YSi V OperatorManual

High-speed High-precision Hybrid AOI
YSi
Operator’s Manual
YSi-V
EPM9174210
Safety instructions
Safety instructions
w
Be sure to read these safety instructions before using YAMAHA surface mounters or related products.
Contents
CE marking i
1. Safety ii
1.1 To ensure safety ii
1.1.1 Defining safety ii
1.1.2 Causes of injuries and accidents ii
1.2 Using safety gear ii
1.3 Restrictions on machine use iii
1.3.1 Defining the operator and service personnel iii
1.3.2 Restricting machine operation with passwords iii
1.3.3 Lock out the main switch and the air supply/exhaust switch iii
1.4 Cautions during machine operation iv
1.5 Cautions during power outage iv
1.6 Cautions regarding ferromagnetic fields iv
1.7 Handling the internal tape cutter iv
1.8 Keeping hands away from moving parts v
1.9 Handling solvents (including solder, adhesive and flux) vii
1.10 Handling the X-ray unit viii
1.11 Handling the laser viii
1.12 Handling grease and oil ix
1.13 Handling batteries ix
1.14 Handling heavy objects ix
1.15 Components and materials to be used x
2. Safety message xi
2.1 Safety message and categories in this manual xi
2.2 Typical warning text found in manual xii
2.2.1 Safety instruction xii
2.2.2 Operation and handling precautions xiii
2.2.3 Facilities and environmental condition xiv
3. Warning labels xv
3.1 Warning label format and mark description xv
3.1.1 Warning label format xv
3.1.2 Meaning of marks xv
SFSMT-EN-16A-0100
3.2 Warning labels xvi
3.2.1 Handling safety covers xvi
3.2.2 Pinching or crushing injury xvii
3.2.3 Effects on human body xviii
3.2.4 Handling each section xxi
3.3 Caution labels xxiii
3.3.1 Machine damage xxiii
3.4 Label positions xxviii
CE marking
This equipment conforms to the EU Machinery Directive 2006/42/EC (description A1 below) and EMC
Directive 2014/30/EU (description A2 below).
However, this equipment does not bear CE marking if a custom order item was installed.
Safety instructions
A1.
Cautions regarding the official language of EU countries and the language used in operation
manuals, CE declarations, operation screen characters, and warning labels when this equipment is
installed in an EU countr y.
• All materials except warning labels are written in English only.
n NOTE
Warning labels only have pictographs or else include warning messages in English, Chinese, Korean and Japanese
language.
A2.
EMC description
• Electromagnetic immunity (Immunity)
Complies with test standards as specified by EN 61000-6-2.
• Electromagnetic emissions (Emission)
Complies with test standards for ISM category: Group 1, Class A, as specified by EN 55011.
n NOTE
Class A equipment is intended for use in industrial environments. If used in other environments, ensuring
electromagnetic compatibility (EMC) might be difficult. Refer to EN 55011 standards for detailed information.
i
1. Safety
To ensure that the machine you purchased is used safely and correctly, always comply with the instructions
and rules in this manual regarding safety. However this manual cannot cover all items regarding safety in
detail. So it is extremely important that the operator or person handling the machine make correct decisions
Safety instructions
regarding safety.
1.1 To ensure safety

To maintain the safety of the operator or person working with this machine, it is essential that it (including
external parts feeders) be installed correctly in compliance with the safety standards and conditions of that
country.
Complying with the safety regulations and laws of that country is the responsibility of the customer who
purchased this machine. The supervisor of this machine must take responsibility to ensure all measures have
been taken for machine safety.
1.1.1 Defining safety

1. Safety has priority over all other operations.
2. Safety is more important than any other task.
3. Safety is the foundation for work efficiency.
4. Safety begins with maintaining (keeping it neat and orderly) the work environment.
1.1.2 Causes of injuries and accidents

Most accidents are not something that occurs but something that are caused. So it is important to make an
effort NOT to cause accidents.
n Hazardous actions
• Ignoring causes of accidents
• Working or operating equipment in cramped locations
• Working in locations or positions where safety cannot be ensured
• Unsafe machine operation and using equipment whose safety cannot be ensured
• Working or operating equipment at speeds where safety cannot be ensured
• Working or operating machines with safety equipment removed
• Performing work or tasks on top of a machine currently in operation
• Playing around or goofing off during work
• Performing maintenance or inspections without wearing safety gear
1.2 Using safety gear

Always wear safety gear when operating or servicing equipment.
Helmet : Use during maintenance work
Safety glasses or goggles : Use around light harmful to eyes and when applying lubricant and when handling organic
solvents.
Respiratory gear : Use when handling organic solvents
Safety gloves : Use when applying lubricant and when handling organic solvents.
ii
1.3 Restrictions on machine use
1.3.1 Defining the operator and ser vice personnel
c CAUTION
Only the operator and service personnel having sufficient knowledge of this machine should handle this machine.
Safety instructions
Operator:
The operator is someone who has been trained by us in machine operation, has a thorough knowledge of the machine
operation manual and demonstrates adequate knowledge of machine operation and safety.
Main tasks of the operator include pre-operation checks, operation (component mounting) and making setups
(changeovers). The machine is only used in normal operating mode.
Ser vice personnel:
The service personnel are those trained by us in machine maintenance as well as safety instruction and demonstrate a
thorough knowledge of safe handling of the machine according to the type and location of machine operation. They must
also understand hazardous sections of the machine and residual risks.
Main tasks of the service personnel include machine maintenance, repair, adjustment and management of the system.
The service personnel may make changes to the machine settings and operation in factory adjustment mode.
1.3.2 Restricting machine operation with passwords

Machine operating levels usable by the operator and service personnel (mentioned above) must be restricted
by password. This prevents the operator and service personnel from using the machine at a higher level than
allowed.
1.3.3 Lock out the main switch and the air supply/exhaust switch
When the maintenance work is performed with the power supply and the air supply off, make sure to lock the
main switch and the air supply/exhaust switch with a padlock as shown below before the work. This is to
prevent a bystander from accidentally turning on the power and the air supply during the maintenance work.
Also, make sure to lock the main switch and the air supply/exhaust switch with a padlock when the machine is
left unused for a long period of time. Manage the key of the padlock according to the customer's rules.
Lock out the main switch and the air supply/exhaust switch
Main switch
: Position where the padlock can be set
“ ”Circle Mark
(OFF position)
ø4 to ø6
OFF
Padlock
Padlock
Air supply / exhaust switch

Example: YS100 Example: YCP10
OFF
OFF
OFF position OFF position
Padlock
91208-L0-00
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1.4 Cautions during machine operation
• Always make pre-operation checks before turning on the main power switch.
• Do not use an air blow tool when cleaning the machine. (Airborne dust will badly affect machine operation.)
• Stop all machine operation before cleaning around the machine.
Safety instructions
• Do not turn off the air during operation.

• Always make periodic inspections to prevent unexpected machine breakdowns.
• Allow only properly trained, experienced workers to perform repair and adjustment.
1.5 Cautions during power outage

If a power outage (blackout) occurs during automatic machine operation, always turn the main power switch
off to prevent faulty operation and equipment damage after power has been restored. Remove items such as
boards that remain inside the machine.
1.6 Cautions regarding ferromagnetic fields

Some machines contain parts generating strong magnetic fields which may cause death, bodily injury, or
device malfunction. Always comply with the following instructions.
• Persons wearing electronic medical devices such as cardiac pacemakers and/or hearing aids must not put
any of their body parts into the machine.
• Persons wearing ID cards, purses, and/or wristwatches must keep away from the linear motor.
• Do not attempt to disassemble the linear motor (including surrounding covers).
• Do not bring tools close to the linear motor.
• Do not bring tools close to the magnetic scale.
• Do not put magnetic materials or objects close to the linear motor.
• Do not touch a portion close to the linear motor during operation or immediately after the operation has been
finished since such part is hot.
c CAUTION
When disposing of a part generating strong magnetic fields such as a linear motor, dispose of it in compliance with
the laws and regulations of the country where the machine is used. If you have any questions about disposal of the
parts, please contact our sales representatives.
1.7 Handling the internal tape cutter

• Never supply electrical power and air to the machine while the covers for the tape cutter are removed.
• Tape cutter maintenance tasks must be performed by YAMAHA service personnel.
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1.8 Keeping hands away from moving parts
During use of this machine, the customer’s equipment and operating conditions might allow the operator’s
hands to come into contact with moving parts.
Use the following safety measure options to avoid possible danger where openings or gaps are found on the
machine.
Safety instructions
■ Dummy feeder
Use dummy feeders as safety measures to fill a gap between tape feeders. Install dummy feeders on the feeder plate the
same way as normal feeders in order to prevent hands from entering.
Prevention of hand entry

Dummy feeder
Clamp lever
Dummy feeder (Wide-size)
Dummy feeder (8mm-size)

91203-L0-20
c CAUTION
To install or remove a dummy feeder, be sure to first press the emergency stop button and then open the cover. The
machine has a structure that does not allow installing or removing a dummy feeder when the machine is in operation.
However, inserting a dummy feeder inside the cover during operation may cause serious accidents, so be careful not
to attempt it.
■ One-stop cover (for machines designed for use with feeder exchange carriage, excluding YSM40/YSM40R)
If not using a feeder exchange carriage in the machine that is to be used with feeder exchange carriages, install a
one-stop cover in the position where a feeder exchange carriage is to be installed.
Prevention of hand entry

One-stop cover
One-stop cover
91204-L0-10
n NOTE
One-stop covers cannot be installed or removed during operation. The machine must be in a stopped state because
the section where a feeder exchange carriage is to be installed will move up and down for the installation or removal
of the feeder exchange carriage.
v
■ Muzzle plate
Use these plates as a safety measure for the board conveyor entrance and exit openings. Each plate is movable, so adjust
the mounting position to match the boards to be produced.
Muzzle plate
Safety instructions
Upper muzzle plate
Board conveyance plane
Lower muzzle plate
91205-L0-00
Upper clearance Lower clearance Remarks
YS100, YS88 8.0 to 38.5mm 1.0 to 31.0mm
YS12, YS12P, YS12F, YS24,

5.0 to 20.0mm 4.2 to 39.2mm
YS24X,YSD
YSM40/YSM40R 0 to 44.0mm 0 to 39.0mm
Z:LEX(YSM20/YSM20W) 0 to 36.0mm 4 to 40.0mm
YSM10 0 to 44.0mm 4 to 40.0mm From board conveyor plane
YC8 13.4 to 80.4mm 4.6 to 39.2mm
YSB55w 0 to 10mm 6mm (fixed)
YSP 0 to 6.6mm 0 to 26.4mm
YSi-V 0 to 48.0mm 0 to 102mm
n NOTE
The values above show the maximum adjustable range of the muzzle plate.
See the product specification of each machine for the component mountable height and the restrictions of the substrate.
c CAUTION
When installing a unit such as a loader or an unloader on the upstream or the downstream side of the machine, set the
muzzle plates to the opening of the board conveyor entrance or the board conveyor exit to make the opening small.
vi
1.9 Handling solvents (including solder, adhesive and flux)
Cleaning organic solvents, such as isopropyl alcohol (IPA) and ethanol are used for the maintenance of this
machine (including optional units). Additionally, the solder paste printers, dispensers, and some hybrid placers
and flip chip bonders use solder, flux, or bond, etc. during normal production. Since many of these materials
include organic solvents, great care should be taken when handling them.
Safety instructions
Cautions on handling solvents
1. Hazards to human health
Organic solvents constantly vaporize and contaminate the surrounding atmosphere. Inhaling or coming in contact with
organic solvent vapor may cause serious damage to human health.
2. Flammability
Organic solvents are highly flammable substances and can easily catch fire if handled improperly.
3. Adverse effects on machines
Some kind of solvent may deteriorate parts used in the machine, electric cable sheathes, and other resin parts.
To prevent accidents caused by solvents

