Installation PDF

Installation Manual
AX-301/501
DOCUMENT DATA
Document . . . . . . . . . . . . . . . . . . Installation Manual AX-301/501

Based on . . . . . . . . . . . . . . . . . . -
Order number . . . . . . . . . . . . . . . 4022 593 52151
Supplied with. . . . . . . . . . . . . . . . AX-3: PA 1120/00/01/02
......................... AX-5: PA 1121/00/01/02
......................... AX-301: PA 1120/03 and up
......................... AX-501: PA 1121/03 and up
HISTORY
ISSUE DATE ORDER NUMBER REVISION CODE STATUS RELEASE DOCUMENT
First issue November 2007 4022 593 52151 07.01 Current DI-A-series-016
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© Assembléon Netherlands BV
All rights reserved. No part of this book may be reproduced in any form, by print, photoprint, mi-
crofilm or any other means without the written permission from Assembléon.
CONTENTS
Table of Contents
CHAPTER 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Estimated installation time. . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Useful conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
CHAPTER 2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.2 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.3 Basic safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.4 Safety compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.5 Danger, warning and caution. . . . . . . . . . . . . . . . . . . . . . .9
2.6 Safety stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.7 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.8 Noise levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.9 Emergency contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.10 Liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.11 Recommended tools for working safely . . . . . . . . . . . . . . . 13
CHAPTER 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Moving the machine to the site. . . . . . . . . . . . . . . . . . . . 14
3.1.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1.2 Machine dimensions and weight excluding trolleys . . . 17
3.1.3 Machine dimensions and weight including trolleys . . . 18
3.1.4 Transportation to the site. . . . . . . . . . . . . . . . . . . . 19
3.1.5 Positioning the machine in the flow line. . . . . . . . . . 21
3.1.6 Removing the transport brackets . . . . . . . . . . . . . . . 23
3.1.7 Mounting of the transport belts . . . . . . . . . . . . . . . . 23
3.1.8 Levelling the machine . . . . . . . . . . . . . . . . . . . . . . 24
3.1.8.1 Transport height . . . . . . . . . . . . . . . . . . . . . . 24
3.1.8.2 Levelling procedure . . . . . . . . . . . . . . . . . . . . 24
3.1.9 Seismic protection. . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Mounting the accessories . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.1 Mounting the lamp post . . . . . . . . . . . . . . . . . . . . . 27
3.2.2 Mounting the screen stand(s) . . . . . . . . . . . . . . . . . 27
3.3 Mounting the touch screen(s) . . . . . . . . . . . . . . . . . . . . . 28
3.4 Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4.1 Installing feeder lane identification strips. . . . . . . . . 29
3.4.2 A-series trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4.2.1 Unpacking A-series feeder trolley crate . . . . . . . 30
3.4.2.2 A-series trolley, height adjustment . . . . . . . . . . 30
3.4.3 FCM feeder trolleys . . . . . . . . . . . . . . . . . . . . . . . . 32
4022 593 52151 Installation Manual

07.01 AX-301/501 3
CONTENTS
3.4.3.1 Installing FCM feeder trolleys . . . . . . . . . . . . . 32

3.4.3.2 Mounting the base arms . . . . . . . . . . . . . . . . . 32
3.4.3.3 Unpacking FCM feeder trolley crate. . . . . . . . . . 32
3.4.3.4 Upgrading the FCM feeder trolley for
use on the AX-301/501 . . . . . . . . . . . . . . . . . 32
3.4.3.5 FCM feeder trolley, height adjustment . . . . . . . . 33
3.5 Unpacking other crates . . . . . . . . . . . . . . . . . . . . . . . . . 34
CHAPTER 4 Connections to services . . . . . . . . . . . . . . . . . . . . . . . . 35

4.1 Location of connection points. . . . . . . . . . . . . . . . . . . . . 35
4.2 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2.2 Adapting mains voltage . . . . . . . . . . . . . . . . . . . . . 37
4.2.3 Connecting the machine to the power supply. . . . . . . 38
4.2.4 Switching on and checking the mains. . . . . . . . . . . . 42
4.3 Connecting the machine to an external emergency circuit . . 43
4.3.1 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CHAPTER 5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1 SMEMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1.1 interface connections . . . . . . . . . . . . . . . . . . . . . . 45
5.1.1.1 SMEMA, electrical interface cable . . . . . . . . . . . 45
5.1.1.2 SMEMA, electrical interface, connection diagram 45
5.1.1.3 SMEMA, electrical interface, features . . . . . . . . 46
5.1.2 Network configuration (internally), setting . . . . . . . . 47
5.1.3 Network connection (externally), setting . . . . . . . . . 47
5.1.4 External network adaptor, enabling . . . . . . . . . . . . . 48
5.1.5 Set pre-defined network location . . . . . . . . . . . . . . . 49
CHAPTER 6 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.1 Board identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.1.1 Board identification, installing . . . . . . . . . . . . . . . . 50
CHAPTER 7 Software installation . . . . . . . . . . . . . . . . . . . . . . . . . . 55

CHAPTER 8 Final testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.1 Transfer speed, adapting . . . . . . . . . . . . . . . . . . . . . . . . 56
8.2 Putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3 Running in simulation mode . . . . . . . . . . . . . . . . . . . . . . 56
8.4 Running the acceptance test. . . . . . . . . . . . . . . . . . . . . . 56
CHAPTER 9 Relocating the machine . . . . . . . . . . . . . . . . . . . . . . . . 57

9.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.2 Preparing machine for transport . . . . . . . . . . . . . . . . . . . 57
9.3 Machine transportation . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installation Manual 4022 593 52151

4 AX-301/501 07.01
CONTENTS
9.4 Site preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

9.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.6 Transport material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
CHAPTER 10 Packing / unpacking instructions trolley FCM . . . . . . . . 61

07.01 AX-301/501 5
CONTENTS

07.01 AX-301/501 6
1
CHAPTER 1 Introduction
Before installing this machine, make sure that the site is in accordance with the
pre-installation instructions (see Pre-installation Manual AX-301/501).
The information in this manual is intended to be a guide for the installation of a
AX-301 or AX-501, including built-in options.
The described (re-)installation may only be carried out by trained service/
maintenance engineers.
NOTE: Engineers are expected to be informed about the content of:

- the Operating Manual AX-301/501
and
- the Service Manual AX-301/501.
ch01.fm

07.01 AX-301/501 7
1
1.1 Estimated installation time

These estimated times can be used to plan personnel and other resources for an
installation.
NOTE: Defined times are average times and are only valid when requirements are
according the pre-installation manual.
Installation part Time
CHAPTER 3.Installation 5 Hours with 2 persons.
CHAPTER 4.Connections to services 1 Hour with 1 person.
CHAPTER 5.Communication 1.5 Hour with 1 person.
6.1.Board identification 2 Hours with 1 person.
CHAPTER 7.Software installation 2 Hours with met 1 person.
CHAPTER 8.Final testing 2 Hours with 1 person, depends on
customer’s application (board).
CHAPTER 9.Relocating the machine 8 Hour with 2 persons.
CHAPTER 10.Packing / unpacking instructions trolley FCM Average 1.5 Hour with 2 persons.
Figure 1
1.2 Useful conversions

