrations
and Proper measurements.

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Chapter 5 5.2 Measuring Q-Axis Proper Data

5.2 Measuring Q-Axis Proper Data

Min Limit Position Q
Definition: Min Limit Position is a software travel limit which prevents the Q-
axis from physically driving into the negative stopper.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been
received to the host computer.

1. Boot the machine in mecha-check mode by pressing and holding the jog
“3” key and press Power ON.

2. Zero set the Q-axis only. To do this, press [SERVO] and then press [+
PAGE] several times until the desired Q-axis page displays, then press
[SERVO MOVE] → [SERVO ON] and then press the START button.

3. Press an EMERGENCY STOP button.

4. Manually rotate the Q-motor until the flag contacts the negative physical
stopper. Record the servo pulse count.

5. Add 100 pulses to this value (e.g. -4215+100=-4115).

6. This new value is the Min Limit Position Q for that axis. Enter this value
into the corresponding Proper data setting at the host system.

7. Transmit the new Proper and restart the machine to register the new
position.

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Chapter 5 5.2 Measuring Q-Axis Proper Data

Max Limit Position Q

Definition: Max Limit Position is a software travel limit which prevents the Q-
axis from physically driving into the positive stopper.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Boot the machine in mecha-check mode by pressing and holding the jog
“3” key and press Power ON.

2. Zero set the Q-axis only. To do this, press [SERVO] and then press [+
PAGE] several times until the desired Q-axis page displays, then press
[SERVO MOVE] → [SERVO ON] and then press the START button.

3. Press an EMERGENCY STOP button.

4. Manually rotate the Q-motor until the flag contacts the positive physical
stopper. Record the servo pulse counts.

5. Subtract 100 pulses from this value.

6. This new value is the Max Limit Position Q for that axis. Enter this value
into the corresponding Proper data setting at the host system.

7. Transmit the new Proper and restart the machine to register the new
position.

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Chapter 5 5.2 Measuring Q-Axis Proper Data

Q Origin Position
Definition: Q Origin Position is the position to which the Q-axis will default to
after zero-setting. The purpose of Q origin is to align the nozzle
chuck on the Q-axis square to each nozzle.

Required Tools: 1 Metric Allen Wrench Set

1 Dial Indicator (0.01 mm)
1 Magnetic Base

Required Jigs: Jig Nozzle (Z9855MQP5780)

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Boot the machine in mecha-check mode by pressing and holding the jog
“3” key and press Power ON.

2. Zero set the Q-axis only. To do this, press [SERVO] and then press [+
PAGE] several times until the desired Q-axis page displays, then press
[SERVO MOVE] → [SERVO ON] and then press the START button.

3. Refer to the Q Min and Q Max travel limits. Find the difference between
the two travel-limits (i.e., MIN+MAX/2) (e.g., -4000 + 120000/2 =
58,000).

4. Inch the Z-axis to be high enough so the axis will not strike anything if
the X-axis is inched.

5. Jog the Q-axis to the sum calculated in the previous step.

6. The Q-axis chuck must be square to this new Q origin position. To

square the chuck, place the jig nozzle on the head.

7. Set the dial indicator to read the flat surface of the jig and zero the dial
on the indicator.

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Chapter 5 5.2 Measuring Q-Axis Proper Data

8. Using the inching keys, slowly jog the X-axis so the dial gauge moves
across the flat surface of the jig. Note the amount of deflection displayed
on the indicator.

9. The amount of deflection must NOT exceed +/- 0.01 mm. If adjustment
is necessary, do not jog the Q-axis to correct the deflection. Rather,
loosen the allen bolt on the nozzle chuck and adjust the nozzle chuck to
correct the amount of deflection. Remeasure the deflection and repeat as
necessary.

Note: If a deflection of “0.01 mm” is the best that can be acquired, jog the Q-axis to square the
chuck. The amount of the axis can be jogged to correct deflection must not be more than
100 pulses different than the value determined in step 3.

10. Once the amount of deflection is acceptable, record the Q-axis position.

11. This new value is the Q origin for that axis. Enter this value into the
corresponding Proper data setting at the host system.

12. Remove the nozzle jig and dial indicator. Then transmit the new Proper
and restart the machine to register the new position.

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Chapter 5 5.3 Training Evaluation

5.3 Training Evaluation

Circle the most appropriate answer from the choices given below.

(1) After replacing the Q-motor, Z-motor adjustments are necessary.

a. True
b. False

(2) After replacing the Z-motor, Q-motor adjustements are necessary.

a. True
b. False

(3) When performing the Q-motor zero-set adjustment, use (___) mode.
a. mecha-check
b. normal

(4) Q Origin is the 0 pulse position.

a. True
b. False

(5) Nozzle change is performed at (___).

a. 0 pulse position
b. Q Origin position

(6) A wrong Q Origin postion affects camera Proper measurements, which

in turn leads to bad placing accuracy.
a. True
b. False

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Chapter 5 5.3 Training Evaluation

Notes:

Edition 2.0 5-12 IP-3 Level 3 Tutorial

 Chapter 6
Z-Motor

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the Z-
motor to FUJI specifications.
Chapter 6 6.1 Replacing Z-Motor

6.1 Replacing Z-Motor

Required Tools: 1 Set Metric Allen Wrenches
1 (0.01 mm) Dial Indicator and Magnetic Base
1 Open End Wrench

Required Jigs: 1 Jig Plate

Removal

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Turn off the machine.

2. Disconnect the two (2) motor connectors.

IP3T36001

3. Hold the motor while removing the four (4) mounting bolts, and slip the
timing belt off of the top from the gear and remove the motor from the
machine.

4. Remove the old motor from the mounting bracket by removing two (2)
bolts, and loosen the set screw in the motors’ gear and remove the gear
from the motor’s shaft.

Note: If removing the Q-axis motor, return to the Q-axis replacement section, step 3 at this
time.

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Chapter 6 6.1 Replacing Z-Motor

Installation

Procedure:

1. Install the new motor on its mounting bracket in the reverse order from
removal. Belt tension should be 260 hz (+/- 10) for the <H4485T>
212p2M6-530 timing belt (brown teeth), and 403 hz (+/- 10) for the
<H4485H> 212P2M6 timing belt (black teeth).

2. With the proper belt tension, lock the bracket in place with two (2)
opposing mounting bolts as shown in the figure below.

Note: Set the Z-axis height halfway between the interlock and the speed reduction sensor.

IP3T36002

3. Connect the two (2) electrical connectors to the machine.

Warning
When manually zero-setting, remember that the Z- axis is temporarily
installed. If not cautious, personal injury and machine damage can
result. WN014

4. Remove any nozzles on the head and then boot the machine in mecha-
check mode by pressing and holding the jog “3” key and press Power
ON.

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Chapter 6 6.1 Replacing Z-Motor

5. Zero set the Q-axis only. To do this, press [SERVO] and then press [+
PAGE] several times until the desired Q-axis page displays, then press
[SERVO MOVE] → [SERVO ON] and then press the START button.

6. Inch the Q-axis to the Q-origin position recorded in the Proper data for
that side.

Warning
Zero-setting for the Z-axis will have to be done manually. Be extremely
cautious, personal injury and machine damage can result. WN013

7. Manually zero set the Z-axis. To do this, press [SERVO] and then press
[+ PAGE] several times until the desired Z-axis page displays, then press
[SERVO MOVE] → [SERVO ON] to enable START.

8. When START is pressed, manually flag the speed reduction sensor to

complete the zero setting for the Z-axis.

IP3T36003

9. After the zero-setting is completed, press an EMERGENCY STOP button

and verify that the Q has maintained its origin.

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Chapter 6 6.1 Replacing Z-Motor

10. Loosen the timing belt by loosening the four (4) mounting bolts on the
bracket, and move the Z-axis into the upper mechanical stopper.
Manually rotate the Z-motors’ gear to a value of - 500 (+/-90) and tighten
the timing belt. See the figure below, and the following note. Tighten the
belt tension to 415 hz (+/- 10).

Note: When in mecha-check mode the Z-axis minus and plus signs are switched.

IP3T36004

Note: When installing the Z-axis, the Q-axis must remain at its origin value. The Z-axis must
remain against its upper mechanical stop and the Z-motor must remain at -500 (+/-90)
pulse counts when installing the belt. Failure to do so will result in Z-axis overtravel
and Z-axis amp alarms (one tooth on the timing belt is equal to 150 pulse counts).

11. After installation is complete, zero set the axis several times to verify the
zero set repeatability of the Z-axis. Ensure the Z-axis does not run into
overtravel or cause servo amp alarms.

12. Establish where the Z-axis speed reduction sensor activates by jogging
the axis to + 650 pulse counts. Verify that the speed reduction sensor is
“ON” at + 650 ± 50 pulse counts.

13. If the speed reduction sensor position is off by more or less than 50 pulse
counts, adjust the sensor position.

Caution
When calibrating any one of the Z Proper items, it’s crucial that the
Q-axis remains at its origin position or picking, placing and nozzle
change errors will result. CN001

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Chapter 6 6.1 Replacing Z-Motor

Due to the removal of the Z-axis motor, the following Proper calibrations need to be
completed:
Max
Min
Z Origin
MFU Z Origin
Carrier Z Origin
Nozzle Change Z Height.

Warning
Do not attempt to do any axis functions until all Z-axis Proper
calibrations are completed. WN015

Z-Axis
1 pulse = 0.002 mm

Mechanical
Stopper 500 pls 100 pls
+/- 90 Max Travel
Limit
0 Position
650 pls
+/- 50 Speed
Reduction
Sensor

Z Interlock
Sensor

3530 pls
+\- 20

Z0 Origin

Mechanical Min Travel

Stopper Limit
100 pls

IP3T36005

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Chapter 6 6.2 Measuring Z-Axis Proper Data

6.2 Measuring Z-Axis Proper Data

Max Limit Position Z
Definition: Max Limit Position Z is the software travel limit in which prevents
the Z-axis from moving into the positive physical stopper.

Required Tools: None

Required Jigs: None

Procedure::

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Zero set the machine.

2. Display the servo pulse count screen and verify that the Q-axis is at its
origin. Press [SET] → [SERVO], and ensure that the servo pulse count
menu is set to “Mode 1, World Zero”.

3. Press an EMERGENCY STOP button. Manually push the Z-axis up until

it contacts the positive physical stopper. Check the Q origin. If it is not
at its’ origin, manually rotate the Q-axis until Q origin is obtained.
Record the Z-axis servo position.

4. Subtract 100 pulse counts from this to determine the new value for the Z
max limit and enter this data into the machine Proper.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually
enter the limit position into the Proper. Re-send the Proper to the
machine.