1. Be careful not to inhale toxic vapors of solvents for extended periods.
2. Do not use solvents near fire or flame. Keep solvents away from flame or fire.
3. Use only the specified solvent in the correct manner. Do not reuse any solvent repeatedly, and do not mix with other
solvents or chemicals.
4. Check the contents of the safety data sheet (MSDS/SDS), thoroughly notify work personnel of toxicities of included
chemical materials and measures to be taken in case of an accident, and take necessary countermeasures.
5. Use appropriate safety gear (safety goggles, protective gloves, and respiratory protective devices) corresponding to the
solvent or material types.
6. See the safety data sheet (MSDS/SDS) for how to dispose the solvents and the cloths used for wiping off the solvents.
c CAUTION
If no safety data sheets (MSDS/SDS) are supplied with solvents or materials you have purchased, be sure to acquire
the safety data sheets from the suppliers.
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1.10 Handling the X-ray unit
Some YS series inspection equipment models contain an X-ray unit. Take the following precautions when using
with an X-ray unit.
1. The X-ray output window of the X-ray source is made of ver y thin ber yllium foil.
Safety instructions
· Beryllium in the form of dust particles can cause acute toxicity or chronic toxicity, and may induce respiratory
problems if inhaled.
· To ensure safety, the X-ray unit is designed so that the X-ray window cannot be touched. However, should the X-ray
output window be broken for some reason, immediately turn off the power switch and use extreme care not to inhale
the dust particles.
· Chlorine gas can corrode the beryllium window of the X-ray tube, causing permanent damage to the X-ray tube. Do
not use the X-ray unit in environments where chlorine gases are generated. Take special care when handling samples
such as vinyl chloride materials which may generate chlorine gases.
2. Lead is used in the covers of machines equipped with an X-ray unit.
Although lead is sealed within the covers so that the lead portions cannot be directly touched, use caution since lead is
known as heavy metal having harmful effects.
3. A safety key is provided for machines equipped with an X-ray unit.
The safety key must be managed by the supervisor of the machine.
4. Safety education about X-ray
Appropriate measures are taken for YAMAHA's X-ray unit so that the amount of the X-ray leak to the outside of the
equipment is very small. Therefore, when using this equipment in Japan, it is not necessary to set controlled areas defined
in Article 3 of the Ordinance on Prevention of Ionizing Radiation Hazards.
It is not legally obligated to conduct the safety education, but it is recommended to conduct the education by the
customer.
When operating this equipment outside Japan, the safety education is conducted as required according to the relevant
country's laws, regulations, and standards.
TIP
When conducting the safety education in Japan, the contents stated in “Special Education Standard for Radiography
(Ordinance of the Ministry of Health, Labor and Welfare No. 50)” are recommended. However, the safety education
does not necessarily need to be these contents.
c CAUTION
When disposing of an X-ray unit (X-ray source), dispose of it in compliance with the laws and regulations of the
country where the machine is used. If you have any questions about disposal of the unit, please contact our sales
representatives.
1.11 Handling the laser

In this machine (including optional units), there are portions using the laser, such as a sensor and barcode
reader.
c CAUTION
The laser to be used by this machine is class 2 (visible light and low output) at a maximum.
Knowledge and information about laser

1. Harmful to human body
Never look at the laser directly even when it is weak. In particular, if the laser is irradiated to an eye for a long time,
this may cause serious injury.
2. Reflection of laser
The laser is reflected by a glass or metal surface. Pay special attention to the reflected laser light during maintenance
work.
To prevent accidents caused by laser

1. Do not align your eye with the laser height so that you do not look at the laser directly.
2. Wear safety goggles during work, when necessary.
3. Shield the laser during work, when necessary.
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1.12 Handling grease and oil
Grease or oil is used for the operating axes of this machine. When performing the lubrication work, strictly
observe the cautions shown below.
Cautions on handling grease and oil
Safety instructions
1. If grease or oil enters your eye or sticks to your skin, this may cause inflammation. Be sure to wear safety goggles and
protective gloves during work. Additionally, if you swallow grease or oil by mistake, this may cause vomiting or
diarrhea.
2. If grease other than that specified is used, this may cause damage to the machine.
3. If grease with different characteristics is mixed with proper grease, this may cause the machine performance to lower.
4. Be sure to cap tightly after use to prevent entry of dust or water content. When storing the grease or oil, avoid the
direct sunlight, keep it away from a fire, and store it in a dark place.
n NOTE
When the safety data sheet (MSDS/SDS) about the grease or oil that is used for the maintenance wok is needed,
contact our sales representatives.
1.13 Handling batteries

Batteries are used for some motors of this machine and the optional uninterruptible power supply (UPS).
Cautions on handling batteries

1. Do not disassemble the battery or touch its inside. Otherwise, electrical shock may result.
2. Do not over-heat or apply a strong impact to the battery. Otherwise, fluid leakage, explosion, or heat generation, etc.
may result. Never use the battery, to which a strong impact has been applied, such as dropping to the floor since its
battery fluid may leak.
3. Only engineers who have the experience and knowledge about electrical work are allowed to replace the battery.
4. The battery may discharge naturally. When purchasing a spare battery, do not store it for a long period and prepare it
one to two months before the scheduled replacement work. Additionally, when storing the battery, avoid a place where
the temperature increases and be sure to store it at room temperature.
n NOTE
When the safety data sheet (MSDS/SDS) about the battery is needed, contact our sales representatives.
c CAUTION
For details about how to handle the UPS, see the user's manual prepared by the manufacturer that is supplied with the
UPS.
c CAUTION
When disposing of a battery, dispose of it in compliance with the laws and regulations of the country where the
machine is used. If you have any questions about disposal of the battery, please contact our sales representatives.
1.14 Handling heavy objects

This machine (including optional units) may require the operator to handle heavy objects during work. (For
example, magazine or cassette replacement) If you hold up a heavy object in an unnatural posture, this may
cause damage to your back. Additionally, if you fall a heavy object to your feet, this may cause serious
personal injury. Or, falling a heavy object may cause damage to the magazines or internal tray components.
Cautions on handling heavy objects

1. Be careful not to take an unnatural posture during work. In particular, be aware that you may take an unnatural posture
easily when holding up a heavy object from a low place. It is recommended to hold up a heavy object by bending and
stretching your knee instead of bending your waist or prepare a cart with an appropriate height when necessary.
2. When a handle is provided, such as magazine and cassette, hold the handle securely and perform the work.
3. To prevent personal injury caused by heavy object dropping, be sure to wear safety shoes.
c CAUTION
When heavy object handling standards are defined at the customer's factory, be sure to follow the standards during
work.
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1.15 Components and materials to be used
This machine uses not only the surface-mounted components but also the various types of materials such as
trays, wafer components, dicing tapes and so on. In selecting these components and materials, observe the
following.
1. Do not use the flammable (explosive) material.
Safety instructions
2. Do not use the material whose function is impaired by heating.

For example, some flip tip bonders are equipped with a heater inside the unit (e.g. YSB55w : The dicing tape is heated
to approx. 60 degrees.) Do not use the flammable materials or the materials impaired by heat.
3. Do not use the materials that reacts chemically with solders, flux, adhesive and solvents used for cleaning them.
4. Select components and materials that meet the specifications of the machine.
n NOTE
Check the detailed specifications of the components and materials with the suppliers beforehand. If you have any
questions about the specifications of the machine, please contact our sales representatives.
x
2. Safety message
This section describes information you should always comply with to prevent unforeseen accidents that might
lead to injury of the operator and others or damage the machine. Hazards and injuries that might result from
ignoring safety instructions and operating the machine incorrectly are categorized as follows.
Safety instructions
2.1 Safety message and categories in this manual
This manual uses the following safety alert symbols, signal words, and format styles according to the degree of
hazard.
n Safety alert symbols and signal words
w WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
These are points most essential for protecting the safety of the machine operator, inspector and service
personnel.
c CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor injury, or material loss or damage
to the machine. These points are important for protecting the safety of the machine and data, etc.
n NOTE
Gives helpful information or key points when operating the machine, in a simple and clear manner.
e EMERGENCY STOP
This mark indicates the emergency stop button must first be pressed before continuing the procedure.
xi
2.2 Typical warning text found in manual
The following are typical warning message text found in the YAMAHA surface mounter or related product
manual.
2.2.1 Safety instruction

Safety instructions
When you see the following cautions or warnings, always read them thoroughly and make sure you fully
understand them.
n Warnings
w WARNING
The signal light (signal tower) installed on the top of the machine is an important device that shows the
operating status of the machine. BEFORE OPERATING THE MACHINE, MAKE SURE THAT EACH LAMP OF THE SIGNAL
TOWER LIGHTS UP CORRECTLY (GREEN DURING OPERATION, YELLOW WHEN ERROR OCCURS OR INTERLOCK IS DETECTED,
AND RED DURING EMERGENCY STOP). NEVER PLACE ANY PART OF THE BODY IN THE HEAD unit MOVEMENT RANGE WHILE
THE GREEN LIGHT IS ON. (On machines designed to meet EU specifications, green/white/blue lamps are used
instead of green/red/yellow lamps.)
w WARNING
Never allow any part of your body (hands, head) to enter within the machine movement range during
operation.
w WARNING
Be careful when using isopropyl alcohol, since inhaling its fumes over long periods can be hazardous
to health.
n Cautions
c CAUTION
The person operating the machine must have been trained in correct machine operation and safety.
c CAUTION
This machine contains parts generating strong magnetic fields. Great care should be taken when a part of your body
is put inside the machine for the maintenance work. Cautions regarding ferromagnetic fields are described in the
section, “Safety Instructions”, at the beginning of this document. Always thoroughly read this section to fully
understand its contents.
c CAUTION
The exhaust air blow might strike your face, so be sure to wear safety goggles.
xii
2.2.2 Operation and handling precautions
When seeing the following cautions or warnings, always read them thoroughly and make sure to fully understand them.
n Warnings
w WARNING
Safety instructions
Inflammation may occur if grease or lubricant gets in the eyes. Before handling the grease, wear safety
goggles to ensure the grease will not come in contact with the eyes.
w WARNING
Inflammation may occur if the grease or lubricant comes into contact with skin. Be sure to wear
protective gloves to prevent contact with skin.
w WARNING
Do not take orally or eat the grease or lubricant. Eating will cause diarrhea and vomiting.
n Cautions
c CAUTION
Always stop the machine before installing the parts feeder into the machine. Hands or other parts of your body might
otherwise be caught in the moving parts.
c CAUTION
During operation only press the emergency stop button in cases of emergency.
c CAUTION
Always turn off the power with the correct procedure. Using hasty or incorrect procedures to turn off power might
damage the flash disk in the machine.
c CAUTION
When installing push-up pins on the push-up plate, set them in positions where they will not interfere with the conveyor
rails or other parts when the push-up plate is raised.
c CAUTION
When the machine you are using is not equipped with a nozzle station, you must change the nozzle by hand if it is not
a specified nozzle. In this case, always first press the emergency stop button.
c CAUTION
If an abnormality occurs during warm-up, immediately stop the machine, find the cause of the problem and eliminate it.
c CAUTION
When storing the grease after use, tightly close the cap of the grease tube or container to prevent dust and moisture
from entering inside. Store it in a dark place to avoid direct sunlight, and keep away from fire and heating sources.
c CAUTION
After copying board data or system data into a USB flash memory, do not leave that data in the USB flash memory for
a long time. Use the USB flash memory just as a copy medium for backup data. Prepare other backup media
(CD, DVD, MO, etc.) to store backup data more safely.
c CAUTION
You can also clean and grease the ball screw after removing the push-up plate. However, the push-up plate is heavy.
So, take great care during handling.
c CAUTION
A strong air flow is exhausted during the cleaning blow. Always remove all nozzles attached to the heads before
starting the cleaning blow. Starting the cleaning blow while the nozzles are still attached may blow the nozzles away
from the heads causing the nozzles to break or become lost.
xiii
2.2.3 Facilities and environmental condition
When you see the following cautions or warnings, always read them thoroughly and make sure you fully
understand them.
n Warnings
Safety instructions
w WARNING
Always shut off the power and air supply before replacing parts or performing repairs.
w WARNING
During teaching or when making machine adjustments, always keep alert so that you can stop the
machine whenever needed.
w WARNING
Safety devices (safety interlocks) that stop machine operation should always be in good operating
condition.
w WARNING
The machine should never be used in locations with inflammable gas or in extremely dirty or polluted
environments.
w WARNING
• Persons wearing electro-medical devices such as cardiac pacemakers must be kept away from the
head unit.
• Persons with implanted magnetic metals must be kept away from the head unit.
• Do not bring ferrous objects such as metal tools and screws close to the parts where a strong
magnetic field warning is indicated.
• Do not bring magnetic cards or objects vulnerable to magnetic fields close to the head unit.
w WARNING
To avoid the risk of electrical shock, make sure that the power source is off before connecting the
power cable. Also make sure that the ground cable is securely connected to the machine.
n Cautions
c CAUTION
When disconnecting the air hose, be careful not to allow oil, water or impurities to splash outwards. Additionally, take
great care since a large air exhaust sound is produced when disconnecting the coupler.
c CAUTION
Use a power cable whose conductor cross-section area is greater than xx mm2.
xiv
3. Warning labels
To use the YAMAHA machines safely and correctly, warning labels are attached to the machine body and
peripheral equipment. Check that the information on each warning label is clearly legible and comply with
the instructions.
Safety instructions
3.1 Warning label format and mark description
3.1.1 Warning label format