Physical quantity SI symbol Conversion factors
Length m 1 mm = 0.004 inch
1 m = 39.37 inches
1 inch = 25.4 mm
Volume m3 1 imp. gall. = 4.55 l
1 US gall. = 3.79 l
Air flow 1 Nl = 1 l at 0 ºC and 1 atm.
Mass kg 1 kg = 2.2 lb
1 lb = 455 g
1 oz = 28.35 g
Force N 1N = 1 kgm/s2
Pressure Pa (N/m2) 1 atm. = 1013.25 mbar
1 Torr = 1.33322 x 102 Pa
1 mbar = 100 Pa
1 PSI = 6900 Pa
Work/energy J (Nm, Ws) 1 J = 107ergs
1 cal. = 4.1868 J
ch01.fm
Power W (J/s) 1 HP = 735.5 W

Temperature ºC = 5/9x(ºF-32)
ºF = (9/5xºC)+32
Figure 2 Conversion table

8 AX-301/501 07.01
2
CHAPTER 2 Safety
2.1 General
For the correct and safe use of this machine, it is essential that all personnel should
follow generally accepted safety procedures in addition to the safety precautions
specified in this manual. All manuals have danger, warning and cautionary
statements throughout the manual where applicable.
Danger, warning and cautionary statements and / or symbols are present on the
machine where applicable.
2.2 Personnel qualification

Operation, adjustment, maintenance and repair of this machine shall be carried out
by qualified and trained personnel only.
The following training levels are defined:
■ Operator level.
■ User or supervisor level.
■ Maintenance or service level.
NOTE: For each level an official Assembléon training is available.
2.3 Basic safety rules

• Do not use the machine in an environment where flammable gasses are
present or where it is extremely dirty.
• When any personal protection equipment (PPE) is mentioned, it should be
used in accordance with the manufacturers instructions.
2.4 Safety compliance

The safety of this machine is based on industry-specific criteria (international
codes, regulations, and standards).
Since this machine is designed for operation in a flow line, full mechanical safety in
accordance with these criteria is only guaranteed when openings of the run-in and
run-out sections are covered by the preceding and succeeding equipment in the
flow line.
This machine should not be operated as a stand-alone machine.
2.5 Danger, warning and caution

■ Danger
Danger indicates an imminently hazardous situation which, if not avoided, will
ch02.fm
result in death or serious injury.

A danger statement is displayed in this manner:
HAZARD IDENTIFICATION
DANGER Hazard consequence.
Hazard avoidance.

07.01 AX-301/501 9
2
■ Warning
Warning indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
A warning statement is displayed in this manner:
WARNING Hazard consequence.
Hazard avoidance.
■ Caution
Caution indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury. It may also be used to alert against unsafe
practices.
A caution statement is displayed in this manner:
CAUTION Hazard consequence.
Hazard avoidance.
2.6 Safety stickers

Pictogram Category Meaning
1 WARNING DANGER, HIGH VOLTAGE
Contact may cause electric shock or burn.
Turn off & lock out system before servicing.
2 WARNING DANGER OF CLAMPING FINGERS

Serious injury to fingers.
Keep hands away from moving parts.
Figure 3 Safety stickers
2
2
2
1 2
ch02.fm
Figure 4 Location of safety stickers

10 AX-301/501 07.01
2
2.7 Safety devices

Machine condition
Hazard
Safety device Detection method after safety device is
protected
activated
1 Safety Hazardous Safety circuit interruption by All moving parts will be
interlock. moving opening any (left or right) stopped and power to
parts. transport cover. servo systems is turned
2 Safety circuit interruption by off.
opening any robot.
3 Safety circuit interruption by
opening any safety cap.
lowering any trolley.
removing any trolley lift cover.
6 Emergency Hazardous Safety circuit interruption by All moving parts will be
stop button. moving pushing the emergency stop stopped and power to
parts. button. servo systems is turned
off.
7 Electrical Hazardous Mains power supply to the All power to the machine
disconnect. voltage. machine interruption by turning is turned off.
the electrical main switch to 'off'.
8 Air Hazardous Main air supply to the machine All air pressure to the
disconnect. air interruption by turning the main machine is turned off,
pressure. air switch to 'off'. and present air
pressure is released
safely.
Figure 5 Safety devices
Locations of safety devices are depicted in figure 6 and figure 7.

ch02.fm

07.01 AX-301/501 11
2
2 3 6
5
1 4
Safety interlock
8
7
6
Figure 6 Location of safety devices
5.5
ch02.fm
6 7
Figure 7 Safety devices, rear
Pull the red emergency stop buttons (6) to release the emergency.
Lock the electrical main switch (7) and the air main switch (8) by a padlock to
avoid unauthorized use.

12 AX-301/501 07.01
2
2.8 Noise levels
Location Noise level
Average sound-pressure level measured at 3 operator ≤ 75 dB(A)
positions at height = 1.6 m and distance = 1 m
Sound pressure at operator’s position ≤ 72 dB(A)
Average environmental noise level during measurement 58 dB(A)
Figure 8 Noise levels
2.9 Emergency contact

In case assistance is needed during an emergency situation, contact the regional
Assembléon organization.
Region Number
Asia +65-62-61-4611
America's 1-800-474-4547
Europe +31-20-5040679
Figure 9 Numbers
2.10 Liability
Assembléon will not be liable for any costs, damages or personal injuries if the
machine is not used according to the safety rules given in this manual.
Instructions written in English are original instructions.
Instructions written in other languages are a translation of the original.
2.11 Recommended tools for working safely

Description Picture Application
1 Stepstool Useful for smaller persons:
reaching inside the machine
or closing robots.
2 Pallet truck Lifting and moving of

heavy modules.
3 Gloves Skin protection during

lubrication.
ch02.fm

07.01 AX-301/501 13
3
CHAPTER 3 Installation
3.1 Moving the machine to the site
3.1.1 Unpacking
NOTE: For some (European) markets this machine can be packed in just foil and
placed on a crate bottom, leading up to a simplified unpacking procedure.
■ Move the crate as close to the site as possible, to minimize the chance on
machine damage during transport of the unpacked machine.
■ Remove the top cover and sides of the crate.
■ Take care for the accessories, stored in front of the machine.
accessories
Figure 10 AX-301/501 in crate
Length Width Height Gross weight

Crate with AX-301 3050 mm 2025 mm 1600 mm 2614 kg
Crate with AX-501 4010 mm 2025 mm 1600 mm 3624 kg
Crate with four feeder trolleys 1200 mm 2360 mm 1150 mm 400 kg
Crate with one feeder trolley 1200 mm 720 mm 1150 mm 100 kg
Figure 11 Crate dimensions and weight

ch03.fm

14 AX-301/501 07.01
3
■ Take away the accessories
Figure 12 Accessories stored in crate
List of accessories:
• Calibration plate.
• Lamp post.
• Base arms.
• Touch screen(s).
• Touch screen stand(s).
• Feeder lane identification strips.
ch03.fm

