Yamaha SIGMA-G5SII Operating and installation instructions

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MACHINE TYPE : SIGMA-G5SII
CLASSIFICATION : Installation / Adjustment / Maintenance
REFERENCE :
SIGMA-G5SII Service Manual
General description
This service manual is intended for service engineers who maintain the machine.
Make sure to read this service manual carefully and use the machine safely.
Keep this service manual in a safe place within reach.
Regarding the basic work procedure until installing the machine, see “Chapter 2 Basic Operations for
Maintenance”.
Fill out the adjustment results when installing the machine in the “installation check sheet” and keep it in your
office.
When installing the machine by an overseas agency, make sure to fill out the “installation check sheet” and
submit it to YAMAHA Japan office.
Make sure to submit the installation check sheet as it is the absolute condition of starting the warranty period.
About this document:
This document is intended for service engineers.
Make sure to use it under the instruction of those who have completed the maintenance training or a
YAMAHA serviceman.
YAMAHA is not responsible for any problems caused by the misuse of the document.
This document contains the method to edit the system data that affects the customer’s machine
condition.
Make sure to thoroughly understand the contents of the document, and perform the adjustments on
your own responsibility.
This document contains the password to log in the adjustment utility. Be careful when handling it.
All rights reserved.
About the safety:
Strictly follow the safety precautions in the “Safety” section in the “Operation Manual”.
Disclaimers:
This document contains the preliminary information subject to change in the future.
The information contained in this document represents the current view of YAMAHA on the issues
discussed as of the date of issuance. As YAMAHA must respond to changing market conditions, it should
not be interpreted to be a commitment on the part of YAMAHA, and YAMAHA cannot guarantee the
accuracy of any information presented after the date of issuance.
This document is provided for information purposes only, and it is provided without any warranties, either
express or implied.
It is the responsibility of the user to comply with all applicable copyright laws. Without limiting the rights
under copyright, no part of this document may be reproduced, stored in or introduced into a retrieval
system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or
otherwise), or for any purpose, without the written permission of YAMAHA.
However, this shall not be construed to limit the user’s right granted by Copyright law.
YAMAHA may have patents, patent applications, trademarks, copyrights, or other intellectual property rights
covering subject matter in this document. Except as expressly provided in any written license agreement
from YAMAHA, this document does not give users any license to these patents, trademarks, copyrights, or
other intellectual property.
The names of actual companies and products mentioned in this document may contain the trademarks of
their respective owners.
No: SI1705004E-000
ISSUED DATE: December 27 2017

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Table of Contents
1. Installation .................................................................................................................................7
1.1. Machine Specifications............................................................................................................ 7
1.2. Connection of the Power and Earth Cable........................................................................... 11
1.2.1. Installation of the Machine Power Unit ........................................................................... 11
1.3. Air Connection ....................................................................................................................... 14
1.3.1. Air Pipe Connection ........................................................................................................... 14
1.4. Installation Procedure........................................................................................................... 15
1.4.1. Preparation for the Installation........................................................................................ 15
1.4.1.1. Removal of the Fixtures (X-Axis Beam)........................................................................ 15
1.4.1.2. Removal of the Fixtures (Y-Axis) .................................................................................. 15
1.4.1.3. Attachment of the Tower Light ..................................................................................... 16
1.4.1.4. Removal of the cover and cutter guide cover in the power breaker section ............... 16
1.4.1.5. Preparation of the Machine Installation Jigs............................................................... 17
1.4.2. Machine Installation.......................................................................................................... 19
1.4.2.1. Machine Installation (Leveling) .................................................................................... 19
1.4.3. Preparation before Offset Adjustment ............................................................................. 22
1.4.3.1. Running-in Operation before Adjustment (Standard: 1 hour) .................................... 22
1.4.3.2. Preparation of Offset Adjustment Jigs and Tools ........................................................ 22
1.4.4. Offset in the Installation Operation (High-Speed Head) ................................................ 23
1.4.4.1. Differences from SIGMA-G5S and Precautions (Installation Adjustment Related) . 23
1.4.4.2. Preparation before the Post-Installation Adjustment Operation ............................... 24
1.4.5. Offset Teaching (Ship. Adj.) Window................................................................................ 25
1.4.5.1. NL-Axis Origin Offset/Master Nozzle Level ................................................................. 27
1.4.5.2. Placement Level Offset (Head Up/Down Offset) .......................................................... 29