Method 2 Jog the axis to correct position and press [SET] → [PROPER], and
enter the password and press CR, [Q,Z], and select the correct head,
[Z MAX] → [SET] to set the current Z-axis position as the new Z
max position. Receive the Proper to the host computer.

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Chapter 6 6.2 Measuring Z-Axis Proper Data

Min Limit Position Z

Definition: Min Limit Position Z is the software travel limit in which prevents
the Z-axis from moving into the negative physical stopper.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Zero set the machine.

2. Press [SET] → [SERVO] and check that the Q axis is at its origin. Ensure
that the servo pulse mode is set to “Mode 1, World Zero”.

3. Press an EMERGENCY STOP button. Manually push the Z-axis down

until it contacts the negative physical stopper. Check the Q origin. If it is
not at Q origin, manually rotate the Q-axis until the Q origin is obtained.
Record the Z-axis position.

4. Add 100 pulse counts to the value from step 3 to determine the new Z
min limit position and enter this into the machine Proper.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually
enter the limit position into the Proper. Re-send the Proper to the
machine.

Method 2 Jog the axis to correct position and press [SET] → [PROPER], and
enter the password and press CR, [Q,Z], and select the correct head,
[Z MIN] → [SET] to set the current Z-axis position as the new Z min
position. Receive the Proper to the host computer.

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Chapter 6 6.2 Measuring Z-Axis Proper Data

Origin Position Z
Definition: Origin Position Z is the servo pulse count value which the machine
uses to calculate the placement height for the Z-axis.

Required Tools: 1 Dial Indicator (0.01 mm)

1 Magnetic Base

Required Jigs: 1 Jig Plate, Part Number: FPJ 1030

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Zero set the machine and manually place a nozzle in the chuck. Ensure
that the servo pulse count menu is set at “Mode 1, World Zero”. The
nozzle must be a standard 26 mm length nozzle.

Note: While calibrating Z Origin, monitor the Q Origin. The Q-axis must remain at Q Origin
throughout this calibration. Failure to do so will result in skewed placement. Also, Z
Origin must be determined while using a straight 26 mm (length) nozzle.

2. Note the Q Origin position for the head to be calibrated.

3. Load and clamp the jig plate, Part number: AFPJ 1011, onto the Y-table.

4. Use the inching keys to jog the Y-table and the X head over to where the
nozzle lies directly over the upper flat surface of the jig plate.

5. With the nozzle over the jig plate, lower the Z-axis until the nozzle tip
lies just above the plate (approximately 0.5 mm).

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Chapter 6 6.2 Measuring Z-Axis Proper Data

6. Set a dial indicator under the dispersion disk, as shown in the figure
below and lower the Z-axis until the dial indicator just stops moving.

IP3T36006

7. When contact is made, verify that the Q remained at its origin position.

8. Once the Z-axis is in position and Q is at Q origin, save the value to the
machines’ Proper as “Z Origin”.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually
enter the new position into the Proper. Re-send the Proper to the
machine.

Method 2 Jog the axis to the correct position and press [SET] → [PROPER],
and enter the password and press CR, [Q,Z], and select the correct
head, [Z ORIGIN] → [SET] to set the current Z-axis position as the
new Z origin position. Receive the Proper to the host computer.

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Verify the Z Interlock Sensor Position

Definition: This sensor prevents the head from moving during production when
activated. This is to prevent the head from striking objects.

Required Tools: 1 Metric Allen Wrench Set

Required Jigs: None

Procedure:

1. Take the value for the current Z Origin and add 3530 pulse counts to
determine the location for the Z interlock sensor to be activiated.
Example: Z-Origin = -22500 add 3530 pls = -18970 (Z-interlock sensor
position)

2. Press [SET] → [POSITION] → [POSITION] → [COUNTER] and use the

arrows to navigate to [Z], and type in the value obtained in the previous
step. Press [MOVE] and then the START button.

3. Verify that the Z Interlock sensor is active (i.e., the red light is on at the
sensor).

4. If the sensor is not active at the described pulse count, adjust the sensor
not the flag until the sensor is just activated.

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Carrier Position Z1 and Z2

Definition: Carrier Position Z1 and Z2 is the position in which the Z-axis will
reference when picking a part from the MTU4 part carrier.

Required Tools: 1 Dial Indicator (0.01 mm)

1 Magnetic Base

Required Jigs: None

Procedure::

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Zero set the machine and manually place a nozzle in the chuck. The
nozzle must be a standard 26 mm length nozzle. Ensure that the servo
pulse count mode is set to “Mode 1, World Zero”.

2. Note the Q Origin Position for the head being calibrated.

3. Advance the carrier from the MTU4 control box.

4. Using the “POSITION” screen, position the corresponding head to “Ø”

pulse counts (the center of the carrier is not necessary).

5. Lower the Z-axis until the nozzle lies just above the parts carrier pad
(about 0.5 mm).

6. Place a dial indicator on the underside of the nozzles’ dispersion disk

and zero the gauge.

7. Lower the Z-axis until the dial indicator just stops moving. When
contact is made, verify that Q remained at Q origin position.

8. With the Z-axis in position and Q at its origin, save the value to the
machines’ Proper as “Carrier Z Origin”.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually
enter the new position into the Proper. Re-send the Proper to the
machine.

Method 2 Jog the axis to the correct position and press: [SET] → [PROPER],
and enter the password and press CR, [DEVICE], and select the
correct carrier, [Z] → [SET] to set the current Z-axis position as the
new Z carrier position. Receive the Proper to the host computer.

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MFU Position Z
Definition: MFU Position Z is the position in which the Z-axis will reference
when picking parts from the feeders.

Required Tools: 1 Dial Indicator

1 Magnetic Base

Required Jigs: Feeder Jig, Part Number: Z9402-PJ-0280

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Install the feeder jig into any device location.

2. Zero set the machine. Ensure that the servo pulse mode is set to “Mode
1, World Zero”.

3. Install a nozzle onto the head. The nozzle used for this measurement
must be a standard 26 mm length nozzle. Note the Q Origin Position for
the head to be calibrated.

4. Jog the head to the corresponding device location (center of the device jig
is not necessary).

5. Lower the Z-axis until the nozzle lies just above the device jig
(approximately 0.5 mm).

6. Place a dial indicator on the underside of the nozzles’ dispersion disk

and zero the dial.

7. Lower the Z-axis until the dial indicator just stops moving.

8. When contact is made, verify that Q remained at its origin position.

9. With the Z-axis in position and Q at its origin, save the Z position value
to the machines’ Proper as “MFU1/2 Position Z”.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually
enter the MFU Z Origin position into the Proper. Re-send the
Proper to the machine. Restart the machine.

Method 2 Jog the axis to the correct position and press [SET] → [PROPER],
and enter the password and press CR, [DEVICE], and select the
correct MFU, [SET] to set the current Z-axis position as the new
MFU1/2 Position Z. Receive the Proper to the host computer.

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Nozzle Change Position Z

Definition: Nozzle Change Position Z is the position in which the Z-axis will
drive when changing nozzles.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer and the Placing Pressure Check Sensor has been properly adjusted.

Warning
Failure to follow this procedure in the correct order can cause severe
damage to the machine. Take notice of all servo speeds, as they must
not exceed 0.5%. WN006

1. Using the machines’ [CHG UNIT] screen, page 533 in the Proper, record
the X pulse count of changer 1 for the side being calibrated.

2. Using the arrow keys, highlight or type in the corresponding changer to

be calibrated (e.g., “CHG 1”) and press [SELECT].

3. Press [POSITION] and note the “Servo Counter” column. The counter
column must read “Mode 1, World Zero”. If the column does not read
“Mode 1, World Zero” press [MODE] several times to establish this
condition.

4. Note the “Servo Counters” corresponding Z pulse count. It must read

“Ø”. If it does not, use the arrow keys and highlight the corresponding
Z under the position column. Type “Ø” and press the CR button.

5. Press [MOVE] and then the START button.

6. Highlight the corresponding X-axis under the “POSITION” column and

type in the X position recorded in Step 1. Note whether it is a positive or
negative pulse count (e.g., “CHG 1” on Head 1= -24717).

7. Press [MOVE] and then the START button. This moves the
corresponding head to the nozzle changer to be calibrated.

Note: If the head does not move after pressing the START button, check the servo counter
mode. It must read “Mode 1, World Zero”. If it is not in Mode 1, see Step 3.

8. If there is a nozzle in the head, remove it at this time.

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9. Exit the Servo counter screen and return to the Proper screen on machine
page 533. All the nozzle change positions are displayed on the screen.
Note the changer that is highlighted. It should be the changer that was
selected in Step 2.

10. Once the corresponding Z pulse is at “Ø” and the X-axis is in position,
press [CHANGER ORG] and check that the advancing changer is clear of
objects before pressing the START button. The changer that was
highlighted in Step 2 will advance at this time.

11. Place a nozzle into the changer that is going to be calibrated.

12. Check that the Q-axis is at its origin.

13. Use the jog keys to move the Z-axis spline shaft into the nozzle. Make
sure there is a smooth transition.

Warning
Do not jog the X-axis with the spline shaft inside the nozzle. This will
damage the machine. WN016

14. Continue to lower the nozzle shaft until the placing pressure sensor
turns red.

Note: Of the two sensor amps located on the face of the head, the placing pressure sensor amp is
the one located on the right for both heads 1 & 2.
(The left sensor amp is for Nozzle Confirmation detection)

15. When the placing pressure sensor amplifier turns red, record the Z-axis
servo pulse count.

16. With the recorded servo pulse counts from the previous step, add 50
pulses. This new value is the new nozzle change position Z.

17. Enter this new value into the machine Proper.

There are two methods for entering this information into the machine Proper.

Method 1 Receive the machine Proper to the host computer and manually
enter the new position into the Proper. Re-send the Proper to the
machine. Restart the machine.

Method 2 Jog the axis to the correct position and press: [SET] → [PROPER],
and enter the password and press CR, [NZL CHGR], and select the
correct head, [SET] to set the current Z-axis position as the new
nozzle change position Z. Receive the Proper to the host computer.

18. Return each axis to their “Ø” position and change the nozzles
automatically for all adjusted nozzle changers. Check for smooth
transitions. If adjustment is necessary, repeat remeasuring the Z
position. Once completed, resume production.

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Chapter 6 6.3 Training Evaluation

6.3 Training Evaluation

Circle the most appropriate answer from the choices given below.