07.01 AX-301/501 15
3
■ Remove the foil.

■ Inspect the machine for transport damages.
■ Remove the six nuts underneath the mounting brackets.
Use an open-ended spanner (width 36 mm), part of the AX-301/501 installation
tooling, see Figure 13.
36 mm
Figure 13 Mounting nuts
NOTE: Packing materials and transportation brackets are necessary to ship the
machine to another location. Store these materials for future use.
ch03.fm

16 AX-301/501 07.01
3
3.1.2 Machine dimensions and weight excluding trolleys

Sizes without trolleys, but with lamp post and touch screen(s)
(Sizes in millimetres)
Machine Weight
AX-301 2500 kg
AX-501 3480 kg
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07.01 AX-301/501 17
3
3.1.3 Machine dimensions and weight including trolleys

Sizes with trolleys, lamp post and touch screen(s)
(Sizes in millimetres)
2760 (AX-301)
3720 (AX-501)
1907
1069
664
1443 (AX-301)
1706
2403 (AX-501)
560
AX-301 AX-501
Weight incl. trolleys and feeders approx. 3220 kg. approx. 4400 kg.
Average floor loading approx. 2930 N/m2 approx. 2973 N/m2
Floor loading per foot approx. 61x104 N/m2 approx. 83x104 N/m2
ch03.fm

18 AX-301/501 07.01
3
3.1.4 Transportation to the site

■ Use a forklift truck to take the machine from the crate bottom. Use two wooden
beams to avoid damaging of the trolley lift covers, and shifting of the system.
NOTE: The various configurations can influence the centre of mass.
max.
Figure 14 Lifting the machine
Centre of mass, see figure 17 and figure 19.

Transportation Equipment Fork position Equipment specification
Lengthwise Heavy forklift AX-301: Lifting capacity 6000 kg, fork length > 1.6 m.
truck AX-501: Lifting capacity 11000 kg, fork length > 1.6 m.
Use two wooden beams 1.6 m long, 10 x 10 cm
square. Pick at mains supply unit side.
(In case of 2 Pallet cars Use two wooden beams 1.6 m long, 10 x 10 cm
narrow square.
passages)
Installation Special prepared set with foot guide area, for

wheel set transportation by using hand power. A smooth floor
without irregularities is necessary when using the
installation wheel set.
Crosswise Forklift truck AX-301: Forklift truck, lifting capacity 3000 kg.
AX-501: Forklift truck, lifting capacity 4000 kg.
Fork length > 1.4 m.
Use two wooden beams 1.6 m long, 10 x 10 cm
square.
Figure 15 Transportation to the site

ch03.fm
NOTE: Avoid damaging of the covers when using manpower

07.01 AX-301/501 19
3
Push
Figure 16 Overview where to push when using manpower
■ Pre-adjust the feet to the preferred height before lowering the machine at its
final location, see chapter 3.1.8.2 "Levelling procedure". ch03.fm

20 AX-301/501 07.01
3
3.1.5 Positioning the machine in the flow line

Determine the correct X position. The required distance between adjoining
machines is 1 to 3 mm. Place the system on the correct X,Y position in the line.
Use a plumb line for the correct Y position. Check at both sides of the machine.
Use the front transport rail (1) on figure 17 and 19 as reference.
■ AX-301
The listed center of mass is applicable for a complete machine (including base,
robots, trolleys and feeders). The Z-co-ordinate of the center of mass is 700 mm
above the floor. The feet of the machine are represented as circles in figure 17.
Service & maintenance area
2760
1743 508
2295
AX-301
Centre of
1175
1705
mass
135
585
410.5
Front tranport 802 ± 50
560
rail for board
Trolleys
transport
1970
(1).
1443 664
Operator & trolley area
Figure 17 Foot print AX-301
Possible routes
of a cable duct
AX-301
on the floor.
Cable duct size
max. 200 x 100
ch03.fm
Handling area for reconfiguration lift,

needed for robot exchange.
Figure 18 Possible cable duct routes AX-301
■ AX-501

07.01 AX-301/501 21
3
The listed center of mass is applicable for a complete machine (including base,
robots, trolleys and feeders). The Z-co-ordinate of the center of mass is 700 mm
above the floor. The feet of the machine are represented as circles in figure 19.
Service & maintenance area
3720
2703 508
2295
Centre of
mass AX-501
1175
1705
135
526
410.5
Front tranport 1245 ± 70
rail for board
560
transport
(1). Trolleys
1970
2403 664
Operator & trolley area
Figure 19 Foot print AX-501
Possible routes
of a cable duct
AX-501
on the floor.
Cable duct size
max. 200 x 100
Handling area for reconfiguration lift,

needed for robot exchange.
Figure 20 Possible cable duct routes AX-501

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22 AX-301/501 07.01
3
3.1.6 Removing the transport brackets

Remove the brackets securing the robots (Allen key 3mm).
Figure 21 Removing the transport brackets
NOTE: Packing materials and transportation brackets are necessary to ship the
machine to another location. Store these materials for future use.
3.1.7 Mounting of the transport belts

Remove the tie-wraps and mount the 4 belts on front and rear transport rail.
Figure 22 Transport belt

ch03.fm

07.01 AX-301/501 23
3
3.1.8 Levelling the machine

3.1.8.1 Transport height
Adjust the transport height of all AX-301/501 and FCM machines in the factory, if
possible, to the same height within SMEMA range or at least within 13 mm of each
other (Figure 23). This improves exchangeability of FCM-II upgraded trolleys
between several AX-301/501 and FCM machines and prevents re-adjustment of
trolleys.
SMEMA 1 SMEMA 2
Figure 23 Adjustment of transport height
3.1.8.2 Levelling procedure
NOTE: Level the machine while it stands on three feet.

Preferably pre-adjust the feet (1,2,3) before lowering the machine at the
site. This to simplify adjustment of the feet.
7
5
ch03.fm
Figure 24 Levelling the machine
• Check the required transport height and adjust feet 1,2,3 to the corre-
sponding height(7), see Figure 25. Loosen the lock nut (6) and turn the foot

24 AX-301/501 07.01
3
(5). Use the hook wrench present in the installation tool kit.
Turn foot 4 in, so this foot does not affect the levelling of the machine.
SMEMA transport height Foot distance (7)
Measured value (mm) Inch Measured value – 843 mm=
940 mm 37” 97
965 mm 38” 122
Figure 25 Foot adjustment table
• Lower the machine on the three feet. (Foot (4) is still turned in).
• Check the pre-adjusted transport height and correct if necessary.
• Check and correct the alignment (X,Y direction) of the machine.
• Put a spirit level on the transport beam in X direction of the machine and
adjust the level of the machine within 0.5 mm/meter.
The spirit level can be positioned according picture.

