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Fuji IP-II Troubleshooting

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Fuji IP-II Troubleshooting | 12 June, 2014

Hello Everyone,

I will try to keep this short and sweet while explaining the best I can. I have a Fuji IP-II that I have been working on trying to correct some issues that the previous operator caused.

Over the last month or so I have been working to bring our MTU back online so we can use it again. Most of the issue has been with the Z1 placement head. The MTU is working fine. Since starting on the repair, I have replaced the shaft, rebuilt the nozzle chuck, replaced the vac lines on the head and rewrote the proper.

You would thing that would fix all my issues right? Well here is what has stumped me. When I tell the machine to pick up the nozzle on that head, it will move to the position, scan, then lower down to pick the nozzle. Half way down however when it should be releasing the chuck to attach to the nozzle, the machine locks up errors out and e-stops.

I have gone though everything I can think of and I am just at a loss. Has anyone else had this issue? Is there anything that might help me to solve this? I am leaning towards an encoder error, but I am just not sure.

Any help would be appreciated. If you need any more info about the issue, I will happily tell you anything you need.

Thank all of you in advance!

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Fuji IP-II Troubleshooting | 12 June, 2014


Red army does not immediately make me want to help, anyway.

What is the exact error displayed? There is a chuck open/closed sensor, if not made at the right time it will e-stop with some error that I don't recall. I assume this is on H1. Let me know.

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Fuji IP-II Troubleshooting | 13 June, 2014

Haha, I can assure you sir I cannot see Russia from my house. Will admit that I do have some form of connection with the USAF.

The error that comes up is a cycle alarm and a chuck set. I have attached a reference image of the machine screen.

I also have a video of what happens when the nozzle change command is given if that would help.


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Fuji IP-II Troubleshooting | 13 June, 2014

There is a small cylindrical sensor on the air cylinder that that actuates the chuck. I can't remember if there are one or two. Its (they) are about 4mm x 20mm and I think (it) they have a signal light. Make sure it is mechanically working properly using the I/O outputs, then check the inputs in the I/O to verify the sensor operation. You are in Ohio, aren,t you.

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Fuji IP-II Troubleshooting | 13 June, 2014

That little cylinder comes apart. Sometimes they get gummed up and need to be taken apart and cleaned.If it does not make the sensor in time, it pops an error up.

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Fuji IP-II Troubleshooting | 10 July, 2014

Ok so here is where I am with everything.

I pulled the cylinder and cleaned it out. Didn't find anything out of the ordinary inside. I set everything back up and tested it. Still nothing.

I went into the I/O map and tracked down that input, I then took a magnet and ran it across the sensor and it registered nothing from the sensor. I went over to the other head and did the same thing and it changed state.

Once I knew that I powered down and took a volt meter and ohmed everything out. I have no breaks all the way down to the VME board. Good signal and the sensor works when the meter is connected and you hit it with a magnet.

So here I am now, I am guessing that its a problem in the board itself? My question now is there a diagram that shows how the DIP switches are supposed to be set so I can verify those? And does anyone have any other suggestions?

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Fuji IP-II Troubleshooting | 10 July, 2014

Mr. Sarge,

Just call me, I know who you are, and you know who I am, I'll give you some s###, but just call and post the solution

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