Apollo seiko J-cat200 comet User manual

J-CAT COMET Series

Operation Manual

Thank you for purchasing the J-CAT COMET.

Read these instructions thoroughly for proper use of this machine.

Make sure to read "Safety Notes" before you use machine.

This information protects you from possible dangers during use.

Apollo Seiko Ltd.

Rev.201505

Page 2 of 60

Safety Notes

 This manual includes the important information to use this machine safely. This also includes

useful information to prevent injury or damage to property. Please read this manual carefully

prior to connecting or operating the J-CAT COMET.

 Keep this manual near the machine at all times.

Supply only specified voltage

 Do not connect to a power supply greater than the specified voltage. If voltage is exceeded,

electrical shock and /or damage to the unit may occur.

 Make sure that the electrical outlet is properly grounded. If the outlet is not properly

grounded, electrical shock and/or damage to the unit may occur.

Working ambient temperature and relative humidity

 This machine has been designed for use between 0～40 degrees C,10%～90%. Do not use

this machine exceeding these conditions.

Handle with care

 This machine is designed to use a solder feeder and hot iron for soldering.

Touching a heated soldering iron will cause severe burns. Make sure the iron has cooled

down before you are touching it for replacing the iron cartridge.

 Please handle this machine with care. If the machine is dropped or sustains great impact /

vibration, it may cause malfunction.

If you do not use the machine for a long time

 Please turn off the power, remove the power cable and keep it in a dry and cool place.

If you note malfunction on machine

 If the machine malfunctions, turn off the power immediately and contact the dealer you

purchased the machine from.

Immunity from responsibility

 We do not take responsibility for damage caused by misuse, mistakes, accidents, use in

abnormal conditions or natural disasters, such as in an earthquake, a fire etc.

 We do not take responsibility on contingency loss,（Business loss, Business stop） caused

by machine stop.

 We do not take responsibility for losses or damages caused by operating with other means

not mentionined in this manual.

 We do not take responsibility for losses or damages caused by a wrong connection with

other equipment.

 If for any reason the internal circuitry is tampered with altered or repaired without written

consent of Apollo Seiko, the warranty is null and void. The customer is allowed to make

necessary tooling adjustments, replace solder iron tips and make any necessary

adjustments to the temperature controller.

Page 3 of 60

INDEX

Safety Notes ................................................................................................................................. 2

INDEX .......................................................................................................................................... 3

1. Summary of J-CAT COMET ............................................................................................. 4

2. Specification .................................................................................................................... 4

3. Dimensions ...................................................................................................................... 5

4. Description ....................................................................................................................... 9

5. Preparation..................................................................................................................... 11

6. How To Set Temperature Controller ............................................................................. 12

7. Operation Process ......................................................................................................... 14

8. Start Up Preparation ...................................................................................................... 15

9. Program Number Selection .......................................................................................... 17

10. Teaching Pendant Basic Key Operation .................................................................... 18

11. Point Soldering Program Setting ............................................................................... 19

12. Slide Soldering Program Setting ................................................................................ 22

13. Easy Slide Soldering Program Setting ...................................................................... 28

14. The Other Program Setting ........................................................................................... 29

15. Point Type List ............................................................................................................. 33

16. How To Save The Teaching Data ................................................................................ 35

17. Initial Value and Adjustable Range of Soldering Condition ....................................... 36

18. Point Edit Menu ............................................................................................................ 37

19. Soldering System Settings ......................................................................................... 42

21. Error sign ..................................................................................................................... 52

22. Troubleshooting ........................................................................................................... 53

23. Maintenance ................................................................................................................. 54

24. ZSB feeder adjustment and alignment (Option) ........................................................ 55

25. Handling of Iron Tip ..................................................................................................... 57

26. How To Change Iron Tip .............................................................................................. 59

Page 4 of 60

1. Summary of J-CAT COMET

This 4-axis soldering robot consists of the soldering controller unit “COMET”, the solder feeder and

the iron unit “RSP/RSL”. You can easily set the soldering condition such as pre-heat, heating time

by the teaching pendant.

*Please refer to JANOME “Quick Start” and “Teaching Pendant” operation manuals for more details.