Accuracy ± 0.1 mm in both X and Y direction.
In the drawing the positioning of the spirit level is shown. There is no room on the
transport base plate to measure the Y direction. There fore this could be measured
at top of the transport at the position of the Z spindles.
• Repeat the level adjustment in Y direction: 0.0 mm/meter ± 0.1 mm/meter.
• Secure feet 1,2,3 by tightening the lock nut (6). Using the hook wrench.
• Adjust and secure the remaining foot and make sure the weight of the
machine is carried by all four feet to prevent imbalance.
ch03.fm

07.01 AX-301/501 25
3
3.1.9 Seismic protection

For protection during an earth quake the steel feet of the machine can be anchored
to the floor. The exact location of the feet is shown in figure 17 (AX-301) and figure
19 (AX-501).
13 ± 0.5
10 ± 0.5 37.5 ± 0.5
Figure 26 Foot
Anchoring the machine to the floor can be done in two different ways.
■ Anchoring the machine to the floor, after the machine is placed in line
After the definite position of the system is determined (and the system is levelled
and placed in line with the previous and next system in the line), take the
following steps:
• Mark the holes in the feet with an e.g. felt-tip marker on the floor.
• Lift the machine and move it away to get access to the spots where the holes
need to be drilled.
• Drill the required holes and place the floor anchors or cotter bolts.
• Lift the machine again and place it over the floor anchors.
• Check the levelling of the machine.
• Fix the feet to the floor by tightening the blots or nuts, depending on chosen
floor anchor.
■ Anchoring the machine to the floor, using the foot print
After the definite position of the system is determined (by using the foot print),
take the following steps:
• Define the position of the feet by referring to figure 17 (AX-301) or figure 19
(AX-501).
• Mark the positions of the four feet on the floor with e.g. a felt tip marker.
• Drill the holes and place the selected cutter bolts or nuts.
• Place the machine and place the feet on the marked position.
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• Level the machine.

• Fix the machine to the floor by using the nuts or bolts depending on the used
floor anchor.

26 AX-301/501 07.01
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3.2 Mounting the accessories

3.2.1 Mounting the lamp post
Guide the lamp post cable through the hole on top of the run-in section.
Connect the cable.
Figure 27 Mounting of the lamp post
3.2.2 Mounting the screen stand(s)
Figure 28 Mounting the screen stand

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07.01 AX-301/501 27
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3.3 Mounting the touch screen(s)

Unpack the touch screen(s), and mount it on the stand.
Connect the mains cable to the touch screen(s):
• Mains
• VGA
• RS232
Figure 29 Mounting the touch screen
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28 AX-301/501 07.01
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3.4 Feeding
3.4.1 Installing feeder lane identification strips
Unpack the feeder lane identification strips and mount them on the base.
Each identification strip is secured with 4 bolts (A).
A A A A
B
Figure 30 Feeder lane identification strip
Note that each identification strip is marked with a trolley slot number (B).
Make sure these numbers correspond to the actual position of the strip on the base.
The identification strips for trolley slot 4 and 5 only apply in case of a base with 5
trolley positions.
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07.01 AX-301/501 29
3
3.4.2 A-series trolley

3.4.2.1 Unpacking A-series feeder trolley crate
Tbd.
3.4.2.2 A-series trolley, height adjustment
NOTE: This procedure applies when changing the board transport height from
SMEMA range to JIS range, or vice versa.
HEAVY OBJECT (± 103 kg)
CAUTION Improper lifting method may cause injury.
Use 3 persons to lift the object.
1. Prerequisites
• Remove both side plates (1) (2x12 cross head
1 1
screws).
• Remove the cover strip (2) (3 Allen bolts).
• Remove the cover plate (3) (2 Allen bolts). 4
• Remove the two small cover plates (4) (2x1
Allen bolt).
3
2. Put the trolley to the correct height

• Lift the trolley frame (5), using 3 persons.
• Unscrew the trolley frame from the trolley 5
wheel base (6) (2 Allen screws at each side).
• Lower or lift the trolley frame to the correct
height. 6
• Fasten the trolley frame to the trolley wheel
base (6) (2 Allen screws at each side). 6
SMEMA
JIS
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30 AX-301/501 07.01
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3. Mount both side plates

• Place both side plates (2x12 cross head screws)
The screws have 3 different lengths (see 5
picture):
Large: location 7 and 8.
Medium: location 9 and 10. 6
Small: all other locations.
6
7 8 9 10
4. Finalize
• Place the two small cover plates (4) (2x1 Allen
4
bolt) back according picture.
JIS SMEMA
• Place the cover plate (3) back (2 Allen bolts).

• Place the cover strip (2) back (3 Allen bolts). 4
4
3
2
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07.01 AX-301/501 31
3
3.4.3 FCM feeder trolleys

3.4.3.1 Installing FCM feeder trolleys
To make FCM feeder trolleys suitable for the AX-301/501, a feeder trolley upgrade
kit PA 2631/50 is available, including 3 base arms, 5 feeder lane identification
strips, and 6 trolley upgrade sets. For an AX-501, two kits are needed.
3.4.3.2 Mounting the base arms
Mount the base arms underneath the base using the 4 bolts.
Tightening torque 16 Nm.
Figure 31 Base arm
3.4.3.3 Unpacking FCM feeder trolley crate

Refer to Appendix A, Packing / Unpacking Instructions Trolley FCM.
NOTE: Preserve the crate for eventual future movements.

3.4.3.4 Upgrading the FCM feeder trolley for use on the AX-301/501
Use PA 2631/50 with enclosed instructions.
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32 AX-301/501 07.01
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3.4.3.5 FCM feeder trolley, height adjustment

If a trolley is used on several machines in a factory they might have to be
readjusted if the difference in height between the highest and the lowest machine
exceeds 13 mm.
If a machine is adjusted on the lower end of the SMEMA range then the feeder
trolley interface can collide with the base of the machine. If a machine is adjusted
at the upper end of the SMEMA range then the inlet of the trolley can collide with
the base arm of the machine.
Exchangeability of feeder trolleys between several machines is best when:
• The floor is according specification, see Pre Installation Manual
• The FCM feeder trolley is correct adjusted, see procedure below:
1. Trolley height definition

• Define the highest height (A1,A2....) between
the floor and the top of the base arms of all
machines in the factory.
SMEMA 1
A1
SMEMA 2
A2
2. Release trolley adjustment screws

• Turn the trolley over and loosen screws 1 and 2
a bit, which lock screws 3 and 4 (see step 3).
• Place the trolley upright.
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07.01 AX-301/501 33
3
3. Adjust trolley height

• Adjust the height of the trolley to the highest
“A” (see step 1) by turning screw 3 with the
trolley removed from the machine. Add 4 mm.
∗ Raise trolley: turn screw 3 clockwise.
∗ Lower trolley: turn screw 3 counter
clockwise.
Ball
A+4mm
4. Level trolley at the machine

• Move the trolley towards the machine so that
the ball (see step 3)of the trolley inlet touches
the base arm.
Note: Do NOT lift the trolley.
• Level the trolley by adjusting screw 4 (see step
3). The trolley is levelled when the distance
1+20 mm
between trolley interface plate and front-rail is
1+2mm.
Note: The trolley height does NOT affect the pick
position. The pick position is fixed when the
trolley is lifted.
5. Finalize
• Turn the trolley over again and re-tighten screws 1 and 2 (see step 2).
• Place and lift the trolley and check:
∗ if the wheels closest to the machine are free from the ground.
∗ if the trolley step (see step 3) can be lifted when the trolley is in
the upper position.
• If not, readjust the machine and trolley according to the procedures.
3.5 Unpacking other crates

