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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.
Service Information
ISSUED DATE: December 27 2017
SI1705004E-00=SIGMA-G5SII Service Manual
1/273
For Service Engineer
No: SI1705004E-000

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Summary of Contents for Yamaha SIGMA-G5SII

  • Page 1 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.
  • Page 2: Table Of Contents

    "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 SI1705004E-00=SIGMA-G5SII Service Manual 2/273...
  • Page 3 Preparation of Adjusting Jig ................... 117 3.8.2. Adjusting Procedure ......................118 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 SI1705004E-00=SIGMA-G5SII Service Manual 3/273...
  • Page 4 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 SI1705004E-00=SIGMA-G5SII Service Manual 4/273...
  • Page 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 5.3.2.
  • Page 6 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 SI1705004E-00=SIGMA-G5SII Service Manual 6/273...
  • Page 7: Installation

    : 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 Unit: mm Note: The dimensions are those for design reference. SI1705004E-00=SIGMA-G5SII Service Manual 7/273...
  • Page 8 For Service Engineer Service Information < Feeder Cart > 792mm Fig. A2-1 975.8mm 962mm Fig. A2-2 Fig. A2-3 SI1705004E-00=SIGMA-G5SII Service Manual 8/273...
  • Page 9 For Service Engineer Service Information < 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....
  • Page 10 ・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 ① CPH : 75K to 90K ② Production capacity : Up to 20%, actual production 10% UP SI1705004E-00=SIGMA-G5SII Service Manual 10/273...
  • Page 11: Connection Of The Power And Earth Cable

    Remove carefully the two truss head screws on the upper section, so that any of them does not drop in the linear section. Caution Fig. A4-1 Step 2 Set the breaker dial to "OFF" and turn it further to the left to remove the cover. Attachment/Detachment Fig. A4-3 Fig. A4-2 SI1705004E-00=SIGMA-G5SII Service Manual 11/273...
  • Page 12 * If the cable is connected directly to the terminals without crimping, the breaker section might catch fire. The earth cable is connected to the plate "PE" section through the round terminal. AC 200V Fig. A5-5 Fig. A5-6 SI1705004E-00=SIGMA-G5SII Service Manual 12/273...
  • Page 13 In this case, the use of the crimp-style terminal is also available. In the case of strand wire cable, divide the wires and insert them separately. Then, fasten them. Tightening Torque: 3 (N.m) SI1705004E-00=SIGMA-G5SII Service Manual 13/273...
  • Page 14: Air Connection

    The user should provide the socket before the machine installation. In the case that the user does not know the model No., and need a check, the user should access the following web page to find the socket model No., appropriate for the air hose in the user’s facility. http://www.smcworld.com/products/en/global.do?kw=kk130 SI1705004E-00=SIGMA-G5SII Service Manual 14/273...
  • Page 15: Installation Procedure

    (1) Remove the X-axis beam unit metal fittings (BEAM1, BEAM2). Be careful not to drop any setscrew. Fig. A9-1 1.4.1.2. Removal of the Fixtures (Y-Axis) (1) Remove the Y-axis beam metal fittings (BEAM1, BEAM2). Fig. A9-2 Be careful not to drop any setscrew. Fig. A9-3 SI1705004E-00=SIGMA-G5SII Service Manual 15/273...
  • Page 16: Attachment Of The Tower Light

    1.4.1.4. Removal of the cover and cutter guide cover in the power breaker section Fig. A11-1 Fig. A11-2 Remove the cover in the power Remove the cutter guide cover at breaker section. the front and rear of the machine. SI1705004E-00=SIGMA-G5SII Service Manual 16/273...
  • Page 17: Preparation Of The Machine Installation Jigs

    (For High-Speed Head) HV19C Jig Nozzle FF01 Jig Nozzle (For multi-functional head camera teaching) FA04 Jig Nozzle (For multi-functional head height automatic teaching) JG-0233 Traverse Teaching Jig JG-0258 Table Offset Teaching Glass PCB Jig (460 × 460 ㎜) SI1705004E-00=SIGMA-G5SII Service Manual 17/273...
  • Page 18 No. 1, are commonly used with those for Sigma-G5. In addition to the above jigs, the accuracy measurement nozzles, accuracy measurement chip components and mirror should be prepared. When accuracy measurement is required, a nozzle appropriate for NOTICE the chip component should be prepared. SI1705004E-00=SIGMA-G5SII Service Manual 18/273...
  • Page 19: Machine Installation

    In the case that the machine is connected with an existing machine, the feed height in the existing machine should be taken as the feed reference. (Target value shall be 905mm from the floor to the component transfer surface) About 84 mm Fig. A13 SI1705004E-00=SIGMA-G5SII Service Manual 19/273...
  • Page 20 Do not adjust the level at the adjustment section using the hook spanner in the main machine frame section (Adjustment at the above adjustment section is performed only immediately after the assembling). Now, the main machine installation operation is completed. SI1705004E-00=SIGMA-G5SII Service Manual 20/273...
  • Page 21 When the unit is to be installed in front of the nozzle stocker, the cable re-wiring route is required. When the leveling instrument is to be placed under the component trash box, the removal of the bracket under the component trash box is required. SI1705004E-00=SIGMA-G5SII Service Manual 21/273...
  • Page 22: Preparation Before Offset Adjustment

    1.4.3.2. Preparation of Offset Adjustment Jigs and Tools (1) Prepare the offset adjusting jigs, offset sheet and tools. Refer to "1.4.1.5 Preparation of the Machine Installation Jigs" in Chapter 1, for the offset adjusting jigs. SI1705004E-00=SIGMA-G5SII Service Manual 22/273...
  • Page 23: Offset In The Installation Operation (High-Speed Head)

    (3.1) For the high-speed nozzle, use the nozzles for SIGMA series. (0402/HG24C, 0603/HG33C, 1005/HG52C) (3.2) For BARON accuracy measurement program, the SIGMA-G5SII dedicated data is required. (There are data items each for L/R flow and Reference.) (3.3) The tape feeder for SIGMA-G5S is used and the components are set on it.
  • Page 24: Preparation Before The Post-Installation Adjustment Operation

     It is available also after the accuracy measurement (CPK measurement). (1) Select the "After" folder using the "Path" in the "Sys. Setting" window in the main menu of NT-100. (2) Communicate with the subject machine to receive the "Sys. Setting" data. SI1705004E-00=SIGMA-G5SII Service Manual 24/273...
  • Page 25: Offset Teaching (Ship. Adj.) Window

     Jig to be used: Table Offset Jig: JG-0258 [7] Component Recognition Camera Position  Jig to be used : QFP Glass Jig : JG-0188, HA19C [8] Head Rotation Theta Axis  Jig to be used : QFP Glass Jig : JG-0188, HA19C SI1705004E-00=SIGMA-G5SII Service Manual 25/273...
  • Page 26  Jig to be used : QFP Glass Jig : JG-0188, HA19C [9] Head Rotation Center/Base Mark Position  Jig to be used : QFP Glass Jig : JG-0188, HA19C [13] Self-Calibration (Machine Inside CPK Measurement) * The jigs are the same as above "Normal" case. SI1705004E-00=SIGMA-G5SII Service Manual 26/273...
  • Page 27: Axis Origin Offset/Master Nozzle Level

    (2) Write down the previous value set in the "NL Origin" box (Operation Sequence: Select [Sys. Setting] - [Offset Data] - [Head] - [Head Offset] tabs in this order). It is not required to set the "NL Origin" value to "0". SI1705004E-00=SIGMA-G5SII Service Manual 27/273...
  • Page 28 (7) Using the "Head Select" function, the teaching is performed for the remaining head. Perform the steps (3) through (6). (1) Set the mode to "Debug Mode". Refer to "2.9 Change Procedure to Debug Mode" in Chapter 2, for the change procedure to the debug mod SI1705004E-00=SIGMA-G5SII Service Manual 28/273...
  • Page 29: Placement Level Offset (Head Up/Down Offset)

    * Set so that the center reference pin is positioned at the center of the PLATE as shown in the figure. FDR Cart JG-0191 Fig. A23 Do not move up the stopper LR. Start the operation after removing NOTICE all the support pins and backup jigs. SI1705004E-00=SIGMA-G5SII Service Manual 29/273...
  • Page 30: Chute Level (Perform The Teaching Selecting "Teach Start (Shipment)")

    (2) Attach the master nozzle onto the No. 1 nozzle position in the other head and preform the chute level teaching after the NL and master nozzle teaching operations. (3) Save the data. 1.4.5.3. Chute Level (Perform the teaching selecting "Teach Start (Shipment)") Fig. A25 SI1705004E-00=SIGMA-G5SII Service Manual 30/273...
  • Page 31 "For Shipping" are performed. Do not perform the height teaching operations for "Replacement". Teaching Operations "For Replacement": Perform them after the head change. The teaching operations for the head up/down, nozzle stocker level and feeder A offset (height) are not required. SI1705004E-00=SIGMA-G5SII Service Manual 31/273...
  • Page 32: Stocker Master

    Attach the teaching jig onto the feeder cart with the lower pins pressed against the Fig.A28-2 FDR Cart feeder base. Set the jig at the F101 position. Set the jig according to the F*** position instruction. Fig.A28-1 SI1705004E-00=SIGMA-G5SII Service Manual 32/273...
  • Page 33: Pec Recognition Camera & Beam Offset

    * When there is a glass jig, select [Use] button. (3) Press the [Teach Start] button and [START] button. (4) Make a note of the values in "Before" and "After" sections. (5) Press the [Save] button to save the data. Fig.A29 SI1705004E-00=SIGMA-G5SII Service Manual 33/273...
  • Page 34 (5) Select the [Teach Start] button and press the [START] button. (6) Make a note of the values in "Before" and "After" sections. Then, press the [Save] button to save the data. (7) Unclamp the PEC recognition calibration jig and remove the jig manually. SI1705004E-00=SIGMA-G5SII Service Manual 34/273...
  • Page 35: Component Recognition Camera Position

    The deviation from the designed distance from the machine reference coordinate origin to the component recognition camera center is adjusted. Required Jig and Tool QFP Glass Jig : JG-0188 1 unit Vacuum Nozzle : HA19C 1 unit QFP Glass Jig JG-0188 Fig. A31-2 Fig.A31-1 SI1705004E-00=SIGMA-G5SII Service Manual 35/273...
  • Page 36 "Teaching Plate" window and push the plate in.  When the QFP glass jig is to be placed in the jig storage space, place the jig pressing it against the corner of the pocket.  Check the teaching nozzle and head attachment condition. SI1705004E-00=SIGMA-G5SII Service Manual 36/273...
  • Page 37: Head Rotation Center/Base Mark Position Teaching

