KE2010.Instruction Manual.ver.2.01.Rev.08

KE-2010 (2.01)
INSTRUCTION MANUAL
Thank you very much for purchasing a product of our company.
CAUTION
In order to ensure safe use of the KE-2010, be sure to read this Manual
before using the machine.
After reading this Manual, keep it at a fixed location so that it will be
available at any time.

(1) This manual or software may not be copied or reproduced (duplicated), in whole or part,
without the express prior written consent of JUKI Corp.
(2) This manual is subject to change without notice.
(3) This manual is written as carefully as possible. However, if you have a question,
or find a mistake or missing information, contact our dealers or JUKI Corp.
(4) JUKI Corp. is not responsible for any defects or malfunction due to your abnormal
operation.
Important

Warning For the safe operation of machinery!!
All personnel engaged in the operation of the chip placer and its accessories (here after
referred to as "machines") including the operators, service and maintenance personnel are
required to read through this safety warning to make familiar with its handling to prevent
accidents and injuries.
This "Warning: For the safe operation of machinery" instructions contain aspects that are
not included in the instruction sheet attached to the product.
The following symbols are used throughout this instructions and on the product for the better
understanding of various warning labels. Please make yourself familiar with the contents
and act accordingly.
1) Danger levels
Dangerous
Parts of machinery the negligence or mishandling of which committed during the operation, maintenance or other services on such parts will lead to severe accidents involving serious personal injuries or even death.
Warning
Parts of machinery the negligence or mishandling of which committed, or are left unattended, during the operation, maintenance or other services on such parts may cause potential danger to the personnel which may lead to injuries and/or even death.
Attention
Parts of machinery the negligence or mishandling of which committed, or are left unattended, during the operation, maintenance or other services on such parts may cause the medium-to-light level of hazards to the personnel involved.
2) Warning, prohibition and directive marks
Warning, prohibition and directives are marked with the following symbols:
Warning marks
caught by the machines.
Beware of moving parts.
injuries.
burn.
injuries.
lay your hand on the machine,
it may be damaged.
grounding wire.

Matters of Caution Regarding Safety
To prevent accidents due to electric shock, turn off power supply if it is necessary to
open the electrical equipment box. For added precaution, open the lid of the box only
after a lapse of more than five minutes.
Basic Matters of Precaution
1. Be sure to read all documents included in this Manual and the attached booklet
before using this machine. Also, keep this Manual carefully so as to be able to
read it whenever necessary.
2. Contents of this Manual include items that are not included in specifications of the
machine purchased.
3. The machine should be operated only by the operator who has learned how to run
it.
4. Regarding the repair or maintenance (excluding daily inspection and other matters
specified in the Manual), ask our company or its agent to do it.
5. General maintenance, inspection, and repair (matters specified in this Manual) shall
be conducted only by specialized maintenance engineers who have finished the
maintenance course specified by our company.
With regard to repair (matters specified in this Manual), use genuine parts of our
company.
Safety Equipment, Alarm Label
1. In order to prevent accidents due to nonpresence of safety equipment, start to
operate this machine only after confirming that the equipment is suitably installed at
the specified position.
2. If the safety equipment is dismantled, be sure to attach it to its original position, and
confirm that it operates normally.
3. Make sure that the warning label stuck to the machine will be always clearly visible.
If it has been peeled off or stained, order new labels from our company and
exchange old labels with new ones.
4. If the safety equipment is damaged, remove it. Never operate the machine. If
you operate the machine without the safety equipment, it may lead to severe
accidents involving serious personal injuries or even death.
Application
1. Never use this machine for purposes other than its original application.
Our company will not be responsible in the case of its use for other application.
2. Do not remodel this machine. Our company will not be responsible for any
accident arising as a result of its remodeling.
Operational Training
1. To prevent accidents due to unaccustomed handling, operation of this machine
must be limited to operators who have participated in the operation training
specified by our company and have appropriate knowledge and operating skills.
DANGER
CAUTION
a power plug from a receptacle or to
separate the power cable from the supply
side.
Hereinafter the same.
Situations in Which It Is Necessary to Turn Off Power Supply
1. In the case of an abnormality or an accident, or in the event of power failure,
immediately turn off power supply.
2. In order to prevent accidents due to unintended start-up of the machine, carry out
inspection, repair, or cleaning of the machine only after turning off power supply.
3. When drawing out the power supply plug, do it by holding the plug itself, not the
cord.
Transport
1. When lifting the machine or moving it, take sufficient safety measures so that no
dropping accidents will occur.
2. Never cut tapes with a cutter.
3. Retain delivery-use materials.
Installation
1. To prevent the occurrence of any accident due to unintended moving of the
machine in operation, make casters float using a height adjuster.
2. Install this machine at a flat position.
3. To prevent the occurrence of electric shock, power leakage, or fires, use attached
products regarding cables, and link them to the specified positions.
4. To prevent electric shock, power leakage, or fires, make sure that irrational force
will be applied to the cables while the machine is in operation.
5. Securely fix the power supply plug and the connector of an I/F cable. When
drawing out the power supply plug or the I/F cable, do it by holding the connector
unit.
Before Operation
1. To prevent accidents to human bodies, make sure before supplying power that
there is no damage, coming off of parts, or loosening of connectors and cables.
2. To prevent bodily accidents, never put in your hand into the driving unit.
CAUTION
1. Regarding greasing, use Albania Grease.
2. To prevent the occurrence of an inflammation or rash, immediately wash the
related portions if grease adheres to your eyes or other parts of your body.
3. If grease is mistakenly swallowed, immediately consult a physician to prevent
diarrhea or vomiting.
Maintenance
1. To prevent accidents due to unaccustomedness, repair and adjustment shall be
conducted by maintenance engineers who are versed in the machine. In
replacing parts, use genuine parts of our company. We will not assume any
responsibility for an accident due to the use of non-genuine parts.
2. To prevent accidents or electric shock due to unaccustomedness, entrust
electrical repair or maintenance work (including wiring work) to persons versed in
electricity, or ask engineers of our company or its sales company to do it.
3. To prevent accidents due to unintended start-up of the machine, conduct repair or
adjustment only after removing air supply pipes and discharging residual air.
4. To prevent bodily accidents, confirm after such work as repair, adjustment, or
parts replacement that no screws or nuts are loosened.
Use Environment
1. Use the machine in the environment free from effects of noise sources (magnetic
waves), such as high-frequency welders, in order to prevent accidents due to
erroneous actions.
2. In order to prevent accidents due to erroneous actions, use the machine in the
environment where source voltage surpasses 200V (220V, 240V)± 10%.
3. In order to prevent accidents due to erroneous actions, do not use the machine in
the environment where the supplied air pressure is 0.5 to 1.0MPa.
4. To ensure safety, use the machine under the following environment:
Ambient temperature during operation + 10 C - +35 C
Relative humidity during operation 50% or less (35 C)
90% or less (20 C)
5. To prevent accidents due to breakdown of electric/electronic parts, turn on power
supply sufficiently after the fear of dew condensation is eliminated, because such
condensation may occur when the machine is rapidly moved from a cold place to a
warm location.
6. To prevent accidents due to breakdown of electric/electronic parts, stop the use of
the machine during lightning, and draw out the power supply plug.
CAUTION
[Front]
[Rear]
caught in the machine"
caught in the machine"
DANGER
1. To prevent accidents due to electric shock, do not open the electrical equipment box while power supply is on.
2. To prevent electric shock, do not operate the machine, with the grounding line unlinked.
CAUTION
1. To prevent damage to human bodies, do not operate the machine, with the safety cover or equipment removed.
2. To prevent damage to human bodies, make sure that hair, clothes, etc., will not be caught by the conveyor chain. Also, keep off gloves.
3. To prevent damage to human bodies, turn off power supply during maintenance (greasing, adjustment, and daily inspection).
4. To prevent damage to human bodies, use an earth leakage breaker for the power line.
CAUTION
adopted as the Operating System of this machine.
If you install on this machine any software not designed for this
machine, we cannot guarantee that the machine functions
properly. if you move, rename or copy a file stored in the
hard disk drive, we cannot guarantee that either.
• Should the machine not properly due to any operation above,
replace your hard disk drive with new one and your data may
be lost.
CAUTION
1. A UPS is incorporated into this machine to protect a production
program and any other data at power failure.
To prevent a battery built into the UPS from degrading, do not
leave this machine without turning it on for six months or longer.
• Only when the main circuit breaker and main switch are set