2. Specification

Type

J-CAT200

COMET

J-CAT300

COMET

J-CAT400

COMET

J-CAT500

COMET

Drive Method 5-phase stepping motor

Encoder 4-axes applicable

Resolution X, Y, Z Axes 0.01mm

R Axis 0.08°

Operation Range

X, Y Axes 200 x 200 mm 300 x 320 mm 400 x 400 mm 510 x510 mm

Z Axis 50mm 100mm 100mm 150mm

R Axis ±360°

Portable Weight 7.0kg 11.0kg

Maximum Speed

X, Y Axes 700mm/sec 800mm/sec

Z Axis 250mm/sec 320mm/sec

R Axis 600°/sec 800° /sec

Repeatability X, Y, Z Axes ±0.01mm

R Axis ±0.008°

Teaching Method Remote teaching (JOG)

Manual data input (MDI）

External Input / Output Input: 16 Output: 16

Program Capacity 255 programs

Memory Capacity 30,000 points

Soldering Condition 500 conditions

Setting Temperature 0~500℃ (1℃ increments)

Solder Feeding Speed 1.0mm/sec ~ 50.0mm/sec

Solder Feeding Amount Resolution 0.1mm

Solder

Diameter

Using ZSB Feeder φ0.4 ~ φ1.0mm （Option: φ0.3, 1.2, 1.6mm）

Using Normal Roller φ0.3 ~ φ1.6mm

Heater Capacity 130W

Air 0.4 ~ 0.5MPa Dry-Clean Air

Power Source AC94 ~ 260V (Single-phase)

Power Consumption 366W

Usage

Environment

*Indoor use only

Temperature

Range

0 ~ 40℃

(This is different from the temperature to keep the yield rate of the

product.）

Humidity Range 10% ~ 90% (Non condensing)

Page 5 of 60

3. Dimensions

J-CAT200 COMET

Page 6 of 60

J-CAT300 COMET

Page 7 of 60

J-CAT400 COMET

Page 8 of 60

J-CAT500 COMET

Page 9 of 60

4. Description

*The below figure is J-CAT200 COMET.

COMET controlle

r

Emergency stop switch

Program selection key

Start button

Iron unit

Solder feeder

Solder tube

Teaching Pendant

Program number display

Solder wire position

adjusting screws

<Back>

Power switch for

robot

Z-axis

(

-

)

(

+

)

X-axis

(

-

)

(

+

)

Y-axis

(

-

)

(

+

)

(

-

)

(

+

)

R-axis

Page 10 of 60

Soldering Controller COMET Description

1. Temperature Controller:

Displays the present and set iron temperature

The temperature can be set by the buttons.

Refer to “How to Set The Temperature Controller” page.

2. Iron Down Button

Pressing this button will actuate the iron, holding it the

down position.

While teaching the soldering position, the position can be

checked with this button

.

3. Solder feed forward button

Solder wire is forwarded while this button is pressed.

4. Power switch for COMET

Temperature will be displayed on the temperature

controller when the power turned on after a while.

COMET back

Earth connector

Air in （diameter 6mm）

I/O connector

RS232C Connector

Feeder cable connector

Iron unit

Air OUT

Iron connector

Fuse box 3A

Power inlet plug

Page 11 of 60

5. Preparation

Set Solder Wire

1) Remove the feed tube and pull solder wire through

first. Then attach the solder tube.

2) Set the solder wire as per the diagram, and make

sure to set solder wire on top of the solder shortage

senseor arm.

3) If the release lever is upper position, the cutting

blade/pinch roller will not feed the solder wire. When

ready to feed the wire, put the leaver in the “down”

position.

4.2 How to Adjust RSP Iron Unit

4) Solder wire feeding position can be adjusted.

Upper adjusting screw : Up/down direction

Lower adjusting screw : Left/right direction

5) Iron up down speed can be adjusted by turning screws

after loosening the locking nut.

Upper black screw : Iron Up Speed

Lower white screw : Iron Down Speed

6) Second solder feeding position can be altered

by moving this screw. Using this adjustment screw, solder

can be prefed under the tip then fed into the joint with the

iron down.

Lowering the screw position:

 Decreases the distance the Iron moves for second

feed.

Rasing the screw position:

 Increases the distance the iron moves for second feed.

(1)

(3)

(2)

Page 12 of 60

6. How To Set Temperature Controller

6.1 Parameter showing

Description Setting detail Initial

value

PVS1 PV calibration zero setting Use ▲or▼key to change .

-500~500 (℃)

-35

AT Auto-tuning operation mode Push ▲or▼key to turn on.

“AT” is flashing during auto-tuning on the SV

line.

It finishes when oFF is displayed

(When ERR02 is displayed, the solder wire

may not be set properly.)

oFF

E2H PV value alarm

upper limit setting

Use ▲or▼key to change .

0~500 (℃)

50

E2L PV value alarm

lower limit setting

Use ▲or▼key to change .

0~500 (℃)

50

PASS

(flash)

Password setting No need to set －

<Temperature calibration PVS1> *Make sure to carry out after replacing iron cartridge.

MODE FUNC

4 sec.

Initial setting mode Operation screen

*When the PV display shows in green color,

PV value alarm is within the setting range.

When it is in red, it is out of its range.

PV (Present temperature)

SV (Set temperature)

SV can be changed by

pushing

(0~500℃)

Parameter change

Refer to Flow chart.

Change value

by

Press once.