As shown below, a warning label indicates the degree of hazard by means of a signal word and the color of the
signal word panel. A mark and a pictogram are also used to emphasize the message. Basically, labels attached
to the outside of machines are in 4 languages (English, Chinese, Korean and Japanese) while labels attached to
the inside of the machines are only a pictogram.
Warning label format

Warning message and mark (pictogram) example
Safety alert symbol Signal word
WARNING Signal word panel

Danger : Red
Pinch or crush hazard. Warning : Orange
Caution : Yellow
Mark and pictogram
Message
90K41-000380
91206-L0-00
3.1.2 Meaning of marks

The following 3 types of marks are used on warning labels. Each mark has its own meaning and is typically
used with a pictogram to emphasize the message.
Mark and pictogram

Marks and examples used with pictogram
Warning mark Prohibition mark Instruction mark
WARNING WARNING WARNING
Usage examples
91207-L0-00
Meaning of the above

Definition Shape/Color
examples
Indicates a hazard, how to Yellow triangle with black Risk of electrical shock
avoid the hazard, and potential border. Pictogram is black on
Warning
consequences of ignoring the yellow.
warning.
Indicates a prohibited action to Red circle with slash. Pictogram Do not modify or disassemble
Prohibition avoid the potential hazard. is black and located behind safety cover switch.
slash.
Indicated an action that must Blue circle. Pictogram is white Read the manual to understand
Instruction be taken to avoid the potential on blue. procedure before starting
hazard. operation.
xv
3.2 Warning labels
Safety instructions
3.2.1 Handling safety covers

Potential
Injury from touching moving parts during machine operation
hazard
To avoid Do not touch or tamper with safety cover switches and do not operate machine if any safety cover
hazard switches were deactivated.
Applicable
All YS series machines, tray changers, etc. Case All case
machines
Potential
Unexpected accidents may occur if safety mechanisms are disabled.
hazard
To avoid Do not remove or disassemble any specified safety mechanism (protective cover, safety cover,
hazard etc.).
Applicable
Z:LEX(YSM20/YSM20W), YS24, YS24X, YSH20, etc. Case All case
machines
Potential
Risk of injury
hazard
To avoid
Be sure to return the cover to its original position before starting the operation.
hazard
Applicable
YSP Case All case
machines
xvi
3.2.2 Pinching or crushing injur y
Potential · Hands or fingers might be caught between moving parts and covers, causing injury.
Safety instructions
hazard · Hands or fingers might be pinched by moving parts, causing injury.
To avoid
Never place hands or fingers in machine during operation such as when handling tray magazines.
hazard
Applicable Z:LEX(YSM20/YSM20W), YSM40/YSM40R, all YS series machines,
Case All case
machines tray changers
Potential
Hands or fingers might be pinched or crushed by clamp plate, causing injury.
hazard
To avoid
Never place hands or fingers in the machine when clamping a mask.
hazard
Applicable • Setup
YCP10,YSP,YSP20 Case
machines • Maintenance
Potential
Injury from tape cutter
hazard
To avoid
Do not put hands into cutter unit while power or air is supplied.
hazard
Applicable
Machines equipped with tape cutter. Case Maintenance
machines
xvii
3.2.3 Effects on human body
Potential
Safety instructions
Electrical shock hazard

hazard
To avoid
Do not touch and disassemble ionizer discharge needles. Keep them away from water.
hazard
Applicable
Machines equipped with ionizer (option) Case All case
machines
To prevent the electric shock or damage.

Do not touch electrodes.
WARNING Do not disassemble this unit.
Keep unit away from water and high
humidity
可造成触电和故障的原因。
别用手触摸电极部位。
警告不可私自拆分部件。
请避免部件接触水分并远离极度潮湿环境。
感電や故障の原因になります。
放電針に手を触れないで下さい。
警告分解はしないで下さい。
電気部に水をかけないで下さい。
Potential
Death, serious injury or equipment malfunction
hazard
To avoid
Observe precautions necessary due to strong magnetic fields.
hazard
Applicable
YS12, YS12P, YS12F, YS24, YS24X, YSH20,YSM40/YSM40R etc. Case All case
machines
Potential
hazard
To avoid
Do not touch power supply inside cover.
hazard
Applicable
All machines Case All case
machines
xviii
Potential
Burn hazard
hazard
Safety instructions
To avoid
Heater becomes very hot during and shortly after operation, so do not touch it.
hazard
YSD,YSH20 machines equipped with heater (option) Case
Potential
hazard
To avoid
Do not touch while power is supplied.
hazard
Applicable Z:LEX(YSM20/YSM20W), YSM40/YSM40R, All YS series machines
Case Maintenance
machines (controller unit) except for inspection equipment
Potential
Loss of eyesight
hazard
To avoid
Do not directly look into laser beam.
hazard
Applicable IT options such as barcode readers (Class 2 laser)
Case All case
machines YS series machines (Class 1 laser)
xix
Potential
Electrical shock
hazard
Safety instructions
To avoid
Keep the ionizer away from eyes. Do not disassemble or touch the discharge needles.
hazard
Applicable
Machines equipped with ionizer (option) Case All case
machines
Potential
Electrical shock
hazard
To avoid
Always turn off UPS switch when performing maintenance work.
hazard
Applicable
Machines equipped with UPS (option) Case Maintenance
machines
Potential
Electrical shock
hazard
To avoid
Always turn off UPS switch when performing maintenance work.
hazard
Applicable
machines
xx
3.2.4 Handling each section
Potential
Safety instructions
Solvent may catch fire.
hazard
To avoid
Keep solvents such as alcohol away from fire or flame.
hazard
All solder paste printers Case
Potential
hazard
To avoid
Before opening covers wait at least 100 seconds after turning power off.
hazard
Applicable
All machines Case Maintenance
machines
Potential
Possible skidding or slipping causing injury
hazard
To avoid
Do not step on base section.
hazard
Applicable
YS24X (machines equipped with sATS II) Case All case
machines
xxi
Potential
Damage to machine or injury to person
hazard
Safety instructions
To avoid Before handling the product (equipment) always read manuals and make sure you fully understand
hazard the contents.
Applicable Z:LEX(YSM20, YSM20W), YSM40/YSM40R, all YS series machines,
Case All case
machines etc.
Potential
Exposure to radiation
hazard
To avoid
Keep covers closed during operation.
hazard
Applicable
YSi-X Case All case
machines
Potential
Risk of injury
hazard
To avoid
Do not open any cover without permission from YAMAMA service personnel.
hazard
Applicable
Maintenance parts for linear motors (strong magnetic fields) Case Maintenance
machines
xxii
3.3 Caution labels
Safety instructions
3.3.1 Machine damage
Potential
Adverse effects on component mounting accuracy
hazard
To avoid
Do not touch camera unit or apply impacts to it.
hazard
All machines Case
Potential
Risk of damage
hazard
To avoid
Remove shipping bolts and clamps before using machine.
hazard
Applicable
YS series machine feeder exchange carriage (option) Case Installation
machines
Potential
Machine damage or malfunction
hazard
To avoid
Connect power only at the specified voltage.
hazard
Applicable
All machines Case Installation
machines
Example for machines that must be connected to 200 VAC
Potential
Machine damage or malfunction
hazard
To avoid
Do not use any solvent, such as alcohol.
hazard
Applicable
All inspection machines Case Maintenance
machines
xxiii
Potential
Machine damage
hazard
Safety instructions
To avoid
Make sure push-up pins are arranged within specified area.
hazard
Applicable
Z:LEX(YSM20/YSM20W), YS24, YS24X Case Setup
machines
Potential
Machine damage or fire
hazard
To avoid
Do not use other than specified solvent.
hazard
Potential
Machine damage
hazard
To avoid
Always use gauze rolls of proper size.
hazard
xxiv
Potential
Machine damage
hazard
Safety instructions
To avoid If machine is not to be used for 6 months or more, block off the solvent path to protect solvent
hazard pump.
Applicable
All solder paste printers Case Maintenance
machines
Potential
Might disable machine functions
hazard
To avoid
Periodically replace USP battery since it has a limited service life.
hazard
Applicable
machines
Potential
Machine damage
hazard
To avoid
Read manuals and use correct procedure to operate machine.
hazard
Applicable
YS24X (machines equipped with sATS II) Case All case
machines
xxv
Potential
Could cause machine damage (collisions with head, etc.).
hazard
Safety instructions
To avoid Verify that no objects have been placed on the top cover of the feeder exchange carriage (for
hazard YSM40).
Applicable
Feeder exchange carriage (YSM40) Case Setup
machines
Potential
The carrier tape could make contact with the head, possibly causing machine damage.
hazard
To avoid When a feeder is extracted from its loaded position, be sure that the feeder has been completely
hazard extracted before pressing it back into its loaded position.
Applicable
Z:LEX(YSM20/YSM20W), YSM40/YSM40R Case Setup
machines
Potential
Pallet may drop if setting up components on the component supply station.
hazard
To avoid
Remove pallets before setting up components.
hazard
Applicable
cATS (YSM40/YSM40R) Case Setup
machines
xxvi
Potential
hazard
Safety instructions
To avoid Verify that no objects have been placed on the top cover of the feeder exchange carriage (for
hazard YSM40 and Z:LEX (YSM20)).
Applicable Feeder exchange carriage
Case Setup
machines (YSM40/YSM40R, Z:LEX(YSM20/YSM20W))
Potential
hazard
To avoid Verify that no objects have been placed on the top cover of the feeder exchange carriage (for YSM40
hazard and Z:LEX (YSM20)).
Applicable Feeder exchange carriage
Case Setup
machines (YSM40/YSM40R, Z:LEX(YSM20/YSM20W))
Potential
Machine damage
hazard
To avoid
Do not insert or remove any connector while power is on.
hazard
Applicable
cATS10 (Z:LEX(YSM20/YSM20W) ) Case Setup
machines
xxvii
3.4 Label positions
The following warning/caution labels are attached to the YAMAHA products to ensure safe and correct use.
Check that the information on each label is clearly legible and comply with the instructions.
For safety precautions other than those on the labels shown in this section, see the instructions in "1. Safety".
n
Safety instructions
NOTE
Basically, labels are attached to the positions shown below, although they may differ slightly depending on the
machine model.
n NOTE
When connecting power to this equipment, refer to "Power connection terminals" described in the appendix.
Warning/caution labels
Front side
■ Open/close cover inner side
■ Conveyor opening
(right and left sides)
■ Open/close cover
■ Left of main switch
■ Lower panels
■ Main switch
■ Panels inner side
■ Top of controller
■ UPS unit inside rear cover