CHAPTER 1 GENERAL
1.1.1 Highlights............................................................................................. 1-1
1.2 Basic Configuration and Parts Identification .................................................... 1-22
1.2.1 Entire system views............................................................................. 1-22
1.2.3 Component feeder............................................................................... 1-26
1.2.5 ATC unit (Automatic tool changer): parts identification..................... 1-33
1.2.6 Nozzle.................................................................................................. 1-34
1.4 Interface With Extenal Devices........................................................................ 1-38
CHAPTER 2 DESCRIPTION OF THE OPERATOR CONTROLS
2.1 Function of Keys and Switches........................................................................ 2-1
2.1.1 Keyboard ............................................................................................. 2-1
2.1.3 Track ball ............................................................................................. 2-5
CHAPTER 3 OPERATION OVERVIEW
3.1.1 When the machine is used as a standalone machine......................... 3-1
3.1.2 When using the HLC ........................................................................... 3-3
3.2 Turning Power ON ........................................................................................... 3-4
3.2.1 Operation sequence from power-on.................................................... 3-4
3.5 Menu Organization........................................................................................... 3-15
3.5.3 Production local menu ......................................................................... 3-17
3.5.4 Machine setup local menu ................................................................... 3-18
3.6 File Operation................................................................................................... 3-19
3.6.1 Create New.......................................................................................... 3-19
3.6.8 Saving a control data file...................................................................... 3-27
3.6.9 Saving the machine information .......................................................... 3-29
3.6.10 Saving vision data................................................................................ 3-30
3.7 Corrective Action for A Power Failure .............................................................. 3-31
3.7.1 Process to be performed when a power failure occurs ....................... 3-31
3.7.2 Recovering process after a power failure occurs
(turning on the machine) ...................................................................... 3-33
CHAPTER 4 EDITING THE PROGRAM
4.1 Overview .......................................................................................................... 4-1
4.1.3 Menus and their corresponding guidance messages .......................... 4-5
4.2 File.................................................................................................................... 4-6
4.6.3 Range check........................................................................................ 4-63
4.7 Component Data.............................................................................................. 4-65
4.7.2 How to enter data ................................................................................ 4-68
4.7.3 Tack control section (Component package page)............................... 4-81
4.7.4 Tack control section (Centering page) ................................................ 4-88
4.7.5 Tack control section ("Add. info." page) .............................................. 4-90
4.7.6 Tack control section (Expansion page) ............................................... 4-93
4.7.7 Tack control section (Inspection page)................................................ 4-97
4.7.8 List window.......................................................................................... 4-101
4.7.10 Replacing Component data ................................................................. 4-105
4.8 Pick Data.......................................................................................................... 4-110
4.9 Checking Data Completion Status................................................................... 4-128
4.9.2 Line coherence check.......................................................................... 4-129
4.10.3 Nozzle layout ....................................................................................... 4-170
5.3.2 Teaching X/Y-axis................................................................................ 5-8
5.4.2 Teaching of the User Defined Template .............................................. 5-18
CHAPTER 6 PRODUCTION PROCEDURES
6.2 Production ........................................................................................................ 6-14
6.3 Retry List Display ............................................................................................. 6-43
6.3.1 Retry List display after the end of board production ............................ 6-51
6.3.2 Retry list display during board production............................................ 6-53
6.3.3 Pick point correction ............................................................................ 6-56
6.3.4 Printing the Retry List........................................................................... 6-60
6.4 Operation during Board Production.................................................................. 6-61
6.4.3 Mark recognition error.......................................................................... 6-71
6.4.4 Cover was open................................................................................... 6-73
6.4.7 Pause as component protection .......................................................... 6-75
6.4.8 Checking to see if a laser head is stained ........................................... 6-76
6.4.9 Filling the feeder with components when the system pauses
a production operation ......................................................................... 6-79
6.4.12 Cycle stop ............................................................................................ 6-88
6.4.13 Editing data .......................................................................................... 6-89
6.4.15 Resuming and Returning All Axes to Their Home Positions................ 6-111
6.5 Trial Run........................................................................................................... 6-113
6.5.4 Pickup tracking .................................................................................... 6-118
6.6.2 Display of the production status .......................................................... 6-124
6.6.3 Monitoring by camera .......................................................................... 6-124
6.7 Checking.......................................................................................................... 6-125
6.7.2 Laser height check .............................................................................. 6-134
6.7.3 SOT Direction Check........................................................................... 6-151
7.2.3 Disp (Display) ...................................................................................... 7-49
7.3 Mechanical Setup ............................................................................................ 7-50
CHAPTER 8 MANUAL CONTROL
8.2.3 Laser control........................................................................................ 8-18
8.3.3 Automatic PWB width adjustment control ........................................... 8-36
8.3.4 Movable station control (Supported by a KE-2030) ............................. 8-37
8.3.5 Vacuum Table Control......................................................................... 8-39
8.4.1 VCS control (supported by a KE-2020 and KE-2040) ......................... 8-41
8.5 Feeder.............................................................................................................. 8-45
8.5.3 DTS control.......................................................................................... 8-50
8.6.3 Component verification........................................................................ 8-58
8.6.5 Calibration block control ...................................................................... 8-61
8.6.6 Other sensors ...................................................................................... 8-63
8.6.7 Driver state .......................................................................................... 8-64
CHAPTER 9 MAINTENANCE MODE
9.2.3 Warming-up operation ......................................................................... 9-4
9.3 Idle Conveyor ................................................................................................... 9-5
9.4 Machine Management Information .................................................................. 9-6
9.4.1 Machine operation information ............................................................ 9-6
9.4.2 Nozzle operation information ............................................................... 9-10
9.4.3 Head operating information ................................................................. 9-15
9.4.4 Light operation information .................................................................. 9-17
9.4.5 Driver operation information ................................................................ 9-18
9.4.6 Resetting the operation information data............................................. 9-19
9.5 Operation to Be Performed When a Nozzle Attachment Error Occurs............ 9-22
9.5.1 Semi-automatically returning a nozzle................................................. 9-22
9.6 Saving the Machine Information....................................................................... 9-29
9.6.1 Starting up from the menu invoked from the "Production" screen....... 9-29
9.6.2 Starting up from the "Emergency stop" screen.................................... 9-29
9.6.3 Saving .................................................................................................. 9-30
10.3 Laser Sensor Height ........................................................................................ 10-5
10.4 Rotation Center of the Nozzle .......................................................................... 10-8
10.5 Head Offset ...................................................................................................... 10-11
10.7 VCS Binary-Coded Threshold (Not Available with a KE-2010) ..................... 10-17
10.8 Vacuum Calibration.......................................................................................... 10-20
11.4 Operation Option.............................................................................................. 11-4
11.4.2 Setting the Production (Display) option................................................ 11-7
11.4.3 Setting the Production (Function) options............................................ 11-9
11.4.4 Setting the Production (Function2) option............................................ 11-12
11.4.5 Setting the Production (Pause) option ................................................. 11-14
11.4.6 Setting the Production (Check) option ................................................. 11-17
11.4.7 Setting the Function enable option ...................................................... 11-19
CHAPTER 12 HANDLING THE FEEDERS AND OPTIONS
12.1 Replacement of the Tape Feeder .................................................................... 12-1
12.1.1 Replacement of the tape feeder
(8 mm, 12 mm, 16 mm, 24 mm, and 32 mm)...................................... 12-1
12.1.2 Replacement of 32-mm adhesive tape feeder..................................... 12-2
12.2 Replacement of the Bulk Feeder ..................................................................... 12-3
12.3 Replacement of the Stick Feeder..................................................................... 12-4