Remove the cover and sides of the crates and inspect the accessories for transport
damages.
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34 AX-301/501 07.01
4
CHAPTER 4 Connections to services

4.1 Location of connection points
A
4 4
Rear view
5
3
C 2 B
Top view
C B
Figure 32 Connection points
Item to connect Leaving the machine at location:

1 Mains supply unit A or B
2 Air supply unit B
3 Network connection C
4 SMEMA C and B
5 External emergency circuit. B
Figure 33 Connection points

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07.01 AX-301/501 35
4
4.2 Power supply

4.2.1 Precautions
NOTE: Connecting to the mains should only be carried out by competent qualified
personnel.
1. Ensure that the mains supply to the system is inactive by removing the relevant
factory fuses.
2. Set the electrical main switch (1) to OFF (at the back of the machine, see Figure
34 and lock with a padlock .
1
Figure 34 Main switch
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36 AX-301/501 07.01
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4.2.2 Adapting mains voltage

DANGER, HIGH VOLTAGE
WARNING Contact may cause electric shock or burn.
Turn off and lock out system as described in the safety chapter before servicing.
Adapt the interconnections on the terminal block (of the transformer) to the
nominal local supply voltage, see figure 35.
Figure 35 Possible interconnection settings for different supply voltages

480V
400V
230V
208V
0V
0V
480V
400V
230V
208V
0V
0V
480V
400V
230V
208V
0V
0V
480V
480V
400V
230V
208V
0V
0V
480V
400V
230V
208V
0V
0V
480V
400V
230V
208V
0V
0V
400V
480V
400V
230V
208V
0V
0V
480V
400V
230V
208V
0V
0V
480V
400V
230V
208V
0V
0V
230V
480V
400V
230V
208V
0V
0V
480V
400V
230V
208V
0V
0V
480V
400V
230V
208V
0V
0V
208V
Figure 36 Adapting mains voltage

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07.01 AX-301/501 37
4
4.2.3 Connecting the machine to the power supply

DANGER, HIGH VOLTAGE
Turn off and lock out system as described in the safety chapter before servicing.
The mains cable must be routed through a separate metal duct or pipe.
This duct or pipe must be grounded, to avoid EMI (electromagnetic interference)
problems. For safety reasons it is not allowed to route signal cables through this
duct or pipe configurations.
AX-301 AX-501
Voltage configuration 3-phases and ground
Frequency 50 - 60 Hz
Frequency stability ± 2%
Maximum power consumption 5 kVA 7 kVA
Nominal mains voltage ± 10%
(between phases) 208 230 400 480 Volts 208 230 400 480 Volts
Corresponding full load current 14 13 7 6 Amp. 19 18 10 8 Amp.
Corresponding external fuse 16 16 16 16 Amp. 20 20 16 16 Amp.
External fuse type Slow-blow “D-type”
Inrush current ≤ 150 Amp. (5 msec)
Power factor ≥ 0.85
Line voltage fluctuation According to EN 60204 and IEC 60204:
Voltage
Steady state voltage: 0.9 ... 1.1 of nominal voltage.
Frequency
0.99 ... 1.01 of nominal frequency continuously;
0.98 ... 1.02 short time.
Harmonics
Harmonic distortion not to exceed 10 % of the total r.m.s. voltage
between live conductors for the sum of the second through to the fifth
harmonic. An additional 2 % of the total r.m.s. voltage between live
conductors for the sum of the sixth through to the 30th harmonic is
permissible.
Voltage unbalance
Neither the voltage of the negative sequence component nor the
voltage of the zero sequence component in three-phase supplies
shall exceed 2 % of the positive sequence component.
Voltage interruption
Supply interrupted or at zero voltage for not more than 3 ms at any
random time in the supply cycle. There shall be more than 1 s
between successive interruptions.
Voltage dips
Voltage dips shall not exceed 20 % of the peak voltage of the supply
for more than one cycle. There shall be more than 1 s between
successive dips.
Mains cable Connection to facility power supply system shall be made by a 4-core
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cable.
type and cross-section according to appropriate international standard
or local regulatory requirement.
E.g. AWG 12.

38 AX-301/501 07.01
4
■ Grounding
Connection The machine must be connected to factory grounding

via the mains cable
Earth resistance < 0.1 Ohm
1. Prerequisites
• Turn off and lock factory fuses that supply power to the machine.
• Turn main switch of the machine to ‘off’ position and lock it with a
padlock
2. Remove panel
• Remove panel
• Remove the 4 bolts and take away the panel.
• Put the panel aside.
3. Remove the electrical main switch

assembly
• Remove the two bolts and take the assembly
off (this can only be done when the main
switch is in the ‘off’ position).
4. The power cable can be routed:

• from underneath, see step 5a.
• from above, see step 6b.
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07.01 AX-301/501 39
4
5. Route the power cable, from underneath

• Mount the power cable in the brackets.
6. Route the power cable, from above

• Remove the cap and guide the power cable to
the electrical main switch.
Note: This hole is only to be used for the power
cable.
• Mount the power cable in the bracket.
7. Connecting the power cable

• Mount the power cable:
Power cable Machine

Ground Earth stud*
Phase 1 X1.L1
Phase 2 X1.L2
Phase 3 X1.L3
∗ Mount the cable eye of the ground cable

between the two washers.
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40 AX-301/501 07.01
4
8. Finalize
• Finger-tight the electrical main switch
assembly.
• Mount the factory fuses.
• Check the mains.
See 4.2.4.
• Mount the panel flush with the machine.
• Push the electrical main switch assembly
against the panel and tighten it.
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07.01 AX-301/501 41
4
4.2.4 Switching on and checking the mains

DANGER, HIGH VOLTAGE PRESENT DURING TEST
Avoid contact with any 'live' circuits or use proper insulated tools.
1. Power supply check on F10

• Check if the circuit breaker in the mains
supply unit is switched off.
• Switch on the electrical main switch.
• Check the voltage (230V ± 10%) on F10
between each phase and ground.
• f not OK, refer to 4.2.2.
230 Volt ± 10%
2. Switching on
• Switch on circuit breaker F10 in the mains
supply unit.
• Set the main switch to on.
• LED 1,2 and 4 must be on.
1
Note: The phase-detection LED (3) on the phase
2
guard relay (K1) must be off, indicating that
the three phases are present. 3
• If the LED (3) is on, interchange two phases 4
on the connectors L1 to L3 at the main
switch.
See 4.2.3 step 5.
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42 AX-301/501 07.01
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4.3 Connecting the machine to an external emergency circuit