    : JG-0188 1 unit Vacuum Nozzle : HA19C 1 unit Purpose (Head Rotation Center Offset) The deviation from the designed value for the distance from the head rotation center to the PEC recognition camera center is adjusted. Fig.A32-1 SI1705004E-00=SIGMA-G5SII Service Manual 37/273...
  • Page 38 (6) When the teaching is completed, compare the values in "Before" and "After" sections. If there is no problem, make a note of them. (7) Press the [Save] button to save the data. Note: After saving the data, go to the next "Base Mark Position Teaching" operation. SI1705004E-00=SIGMA-G5SII Service Manual 38/273...
  • Page 39 When the nozzle is attached manually, enter "HA09C" or "HA19C" in the nozzle arrangement position for the subject head using the debug operation. If it is not entered, the QFP glass jig can not be picked up. SI1705004E-00=SIGMA-G5SII Service Manual 39/273...
  • Page 40 (subject nozzle) turned at an angle of 90° or 270°, and the mark is captured using the PEC recognition camera. Head Rotation Center PEC Recognition Camera Center Base Mark Fig. A34 SI1705004E-00=SIGMA-G5SII Service Manual 40/273...
  • Page 41: Fly Recognition Camera Offset Teaching

    Set it onto the nozzle No. 1 position on the head in question using the nozzle change operation (Unit Adj.). (4) Press the [Maint.], [Ship. Adj.] and [Fly Recog Camr] buttons in this order. Select "Mark Pos" and select the applicable head. (5) Press the [Teach Start] button and [START] button. SI1705004E-00=SIGMA-G5SII Service Manual 41/273...
  • Page 42: Nozzle Inclination Offset Teaching

    The deviation of the set nozzle height at the component recognition operation from the actual nozzle height is adjusted using the offset adjustment operation. This offset is available when the component with the 0603 size or smaller, is placed. Fig. A36 SI1705004E-00=SIGMA-G5SII Service Manual 42/273...
  • Page 43: Table Offset Teaching

    0603 size or smaller, is placed. Note:  Any support pin is not required.  When the size of a chip component to be placed by the user is 1005 or larger, there is no problem without jig. SI1705004E-00=SIGMA-G5SII Service Manual 43/273...
  • Page 44 (6) Set the Z-clamp pressure to "0.1Mpa" so as not to break the glass jig PCB. (7) Place the PEC recognition calibration jig onto the upstream side stopper position manually. Note:  Press the PEC recognition calibration jig reference onto the machine reference side manually. SI1705004E-00=SIGMA-G5SII Service Manual 44/273...
  • Page 45 (13) As the same as on the upstream side, fix the PCB onto the PEC recognition calibration jig and select the [Teach Start] button and press the [START] button. (14) Make a note of the values in "Before" and "After" sections. Then, press the [Save] button to save the data. SI1705004E-00=SIGMA-G5SII Service Manual 45/273...
  • Page 46: Machine Inside Cpk Offset Teaching

    CPK measurement machine as usual. The applicable machines are only following two types. (1) High speed head - High speed head (A-type) (2) High speed head - Multi-functional head (D-type) SI1705004E-00=SIGMA-G5SII Service Manual 46/273...
  • Page 47: Self-Calibration Placement Condition

    × Placement Result Captured by NT Linkage with NT-100 × × × Offset Correction in NT-100 NG point manual measurement Additionally Requested Management Information Message in Offset Clear Function Operation Change of Component to be placed SI1705004E-00=SIGMA-G5SII Service Manual 47/273...
  • Page 48 The results are reported (Procedure Completed) * In the case that some values are not within the range of company specified values; The following causes might be considered. (1) Device offset teaching error (2) Head hardware trouble SI1705004E-00=SIGMA-G5SII Service Manual 48/273...
  • Page 49  Unless the support jig and support pins are not removed, the glass jig PCB might be broken. (2) Set the mirror jig on the back-up table. Insert the leg sections of MIRROR_PLATE into the pin insertion holes of the back- up base to install. Fig. A39-2 Fig. A39-1 SI1705004E-00=SIGMA-G5SII Service Manual 49/273...
  • Page 50 Select [Machine Menu] → [OPERATION] → [Opr, Mode] in this order, and the set the "Mode" data to "No Designate". Fig. A40 Select [Machine Menu] → [OPERATION] → [Test Mode] in this order, and the set the "TEST PATTERN" data to "Disable". Fig. A41 SI1705004E-00=SIGMA-G5SII Service Manual 50/273...
  • Page 51 (5) Preparation before Placement Change the pattern program to one for placement accuracy measurement. Because the head offset is initialized, make a backup of the data as necessary. The restoration of the last data is available. Fig. A43 SI1705004E-00=SIGMA-G5SII Service Manual 51/273...
  • Page 52 (7) Change the conveyor width to 71.0 mm (The default clearance value is acceptable). It is changed in the [Automatic Operation Specified Target Position Move] window. (Operation Sequence: Select [Setup], [Conveyor Setup], [Automatic Operation Specified Target Position Move] in this order) Fig. A45 SI1705004E-00=SIGMA-G5SII Service Manual 52/273...
  • Page 53 (8) Attach the nozzle (HG33C) to the high-speed type head. Attach it manually or edit the stocker data where the nozzle is housed in the window as shown in the following window to perform the nozzle attachment operation. Fig. A47 SI1705004E-00=SIGMA-G5SII Service Manual 53/273...
  • Page 54 Fig. A48 (9) In the case that the stocker where HG33C nozzles are housed, is arranged in the second line when the head #2 is adjusted, select the box enclosed by a broken line. Fig. A49 SI1705004E-00=SIGMA-G5SII Service Manual 54/273...
  • Page 55 For Service Engineer Service Information (10) Perform the Fdr P-u Tch operation. Fig. A50 Fig. A51 * The teaching of two sections, F117/F217, is started. SI1705004E-00=SIGMA-G5SII Service Manual 55/273...
  • Page 56  When the double-sided tape is to be put, put it so that any bubble is not left between the board and tape. Such bubble might cause a measurement error. Fig. A52 Fig. A53 SI1705004E-00=SIGMA-G5SII Service Manual 56/273...
  • Page 57 Note: It has been designed that the results of the CPK measurement of a board in the machine, cannot be output to NT-100. When the measurement result data is required, the measurement using BARON is needed. SI1705004E-00=SIGMA-G5SII Service Manual 57/273...
  • Page 58 1.2 Maintenance Part List Table H2 Name of product Part No. Model (No.) Unit Remarks Glass Jig PCB KYF-M860M-00 JG-0195-01 Common to all Cpk measuring instrument models except for those for manual operation Mirror jig KYB-M882N-00 JG-0357 Rectangular mirror SI1705004E-00=SIGMA-G5SII Service Manual 58/273...
  • Page 59 For Service Engineer Service Information SIGMA-G5SII Instllation check sheet CS1705002E-000 (ver.1600) Date: Time: Work Started T ype Date: Time: Work Ended Tr an sfe r Single tranfer Dual transfer Customer P CB Flo w L→R R→L K e ybo r ad...
  • Page 60 ① Slect MENU Ship.Adj. >Hd Rot Center Before After Before After ② Select Head ==> ALL or 1 or 2 ③ Select Camera ==> ALL or 1 or 2 CAM 1 ④Select [Head Cntr] button Press [Teach Start] CAM 2 SI1705004E-00=SIGMA-G5SII Service Manual 60/273...
  • Page 61 Multi function head : QFP Jig use 1 5 Th e data bac k- u p by NT- 1 0 0 th at afte r all c alibration c omple te d. check 〈 Re mark〉 SI1705004E-00=SIGMA-G5SII Service Manual 61/273...
  • Page 62: Basic Operations For Maintenance

    Basically, when this operation is performed and a confirmation or error window is displayed, the subject section is to be returned to enable the home return operation. 2.2.2. Individual Zero The individual home return operation is described with the following some examples. SI1705004E-00=SIGMA-G5SII Service Manual 62/273...
  • Page 63: Unit Home Return

    Select " Block #1 " , " NL " and " Sel axis " in this order and press the [START] button on the operation panel. * During the operation, the [START] button illuminates in green and when the operation is completed, the button's illumination is turned OFF and the home return operation of the NL-axis only is completed. SI1705004E-00=SIGMA-G5SII Service Manual 63/273...
  • Page 64: Nozzle Change Procedure

    "Move" button and press the [START] button on the operation panel. (2) Placing the Nozzle onto the Head Select the subject head and "Change" and press the "Move" button and press the [START] button on the operation panel. SI1705004E-00=SIGMA-G5SII Service Manual 64/273...
  • Page 65: Nozzle Change Procedure In The "Unit Adj." Window

    Select "Reset Select the "Head No. 1" and the nozzle is to be housed Nozzle". "Nozzle No. 1". (Position No. 1 in the H1- Stocker No. 1) START Press the [START] button on the operation panel. SI1705004E-00=SIGMA-G5SII Service Manual 65/273...
  • Page 66: Conveyor Width Adjusting Procedure

    The conveyor width is changed to the set value. Then, perform the following operation. * When the user set value for the "Clearance" is changed, return to the previous value when the operation is completed. SI1705004E-00=SIGMA-G5SII Service Manual 66/273...
  • Page 67: Pcb Transfer Procedure

    (3) In the "PCB XFER" window, select the transfer location ([1] to [3]) to be designated. Pressing the [START] button on the operation panel within 5 seconds after the location selection, transfers the PCB to the designated position. SI1705004E-00=SIGMA-G5SII Service Manual 67/273...
  • Page 68 (3) Select " MNL XFER " . (4) Select one of the "XFER Start" arrows. Then, within 5 seconds, pressing the [START] button transfers the PCB. Each pressing moves the PCB a certain distance in the designated direction. SI1705004E-00=SIGMA-G5SII Service Manual 68/273...
  • Page 69 (5) For the individual operation of "PCB Positioning" or "Stopper", select each operation on the designated "L" or "R" side ("L" / "R"), and within 5 seconds, press the [START] button on the operation panel. The designated operation will be performed. SI1705004E-00=SIGMA-G5SII Service Manual 69/273...
  • Page 70 [1] Click "Maint. ", "Unit Adj. " and "Cnvr" button in this order to select. Select "Hi Speed" or "Low Speed" for the conveyor speed, and click "Pass Opn START". Then, within 5 seconds, press the [START] button on the operation panel. SI1705004E-00=SIGMA-G5SII Service Manual 70/273...
  • Page 71: Unit Adjustment

    In this operation window, individual nozzle is attached or removed. Note: The items in the red frame, are displayed only in the Debug mode. Only the trained person can operate the items in the red frame, because such operation might damage the nozzle. SI1705004E-00=SIGMA-G5SII Service Manual 71/273...
  • Page 72: Conveyor" Window (In Debug Mode)

    This error occurs when the conveyor width is changed manually during the power OFF condition in the machine delivery. 2.6.3. "PCB Stpr" Tab Sheet in the "CONVEYOR" Window Note: This tab sheet is used to measure each stopper operation time. SI1705004E-00=SIGMA-G5SII Service Manual 72/273...
  • Page 73: Driver Mng." Tab Sheet In The "Conveyor" Window