1.4.5.3. Chute Level (Perform the teaching selecting "Teach Start (Shipment)")................... 30
1.4.5.4. Stocker Master ............................................................................................................... 32
1.4.5.5. Pick-up Level Offset (Value "L" for the Feeder Offset A) ............................................ 32
1.4.5.6. PEC Recognition Camera & Beam Offset..................................................................... 33
1.4.5.7. Component Recognition Camera Position .................................................................... 35
1.4.5.8. Head Rotation Center/Base Mark Position Teaching .................................................. 37
1.4.5.9. Fly Recognition Camera Offset Teaching ..................................................................... 41
1.4.5.10. Nozzle Inclination Offset Teaching ............................................................................... 42
1.4.5.11. Table Offset Teaching .................................................................................................... 43
1.4.5.12. Machine Inside CPK Offset Teaching ........................................................................... 46
1.4.5.13. Self-Calibration Placement Condition .......................................................................... 47
2. Basic Operations for Maintenance ...........................................................................................62
2.1. Home Return Operation........................................................................................................ 62
2.2. Home Return Operation Procedure...................................................................................... 62
2.2.1. All Zero ............................................................................................................................... 62
2.2.2. Individual Zero................................................................................................................... 62
2.2.2.1. Unit Home Return.......................................................................................................... 63
2.2.2.2. Selected Axis Home Return ........................................................................................... 63
2.3. Nozzle Change Procedure ..................................................................................................... 64
2.3.1. Nozzle Change Procedure in the "Setup" window. .......................................................... 64
2.3.2. Nozzle Change Procedure in the "Unit Adj." Window ..................................................... 65
2.4. Conveyor Width Adjusting Procedure.................................................................................. 66
2.5. PCB Transfer Procedure ....................................................................................................... 67
2.6.Unit Adjustment .................................................................................................................... 71
2.6.1. "NOZ.CHNG" Window (in Debug Mode) .......................................................................... 71
2.6.2. "CONVEYOR" window (in Debug Mode).......................................................................... 72
2.6.3. "PCB Stpr" Tab Sheet in the "CONVEYOR" Window ..................................................... 72
2.6.4. "Driver Mng." Tab Sheet in the "CONVEYOR" Window................................................. 73
2.6.5. "X Axis grease up" Window ............................................................................................... 73

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2.6.6. "FDR BASE" Window ........................................................................................................ 74
2.7. Manual Operation ................................................................................................................. 74
2.7.1. Unit Adjustment ................................................................................................................ 75
2.7.1.1. Linear Measure Detection Test ..................................................................................... 75
2.7.1.2. Cutter Operation ............................................................................................................ 75
2.7.2. Device Check (Input/Output) ............................................................................................ 76
2.7.2.1. Manual Operation of Each Section ............................................................................... 76
2.7.3. Manual Axis Operation ..................................................................................................... 76
2.7.3.1. 《Example: In the case that the nozzle does not touch the jig》................................ 77
2.8. System Data Editing Procedure ........................................................................................... 77
2.9. Change Procedure to Debug Mode ....................................................................................... 80
2.9.1. Main Additional Items in the "Debug Mode" ................................................................... 82
2.9.2. Escape from Debug Mode .................................................................................................. 82
3. Mechanism ...............................................................................................................................83
3.1. Nozzle Stocker Unit Change Procedure ............................................................................... 83
3.1.1. Removal of the Nozzle Stocker Unit ................................................................................. 83
3.1.2. Attachment of the Nozzle Stocker Unit............................................................................ 83
3.1.3.Description of Connecting Connector ............................................................................... 84
3.1.4. Connection Example .......................................................................................................... 85
3.1.4.1. Nozzle Stocker Configuration High - High - High –High ........................................... 85
3.1.4.2. High - High - None - Multi............................................................................................. 86