(1) When the Z-axis is adjusted, Q-axis must always be at (___) position.
a. 0 pulse
b. Q-Origin

(2) The Z-axis speed reduction sensor bracket should be located near the
middle of the adjustment range.
a. True
b. False

(3) Plus and minus of the Z-axis are (___) in normal mode to that in mecha-
check mode.
a. the same
b. opposite

(4) Origin position Z is the (___) height.

a. device pick up reference
b. placing reference

(5) When measuring origin position Z, the point where the nozzle spring is
compressed becomes the new Origin Position Z.
a. True
b. False

(6) After temporally zero-setting, if the timing belt is detached when the
servo lock is on, the motor runs out of control.
a. True
b. False

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Notes:

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 Chapter 7
Fiducial Camera

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the
Fiducial Camera to FUJI specifications.
Chapter 7 7.1 Replacing Fiducial Camera

7.1 Replacing Fiducial Camera

The fiducial camera is the reference point for all machine centers. If for any reason
the fiducial camera has been damaged or removed, the calibrations that follow in
the list below must be done In this order

Focus
Resolution and Delta
Origin Position X, Y
Image Camera(1 & 2) Position
Nozzle Position (1 & 2)
Camera (1 & 2) Offset X, Y
Nozzle (1 & 2) Position X, Y

Both Image cameras use the fiducial as a reference, therefore both image cameras
must be calibrated with the new fiducial camera position.

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Chapter 7 7.1 Replacing Fiducial Camera

Removal

Required Tools: 1 Metric Allen Wrench Set

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Turn off the machine.

2. Disconnect the electrical connector from the top of the camera and the
two pin connector from the light housing.

3. While holding the camera, remove the two mounting bolts located to the
right of the camera module and remove the camera.

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Fiducial Camera Installation

Required Tools: 1 Metric Allen Wrench Set

Required Jigs: None

Procedure:

1. Remove the mounting plate from the camera by removing the four (4)
attaching bolts and loosen the single set screw found on the right side of
the mounting bracket.

Note: Do not loosen the two (2) set screws on the left side as this will effect the camera’s tilt

2. Lift the old camera straight up when removing the camera from the
mounting bracket in order to clear the light housing.

3. Detach the half-lens assembly from the old camera and re-install it onto
the new camera, ensuring the half lense faces the back side of the camera.

Note: Do not remove the half lens from its collar. If removal is necessary, measure the distance
before removing it for later reference and install the new half lense in the same position
on the collar.

4. Mount the new camera in the bracket and verify that the half lens faces
the back side of the camera.

5. Reattach the focusing bracket to the head and connect the electrical
connectors to the camera and light housing.

Note: The light housing can damage the half lens. Exercise extreme care when installing the
camera onto its bracket.

6. Verify that there is approximately 1 mm between the tip of the half lens
and the top of the dispersion disk (See the figure below).

7. If 1 mm is not present, loosen the two (2) bolts holding the housing and
adjust until a 1 mm gap is reached.

Note: If a white image appears surrounding the camera’s center, check the distance between the
dispersion plate and the half lense. If the distance is 1 mm and the white image still
appears, adjust the height of the dispersion plate until the white image does not appear.

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7.2 Calibrating Fiducial Camera

After the camera has been removed and re-installed, proceed with the following
calibrations. In the following order:

Focus
Resolution and Delta
Origin Position X, Y
Image Camera(1 & 2) Position
Nozzle Position (1 & 2)
Camera (1 & 2) Offset X, Y
Nozzle (1 & 2) Position X, Y

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Focus
Required Tools: 1 Metric Allen Wrench Set

Required Jigs: Jig Plate AFPJ-1011

Button Jig FPJ-1030

Procedure:

1. Zero set the machine.

2. Load and clamp the jig plate.

3. Press [SET] → [PROPER], and enter the password and press CR,
[CAMERA] → [RESOLUTION] to display an image from the fiducial
camera on the monitor.

4. Jog the X- and Y-axes to the point at which the scribe marks on the jig
plate lie beneath the camera and appear on the monitor.

5. Check the focus. Loosen the two camera focusing bolts and raise or
lower the fiducial camera until the scribe marks on the jig plate are
clearly focused. Once focused, tighten the mounting bolts.

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Resolution and Delta

Definition: Resolution is the Proper calibration that measures the number of
pixels within a given area.

Required Tools: None

Required Jigs: AFPJ-1011 Jig Plate

FPJ-1030 Button Jig

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. The camera must have good focus before performing this calibration.

2. Place a piece of double-sided tape into the channel of the jig plate and
place the button jig on top of the tape with the fiducial dot facing up.

3. Load the jig plate and inch the camera to be above the fiducial mark on
the button jig.

4. Press [SET] → [PROPER], and enter the password and press CR,
[CAMERA] → [RESOLUTION] → [MARK CAMERA] to enter the
“RESOLUTION” screen in the Proper and align the button jig to the
cross hair displayed on the monitor.

5. Once the cross hairs are aligned, press the START button to begin the
test.

Note: The machine begins to calibrate the fiducial cameras’ resolution. At the same time the
machine measures the Fiducial Cameras’ Delta Q.

6. Once the test is finished, a series of numbers will appear on the monitor.
Record the “MARK READ X” and “MARK READ Y” values.

7. The values should be between 1212416 ~ 1277952 for the Sony cameras
and 1179648 ~ 1245184 for the Toshiba cameras.

8. If the values fall out of range, check the fiducial cameras’ focus and
repeat the resolution calibration.

9. The DELTA Q value should be within +/- 0.03 degrees.

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10. If the value is not within +/- 0.03 degrees, loosen the locking bolt and
turn the eccentric screw (shown in the figure below) to change the
cameras’ angle.

11. Making sure to lock the unit down after every adjustment. Repeat this
procedure until Delta Q equals “Ø”.

Fuji recommends the following calibrations at this point.

Origin Position X, Y
Image Camera(1 & 2) Position
Nozzle Position (1 & 2)
Camera (1 & 2) Offset X, Y
Nozzle (1 & 2) Position X, Y

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Chapter 7 7.3 Training Evaluation

7.3 Training Evaluation

Circle the most appropriate answer from the choices given below.

(1) If the fiducial camera is out of focus, it is impossible to obtain a

resolution value within the specified range.
a. True
b. False

(2) When a white image appears surrounding the camera center, adjust the
(___).
a. light dispersion plate height
b. focus

(3) When measuring Delta Q, the fixing bolts should be loose.

a. True
b. False

(4) The half mirror must be facing toward the (___) of the machine.
a. front
b. rear

(5) After replacing the fiducial camera, it is necessary to measure Origin

Position X, Y.
a. True
b. False

(6) The camera lamp is replaced by detaching the camera.

a. True
b. False

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 Chapter 8
Image Camera

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the
Image Camera to FUJI specifications.
Chapter 8 8.1 Replacing Parts Camera

8.1 Replacing Parts Camera

Removal

Required Tools: 1 Metric Allen Wrench Set

1 Dial Gauge and Magnetic Stand

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

Note: To make later calibrations easier, measure or mark the cameras’ height of the camera
bracket before removing the image camera from the machine. The measurement taken
will be used to install the new camera.

1. Remove the old camera from the machine by removing the four (4)
camera mounting bolts and disconnect the two (2) electrical connectors
at the bottom of the camera body shown in the figure below.

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2. Remove the bolts securing the blue locking ring in place and the
remaining bolts from around the lens. These bolts are labelled B in the
figure below.

3. Remove the two (2) bolts securing the camera and lens assembly to the
mounting bracket.

B IP3T38002

Note: Before removing the lens from the camera, record the aperture and focus settings.

4. Unlock the lens ring and remove the lens from the old camera body.

5. Remove the camera from the bracket.

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Installation

1. Assemble the hardware to the new camera in the reverse order. The
camera’s scan arrow must point towards the front of machine.

2. Ensure that the image camera bracket for adjusting Delta Q is in the
middle of its range.

This bracket should

be in the middle of
range for rotation

IP3T38003

Note: Set the aperture and focus on the lens to the settings recorded earlier. If the settings are
lost, set the aperture to “4.0”. If a vision process error occurs, set value to “5.6”.

3. To minimize Delta Q adjustment in later camera calibrations, use the

camera jig platform to square the camera to the mounting bracket. If the
camera jig platform is not available, then place the camera and bracket
on a flat table as shown in the picture below and twist the camera in the
bracket until the back of the camera and the camera bracket are flat on
the table.

SCAN
.. .. .. .. .. .. .

Table

Flat against
the table

Table
IP3T38004

4. Attach the blue focus lock ring.

5. Re-install the camera to the machine to the height recorded earlier.

Note: If installing a camera with a different field of view than the previous camera, consult Fuji
for the corresponding camera heights.

Note: The image camera must now be calibrated, have Proper measurements made, and have
Placing Accuracy Measurements performed before using the camera in production.

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8.2 Calibrating Parts Camera

The calibrations in the list below must be performed after an image camera has
been removed.

Image Camera Y
Focus
Resolution and Delta Q

Image Camera Y Adjustment

Definition: Image Camera Y Adjustment aligns the camera to the center of the
nozzle in the Y-direction.

Required Tools: 1 Metric Allen Wrench Set

1 Metal Scale

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

Note: 1. It is very important that the camera is set to the correct height before beginning this
calibration. Otherwise, the machine will not recognize the nozzle.

2. If you continue to get Vision Process Errors (i.e., camera cannot find the nozzle)
temporarily skip this section and perform the next camera calibration “Camera Focus”
and then return to this section to finish the image camera Y adjustment. If you
continue to experience problems, contact your local Fuji representative.

1. Change the nozzle on the head on the side of the image camera being
adjusted to a 10 mm nozzle.

2. Navigate to “Camera Position Calibration” (Page 532) for the head on the
side of the image camera being adjusted. To navigate to this screen,
press [SET], [PROPER], and enter the password and press CR. Next
select [CAMERA], [CAMERA PSN], and select the head for the side
being calibrated. Press the START button to perform this calibration and
display the nozzle image on the parts monitor.

3. After the test is finished, verify (by eye) that the nozzle is centered on the
parts monitor.

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4. If the nozzle is not centered, loosen the four (4) allen bolts shown in the
figure below and slide the camera back or forward.

Note: Moving the camera toward the front of the machine will move the image to the left (this is
not a live image).

5. Tighten the four (4) bolts and repeat this calibration until the nozzle
display is centered on the parts monitor.

6. Receive the machine Proper to the host computer.

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Camera Focus
Definition: This calibration is performed to set the focus at the sharpest focus
possible. This allows the machine to perform accurate vision
processing and part placements.

Required Tools: 1 Metric Allen Wrench Set

Required Jigs: One 340 pin glass part for the standard 2048 pixel camera.
One 332/160 pin glass part for the optional 1024 pixel camera.