■ Panels inner side
■ Servo controller
93201-M9-00
xxviii
Warning/caution labels
Rear side
■ XY-axis ball screw cover
■ Laser unit (Option)
Safety instructions
■ CZ-axis motor
(Option)
■ OPT-CL board
■ Behind rear door
■ Rear panels
Capacitor for R/CZ-axis (Option)
93202-M9-00
xxix
General Contents
Before using the YSi-V

1. Using this manual i
1.1 Available manuals i
1.2 Manual contents i
2. Warranty ii
3. Contents of each chapter iii
4. Page layout iv
Chapter 1 Part names and functions

1. YSi-V main unit 1-1
2. Conveyor unit 1-4
3. Axis configuration 1-5
4. Option units 1-7

4.1 Marking unit 1-7
4.2 Laser height sensor 1-8
4.3 3D projector 1-9
4.4 4D angular camera 1-10
4.5 High-speed dual lane 1-11
Chapter 2 Basic operation

1. Before operation 2-1
1.1 Canceling emergency stop 2-1
1.2 Clearing an error 2-1
2. Starting and ending the YSi-V and software operation 2-2

2.1 Starting 2-2
2.2 Ending 2-3
Chapter 3 Daily operation

1. Overview 3-1
2. Warm-up operation 3-2
3. Selecting a board 3-3
4. Conveyor unit setup 3-4
EPM9174210
Chapter 4 Maintenance
Before beginning work 4-1
1. Maintaining YSi-V performance 4-2

1.1 Essential conditions and working environment 4-2
1.2 Importance of periodic inspections and cleaning 4-3
2. Maintenance list 4-4
3. Preparing for maintenance tasks 4-5

3.1 Consumable parts 4-5
3.2 Maintenance tools 4-6
3.2.1 Cleaning tools 4-6
3.2.2 Lubricating tools and grease 4-7
3.3 Required tools 4-8
4. Weekly inspection 4-9

4.1 Checking the board sensor condition 4-9
4.2 Checking the board clamp condition 4-9
5. Monthly 4-10
5.1 Inspecting each axis 4-10
5.2 Cleaning and greasing the ball screws and linear guides 4-11
5.2.1 Cleaning and greasing the X axis ball screws 4-11
5.2.2 Cleaning and lubricating the X axis guides 4-12
5.2.3 Cleaning and greasing the Y axis ball screws 4-13
5.2.4 Cleaning and greasing the Y axes guides 4-15
5.3 Cleaning the camera lighting unit 4-16
6. Three-month inspection 4-17

6.1 Air intake fan filter 4-17
6.2 Cleaning and greasing the CZ axis (option) ball screws 4-18
7. Six-month inspection 4-19

7.1 Cleaning and greasing the marking unit (option) cam 4-19
7.2 Cleaning controller filter (For Type HS2 only) 4-20
8. One-year inspection 4-21

8.1 W axis 4-21
8.1.1 Cleaning and greasing the W axis ball screws 4-21
8.1.2 Cleaning and greasing the W axes guides 4-22
8.1.3 Cleaning and greasing the hexagon spline 4-23
8.2 Inspecting and cleaning the air/mist filters 4-24
9. How to replace consumable parts 4-26
9.1 Cleaning and replacing the conveyor belts 4-26
9.2 Replacing the UPS (uninterruptible power supply) battery 4-28
Chapter 5 Lubrication points

1. Applicable grease and grease gun 5-1
1.1 Applicable grease 5-1
1.2 Grease gun 5-1
2. Lubrication of each unit 5-2

2.1 Each axis unit 5-2
2.1.1 X and CZ axis guide and ball screw 5-2
2.1.2 Y axis guide and ball screw 5-3
2.1.3 W axis guide and ball screw 5-4
Appendix
1. Power connection terminals A-1
2. Connection between machines A-2
3. UPS (Uninterruptible Power Supply) A-3

3.1 Safety precaution A-3
3.1.1 Precautions when shipping or exporting the UPS A-3
3.1.2 Disposing of used battery after replacement A-3
3.1.3 Safety precautions A-3
3.2 About the UPS A-5
3.3 Operation and setting A-6
3.3.1 Front panel A-6
3.3.2 Operation during normal operation (power is normal) A-6
3.3.3 Operation during power failure or trouble A-6
3.4 Maintenance A-7
3.4.1 Battery replacement period A-7
3.4.2 Battery replacement A-7
3.4.3 Replacement battery storage A-7
3.5 Troubleshooting A-8
Index
Contents
1. Using this manual i

1.1 Available manuals i
1.2 Manual contents i
2. Warranty ii
3. Contents of each chapter iii
4. Page layout iv
The instruction manual of this machine is written for those who operate
this machine.
Please read this manual carefully for correct operations and pay
special attention to safety precautions.
After reading through this manual, please use this manual as an
occasional reference and keep it within reach.
1. Using this manual

1.1 Available manuals
There are several different manuals available including this manual to help users use the YSi-V effectively
depending on their skills, expertise, and applications. Available manuals are shown below.
■ Available manuals
Manuals supplied with YSi-V
The following manuals are supplied with the YSi-V you purchased.
Programming Manual
Operator's Manual
This manual
23000-M9-00
1.2 Manual contents

The contents of each manual are briefly explained below.
■ Contents of manuals supplied with YSi-V
Operator's Manual Programming Manual
This manual is intended for YSi-V operators. It provides This manual is intended for those who program inspection
an overview of the YSi-V and information necessary to data. It describes how to create and edit data needed for
operate the YSi-V. YSi-V operation and board inspection.
Before using the YSi-V Before using the machine
Chapter 1: Part names and functions Chapter 1: Basic operation
Chapter 2: Basic operation Chapter 2: Creating an inspection program
Chapter 3: Daily operation Chapter 3: Creating a component library
Chapter 4: Maintenance Chapter 4: Setting the inspection item
Chapter 5: Lubrication points Chapter 5: Setting the inspection machine
Appendix Specifications, UPS Appendix
Option Manual Software option manual (CD)
The manual for each software option for inspection

Explains the handling of the optional units to the YSi-V.
equipment is stored on the installation CD.
■ Laser height sensor ■ Repair station
■ Marking unit ■ Remote judgment station
c CAUTION
The contents of these manuals are subject to change without prior notice.
i
2. Warranty
The machine you have purchased is warranted against malfunctions as described below.
n Warranty description:
If a failure or breakdown occurs due to defects in workmanship or materials used to manufacture this machine within
one year or 5,000 hours of operation (whichever comes first) after the incoming inspection is complete, then YAMAHA
will repair the defective parts free of charge.
n Warranty period
The warranty period ends when any of the following applies:
1. After one year has elapsed from the time of installation.
2. After 5,000 hours of operation.
n Items not covered by the warranty

The warranty does not cover any of the following conditions:
1. Damage as a result of deterioration due to age or wear (e.g., normal discoloration of painted or plated surfaces, wear
of replaceable parts, etc.).
2. Incidents associated with sensory perceptions which have no bearing on the quality or function of the machine (e.g.,
signal sounds emitted by the controller, rotating sounds of the motor, etc.).
3. Damage caused by the user environment (e.g., impurities in the air supply, dust, debris and oil mist in the machine).
n Exception to warranty repairs

Warranty repairs will not be made if damage is caused by the following:
1. Defects arising from earthquake, tsunami, lightning, wind or flood damage, or other natural disaster or force majeure.
2. Modifications or conversions not approved by YAMAHA or its dealers.
3. Use of non-genuine parts, greases or lubricants.
4. Lack of proper maintenance and inspection procedures.
5. Maintenance handled by someone other than the approved dealers.
6. Damage or malfunction due to changes in the machine installation level that may be caused by changes in the
foundation or surrounding environment.
7. The machine was modified or changed in specifications after the incoming inspection is complete.
8. When defective parts replaced free of charge were not returned to the location specified by YAMAHA or YAMAHA
sales representatives within 30 days.
n Note on network connections

A precondition for network connections with the YAMAHA machines is that such connections will be used in closed
networks comprised of this machine and an offline PC. The customer must take responsibility for connections to company
in-house networks and to external networks. Please acknowledge that YAMAHA can bear absolutely no responsibility for
networks configured by other than just this equipment and off-line PC nor can accept responsibility for problems
occurring due to network settings and connections.
ii
3. Contents of each chapter

This manual is comprised of the following chapters.

Explains major part names and functions of the YSi-V that you should know before attempting operation.

This chapter explains how to start up the YSi-V and turn it off, as well as the basic menus and elements displayed on the
operation screen.

Chapter 3 describes the daily work performed by the operator for board inspection.
This chapter describes checkpoints and procedures for daily and periodic inspections that must be perform to avoid
trouble with the YSi-V.

This chapter describes the instructions about lubrication points and how to lubricate the ball screws or guides of each
axis.
Appendix
The appendix provides specifications for power supply connections and machine-to-machine connections, as well as
information about UPS.
Index
The index at the end of this manual helps you quickly find where necessary items are explained.
iii
4. Page layout
The description below shows a typical page layout used in this manual.
Typical page layout
2. Warm-up operation
After starting the machine, perform warm-up (aging operation) of servo motor axes.
n NOTE
A warm-up period of 15 minutes is sufficient.
Note that no warm-up operation is necessary if less than 2 hours have elapsed since the last operation.
Step 1 Carry out the pre-operation check before starting the YSi-V.
Sub step or For pre-operation checks and starting up the machine, see Chapter 2, "Basic operation".
description of step 2 Start warm-up operation.

c CAUTION
Check that there are no boards on the conveyor before beginning warm-up. If push-up pins are used, remove them. If
3
a problem occurs during warm-up, press the [Stop] button to stop the operation. Then check the cause of the problem
Chapter number and eliminate it.
1. Press the [Aging] button to open the warm-up screen.

2. Press the [Start] button to start warm-up operation.
Figure, picture
Daily operation
"Setup" screen
Chapter title Warm-up or table caption
24300-M9-10
Note, Caution n NOTE
or Warning If you want to specify the warm-up time, press the [Stop after time-over] button and enter the desired warm-up time.
3 End the warm-up operation.

Press the [Stop] button to end the warm-up operation. In most cases, a warm-up period of 15 minutes is
sufficient.
4 Press the [Close] button to return to the operation screen.
3-2
23001-M9-00
n Step
This describes the procedure for each operation.
n Substep or description of step

This provides detailed information on the steps in each procedure.
n Figure, picture or table caption

This is the title of the figure, picture or table and appears at the upper left.
n Note, Caution or Warning

These are explained in detail in "Safety" instructions.
iv
Contents
1. YSi-V main unit 1-1
2. Conveyor unit 1-4
3. Axis configuration 1-5
4. Option units 1-7

4.1 Marking unit 1-7
4.2 Laser height sensor 1-8
4.3 3D projector 1-9
4.4 4D angular camera 1-10
4.5 High-speed dual lane 1-11
1. YSi-V main unit
This section describes names and functions of major parts of the YSi-V main unit.
1
YSi-V main unit
Part names and functions

Signal light Operation display and data input unit
(signal tower)
Alarm buzzer
[READY] button
Safety cover Emergency stop button
Board conveyor entrance/exit
USB port
(behind panel)
Pressure gauge
Main switch
Power connection terminals

Air supply/shutoff switch (behind panel)
(behind panel) UPS
(Inside panel)
23100-M9-00
n Signal light (signal tower)

Indicates the state of the YSi-V in green, yellow and red or in green, blue and white.
Default lighting pattern

Operation status Description
Red (White) Yellow (Blue) Green
Waiting for board to be supplied from the previous
Standby OFF OFF Flashing
stage.
Auto inspection OFF OFF ON Board has been loaded and is being inspected.
Waiting for judgment OFF ON OFF Waiting the final pass/fail decision input.
Other than AUTO OFF OFF OFF Machine is in a mode other than "auto inspection".
Machine error ON OFF OFF A machine error or emergency stop has occurred.
Emergency stop ON OFF OFF Machine is in emergency stop.
n NOTE
Signal tower lighting pattern can be customized by machine setting.
n Alarm buzzer
This buzzer sounds if an error or abnormal operation occurs. (The buzzer volume can be adjusted by turning the buzzer
ring right or left.)
n Safety cover
Always use the handle when opening or closing this cover.
n Emergency stop button