vii
12.4 Procedure for Mounting the Matrix Tray Holder on the Feeder Bank .......... 5
12.5 Installing the Matrix Tray Changer (MTC)........................................................ 12-6
12.5.1 Installing the Matrix Tray Changer (MTC) ........................................... 12-8
12.6 Handling the Feeder Position Indicator (FPI)................................................... 12-10
12.7 Handling Bad Mark Sensor .............................................................................. 12-11
12.8 Handling HMS.................................................................................................. 12-12
12.11 Handling a Portable Type Tray Server (DTS) .................................................. 12-18
12.12 Handling a Gripper Nozzle............................................................................... 12-19
13.2 Check............................................................................................................... 13-3
13.2.3 Unit air cylinder.................................................................................... 13-4
13.2.5 Air filter (CAL block)............................................................................. 13-8
13.3 Cleaning........................................................................................................... 13-12
13.3.2 Transport sensors ............................................................................... 13-14
13.3.4 Nozzle.................................................................................................. 13-16
13.3.9 CVS (Component Verification System) (Option) ................................. 13-22
13.3.10 Overall feeder exchange trolley (optional) ........................................... 13-23
13.3.11 OCC (Polarizing filter).......................................................................... 13-24
13.4.3 Transport guide shaft........................................................................... 13-27
13.4.5 Ball screws and Linear way (Head part).............................................. 13-28
13.4.6 Backup table........................................................................................ 13-29
13.4.8 Overall feeder exchange trolley (optional) ........................................... 13-30
13.5 Replacing the UPS Battery with a New One.................................................... 13-31
13.5.1 Removing the UPS .............................................................................. 13-31
13.5.2 Replacing Batteries ............................................................................. 13-34

1.1 Highlights and Specifications
This machine is an SMD chip shooter designed as one of the KE-2000 series products
which are successors of the KE-700 series chip placers, and features high-speed chip
placement.
A host line computer (HLC) controls a line consisting the KE-2000 series chip
placer/shooter, KE-700 series chip placer, JUKI dispenser and solder-paste printer as
well as a line consisting of KE-2000 series chip placers/shooters only. This feature
allows you to configure a line which realizes high productivity and is appropriate for
every applications.
For software, WindowsNT is adopted as the Operating System (OS) to increase the
operability of this machine.
1.1.1 Highlights
– Equipped with the newly developed laser alignment sensors (MNLA) each of which
allows four nozzles to recognize components simultaneously. These four nozzles
simultaneously pick up and mount components whose size is up to 10 mm x 10
mm after centering them without touching: this allows high-speed mounting of
components, 11,000 cph (this is rough estimate calculated on the assumption that
four components are simultaneously picked up, then one component is
alternatively placed on the almost entire area of a 330 mm x 250 mm board).
– An offset correction camera, a height measurement device (option), and a feeder
preparation function (option) can be installed to minimize the time required for the
machine halt for preparation, realizing high operating ratio.
– An offset camera correction uses its pattern matching function to recognize a
fiducial mark at high speed. Together with high-speed board transfer, it provides
you with an overall high-speed placement capability.
– Pick and placement reliability is remarkably improved through chip rise detection
performed during laser/align measurement.
– The board support section (for backing up a board) is driven by a motor to prevent
any vibration from occurring when a clamped board is released, then prevent a
placed component from being shifted from the regulated position, shortening the
time required to clamp or release a board.
– Using the offset correction camera and the height measurement device,
preparation is possible without opening the cover, provided as good safety
features.
– Newly attached LED indicators (optional) (Feeder Position Indicator: FPI) on the
feeder setting section notify an operator that components run out, and generates
the warning on the number of the remaining components to increase the
operability for replacing components.

Instead of using conventional mechanical centering system, this machine uses
touchless centering system where laser align sensor is used to read the position and
angle of components. This can be achieved by detecting the shade of the
components created by the laser rays applied horizontally to the components.
Z
Figure 1.1.2.1
By moving Z-axis up and down, a component is picked with vacuum, and the laser is
applied to the component. A shade is made where the laser is obstructed by the
component. By turning the component along q-axis, the shade changes.
According to the change of the shade, offsets of the position and angle of the picked
component are calculated. These offsets are corrected when mounting.
The laser align sensor conforms to IEC825 Class 1 and CDRH Class 1 regulations.
The laser align sensor can be used safely as far as it is used by following the
instructions described in this manual.
CAUTION Any operation of controls and adjustments which is not described in
this manual can cause an excessive exposure of laser lays which
may be dangerous to human bodies.
Laser align sensor
;
; ; ;
;
;
;
;
t i o n
Rotate in (-) direction along θ-axis. (Preload)
Pick the component by driving Z-axis, and adjust the component at laser align height.
Rotate in (+) direction along θ-axis, and start measurement with laser align.
Placement is performed by correcting position offset (dX, dY) and angle offset (dθ).
While measuring the shade, find two positions and where the shade is minimum. Because the nozzle center is a known factor, according to the difference between the nozzle center and the component center, offset in Y direction (dX) and that in X direction (dY) can also be known. By referring to the encoder output of the θ motor at or
, offset angle dθ can also be known.
(Compo-
nent
center)
L a s e r a
l i g n m e a s u r e m e n
t
0 . 2
bottom surfaces of the
Mold
of the component and the foot of the
leads)
of the component and the foot of the
leads)
mold and the foot of the leads)
Laser align
mold and the foot of the leads)
Laser align
the mold)
Laser align
− Laser measurement height (in laser centering method)
The figure below indicates the measurement position when the laser centering
method is selected. The distance between the nozzle tip to the measurement
position which is radiated with a laser beam is called “laser height”. The laser height
is specified in the component data.
Figure 1.1.2.5 Definition of Laser Height
− Default Laser height
Default laser heights are set for some component types and heights. Table 1.1.2.5
shows the relation between component heights and default laser heights.
Table 1.1.2.5 Component Types and Default Laser Heights
Component type Measurement position Laser height (mm)
Square chip
SOT -
= 0.25
SOP
BGA
square chip
Rear side operation unit
UPS
Offset correction camera
Feeder bank driver
Power unit
CPU board
Non-stop operation function
Bad mark reader
External Programming Unit (EPU)
Support for a 20-mm component *1

Board Viewer

DTS : Double Tray Server
MTS : Matrix Tray Server
MTC : Matrix Tray Changer
BMR : Bad Mark Reader
1.1.4 Mechanical specifications
(1) Placement accuracy
The following table lists the placement accuracy data for different types of
components. A poorer accuracy results depending on the components that may
have an edge or plastic mold burrs at the area detected with the laser align
function, and that may have a moving part to be detected with respect to the pick
port.
Square chip ± 0.08
the lead (Burr on one side: 0.15 or less)
±0.2 in the direction parallel to the lead
PLCC, SOJ ± 0.2
BGA ± 0.2
Other large-size components ± 0.3
(2) Placement cycle time
The optimized placement cycle time is shown below. The cycle time required
when a component is placed on a board actually varies depending on the board
size or how many times a nozzle is replaced.
When Five nozzles pick up and place components simultaneously and center
them with laser
Small chip component
11,000 components/hour 0.33 seconds/component)
The value above is a rough estimate calculated on the assumption that five
components are simultaneously picked up and one component are
simultaneously placed on the almost entire area of a 330 mm x 250 mm
board.
Definition
(4) Automatic tool changer (ATC)
The ATC can accommodate up to 23 nozzles.
(5) Transport rail height
900 mm ± 20 mm
W : [KE-2010M] 1300 mm
D : [KE-2010M] 1471mm
[KE-2010L] 1599 mm
H : [KE-2010M] 1550 mm
(height of the main unit when the PWB transfer height is 900
mm)
[KE-2010L] 1834 mm
(height of the vision monitor when the PWB transfer height is 900
mm)
[KE-2010E] 2200 mm
(height of the signal tower when the PWB transfer height is 900
mm)
[KE-2010L] 1410 kg
[KE-2010E] 1510 kg
(7) Air requirements
Air pressure : 0.49 ± 0.05 Mpa Air consumption : 200 L/min.(ANR) Dry air : Atmospheric dew point -17°C or lower
(8) Noise level
Ambient temperature: +10° C to +35 ° C
Relative humidity: 50% or less (at 35° C) 90% or less (at 20° C)
Transport and storage Temperature: -25° C to +70 ° C Relative humidity: 20% to 95% (No condensation)
(11) Installation category: Installation category II (IEC664-1)
(12) Pollution degree: Pollution degree II (IEC664-1)