3.1.4.3. Multi - None - None - None............................................................................................ 87
3.1.4.4. Multi - None - High - High............................................................................................. 88
3.1.4.5. Multi - None - None - High ............................................................................................ 89
3.1.4.6. Multi - None - None - Multi ........................................................................................... 90
3.1.5. Various Settings................................................................................................................. 91
3.1.5.1. High-Speed Nozzle Stocker............................................................................................ 91
3.1.5.2. Multi Functional Nozzle Shutter .................................................................................. 92
3.1.5.3. Nozzle Up-Status Detection Sensor Amplifier Adjustment ........................................ 93
3.2. X-Axis Ball Screw Change Procedure .................................................................................. 96
3.2.1. X-Axis Ball Screw Removal Procedure ............................................................................. 96
3.2.2. X-axis Linear Guide Attachment Procedure .................................................................... 98
3.2.3. Treatment if any value is out of the standard range:.................................................... 100
3.2.3.1. Adjustment Procedure ①............................................................................................ 100
3.2.3.2. Adjustment Procedure ②............................................................................................ 100
3.3. Y-axis Linear Guide Attachment........................................................................................ 101
3.4. X-axis Linear Guide Attachment........................................................................................ 103
3.5. X-Axis Linear Scale Change Procedure ............................................................................. 106
3.5.1. X-Axis Linear Scale Removal .......................................................................................... 106
3.5.2. X-Axis Linear Scale Attachment..................................................................................... 106
3.6. Y-Axis Linear Scale Change Procedure ............................................................................. 109
3.6.1. Y-Axis Linear Scale Removal .......................................................................................... 109
3.6.2. Y-Axis Linear Scale Attachment..................................................................................... 109
3.7. X-Axis Scale Head Adjustment Procedure......................................................................... 112
3.7.1. Preparation of Adjusting Jig ........................................................................................... 112
3.7.2. Adjusting Procedure ........................................................................................................ 113
3.8. Y-Axis Scale Head Adjustment Procedure......................................................................... 117
3.8.1. Preparation of Adjusting Jig ........................................................................................... 117
3.8.2. Adjusting Procedure ........................................................................................................ 118
4. Maintenance ...........................................................................................................................120
4.1. CPU-1 PCBs U91 and U92 Change.................................................................................... 120
4.1.1. Removal of CPU1-BOX .................................................................................................... 120
4.1.2. Removal of Control Board U91 or U92 ........................................................................... 121

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4.1.3. Attachment of CPU1-BOX............................................................................................... 123
4.2. Control Board Change......................................................................................................... 126
4.2.1. CPU-2 PCBs U85 and U82 Change ................................................................................ 126
4.2.2. Control Board Removal ................................................................................................... 126
4.2.3. Handling of Control Board .............................................................................................. 127
4.2.4. Change of PCB U81 (CPU2 Main Board)....................................................................... 128
4.3. Change of Lighting Control Board U95 ............................................................................. 130
4.3.1. Removal of U95 LED Lighting Control Board ............................................................... 131
4.3.2. U95 Attachment............................................................................................................... 132
4.4. Multi-axis Board Change Procedure .................................................................................. 134
4.4.1. Multi-axis Board Change Procedure .............................................................................. 135
4.5. PEC Recognition Camera Unit Change ............................................................................. 137
4.5.1. Removal Procedure for the PEC Recognition Camera Unit.......................................... 137
4.5.2. Attachment Procedure for the PEC Recognition Camera Unit .................................... 137
4.6. Component Recognition Camera Unit Change.................................................................. 138
4.6.1. Removal Procedure for the Component Recognition Camera Unit .............................. 138
4.6.2. Attachment Procedure for the Component Recognition Camera Unit......................... 138
4.7. Removal of Nozzle Up/Down (NL) Axis Motor................................................................... 139