Pressing this button triggers emergency stop and turns off the servo power. To release the emergency stop button, turn it
to the right.
n [READY] button
When emergency stop is canceled, pressing this [READY] button turns on the servo power and the button lights up.
1-1
n Operation display and data input unit
The keyboard and mouse to be used for YSi-V operation and data input are equipped with the YSi-V as a standard
1
feature.
n Board conveyor entrance/exit

Board loading/unloading openings that are connected to the upstream and downstream conveyors.
n Pressure gauge
Shows the supply air pressure (upper display) and pressure-drop detection level (lower display). Use the pressure
regulator knob and the pressure-drop detection level adjust buttons on the pressure gauge to set each pressure value as
follows:
• Supply air pressure (upper display) : 0.40 MPa (0.39 MPa to 0.41 MPa)
• Pressure-drop detection level (lower display) : 0.33 MPa
n Main switch
Turns on or off the power to the YSi-V. The power is on when turned to the right.
c CAUTION
Wait about 10 seconds before turning this power switch back on after turning it off.
YSi-V main unit
■ Behind center left front panel ■ Behind center left front panel
Pressure regulator
USB port
Source air connector Air supply/shutoff switch
23111-M9-00
n USB port
Use this USB port when making a backup of data.
n Air supply/shutoff switch

Turning this switch to the right shuts off air supply and exhausts air that remains in the air path.
n Pressure regulator
Adjusts the air pressure supplied to this YSi-V. Turn the knob to adjust the air pressure so that the upper display on the
air pressure gauge indicates 0.40 MPa (0.39 MPa to 0.41 MPa).
n Source air connector

Prepare an air hose with an inner diameter of at least 8mm having a 30SH socket (Nitto Kohki, or equivalent), and
connect it to this connector. Use dry, clean air passed through an air filter.
1-2
YSi-V main unit
■ Behind lower right front panel ■ Inside front lower part of central panel

Controller UPS (uninterruptible power supply)
Main power cable
Main breaker Power connection terminals

23112-L9-10
YSi-V main body

Type HS2 specifications
■ Inside front lower part of central panel
Controller
UPS (Uninterruptible power supply)
23115-L9-00
n Power connection terminals

Connect a 3-phase AC power cable to this terminal block. ( (For more details, see Appendix 1, "Power connection terminals".)
n UPS (uninterruptible power supply)

The UPS retains (backs up) the power even if abnormal conditions such as power failure or voltage fluctuations occur.
(For more details, see Appendix 3, "UPS (uninterruptible power supply)".
n Machine-to-machine connection connectors (Behind rear panel)

Connector labeled "NEXT INTERFACE" connects to the downstream machine, and the connector labeled "PREVIOUS
INTERFACE" connects to the upstream machine. (For more details, see Appendix 2, "Connection between machines".
Machine-to-machine connection connectors

Behind rear panel
PREVIOUS INTERFACE connector

(For connection to upstream machine)
NEXT INTERFACE connector

(For connection to downstream machine)
23108-M9-00
1-3
2. Conveyor unit
1 Conveyor unit
YSi-V conveyor (An example of single lane)
1. Main stopper 4. Board hold plate
5. Board edge clamp unit
6. Board sensor 3. Push-up pins 2. Push-up plate

23102-M9-00
1. Main stopper
When a board is carried in on the conveyor, the main stopper halts travel of the board in the component mounting
position.
2. Push-up plate
The push-up plate clamps the board up against the conveyor rails, with the supporter pins attached by magnet on the
push-up plate.
3. Push-up pins
Install the push-up pins on the push-up plate to support the board from the lower portion. The height of push-up pins can
be adjusted according to the board thickness.
4. Board hold plate (movable)
These plates hold the edges of the board from above when the board is clamped in the mounting position.
5. Board edge clamp unit
This unit clamps the board by pushing its edges up against the board hold plates.
6. Board sensor
Board sensors are arranged at the conveyor entrance and exit, and at the board clamp position, etc.
1-4
3. Axis configuration
The YSi-V servomotor-controlled axis configuration and movement are shown in the drawing and table below.
n Single lane
1

Axis configuration
Example of single lane, right-to-left flow
Plus direction
Laser height sensor : option Minus direction
Inspection head
CZ-axis
(option)
R-axis
Y-axis
X-axis
Board
W-axis
Conveyor rail
23113-M9-00
n Function of each axis
Axis Function
X-axis Moves the camera in parallel with the board transport direction of the conveyor.
Y-axis Moves the camera perpendicular to the board transport direction of the conveyor.
CZ-axis * Changes the distance between the inspection head and board.
W-axis Changes the conveyor width.
R-axis Rotates the laser height sensor. (Single lane)
* Option
1-5
n Dual lane (Option)
1
Axis configuration
Example of dual lane, right-to-left flow
Plus direction
Minus direction
Inspection head
CZ-axis
(option)
Y-axis
X-axis
Board
W2-axis
Lane 2 Board
W1-axis
Conveyor on
reference side Lane 1
Conveyor rail
23113-M9-00
n Function of each axis
Axis Function
X-axis Moves the camera in parallel with the board transport direction of the conveyor.
Y-axis Moves the camera perpendicular to the board transport direction of the conveyor.
CZ-axis * Changes the distance between the inspection head and board.
W1, W2-axis Changes the conveyor width.
* Option
1-6
4. Option units
4.1 Marking unit
The YSi-V can be optionally equipped with a marking unit that draws marks and writes character strings on
1
boards depending on the results of board inspection.

Marking unit
YSi-V
Pen cap (moves back and forth)

Marker pen Marker pen holder
clamp knob
Marker pen
insertion hole
23104-M9-00
n Marker pen
Draws marks and writes character strings on boards.
n Marker pen holder

Holds the marker pen. When the dedicated pen is in contact with the stopper (upper) of the pen holder, the height
becomes correct.
n Marker pen clamp knob

Use this knob to clamp the marker pen. Turning the knob clockwise tightens the clamp and turning it counterclockwise
loosens the clamp.
n Pen cap
This is used as the cap for the marker pen tip. The cap moves back and forth, and is in the back position when the
marking pen is being used.
TIP
For instructions on how to use the marking unit, see the option manual "Marking unit" at the end of this manual.
1-7
4.2 Laser height sensor
The YSi-V can be optionally equipped with a laser height sensor for measuring heights.
1 Laser height sensor

YSi-V
Laser height sensor

(rotary type)
23105-L9-00
n Laser Measurement
The Laser Measurement is one of the Algorithms. Use the laser height sensor to measure the height in the step. If it is
judged whether or not the measurement result is within the range set by the user. When the measurement result is within
the range, it is determined as “OK”. If not, it is determined as “NG”.
n Major applications
Checking Body Lifting

Measures the BGA height to detect defective connections caused by a Body Lifting of BGA, pinching parts and so forth.
It also measures the height and other parameters of recessed polarity marks to detect the polarity.
Checking Lifted Lead
Measures the differences in heights of lead parts such as a QFP and SOP to detect a Lifted Lead.
Checking Chip Tombstoning
Measures the differences in heights of chips and other parts to detect a Chip Tombstoning or presence/absence of
parts.
TIP
For instructions on how to use the laser height sensor, see the option manual "Laser height sensor" at the end of this
manual.
1-8
4.3 3D projector
The YSi-V can be optionally equipped with a 3D projector for three-dimensional measurement.
3D projector
YSi-V
1

3D projector
23114-M9-00
n 3D projector
The main camera of the 3D projector captures the projector images of a device at 4 directions for three-dimensional
measurement.
When extracting a part or a lead to inspect one for defective lifting for instance, designating three-dimensional heights
enables to do so conveniently and accurately without variation.
1-9
4.4 4D angular camera
The YSi-V can be optionally equipped with a 4D angular cameras that capture images obliquely from 4
1 directions.
4D angular camera
YSi-V
4D angular camera
23106-M9-00
n 4D angular camera
The 4D angular camera captures images obliquely from 4 directions.

When the visual inspection has to judge pass or fail (OK or NG) at the repair station, inspecting 4D images makes the
judgment easier.
Since the 4D images are saved in the program, it can be tuned offline.
1-10
4.5 High-speed dual lane
The YSi-V can be optionally equipped with a high-speed dual lane that transfers two boards simultaneously.
High-speed dual lane

YSi-V
1

Lane 2
Lane 1
23107-M9-00
n High-speed dual lane
This high-speed dual lane can transfer two boards simultaneously to increase the production volume per hour.
1-11
Contents
1. Before operation 2-1

1.1 Canceling emergency stop 2-1
1.2 Clearing an error 2-1
2. Starting and ending the YSi-V and software operation 2-2

2.1 Starting 2-2
2.2 Ending 2-3
1. Before operation
This section describes how to reset an emergency stop status and clear an error that the YSi-V experiences.
Be sure to read thoroughly before operating the YSi-V.
1.1 Canceling emergency stop

Follow these steps to cancel emergency stop.
1 Check safety.
Before continuing the procedure, check the surrounding area for safety. 2
2 Release the emergency stop button.
When the emergency stop button is pressed, turn it clockwise to release it
basic operation
3 Press the [READY] button.
Pressing the [READY] button on the operation panel turns on the servomotors.
[READY] button
[READY] button
23200-M9-00
1.2 Clearing an error

If an error occurs a buzzer sounds and a warning screen appears. To clear the error, use the following steps.
1 Turn off the buzzer.

Press the [BUZZER OFF] button on the error screen to turn off the buzzer.
Error screen
24200-M9-00
2 Check the cause of the error.

Possible causes are displayed on the lower part in the error screen, so check or make a note of the
description.
3 Clear the error screen.

After removing the cause of the error, press the [OK] button on the error screen to clear the error screen.
2-1
2. Starting and ending the YSi-V and software operation
2.1 Starting
Following a pre-operation inspection, use the following procedure to start up the YSi-V and software.
w WARNING
Always be sure to press the emergency stop button before inspecting the YSi-V interior.
2 n Pre-operation inspection
Check item Check content
Check that the upper part of the air pressure gauge on the YSi-V reads 0.40
Air
MPa (between 0.39 MPa and 0.41 MPa).
basic operation
Check that the specified power is connected to the power supply box located
Power supply
behind the front lower right panel of the YSi-V.
Safety cover Check that the covers are closed.
Check that no chips or debris are on the conveyor.

Conveyor Check that the conveyor units do not interfere with each other, such as push-up
pins under the conveyor rails.
Marker pen (option) Check that the pen is attached correctly.
1 Turn the main switch ON.

The main switch is located at the lower right on the YSi-V front panel. Turn the switch clockwise to the
ON position.
Main switch
ON
Main Switch
OFF
24201-M9-00
2 Perform return-to-origin.
1. Close the safety cover.
2. Cancel the emergency stop state and press the [READY] button.
3. Pressing the [Yes] button on the screen starts the return-to-origin operation.
Return-to-origin
24201-M9-00
2-2
2.2 Ending
To end the YSi-V operation, follow these steps.
1 Press the [Off] button in the button area.

[Off] button
basic operation
24204-M9-10
2 The power-off confirmation dialog appears. Follow the instructions on the screen.
Power-off screen
24205-M9-00
e Pressing the emergency stop button exits the YSi-V application program and the Windows.
c CAUTION
Use the emergency stop button when “having to immediately stop the YSi-V operation in an emergency situation”
and “instructed to do so in a dialog”. Do not use it while the YSi-V operates normally.
3 Turn off the main switch on the YSi-V.