(1) Number of placement points
Up to 3,000 placement points can be defined per program. For multi-matrix PWBs, up to 10,000 points can be defined, which is the number of circuits multiplied by the number of placement points.
(2) Control Systems
0.005mm
0.00125mm
0.02°
Character display : 10.4" color (TTF liquid crystal display panel) Graphics display : 9" monochrome
(5) Data and program input/output
A program which has been generated with an external programming device or manually created from the keyboard can be input by means of a 3.5" floppy disk.
(2HD/1.44 MB type only) When the machine is connected to a host line computer, the LAN interface permits high-speed communications.
(6) Printer interface
Voltage : Three-phase, 200 V, 220 V, 240 V
(for Japan) 200 V, 220 V, 240 V, 380 V, 400 V, 415 V
AC (for the machines to be exported)
Allowable voltage range: ± 10 % (for the rated voltage)
Apparent power : 3 kVA
or more
Size of the protective grounding lead wire : 6 mm 2
or more
(8) UPS
This machine is equipped with the uninterruptible power supply (UPS) to prevent data from being damaged or lost due to power failure. Batteries are used as the back-up power supply of the UPS, so the UPS is

(1) Applicable component sizes (For laser recognition)
Item Specifications Component height specifications 6 mm 20 mm (option at the
factory) Head Laser recognition (MNLA)
Min. 0.2 mm Component height
Max. 6 mm 20 mm Min. 0.6 mm x 0.3 mm Component size
(Length x Width) Max. 20 mm x 20 mm or 26.5 mm x 11 mm (Diagonal line should be 30.7 mm or less.)
Lead pitch Min. 0.65 mm
(2) Applicable component
Component Name Shape Package
Square chip resistor 0603, 1005, 1608, 2012, 3216, 3225 (5025, 6432)
Network resistor (Excluding SOP, SOJ, PLCC types)
MELF resistor 1.6 x φ1.0mm, 2.0 x φ1.25mm, 3.5 x φ1.4mm,
5.9 x φ2.2 mm
(5632)
6.0 mm or less Aluminum electrolytic
capacitor Height: 10.5 mm or less
(applicable if the component height specifications
is 20 mm.)
Chip film capacitor
Chip ferrite beads
SOT-89, SOT-143, SOT-223
SOJ 16, 18, 20, 24, 26, 28-pin
PLCC 18, 20, 22, 28 (Square), 28 (Rectangle),
32, 44-pins
QFP, BQFP Lead pitch: 0.65 mm or less 20mm or less
BGA 20mm or less
Laser recognition must be possible.
IC socket 20mm or less with 0.65mm or more pitch,
Laser recognition must be possible.
Tape
Stick
Tray

1 − 16
Note: For the shape of chip comp onents to be mou nted
(1) For the parts whose shape is cylindrical, there is no minimum shade when turned,
and chip recognition by laser align is therefore impossible.
(2) A poor pickup or placement accuracy could result if the top surface of the
component to be placed is curved, protruded, or dented. Avoid using such
components. (Some such components may, however, be handled by changing
the nozzle number.)
<Typical pickup failures>
1. Board size
Min. : X 50 mm x Y 30 mm
Note that the minimum size becomes 50 mm x 50 mm (X/Y) (optional)
when the machine is equipped with the automatic PWB width
adjustment function.
[KE-2010L] X 410 mm x Y 360 mm
[KE-2010E] X 510 mm x Y 460 mm
X : Along the movement of the board
Y : From front to rear (and reversely) of the machine
2. Board thickness
Min. : 0.4 mm
Max. : 4 mm
1 mm or less both for upward and downward directions
(Conforms to JIS B 8641.)
4. Board limitations
(1) Marginal area
φ2.5 - φ4 +0.1 mm (Optional) 0
[KE-2010M] 30 - 250mm
[KE-2010L] 30 - 360mm
[KE-2010E] 30 - 460mm
Marginal area
[KE-2010M] 50 - 330mm, [KE-2010L] 50 - 410mm, [KE-2010E] 50 -510mm

(2) Area in which backup pins cannot be proved KE-2010M
2 0 m m
2 1 m m
2 2 m m

Note: When the PWB is transferred from right to left, the marginal area of 50mm x 20mm is set on the left. When the PWB is transferred from right to left, the marginal area of 36mm x 105mm is set on the right.
(3) Area in which backup pins cannot be proved KE-2010L
2 0 m m
2 1 m m
3 7 m m
4 m m

Note: When the PWB is transferred from right to left, the marginal area of 50mm x 20mm is set on the left. When the PWB is transferred from right to left, the marginal area of 36mm x 105mm is set on the right.105mm is set on the right.
Movement of PWB
Conveying rail (fixed)
( V a r i a
b l e )
h e n
t h e
P W B i s t r a n s
f e r r e
d f r o m r i g
h t t o l e f t )
Stopper position
Movement of PWB Area in which backup pins cannot be provided
Conveying rail (fixed) ( 3 5 m m w
h e n
t h e
P W B i s t r a n s
f e r r e
d f r o m r i g
h t t o l e f t )
Medium size board specifications
Large size board specifications
b l e )
(4) Area in which backup pins cannot be proved KE-2010E
2 0 m m
2 1 m m
3 7 m m
4 m m

Note: When the PWB is transferred from right to left, the marginal area of 50mm x 20mm is set on the left. When the PWB is transferred from right to left, the marginal area of 36mm x 105mm is set on the right.
Movement of PWB
Conveying rail (fixed)
( V a r i a
b l e )
h e n
t h e
P W B i s t r a n s
f e r r e
d f r o m r i g
h t t o l e f t )
Stopper position

1 − 20
(5) Allowable height of a component to be placed and allowable height of the rear of
a board
Figure 1.1.7.1
SC specification 6
HC specification 20
5. Board Recognition Marks
Create the board recognition marks under the following conditions. (See Figure
1.1.7.2.) We recommend the filled circle for the mark. The clearance area
around the mark shall be as shown in Figure 1.1.7.3. Within this area, there
shall not be any silk patterns, strip lines (including inner layer patterns), through
holes, resists, and other components.
A size: 0.5 to 3.0mm ±10
B size: 0.2 mm or more
C size: 0.5 to 3.0 mm ±10
A
B
B
B
A
A
A
C
Max. 6 mm (SC specification)
Max. 20 mm (HC specification)
Marginal area on the back no plecement of PWB see 3mm
Max. 40m
3 3
1 − 21
Notes: 1. When recognition, the mark shall be placed in the angle shown above.
However, if you specify "Use of each circuit mark" for a non-matrix PWB,
the mark can be recognized only when all marks of the reference circuit
are positioned in the angle described and the circuit is positioned at 90,
180, 270 or 360 degrees.
2. The fiducials of the same shape and same size is preferable within a
board.
3. When processing, copper foil or solder plating can be recognized.
4. Maximum number of marks which can be registered
Board mark: 1 set (2 marks or 3 marks)
IC mark: 50 sets (Pairs of 2 marks)
5. Items that can be registered
Mark number
Mark shape
Outer dimensions
Matching
6. If there is no recognition mark on a board, register a user designated
template to allow the machine to recognize marks.
Figure 1.1.7.3
Clearance area
Recognition mark