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

Note: The focus does not calibrate the pixel size, rather it brings focus to the existing pixel size
to allow the running of further calibrations.

1. Change the nozzle on the head on the side of the image camera being
adjusted to a 20 mm nozzle.

2. By using the I/O, turn on the vacuum for the head on the side of the
image camera being adjusted and place the glass part squarely on the
nozzle. To access the screen to turn the vacuum on, select [SET] →
[MANUAL] → [I/O] → [STANDARD I/O] → [OUTPUT], and scroll to
Y020 for head one or Y024 for head two. Select [ON/OFF] to turn on the
vacuum.

3. Press [Return] until page 000 displays. Then select [SET] → [MANUAL]
→ [VISION] → [ADJUST], and enter the password and press CR, then
press [CHK IMAGE] to enter the vision adjustment screen. Select the
camera being calibrated using [SLCT CAMERA].

4. Select [GET ACQ] and press the START button when it begins flashing
to display an image of the glass part.

5. Using the “Zoom” command, enlarge the picture until the first set of
numbers appear on the screen for the pixel brightness. Press [RETURN]
→ [ACQUIRED IMG], and continue to press [ZOOM IN] until numbers
appear in the parts monitor.

6. Scroll by pressing [SCROLL] and scroll a direction until leads come into
view in the parts monitor.

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7. If the focus needs to be adjusted, loosen the allen bolts marked A in the
figure below to loosen the focus lock bracket. Then adjust the cameras’
focus.

Note: The image in the parts monitor is not a live image so while adjusting the focus the image
does not change.

FOCUS VARIABLES
Camera Height
Focus Ring (Lens height to pixel array)
Aperture
Gain/Offset

IN FOCUS
Center (2) Pixel Leads as close to 0 as possible (sharp transition on lead
edge)
Inside Part Body pixels as close to 0 as possible
Outside body (dispersion disc) as close to 255 as possible.

250 125 255 160 125

110 255 150 250 125

125 15 7 35 150

255 7 3 25 110

150 20 4 15 250

IP3T38007

9. Press [Return] 2 times to return to page 522 to acquire a new image from
the camera. Repeat steps 4 to 9 until the center pixels of a lead display a
number close to zero and outside of the leads the pixels are as close to
255 as possible.

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Image Camera Resolution

Definition: The “Image Camera Resolution” is a calibration in which the
machine calculates the pixel amount within a given area. The
number of pixels within the specified area must be within a given
value.

Required Tools: 1 Metric Allen Wrench Set

1 Dial Indicator
1 Magnetic Base

Required Jigs: Wide View Jig; Part number: AQPJ-1010

Narrow View Jig; Part number: AQPJ-1020

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Insert the corresponding resolution jig AQPJ-1010 for the wide field of
view camera or AQPJ-1011 for the narrow field of view camera. Square
the jig by eye.

2. Mount a dial indicator to the machine and jog the corresponding head
with the jig to be set to the indicator.

3. Set up the dial indicator to one end of the resolution jig and zero the
gauge.

4. Measure the amount of deflection on the dial gauge from one side to the
other side.

IP3T38008

5. If the amount of deflection is more than +\- 0.01 mm, display the servo
counter and jog the Q-axis for the head with the jig until the amount of
deflection is +\- 0.01 mm. Record the value for the Q-axis.

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6. Once the jig is square and the Q pulse count has been recorded, enter the
“RESOLUTION” page to measure the Proper. This screen is accessed
from page 000 by pressing [SET] → [PROPER] and enter the password
and press CR, then press [CAMERA] → [RESOLUTION] and select the
camera that the resolution is to be measured for.

7. Press the START button to begin the test. Measurements by the machine
will begin. Once the calibration stops, look at the DELTA Q value and
the RESOLUTION numbers.
Verify that the RESOLUTION X um/px (CIA) and Y um/px (CIA)
values fall between the following ranges.
2048 Wide 2942567 ~ 2955673
2048 Narrow 1468007 ~ 1481113
1024 4410000 ~ 4430000

8. If the X and Y values are out of range, the camera height needs
adjustment. Change the camera height by loosening the four (4) locking
bolts (labeled B, in the figure below) and turn the adjusting bolt (labeled
A, in the figure below) to change the cameras’ height. Repeat the
procedure until the resolution for X and Y fall in range.

Note: Be aware that by raising or lowering the cameras’ height, the camera’s focus is affected.
You must readjust the focus again.

Raise or lower the

camera to bring the A - Adjustment bolt
resolution in range

If the measured value is too high,

raise the camera B - Locking bolts

If the measured value is too low,

lower the camera

IP3T38009

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9. Once resolution and focus are within range, if the DELTA Q value is not
+\- 0.01, loosen the four (4) locking bolts (labelled A, in the figure below)
and turn the two (2) jack screws (labeled B, in the figure below) to adjust
the angle of the camera.

A For the right side camera,

Locking bolts
counterclockwise rotation increases the Delta Q value

For the left side camera,

clockwise rotation increases the Delta Q value

Adjustment Delta
bolts Adjustment
IP3T38010

10. Once the camera angle has been adjusted, tighten the four (4) locking
bolts and run the resolution test again. Repeat these steps until Delta Q
is +\- 0.01.

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Chapter 8 8.3 Measuring Parts Camera Proper Data

8.3 Measuring Parts Camera Proper Data

The Proper Measurements in the list below must be performed after an image
camera has been removed or if the fiducial camera has been changed or moved.

Camera Origin X, Y
Camera Scan Position
Nozzle Position

Origin Position X, Y
Note: The fiducial camera is the reference point for all machine centers. If for any reason the
fiducial camera has been damaged or removed, ALL camera Proper measurements
pertaining to the fiducial camera, as well as the image cameras, must be re-measured.

Definition: Origin Position X, Y is the relationship between the center of the

fiducial camera to the center of the main tooling pin. Doing X, Y
calibrations insures that all image camera calibrations are taught
from a true machine origin.

Required Jigs: Jig Plate; Part number: AFPJ-1011

Required Tools: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Zero set the machine.

2. Load and clamp the jig plate. Make sure that the plate is square to the
machine Ø. Physically insert the tooling pin into the machine and
ensure that it mechanically aligns with the jig plate.

3. Enter the “XØ, YØ” page (page 532-4) in the machine’s Proper. To
navigate to this screen, press [SET] → [PROPER], and enter the password
and press CR, and then press [CAMERA] → [XØ, YØ].

4. Jog the jig plate to the center of the machine and align the fiducial
camera cross hairs over the main tooling pin hole by eye.

5. Press [SET] to set that position as the machine’s new origin point
(Machine Ø).

6. Receive the machine’s Proper to the host computer.

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Chapter 8 8.3 Measuring Parts Camera Proper Data

Camera Scan Position

Definition: Camera Scan Position is the relationship between the center of the
nozzle and the center of the image camera.

Required Tools: None

Required Jigs: 1 Straight 10 mm Nozzle

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

Note: In the current Proper, change the camera offsets for X, Y, and Q to 0 for the side of the
machine being adjusted. Transmit this Proper to the machine before performing the
Proper measurements from this point.

1. Change the current nozzle to a straight 10 mm nozzle on the head of the

side of the camera being calibrated.

Note: The 10 mm nozzle that is going to be used must be straight. If possible, perform this
calibration with a nozzle that has never been used in production (A NEW Nozzle).

2. Enter the “Camera Position” page (page 532-2) in the Proper . To

navigate to this screen, press [SET] → [PROPER], and enter the password
and press CR, then press [CAMERA] → [CAMERA PSN], and select the
head on the side of the camera being calibrated.

3. Press the START button and the machine measures the center of the
nozzle in relation to the center of the image camera.

4. When the calibration is finished, the machine will automatically adjust

the “Camera Scan”, “Camera_Origin_X”, and “Camera_ Origin_Y”
positions.

5. Repeat the measurements until the Camera Origin X and Camera Origin
Y values stabilize. Usually 3 or 4 times is sufficient. There are no range
limitations. If the Camera Origin X and Camera Origin Y continue to
change, contact your local Fuji representative.

6. Receive the current machine Proper to the host computer.

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Chapter 8 8.3 Measuring Parts Camera Proper Data

Nozzle Position
Definition: Nozzle Position is the relationship between the center of the nozzle
and the center of the fiducial camera.

Required Tools: None

Requirements: 1 Jig Plate; Part number: AFPJ-1011

1 Button Jig; Part number: FPJ-1030
1 Board Program for Setting the Nozzle Position

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Ensure that the program for setting the nozzle position is loaded in the
foreground and also ensure that the XØ, YØ calibration has been
completed. If the program for setting the nozzle position is not available,
contact your local Fuji representative.

2. Change the current nozzle to a straight 10 mm nozzle on the head the

camera is being calibrated.

3. Place double sided tape on the jig plate and load the jig plate into the
machine.

4. Enter the “Nozzle Position” page in the Proper. To navigate to this

screen press [SET] → [PROPER], and enter the password and press CR,
and then press [CAMERA] → [NOZZLE PSN], and select the head on the
side that the camera is being calibrated. At this time, the vacuum will
turn on and the START button flashes.

5. Place the button jig, Part number: FPJ-1030, on the tip of the 10 mm
nozzle with the fiducial facing up.

6. Press the START button to begin the calibration. At this time, the
machine places the button jig and checks the placement with the fiducial
camera. Then the machine automatically calculates the nozzle X, Y
position values.

7. After the first measurement, note the nozzle X, Y position values.

8. Run the test a second time and note the amount of change between the
first and second running of the calibration (± 15 is acceptable). If the
value is far above ± 15, the button jig may be slipping on the the jig plate.
Try replacing the double sided tape and run the test two more times.
Even if the values continue to fall out of range, the deflection can be
corrected in the fine adjustment using glass parts and a board. (For
details, refer to section 8.4 “Measuring Placing Accuracy”.

Note: The use of the calibration jigs are preliminary adjustments. Fine adjustments are done
by how parts are placed on a board. The fine adjustments are called placement accuracy
measurements.

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Chapter 8 8.4 Measuring Placing Accuracy

8.4 Measuring Placing Accuracy

The Proper Measurements in the list below must be performed after an image
camera has been removed or if the fiducial camera has been changed or moved.

Camera Offset Position X, Y

Nozzle Position X, Y

Definition: Placing accuracy measurements are used to fine tune the Proper
measurements to ensure the highest possible accuracy for part
placement.