    This menu is used to check the version for the conveyor driver. 2.6.5. "X Axis grease up" Window Note: This menu is used for the X-axis ball screw greasing-up operation. The steps (1 to 10 in the window) should be performed in the numerical order. SI1705004E-00=SIGMA-G5SII Service Manual 73/273...
  • Page 74: Fdr Base" Window

    [2] Device Check : This operation is used for checking of operation in each section using the "Output Check" window and dimension measurements such as height, using the manual axis operation. SI1705004E-00=SIGMA-G5SII Service Manual 74/273...
  • Page 75: Unit Adjustment

    Connect the feeder cart connecting connector to the main machine and perform the "Zero for maintenance" operation in the window. Then select a mode in the window and press the "Manual Opn" button and press [START] button on the operation panel. SI1705004E-00=SIGMA-G5SII Service Manual 75/273...
  • Page 76: Device Check (Input/Output)

    The HL-axis up/down operation is performed using for manual axis operation, when the "Head Up/Down Offset" teaching is performed in the Head No. 1: This item describes only the manual axis operation. Refer to "1.4 Installation Procedure" in Chapter 1 for the main operation procedure. SI1705004E-00=SIGMA-G5SII Service Manual 76/273...
  • Page 77: Example: In The Case That The Nozzle Does Not Touch The Jig

    Refer to "2.9 Change Procedure to Debug Mode" for the transfer procedure to the Debug Mode. (2) In this section, the operation procedure is described taking an example of the "Cut operation Set-up". When the "Block 1 Cutter" stops functioning, this function is set to "Temporarily Disable". SI1705004E-00=SIGMA-G5SII Service Manual 77/273...
  • Page 78 [1] Select "Ope. Palam", "Auto Ope. Set-up" and "Set-up2" in this order. [2] When the setting section (white background) for the "Mode" item of "Cut. Operation Set-up" group in "Block 1" column is selected, the pull-down menu appears. SI1705004E-00=SIGMA-G5SII Service Manual 78/273...
  • Page 79 Time [sec]" for Head No. 1 is clicked, the "Ten-key" pad is displayed. When the changed value is entered and the "Set" button is pressed, the parameter is changed. [3] The "Ten-key" window will disappear. When "Save" is clicked, the data is changed. SI1705004E-00=SIGMA-G5SII Service Manual 79/273...
  • Page 80: Change Procedure To Debug Mode

    When the area in the red frame on the upper left of the window is pressed for 5 seconds or more, " " is displayed in the indication area and the Maintenance Mode Change Mode is started. Indication Area SI1705004E-00=SIGMA-G5SII Service Manual 80/273...
  • Page 81 ", the indication is changed to " ". When the section shown as " " in the lower right is pressed for 3 seconds or more after the indication is changed to “ “, the indication is changed to “ “. SI1705004E-00=SIGMA-G5SII Service Manual 81/273...
  • Page 82: Main Additional Items In The "Debug Mode

     Perform the following operation in the window. Return → Setup → Operator 1 → Return → Setup (or Maint.) → Supervisor  Shut down the machine.  Perform the same procedure which was done to set the machine to Debug Mode SI1705004E-00=SIGMA-G5SII Service Manual 82/273...
  • Page 83: Mechanism

    (3) Start supplying air and power to the machine. Set the nozzle stocker and perform the nozzle stocker position teaching. Select " Shipping Adj " , " Nozzle Stocker Position " and " Select Stocker " (select the change location) in this order. SI1705004E-00=SIGMA-G5SII Service Manual 83/273...
  • Page 84: Description Of Connecting Connector

    (3) Connector for Nozzle Up-status Detection Sensor for Multi-Functional Nozzle Stocker (XSFL) *(This is applied only when the nozzle stocker for multi-functional nozzle is used). Blue Black Orange Brown Fig. C5 Connector (XSFL) Wiring 4 pins SI1705004E-00=SIGMA-G5SII Service Manual 84/273...
  • Page 85: Connection Example

    " " " " mark additionally to each connector using a magic pen, etc., as shown in the following figure. Fig. C6 SI1705004E-00=SIGMA-G5SII Service Manual 85/273...
  • Page 86: High - High - None - Multi

    Because the print mark for the connectors for the nozzle stocker addition valves is only " " " " mark additionally to each connector using a magic pen, etc., as shown in the following figure. Fig. C7 SI1705004E-00=SIGMA-G5SII Service Manual 86/273...
  • Page 87: Multi - None - None - None

    (3) The shutter valve (for addition) for the nozzle stocker for high-speed nozzle has been attached as standard configration. However, unless the nozzle stocker for high-speed nozzle is added, it does not function. Fig.C8 SI1705004E-00=SIGMA-G5SII Service Manual 87/273...
  • Page 88: Multi - None - High - High

    (3) The shutter valve (for addition) for the nozzle stocker for high-speed nozzle functions for the shutter open/close operation for the high-speed nozzle stocker for to be added. Fig.C9 SI1705004E-00=SIGMA-G5SII Service Manual 88/273...
  • Page 89: Multi - None - None - High

    (3) The shutter valve (for addition) for the nozzle stocker for high-speed nozzle functions for the shutter open/close operation for the high-speed nozzle stocker to be added. Fig.C10 SI1705004E-00=SIGMA-G5SII Service Manual 89/273...
  • Page 90: Multi - None - None - Multi

    " (3) For the shutter open/close for the added nozzle stocker for multi-functional nozzle, the shutter " open/close #3 is applied. The shutter valve (for addition) for the high-speed nozzle is not used. Fig. C11 SI1705004E-00=SIGMA-G5SII Service Manual 90/273...
  • Page 91: Various Settings

    No. of Cylinders mounted in the Needle Opening Angle Stocker Cylinder Section 225 degrees (Standard) 1 Unit 2 Unit 3Unit 4 Unit Stocker Change Section 160ms 200ms 200ms 250ms Only one stocker mounted 230ms 350ms 390ms 400ms SI1705004E-00=SIGMA-G5SII Service Manual 91/273...
  • Page 92: Multi Functional Nozzle Shutter

    (c) The light receiving level should be "0" or more when the nozzle is risen 1.3mm (as much as the total thickness of flat washers M2 + M5). Set the multi-functional nozzle also in the stocker No. 5. Fig. C15 SI1705004E-00=SIGMA-G5SII Service Manual 92/273...
  • Page 93: Nozzle Up-Status Detection Sensor Amplifier Adjustment

    Standard: The nozzle stockers for multi-functional nozzle are setup in first and the fourth lines. CH1:Connect the first line. CH2:Connect the four line. (2) Sensor Amplifier Teaching Set the nozzle up-status detection fiber amplifier using the following procedure. SI1705004E-00=SIGMA-G5SII Service Manual 93/273...
  • Page 94 6) Press the MODE key once to go to the RUN Mode Display Setting. Change the indication so that the left indication shows the light receiving level and the right indication shows the threshold value. Light Receiving Level Threshold Value SI1705004E-00=SIGMA-G5SII Service Manual 94/273...
  • Page 95 In order to cancel it, using the same procedure for key locking operation, press the UP key for 3 seconds or more with the MODE key pressed. The sub-digital indicator will flash twice and the key input operation is enabled. SI1705004E-00=SIGMA-G5SII Service Manual 95/273...
  • Page 96: X-Axis Ball Screw Change Procedure

    Slide the head to the motor side. Turn the upper cover and remove it on the opposite side of the motor. Remove the 7 bolt screws on the locations specified with the left red Fig.C19 circles. SI1705004E-00=SIGMA-G5SII Service Manual 96/273...
  • Page 97 The collar is included in the block. Take care not to lose the collar. M3 Setscrew Lock nut Fig.C22 (9) Slide the ball screw axis about 20mm to the opposite side of the motor. SI1705004E-00=SIGMA-G5SII Service Manual 97/273...
  • Page 98: X-Axis Linear Guide Attachment Procedure

    First, attach the ball screw on the opposite side of the motor. After it is inserted, attach the ball screw on the motor side. After the attachment, set it up together with the two bearings that have been removed in Step (10). Fig.C25 SI1705004E-00=SIGMA-G5SII Service Manual 98/273...
  • Page 99 Move the head plate in the direction ① to Fix the ball screw movable section onto head plate temporarily. center the ball screw. Fig. C28 (8) Slide the head onto the center of the beam and tighten the two lower bolts lightly. SI1705004E-00=SIGMA-G5SII Service Manual 99/273...
  • Page 100: Treatment If Any Value Is Out Of The Standard Range

    (1) Loosen the set bolt for the bearing holder on the M5 Bolt ball screw side. Slide the head to the opposite side of the motor and tighten the bearing holder set bolt. Note: The procedure ① cannot be performed together with the procedure ②. Fig.C33 SI1705004E-00=SIGMA-G5SII Service Manual 100/273...
  • Page 101: Y-Axis Linear Guide Attachment

    Press the linear guide on the Y2-axis against the setup section and fasten it with the set bolt. * Wipe out anti-rust oil in advance from the linear guide. * Tighten the linear guide from the center position. (Tightening Torque: 14.7N.m) SI1705004E-00=SIGMA-G5SII Service Manual 101/273...
  • Page 102 (5) After the attachment, push the blind plugs into the holes of the linear guide set bolts in parallel each other. * Any blind plug or burr should not come out from the linear guide upper surface. SI1705004E-00=SIGMA-G5SII Service Manual 102/273...
  • Page 103: X-Axis Linear Guide Attachment

    * Tighten the linear guide from the center position. (Tightening Torque: 1.3~1.6Nm) Apply Screw Lock (1341) on the tap side. * After fixing, make sure that the 0.01mm shim cannot be inserted to the end in the linear guide reference surface contact section. SI1705004E-00=SIGMA-G5SII Service Manual 103/273...
  • Page 104 Measure the gap using the shim in the section with red lines in the figure. Compare the values measured in the three locations and adjust so that the difference between the maximum and minimum values is within 0.03mm. Surface Plate Fig.C39 SI1705004E-00=SIGMA-G5SII Service Manual 104/273...
  • Page 105 * Standard Range: 1000g or less From the surface plate to the DD center (84.5mm) From the beam center position to the component placement level (200mm) Direction Y Direction Z Surface Plate Straight Edge Fig.C40 SI1705004E-00=SIGMA-G5SII Service Manual 105/273...
  • Page 106: X-Axis Linear Scale Change Procedure