4.7.1. Attachment of Nozzle Up/Down (NL) Axis Motor.......................................................... 139
4.8. Removal of the Nozzle Selection (NS) Axis Motor............................................................. 142
4.8.1. Attachment of Nozzle Selection (NS) Axis Motor .......................................................... 142
4.9. Head Up/Down (HL) Axis Motor Removal......................................................................... 144
4.9.1. Head Up/Down (HL) Axis Motor Attachment................................................................ 145
4.10. Slip Ring Change Procedure ........................................................................................... 149
4.10.1. Slip Ring Removal ........................................................................................................ 149
4.10.2. Ring Attachment .......................................................................................................... 150
4.11. Nozzle Shaft Removal and Attachment (Single Unit) ................................................... 153
4.11.1. Nozzle Shaft Removal and Attachment (Single Unit) ............................................... 153
4.11.1.1. Nozzle Shaft Removal (Single Unit) ........................................................................... 153
4.11.1.2. Nozzle Shaft Attachment (Single Unit) ...................................................................... 153
4.11.2. Nozzle Shaft Total Disassembling, Cleaning and Assembling.................................. 154
4.11.2.1. Purpose ......................................................................................................................... 154
4.11.2.2. Required Items for the Work ....................................................................................... 154
4.11.3. Preparation for the Work............................................................................................. 155
4.11.4. Disassembling Work .................................................................................................... 156
4.11.5. Operation Check........................................................................................................... 168
4.12. Maintenance in Trouble Occurrence (Mechanism)........................................................ 169
4.12.1. High-speed Head Change ............................................................................................ 169
4.12.1.1. Removal of Electric Wiring, etc. .................................................................................. 169
4.12.1.2. Head Assembly Removal ............................................................................................. 169
4.13. Head Assembly Attachment............................................................................................ 170
4.13.1. SVC Offset Value Input (SVC = Side View Camera) .............................................. 170
4.13.2. Various Offset Adjustments ........................................................................................ 171
4.14. Cutter Unit Attachment/Removal Procedure ................................................................ 172
4.14.1. Cutter Unit Removal.................................................................................................... 172
4.14.2. Cutter Unit Attachment to the Feeder Cart .............................................................. 173
4.15. Clamp Lever Change Procedure ..................................................................................... 174
4.15.1. Clamp Lever Removal.................................................................................................. 174
4.15.2. Clamp Lever Change.................................................................................................... 175
4.15.3. Clamp Lever Attachment ............................................................................................ 175
4.16. Cutter Blade Assembly Change Procedure .................................................................... 176
4.16.1. Cutter Blade Assembly Removal................................................................................. 176
4.16.2. Cutter Blade Assembly Attachment ........................................................................... 176
4.16.3. Cutter Driver (A63B, A63F) Change Procedure......................................................... 177
4.16.4. Cutter Unit Operation Check ...................................................................................... 178
4.17. Fuse Replacement............................................................................................................ 180
4.17.1. Relay PCB (U27) Fuse Replacement........................................................................... 181

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4.17.2. Replacement of Fuse located on the side panel rear .................................................. 181
4.17.3. Lightening Surge Protector Replacement................................................................... 182
4.17.4. Lighting Control Board (U95) Fuse Replacement...................................................... 182
4.17.5. Fuse Change in the CPU2 I/O Host Board (U85)....................................................... 183
4.18. Servo Amplifier Change Procedure ................................................................................ 184
4.18.1. Servo-Amplifier Removal............................................................................................. 184
4.18.2. Servo-Amplifier Attachment........................................................................................ 185
4.18.3. Adjustment after Servo Amplifier Replacement ........................................................ 186
4.19. Disengaged Latch Detection Sensor Change Procedure ............................................... 188
4.19.1. Disengaged Latch Detection Sensor Removal ............................................................ 188
4.19.2. Disengaged Latch Detection Sensor Attachment....................................................... 188
4.19.3. Disengaged Latch Sensor Amplifier Adjustment....................................................... 189