1.2.1 Entire system views
Vision monitor Track ball
LCD display Signal tower
HOD unit Main switch
X-Y unit
1. Pin reference
1) When a board is carried in and the IN sensor detects the board, the PWB
transport motor drives the drive shaft to start transporting the board
with the PWB transport belt. At the same time, the stopper is turned on.
2) When the board reaches the stopper , the STOP 3 sensor detects it, then
the BU plate moves up. The board is fixed with the centering pin and
BU pin which are attached on the BU plate .
3) After the board is fixed, the next board is carried in the same manner, and it
waits at the Wait sensor .
4) After production finishes, the fixed board is released, then the machine starts
ejecting it.
5) When the first board passes the C-OUT sensor , the stopper is turned on
again and the next board is fixed.
2. Edge reference <Optional>
The board transfer mechanism is the same as that of the pin reference above.
When the board is fixed, edges of the boards are held by the stopper pusher,
X (in the X direction) pusher, (in the Y direction) and BU pin .
The transfer operation that follows is also the same as that of the pin reference
above.
STOP sensor Centering pin
C-OUT sensor BU table
BU-UP sensor Motor control
BU-DOWN sensor BU pin
Drive shaft Wait sensor
1.2.3 Component feeder
Totally two component feeder banks are provided: one bank is located at the front
and rear of the PWB transport unit respectively. The component supply method
varies depending on the package style of components: tape, bulk, stick or tray.
Components fed by a tape (chip components) or those fed in a stick are mounted on
the feeder bank with using a tape feeder, bulk feeder, stick feeder or stacked stick
feeder, then carried in the main unit. A tray component is fed from a tray holder,
matrix tray changer, or matrix tray server. A tray holder, matrix tray changer or
matrix tray server.can be mounted on the rear of the machine.
When using an overall feeder exchange trolley (option), the feeder bank can be
( )

1. Feeder bank parts identification (See Figure 1.2.3.2.)
The tape feeder loaded with taped components, stick feeder loaded with
components in sticks bulk feeder loaded with components in bulk are positioned
and secured by the fixing plate , and lock shaft .
The component feeding device is driven by the drive cylinders .
The position label is used to determine the position at which each feeder is
installed. You can see LED status of the FPI (optional) to decide where to set
each feeder.
The bank mark is the mark for correcting the position of the feeder set.
6 2
4 1
57 3
Lock shaft
Figure 1.2.3.2
(See Figure 1.2.3.3.) (Optional)
The Overall feeder exchange trolley is used to remove the feeder bank from the
main unit for easy preparation.
The feeder bank can manually be moved by holding the trolly handle r which
is attached to the floor trolley equipped with casters . Positioning to the
main unit of this machine is carried out with the bank locate pins t on the left and
.
Casters Trolly stopper
3. Tape feeder parts identification
The tape feeder uses a tape whose width is 8 mm, 12 mm, 16 mm, 24 mm, or 32
mm to supply components.
FF05/08 Parts identification (1/2)
5
1
2
X axis reference pin A Stopper Guide cover
X axis reference pin B Free link Unreeling plate
Sprocket wheel Tape holder Unreeling guide roller
Upper cover Cover tape fixing plate Reel support
Upper cover hook Lock release lever Tape groove
Shutter Lock holder

X axis reference pin B Free link Unreeling plate
Sprocket wheel Tape holder Unreeling guide roller
Upper cover Cover tape fixing plate Reel support
Upper cover hook Lock release lever Tape groove
Shutter Lock holder

Figure 1.2.4.1 Head-related unit (MNLA head)
Nozzle outer θ-axis encoder
Z-axis motor Linear way
Z-axis encoder Head-up spring
θ-axis motor Z slide bracket

(1) Main body of head
The head unit consists of the laser align sensor used to detect placement and
angle offsets of the component, and the Z slide shaft which can be moved up and
down, or be turned.
The Z slide shaft and the Z slide bracket of the Z axis are driven with rotations of
the ball screw.
The θ-axis encoder located on the upper section of the θ-axis motor detects the
angle of a component.

1.2.5 ATC unit (Automatic tool changer): parts identification
The slide plate w is opened and closed by the air cylinder to store or
attach/detach the nozzle . The ATC OPEN sensor and the ATC CLOSE
sensor detect whether the slide plate is opened or closed, and the speed
controller adjusts the speed for opening or closing the slide plate.
1
5
6
8
7
9
Nozzle outer support ATC numbers (1 to 24)
Air cylinder Nozzle
1 − 34
1.2.6 Nozzle
(1) Select the nozzle from No.501 through No.508, according to the shape and size
of the components to be mounted.
Table 1.2.6.1 Nozzles for laser recognition
NO. 500 501 502 503 504 505 506 507 508
Appearance
Outer
Diameter
1.0x
0.5mm
0.7x
Inner
Diameter
φ0.4mm
x2 φ0.25 mm φ0.4mm φ0.6mm φ1.0mm φ1.7mm φ3.2mm φ5.0mm φ8.0mm
(2) Nozzle selection
The nozzle can be automatically recognized if you follow the explanation of "3.4.1
ATC Nozzle Selection". If you manually select the nozzle, select the nozzle with
extreme care to prevent poor pickup and placement of a compornent.
The nozzle numbers for major types of components to placed be are shown in
Table 1.2.6.2. However, to keep accuracy of pickup and placement, select the
appropriate nozzle No. by referring to the minimum size of the suction area of
each component.
See the item (3) for the minimum width (D) of the sucked area of each
component.
Nozzle
No.
Minimum
component
to be placed
SOT(Molded part: 2.0 x 1.25)
0603
1005
2012, SOT(Molded part: 2.0 x 1.25)
2012, 3216, SOT(Molded part: 2.0 x 1.25),
SOT23,
electrolytic capacitor
QFP, PLCC,BGA,
!1
1.2.7 OCC parts identification
(1) Offset correction camera
The machine is equipped with a coaxial light and polarizing filter as the standard
devices. The camera detects a BOC mark and corrects the detected mark
automatically.
Adju st ing the polarizing fi l ter
1) Place a white ceramic board on the calibration block, then move the camera over
this board.
2) Loosen the screw to turn the filter holder to the right and left. When the screen
becomes brightest, fix the screw.

1.3 X, Y, and Z Axes Descriptions
The following four axes (X, Y, Z, and θ) are numerically controlled in this machine.
(1) X- and Y-axis
The X-axis represents the left and right directions of the machine, while the
Y-axis represents the front and rear directions: a position is given as X = 000.00
mm and Y = 000.00 mm in increments of 0.01 mm. Two coordinate systems are
available: one given by the production program and another given by teaching
operation. Both coordinate systems are automatically changed, so you do not
have to switch the coordinate system by yourself.
(2) Z-axis
The Z-axis represents the height, given as Z = . mm, in 0.01-mm
increments. The upward direction is positive (+), with the top side of a board
clamped (any jig is not used) being 0.
(3) θ-axis
The q-axis represents the rotation angle of the head, given as "A = . " (in
0.05 increments.) The value is positive for counterclockwise rotation and
negative for clockwise rotation.
Third nozzle axis
1.4 Interface With Extenal Devices
is the 14-Pin READY OUT (IN) connector for use when the machine is
configured with other equipment in an on-line environment.
The pin layout (assignment) of the connector for a Ready OUT (IN) signal differs
as shown in Tables 1.4.1 and 1.4.2 depending on the board transfer direction
(from left to right, and from right to left, respectively).
See Table 1.4.3 for the pin assignment of this printer connector.
is a DSub 25-Pin connector for the printer (conforming to the Centronics
Interface standards).
is an Ethernet connector (8-pin modular type connector).
See Table 1.4.6 for the pin assignment of this Ethernet connector.
Figure 1.4.1 Left side panel of the main unit Figure 1.4.2 Right side panel of the main
unit
is a connector for interface with a matrix tray changer (50-pin).