Required Tools: 1 Microscope

Required Jigs: 1 Glass Board and Program

(1 placement at 180 and 1 placement at 0 degrees).
2 Glass Parts and Part Data

Note: Because of the fine pitch nature of the part, there are many variables which can effect
placement. During the following calibration, procedures must repeated exactly in the
same way (e.g., placing the glass part on the nozzle the same way and direction). You
will be using a glass board and glass parts. The glass board must be loaded with the same
orientation after every measurement. The glass parts must be hand placed on the nozzle,
and placed in the same X, Y location after every measurement. Failure to follow this
procedure will give poor results.

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Chapter 8 8.4 Measuring Placing Accuracy

Component Theta Skew

Procedure:

This must be done before proceeding with the following Proper adjustments.
Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Run the glass board calibration program and place one (1) glass part at
zero (Ø°) (preferably on one of the scales closest to the center of the glass
board).

2. When the machine goes to pick a part from a feeder location, press the
red F key and the machine will pause with the vacuum on.

3. Manually place the glass part on the nozzle as square as possible and
press the START button when safe. The part then is placed on the board.

4. Finish the program placement sequences by repeating steps two and

three again and unload the glass board. Carefully remove the glass
board from the machine so the glass parts will not shift and affect the
readings.

Caution
The machine is waiting for another board once the original glass board
sequences have been finished and the board has been unloaded.
Select [S STOP] during the unloading of the original board to stop the
machine from continuing production and waiting for another board. CN002

5. Utilizing a microscope, document the direction and the number of pads

the part is being placed off center. Use the figure on the following page
to establish if there is a theta skew and how to determine how much to
alter the camera Q offset.

Note: Look for all possible reasons the part is skewing before putting in an offset.

6. Alter the existing camera Q offset in the Proper by the amount specified
amount with a CCIMF editor and save the file.

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Chapter 8 8.4 Measuring Placing Accuracy

7. Transmit the new Proper to the machine and repeat this procedure until
an acceptable component skew is achieved.

Note: If placements are such that consistent results cannot be achieved, do not continue the
calibration. Placements should be consistent. If the first placement shows the X and Y
placements to appear as if the part is rotating, then further research must be done to
correct this. Skewing can be caused by poor tape on the board, Delta Q not at 0.01, or
even a bent spline shaft.

Board Vernier

2 lines off
counterclockwise
Offset Q +20 (340 pins)
Leads

3 lines off
clockwise
Offset Q -30 (340 pins)

IP3T38011

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Chapter 8 8.4 Measuring Placing Accuracy

Camera Offset X, Y and Nozzle Position X, Y

Calculations
Definition: Camera Offset X, Y calibrates the Ø degree and 180 degree rotations
to be placed on the same pad. The objective is to place the part on
the same pad (Precision).
(i.e., If “Ø°” is placed on the 7th pad, then 180° must be placed on the
7th pad.)
Nozzle Position X, Y calibrates the Ø° and the 180° to the scales
center pad. The objective is to center the part on the scale (Accuracy).

Required Tools: 1 Microscope

Required Jigs: 1 Glass Board and Program

(1 placement at 180 and 1 placement at 0 degrees).
2 Glass Parts and Part Data

Note: Because of the fine pitch nature of the part, there are many variables which can effect
placement. During the following calibration, procedures must be repeated exactly in the
same way (e.g., placing the glass part on the nozzle the same way and direction). You
will be using a glass board and glass parts. The glass board must be loaded with the same
orientation after every measurement. The glass parts must be hand placed on the nozzle,
and placed in the same X, Y location after every measurement. Failure to follow this
procedure will give poor results.

Procedure:

This must be done after completing the Component Theta Skew adjustment.

1. Run the glass board calibration program for the camera type being
calibrated and place two (2) glass parts, one at zero degrees (0°) and the
other at one hundred and eighty degrees (180°).

2. When the machine goes to pick a part from a feeder location, press the
red F key and the machine will pause with the vacuum on.

3. Manually place one of the glass parts with the bevelled edge down and
toward the front of the machine on the nozzle as square as possible and
press the START button when safe. The part is then placed on the board.
(Placing the glass parts on the nozzle with the bevelled edge down
ensures that the printing on the glass is on the bottom.)

4. When the machine goes to pick the second part from a feeder location,
press the red F key and the machine will pause with the vacuum on.

5. Again, manually place one of the glass parts with the bevelled edge
down and toward the front of the machine on the nozzle as square as
possible and press START when safe. The second part is placed on the
board.

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Chapter 8 8.4 Measuring Placing Accuracy

6. After placing the two components at zero degrees (Ø°) and at one
hundred and eighty degrees (18Ø°), unload the glass board. Carefully
remove the glass board from the machine so the glass parts will not shift
and affect the readings.

Caution
The machine is waiting for another board once the original glass board
sequences have been finished and the board has been unloaded.
Select [S STOP] during the unloading of the original board to stop the
machine from continuing production and waiting for another board. CN002

7. Copy the “IP-3E Pam Worksheet for 0 and 180 Degrees” found in the
back of this manual. Utilising a microscope, document the direction and
the number of pads the part is being placed off center.

8. On the copy of the PAM worksheet, enter the figures found in step 5 as
displayed in the picture below.

-8 -2

6 0 4 -2 180 3

-4 10

9. Following the arrows from the boxes, copy the figures into the new
boxes. The picture below is an example for X.

-8 + -4
= -6 -6 + 4
2 = -1
X0A
2
XB
-1
5

-2 + 10
= 4
2
X180A

-8 -2

6 0 4 -2 180 3

-4 10

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Chapter 8 8.4 Measuring Placing Accuracy

10. Perform the calculations to determine the averages for X at 0° (X0A) and
180° (X180A) degrees and Y at 0° (Y0A) and 180° (Y180A) degrees. The
picture above is an example for X.

11. Copy these figures into the new boxes by following the arrows.

12. Add the averages for X and then divide this by 2 to calculate the X bisect
point (XB). Repeat for Y. The picture below shows an example for X.

-8 + -4
= -6 -6 + 4
2 = -1
X0A
2
XB
-1
5

-2 + 10
= 4
2
X180A

13. Copy the X and Y bisect point figures into the new boxes by following
the arrows. The picture below shows an example for X.

IP-IIIE Pam Worksheet for 0 and 180 Degrees

-6 -6 + 4
X0A = -1 -1 X -5 = 5 / 2.8 = 1.79 ( -1 - -6 ) X -5 = -25
2
-1
XB Nozzle Position X Camera Offset X
5

14. For determining the amount to change the nozzle position, first multiply
the bisect point by -5 and enter this new figure into the next box. Next,
divide this figure by 2.8 for X or 2.5 for Y to convert the figure into
pulses. Enter this new figure into the last box. The picture below shows
an example for X.

-1 X -5 = 5 / 2.8 = 1.79
Nozzle Position X

15. For determining the amount to change the camera offset, first subtract
the zero average from the bisect point and then multiply this by -5 and
enter this new figure into the next box. This measurement is in microns.
The picture below shows an example for X.

( -1 - -6 ) X -5 = -25
Camera Offset X

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Chapter 8 8.4 Measuring Placing Accuracy

16. Copy these new figures into the new boxes by following the arrows. The
picture below shows an example for X.

-1 X -5 = 5 / 2.8 = 1.79 ( -1 - -6 ) X -5 = -25

Nozzle Position X Camera Offset X

Nozzle Position X Camera Offset X

102 Nozzle1_ Old Proper value 143 Camera1_ Old Proper value
Position_X Offset_X
58615 43
104 Nozzle2_ 150 Camera2_
Position_X Offset_X
+ 2 + -25

microns
pulses
58617 18
New Proper value New Proper value

17. Open the current machine Proper data with an CCIMF editing program
and enter the current Proper values into the Old Proper value boxes for
the corresponding section. The picture above shows an example for X.

18 Add the calculated figures to the old Proper values and enter the new
values into the Proper data and save the Proper data file.

19. Transmit the new Proper to the machine and repeat this until all of the
sides deviation for 0° and 180° degrees is within 5 bars.

20. Run the board two more times to ensure that the placement deviation is
5 bars or less. Resume production and monitor the component
placement repeatability.

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Chapter 8 8.5 Training Evaluation

8.5 Training Evaluation

Circle the most appropriate answer from the choices given below.

(1) When the placing accuracy is bad, replace the camera.

a. True
b. False

(2) When installing a new camera, make sure that the arrow printed on the
bottom of the camera is pointing towards the (___) of the machine.
a. rear
b. front

(3) The Delta Q adjusting bolts should be loose during Delta Q adjustment.
a. True
b. False

(4) If a taken image is shifted to the left on the monitor, move the camera
(___).
a. forward
b. backward

(5) If the resolution values are out of range after the focus adjustment, re-
adjust the focus to bring the resolution values into range.
a. True
b. False

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Notes:

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 Chapter 9
MTU4 SX-Motor

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the
MTU4 SX-Motor to FUJI specifications.
Chapter 9 9.1 Replacing MTU4 SX-Motor

9.1 Replacing MTU4 SX-Motor

Required Tools: 1 Metric Allen Wrench Set
1 8 mm Open End Wrench
1 Tension Gauge

Required Jigs: None

Removal

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Turn off the machine.

2. Disconnect the two (2) electrical connectors from the motor.

3. Loosen the four (4) slotted bolts (from below the motor) securing the
motor mounting plate and remove the motors’ belt.

4. Remove the four (4) bolts securing the motor mounting bracket to the
machine and remove the old motor.

5. Remove the four (4) bolts securing the motor to the mounting bracket.

6. Loosen the two (2) set screws in the gear assembly and remove the gear.

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Chapter 9 9.1 Replacing MTU4 SX-Motor

Installation

1. Install the new motor in the reverse order as described in the Removal
section. DO NOT attach the timing belt at this time.

Warning
Care should be taken when performing the next step. Failure to do so
may result in machine damage. WN007

2. Press Power ON to turn on the machine and manually flag the zero set
sensor and complete zero-setting.

3. After the zero-setting is completed, set a gap of 10 mm between the axis

and the minus physical stopper.

4. Install the timing belt over the gear and tighten the belt tension to “0.38
kgf” per 1.2 mm of travel.

After installing the SX-motor, the following Proper measurements must

be completed:
Max Limit SX
Min Limit SX
Origin Position SX
CARRIER Position SX
Tray Out SX

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Chapter 9 9.2 Measuring MTU4 SX-Axis Proper Data

9.2 Measuring MTU4 SX-Axis Proper Data

Max Limit Position SX
Definition: Max Limit Position is the positive software travel-limit for the SX-
axis.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Manually push the SX-axis until the SX “+” overtravel sensor light just
illuminates.