The machine can be connected to the emergency circuit of adjacent equipment.
Depending on the required behaviour of the machine it can be connected via the
'slave' input or the 'master' output in the mains supply unit. The circuit that is
connected must consist of one or more potential free contacts.
X5
Figure 37 External emergency circuit connections in the mains supply unit
■ Slave setting
By connecting an external emergency circuit on X5, connections 3 and 4 (‘slave’
input), the machine is set as 'slave'. The external emergency circuit will interrupt
the internal safety circuit by acting as an extra safety switch.
External Internal safety

emergency circuit switch
X5 3-4
K2
Figure 38 External emergency circuit, slave setting
■ Master setting
By connecting an external emergency circuit on X5, connections 1 and 2 (‘master’
output), the machine is set as 'master'. The external safety circuit is interrupted by
a switch, operated by the internal emergency relay (K2) when activated.
Internal External
emergency relay emergency circuit
X5 1-2
K2
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Figure 39 External emergency circuit, master setting

07.01 AX-301/501 43
4
4.3.1 Air supply

Pressure 6-8 Bar
Air consumption AX-301 AX-501
150 Nl/min. (Tape feeding only) 230 Nl/min. (Tape feeding only)
185 Nl/min. (Tape & bulk feeding) 290 Nl/min. (Tape & bulk feeding)
Max. oil content < 0.1 mg/m3
Dew point <2°C at 7 bar
<4°C at 7.2 bar
Dust particles size < 10 µm
NOTE: The specified pressure must be maintained at maximum flow.

Compressed air supply can be delivered by metal pipes or hoses.
To prevent transfer of vibration, it is recommended to connect a piece of flexible
hose between the fixed pipe and the system.
1. Connecting the air supply

• On the location underneath the machine, as
indicated on figure 32, fit a hose pillar or
coupling to the G1/4 coupling.
• Connect the hose to the hose pillar or
coupling.
2. Turn on the compressed air supply

3 4 2 1
• Open the air main switch (1).
• Check/adjust the air pressure on the digital
pressure switch (4).
• Adjust the air pressure by means of the
5.9
pressure regulator (2), to 5.9 bar.

Unlock the knob of the regulator (2) by
pulling it downwards.
5.9 Bar
• When using bulk feeders: open the air switch
(3).
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44 AX-301/501 07.01
5
CHAPTER 5 Communication
5.1 SMEMA
5.1.1 interface connections
To let the machine work with adjacent equipment in a flow line, it complies with
the SMEMA standards.
To sequence boards properly from machine to machine two signal lines are used:
“Busy” and “Board available”.
5.1.1.1 SMEMA, electrical interface cable
One SMEMA interface cable (length 2000 mm) is supplied with the machine.
Cable specifications:
• 4 wires.
• Cable connector for both ends consisting of the following parts per connector:
• CPC 14p connector pin: AMP 206044-1
• 5-pin contacts: AMP 202236-1
• cable clamp: AMP 206070-1
5.1.1.2 SMEMA, electrical interface, connection diagram

Direction of the boards
Upstream AX-301/501 Downstream
24V 1 1 24V 1 1
Not busy Not busy

2 2 BUSY 2 2 BUSY
Board Board
Available 3 3 24V Available 3 3 24V
Board
Board Available Available
4 4 4 4
5.1.1.3 SMEMA, electrical interface, features
1 2 3
4 5 6 7
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8 9 10 11
12 13 14
PIN Connector upstream machine Connector downstream machine

07.01 AX-301/501 45
5
1 24V from upstream machine 24V to downstream machine

1-2 AX is: Downstream machine is:
NOT BUSY1 - 2 Closed NOT BUSY: 1 - 2 Closed
BUSY1 - 2 Open BUSY 1 - 2 Open
3 24V to upstream machine 24V from downstream machine
3-4 Upstream machine has: AX has:
BOARD AVAILABLE3 - 4 Closed BOARD AVAILABLE3 - 4 Closed
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46 AX-301/501 07.01
5
5.1.2 Network configuration (internally), setting

To verify or change the internal network settings start the network configuration
tool on the windows desktop.
NOTE: DO NOT use the standard Windows ‘settings’-‘control panel’-‘network connections’

option to change the parameters for the internal network. This will result in a non-
working machine because there is a relationship between these settings and the
machines database.
The network configuration tool takes care of this relationship.
The network configuration tool is also part of the installation software for the
application software.
1. Prerequisites
• Ask the local network administrator for:
∗ The used IP-address range used for the external network.
∗ The desired computer name of the machine. This information is
necessary to prevent a conflict between internal and external
addressing.
2. Procedure
• Log on as 'installer', password 'installer'.
• Close all programs on the machine.
• Open the short-cut on the desktop to start the network configuration
tool.
• Follow the wizard instructions on the screen.
5.1.3 Network connection (externally), setting

To connect the machine to an external network:
1. The machine's internal network IP address must not conflict with the external
network IP address. Also the computer name has to be verified, and changed if
necessary, see 5.1.2.
2. The external network adaptor needs to be enabled, see 5.1.4.
3. Optional: Set a pre-defined network location, see 5.1.5
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07.01 AX-301/501 47
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5.1.4 External network adaptor, enabling
1. Prerequisites
∗ DHCP server used, or
∗ IP address, subnet mask and (if the machine is connected to a
remote network) default gateway
2. Procedure
• Log on as 'Administrator' (default password
'Administrator').
• Select ' Start'-'Settings'-'Network Connections'
• Right-click 'Local Area Connection' and select
'Enable'.
Note: Do not change the settings of the 'AX Internal

Network'
• Right-click 'Local Area Connection' and select

'Properties'.
• Select 'Internet Protocol (TCP/IP)' and select
'Properties'.
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48 AX-301/501 07.01
5
• Enter the correct IP address, subnet mask for

the customer's network and default gateway (if
the machine is connected to a remote
network)
(In case of DHCP select 'Obtain an IP address
automatically'.)
• Select OK to accept the changes.
3. Connecting the LAN Ethernet cable

• Connect the LAN ethernet cable to the external
network connection (1) at the rear side of the
base.
If this is not provided: 2
• Connect the LAN ethernet cable to the external
ethernet connector (2), at the back of the
system controller.
Use category 5 (UTP) cable with RJ45 1
connector.
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07.01 AX-301/501 49
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5.1.5 Set pre-defined network location
1. Prerequisites
∗ Network path to the desired predefined network location. This
location will be used as the archive for placement programs etc.
Note: All accounts as described in Service Manual ‘A5.3.1 Logon in operating
system’ need to have read and write access to the network location.
2. Procedure
• Log on as 'admin', see Service Manual, chapter A5
• Mount the network location using common windows functionality.
• On the desktop, select 'SetArchiveLocation'.
• Select '…'.
• Go to the desired archive location.
• Select 'OK'.
• Select 'OK'.
5.1.6
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50 AX-301/501 07.01
6
CHAPTER 6 Options
6.1 Board identification
6.1.1 Board identification, installing
NOTE: The use of barcode identification is optional, so only perform these steps if
applicable.
Reference:
Start i 1.Preparation
It does not make
sense to start with
1 a next step if the 2.Setup (configure) barcode scanner
Collect information previous step fails
3.Connect scanner to laptop and check
2 4.Connect scanner to machine