Press for 4 sec. Press

for 2 sec to return.

*For more higher

accuracy, leave

the soldering unit

for 30 min. Then

start temperature

calibration.

Page 13 of 60

MODE FUNC

MODE FUNC

<Auto tuning AT> *Make sure to carry out after replacing iron cartridge.

Press for 4 sec. Press once.

Press until

above screen appears.

Press once. Press

for 2 sec to return.

Press for 4 sec. Press until

above screen appears.

Press once. Press

for 2 sec to return.

Change value

by

Press for 4 sec. Press until

above screen appears.

Press twice. Press

for 2 sec to return.

Change value

by

Push once

to change 1st digit.

FUNC Push twice

to change 2nd digit.

FUNC Push three times

to change 3rd digit.

FUNC

Press or

leave for 4 sec to return.

MODE FUNC

Press for 4 sec. Press until

above screen appears.

Press once.

0:off

1:All lock

2:Lock in operation mode

3:Lock except operation mode

Press

for 2 sec to return.

Page 14 of 60

7. Operation Process

This robot variously operates by program operation.

To operate the robot, creating program is firstly necessary.

Operating process is as follows:

“Teaching” means creating program and inputting any setting to the robot.

It is called “Teaching data” that is registered to the robot by “Teaching”.

Start up preparation

Program number selection

Point coordinates input

Point type selection

Soldering condition number input

Soldering condition input

Tes t

Running

Point teaching

Repeat as many as

the number of

p

oint

Refer to “8.Start Up Preparation” for more

detail.

Refer to “9. Program Number Selection” for

more detail.

Refer to “11~14. Program Setting” for more

detail.

Refer to JANOME operation manual,

Quick start for more detail.

Refer to JANOME operation manual,

Quick start for more detail.

Page 15 of 60

8. Start Up Preparation

8.1 Returning to Home Position (Mechanical Initializing)

After turning on the power switches of COMET and the robot, proceed to home the machine

(initializing) according to the display of the teaching pendant.

・Teaching Mode: Display Example of Teaching Mode

Initialized by F4 key on the teaching pendant

・Switch Run Mode:

Initialized by the start button on the robot

・External Run Mode:

Initialized by the external start.

8.2 Mode Switching

By pressing MODE key, “Change Mode” display is shown on the teaching pendant.

Select “Switch Run Mode” for running program.

Select “Teaching Mode” for Teaching.

Then press ENTER.

* In order to run program, make sure that LED of Start button

is flashing.

Then press Start button.

・External Run Mode…… To start running programs using a signal from the I/O SYS or COM1

・Switch Run Mode………To start running programs by pressing Start button on the robot

・Teaching Mode…………To create programs

・Administration…………. For administration and adjustment

LED lights on the teaching pendant indicate the current mode.

・E.RUN………External Run Mode

・RUN ………..Switch Run Mode

・TEACH……..Teaching Mode

・CUSTOM…..Customizing Mode

・ADMIN…….. Administration

Teaching Mode

Press F4 Key

For Mechanical Initializing

LANG INIT

Change Mode

External Run Mode

Switch Run Mode

Teaching Mode

Customizing Mode

Administration

Page 16 of 60

8.3 Emergency Stop

Use the emergency stop switch to stop the robot if any accident has occurred during operation.

The motor’s power (power to the motor) will be turned off and the robot will stop running by pressing

this button.

Also during soldering, the soldering will be stopped and the iron tip will go up.

How to release the emergency stop:

Turn the depressed emergency stop switch clockwise.

Then initialize the robot according to the teaching pendant display.

Emergency stop switch

Release

Page 17 of 60

9. Program Number Selection

When pressing PRO. NO key on the teaching pendant at Teaching mode, the following display is

shown.

If there is no registered program, the following display simply appears by starting Teaching mode.

DEL: Deletes program.

COPY: Copies program number.

NEW: Displays the list of unset program number.

LIST: Displays the list of set program number.

GLIST: Shows the programmed teaching point

on the sreen.

For setting the new program number, press in order to display the unset program number list.

Select the setting program number by CURSOR key,

then press ENTER to register.

Point 1 (P1) screen of the selected program number appears.

Enter a number

Program Number 1

DEL COPY NEW LIST GLIST

Select Itme

01

02

03

04

05

06

07

08

09

10

11

12

13

Program 1 P1

X 0mm

Y 0mm

Z 0mm

FUNC JOG MDI INIT

F0

F1

F2

F3

F4

F2

F0 F1 F2 F3 F4

Page 18 of 60

X

Y

Z

RR

T. E N V

MODE SAVE GO

EDIT

ESC MENU

DEL

ENTR

1 2 3

4 5 6

7 8 9

.

0

SHIFT CTRL

10. Teaching Pendant Basic Key Operation

 In the Teaching Mode

Soldering is operated with the iron staying at the lower position.