When the YSi-V gets ready for turning off, turn the main switch counterclockwise on the YSi-V.
c CAUTION
If you turn off the power without following the correct sequence, the data may be damaged.
2-3
This chapter explains the routine operations which an operator performs, using an inspection program which
has already been created. Before reading this chapter, make sure that you understand the basic procedures
and key points explained in Chapter 2, "Basic operation". For instructions on how to create a new inspection
program and/or change the existing data, see Chapter 2, "Creating an inspection program", in the separate
"Programming Manual".
Contents
1. Overview 3-1
2. Warm-up operation 3-2
3. Selecting a board 3-3
4. Conveyor unit setup 3-4

1. Over view
This chapter explains typical daily operation per the flow chart shown below.
Daily operation flow
Pre-operation inspection
Start YSi-V
Warm-up operation
3
Select board
NO
Daily operation
Inspect same board as previous time?
YES
Start inspection Change inspection program

(automatic inspection) Change conveyor unit setup
End inspection
Turn power off
23300-M9-00
3-1
2. Warm-up operation
After starting the YSi-V, perform warm-up (aging operation) of servo motor axes.
n NOTE
A warm-up period of 15 minutes is sufficient.
Note that no warm-up operation is necessary if less than 2 hours have elapsed since the last operation.
1 Carry out the pre-operation check before starting the YSi-V.

For pre-operation checks and starting up the YSi-V, see Chapter 2, "Basic operation".
2 Start warm-up operation.

c CAUTION
Check that there are no boards on the conveyor before beginning warm-up. If push-up pins are used, remove them. If
3
a problem occurs during warm-up, press the [Stop] button to stop the operation. Then check the cause of the problem
and eliminate it.
1. Press the [Warm-up] button to open the warm-up screen.

2. Press the [Start] button to start warm-up operation.
Daily operation
"Setup" screen
Warm-up
24300-M9-10
n NOTE
If you want to specify the warm-up time, press the [Stop after time-over] button and enter the desired warm-up time.
3 End the warm-up operation.

Press the [Stop] button to end the warm-up operation. In most cases, a warm-up period of 15 minutes is
sufficient.
4 Press the [Close] button to return to the operation screen.
3-2
3. Selecting a board
Select the board to be inspected from the list of created programs.
1 In the inspection program list, select the board to be inspected.

Press the [Select] button to read out the board in the list or directly double-click on the corresponding
row in the list to load the inspection program.
c CAUTION
When the inspection program is loaded, the conveyor width will be automatically adjusted to the board width (board
size Y). Remove the push-up pins before selecting the board.
Selecting board
Name of inspection program loaded Select board. Image of board
Daily operation
[Select] button
24301-M9-10
2 Check the loaded inspection program.

The name of the loaded inspection program appears in the status area. Check that this particular name
agrees with the name of the selected board.
3-3
4. Conveyor unit setup
When push-up pins are used for board support and the board to be inspected is different from the previous
one, the conveyor unit requires setup.
The conveyor width is automatically adjusted when loading the inspection program.
Here, the manual explains the procedure for laying out the push-up pins and the method of confirming the
status of supporting the board.
n NOTE
When using the push-up plate, press the [Inspection Data] button to set the "Use Push Up Unit" item of the [Board] tab
to “Standard Use” or “Fast Use”.
■ Setup process flow diagram
Setup process flow diagram
3 Push-up pin layout
Enter state of emergency stop.

Daily operation
Remove push-up pins.
Align push-up pin heights.
Reset state of emergency stop.
Select board.
[Change] button ON
Load board.
Enter state of emergency stop.
[Push Up] button ON
Lay out push-up pins.
[Push Up] button OFF
Check that board is secured correctly.
Reset state of emergency stop.
[Change] button OFF

Unload board.
23301-M9-00
3-4
■ Setup procedure
e1
2
Press the emergency stop button and then open the safety cover.
Remove the push-up pins.
Remove the push-up pins to set up the board to be inspected.
3 Adjust the push-up pin height.

Turn the support pins to adjust the height according to the thickness of the board to be inspected.
The push-up pin height of the single lane may vary from that of the dual lane.
• Support pin height for single lane : 140 mm – board thickness
• Support pin height for dual lane : 76 mm – board thickness
Push-up pin
Height adjustment
3
■ For single lane ■ For dual lane
Board
Support pin
Board
Daily operation
Support pin
76 mm
140 mm
Magnet stand
Magnet stand
23302-M9-00
4 Close the safety cover and reset the state of emergency stop.
Close the safety cover, cancel the emergency stop state, and press the [READY] button.
5 Select the board.

Select the board to be inspected.
6 Place a board at the inspection position.

Press the [Change] button and then place a board at the entrance of the conveyor.
[Change] button
[Change] button
24302-M9-10
e7 Open the safety cover.

After making sure the board is clamped, press the emergency stop button and then open the safety
cover.
3-5
8 Arrange the push-up pins.
1. Press the [Unit] button in the button area, and press the [Push Up] button to lower the push-up plate.
[Push Up] button
[Unit] button
3 [Push Up] button
2. Arrange the push-up pins by taking the board size or mounting component positions into
24303-M9-00
consideration.
Daily operation
Arranging the push-up pins
Push-up pins
23303-M9-00
c CAUTION
Be sure to lay out the push-up pins in a manner that they do not come into contact with the conveyor rails or other
components when the push-up plate is raised.
c CAUTION
If the height of parts on the bottom of the board exceeds 30mm, do not use the push-up pin. Otherwise, the push-up
pin may interfere with a part.
9 Check that the board is uniformly clamped on the conveyor.

1. Press the [Push Up] button to raise the push-up plate.
2. Lightly press on the board by hand to check that there is no warp or play.
n NOTE
If the tip of a push-up pin does not reach the backside of the board or pushes up the board too much, the push-up
pin height must be readjusted.
0 Unload the board.

1. Close the safety cover and reset the state of emergency stop.
2. Press the [Change] button to unload the board.
3-6
Contents
Before beginning work 4-1
1. Maintaining YSi-V per formance 4-2

1.1 Essential conditions and working environment 4-2
1.2 Importance of periodic inspections and cleaning 4-3
2. Maintenance list 4-4
3. Preparing for maintenance tasks 4-5

3.1 Consumable parts 4-5
3.2 Maintenance tools 4-6
3.2.1 Cleaning tools 4-6
3.2.2 Lubricating tools and grease 4-7
3.3 Required tools 4-8
4. Weekly inspection 4-9

4.1 Checking the board sensor condition 4-9
4.2 Checking the board clamp condition 4-9
5. Monthly 4-10
5.1 Inspecting each axis 4-10
5.2 Cleaning and greasing the ball screws and linear guides 4-11
5.2.1 Cleaning and greasing the X axis ball screws 4-11
5.2.2 Cleaning and lubricating the X axis guides 4-12
5.2.3 Cleaning and greasing the Y axis ball screws 4-13
5.2.4 Cleaning and greasing the Y axes guides 4-15
5.3 Cleaning the camera lighting unit 4-16
6. Three-month inspection 4-17

6.1 Air intake fan filter 4-17
6.2 Cleaning and greasing the CZ axis (option) ball screws 4-18
7. Six-month inspection 4-19

7.1 Cleaning and greasing the marking unit (option) cam 4-19
7.2 Cleaning controller filter (For Type HS2 only) 4-20
8. One-year inspection 4-21

8.1 W axis 4-21
8.1.1 Cleaning and greasing the W axis ball screws 4-21
8.1.2 Cleaning and greasing the W axes guides 4-22
8.1.3 Cleaning and greasing the hexagon spline 4-23
8.2 Inspecting and cleaning the air/mist filters 4-24
9. How to replace consumable parts 4-26

9.1 Cleaning and replacing the conveyor belts 4-26
9.2 Replacing the UPS (uninterruptible power supply) battery 4-28
Before beginning work
In most cases, maintenance should be performed with the main power turned off.
However, some maintenance tasks are performed under emergency stop conditions with the power turned on.
In such cases, ensure adequate safety and press the emergency stop before beginning the maintenance.
The power is turned on during maintenance where any servo-axis must be operated or YSi-V operation
checked. In this case, also ensure adequate safety before beginning the maintenance.
When operating the YSi-V, make sure the following conditions are met.
n Operating conditions
1. Supply air pressure is kept at correct pressure.
2. All safety covers are closed.
3. Power cable is correctly connected.
Maintenance
4-1
1. Maintaining YSi-V performance
The most important condition essential for maintaining the performance of the YSi-V you purchased is using
it under good environmental conditions. Performing daily maintenance and periodic inspections is also
absolutely essential.
1.1 Essential conditions and working environment
n Air
Item Description
Supply air pressure: 0.45MPa

Air pressure Setting air pressure: 0.40MPa (0.39MPa to 0.41MPa)
Head unit air pressure: 0.040MPa (0.039MPa to 0.041MPa)
Air consumption Air consumption: 24L/min. (ANR) or more can be kept.
Use an air hose with an inner diameter (I.D.) of 3/8-inch and a Hi Cupla (30SH).
Use conditions
Clean air passed through air dryer and air filter should be used.
n Power
Item Description
Power supply 200/208/220/240/380/400/416VAC (±10%), 3-phase AC line
4 Frequency
Power supply capacity

50 Hz or 60 Hz
7.0KVA
Average power consumption 0.7KW
Power supply connection Conductor cross-section area of power cable: 3.3mm2 (AWG12) or more
Maintenance
n Environment
Item Description
Noise Complies with EN61000-6-2 standard.
Humidity 20 to 80% (no condensation), optimal range: 50 to 60%
Temperature Functions guaranteed within 15 to 35°C. Machine precision guaranteed within 20 to 28°C.
Overvoltage category category III
Pollution degree degree 2
Altitude 1000m or less above sea level
No dust or powder.(The number of dust particles of more than 0.5 μm in diameter should
Atmosphere be less than 100000/feet 3) No organic solvent vapor, sulfurous acid gas, chlorine gas
and flammable gases, etc.
Flat level location sturdy enough so no vibration occurs during operation.
Wooden floors in particular are unsuitable.
Floor load-bearing strength should be 1050 kg/m2 or higher.
Installation floor condition
For load-bearing strength, consult a professional contractor who is familiar with the
installation location with information on the equipment weight, floor space, positions for
adjuster feet, etc.
n NOTE
If using an industrial humidifier to prevent generation of electrostatic charges, use pure water or equivalent.
4-2
1.2 Importance of periodic inspections and cleaning
Periodic inspections and cleaning are extremely important maintenance tasks. Failure to perform inspections
and cleaning will prevent the YSi-V from delivering full performance and may lead to inspection errors or
YSi-V breakdowns.
Examples:
• Dirty optical system (camera, lighting, etc.) may cause recognition errors.
• Poor greasing of axes may cause abnormal noises.
• Poor inspections such as of valves may cause errors in PCB clamping and conveying.
As these examples show, failure to make inspections may lead to YSi-V problems. We strongly recommend you
perform periodic inspections and cleaning to ensure the YSi-V is used under optimal conditions.
Maintenance
4-3
2. Maintenance list
n Maintenance list
The following maintenance procedure codes are used:
S: Inspection C: Cleaning L: Lubrication E: Replacement ( ): Procedure required only when a problem exists.
n NOTE
Example) C (E) is indicated in the Others, Air, Mist filter, and Filter items of the table shown below. This indication means
that the part needs to be replaced if the contamination cannot be removed as a result of the filter cleaning work.
Section Unit name Check items Weekly Monthly 3 Mon. 6 Mon. 1 Year 2 Years 3 Years
Ball screw SCL

X-axis
Guide SCL
Servo
Ball screw SCL
controlled axes Y-axis
Guide SCL
CZ-axis (option) Ball screw SCL
Board sensor SC
Board transport unit Board clamp S
Conveyor belt SC E
Conveyor
Ball screw CL
W-axis Guide CL
4 Vision system
Lighting unit
Optical camera
Hexagon spline
Camera lighting
unit
CL
CL
Base unit Filter C (E)

Others
Air/mist filter Filter, Cup C (E)
Maintenance
Filter
Main unit Controller (For Type HS2 C (E)
(inside) specification only)
UPS UPS battery *1
Option Marker pen unit Cam block CL