    ① The 0.01mm shim cannot be inserted in the gap between the linear scale and knock pin. ② The laterally adjusted position of the X-axis linear scale should be the position with the center value. SI1705004E-00=SIGMA-G5SII Service Manual 106/273...
  • Page 107 (5) Put the scale head adjusting jig (t = 0.4mm) between the scale head and linear scale and loosen the temporarily tightened setscrews. Then, tighten the setscrews at the position where the jig can be pulled out with some difficulty. (Refer to Fig. C45). Fig.C45 SI1705004E-00=SIGMA-G5SII Service Manual 107/273...
  • Page 108 2. The scale head jig with thickness 0.5mm can not be entered. Fig.C46 Note: Basically, the position adjustment is performed only at one location. (It is because the final adjustment is performed using the software (PC)). SI1705004E-00=SIGMA-G5SII Service Manual 108/273...
  • Page 109: Y-Axis Linear Scale Change Procedure

    Because the adjustment operation is required after Step (2), it should be fixed temporarily. Fig.C49 (2) Tighten the nine setscrews to temporarily fix the linear scale. * For the linear scale position adjustment, the following conditions should be satisfied. SI1705004E-00=SIGMA-G5SII Service Manual 109/273...
  • Page 110 (t = 0.4mm) between the scale head and linear scale and loosen the setscrews. Then, tighten the setscrews in the position where the jig can be pulled out with some difficulty. (Refer to the right figure). Fig.C52 SI1705004E-00=SIGMA-G5SII Service Manual 110/273...
  • Page 111 2.The scale head jig with thinkness 0.5mm can not be entered. Fig. C53 Note: Basically, the position adjustment is performed only at one location. (It is because the final adjustment is performed using the software (PC)). SI1705004E-00=SIGMA-G5SII Service Manual 111/273...
  • Page 112: X-Axis Scale Head Adjustment Procedure

    Also, because there are two types of cable, use them according to the situation (Refer to Fig.C54). ②This cable is used to connect to the connector on the relay panel. ①This cable is used to connect to the scale head connector. Fig.C55 SI1705004E-00=SIGMA-G5SII Service Manual 112/273...
  • Page 113: Adjusting Procedure

    Then, connect the USB cable again and turn ON the power to the jig unit. (6) Adjust the scale head to be attached. Basically, adjust it from No. ① in the Fig. C57 in the order. The adjustment procedure is described as follows. Fig.C57 SI1705004E-00=SIGMA-G5SII Service Manual 113/273...
  • Page 114 OFF the power to the adjusting jig and close the PC software. ⑥規格値上限・下限表示 規格値は、▽印の内側であること Fig. C60 In the case that there is no problem, press the [終了(ESC)] button to return the initial window. SI1705004E-00=SIGMA-G5SII Service Manual 114/273...
  • Page 115 Refer to "Fig. C60 Standard Value Upper Limit/Lower Limit Display". In the case that there is no problem, press the [終了(ESC)] button to return the initial window. Note: When the beam is to be moved, take care that no cables interfere with the machine. SI1705004E-00=SIGMA-G5SII Service Manual 115/273...
  • Page 116 In the case that the cable ties, etc. have been released except for the cable connector, return them to the original condition and move the beam by hand again to make sure that it does not interfere with any other section. (14) Perform the X/Y home position teaching of "4.18 Servo Amplifier Change Procedure". SI1705004E-00=SIGMA-G5SII Service Manual 116/273...
  • Page 117: Y-Axis Scale Head Adjustment Procedure

    Also, because there are two types of cable, use them according to the situation (Refer to Fig.C67). ②This cable is used to connect to the connector on the relay panel. ①This cable is used to connect to the scale head connector. Fig.C67 SI1705004E-00=SIGMA-G5SII Service Manual 117/273...
  • Page 118: Adjusting Procedure

    Disconnect the USB cable and turn OFF the power to the jig unit. Then, connect the USB cable again and turn ON the power to the jig unit. Refer to (6) through (10) in "3.7.2 Adjusting Procedure" for the following procedure. SI1705004E-00=SIGMA-G5SII Service Manual 118/273...
  • Page 119 (9) Perform the X/Y home position teaching of "4.18 Servo Amplifier Change Procedure". SI1705004E-00=SIGMA-G5SII Service Manual 119/273...
  • Page 120: Maintenance

    (1) Shut down the machine and turn OFF the breaker. (2) Disconnect all the connectors on the CPU-1 section. For the cables to the Connector X19105 and X19106 (USB), undo the binding bracket is available. *Refer to Fig. D2 Fig.D2 SI1705004E-00=SIGMA-G5SII Service Manual 120/273...
  • Page 121: Removal Of Control Board U91 Or U92

    SSD. Fig. D3 4.1.2. Removal of Control Board U91 or U92 Setscrews (1) Remove the board fixing block. * Loosening the two setscrews, can remove the board fixing block as shown in the figure. Fig. D4 SI1705004E-00=SIGMA-G5SII Service Manual 121/273...
  • Page 122 * When U91 is to be removed from the locations each shown by a red circle in the left figure, press the connector section arranged in front of the board to slide as shown in the following figure. Fig. D6 SI1705004E-00=SIGMA-G5SII Service Manual 122/273...
  • Page 123: Attachment Of Cpu1-Box

    After the wiring arrangement, bind the power line cables with cable ties. Because there is a convex mount in the location shown by a red circle, collect and tie the power line cables there. Fig. D9 SI1705004E-00=SIGMA-G5SII Service Manual 123/273...
  • Page 124 Take care not to step on the cables when the CPU1 BOX is returned (Refer to the following figure). After it is returned, fix it in the two locations at the front using the screws (Refer to the right figure). Fig.D14 SI1705004E-00=SIGMA-G5SII Service Manual 124/273...
  • Page 125 Note: There are three types of CPU. Before wiring, check the board type (Refer to Chapter 5). Fig.D15 Then, the change procedure closes. Turn ON the power and make sure that the system is operated normally. SI1705004E-00=SIGMA-G5SII Service Manual 125/273...
  • Page 126: Control Board Change

    (2) Unplug the connector of the PCB to be removed. * Take care not to deform the cables (fiber optic cables) for the connector X8201 and X8202. This connector can be removed by means of pressing its right side. Fig.D17 SI1705004E-00=SIGMA-G5SII Service Manual 126/273...
  • Page 127: Handling Of Control Board

    SW and jumper pin, and make a note of them. Fig.D19 Note: The basic settings for each board are described in Chapter 5.However, the settings might be different depending on the design changes. Therefore, make a note of the settings as currently as possible. SI1705004E-00=SIGMA-G5SII Service Manual 127/273...
  • Page 128: Change Of Pcb U81 (Cpu2 Main Board)

    The main board can be replaced in the machine with a different type or option from that of the machine in this series. However, there might be compatibility issues because they are different versions. Fig.D21 SI1705004E-00=SIGMA-G5SII Service Manual 128/273...
  • Page 129 PCB with the tool. The nut does not need to be fastened tightly. ⑤ Insert the PCB into the BOX using the same procedure in the case of U85 and U82, and connect the connectors. SI1705004E-00=SIGMA-G5SII Service Manual 129/273...
  • Page 130: Change Of Lighting Control Board U95

    Fig.D26 Note: For G5S, only when coplanarity check function (Option) has been included, the image distributor is added. Normally, such distributor is not required because the video signal is fed directly to the monitor from CPU1. SI1705004E-00=SIGMA-G5SII Service Manual 130/273...
  • Page 131: Removal Of U95 Led Lighting Control Board

    Fig.D27 above figure and disconnect the earth wires. Disconnect all the connectors which have been plugged into the board. * Black connectors on the rear side (Remove the lighting signal line according to the instructions). Fig.D28 SI1705004E-00=SIGMA-G5SII Service Manual 131/273...
  • Page 132: U95 Attachment

    (1) Confirm the DIP-SW and Jumper Setting for the prepared U95 board. These settings are for the initial type of the U95 board. They might be changed, so confirm the settings referring to the removed board. JP: All Open SW1: All OFF Fig.D30 SI1705004E-00=SIGMA-G5SII Service Manual 132/273...
  • Page 133 * After the panel has been fixed, fix securely the four earth wires at the front. If loosened, unexpected movement might occur. (4) Turn ON the machine and perform the component recognition and PEC recognition camera lighting teaching. (Refer to Item 1.4.5 Offset Teaching (Ship. Adj.) Chapter 1 Window). SI1705004E-00=SIGMA-G5SII Service Manual 133/273...
  • Page 134: Multi-Axis Board Change Procedure

    The section shown in the figure, shows the multi-axis board housing section. FRONT REAR (Breaker Side) Fig.D32 The names of multi-axis board are as follows. PART Fig.No NAME SYMBOL PART NAME Remarks CODE Key.No Multi-Axis A31F FigD3-5 Front/Rear Head, UNIT_DRIVER Board A31B No.401 Multi-Functional Head SI1705004E-00=SIGMA-G5SII Service Manual 134/273...
  • Page 135: Multi-Axis Board Change Procedure

    Locations each shown in a red circle in the left figure (Remove the screws in the total nine locations). * When the screws are removed, the board behind the A31F board fixed by spacers is found can be accessible. Remove it as well. Fig.D34 SI1705004E-00=SIGMA-G5SII Service Manual 135/273...
  • Page 136 (7) Connect the wires that have been disconnected first, as before. *The connections of the fiber cables are as follows. Fiber Cable Connection Order 1. Black and Red Arrows:CPU⇒A31B(CN1A) 2. Red Circle:A31B(CN2A)⇒A31F(CN1A) Make sure to connect the fiber cables in the correct order. Fig.D36 SI1705004E-00=SIGMA-G5SII Service Manual 136/273...
  • Page 137: Pec Recognition Camera Unit Change

    (3) After adjustment, connect the camera cable and bind the remaining section When the block is pressed, make sure that there using cable ties. is no clearance between the head base unit and the side surface of the camera. Fig.D38 SI1705004E-00=SIGMA-G5SII Service Manual 137/273...
  • Page 138: Component Recognition Camera Unit Change

    * Press the camera based on the right rear reference and fix, referring to the lower left photo. Connect each of the lighting cable, reference mark, front lighting and camera cables. * After connecting the connectors, bind the cable using cable fies. Fig.D40 SI1705004E-00=SIGMA-G5SII Service Manual 138/273...
  • Page 139: Removal Of Nozzle Up/Down (Nl) Axis Motor

    If all the above conditions can not be met, fix the bolts temporarily. In the case of temporary fixing, the following items are performed. Fig.D41 SI1705004E-00=SIGMA-G5SII Service Manual 139/273...
  • Page 140 (cam follower) delivery level (stage difference) becomes within "+/- 0.01 mm". * Adjust it by loosening it slightly and gradually unscrewing the coupling set screw, looking at the dial gauge. Fig.D43 SI1705004E-00=SIGMA-G5SII Service Manual 140/273...
  • Page 141 (+) Soft Limit 22.0±0.4mm Unit : mm (+) Mechanical Stopper Fig.D44 (12) After the adjustment, teach the [NL-Axis Origin Offset] and save the data. Refer to "1.4.5.1 NL-Axis Origin Offset " in Chapter 1, for the teaching operation. SI1705004E-00=SIGMA-G5SII Service Manual 141/273...
  • Page 142: Removal Of The Nozzle Selection (Ns) Axis Motor