is a 9-Pin connector for the trackball.
See Table 1.4.5 for the pin assignment of this trackball connector.
is a 50-Pin connector for the keyboard.
See Table 1.4.4 for the pin assignment of this keyboard connector.
is a 5-Pin connector for the Hand-held operating device (HOD).
Figure 1.4.3 Machine right side panel
Note: The shape of the track ball connector and that of the keyboard connector is
the same. If you accidentally make the wrong connections, the system will
not be started up.
Table 1.4.1 List of connectors on the left side panel
Signal name (left to right) Signal name (right to left) Connector used
1 READY OUT READY IN
2 READY OUT READY IN GND
3 BOAD AVAILABLE IN BOAD AVAILABLE OUT
4 BOAD AVAILABLE IN GND BOAD AVAILABLE OUT
5 N.C. N.C.
6 N.C. N.C.
7 N.C. N.C.
8 N.C. N.C.
9 N.C. N.C.
10 N.C. N.C.
11 N.C. N.C.
12 N.C. N.C.
13 N.C. N.C.
14 N.C. N.C.
Table 1.4.2 List of connectors on the right side panel
Signal name (left to right) Signal name (right to left) Connector used
1 READY IN READY OUT
2 READY IN GND READY OUT
3 BOAD AVAILABLE OUT BOAD AVAILABLE IN
4 BOAD AVAILABLE OUT BOAD AVAILABLE IN
GND
1 − 41
Figure 1.4.4 shows the interface circuits for READY OUTs (IN) and BOARD
AVAILABLE signals.
GND24V
Signal name Connector used
Signal name Signal name Connector used
1 RD0 26 GND
3 RD2 28 GND
4 RD3 29 R/B0(N)
5 GND 30 GND
6 GND 31 R/B1(N)
10 RD7 35 C • OPEN (N)
11 GND 36 MTC OPEN
12 GND 37 + 5V
13 WD0 38 + 5V
14 WD1 39 + 5V
15 WD2 40 + 5V
Socket contact
AMP 66360-2
CAUTION
Check that the machine is level lying completely flat on the floor.
Check that the lock nuts are tightened securely on the four feet of the
machine.
Check that correct electrical power and air are supplied to the machine.
Main switch Breaker Adjuster
Pressure gauge Filter regulator

Note: To avoid the laser sensor detection error, install the machine where not subject
to direct sunlight.
1.6 Checking circuit protector
If the machine does not operate properly after it has been turned ON, check the
condition of the circuit protector in the power unit found on the back side of the
machine. If push-button type the circuit protector front face protrudes to show the
red mark, push the face back in. When the lever of the lever-type circuit protector is
lowered, raise it.
CAUTION
To avoid risk of serious injury or death caused by electric shock hazard,
turn off the main power switch of the house current which is installed in
the building where the machine is used.
Note that it is not the main power switch of the machine.
Figure 1.6.1
CONTROLS
2.1.1 Keyboard
~ `
} ]
_ -
+ =
Z X C V B N M < ,
> .
Key Function
F1 Use to obtain a help screen (for future expansion) on the display.
F2 Use to change data already entered.
Use to obtain a pop-up list on the display.
F3 Use to copy data.
F4 Use to delete data.
F5 Use to move data.
F6 Use to change the window in the forward direction.
F7 Use to search for particular data in the forward direction.
F8 Use to search for particular data in the backward direction.
F9 Use to select either the list or form display, the key toggling between the two.
F10 Unused
ESC Use to cancel an entry.
Alt Use to select the menu.

2 − 2
Key Function
INSERT Use to select either the insert or overtype mode, the key toggling between the two.
DELETE Use to erase the character at the cursor.
HOME Use to move the cursor to the beginning of the line.
END Use to move the cursor to the end of the line.
PAGE
DOWN
PAGE
UP
Tab Use to move the window forward.
Use to move the cursor forward.
Tab + Shift Use to move the window backward.
Use to move the cursor backward.
Use to move the cursor in the direction of the arrow.
0-9, A-Z, -, +,
other symbols
Note: The mark is entered by ¥ . (Japanese only)
ScrlL Use to move the cursor backward and, at the same time, erase the character at the cursor.
ENTER Use to validate the data entered.
Caps Lock Use to switch between uppercase and lowercase letters.
The LED lights up when this function is slelcted.
Num Lock Use to lock the numeric key functions.
The LED lights up when this function is slelcted.

Figure 2.1.2 HOD: Handheld operating device operation panel
CAUTION To avoid a risk of injury, do not place your hand in the machine, nor
move your face or head close to the machine during operations of the
HOD.
When selected, its LED lights.
HEAD • Use this key to perform a teaching function with a head.
CAMERA • Use this key to perform a teaching function with the OCC.
VACUUM • Use this key to teach the vacuum pressure.
When selected, its LED lights..

Key name Function
F1 • Assigns the X-Y axes after a device is selected.
• Selects another axis or specifies the number of points during teaching.
F2 • Assigns the Z axis after a device is selected.
F3 • Assigns the θ axis after a device is selected.
F4 • Assigns an axis after a device is selected.
No • Increments or decrements the number for selecting an axis.
• Specifies the axis number displayed on the LCD.
DEV NAME • Increments or decrements a device number to be selected.
• Specifies the device number displayed on the LCD.
-X+Y <When XY is selected> Moves the X-Y axes to the direction indicated with the
arrow mark.
<When CAMERA is selected> Moves the cursor to the direction indicated with the arrow mark.
+Z+Y
<When XY is selected> Moves the X-Y axes to the direction indicated with the
arrow mark.
<When the Z axis is selected> Moves the Z axis to the direction indicated with the arrow mark.
-X+Y <When XY is selected> Moves the X-Y axes to the direction indicated with the
arrow mark.
-θ-X <When XY is selected> Moves the X-Y axes to the direction indicated with the
arrow mark.
<When CAMERA is selected> Moves the cursor to the direction indicated with
the arrow mark.
<When the θ axis is selected> Moves the theta axis to the desired angle.
FAST • Moves the axis at high speed.
• When selected, its LED lights.
+θ+X <When XY is selected> Moves the X-Y axes to the direction indicated with the
arrow mark.
<When CAMERA is selected> Moves the cursor to the direction indicated with
the arrow mark.
<When the θ axis is selected> Moves the theta axis to the desired angle.
-X-Y <When XY is selected> Moves the X-Y axes to the direction indicated with the
arrow mark.
-Z-Y <When XY is selected> Moves the X-Y axes to the direction indicated with the
arrow mark.
<When the Z axis is selected> Moves the Z axis to the direction indicated with the arrow mark.
+X-Y <When XY is selected> Moves the X-Y axes to the direction indicated with the
arrow mark.

Key name Function
WINDOW • Switches the cursor displayed on the vision monitor from the cross-hair
cursor to the window cursor, and switches the teaching mode also, then
the LED lights.
NEXT
• Moves the cursor to the next data.
ENTER • Validates the data entered through teaching.
CAUTION When connecting the HOD unit the machine, make sure that the
machine has been turned OFF.
CAUTION The magnet sheet is pasted on the rear of the HOD unit. Keep a floppy
disk away from the HOD because the data stored on the disk may be
erased.
Figure 2.1.3
Note 1: Do not click the middle section of a trackball since any key may not be
accepted depending on your clicking timing.
* Cleaning a ball
Turn clockwise the section which clamps a ball to remove a ball.
Right button
Left button
Note 1
2.1.4 No-fuse breaker
As shown in Figure 2.1.4, the no-fuse breaker is found on the lower right side of the
machine with viewed from its front. Normally raise the lever (to ON status).
This switch functions as a circuit breaker, so it cuts off the power automatically if the
overcurrent is supplied to the machine.
CAUTION Do not turn off the no-fuse breaker when the main switch is turned on.
Figure 2.1.4 Front of the main unit
2.1.5 Main switch
As shown in Figure 2.1.5, the main switch is found on the upper front cover on the
front right side of the machine. This switch is turned off when set horizontally, and
on when vertically.
CAUTION Do not turn on the main switch when the no-fuse breaker is turned off.
Figure 2.1.5 Front right side of the main unit
No-fuse breaker
Main switch
<Front view>
Figure 2.1.6.1
ON LINE
No. Switch Function
1 ONLINE Use to allow the machine to connect to the HLC (enter the online status).
The switch lights up when the machine enters Online mode.
2 ORIGIN Use to zero all the axes.
3
START
4
(PAUSE, STOP)
Use to stop an actual or false production run. Press the switch once to put
the production run in a pause status. Press the switch the second time to
stop the production run.
5 SERVO FREE Use to free the servo motor (X-axis, Y-axis, Z-axis, and q-axis).
The switch lights up when servo motor is set into the free state.
The motor is energized again when the switch is pressed the second time.
6 SINGLE CYCLE Use to stop the production run when one board has been produced.
Press the switch a second time to exit from this status.
7 Emergency Use to bring the machine to an immediate stop if the machine malfunctions
or there could be an imminent personal injury.
When the switch is pressed, it brings the motor and other drive mechanisms
to an immediate stop and turns ON the red lamp of the signal tower.