Setup (configure)
barcode scanner 5.Check on transport controller
Settings in the
scanner, laptop 6.Configure board identification on
3 connection,
machine GUI
Connect scanner hyperterminal
to laptop and setup or barcode
check format are not 7. See User reference manual § A5. Board
correct identification and barcode triggered
change over, setup.
Raw barcode
No
read correctly?
Yes
i Connect scanner
4
Connection to TC
to machine EPC X12 or
hyperterminal
setup is not correct
5
Check on
transport controller
Raw barcode No
read correctly?
Yes
i Configure board
6 Board
identification on identification not
machine GUI configured
correctly
Raw barcode
No
read correctly?
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Yes
i 7
Configure barcode
Finish

50 AX-301/501 07.01
6
1. Preparation
Needed for a correct installation of board identification:
• Laptop with HyperTerminal (windows feature) and serial RS 232 port (for testing).
• Barcode scanner (obtain locally) with optional trigger sensor (depending on the type of
barcode scanner) and connection cables.
• Manual of the barcode scanner to be able to configure the output of the scanner.
• Barcode scanner stand.
• Barcode type used by the customer (e.g. ‘code 39’).
• Raw barcodes used by the customer (e.g. ‘@12(2)3345-7756+89’).
• The part of the raw barcode that is used for board identification (e.g. ‘3345’, the part of the
raw barcode after ‘)’ and before ‘-‘).
2. Setup (configure) barcode scanner

Needed for a correct barcode scanner configuration:
• Barcode scanner configuration tool.
Most of the times the manufacturer of the scanner provides a software tool that is able
to load the configuration file to the scanner. These tools can also help with testing the
scanner on output of the raw barcode string.
• Set the correct output parameters of the scanner that the machine is able to read:
∗ Baudrate: 9600 kb/s
∗ Number of bits: 7
∗ Stopbit: 1
∗ Parity bit: none
∗ X-on/X-off: off
Make sure all information is available.
3. Connect scanner to laptop and check

A small test is necessary to check if the scanner reads the barcode
correctly and sends it through the RS232 connection.
Required for this test is the ‘HyperTerminal’ application and a serial
RS232 port.
HyperTerminal is standard on every windows operated laptop, the RS232
port is not.
The steps are: Barcode Connection Laptop

RS232
• Connect the scanner to the laptop. For example scanner module COM
a scanner with trigger sensor: (optional) port
• Start up the laptop and on the windows task bar
select 'Start'-'Programs'-'Accessories'-
'Communications'-'HyperTerminal'.
Trigger
sensor
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(optional) Power

07.01 AX-301/501 51
6
• Select 'File' and 'New connection'.

• Give a name to the new connection.
• Select 'OK'. The 'Connect To' screen will appear.

• In the 'Connect using' field select the correct
COM port.
• Select 'OK'. The ‘COMx Properties’ screen will

appear.
• Set the port settings as shown in picture.
• Select ‘Apply'.
• Select 'OK'.
• Read the barcode with the barcode scanner.
• Check that HyperTerminal receives the exact raw
barcode string that was sent by the scanner.
∗ If no: check the scanner setup, laptop
connection, HyperTerminal setup and the
barcode format.
∗ If yes: go to the next step.
• Example: Barcode is
(0PCMCIA-10) the result on screen must be as

shown in the picture (last line).
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52 AX-301/501 07.01
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4. Connect scanner to machine Barcode Connection Machine
RS232
scanner module BTCO
For left to right transport direction: (optional) connector
• Mount the barcode scanner (if applicable
including trigger sensor) on the upstream
equipment. (Left-front side of the machine)
The barcode must be read before the ‘run-in Trigger TC.EPC.X12
SMEMA sensor’ of the machine is triggered. sensor Transport
(optional) Power controller
• Connect the barcode scanner.

∗ Power down the machine.
∗ Open the front-left door of the base and
connect the RS-232 communication cable of
the barcode scanner to the 'BTCO' connector
that is located above the transport
controller.
• Connect the cable ‘TC.EPC.X12 SO8/01' (that is
lying next to the transport controller) to
'EPC.X12' on the transport controller (see
C5.4.1.1 Transport controller, connections).
Note: By default the cable from the right side of the
machine with the same label is connected.
Disconnect but not remove this cable.
Machine Connection Barcode

For right to left transport direction:
RS232
BTCO module scanner

• Mount the barcode scanner (if applicable
connector (optional)
including trigger sensor) on the upstream
equipment. (Right side of the machine)
The barcode must be read before the ‘run-in
SMEMA sensor’ of the machine is triggered. TC.EPC.X12 Trigger
Transport sensor
controller Power (optional)
• Connect the barcode scanner.

∗ Power down the machine.
∗ Open the front-right door of the base and
connect the RS-232 communication cable of
the barcode scanner to the 'BTCO' connector
that is located above the system controller.
• Connect the cable ‘TC.EPC.X12 SO8/01' to
'EPC.X12' on the transport controller (see
C5.4.1.1 Transport controller, connections).
Note: by default the cable is already connected.
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5. Check on transport controller

• Power-up the machine.
• Log in as ‘Administrator’, see A5.3.1.1 Logon in operating system, do not start the application.

07.01 AX-301/501 53
6
• Start the DHCP server and make sure the placement controllers and
transport controller are started:
∗ Go to the control panel. Select: 'start' menu – 'Settings' – 'Control
panel' – 'Administrative tools' - 'Services'.
∗ Check if the status of the 'AXDhcpserver' is 'Started'. Start if necessary.
Note: Wait 2 minutes before continuing with the next step. This gives the
controllers time to boot after the 'AXDhcpserver' was just started.
∗ Start the communication with the transport controller.
∗ Open a 'virtual network connection' to the appropriate controller:
Select 'VNC viewer' via the 'Start' menu / 'programs'.
• Type in ‘TC’ in the VNC window and select ‘OK’.
• Type in Password 'a' and select ‘OK’.
• A VNC window will open.
• Use HyperTerminal (see step 3) and check the connection from the
barcode scanner towards the transport controller.
• Check that HyperTerminal on the transport controller receives the
exact raw barcode string that was sent by the scanner.
∗ If no; check the transport controller connection and HyperTerminal setup.
∗ If yes; go to the next step.
6. Configure board identification on machine GUI

■ Configure board identification on the machine.
• Power up the machine.
• Select 'Setup' - 'Machine config'.
• At 'Board identification', select 'Enable'.
• At 'Barcode configuration', enter the correct values for:
∗ 'Header'. (If the barcode scanner suppresses the header, leave empty)
∗ 'Trailer'.
∗ 'No read string'.
∗ 'Time out period' (1000 [ms] is a value that works with most scanners).
∗ 'Characters to strip' For additional information, see paragraph hereafter 'Barcode interpreting'.
■ Test barcode identification.
• Select 'Maintenance' - 'Machine control' - 'Board identification'.
• Trigger the scanner to read the barcode on a board.
• Check the received raw and stripped barcode on the screen.
■ Define mask configuration.
• Select 'Setup' - 'Setup functions' - 'Board identification'.
• At 'Mask configuration', enter the correct values for:
• 'Character'.
• 'Mask'.
• For additional information, see paragraph hereafter ‘Barcode, masking’.
■ Test barcode identification on barcode mask.
• Select 'Maintenance' - 'Machine control' - 'Board identification'.
• Trigger the scanner to read the barcode on a board.
ch06.fm
• Check the received masked barcode on the screen.