    Split Block Split Block Fastening Bolt (2) Fix the NS-axis motor to the head (M2L8) temporarily. (3) Tie up the cables and plug the connectors. Fig.D46 SI1705004E-00=SIGMA-G5SII Service Manual 142/273...
  • Page 143 At that time, arrange the pulley fixing block so that the hexagon hole of the fastening bolt (M2L8) is turned outside (easy positioning for fastening). * Tightening Torque : 56 to 68 cNm Fig.D47 SI1705004E-00=SIGMA-G5SII Service Manual 143/273...
  • Page 144: Head Up/Down (Hl) Axis Motor Removal

    Approach area to the Fig.D48 coupling fixing bolt (3) Separate the HL-axis motor cables which have tied up with a harnessed belt. (4) Loosen the motor fixing bolt (M2. 5L10) on the HL-axis and remove the motor. SI1705004E-00=SIGMA-G5SII Service Manual 144/273...
  • Page 145: Head Up/Down (Hl) Axis Motor Attachment

    ④ Wait until the motor is stopped. (6) Tighten the coupling temporarily in the position where the set bolt can be tightened when the motor is in the home position and the motor is attached (Refer to Item 6.1. (2)). SI1705004E-00=SIGMA-G5SII Service Manual 145/273...
  • Page 146 " Motor " window. Then, select " X " and click " Serve OFF " , and then, select " Y1 " and click " Servo OFF " . * The above serial operation is completed; turn ON the servo-motor. Fig.D51 SI1705004E-00=SIGMA-G5SII Service Manual 146/273...
  • Page 147 (13) Tighten the fixing bolts securely on the upper and lower sections of the coupling. Tightening Torque: 47.04 cNm * Apply Screw Lock (1401B) on the fixing bolts. M2.5 should be used for the set bolts. SI1705004E-00=SIGMA-G5SII Service Manual 147/273...
  • Page 148 Mechanical Stopper -2 ± 0.75 Photo Sensor Overrun X0711 -1±0.1 Soft Limit) 0.5) HL-Axis Zero HL-Axis Full Stroke 25.0 (1.0) ((+) Soft Limit) Unit : mm (+) Mechanical Stopper 27 ± 0.35 Fig.D53 SI1705004E-00=SIGMA-G5SII Service Manual 148/273...
  • Page 149: Slip Ring Change Procedure

    * When the connector is to be disconnected, do not hold and pull the cable section. * Take care not to drop any set screw. * Take care because the wiring harness plate has also been fastened with the set screw. Fig.D56 SI1705004E-00=SIGMA-G5SII Service Manual 149/273...
  • Page 150: Ring Attachment

    ② Bind wires and connectors so that they can be housed in the coupling (inside the dot lines). During repair operation, use the wiring protection tube and house the cables in it. 《Wiring Protection Tube Size》 15 15mm Fig.D57 SI1705004E-00=SIGMA-G5SII Service Manual 150/273...
  • Page 151 About 1 mm *Tightening the set screw after adjusting the one side (spacer adhesion side) to about 1mm, facilitates the adjusting operation. Fig.D60 ② Tightening Torque : 10 to 13 cNm (10.8 to 13.2 kgfcm) SI1705004E-00=SIGMA-G5SII Service Manual 151/273...
  • Page 152 ② Tighten the slip ring set screw at the position where the eccentricity is within the specified range. (8) Connect the slip ring and the connector. * Make sure that the connectors have been connected securely. Fig.D62 SI1705004E-00=SIGMA-G5SII Service Manual 152/273...
  • Page 153: Nozzle Shaft Removal And Attachment (Single Unit)

    (Take care not to apply too much Screw Lock). * Attach the top block and nozzle shaft vertically. * Because the nozzle shaft and the nozzle shaft holder are sold as a set (serial No. management), the replacement of individual parts is not available. SI1705004E-00=SIGMA-G5SII Service Manual 153/273...
  • Page 154: Nozzle Shaft Total Disassembling, Cleaning And Assembling

    Prepared the required number of set screws for replacement (M1. 6L4)  V-Packing: Used in the Nozzle Holder Unit and Nozzle Shaft Outer Casing Section (15 pcs each)  Cleaning Rag and Rags for spreading on the working floor  Nozzle Shaft Cleaning Water SI1705004E-00=SIGMA-G5SII Service Manual 154/273...
  • Page 155: Preparation For The Work

    [START] button in the "Operation" window. When the nozzle has been housed in the stocker, remove the feeder cart to facilitate the operation. (4) Turn OFF the power and air to the machine. (5) Remove the head cover. SI1705004E-00=SIGMA-G5SII Service Manual 155/273...
  • Page 156: Disassembling Work

    * Do not reuse the removed bolts. Dispose of them and replace with new ones. * When the small diffuser plate is to be removed, protect it with the protection tube or wrap to avoid contact with the linear measure sensor. Small Diffusion Plate Large Diffusion Plate Fig.D67 SI1705004E-00=SIGMA-G5SII Service Manual 156/273...
  • Page 157 Separate the linear measure sensor from the pulled out linear measure sensor connector section. * When the linear measures are pulled out, confirm the direction of each of the linear measures. This is because they are returned in the direction same as before when they are attached. SI1705004E-00=SIGMA-G5SII Service Manual 157/273...
  • Page 158 * Removed the Screw Lock attached to the attachment surfaces both of the removed top block and nozzle shaft. (If they are attached as they are, a malfunction would be caused). Arrange them in order M1.6×L3 Fig.D70 SI1705004E-00=SIGMA-G5SII Service Manual 158/273...
  • Page 159 (lower rotor) from the DD motor. When it is removed, pull it down vertically. Remove the three set screws as shown with the " " mark. Fig.D71 Condition where the Nozzle Shaft Assembly has been removed Fig.D72 SI1705004E-00=SIGMA-G5SII Service Manual 159/273...
  • Page 160 * Pay attention to the direction of the V-Packing. (The groove should be located upper side) O-Ring V-Packing Cotton Applicator Fill the groove with grease. Apply grease to the inner ring slightly. Fig.D74 SI1705004E-00=SIGMA-G5SII Service Manual 160/273...
  • Page 161 Apply grease in the groove for the V-packing and apply it slightly also inside. * Pay attention to the direction (Groove is located in the lower section) for the V- Packing when it is inserted. V-Packing Retainer Fig.D76 SI1705004E-00=SIGMA-G5SII Service Manual 161/273...
  • Page 162 * The width of the rag should be 6 to 7 mm. A rag cut to the length of 130mm should be prepared. (Refer to the following figure) Reference: Cleaning Tools Hexagon Wrench Long 1.5 mm Stretch both sides of the rag by hand. Fig.D77 SI1705004E-00=SIGMA-G5SII Service Manual 162/273...
  • Page 163 * When the air is blown into the retainer inside to dry it, take care not to lose the V- packing. * Use something like a bamboo skewer as a tool for applying grease. Do not use an cotton applicator or tooth pick which leaves fiber residue or small piece of wood. Fig.D78 SI1705004E-00=SIGMA-G5SII Service Manual 163/273...
  • Page 164 * Apply grease to the groove on the opposite side. * Apply grease into the cover to the rear as far as possible. Do not apply grease around the hole. Apply grease on the surface slightly. SI1705004E-00=SIGMA-G5SII Service Manual 164/273...
  • Page 165 * Pay attention to the insertion direction of the packing holder. (18) Insert the nozzle shaft assembly gently into the DD motor unit straight from the lower side, so that no load is given to the nozzle shaft. SI1705004E-00=SIGMA-G5SII Service Manual 165/273...
  • Page 166 * Return the top block to where it was, so that it is attached to the correct location. * Spread grease (Daphne Eponex No. 1) film over the cam follower on the top block section and its entire moving surface. SI1705004E-00=SIGMA-G5SII Service Manual 166/273...
  • Page 167 (Otherwise, when the plates are to be removed, it would be difficult). (23) Attach the head cover and check inside and around the machine (such as for a left tool, etc.). Then, return the removed cart to the original position SI1705004E-00=SIGMA-G5SII Service Manual 167/273...
  • Page 168: Operation Check

     0.02 mm for all the nozzles. Data Before Cleaning Data After the Cleaning Fig.D83 (5) When the difference is within  0.02 mm, press the [Save] button to save the data. Also, perform the "Nozzle Position Teaching" and save the data. SI1705004E-00=SIGMA-G5SII Service Manual 168/273...
  • Page 169: Maintenance In Trouble Occurrence (Mechanism)

    The set bolt has been designed that even when it is loosened completely, it cannot be pulled out from the base.(Fig.D86) Pull out the head taking care of the side view camera. Base Fixing Bolt Fixing Bolt Fig.D86 SI1705004E-00=SIGMA-G5SII Service Manual 169/273...
  • Page 170: Head Assembly Attachment

    ], Magnification X and Y [0.01µm/pixel] values for the replaced new head. Select "Sys. Setting", "Offset", "Device Offset", "Line Meas" and "Second Page" in this order and enter the offset values for the subject head boxes. Fig.D88 SI1705004E-00=SIGMA-G5SII Service Manual 170/273...
  • Page 171: Various Offset Adjustments

    ⑦ Fry Recognition Offset ⑧ Nozzle Inclination Offset ⑨ Head Offset A/B, For each angle, N1, For each speed reduction rate Refer to "1.4.4 Offset in the Installation Operation (High-Speed Head)" in Chapter 1, for various offset adjustments. SI1705004E-00=SIGMA-G5SII Service Manual 171/273...
  • Page 172: Cutter Unit Attachment/Removal Procedure

    Undo the lock on the right and left sides (two locations). Fig.D92 (3) Loosen the two set bolts for the cutter unit to remove. Remove the bolts on the right and left sides (two locations). Fig.D93 SI1705004E-00=SIGMA-G5SII Service Manual 172/273...
  • Page 173: Cutter Unit Attachment To The Feeder Cart

    4.14.2. Cutter Unit Attachment to the Feeder Cart Attach the cutter unit onto the feeder cart using the reverse procedure of Item 4.14.1. * After the cable connection, take care not to catch the cable when the unit is pressed against the machine. SI1705004E-00=SIGMA-G5SII Service Manual 173/273...
  • Page 174: Clamp Lever Change Procedure

    * When removing, move the cutter blade assembly to around the center and remove the clamp lever. * When removing, be careful of the cutter blade. Clamp Lever Stay Set Screw Fig.D96 ① ③ ② Fig.D97 SI1705004E-00=SIGMA-G5SII Service Manual 174/273...
  • Page 175: Clamp Lever Change