While teaching the soldering position, check the position with the iron down key “1” or “0”.

 At the setting screen that displays the programmed coordinate

: Used to switch the screen to previous / next screen.

: The axes move to the coordinate value of the displayed current screen.

: The axes move to the coordinate value of the displayed current screen and operates

the programmed point job.

+ : Used to move the axes to the home position.

By F2 and F3 keys, the mode can be switched between JOG and MDI Mode

One Touch Feed Length

Refer to Soldering System

Setting page.

By pressing and holding,

solder wire is fed in reverse.

JOG Keys

Used to move 4-axis in the

JOG Mode*1.

By pressing and holding, air-

blowing

By pressing and holding, Iron

goes down and stays at lower

position.

By pressing once, Iron goes

down.

By pressing and holding,

solder wire is fed.

By pressing once, Iron goes

up.

GO

F4

GO SHIFT

Program1 P1

X 122mm

Y 151.2mm

Z 59.1mm

R 0deg

FUNC JOG MDI INIT

Program1 P1

>X 122mm

>Y 151.2mm

>Z 59.1mm

>R 0deg

FUNC JOG MDI INIT

JOG Mode *1

In the JOG Mode, move the arms to the

setting position by JOG keys.

MDI Mode

In the MDI Mode, enter the setting

coordinate value by the numeric keys.

The arms does not move in the MDI

Mode.

F0 F1 F2 F3 F4 F0 F1 F2 F3 F4

Page 19 of 60

11. Point Soldering Program Setting

11.1 Point Soldering Flow

The flow of point soldering as follows:

*When the soldering feed/ Rev.amount is “0”, it is jumped to next soldering condition.

Name Description

1st solder amount

/ feed speed

Set 1st solder amount and feed speed.

With the iron tip being up, the solder wire feeds to the iron tip.

By feeding a few solder wire to the iron tip, the heat can quickly transfer to the

joint area.

The setting value depends on the joint/ substrate and the type of iron tip.

1st solder Rev. amount

/ Rev. speed.

Set the amount and speed to retract the solder wire after 1st solder feeding.

The purpose of the 1st solder Rev. is to prevent the solder wire from melting by

the heat of iron tip. Also the next solder amount can accurately feed by

retracting the solder wire.

Pre-heat time Set the time that the iron tip goes down and heats the joint/ substrate.

Pre-heat time depends on the size of joint/ substrate.

2nd solder amount

/ speed

Set 2nd solder amount and feed speed that the joint requires.

Although 2nd solder amount depends on the joint, 1st solder Rev. amount also

needs to be considered.

2nd solder Rev. amount

/ Rev. speed

Set the amount and speed to retract the solder wire after 2nd solder.

In the same way as 1st solder Rev, the next solder amount can accurately feed

by retracting the solder wire.

Heating time It is the heating time after 2nd solder is finished.

This heating time allows solder for proper wetting and flow.

3rd solder amount

/ feed speed

If necessary, set 3rd solder amount and feed speed to add flux and prevent

“icicling.”

When the heating time is long after 2nd solder, the flux does not activate and

the solder becomes “icicling.”

3rd solder Rev. amount

/ feed speed

As with 2nd solder Rev, it is the amount and speed to retract the solder wire

after 3rd soldering.

Timer： Pre-heat time Heating time

Soldering

condition：

① *

1st solder

②

Pre-hear

③ *

2nd solder

④

Heating

⑤ *

3rd solder

Page 20 of 60

11.2 Point Soldering Teaching

Using JOG key to move iron cartridge until “Point Soldering”

point.

Press ENTER .

Select the type “Point Soldering” by CURSOR key.

Press ENTER .

Enter condition number 1-100.

Note: 100 conditions can be selected. Do not enter the

same number as the slide soldering condition.

DEL: Deletes soldering condition.

COPY: Copies soldering condition.

NEW: Displays the list of unset soldering condition

number.

LIST: Displays the list of set soldering condition number.

VIEW: Shows the soldering condition of the displayed

number.

*Refer to the next page.

*If the solderting condition is not set,

initial value is displayed.

* The programmed solderting condition number can be used in the other point soldering program.

F0

F1

F2

F3

F4

F0 F1 F2 F3 F4

Program1 P1

X 0mm

Y 0mm

Z 0mm

R 0deg

FUNC JOG MDI INIT

Select Point Type 1/4

Point Soldering

Point Soldering (No Up)

Start of Line Soldering

Line Passing

Arc Point

End of Line Soldering

Start of Easy Line Soldering

Easy Line Passing

Arc Point

End of Easy Line Soldering

Pre Solder

Cleaning Point

Enter a number

Condition Number 1

DEL COPY NEW LIST VIEW

Apollo Seiko J-CAT200 COMET User manual

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