*1: The UPS battery will wear down, reaching the end of its service life. The service life slightly differs depending on the usage
environment (ambient temperature, etc.). As a general guide, the UPS battery should be replaced with a new one after the UPS
has been operated for 2.5 years even under the optimal conditions.
For detailed information on how to replace the UPS battery, see the user's manual that comes with the UPS.
c CAUTION
The inspector has the Camera Check Station illustrated below in its body. The Camera Check Station has some
checking jigs such as the light adjuster/3D checking plates to check the camera condition automatically and
periodically. DO NOT use alcohol upon cleaning these light adjuster/3D checking plates. If the alcohol be applied to,
it would make the surface of plate change in color and interfere the correct checking. As such, dust with a lens
blower brush or wipe gently with dry lint-free cloth upon cleaning.
Camera Check Station
[YSi-12 Camera Check Station] [YSi-V Camera Check Station (3D/optional)]

Light adjuster (Bi-color) Light adjuster (Bi-color)
3D Checking plate
Light adjuster (white)
53457-M9-00
4-4
3. Preparing for maintenance tasks
3.1 Consumable parts
The term "consumable parts" in this manual indicates parts subject to continual wear during use causing
gradual loss of functions.
The following parts are classified in this manual as consumable parts and should be replaced as needed during
maintenance.
n Consumable parts list (optional parts)

Product Name Parts List Designation Parts No.
Conveyor belt (for single lane) BELT 1, CONVEYOR KLT-M9127-00X
Conveyor belt (for dual lane) BELT 1, CONVEYOR KKT-M9127-00X
Air filter element FILTER ELEMENT KLC-M8506-00X
Oil mist filter element MIST FILTER ELEMENT KLC-M8507-00X
Air intake fan filter FILTER,CP FAN KLF-M115J-00X
Filter for controller FILTER KLC-M421L-00X
4
UPS battery BATTERY,UPS2 LG0-M53H8-01X
c CAUTION
• Parts (part numbers) listed in this manual are current as of the time this manual was issued.
• When placing an order, always contact us to obtain the latest information.
Maintenance
• Part numbers are subject to change without notice. Please contact our sales representative before ordering.
4-5
3.2 Maintenance tools
3.2.1 Cleaning tools
Cleaning tools
Parts supplied with YSi-V
CLEANER, VISION SET
Lens blower brush Lens cleaner, cleaning paper
Cotton swab sticks
53406-M9-10
4
n Cleaning tools
Parts supplied with YSi-V
Product Name Parts List Designation Parts No. Note
Cotton swab sticks SWAB KGA-M3802-00X

Maintenance
CLEANER, VISION SET

Lens blower brush BLOWER KGA-M3803-00X
(KHW-M3801-YYY)
Lens cleaner,
CLEANER, LENS KGA-M3801-00X
Cleaning paper
Cleaning tools
Optional parts
Vacuum ASSY Air blow tool
53407-M9-00
n Cleaning tools
Optional parts
Product Name Parts List Designation Parts No. Note
Vacuum ASSY VACUUM ASSY KHY-M88V0-A0X For cleaning (vacuum)
Air blow tool AIR BLOW TOOL KU4-M8590-00X
c CAUTION
Part numbers are subject to change without notice. Please contact our sales representative before ordering.
4-6
3.2.2 Lubricating tools and grease
Lubricating and greasing tools

Optional parts
GREASE GUN SET
Grease gun
Standard nozzle
Grease gun nozzle

(flexible type)
Grease gun nozzle

(30 deg. bent type)
Cleaning wiper Grease (coming with YSi-V)
4
53408-M9-10
n Lubricating and greasing tools

Optional parts
Parts List
Product Name Parts No. Note
Designation
Maintenance
Lithium-based grease GREASE PACK K48-M3856-00X NSL 80g
Grease gun (with standard nozzle) GREASE GUN K48-M3852-01X

GREASE GUN SET
Nozzle (flexible type) GREASE NOZZLE K48-M3857-00X
KHW-M3852-A0X
Grease gun nozzle (30 deg. bent type) GREASE NOZZLE K48-M3854-00X
Cleaning wiper WIPER KGS-M3840-YYY
c CAUTION
Part numbers are subject to change without notice. Please contact our sales representative before ordering.
n Precautions when handling grease
w WARNING
Inflammation may occur if grease or lubricant gets into the eyes. Before handling the grease or
lubricant, wear safety goggles to ensure the grease or lubricant does not get into the eyes.
w WARNING
Inflammation may occur if grease or lubricant comes into contact with skin. Be sure to wear protective
gloves to prevent contact with skin.
w WARNING
Do not take orally or eat grease or lubricant. Eating will cause diarrhea and vomiting.
c CAUTION
After use, tightly cap the grease tube to ensure dust, debris and moisture do not enter inside. Store the grease in a
dark location not exposed to direct sunlight and keep it away from fire and heating sources.
c CAUTION
Be sure to use the specified grease and apply it to the specified location by following the instructions in this manual.
Failure to follow the instructions may cause damage to the YSi-V.
4-7
3.3 Required tools
Prepare the following tools and items necessary for maintenance.
n Tool list
: Supplied with YSi-V, : Options
Name Description Remarks
Phillips screwdriver Large, small D-2
Slotted (flat-blade) screwdriver Large, small
Hex wrench set 1 set HEX, WRENCH SET
Used to remove foreign objects or debris falling

Tweezers
on ball screw or guide.
Grease gun Used to supply grease
Used to clean belt groove and sensor detection

Vacuum ASSY
surface.
Air blow tool Used for cleaning
n Other tool list
4
: Supplied with YSi-V, : Options
Name Description
Grease (lithium-based grease: NSL) Used to lubricate each axis.
Cleaning cloth Used to clean filter cup.

Maintenance
Cleaning wipe Use lint-free cleaning wipe (for clean room).
Square bandage Used to prevent parts from being lost or contaminated. (2 sheets)
Cotton swab stick Used to clean camera lens, half mirror and lighting unit.
Lens cleaner,
Used to clean camera lens and lighting unit.
Cleaning paper
Lens blower brush Used to clean camera lens and lighting unit.
Fine brush (tooth brush, etc.) Used to clean the belt groove, etc.
n Safety goggles and mask
Name Description
Dust-proof goggles
Always wear these goggles and mask when applying grease or when
using an air blow tool.
Dust-proof mask
Always wear protective gloves when applying grease or when removing

Protective gloves
optical camera cover.
4-8
4. Weekly inspection
4.1 Checking the board sensor condition
This equipment uses transmission type fiber sensors as the board sensors. Periodically check that these sensors
correctly operate even when the conveyor rail width is changed.
1 Open the [Unit] – [Conveyor] tab.

Step 2 Changing the conveyor width
2 Press the [Width] button to change
the conveyor width.
1. When the “Conveyor” dialog box
appears, enter the maximum conveyor
width in the "Target Width" box and press
the [OK] button. The conveyor width will
automatically change to the specified
size.
2. Then, enter the minimum conveyor width
(50mm) in the “Target Width” box and
press the [OK] button. The conveyor
width will automatically change to the
specified size.
4
54400-M9-10
3 Check whether an error has Enter the conveyor width here.

occurred.
The conveyor sensor is operating properly
unless an error message appears when the
Maintenance
conveyor width is changed. No further
check is necessary.
If an error message appears, follow the steps
below to adjust the sensor.
n Adjusting the conveyor sensor Tuning conveyor sensor

If an error occurred when the conveyor width was 2
changed, perform the auto-tuning of the conveyor
sensor.
1. Open the [Unit] – [I/O] tab.
2. In the Output list, select “CONVEYOR” (T01000E0).
n NOTE
For the dual lane specifications, (T01000E0) corresponds
to lane 1 while (T01000E2) corresponds to lane 2.
3. Press the [ON/OFF] button to change to 0 (OFF) →

1 (ON) → 0 (OFF) and perform the auto-tuning.
4. Press the [Width] button again to change the
conveyor width in the same manner as described in
Step2. When no error message appears, the sensor
operates correctly.
54401-M9-10 3
4.2 Checking the board clamp condition

Check the following points when a board is clamped on the conveyor.
1. Check that the board is securely clamped and there is no play.
2. Check that there is no clearance between the board hold plate and the board.
3. Check that the board surface is flush with the conveyor rail upper surface.
4. Check that the board clamp unit moves smoothly.
4-9
5. Monthly
5.1 Inspecting each axis
Inspect the ball screws and the guides on each axis.
Check the following points.
n NOTE
A grease spattering prevention cover is attached along each axis. Remove the cover before inspection and reattach
it in place after inspection.
Checkpoints
1. Any foreign matter or chips adhering to the ball screws and linear guides?
2. Do the ball screws and linear guides have the correct amount of grease?
Check if grease has flowed off or splattered in the air failing to adhere. Also check if grease has discolored or
hardened.
3. Any abnormal sounds from the ball screws?
Press the emergency stop button. Then check for any abnormal sounds while pushing the unit by hand along the X-axis
or Y-axis back and forth.
Countermeasures
1. Ball screws and linear guides may be damaged when chips or debris bite into them. If chips or debris are adhering,
4
wipe them off along with the grease or remove with tweezers, etc.
2. Apply grease while referring to "Cleaning and greasing the ball screws and linear guides of each axis" described later.
3. Consult your YAMAHA sales office or representative when abnormal sounds occur even after trying the
countermeasures in the above steps 1 and 2.
c
Maintenance
CAUTIN
• When handling grease or lubricant, read and follow the precautions listed in section 3.2.2, "Lubricating tools and
grease", in this chapter.
• If abnormal noise is emitted from the ball screw or guide of each axis, then contact our sales representative for
assistance. Disassembly and cleaning of the ball screw or guide by the user will void the warranty.
4-10
5.2 Cleaning and greasing the ball screws and linear guides
To clean and grease the ball screws and linear guides of each axis, follow the steps below. See “Chapter 5
Lubrication points” for the modes and points of lubrication.
5.2.1 Cleaning and greasing the X axis ball screws

n Required tool
• Phillips screwdriver
• Lint-free paper wipe
• Grease gun
• Specified grease (NSL)
• Protective glasses
• Protective gloves
c CAUTION
Wear protective glasses and gloves when handling grease.
e1 Press the emergency stop button.

The YSi-V must be in emergency stop to
ensure safety during work.
Step 2 Removing the X-axis grease spattering prevention cover
2 Remove the grease spattering
4
prevention cover.
1. Use a Phillips screwdriver to remove the
left side of the grease spattering
prevention cover.
2. Move the head all the way to the left
side and remove the screws securing the
Maintenance
Cover mounting screw
right side of the grease spattering
prevention cover.
3. Remove the grease spattering prevention
Step 3 Cleaning the X-axis ball screws
cover by pulling it to the right.
53401-M9-00
3 Clean the ball screws.

1. Wipe away the old grease and dirt from
the entire ball screw with a lint-free cloth
or paper towel (for clean room).
2. Move the head to the opposite end of
each axis and wipe the ball screw clean. Cleaning cloth
53402-M9-00 X-axis ball screws
n NOTE
Wipe away the old grease and dirt in the lead groove
Step 4 Greasing the X-axis ball screws
of the ball screw. Also check that no debris or residue
remains in the lead groove.
4 Apply grease to the ball screws.

Use the grease gun to supply the specified
grease (NSL) to the grease nipples.
Then move the head back and forth by
hand along each axis and wipe away
excess grease.
53403-M9-00
5 Reattach the covers. Grease nipple for

Reattach the grease spattering prevention
X-axis ball screws
covers in the reverse order of the removal
procedures.
4-11
5.2.2 Cleaning and lubricating the X axis guides
n Required tools
• Lint-free paper wipe
• Grease gun
c CAUTION

Step 2 Cleaning the X-axis guides
2 Clean the guides.

1. Move the head (or conveyor rails) to one
end of its axis, and wipe away the old
grease and dirt from the guides with a
lint-free cloth or paper towel.
2. Move the head (or conveyor rails) to the
opposite side of its axis and wipe the
4 guides.
53404-M9-00
X-axis guides Cleaning cloth
n NOTE
Wipe away thoroughly the old grease in the grooves of
Maintenance
the guide rails. Step 3 Greasing the X-axis guide
3 Apply new grease to the guide rails.

grease (NSL) to the X-axis guide grease
nipples.
The grease nipples are located behind the
head unit, two each on the right and left at
the positions (heights) of the upper and
lower guides (total of 4 places).
53405-M9-00
4 Remove excess grease.