Figure 2.2.1 Upper right side of the main body
The following table lists the functions (factory-settings) of the three colored lamps of
the rotary beacon tower q. At the machine setup, however, these can be changed as
you desire (See Section 7.2.2.13 "Signal lights").
Table 2.2.1
Lit • In Manual mode, program data is being created.
• The machine pauses during production.
Yellow
continue.)
• The machine cannot continue producing a board due to no
component available.
All lamps Lit • Waiting for the production START key to be pressed in
Production mode.
Signal lights
CHAPTER 3 OPERATION OVERVIEW
This chapter describes the operation overview of this machine: basic operation procedures
and the software configuration.
3.1 Operation Flow
In this section, two types of operation flows are described: when the machine is used
as a standalone machine and when several machines are used via the HLC.
3.1.1 When the machine is used as a standalone machine
3.1.1.1 Producing new type of PWBs
The operation flow for producing new type of PWBs is shown below:
START
(2) Editing a production program • Create a production program.
(See Chapter 4 " EDITING THE PROGRAM ".) You have to teach marks: BOC mark and IC mark. (See Section 5.4 "Teaching a Mark".)
(3) Preparation for production • At Set a feeder and check the nozzle assignment.
(See Chapter 6 "PRODUCTION PROCEDURES".)
(4) Checking a production program • Check to see if a production program is correct by tracking a component
placement position, pick-up position and pick-up height and measuring them. (See Chapter 4 " EDITING THE PROGRAM ".)
(5) Trial run • Perform the trial-run operation once or twice before starting continuous
production to check and adjust the results of components placement operation (See Chapter 6 "PRODUCTION PROCEDURES".)
(6) Continuous production • Produce the preset number of PWBs. • If the stocked components run out, supply components one by one.
END
Setting the PWB transport section
(1) Setting the PWB transport section • Set the PWB transport section according to a PWB to be produced.

The operation flow for producing PWBs repetitively is show below.
START
Continuous production
Post process
(1) Loading a production program • Load a production program which was already edited in order to
produce PWBs. (See Chapter 3.6 " File Operation ".)
(2) Preparations for production (Changeover) • At the machine station, adjust the width of the PWB transport path,
position and adjust the reference pin or stopper pin, adjust the backup support pin, check the nozzle assignment, and install a feeder.
• After installing a component pick-up device, check and adjust the component pick-up position.
(3) Trial run • Before starting continuous production, perform the trial-run operation
once or twice to check and adjust the results of components placement.
(4) Continuous production • Produce the preset number of PWBs. • If the stocked components run out, supply components one by one. (See Chapter 6 "PRODUCTION PROCEDURES".)
END
3.1.2 When using the HLC
The operation flow for producing PWBs with using the HLC is shown below.
START
Editing a production program
(1) Editing a production program • Create and edit production program data required to produce PWBs. • When you are to create or edit a program, you do not have to decide which
component is to be placed on a board or which machine station is to be used. • Program all placement positions on a board at a time. • After creating a program, execute the Optimization utility to allow the HLC to divide
the created placement data automatically. • Pick data on which optimal feeders assignment is specified is created at the same
time. (Refer to "HLC Instruction Manual".)
Production by several production
Preparations for production (changeover)
(2) Reserving production programs with the Production Planning utility and executing the Optimization utility
• Reserve the program to be used for producing PWBs. When you are to use just one program, you do not have to reserve it with the Production Planning utility.
• When you are to use two or more programs, reserve them with the Production Planning utility to optimize them at a time. Note that you can use the option for lessening the number of times feeders are replaced via these programs also. (Refer to "HLC Instruction Manual".)
(3) Down-loading the reserved program(s) onto a station with the Production utility • Directly specify the file(s) reserved with the Production Planning utility or program
data created with the Program Editing utility. • When you select the [Start] menu command, the data which was divided with the
Optimization utility is down-loaded onto each station. • The HLC enters the Line Monitoring mode until the preset number of PWBs are
produced. (Refer to "HLC Instruction Manual".)
(4) Production preparations (Changeover) • With the machine station, adjust the width of the PWB transport path, position and
adjust the reference pin or stopper pin, adjust the backup support pin, check the nozzle assignments, and install feeders.
• After installing a component pick-up device, check and adjust the component pick-up position. (See Chapter 6 "PRODUCTION PROCEDURES".)
(5) Teaching • Be sure to perform the teaching operation to use a BOC mark or IC mark. • Teaching operation is not necessary for the program which has been already used
for production. (See Chapter 5 "TEACHING".)
(6) Trial run • Before starting continuous production, perform a trial-run operation once or twice
to check and/or adjust the result of component placement. (See Chapter 6 "PRODUCTION PROCEDURES".)
(7) Continuous production • Produce the preset number of PWBs. When the preset number of PWBs are
produced, the program data is automatically uploaded to the HLC. • If the stocked components run out, supply components one by one.
(8) Post process • Register the data of production programs which can be reused onto the database. • Check and collect the production management information. To evaluate this
information, execute the Result Summarizer utility. (Refer to "HLC Instruction Manual".)
START
NO
YES
Turn on the power switch (breaker).
Press the ORIGIN key.
select [Warm-up] from [Maintenance]
(See Chapter 10 "MAINTENANCE".)
CAUTION Never operate the machine with any power voltages other than those specified by the company.
Power ON
3.3 Basic Operations
3.3.1 Screen organization
Here is a rundown of the basic components making up a screen.
Title bar
Menu bar
Command button
Work area
Scroll arrow
Scroll box
Pull-down menu
Formula bar
Window border
Status bar
3 − 6
Title bar:
Shows at its center the name of the job (i.e., the window name).
Pull-down menu:
A menu of command options that appear after you have selected the command
name on the menu bar. The command options that can be selected are shown
differently from those that cannot.
Menu bar:
Lists the names of pull-down menus to be selected. The contents of the menu
bar vary depending on the function you selected.
Window border:
Work area:
Area to which data is entered for creating a program data.
Status bar:
Formula bar:
Shows the contents of the cell which at the cursor is located and you can edit
formulas.
Scroll arrow:
Indicates that you can scroll the window in the direction of the arrow to access
more data that are not currently visible on the window.
Scroll box:
Indicates where you are in the contents of a window.
Command button
Displays a menu which is supposed to be frequently called, then allows you to
execute the selected function.
3.3.2 Selecting a menu
There are two possible ways to select a pull-down menu from among those contained
in the menu bar.
Press the Alt key to activate the menu bar.
The [File] menu is highlighted.
Press the cursor keys.
Press → or ← to go among the menu items in the menu bar.
Press ↑ or ↓ to drop down a pull-down menu. Then, press ↑ or
↓ to move among the commands displayed in the pull-down menu.
To activate the command you want to select, press the ENTER key.
During these operations, the message line shows the summary of the
highlighted command. Press the ESC key to close the menu.
(2) Using the short-cut keys
Press the Alt key to activate the menu bar.
The [File] menu is highlighted.

