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Strange problem with Fuji IP1 stopping

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#40772

Strange problem with Fuji IP1 stopping | 30 March, 2006

Just before Christmas we bought a used Fuji IP1 cheap. It took us a while but it's been working great for about a month. Yesterday the IP1 stopped after completing a board but before exiting the board out the conveyer. No error message, no alarm bells - just stopped. I used the CLR OFF button to manually convey the PCB out the conveyer.

The IP1 then stopped at random spots on the next two PCB's. Again, no error message or bells or apparent reason for stopping. Although the machine would respond to key presses of the control panel, I could not get the machine to continue placing parts. After I opened the safety door the machine displayed "emergency stop - safety door" as normal but would no longer respond to key presses of the control panel, even after the safety door was securely closed (continued to display "safety door").

I tried loosening and tightening all the PCB's and connectors inside the front right circuit board area of the IP1 (which took me about an hour). The same results - the IP1 stopped at a random spot in the assembly on the next PCB and refused to continue on. Turning the machine Off and ON did not fix the problem and I now had three partially completed boards.

Resetting the memory and resending the proper data and program data solved the problem for a while then the IP1 stopped again at the end of completing a PCB without running it off the exit conveyer. I reset the memory again and completed the run without further problems.

Does anyone have an idea of where the problem could be?

We use the machine about 8 hours a week and it usually works great.

Regards,

Bert

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#40774

Strange problem with Fuji IP1 stopping | 30 March, 2006

Hi Bert,

There should be an action occuring when the machine hangs-up(ie: Q motor rotating, getting ready to change nozzle, or other action). See if you can find this. The first thing that comes to mind is a loss of the signal for a nozzle in the changer. Yes it should give an error but I have had it hang up the machine sometimes.

Jerry

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#40777

Strange problem with Fuji IP1 stopping | 30 March, 2006

Call Fuji HA HA

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Roland G

#40872

Strange problem with Fuji IP1 stopping | 7 April, 2006

Check firmware version and Fuji upgrade reports because it could be a sofware bug. I remember also 1 random failure on IP1 which was hard to identify: a cable in raceway connected to placement table was getting contact failure when table moves.

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engguy

#40878

Strange problem with Fuji IP1 stopping | 7 April, 2006

This is common with older Fujis. The machine is trying to download production data to the host(MCS?) If the cable is not connected or if the MCS is off, the machine will randomly freeze at the end of prod. Either solve those issues or change the machine status to "local", which then the machine does not attempt to download prod. data.

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#40974

Strange problem with Fuji IP1 stopping | 14 April, 2006

The latest news. We ran another production run for 1-1/2 hours. The IP-1 gave a "memory NG" fault indicator twice after fully completing the first and second PCB's. We've been running the tray speed at 30% but noticed that the speed of the tray robot also went balistic - going so fast that parts were jumping from their tray location. I reloaded the proper data and completed the run like a dream.

After a suggestion, we checked the wiring of the mains power. The mains measures 235VAC from each of the three phases to nuetral but noticed that each of the transformer taps were set at 380 VAC! We rewired the transformer taps to 230 VAC but blew a 15 amp fuse on one of the phases when we turned on the master power switch. Rewiring back to 380 VAC and replacing the fuse restored proper operation of the IP-1.

I'm confused about the 380 VAC wiring of the machine. I measured the 110 VAC output to the MCS-16/F and it reads close to 110 VAC with the transformed taps set to 380 VAC.

Does anyone know why the IP-1 works with the transformer taps sets to 380VAC when they should be set to 230VAC?

Regards,

Bert

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engguy

#41003

Strange problem with Fuji IP1 stopping | 17 April, 2006

Measure the voltage from phase to phase, not to ground or neutral. I have never seen 380VAC in the US. Are you outside the US?

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