    (2) Fix the tape guide cover or side cover, etc., using the screws and fix the cutter unit onto the machine main body (Refer to Item 4.14.2, for the fixing procedure). * Attach the silicon sheet for the tape leading so that it is placed between the clamp levers. SI1705004E-00=SIGMA-G5SII Service Manual 175/273...
  • Page 176: Cutter Blade Assembly Change Procedure

    * Attach the silicon sheet for the tape leading so that it is placed between the clamp levers. (Fix the cutter unit onto the machine main body referring to Item 4.14.2.) SI1705004E-00=SIGMA-G5SII Service Manual 176/273...
  • Page 177: Cutter Driver (A63B, A63F) Change Procedure

    * Refer to Item Section 5.4.10 Fig.D102 (6) Fix the new cutter driver onto the bracket and attach it using the reverse procedure for the removal SI1705004E-00=SIGMA-G5SII Service Manual 177/273...
  • Page 178: Cutter Unit Operation Check

    ④. After ④ has appeared, touch the area ⑤. The debug mode will be displayed. "Debug" is displayed and when the "Unit Adj." is selected, the functions in the red frame become available. Normally, only "Noz Chng" and "Line Meas" functions are available. Fig.D103 SI1705004E-00=SIGMA-G5SII Service Manual 178/273...
  • Page 179 * For a small piece of emboss tape, prepare it so it can reach from the tape leading cover front end to the cutter section. * The manual operation can be started without positioning of the feeder cart in the machine. Fig.D104 SI1705004E-00=SIGMA-G5SII Service Manual 179/273...
  • Page 180: Fuse Replacement

    48V, 2A CPU2 U85(UC16)I/O Host PCB PCI Bus_VIO3.3V 48V, 2A CPU2 U85(UC16)I/O Host PCB AELINK_CH 1 48V, 2A CPU2 U85(UC16)I/O Host PCB AELINK_CH2 48V, 2A CPU2 U85(UC16)I/O Host PCB AELINK_+24V 48V, 2A CPU2 U85(UC16)I/O Host PCB SI1705004E-00=SIGMA-G5SII Service Manual 180/273...
  • Page 181: Relay Pcb (U27) Fuse Replacement

    4.17.2. Replacement of Fuse located on the side panel rear Pull out the fuse case and open the cover. Remove the glass tube fuse using a flathead screwdriver and replace it by a new one. Fig.D107 SI1705004E-00=SIGMA-G5SII Service Manual 181/273...
  • Page 182: Lightening Surge Protector Replacement

     Remove the earth wire (E0) and replace the lightning surge protector by a new one. F200 Fig.D108 4.17.4. Lighting Control Board (U95) Fuse Replacement U95 PCB Fig.D109 Take out the glass tube fuse using a screwdriver, etc., and replace it. SI1705004E-00=SIGMA-G5SII Service Manual 182/273...
  • Page 183: Fuse Change In The Cpu2 I/O Host Board (U85)

    U85 PCB U85 PCB Pull out the blade fuse and replace it by a new one. Fig.D110 SI1705004E-00=SIGMA-G5SII Service Manual 183/273...
  • Page 184: Servo Amplifier Change Procedure

    (3) When the servo amplifier on the H1 side is to be changed, remove the cover on the lower section of the machine front. Remove the head section motor amplifier unit. Fig.D112 (4) Disconnect the cables of the servo-amplifier to be removed. SI1705004E-00=SIGMA-G5SII Service Manual 184/273...
  • Page 185: Servo-Amplifier Attachment

    X2102F X2102LF X2103F A22F XM22PF X221AF X221BF X2202F X2202LF X2203F A23F XM23PF X231AF X2302F X2302LF A21B XM21PB X211AB X211BB X2102B X2102LB X2103B ↓Settng A22B XM22PB X221AB X221BB X2202B X2202LB X2203B A23B XM23PB X231AB A21F-CN1B X2302B X2302LB SI1705004E-00=SIGMA-G5SII Service Manual 185/273...
  • Page 186: Adjustment After Servo Amplifier Replacement

    Rear Side of Machine Set the Y-axis 12mm apart from the mechanical stopper (made of urethane). Front Side of Machine (Breaker Side) Fig.D117 Set the X-axis to the position where it touches the mechanical stopper (made of urethane). SI1705004E-00=SIGMA-G5SII Service Manual 186/273...
  • Page 187 (7) Send (overwrite) the device system data saved before the operation, to the machine. Note: If the teaching is performed without saving the device system data before the operation, all the teaching operation items should be performed. SI1705004E-00=SIGMA-G5SII Service Manual 187/273...
  • Page 188: Disengaged Latch Detection Sensor Change Procedure

    (2) Peel off about 5 cm of the fiber cover on the both end of the cable using the fiber cutter, and take out the core. (3) Attach the fiber cable onto the holder at the position A. (4) Connect the amplifier connector B0520. SI1705004E-00=SIGMA-G5SII Service Manual 188/273...
  • Page 189: Disengaged Latch Sensor Amplifier Adjustment

    ⇒Press the +/- button to set it to the following value and determine the value using the mode change button.  Timer Function ⇒Press the +/- button to set it to the following value and determine the value using the mode change button. SI1705004E-00=SIGMA-G5SII Service Manual 189/273...
  • Page 190 ⇒Press the +/- button to set it to the following value and determine the value using the mode change button.  Highlighted Display Setting ⇒Press the +/- button to set it to the following value and determine the value using the mode change button. SI1705004E-00=SIGMA-G5SII Service Manual 190/273...
  • Page 191 (4) Finally, set up the feeder (8mm or 32mm) and disengage the feeder hook. Then, check that the value is " 1000 " or less. Check it in the three locations (right end, center and left lanes) and if there is no problem, the adjustment is completed. SI1705004E-00=SIGMA-G5SII Service Manual 191/273...
  • Page 192: Tape Component Pick-Up Error Detection Sensor Setting

    (4) Set the power tuning target value for the amplifier to "1000" using the following procedure. Set the SET/RUN switch to "SET" and press the MODE key six times. Change the indication to the following one using the UP/DOWN key. SI1705004E-00=SIGMA-G5SII Service Manual 192/273...
  • Page 193 Then, arrange it so that the light is received in the lower side and check that the light level is "800" or more. For 1CH and 2CH, this operation should be performed on the both sides. (9) After the amplifier setting, return the CH switch to "CH1". SI1705004E-00=SIGMA-G5SII Service Manual 193/273...
  • Page 194: Side View Camera Light Receiver Change

    (2) Remove the existing light receiver. Remove the M21.8 screw and flat washers (two locations) and disconnect the connector (X0710) as shown in the following figure. M2L8 Screw × 2 Fig.D121 SI1705004E-00=SIGMA-G5SII Service Manual 194/273...
  • Page 195: Cable Disconnection And Connection

    * When the connectors are disconnected, mark on the connectors. Fig.D122 Refer to Fig.D123, for the cable routing and connector positions. * Before the connectors are disconnected, remove the board. This is for better workability when the wires are removed. Fig.D123 SI1705004E-00=SIGMA-G5SII Service Manual 195/273...
  • Page 196: Light Receiver Attachment And Position Adjustment

    (3) Press the light receiver attachment adjusting jig and the light receiver against the head and keeping this condition, tighten them using the two light receiver set bolts (M2L8 + FL). (4) Remove the light receiver attachment adjusting jig. SI1705004E-00=SIGMA-G5SII Service Manual 196/273...
  • Page 197: Checks

    ・When the measured value is smaller than “0.500mm”, the nozzle tip end is over the line. ・When the measured value is larger than “0.500mm”, the nozzle tip end is under the line. Nozzle Lateral Position Reference Light Projector Outline Reference Fig.D126 SI1705004E-00=SIGMA-G5SII Service Manual 197/273...
  • Page 198 M2L8 Bolt + Washer (2 pcs) Fig.D128  When the nozzle tip end is located under the reference line, adjust the light receiver so that tilting angle is adjusted to downward. M2L8 Bolt + Washer (2 pcs) Fig.D129 SI1705004E-00=SIGMA-G5SII Service Manual 198/273...
  • Page 199: Data Input

    (2) Change the values for " Magnification X " and " Magnification Y " for the head where the light receiver has been changed, to the data values included in the light receiver. (3) Save the changed values. SI1705004E-00=SIGMA-G5SII Service Manual 199/273...
  • Page 200: Gain Teaching

    " Noz " . (4) Press " Teach Start " and press the [START] button to start the teaching. (5) Press " Save " to save the teaching results. Fig.D131 SI1705004E-00=SIGMA-G5SII Service Manual 200/273...
  • Page 201: Electric System

    For Service Engineer Service Information 5. Electric System 5.1. Home Return Operation Procedure Fig.E1 SI1705004E-00=SIGMA-G5SII Service Manual 201/273...
  • Page 202: Electric System Block Drawing (Sigma-G5Sii)

    For Service Engineer Service Information 5.2. Electric System Block Drawing (SIGMA-G5SII) Fig.E2 SI1705004E-00=SIGMA-G5SII Service Manual 202/273...
  • Page 203: Each Block Electric System Layout

    For Service Engineer Service Information 5.3. Each Block Electric System Layout 5.3.1. Main Machine Corner Front Side and Plate Entire Section in the lower frame section FRONT Terminal Unit Wiring Diagram Lightning Surge Protector SI1705004E-00=SIGMA-G5SII Service Manual 203/273...
  • Page 204 ADLINK Manufacturer ←Ditto ←Ditto ←Ditto Hard PART NAME UNIT_I/O(CF) ←Ditto ←Ditto ←Ditto PART No. 1010BF01 ←Ditto ←Ditto ←Ditto DC1M-512031C Model ←Ditto ←Ditto ←Ditto Manufacturer InnoDisk Software Software Name (1) SF21201 (2) SF21221 (1) Ditto (3) SF21241 SI1705004E-00=SIGMA-G5SII Service Manual 204/273...
  • Page 205: Multi-Axis Board, Lighting Control, I/O Intensive Board, Side View Camera Board

    Front/Rear Head, Multi- KYB-M658U-00 Multi-axis board UNIT_DRIVER A31B No.401 functional Head Fig D3-5 KYB-M6535-00 SVC (Side View Camera) PCB P_C_B_MOUNT Using 5V Power Source No.402 *Refer to "5.4 Electric Parts Settings" for the initial settings for each board. SI1705004E-00=SIGMA-G5SII Service Manual 205/273...
  • Page 206: Power Unit Layout

    Feeder Power (Block2) 24G2B F27 (250V, 6.3A) Inside the U27 board Side Veiw Camera (Head1, 5.8V-6.0V CPU1, 2 Power Supply Table 4: Power Supply Destination List Note: The voltage adjustment is not required for CPU power "G21". SI1705004E-00=SIGMA-G5SII Service Manual 206/273...
  • Page 207: Layout For The Panel Located In The Left Side Surface In The Lower Frame Section