3 − 8
Press the key corresponding to the starting character of the desired menu
item.
When you press the starting character of the desired command, it
immediately executes the command.
3.3.3 Dialog
If additional information is necessary for the machine to execute a command, a dialog
box appears as soon as the command is selected.
A dialog box may contain the following elements:
(1) Push button
When a push button is selected, it immediately executes the command. Most
dialog boxes contain the OK and Cancel buttons.
(2) Check box
Used to let you choose options or toggle an option on or off. You can select as
many check boxes as you want. When the option is turned on, a check mark (√)
appears in the check box.
To change on or off of the option, highlight the option with the cursor, and press
one of the space keys.

(3) Radio button
Unlike check boxes, radio buttons are mutually exclusive of one another and you
can select only one at a time.
The small circle moves with the highlighted cursor. Go to the desired option
to exit from the box.
(4) List box
Gives a list of options to choose from, mainly used for selecting a file name.
The selected option is highlighted. If a list contains too many options to show at
a time, it can be scrolled.

3 − 10
3.3.4 Editing
This section describes the basic data editing method and keyboard operations (Page
Up/Page Down, Home/End, Scroll, Insert and Tab keys operation).
Dialog
No. Key Action
1 Back Space Deletes the character to the left of the cursor’ s position, shifting the character string following the cursor one character space each to the left.
2 Delete Deletes the character at the cursor, shifting the character string following the cursor one character space each to the left.
3 Cursor keys (Left, Right) Moves through the characters entered in the edit box.
4 ENTER Quits the dialog box operation at the same time you press the OK button.
5 ESC Closes the dialog box.
6 Field selection keys Moves through different boxes.
Rewriting data entered in the edit f ield (one or more characters have been
entered)
No. Key Action
2 Cursor keys Moves the cursor in the formula bar.
3 ENTER Fetches the characters shown in the formula bar into the cell. The input cell is not moved.
4 ESC Interrupts the data entry procedure. Empties the data entered so far if pressed during data entry.

3 − 11
Editing the data entered in the edit field using the formula bar (after the EDIT
function key has been pressed)
No. Key Action
2 Cursor keys Moves the cursor in the formula bar in the direction of the cursor arrow. The cursor stops moving ahead when it reaches the starting or ending character string.
5 Field selection keys Validates your input in the formula bar, then advances the cell to the direction the key indicates.
Entering the data into a cell of the spread sheet.
No. Key Action
2 Cursor keys Fetches the characters shown in the formula bar into the cell, and moves to the next cell in the cursor direction. When the current cell is the first or last cell on a line, it laps round to the previous or next line. The current cell stays still when you are at the first cell on the top line or at the last cell on the bottom line.
5 Field selection keys Function in the same manner as the cursor keys do.
(1) Basic editing method
Data entered from the operation panel is entered into the formula bar or edit box.
Data entered in the formula bar is validated at the cursor position by pressing the
ENTER key or moving the cursor. Data entered in the edit box is validated by
pressing any of the filed selection keys or ENTER key.
The machine displays the data coherence check results on the note pad. If you change the “font settings of the note pad”, the results may not be displayed correctly.
Note on changes of the font set t ings

Page up, Page down
When the information covers two or more screen pages, the Page Down key
accesses the following page and the Pageu Up key does the preceding
page.
There is a scroll bar appearing on the right side of the window when
information covers two or more screen pages. It indicates that there is more
information up or down the screen than the one currently shown on the
display. The scroll box inside the scroll bar tells you the approximate location
you are currently viewing in the entire body of information.
Home, End
When the information covers two or more screen pages, the Home key
moves the cursor to the beginning of the line and End key does to the end of
the line.
Scroll
− If the ↑ key is pressed when you are on the top line of a screen page
and if there is more information vertically before it, the key scrolls the
information down one line.
− If the ↓ key is pressed when you are on the bottom line of a screen
page and if there is more information vertically after it, the key scrolls the
information up one line.
− If the ← key is pressed when you are at the beginning of the line and if
there is more information to the left, the key scrolls the information one
field to the left.
− If the → key is pressed when you are at the end of the line and if there
is more information to the right, the key scrolls the information one field to
the right.
Insert
The Insert key toggles data entry mode between the Insert mode and
Overtype mode.
Insert Blinking
Overtype − Blinking
3.4 Starting up or Terminating the System
Windows NT starts up after power-on, then the application manager included as the
software for the main unit is executed: the initialize window appears on the screen.
Figure 3.4.1 Start-up screen
When the system is initialized for a while, the <Returning to ORIGIN> screen appears.
If you do not perform the return-to-origin function, press the <CANCEL> key. When
the system completes the return-to-origin function successfully, the application
manager window appears on the screen.
Figure 3.4.2 <Home-Origin> dialog box
Figure 3.4.3 Zeroing waiting dialog box

Figure 3.4.4 Main window
To terminate the system, click the <Exit> command button. When you click the <Exit>
button, the confirmation dialog box appears on the screen. When you click the <OK>
button displayed on this dialog box, the shut down process starts, then the system
terminates. If you click the <Cancel> button on this dialog box, the main menu
reappears.
When you click the <Exit> button, the shut-down process confirmation dialog box opens.
Figure 3.4.5 Shut-down process confirmation dialog box
To turn off the main unit, be sure to click the <Exit> button on the Main window to shut down the system. Then, turn off the main unit only after the message “You can turn off the power ” appears on the screen. If you turn off the main unit without shutting down the system on the Main window, it may damage the system file or hard disk and you may not be able to start up the system again. If you cannot click the <Exit> button on the Main window by any chance, press the <CTL>, <ALT> and <DELETE> keys at the same time to select the shutdown function. Then, turn off the power after shutting down the system. If the combination of the <CTL>, <ALT> and <DELETE> keys cannot function, press the Emergency Stop button and wait for ten minutes without performing any operation. Then, turn off the power. In this case, the shutdown function is not executed, so it cannot prevent the system from being damaged completely, but it can minimize the damage of the system.
When you start up the main unit, two consol screens (under DOS) are started up at the same time. These consol screens are necessary to control the system. Never close them.
CAUTION
CAUTION
Mech-Parameter Setting
MS-Parameter Setting
File [F] Editor [E] Production [P] Setup [S] Maintenance [M] Options [O] Help [H]
Machine Set up
Retry List
3.5.2 Program editing local menu
This section describes the commands to be used for editing a production program.
Command l is t
Tool bar
The figure below indicates the contents of the tool bar displayed when you edit a
production program.
Replacement [L]
Sort [R]
Version information [A]
Component supply count [S]
Status Dis la D
File [F] Edit [E] Data[C] Optimization [O] Display [V] Machine operation [M] Data Base[D] Help [H]
Component form
Component list
Feeder layout
Tool bar
Vision Form
Vision List
3.5.3 Production local menu
File [F] View [E] Production conditions [P] window [W] Tool [T]
Toolbar [T]
Verify all check
SOT Current check
SOT all check
Save as [A]
File [F] Setting Group [G] Disp [V] Help [H]
Registered nzl. no table [L]
Read Nzl. data [R]
Reference pin position [R]
Shape clamp position [F]
MTS position offset [O]
Component scrap position [T]
Head Wait Position [W]

This section describes how to operate a production program file.
3.6.1 Create New
Operation 1: Select the [File] command on the menu bar, then [Create New]
command on the File menu.
Operation 2: Select the button on the tool bar.
This operation clears production program data.
3.6.2 Open
Operation 1: Select the [File] command on the menu bar, then [Open] command on
the File menu.
This operation selects a production program, then loads it to the system.
Figure 3.6.2 File load dialog box

3.6.3 Overwrite & Save
Operation 1: Select the [File] command on the menu bar, then [Overwrite & Save]
command on the File menu.
This operation saves a production program with the current name.
Note: O

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KE2010.Instruction Manual.ver.2.01.Rev.08

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