■ Finalize barcode identification setup.
• Use the procedure as described in the user reference manual, part application, chapter
board identification setup.

54 AX-301/501 07.01
7
CHAPTER 7 Software installation

No software installation is necessary during installation. The machine is factory
installed with the latest application software.
NOTE: To verify the software version installed, consult the software package as
shipped with the machine.
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07.01 AX-301/501 55
8
CHAPTER 8 Final testing

8.1 Transfer speed, adapting
Adjust the transfer speed of the run-out to the speed of the flow line.
Select ‘Setup’ - ‘Machine config.’ - ‘Transport’ and enter the correct run-out transfer
speed.
8.2 Putting into operation

See operating manual for putting the machine into operation.
Calibration of the machine is recommended.
When running production in local mode however, no calibration is necessary.
See Service Manual for calibration procedure.
8.3 Running in simulation mode

Running in simulation mode is a functional test without using boards and
components.
• Load the placement program.
• Select ‘Setup’ - ‘Machine config.’ - ‘General’ and enter the desired machine
mode.
• Let the system run for a couple of minutes.
8.4 Running the acceptance test

The final phase of the installation procedure is the completion of the “Customer
Acceptance Test” or the “Standard Acceptance Test” as agreed in the sales contract.
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56 AX-301/501 07.01
9
CHAPTER 9 Relocating the machine

9.1 Introduction
This chapter is meant to inform the customer how an installed machine in a flow
line can be removed out of the flow line for re-installation to another location,
without damaging it.
Directives will be given for a smooth re-installation such as cautions and warnings
to take note of if a machine already installed.
In case of doubt, your Assembléon Customer Services representative will be
available for professional advice.
9.2 Preparing machine for transport
NOTE: Never transport the machine without first reading these preparation steps.
1. Prerequisites
• Set the transport width to the minimum value.
• Remove the trolleys.
• Disconnect the power supply to the machine.
• Disconnect the air connection to the machine.
• Disconnect the machine from the preceding and/or succeeding
system(s) and LAN.
• Remove feeder slot identification trips, see 3.4.1 Installing feeder lane
identification strips
• Remove the floor fixation, see 3.1.9 Seismic protection.
• If the transport securities are no longer on site, they can be ordered,
9.6 Transport material.
2. Secure placement heads
• Secure placement head:
• Remove any toolbit from the placement head.
• Insert the black plug (1) into the placement
head.
• Wrap the transport strap (2) around the
placement head to hold the black plug in place. 2
1
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07.01 AX-301/501 57
9
3. Mount transport bracket on the placement

robot 1
• Open the placement robots and mount the

transport bracket on the X-slide.
Note: Be aware that the transport bracket hooks
behind the black plastic bearing (1).
1
4. Secure the placement robots

• Secure the transport bracket at the front (1) of
the robot.
Note: When the bracket is placed correctly according
step 3, it should be secured without tension on
the robot.
• Close the placement robot, and fasten the
transport bracket on the front transport rail
(2).
Note: 1 2
5. Secure placement controllers

• Check that all placement controllers are
secured in the base with two bolts (1).
2
1 1
6. Slacken the transport belts
• Slacken the 4 transport belts (1) and attach (2)
them to the transport rail to ensure that the
belts stay on the wheels at the transport belt
motor
1
Note: When storing the machine for a longer period
of time or transportation of the machine to
another location, These belts relax under
higher temperatures (as can occur in
warehouses). 2
ch09.fm
9.3 Machine transportation

For external transport: pack the machine, packaging material see 9.6.

58 AX-301/501 07.01
9
9.4 Site preparation

Make sure the new site is in accordance with the pre-installation manual.
9.5 Installation
To install the machine correctly, use the information described in CHAPTERS 3 to 8
of this manual, being an installation guide for a basic machine, possibly with built-
in options.
9.6 Transport material

A transport material kit can be ordered.
If the machine should be moved externally, sets with packaging material can be
ordered.
ch09.fm

07.01 AX-301/501 59
9
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60 AX-301/501 07.01
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07.09
4022 593 52151
1 2 3
J K L M N
40 mm
M10× 30 mm
50 mm
4×
AX-301/501
36× 4×
100 mm
H
2×
H
Installation Manual
10×
C A C
G
G A
B (2×)
F
M
E }(4×)
N
D
I B
I B
A
4 5 6 7
J (2×) J (4×) L(12×)
I
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(2×) F
E H G H
C G
CHAPTER 10 Packing / unpacking instructions trolley FCM
L
(3×) L (9×)
61
10
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62 AX-301/501 07.09

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Document . . . . . . . . . . . . . . . . . . Installation Manual AX-301/501

4022 593 52151 Installation Manual

3.4.3.1 Installing FCM feeder trolleys . . . . . . . . . . . . . 32

CHAPTER 4 Connections to services . . . . . . . . . . . . . . . . . . . . . . . . 35

CHAPTER 7 Software installation . . . . . . . . . . . . . . . . . . . . . . . . . . 55

CHAPTER 9 Relocating the machine . . . . . . . . . . . . . . . . . . . . . . . . 57

Installation Manual 4022 593 52151

9.4 Site preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

CHAPTER 10 Packing / unpacking instructions trolley FCM . . . . . . . . 61

4022 593 52151 Installation Manual

4022 593 52151 Installation Manual

NOTE: Engineers are expected to be informed about the content of:

4022 593 52151 Installation Manual

1.1 Estimated installation time

1.2 Useful conversions

Power W (J/s) 1 HP = 735.5 W

Figure 2 Conversion table

Installation Manual 4022 593 52151

2.2 Personnel qualification

NOTE: For each level an official Assembléon training is available.

2.3 Basic safety rules

2.4 Safety compliance

2.5 Danger, warning and caution

result in death or serious injury.

4022 593 52151 Installation Manual

2.6 Safety stickers

2 WARNING DANGER OF CLAMPING FINGERS

Figure 3 Safety stickers

Figure 4 Location of safety stickers

Installation Manual 4022 593 52151

2.7 Safety devices

Figure 5 Safety devices

Locations of safety devices are depicted in figure 6 and figure 7.

4022 593 52151 Installation Manual

Figure 6 Location of safety devices

Installation Manual 4022 593 52151

Figure 8 Noise levels

2.9 Emergency contact

2.11 Recommended tools for working safely

2 Pallet truck Lifting and moving of

3 Gloves Skin protection during

4022 593 52151 Installation Manual

Figure 10 AX-301/501 in crate

Length Width Height Gross weight

Figure 11 Crate dimensions and weight

Installation Manual 4022 593 52151

■ Take away the accessories

Figure 12 Accessories stored in crate

4022 593 52151 Installation Manual

■ Remove the foil.

Figure 13 Mounting nuts

Installation Manual 4022 593 52151

3.1.2 Machine dimensions and weight excluding trolleys

4022 593 52151 Installation Manual

3.1.3 Machine dimensions and weight including trolleys

Installation Manual 4022 593 52151

3.1.4 Transportation to the site

NOTE: The various configurations can influence the centre of mass.