    CPU Power-in No.305 G2 Power-in FigD3-4 ACCESSORY_WIRING KYB-M65AX-00 Circuit Protection Q205 No.313 Vacuum Pump KYB-M65BM-00 CIRCUIT PROTECTOR No.314 Q206 Fig D3-4 KYB-M656T-00 Breaker BREAKER Q221 No.310 Fig D3-4 KYB-M6577-00 Lightning Surge Protector F200 SEMICO_VARISTOR Lightning Surge No.331 SI1705004E-00=SIGMA-G5SII Service Manual 207/273...
  • Page 208: Servo Motor Amplifier Layout

    Y2(Front) Axis Servo Motor Amplifier A23F Fig D3-3 amplifier used in the front UNIT_DRIVER KYB-M6565-00 Y1(Rear) Axis Servo Motor Amplifier A22B No.203 surface is the same as that Y2(Rear) Axis Servo Motor Amplifier A23B used in the rear side . SI1705004E-00=SIGMA-G5SII Service Manual 208/273...
  • Page 209: Layout For The Transfer Unit Over The Lower Frame Section (Single Lane)

    Fig.No NAME SYMBOL PART NAME Remarks CODE Key.No Fig H1-12 TEPPER DRV BRD ASSY KYB-M5806-02 Transfer Driver No.B42 Fig C1-3 16 - 16 I/O Board (UB95) PCB_MOUNT KYB-M91AK-00 No.B41 TEPPER DRV BRD ASSY KYB-M5806-12 Backup Driver SI1705004E-00=SIGMA-G5SII Service Manual 209/273...
  • Page 210: Layout For The Transfer Unit Over The Lower Frame Section (Dual Lane)

    KYB-M91AK-00 16 - 16 I/O Board (UB95) PCB_MOUNT No.B41 KYB-M91DE-00 Backup Driver (D4460) PCB_MOUNT Note: In the case of dual transfer system, the number of drivers is increased because the number of control axes is increased. SI1705004E-00=SIGMA-G5SII Service Manual 210/273...
  • Page 211: Feeder Cart Layout

    PART NAME Remarks CODE Key.No Fig C1-3 KYB-M371H-00 Feeder I/O Board PCB_MOUNT UC26 No.216 U68A Fig C1-3 KYB-M371G-00 PCB_MOUNT U68B No.215 Note: For the U69 board, make sure that there is no error in the SW setting. SI1705004E-00=SIGMA-G5SII Service Manual 211/273...
  • Page 212: Traverse Cart Layout

    No.913 K002:EL2SF K507:EL Door (Lower) K507 K508 : EL Door K508 Fig N1-10 (Upper) KYC-M187Y-00 Relay K509 RELAY No.914 K509:EL Door K512 (Center) K513 K512,K513: Main Circuit K502 Fig N1-10 KYB-M124M-00 Relay K503 RELAY No.916 K504 SI1705004E-00=SIGMA-G5SII Service Manual 212/273...
  • Page 213: Tray Unit Layout

    UB95 No.901 U153 UB95 Fig N1-10 KYB-M918U-00 U154 ASSY_PCB2 UB95 (U153,U154,U155) No.902 U155 * Although the same UB95 is used in U150 through U155, the software where the data is written in, is different each other. SI1705004E-00=SIGMA-G5SII Service Manual 213/273...
  • Page 214: Electric Parts Settings

    For Service Engineer Service Information 5.4. Electric Parts Settings 5.4.1. Breaker Current and Timer Setting SI1705004E-00=SIGMA-G5SII Service Manual 214/273...
  • Page 215: Cpu2 Board Setting

    For Service Engineer Service Information 5.4.2. CPU2 Board Setting X8203 X8204 X8500 X9201 X9202 X8501 X8502 X9108 X85UP X9107 X85DN X85T X8109 X8104 X9106 X9105 X8201 X9109 X8202 X9104 X9103 X8102 X9102 U85 U82 U81 U85(AE-LINK/HSIO) U82(Motion Control) SI1705004E-00=SIGMA-G5SII Service Manual 215/273...
  • Page 216: I/O Board Setting

    For Service Engineer Service Information 5.4.3. I/O Board Setting Note: Although the setting has been performed in the factory before shipping, check it again when replacing the board. SI1705004E-00=SIGMA-G5SII Service Manual 216/273...
  • Page 217: U95 (Uc19) Lighting Control Board Setting

    Service Information 5.4.4. U95 (UC19) Lighting Control Board Setting FRONT REAR Table 10: List of Fuses to be used Note: Refer to "Fuse Change Procedure" for the fuse change procedure. Note: SW1: Set all to "0". SI1705004E-00=SIGMA-G5SII Service Manual 217/273...
  • Page 218: Relay Board U27 (Uc34) Board Setting

    Fuse No Capacity 6.3A 6.3A FRONT REAR 6.3A 6.3A 6.3A 6.3A 6.3A Note: Refer to the U27 Board Layout in the lower left figure for the arranged locations. K2A (Timer Delay) Setting U27 (UC24) Board Layout SI1705004E-00=SIGMA-G5SII Service Manual 218/273...
  • Page 219: Transfer I/O Board Driver Setting (Single)

    SW1 setting A10-1 (Top) Address / Function setting Driver address setting (#1 to #3) U08 Board Settings A11 (D4460) Back-up Driver Settings Backup Driver SW1 setting Address / Function setting Driver address setting (#1 to #3) SI1705004E-00=SIGMA-G5SII Service Manual 219/273...
  • Page 220: Transfer I/O Board Driver Settings (Dual)

    For Service Engineer Service Information 5.4.7. Transfer I/O Board Driver Settings (Dual) Table 12: Various Transfer Unit Driver Settings List A12 to A15(D4920) Transfer Driver A16,A17(D4460) Back-up Driver U08, U09 Board Setting SI1705004E-00=SIGMA-G5SII Service Manual 220/273...
  • Page 221: Multi-Axis Driver Setting

    X314DB CN1A X311AF X311AB SSCNET Communication Cable A31F(CN1B) ⇒ A31B(CN1A) CN1B X311BF Relay Board U27 CNP1 X31P1F X31P1B (X13(X31P1F), X12(X31P1B)) CNP2A X312PAF X312PAB CNP2B X312PBF X312PBB Robot Cable Relay (X131P2F,X131P2B) CNP2C X312PCF X312PCB CNP2D X312PDF X312PDB SI1705004E-00=SIGMA-G5SII Service Manual 221/273...
  • Page 222: X-Axis/Y-Axis Servo Amplifier Setting

    A21F XM21PB L132 L232 L332 L110 L210 XM2102B XM2102LB XM211AB X211BB X2103B  A22F XM22PB L132 L232 L332 L120 L220 XM2202B XM2202LB XM221AB X221BB X2203B  A23F XM23PB L132 L232 L332 L120 L220 XM2302B XM2302LB XM231AB A21F-CN1B Enlarged SI1705004E-00=SIGMA-G5SII Service Manual 222/273...
  • Page 223: Side View Camera Board, Sv-Net Communication Unit Setting

    SV-NET Communication Driver (A63F, A63B) SV-NET Communication Driver Settings (A63F, A63B) Note: The setting is common to front and rear. This setting has been performed in the factory before shipping. However, check it before the installation. SI1705004E-00=SIGMA-G5SII Service Manual 223/273...
  • Page 224: U07 (Head Distrbution Panel) Setting

    For Service Engineer Service Information 5.4.11. U07 (Head Distrbution Panel) Setting The SW setting value varies depending on the head type. When the head is replaced, make sure to check it. SI1705004E-00=SIGMA-G5SII Service Manual 224/273...
  • Page 225: Troubleshooting

    For Service Engineer Service Information 6. Troubleshooting 6.1. System Recovery Procedure The procedure to install OS into CPU1 BOX-PC for SIGMA-G5SII. 6.1.1. Required Items The following items are required for the OS installation operation into CPU1 BOX-PC.  CD-R Drive...
  • Page 226 (4) The Login window appears. Perform the login operation using the following account name and password. :equipment  Account Name  Password :autologon When the focus is moved from "Account" to "Password", press the Tab key (because there is no mouse). SI1705004E-00=SIGMA-G5SII Service Manual 226/273...
  • Page 227: Initial Setting

    Drive D Deletion Processing What is the Drive Drive D Generation Processing D Format Type? NTFS Drive D Formatting Processing Drive D Format Conversion Re-Start Execution Dialog Display End Dialog Display (3)-2 reference (3)-3 reference Re-Start SI1705004E-00=SIGMA-G5SII Service Manual 227/273...
  • Page 228 * Subsequently, the "Machine Software" installation is performed. Insert the "Machine Software Installation CD-ROM" into the CD Drive and re-start the CPU1 BOX-PC. Refer to Item 4 for the machine software installation application. SI1705004E-00=SIGMA-G5SII Service Manual 228/273...
  • Page 229 Select [OK] to delete the confirmation dialog. Then, select the [Close] button located in the lower section of the monitor screen to end the initial setting application. The operation from Item (3)-2 will be executed. SI1705004E-00=SIGMA-G5SII Service Manual 229/273...
  • Page 230: Machine Software Installation

    Refer to Item (4)-1. Refer to Item (4)-3. Unconnected Machine Software Setup CD-ROM Connection Selection Judgment Connected Recovery Refer to Item (4)-2. Copy the machine software installation data from CD-ROM. Refer to Item (4)-4. Is Machine Software Setup Started? SI1705004E-00=SIGMA-G5SII Service Manual 230/273...
  • Page 231 (4)-2 Machine Software Installation Data Copy Processing When the CD-ROM is connected, the installation data copy processing is started. When the copy is completed, the machine software installation confirmation dialog in Step (4)-4 is displayed. SI1705004E-00=SIGMA-G5SII Service Manual 231/273...
  • Page 232 After the installation, select the [Shutdown] button to close Windows. After the machine restart-up, the machine software is started up. After the machine software is started up, when the re-start-up is requested due to the machine configuration, re-start the machine. SI1705004E-00=SIGMA-G5SII Service Manual 232/273...
  • Page 233: Precautions In Installation

     Machine Software Language (In the casa that the Drive D is not to be formatted in the Initial Setting Application execution) 6.2.3. Setting when ACV Barcode Scanner is used When the ACV barcode scanner is attached to Sigma G5S, perform the COM port setting referring to the following material. SI1705004E-00=SIGMA-G5SII Service Manual 233/273...
  • Page 234: Touch Panel Change And Adjustment Procedure

    Fig.F3 There is a fulcrum pin in the monitor fixing section. When the monitor is to be removed, after removing the bolts in all three locations, remove the monitor. SI1705004E-00=SIGMA-G5SII Service Manual 234/273...
  • Page 235: Touch Panel Attachment Procedure