4.20. Tape Component Pick-up Error Detection Sensor Setting ........................................... 192
4.21. Side View Camera Light Receiver Change .................................................................... 194
4.21.1. Light Receiver Change................................................................................................. 194
4.21.1.1. Light Receiver Removal ............................................................................................... 194
4.21.1.2. Cable Disconnection and Connection.......................................................................... 195
4.21.1.3. Light Receiver Attachment and Position Adjustment ............................................... 196
4.21.1.4. Checks ........................................................................................................................... 197
4.21.1.5. Data Input .................................................................................................................... 199
4.21.1.6. Gain Teaching............................................................................................................... 200
4.21.1.7. NL-Axis Origin/Master Nozzle Level Offset Teaching .............................................. 200
5. Electric System.......................................................................................................................201
5.1. Home Return Operation Procedure.................................................................................... 201
5.2. Electric System Block Drawing (SIGMA-G5SII) ............................................................... 202
5.3. Each Block Electric System Layout ................................................................................... 203
5.3.1. Main Machine Corner Front Side and Plate Entire Section in the lower frame section
203
5.3.2. Main Machine Corner Front Side and Plate Entire Section in the lower frame section
204
5.3.3. Multi-axis board, Lighting Control, I/O Intensive Board, Side View Camera Board . 205
5.3.4. Power UNIT layout.......................................................................................................... 206
5.3.5. Layout for the Panel located in the left side surface in the lower frame section......... 207
5.3.6. Servo Motor Amplifier Layout ........................................................................................ 208
5.3.7. Layout for the Transfer Unit over the lower frame section (Single Lane)................... 209
5.3.8. Layout for the Transfer Unit over the lower frame section (Dual Lane) ..................... 210
5.3.9. Feeder Cart Layout.......................................................................................................... 211
5.3.10. Traverse Cart Layout................................................................................................... 212
5.3.11. Tray Unit Layout.......................................................................................................... 213
5.4. Electric Parts Settings ........................................................................................................ 214
5.4.1. Breaker Current and Timer Setting............................................................................... 214
5.4.2. CPU2 Board Setting ........................................................................................................ 215
5.4.3. I/O Board Setting ............................................................................................................. 216
5.4.4. U95 (UC19) Lighting Control Board Setting ................................................................. 217
5.4.5. Relay Board U27 (UC34) Board Setting......................................................................... 218
5.4.6. Transfer I/O Board Driver Setting (Single).................................................................... 219
5.4.7. Transfer I/O Board Driver Settings (Dual) .................................................................... 220
5.4.8. Multi-Axis Driver Setting................................................................................................ 221
5.4.9. X-Axis/Y-Axis Servo Amplifier Setting........................................................................... 222
5.4.10. Side View Camera Board, SV-NET Communication Unit Setting ........................... 223
5.4.11. U07 (Head Distrbution Panel) Setting ....................................................................... 224
6. Troubleshooting......................................................................................................................225
6.1. System Recovery Procedure................................................................................................ 225
6.1.1. Required Items................................................................................................................. 225
6.1.2. Installation Procedure ..................................................................................................... 225

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6.1.2.1. OS Installation Device Connection ............................................................................. 225
6.1.2.2. OS Installation ............................................................................................................. 225
6.1.2.3. Initial Setting ............................................................................................................... 227
6.1.2.4. Machine Software Installation .................................................................................... 230
6.2. Precautions in Installation ................................................................................................. 233
6.2.1. Machine Software Installation with a Removable Media ............................................. 233
6.2.2. Automatic Setting in Re-Recovery Operation ................................................................ 233
6.2.3. Setting when ACV Barcode Scanner is used.................................................................. 233
6.3. Touch Panel Change and Adjustment Procedure.............................................................. 234