4. Record the SX servo pulse count in the position found in Step 3.

5. Input the value in Step 4 into the MTU4 Proper as “Max_Limit_SX.”

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Chapter 9 9.2 Measuring MTU4 SX-Axis Proper Data

Min Limit Position SX

Definition: Min Limit Position is the negative software travel-limit for the SX-
axis.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing the
[Servo Counter].

3. Manually push the SX-axis until the SX “-” overtravel sensor light just
illuminates.

4. Record the SX servo pulse count in the position found in Step 3.

5. Manually input the value recorded in Step 4 into the MTU4 Proper at the
host as “Min_Limit_SX”.

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Chapter 9 9.2 Measuring MTU4 SX-Axis Proper Data

Origin Position SX
Definition: Origin Position SX is the SX pulse count which the machine uses to
determine the first pick-up position for a part in the tray (X Origin
Position for each tray must be taught).

Required Tools: None

Required Jigs: QPJ-1060

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer,

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing the
[Servo Counter].

3. Press an EMERGENCY STOP button.

4. Manually position the SX-axis over the corner of the tray, as shown in
the figure below.

5. Record the SX-axis servo pulse counts in the position found in Step 4.

6. Input the value found in Step 5 into the MTU4 Proper at the host
computer as “Origin Position SX.”

Note: Individual origins are supplied for each tray. If picking errors occur, calibrate a specific
origin for each tray and assign “0” to the SX origin in the Proper at the host computer,

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Chapter 9 9.2 Measuring MTU4 SX-Axis Proper Data

Carrier Position SX
Definition: Carrier Position SX is the SX servo pulse count in which the Sub-
Robot nozzle is aligned directly over the carrier nozzle.

Required Tools: None

Required Jigs: QPJ-1060

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Press an EMERGENCY STOP button.

4. Manually position the SX-axis nozzle directly over the nozzle on the
parts carrier.

5. With the SX-axis in the position found in step 4, record the SX servo
pulse counts.

6. Enter the servo pulse count value found in Step 5 into the MTU4 Proper
at the host computer as “Carrier Position SX”.

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Chapter 9 9.2 Measuring MTU4 SX-Axis Proper Data

Tray Out SX
Definition: Tray Out SX is the SX servo pulse count that the machine uses when
ejecting an empty tray from the machine.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current Proper has been received to the
host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Press an EMERGENCY STOP button.

4. Manually position the SX-axis to the desired position to eject trays.

5. Record the SX-axis servo pulse count with the axis in the position
determined in Step 4.

6. Enter the value found in Step 5 into the MTU4 Proper at the host
computer as “Tray Out SX”.

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Notes:

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 Chapter 10
MTU4 SY-Motor

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the
MTU4 SY-Motor to FUJI specifications.
Chapter 10 10.1 Replacing MTU4 SY-Motor

10.1 Replacing MTU4 SY-Motor

Required Tools: 1 Metric Allen Wrench Set
1 8 mm Open End Wrench
1 Tension Gauge

Required Jigs: None

Removal

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer,

1. Turn off the machine.

2. Disconnect the two (2) electrical connectors from the motor.

3. Loosen the four (4) slotted bolts (from the back side of the motor)
securing the mounting plate and remove the motors’ belt.

4. Remove the four (4) bolts securing the mounting bracket to the machine
and remove the old motor.

5. Remove the four (4) bolts securing the motor to the mounting bracket.

6. Loosen the two (2) set screws in the gear assembly and remove the gear.

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Chapter 10 10.1 Replacing MTU4 SY-Motor

Installation

Procedure:

1. Install the new motor in the reverse order described in the Removal
section. DO NOT attach the timing belt at this time.

Warning
Care should be taken when performing the next step. Failure to do so
may result in machine damage. WN007

2. Press Power ON to turn on the machine, manually flag the SY speed

reduction sensor to complete a zero-setting (the speed reduction sensor
is located underneath the timing belt).

Note: When zero-setting, the speed reduction sensor must remain flagged. If it is not, zero-
setting will NOT be possible.

3. After the zero-setting is completed, set a gap of 10 mm between the axis

and the minus physical stopper.

4. Install the timing belt over the gear and tighten the belt tension to “0.38
kgf” per 1.2 mm of travel.

5. Repeat the zero-setting procedure to ensure correct installation.

After replacing the SY-motor, the following Proper measurements must

be completed:
Max Limit SY
Min Limit SY
Origin Position SY
Carrier Position SY
Tray Out SY

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Chapter 10 10.2 Measuring MTU4 SY-Axis Proper Data

10.2 Measuring MTU4 SY-Axis Proper Data

Max Limit Position SY
Definition: Max Limit Position is the positive software travel limit for the SY-
axis.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter] and press an EMERGENCY STOP button.

3. Manually push the SY-axis until the SY (+) overtravel sensor light just
illuminates (See the figure below).

4. Record the SY servo pulse counts with the SY-axis in the position found
in Step 3.

5. Input the value recorded in Step 4 into the MTU4 Proper at the host
computer as “Max_Limit_SY”.

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Chapter 10 10.2 Measuring MTU4 SY-Axis Proper Data

Min Limit Position SY

Definition: Min Limit Position is the negative software travel-limit for the SY-
axis.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU Control panel by pressing
[Servo Counter] and push an EMERGENCY STOP button.

3. Manually push the SY-axis until the SY (-) overtravel sensor light just
illuminates.

4. Record the SY servo pulse counts with the SY-axis in the position found
in Step 3.

5. Input the value recorded in Step 4 into the Proper at the host computer
as “Min_Limit_SY”.

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Chapter 10 10.2 Measuring MTU4 SY-Axis Proper Data

Origin Position SY
Definition: Origin Position SY is the SY pulse count which determines the first
pick-up position for a part in the tray (there are 2 ~ 4 “Y Origin
Positions” for each tray which must be taught).

Required Tools: None

Required Jigs: QPJ-1060

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Press an EMERGENCY STOP button.

4. Manually position the SY-axis over the corner of the tray as shown in the
figure below.

5. Record the SY-axis servo pulse counts with the SY-axis in the position
found in Step 4.

6. Input the value found in Step 5 into the MTU4 Proper at the host
computer as “Origin Position SY”.

7. Repeat Steps 1 ~ 6 for the remaining tray cells.

Note: Individual origins are supplied for each tray. If picking errors occur, calibrate a specific
origin for each tray and assign “0” to the SY origin in the Proper at the host computer,

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Carrier Position SY
Definition: Carrier Position SY is the SY servo position which the sub-nozzle is
aligned directly over the carrier nozzle.

Required Tools: None

Required Jigs: QPJ-1060

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Press an EMERGENCY STOP button.

4. Manually position the SY-axis nozzle directly over the nozzle on the
Parts Carrier.

5. With the SY-axis in the position found in Step 4, record the SY servo
pulse counts.

6. Enter the servo pulse count value found in Step 5 into the MTU4 Proper
at the host computer as “Carrier Position SY”.

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Chapter 10 10.2 Measuring MTU4 SY-Axis Proper Data

Tray Out SY
Definition: Tray Out SY is the SY servo pulse count used to eject an empty tray
from the machine.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Press an EMERGENCY STOP button.

4. Manually position the SY-axis to the desired position for tray ejection.

5. Record the SY-axis servo pulse counts with the axis in the position
determined in Step 4.

6. Enter the value found in Step 5 into the MTU4 Proper at the host
computer as “Tray Out SY”.

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Chapter 10 10.3 Training Evaluation

10.3 Training Evaluation

Circle the most appropriate answer from the choices given below.

(1) When the manually zero-setting the SX, SY axes, use (___) mode.
a. normal
b. mecha-check

(2) Even when zero-setting the SX- or SY-axis with the timing belt off, the
motor does not run out of control.
a. True
b. False

(3) Before the SX-axis starts to zero set, the (___) sensor of the SY-axis must
be activated.
a. speed reduction
b. SY interlock

(4) Before the SY-axis starts to zero set, the (___) sensor of the SZ-axis must
be activated.
a. speed reduction
b. SZ interlock

(5) Inch an axis until an over-travel error occurs. This position becomes the
new software limit.
a. True
b. False

(6) Origin_Position_SX and SY are entered to fix the first pickup point for all
trays.
a. True
b. False

Edition 2.0 10-8 IP-3 Level 3 Tutorial

 Chapter 11
MTU4 T-Motor

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the
MTU4 T-Motor to FUJI specifications.
Chapter 11 11.1 Replacing MTU4 T-Motor

11.1 Replacing MTU4 T-Motor

Required Tools: 1 Metric Allen Wrench Set
1 Belt Tension Gauge

Required Jigs: 1 Tray Drop Prevention Washer (Z9302PT0030)

1 Tray Drop Prevention Handle (Z9302PT0040)
1 Tray Drop Prevention Pin (Z9302PT0050)

Removal

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer,

1. If possible, zero set the machine.

2. Loosen the bracket holding the (-) overtravel sensor and speed reduction
sensor and rotate the bracket so the sensors can not be activated by the
machine and nothing will strike them.

3. In the Proper data for the MTU4, change the software limit position to
the maximum amount allowed.

4. Inch the bottom drawer slowly down into the minus stopper. Be sure to
stop as soon as the drawer makes contact with the stopper to prevent
damaging the machine. If unable to inch the axis, follow the substep
below.

a. Only if the T-axis can not move, remove the plate covering the top
of the T-axis.

b. Screw in the Tray Drop Prevention Pin and Washer into the hole
in the middle of the T-axis.

c. Mount the Tray Drop Prevention Handle on the installed jigs and
tighten the pin as much as possible.

d. When removing the timing belt, a person must hold this handle
and slowly let the trays down until the bottom drawer contacts the
minus stopper.

5. Turn off the machine and electrically disconnect the motor.

Note: If the handle is being used, beware that the MTU drawers will attempt to drop once the
motor is removed. Be ready for the extra torque on the handle!

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Chapter 11 11.1 Replacing MTU4 T-Motor

6. Remove the four (4) bolts that mount the motor in place and remove the
motor.

Note: If the drawers are not already against the minus stopper, once the motor and/or belt is
removed, the tray drawers will drop down and “bottom-out” against the urethane
stopper. Caution must be practiced to prevent damage or injury. This drop is normal
due to the removal of the brake which is located inside the motor.

7. If replacing the timing belt, loosen the four (4) bolts that mount the gear
reduction housing and adjust so the belt can be easily removed.

8. If the handle is being used, once the bottom drawer is against the minus
physical stopper and there is no more torque being applied to the handle
by the machine, remove the jigs and replace the cover on top of the T-
axis.