    (Refer to Fig. F5). After tap, three icons are displayed on the left hand side. Select the Windows icon. 2. Select the Windows icon. 1. Tap the specified section Fig.F5 SI1705004E-00=SIGMA-G5SII Service Manual 235/273...
  • Page 236 (Refer to Fig. F6). 1. Select "Graphic Properties". Fig.F6 (4) Open the "Graphic Properties" window and perform the setting using the following procedure. 1. Open the Intel ® Graphics HD. 3. Select "Clone Displays". 2. Select "Multiple Displays". Fig.F7 SI1705004E-00=SIGMA-G5SII Service Manual 236/273...
  • Page 237: Touch Panel Front/Rear Setting

    "PnlTool Control" item. The bar will appear in the lower left of the window. Double-click this bar. 2. Select "MANAG" tab and press down the [TP-Device ReSetup] button to perform the front/rear identification. Fig.F8 SI1705004E-00=SIGMA-G5SII Service Manual 237/273...
  • Page 238 If nothing happens in the window in Step 3, touch the key in this window. Fig.F9 SI1705004E-00=SIGMA-G5SII Service Manual 238/273...
  • Page 239 Control" item and close the window. The machine front will be switched to rear or vice versa. Make sure that the Rear is disabled when the Front is enabled, or Front is disabled when the Rear is enabled. Fig.F10 SI1705004E-00=SIGMA-G5SII Service Manual 239/273...
  • Page 240: Application Software Setting

    Security Batch Processing Service Registration Batch Processing LISA Service Registration (ACV Server Service Registration) LISA System Start-up Check (ACV Server Start-up Check) (4) LISA System Start-up Check LISA PC Restart-up LSA System Start-up Check (ACV Server Start-up Check) SI1705004E-00=SIGMA-G5SII Service Manual 240/273...
  • Page 241: Log-On

    " Connection and in the " " click the Local Area Connection icon displayed window, press the in the upper section in the window, [Property] button. " " and select Property SI1705004E-00=SIGMA-G5SII Service Manual 241/273...
  • Page 242: Power Option Check

    (1) Click " Control Panel " in the " Start " menu to display the " Control Panel " window. (2) Click " System and Security " and in the displayed window, select " Power Options " item. SI1705004E-00=SIGMA-G5SII Service Manual 242/273...
  • Page 243: Lisa System Stop (Preparation For Installation)

    In the case that the LISA system is used together with ACV service system, after stopping the both systems, cancel the service registration. " " This Service starts up the application automatically when the PC is started The application is started up without log-on. SI1705004E-00=SIGMA-G5SII Service Manual 243/273...
  • Page 244: Acv Server System Stop And Service Registration Cancellation

    " ACV System - Server Set-up " window will appear. Then, Press the [ Un register] button in the " ACV System - Server Set-up " window to cancel the service. The service cancellation information message is displayed twice. SI1705004E-00=SIGMA-G5SII Service Manual 244/273...
  • Page 245: Installation (Version Up)

    " In the course of the operation, a message displayed. However, the installation setting (folder) cannot be changed (fixed). (4) When the LISA Basic Package installation is completed, continue the setup operation without re-starting the PC. SI1705004E-00=SIGMA-G5SII Service Manual 245/273...
  • Page 246: Software License Setting

    (2) Enter the " Computer Name " or " IP Address " for the license server PC to be referred, in the text box, and press the [OK] button. The connection to the license server PC can be checked after the entry of SI1705004E-00=SIGMA-G5SII Service Manual 246/273...
  • Page 247: Security Partly Cancellation Batch Processing

    * The service is registered using the [Register] button in the LISA Service Control window. "add_taskschedule_LISA.BAT" ⇒ Register LISA in the Task Scheduler. " " Refer to 7.1.6.3 Setting Check for the registration check to the Task Scheduler. SI1705004E-00=SIGMA-G5SII Service Manual 247/273...
  • Page 248: Acv Server System Batch Processing

    ACV Time Master Server 56820 License Server 56795 ACV Event Distribute Server 56817 ACV Master Viewer Server 56818 ACV DB Convert Server 56821 ACV Event Search Server 56823 TFTP Server ACV DB DataOut Server 56827 SysLogD SI1705004E-00=SIGMA-G5SII Service Manual 248/273...
  • Page 249: Setting Check

    (2) Click " System and Security " and in the displayed window, select " Windows Firewall " . (3) Click " Advanced Settings " in the " Windows Firewall " window. Then, in the displayed window, select " Inbound Rules " . SI1705004E-00=SIGMA-G5SII Service Manual 249/273...
  • Page 250 (2) Click " System and Security " and in the displayed window, select " Administrative Tools " . (3) Select (Double-click) " Service " in the displayed list. In the displayed service list, make sure that the registered service name is included and confirm the contents. SI1705004E-00=SIGMA-G5SII Service Manual 250/273...
  • Page 251: Lisa System Start-Up Preparation

    " Status Details " window will be displayed. Make sure (4) Press the [Monitor] button. The that the indication for all the programs is " " in the " Status Details " window. SI1705004E-00=SIGMA-G5SII Service Manual 251/273...
  • Page 252: Acv Service System Service Registration And System Start-Up Check

    " Status Details " window will be displayed. Make sure (4) Press the [Monitor] button. The that the indication for all the programs is " " in the " Status Details " window. SI1705004E-00=SIGMA-G5SII Service Manual 252/273...
  • Page 253: Lisa Pc Restart-Up

    (3) Confirm the ACV Service System with the the " ACV Service System-Server Service Control " window. Moreover, make sure that " " is indicated for all programs using the [Monitor] button. (4) Log off from the LISA PC. SI1705004E-00=SIGMA-G5SII Service Manual 253/273...
  • Page 254: Setting And Communication

    (*Confirm the fixed IP address value with the network manager). " " When PC is started up, press Control Panel in the start menu. ② ① " " " When the Control Panel window is displayed, press Network and Sharning " Center SI1705004E-00=SIGMA-G5SII Service Manual 254/273...
  • Page 255 Properties ① ② " " When the Local Area Connection Properties window opens, press on the character " " string of Internet Protocol Version 4 (TCP/IPv4) to select, and press the [Properties] button. ① ② SI1705004E-00=SIGMA-G5SII Service Manual 255/273...
  • Page 256 : It shows that until which character indicates the network address in the IP address character string. It is the same value as that of the PC in the machine to be communicated. Press the [OK] button in the "Local Area Connection Properties" window. SI1705004E-00=SIGMA-G5SII Service Manual 256/273...
  • Page 257  For the specification details applicable to Windows NT/2000/XP/Vista, refer to the following description. (2-2) Check Window Display Procedure ① OS、CPU、Memory " " " " " " Right-click the Computer in the Start menu and press the Properties ② ③ ① SI1705004E-00=SIGMA-G5SII Service Manual 257/273...
  • Page 258 The " Computer Basic Information Display " window opens. Memory ② Hard Disk Capacity " " " " Press Computer in the Start menu. " " The value indicated in the Free Space box, shows the Hard Disk free space. SI1705004E-00=SIGMA-G5SII Service Manual 258/273...
  • Page 259 Start menu. ② ① " " " " When the Control Panel window opens, press Device Manager " " Device Manager window will open. Display Adaptor : For Graphics Network Adaptor : For employed LAN Function SI1705004E-00=SIGMA-G5SII Service Manual 259/273...
  • Page 260 ② Display the Install Launcher window. Press the "Computer" in the "Start" menu. ② ① When the " Computer " window opens, double-click " DVD RW Drive (D:) " . When the "DVD RW Drive (D:)" window opens, double-click "Launch.exe". SI1705004E-00=SIGMA-G5SII Service Manual 260/273...
  • Page 261 ⑤ PC Restart-up About 30 seconds after the CAD conversion software installation completion, a message urging the restart-up is displayed. Perform the restart-up operation according to the instructions in the window. SI1705004E-00=SIGMA-G5SII Service Manual 261/273...
  • Page 262 Enter the file name in the " " Search programs and files window and execute it. (File Name to be entered in " " Search programs and files : cmd) ② ① " " Command Prompt window will open. SI1705004E-00=SIGMA-G5SII Service Manual 262/273...
  • Page 263 For Service Engineer Service Information " " Enter ipconfig/all and press the [Enter] key on the keyboard in PC. " " " " Host Name IP Address are displayed. SI1705004E-00=SIGMA-G5SII Service Manual 263/273...
  • Page 264: System Software Login Password Setting

    Pattern program data rename  Pattern program change in the machine (3) Component Library Data Communication The component library data is communicated.  Component Library data transmission and receipt  Component Library data deletion  Component Library data rename SI1705004E-00=SIGMA-G5SII Service Manual 264/273...
  • Page 265 The pattern program data, component library data and system data are received from the machine to create backup data. Also, the backup data is recovered.  Backup (The No. of backup files should be 1 to 10, which can be saved).  Recovery SI1705004E-00=SIGMA-G5SII Service Manual 265/273...
  • Page 266 (However, at present, only Sigma F8 and Sigma G-5 are applicable. Sigma G5S is not applicable). ③ When the transmission is completed, a message " It is [ machine software / " installation ] ready is displayed in the machine front side. SI1705004E-00=SIGMA-G5SII Service Manual 266/273...
  • Page 267 It is effective when the components are used up, but it is unsure which maker’s component is used.  " " " " Setting Location in the Machine : Select Product Production Data " " Alternative Component List SI1705004E-00=SIGMA-G5SII Service Manual 267/273...
  • Page 268 For Service Engineer Service Information (12) Operation Mode Selection Communication The operation mode selection data is communicated.  " " Operation Mode Selection File Receipt and Transmission "Operation Mode Selection" data saving destination folder (D: ¥ntdata¥mdata¥Curparam¥Machine Name) SI1705004E-00=SIGMA-G5SII Service Manual 268/273...
  • Page 269: Production Manager Setting

    (2) Production Manager Setting Register the shortcut for the Production Manager at the start-up. " " " " " Right-clicking Production Manager in the Start window and pressing Pin to Start " Menu can register it. SI1705004E-00=SIGMA-G5SII Service Manual 269/273...
  • Page 270 For Service Engineer Service Information Start up the Production Manager and select the setting items as follows. " " " " Select Option Machine Status " " " " " " Select Option Management Data Data Setting SI1705004E-00=SIGMA-G5SII Service Manual 270/273...
  • Page 271 " Press Start Control Panel Power Option Change plan Settings in this " " order to open the Plan Setting Change window. " " " " Set the item Transfer the Computer to Sleep Mode Disable SI1705004E-00=SIGMA-G5SII Service Manual 271/273...
  • Page 272: Management Data Monitoring Function Operation Procedure

    : The totaling is performed using the locally saved data. Enable (Automatic) : If there is any file missing locally, the communication with the machines is performed to collect the data, and totaling operation is performed. SI1705004E-00=SIGMA-G5SII Service Manual 272/273...
  • Page 273 For Service Engineer Service Information Revision history Contents Note Date -000 First release December 27 2017 SI1705004E-00=SIGMA-G5SII Service Manual 273/273...

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