6.3.1. Touch Panel Removal Procedure .................................................................................... 234
6.3.2. Touch Panel Attachment Procedure............................................................................... 235
6.3.3. Touch Panel Adjustment Procedure ............................................................................... 235
6.4. Touch Panel Front/Rear Setting......................................................................................... 237
7. Application Software Setting .................................................................................................240
7.1. LISA Setting ........................................................................................................................ 240
7.1.1. Log-On .............................................................................................................................. 241
7.1.2. Fixed IP Address Setting and Power Option Check ...................................................... 241
7.1.2.1. Fixed Address Setting for LISA PC ............................................................................ 241
7.1.2.2. Power Option Check..................................................................................................... 242
7.1.3. LISA System Stop (Preparation for Installation) .......................................................... 243
7.1.3.1. LISA System Stop and Service Registration Cancellation........................................ 243
7.1.3.2. ACV Server System Stop and Service Registration Cancellation............................. 244
7.1.4. Installation (Version Up)................................................................................................. 245
7.1.5. Software License Setting................................................................................................. 246
7.1.5.1. License Server Setting ................................................................................................. 246
7.1.5.2. License Client Setting.................................................................................................. 246
7.1.6. Security Partly Cancellation Batch Processing ............................................................. 247
7.1.6.1. LISA System Batch Processing ................................................................................... 247
7.1.6.2. ACV Server System Batch Processing ........................................................................ 248
7.1.6.3. Setting Check ............................................................................................................... 249
7.1.7. LISA System Start-up Preparation ................................................................................ 251
7.1.7.1. LISA System Service Registration and System Start-up Check............................... 251
7.1.7.2. ACV Service System Service Registration and System Start-up Check .................. 252
7.1.8. LISA PC Restart-up......................................................................................................... 253
7.1.8.1. LISA System Start-up Check ...................................................................................... 253
7.1.8.2. ACV Service System Start-up Check .......................................................................... 253
7.2. NT-100 Setting and Communication.................................................................................. 254
7.2.1. Software Set-up................................................................................................................ 254
7.2.2. NT-100 System Software Login Password Setting ........................................................ 264
7.2.3. Device Manager................................................................................................................ 264
7.2.4. Communication with Machines ...................................................................................... 264
7.3. Production Manager Setting............................................................................................... 269
7.3.1. Management Data Monitoring Function Setting Procedure ........................................ 269
7.3.2. Management Data Monitoring Function Operation Procedure.................................... 272

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1. Installation
1.1. Machine Specifications
< Main Machine >
Machine Dimensions (W*D*H mm) : 1,280×2,240×1,910
Machine Weight (Kg) : 1800 (Excluding the Bank Feeder Change Carts and the tape
feeders)
Air Consumption (L/min) : 30L/min (During automatic operation)
100L/min (When one feeder base moves up and down)
200L/min (When two feeder base moves up and down)
Power Supply : Three-phase AC200V ± 10V 50/60Hz
Allowable Power Fluctuation AC200V ± 10%
Apparent Power : RATED 8.0 kVA / MAX 12.1 kVA
Power Consumption : 1.9 kWh
Fig. A1
Note: The dimensions are those for design reference.
Unit: mm

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< Feeder Cart >
792mm
975.8mm
962mm
Fig. A2-1
Fig. A2-2
Fig. A2-3

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< Differences from Sigma-G5S and Sigma-G5SII >
1．Position of robot cable
Change the routing of the robot cable to the left side in order to level the beam load.
G5S (right side routing) G5SII (left side routing)
2．XY axis driver placement position
Along with changing the routing of the robot cable, the XY axis driver position changed back and forth.
G5S G5SII
Front
Rear
Front
Rear
Block 1
XY driver position
Block 1
XY driver position
Block 2
XY driver position
Block 2
XY driver position

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3．Multifunction head
・Change details:
①Changed from 2 axis type to 3 axis type.
②L axis spring has been eliminated and L axis is changed to motor with brake.
G5S Multifunction head (2 axis) G5SII Multifunction head (3axis)
③For multifunctional headed machine, the multi-axis board changed to three.
G5S (Twe boards used) G5SII (Three boards used)
5．Footrests
・Change from separation type to integral type. (Wrench size is also 46 mm)
G5S footrests G5SII footrests
6．Production capacity
・Increased production capacity compared to G5S
①CPH : 75K to 90K
②Production capacity : Up to 20%, actual production 10% UP