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Chapter 11 11.1 Replacing MTU4 T-Motor

Installation
1. Ensure that the machine is turned off and electrically connect the new
motor.

Warning
The T-axis speed reduction sensor must be manually flagged. Be very
careful or personal injury may result. When the MTU begins to zero set,
it will zero set all its other axis. Take caution not to stand near the
machine. WN017

2. Turn on the machine and zero set.

T-axis + overtravel sensor

Mechanical Urethane Stopper

IP3T311001

3. When the Tray Axis motor begins to rotate, flag the T-Axis speed
reduction sensor. The motor will stop. Note that the sensor MUST
remain flagged to allow the SX-, SY- and SZ-axes to zero set.

4. After the machine has finished zero setting, inch the T-axis to the value
of -17142 pulses (this is the same distance a 12 mm).

5. Install the motor and tighten the four (4) motor mounting bolts.

6. If the timing belt was replaced, install the belt and set the belt tension to
2.9 kg per 3.2 mm of travel (160 ~ 180 hz).

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Chapter 11 11.1 Replacing MTU4 T-Motor

7. Return the bracket holding the over-travel and speed reduction sensor to
its original position. The bottom of the minus over-travel sensor must be
flush with the bottom of the dog of the drawer. If it is not then adjust the
height of the sensor bracket until it is flush.

8. Turn on the machine and zero set. Ensure that the tray axis does not
activate the overtravel sensor. If the axis activates the overtravel, repeat
the installation procedure.

After replacing either the tray axis motor or the timing belt, the tray axis
sensor locations need to be verified and the following Proper
measurements must be made.

Max Limit Position

Min Limit Position T
Origin Position T0

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Chapter 11 11.2 Adjusting MTU4 T-Axis Sensor Positions

11.2 Adjusting MTU4 T-Axis Sensor Positions

The MTU T-axis sensor positions must be checked to ensure the proper operation of the
MTU4.

Definition: The sensor locations are the physical positions of the tray axis sensors
and flags.

Required Tools: 1 Metric Allen Wrench Set

1 3 mm Spacer

Required Jigs: None

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Chapter 11 11.2 Adjusting MTU4 T-Axis Sensor Positions

Tray Eject Check Sensor

A reflection type sensor is used to detect whether an empty tray has been discarded.

1. Adjust the volume and the angle of the light beam so the empty tray is
detected as it passes between the sensor and the reflective plate.

Positive (+) and Negative (-) Overtravel Sensors

These sensors are used to prevent the T-axis from running into the physical stopper.

1. Adjust the height of the overtravel sensors so that when the axis is
against the pertaining physical stopper, the dog passes through the
sensor and the dog is flush with the outer edge of the sensor.

Speed Reduction Sensor

This sensor is used during zero-setting. When activated the motor stops on the next
home pulse which then is determined to be the zero location.

1. The speed reduction sensor is attached to the negative (-) overtravel

sensor, so the position of this sensor is determined when the negative (-)
overtravel sensor is adjusted.

Sub-Robot Interlock
This sensor is known as the “Tray Space OK” sensor which detects when movement of
the sub-robot (SX, SY and SZ) is possible.

1. Adjust the height of the sensor as shown in the figure below.

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Chapter 11 11.2 Adjusting MTU4 T-Axis Sensor Positions

Tray Set OK Sensor

This sensor is used to detect whether all the tray doors are closed.

1. Adjust the volume and/or the angle of the light beam so an open door
can be detected.

Tray Out OK Sensor

This sensor detects if a tray door is pulled out from its latch.

1. Adjust the volume and/or the angle of the light beam so a pulled-out
tray can be detected.

Tray Position Set Sensors 1 ~ 4

The “Tray Position Set” sensor (see Chapter 10, “MTU4 SY-Motor”) detects the top of a
tray when the tray is at its origin (i.e., approx. 2 mm lower than the Parts Carrier).

1. Position the Z-axis to the height of the parts carrier and press an
EMERGENCY STOP button.

2. Manually move the sub-robot in front of the “Tray Position Set” sensor.

3. Enter the I/O and lower the nozzle 2 mm (i.e., 667 pulses) lower than the
surface of the parts’ carrier. At this position the sensor should be
activated. If the sensor does not trip, adjust the sensor position
accordingly.

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Chapter 11 11.2 Adjusting MTU4 T-Axis Sensor Positions

Tray Add Confirmation Sensors 1 ~ 4

The “Tray Add Confirm” sensor (see Chapter 10, “MTU4 SY-Motor”) detects when a tray
has been added.

1. The “Tray Add Confirm” sensor is mounted to the same bracket as the
“Tray Position Set” sensor so the location of the “Tray Add” sensor is set
when the “Tray Position Set” sensor is set.

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Chapter 11 11.3 Measuring MTU4 T-Axis Proper Data

11.3 Measuring MTU4 T-Axis Proper Data

Definition: Tray axis Proper measurements are necessary after the T-axis motor
or belt are removed or replaced.

Max Limit Position T

Definition: Max Limit Position T is the software travel limit of the T-axis which
prevents the axis from driving into the upper physical stopper.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Inch the T-axis upward until the flag, mounted on the drawer for tray
101 ~104, breaks the beam of the “+” over-travel sensor.

4. Record the servo pulse counts for the T-axis in this position.

5. Enter the pulse count value recorded in Step 4 into the Proper at the host
computer as “Max Limit T”.

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Chapter 11 11.3 Measuring MTU4 T-Axis Proper Data

Min Limit Position

Definition: Min Limit Position T is the software travel limit of the T-axis which
prevents the axis from driving into the lower physical stopper.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Inch the T-axis downward until the flag, mounted on the drawer for tray
137 ~140, breaks the beam of the “-” overtravel sensor.

4. Record the servo pulse counts for the T-axis in this position.

5. Enter the pulse count value recorded in Step 4 into the Proper at the host
computer as “Min Limit T”.

T-axis + overtravel sensor

Mechanical Urethane Stopper

IP3T311001

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Chapter 11 11.3 Measuring MTU4 T-Axis Proper Data

Origin Position T0
Definition: Origin Position T0 is the T-axis position in which the Tray Position
Set sensor detects the top of tray 101 ~ 104.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. At tray drawer 101, (D101) install a block of some kind, equal in height to
the tray wall thickness (Basically two styles: 48 mm, 52 mm.). Place this
block in the middle of the tray cut-out, at device 101.

Note: Alternatively, if you do not have a 48 mm or 52 mm block; use the tray wall at location
D102 and watch for the change of state on Tray Position Set sensor #2.

4. Inch the Tray axis until “Tray Position Set” sensor # 1 becomes activated.

5. Record the servo pulse count for the T-axis in this position.

6. Enter the pulse count value recorded in Step 4 into the Proper at the host
computer as “Origin Position T0”.

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Chapter 11 11.4 Training Evaluation

11.4 Training Evaluation

Circle the most appropriate answer from the choices given below.

(1) There is no danger even if timing belt is detached when the machine
power is off.
a. True
b. False

(2) Before manually zero-setting, the T-axis should be lowered to the minus
stopper.
a. True
b. False

(3) When no tray is present in the drawer, the robot safety sensor is (___).
a. activated
b. not activated

(4) Set a 48 mm height jig on a tray and raise the T-axis until the (___) sensor
is activated. Then, descend the axis by 714 pulses. This position
becomes should be entered as T0 in the MTU Proper data.
a. tray position check
b. additional tray check

(5) At T0 position, the robot safety sensor is (___).

a. activated
b. not activated

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 Chapter 12
MTU4 SZ-Motor

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the
MTU4 SZ-Motor to FUJI specifications.
Chapter 12 12.1 Replacing MTU4 SZ-Motor

12.1 Replacing MTU4 SZ-Motor

Required Tools: 1 Set Metric Allen Wrench Set
1 Tension Gauge

Required Jigs: THTFDSSX 80 mm Block

Removal
Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Turn off the machine.

2. Disconnect the two (2) electrical connectors from the motor by

unscrewing the plugs and removing the four (4) screws securing the
connectors in place.

3. Remove the connectors from the mounting bracket.

4. Remove the four (4) bolts holding the motor cover around the Z-motor
and remove the cover.

Warning
When the timing belt is removed from the axis, the axis will drop to its
physical stop. Support the axis before removing the timing belt. WN018

5. Loosen the four (4) slotted bolts which secure the motor mounting plate
and remove the motors’ timing belt.

6. Remove the four (4) mounting bolts and remove the motor from the
machine.

7. Remove the gear from the motor shaft.

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Chapter 12 12.1 Replacing MTU4 SZ-Motor

Installation

1. Install the new motor, except the timing belt, in the reverse order as
described in the Removal section.

Warning
Manually flag the Z axis speed reduction sensor after all other axis are
zero set. Be careful or personal injury/machine damage may result. WN019

Note: The interlock sensor must remained flagged. If it is NOT, zero-setting will not be
possible.

2. Put a 80 mm block under the SZ robot arm to support the arm during the
zero-setting procedure so it does not strike any objects.

3. Zero set the machine and when the SZ-motor begins to rotate, flag the
SZ-axis speed reduction sensor (see the figure below).

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Chapter 12 12.1 Replacing MTU4 SZ-Motor

4. After the zero set is completed, set a gap of 10 mm between the SZ-axis
and the upmost physical stop (see the figure below).

5. With the SZ-axis at the 10 mm distance from the physical stopper, set the
position of the speed-reduction dog to be 1 to 1.5 mm above the speed
reduction sensor.

6. Install the belt over the gear and tighten the belt tension to 0.24 kg per
1.12 mm of travel. Tighten the motor mounting bolts.

After replacing the SZ-motor and/or the timing belt, perform the
following Proper measurements and calibrations:

Max Limit SZ
Min Limit SZ
Part Position Zt0
Part Position Zc0
SZ Interlock

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Chapter 12 12.2 Measuring MTU4 SZ-Axis Proper Data

12.2 Measuring MTU4 SZ-Axis Proper Data

Max Limit Position SZ
Definition: Max Limit Position SZ is the maximum software travel limit which
prevents the SZ-axis from contacting the mechanical stopper.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter] and press an EMERGENCY STOP.

3. Manually position the SZ-axis against the upper physical limit position
and record the SZ servo pulse counter value.

4. Subtract 100 pulses from the value found in Step 3 and enter this value
into the MTU4 Proper at the host computer as “Max Limit SZ”.

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Chapter 12 12.2 Measuring MTU4 SZ-Axis Proper Data

Min Limit Position SZ

Definition: Min Limit Position SZ is the minimum software travel limit which
prevents the SZ-axis from contacting the mechanical stopper.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Manually position the SZ-axis against the lower physical limit position
and record the SZ servo pulse counter value.

4. Add 100 pulses from the value found in the previous step and enter this
value in the Proper at the host computer as “Min Limit SZ”.

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Chapter 12 12.2 Measuring MTU4 SZ-Axis Proper Data

Part Position ZC0

Definition: Part Position ZC0 is the position the SZ-axis must go in order to place
a part onto the part carrier.

Required Tools: None

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Use the inching keys to position the sub-robot over the part carrier pad.

4. Using the inching keys, lower the SZ-axis until the sub-robot comes into
contact with the parts carrier pad (see the figure below).

IP3T312003

5. Record the servo pulse counter value, with the SZ-axis at the position
found in Step 4, and input this value into the Proper as “ZC0”.

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Chapter 12 12.2 Measuring MTU4 SZ-Axis Proper Data

Part Position ZT0

Definition: Part Position ZT0 is the relationship between the SZ-axis and Tray
Origin

Required Tools: None

Required Jigs: 48 mm Jig

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Use the inching keys to position the tray to a height at which the tray
positioning sensor just activates with the 48 mm jig in the tray drawer
cutout.

4. Inch the sub-robot nozzle to the inside, top inside lower surface of the jig
(the top of the jig has two levels, use the lower level).

5. Record the Z-axis pulse count value as the new “ZT0” value and enter
into the MTU4 Proper at the host computer.

Note: Alternatively, ZT0 = ZC0 - 1000 pulses (Carrier Position ZCO - 3 mm).

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Chapter 12 12.3 Calibrating MTU4 SZ-Motor

12.3 Calibrating MTU4 SZ-Motor

SZ Interlock Sensor
Definition: SZ Interlock Sensor prevents the MTU4 from moving SX-, SY- and
the T-axis at the same time.

Required Tools: 1 Metric Allen Wrench Set

Required Jigs: None

Procedure:

Before beginning this procedure, ensure that the current MTU4 Proper has been received
to the host computer.

1. Zero set the machine.

2. Enter the servo pulse counter on the MTU control panel by pressing
[Servo Counter].

3. Lower the SZ-axis to ZT0” +/- 50 pulse counts.

4. At the position established in Step 3, inch the SZ-axis up 21667 pulse

counts the SZ interlock sensor should just be activated at the bottom of
the dog.

Speed Reduction
Sensor

SZ Interlock
Sensor

IP3T312004

5. If the sensor is not activated at the value found in step 4 +/- 50 pulse
counts, loosen the two (2) bolts securing the sensor and move the sensor
until it activates at the established pulse count value. Tighten the bolts.

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Chapter 12 12.4 Training Evaluation

12.4 Training Evalution

Circle the most appropriate answer from the choices given below.

(1) There are 2 sensors for the SZ-axis, the upper sensor is the (___) sensor.
a. SZ interlock
b. zero-set

(2) It is safer to activate the SZ-motor before the axis starts zero-setting.
a. True
b. False

(3) When the timing belt is detached, the head will drop.
a. True
b. False

(4) The LED of SZ interlock sensor turns (___) when the sensor is activated.
a. ON
b. OFF

(5) A position of 1000 pulses lower from the (___) position becomes ZT0.
a. tray confirmation sensor ON
b. ZC0

(6) If ZC0 is too high:

a. the nozzle may crash into a tray.
b. the part may not be properly held by the vacuum or holder.

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Chapter 12 12.4 Training Evaluation

Notes:

Edition 2.0 12-10 IP-3 Level 3 Tutorial

 Chapter 13
MTU4 Carrier

Objective:

Given a IP-3 machine, technical

documentation and required tools,
remove, replace and calibrate the
MTU4 Carrier to FUJI specifications.
Chapter 13 13.1 Calibrating MTU4 Carrier

13.1 Calibrating MTU4 Carrier

Carrier Stopper
Retract Sensor

Retract Speed Reduction Sensor

Forward Speed Reduction

Sensor
Forward End
Sensor
Part Detection
Sensor

Carrier Vacuum
Filter
Carrier Nozzle
Carrier Stopper

IP3T313001

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Chapter 13 13.1 Calibrating MTU4 Carrier

Advance Limit Adjustment

Definition: Adjusts the position of the carrier pad when extended

Required Tools: 1 Set Metric Allen Wrenches

1 Philips Head Driver

Required Jigs: None

Procedure:

Note: If the advanced stopper is adjusted, the carrier part pickup position for the X-axis for the
IP-3 position, must be calibrated because the carrier advanced position has changed.

1. Remove the belt cover.

Belt Cover

IP3T313002

2. Extend the carrier from the MTU4 control panel.

3. Jog the IP-3 nozzle to the machine’s “carrier” position.

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Chapter 13 13.1 Calibrating MTU4 Carrier

4. With the carrier in its “Advance Limit Position”, adjust the stopper so
the center of the vacuum cup lines up with the IP-3 nozzles’ center.

Carrier

Forward

IP-3 Carrier Pick Position

Carrier Advance Carrier Retract
Limit Position Limit Position

IP3T313003

5. Reattach the belt cover.

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Chapter 13 13.1 Calibrating MTU4 Carrier

Retract Limit Adjustment

Definition: The adjusts the position of the carrier pad when extended.

Required Tools: 1 Set Metric Allen Wrenches

1 Philips Head Driver

Required Jigs: None

Procedure:

Note: If the retract stopper is adjusted, the carrier part position for the SX- and SY-axes for the
MTU4 must be calibrated because the carrier retract position has changed.

1. Remove the belt cover.

2. With the carrier in its’ Advance Limit Position, adjust the unit so there is
400 mm of travel from the carrier to the retracted limit (this adjustment is
NOT from limit position to limit position).

3. Reattach the belt cover.

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Chapter 13 13.2 Adjusting MTU4 Carrier Sensors

13.2 Adjusting MTU4 Carrier Sensors

Forward Limit Sensor and Forward Speed Reduction
Sensor
The “Forward Speed-Reduction Sensor” and “Forward Limit Sensor” control the parts
carrier when the carrier advances to the placement head.

1. Advance the carrier to its physical limit.

2. Adjust the Forward Limit Sensor so that the flag passes through the
sensor and is flush with the edge, as shown in the figure below.

Carrier
Forward
Dog

Forward End
Forward Speed
Sensor 100 mm
Reduction Sensor
IP3T313004

3. Move the Forward Speed Reduction Sensor to be 100 mm from the

Forward End Sensor.

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Chapter 13 13.2 Adjusting MTU4 Carrier Sensors

Retract Limit Sensor and Retract Speed Reduction

Sensor
The Retract Limit Sensor and Retract Speed Reduction Sensor control the Parts carrier
when the carrier retracts after delivering a part to the placement head.

1. Retract the carrier to its physical limit.

2. Adjust the Retract Limit Sensor so the flag passes through the sensor and
is flush with the edge.

Carrier Dog
Retract
Retract End
Sensor

Retract Speed
100 mm
Reduction Sensor IP3T313005

3. Move the Speed Reduce Sensor to be 100 mm from the Retract Sensor.

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Chapter 13 13.2 Adjusting MTU4 Carrier Sensors

Part Detect Sensor

This sensor detects when a part is present on the carrier pad.
1. With a part on the carrier pad, adjust the volume of the sensor so the
lamp display (red) lights up. You may have to turn the carrier vacuum
ON when making this adjustment.

Volume LED (red)

IP3T313006

Part Detect Sensor Carrier Pad

Output

Part Detect Sensor

Fiber Optic Cable IP3T313007

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Chapter 13 13.3 Replacing MTU4 Carrier Pad and Adjusting Its Height

13.3 Replacing MTU4 Carrier Pad and

Adjusting Its Height
Carrier Pad Replacement
1. The carrier pad is glued onto a metallic base, it can easily be attached
and removed by hand. When attaching a new pad, use a non-permanent
adhesive.

Part Nozzle

1.5 - 2 mm Rubber Surface

Plate

Adjustment Bolts IP3T313008

Carrier Nozzle
1. The carrier nozzle is easily removed by simply grasping and pulling the
nozzle straight up. To install a new nozzle, gently slip the new nozzle in
position.

Note: Care must be taken not to damage the nozzle when installing a new one. The nozzle slips
over the parts’ “Detection Sensor” and may be installed in such a way that it may
interrupt the sensor operation.

Carrier Height Adjustment

1. Loosen the two (2) adjusting bolts and raise and/or lower the carrier so
the carrier nozzle is “1.5 to 2 mm” above the carrier pad.

2. Lock the two (2) adjusting bolts holding the carrier in position.

Note: The carrier pickup position for the IP-3 Z-axis and the SZ carrier position must be
remeasured if the carrier height is adjusted.

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Chapter 13 13.3 Replacing MTU4 Carrier Pad and Adjusting Its Height

Carrier Filter Element Replacement

The carriers’ vacuum is generated by a Venturi unit. The Venturi unit receives positive
pressure in one end and creates vacuum out the other. Inside the unit is a micron filter
that needs to be checked periodically.

1. Remove the tubing.

Tube

Metal Fitting

Filter Element IP3T313009

2. Remove the silver metal fitting on the V side.

3. Take out and replace the round filter element.

4. Reconnect the air tubing making sure not to mistake the “V” side and the
“P” side.

Note: The filter should be checked periodically. If the machine is experiencing parts carrying
errors, replace the nozzles’ filter.

Edition 2.0 13-9 IP-3 Level 3 Tutorial

Chapter 13 13.4 Training Evaluation

13.4 Training Evalution

Circle the most appropriate answer from the choices given below.

(1) If the retract stopper is adjusted, the carrier part position for SX- and SY-
axes for the MTU4 must be calibrated.
a. True
b. False

(2) The Retract Limit Sensor should be located based on the Advance Limit
Sensor position.
a. True
b. False

(3) When attaching a new carrier pad, use a permanent adhesive.

a. True
b. False

(4) The carrier pick-up position for the IP-3 Z-axis and the SZ carrier
position must be re-measured if the carrier height is adjusted.
a. True
b. False

(5) The “P” side of the vacuum unit should be facing the carrier pad side.
a. True
b. False

Edition 2.0 13-10 IP-3 Level 3 Tutorial

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IP-3 Level 3 Tutorial Manual

Edition 1.0 September 30, 1999

Edition 2.0 May 31, 2000
Edition 2.1 August 31, 2000

FUJI Machine Manufacturing Co., Ltd.

SMT Equipment
19 Chausuyama, Yamamachi, Chiryu,
Aichi Prefecture, 472-8686 Japan

Copyright  2000 by Fuji Machine Manufacturing Co., Ltd.

Printed in Japan