After moving the axis back and forth a few
times manually, wipe away excess grease.
X-axis guide Grease nipple (Total of 4 places)
4-12
5.2.3 Cleaning and greasing the Y axis ball screws
n Required tools
• Hex wrench
• Lent-free cleaning wipe
• Grease gun
c CAUTION
Step 2 Remove the rear cover.
e
1 Press the emergency stop button.
Phillips screwdriver
2 Remove the rear cover.

Use a Phillips screwdriver to remove the four
screws and then remove the rear cover.
53411-M9-00
3 Remove the grease spattering

prevention covers.
Remove the Y-axis grease spattering
prevention covers as follows:
4
1. Using the hex wrench, remove the bolts
Maintenance
(3 pcs.) that secure the Y-axis front
grease spattering prevention cover.
2. In the same way, remove the bolts
(2 pcs.) that secure the rear grease
spattering prevention cover. Step 3 Removing the Y-axis grease spattering prevention cover
3. Remove the grease spattering prevention
cover by pulling it toward you (YSi-V front
side).
53412-M9-00
TIP
When reattaching the Y-axis grease spattering
prevention covers, use the reverse order of the above
procedure.
4 Clean the ball screws.

1. Using the handle, move the head unit to
the rear side of the Y-axis. Cover mounting bolt
the entire ball screws with a lint-free
cloth or paper towel (for clean room).
3. Move the head unit to the opposite side
of the Y-axis and wipe the ball screws on
the opposite side.
n NOTE
Wipe away thoroughly the old grease in the lead
grooves of the ball screws. Also check that no debris or
residue remains in the lead grooves. Grease spattering prevention cover
4-13
5 Apply grease to the ball screws. Step 5 Greasing the Y-axis ball screws
grease (NSL) through the grease nipples
shown in the figure at right. Then move the
head unit back and forth by hand along the
Y-axis and wipe away excess grease.
53414-M9-00
6 Reattach the cover.

Reattach the grease spattering prevention
covers in the reverse order of the removal
procedure.
Grease nipple for

Y-axis ball screws
4
Maintenance
4-14
5.2.4 Cleaning and greasing the Y axes guides
n Required tools
• Grease gun
c CAUTION

Step 2 Cleaning the Y-axis guide
2 Clean the guides.

1. Using the handle, move the head to the
rear side.
the entire guides with a lint-free cloth or
paper towel (for clean room).
3. Move the head to the opposite side and
4
wipe also the guide on the opposite side.
53415-M9-00
n
Cleaning cloth
NOTE
Wipe away thoroughly the old grease in the grooves of Y-axis guide
the guide rails.
Maintenance
Step 3 Greasing the Y-axis guide
3 Apply grease to the guides.
Use the grease gun to supply the specified Front side
grease (NSL) through the grease nipples for
the Y-axis guides. There is one grease nipple
each on the left and right sides as shown in
the figure at right. (4 places in total,
including the front and rear nipples)
53416-M9-00

After moving the axis back and forth a few Grease nipple (4 places) for Y-axis guide
times manually, wipe away excess grease.
Rear side
4-15
5.3 Cleaning the camera lighting unit
Dirt or dust particles sticking to the lighting unit of the optical camera can cause recognition errors during
inspection. Monthly inspection and cleaning are recommended to prevent this problem.
c CAUTION
Do not apply strong force or shock to the camera unit and lighting unit during cleaning. Optical axis adjustment might
become unreliable.
n Required tools
• Optical lens brush
• Lens cleaner and cleaning paper

c CAUTION
To ensure safety, make sure that the YSi-V power switch
is off or the emergency stop button is pressed before
starting work.
4 2 Remove the diffuser plate.

Using the Phillips screwdriver, remove the
Step 2 Removing the diffuser plate
four screws holding the diffuser plate and

remove the diffuser plate.
Maintenance
53425-M9-10
c CAUTION
When removing the diffuser plate mounting screws, be
careful not to lose the spacer.
3 Clean the diffuser plate. Spacer (5 pieces)

Remove dirt and dust on the entire diffuser
plate with a paper wipe. Diffuser plate Diffuser plate mounting screw (five screws)
4 Clean the optical camera lighting Step 4

unit. Cleaning the lighting for optical camera
Use a lens blower brush to remove dust on
the lighting unit of the optical camera
lighting unit.
If excessively dirty, wet a piece of cleaning
paper with a few drops of lens cleaner and
wipe the dirt off.
53426-M9-00
5 Reattach the diffuser plate.

Reattach the diffuser plate in the reverse
order of the removal procedure.
Optical lens brush Camera lighting
4-16
6. Three-month inspection
6.1 Air intake fan filter
Failure to clean the filter may cause filter clogging, leading to increase in temperature inside the YSi-V. To
prevent YSi-V malfunction or shortening of the service life, be sure to clean each filter. The filter to be cleaned
is one kind and installed at two locations shown in the figure below.
Filter installation location
Filter
YSi-V rear side

4
Filter
YSi-V front side
Maintenance
53450-M9-00
n Cleaning the filter

Step 2 Removing the filter
1 Perform the preparations for work. ■ Front filter
1. Turn off the YSi-V power and open the
cover. Filter
2. Prepare a vacuum cleaner to be used

Handle
for the cleaning.
2 Remove the filter.

Remove the filter as shown in the figure at
right.
53451-M9-00
3 Clean the filter.

Suck the filter with the vacuum cleaner.
c CAUTION
When using the filter in the wet state, dust may be ■ Rear filter
solidified by moisture, causing filter clogging to easily
occur. Since the filter can be cleaned enough with the
vacuum cleaner, do not use any water to clean the
filter.
Filter
n NOTE
If the contamination cannot be removed or the filter Handle
deteriorates, replace the filter with a new one.
4 Reattach the filter in place.

Reattach the filter in the reverse order of the
removal procedures.
4-17
6.2 Cleaning and greasing the CZ axis (option) ball screws
n Required tools
c CAUTION

2 Clean the W axis ball screw. Step 2 Cleaning the CZ axis ball screw
Wipe away the old grease and dirt from the
entire ball screw with a paper wipe.
53466-M9-00
n NOTE
Wipe away the old grease and dirt in the lead groove
of the ball screw. Also check that no debris or residue
4
remains in the lead groove.
3 Apply grease to the ball screw.

Apply the specified grease (NSL) by hand
uniformly over the entire ball screws. Paper wipe
Maintenance
4 Wipe away excess grease.

After moving the CZ axis up and down, wipe
away excess grease with a paper towel. Ball screw
4-18
7. Six-month inspection
7.1 Cleaning and greasing the marking unit (option) cam
n Required tools
• Hex wrench (3mm)
c CAUTION

Step 2,3 Cleaning each part
2 Remove the grease cover.

Using the hex wrench, loosen the bolts that
4
secure the grease cover and remove the
cover.
53452-M9-10 Cam block
Grease cover
clamp bolt (2 pieces) Cleaning cloth
3 Clean each part.
Wipe away the old grease and dirt from the
Maintenance
cam block, cam follower, and grease cover
with a lint-free cloth.
4 Apply the grease.

Cam follower
uniformly over the slant surface of the cam
block. Grease cover
53453-M9-00

After moving the marking unit up and down, Step 4 Applying the grease
wipe away excess grease with a lint-free
cloth.
6 Reattach the grease cover.

Reattach the grease cover in place that has
Grease
been removed in Step2.
4-19
7.2 Cleaning controller filter (For Type HS2 only)
The controller for controlling the YSi-V is equipped with a filter. Depending on the operation of the YSi-V, the
filter requires cleaning every 6 months as a guideline.
n Required tools
• Vacuum cleaner or vacuum assembly (option)
1 Turn off the power supply to the

YSi-V. Step 2 Removing front lower panel
2 Remove the front lower panel.
1. Open the safety cover.
2. Pull out the front center panel. Safety cover
3. Pull out front lower panel.

53454-M9-00
3 Remove the filter.

Remove the filter installed on the back of
the controller with hands.
53455-M9-00
c CAUTION
Note that the circuit breaker is near the filter. Do not
4
unintentionally turn off the circuit breaker when pulling Front lower panel
out the filter. Front center panel
4 Remove the dirt on the filter.

Use a vacuum cleaner or a vacuum Step 3 Removing filter
Maintenance
assembly (option) to remove dirt on the

Filter
filter.
53456-M9-00
n NOTE
If the dirt is too excessive to remove or if the filter is
deteriorated, replace the filter with a new one.
5 Re-assemble the filter.

1. Install the filter in the original place.
2. Install the front lower panel. Close the
front center panel and safety cover.
c CAUTION
When installing the filter, do not unintentionally turn off
the nearby circuit breaker.
Step 4 Cleaning filter
Vacuum assembly
4-20
8. One-year inspection
8.1 W axis
8.1.1 Cleaning and greasing the W axis ball screws

n Required tools
c CAUTION
e1 Clean the ball screws.

1. Operate the [Width] button on the “Unit”
– “Conveyor” screen to set the conveyor
Step 1 Cleaning the W-axis ball screws
width to the maximum. Put the YSi-V in

the state of emergency stop.
4
the entire ball screws with a lint-free
cloth (for clean room).
3. Cancel the emergency stop state. After
e narrowing the board width, press the

emergency stop button again and wipe
Maintenance
the remaining parts.
53421-M9-00
n NOTE
Carefully wipe away the old grease and dirt in the lead
groove of the ball screw during cleaning work. Also
check that no debris is generated.
Cleaning cloth W-axis ball screws
2 Apply grease to the ball screw.

uniformly over the entire ball screw.
n NOTE
Adjust the board width in the same manner as
described in Step1, and then apply the grease over the
entire ball screws.
4-21
8.1.2 Cleaning and greasing the W axes guides
n Required tools
• Grease gun
c CAUTION
e1 Clean the guide.

Step 1,2 Cleaning and greasing the W axes guides
Grease nipple for W-axis guides

2. Use lint-free cleaning paper (for clean
room application) or a similar one to
wipe off old grease and dirt on the entire
guide.
3. Reset the state of emergency stop.
e
4
Narrow the board width. Then, press the
emergency stop button to clean the rest
of the area.
53423-M9-00
n NOTE
Maintenance
Wipe away thoroughly the old grease in the grooves of

the guide rails.
2 Inject new grease.

Prepare a grease gun and inject the Cleaning cloth W-axis guides
specified grease (NSL) from the right grease
nipple.
The grease nipple is provided at one
location on each of the left and right guides
(two locations in total).
n NOTE
See Chapter 5, “Lubrication points”, for details on the
lubrication points and grease gun nozzles.
3 Wipe away excess grease.

1 Widen and narrow the conveyor width
several times.
2 Press the emergency stop button again
e and wipe away excess grease with a

lint-free cloth.
4-22
8.1.3 Cleaning and greasing the hexagon spline
n Required tools
c CAUTION
e1 Clean the hexagon spline.

Step 1 Cleaning the hexagon spline

the entire hexagon spline with a lint-free
paper wipe (for clean room).
3. Cancel the emergency stop state. After
e narrowing the board width, press the

emergency stop button again and wipe
the remaining parts.
2 Apply the grease.

53448-M9-00
4
uniformly over the entire surface of the
Maintenance
hexagon spline.
53449-M9-00 Hexagon spline
Paper wipe
n NOTE
Adjust the board width in the same manner as
Step 2 Applying the grease
described in Step1, and then apply the grease over the
hexagon spline.
Apply the grease thinly

and uniformly.
Grease
4-23
8.2 Inspecting and cleaning the air/mist filters
Air/mist filters are used to prevent oil, mist and other impurities in the air compressor from penetrating into the
YSi-V. These filters should be inspected and cleaned periodically as instructed below.
c CAUTION
Remove the coupler to ensure safety during work. At this time, pay special attention so that oil, water, or impurity does
not scatter.
Additionally, be aware that a large air exhaust sound is heard when removing the coupler.
n Required tools
• Neutral detergent
• Air blow tool (Option tool to be purchased)
• Cloth rag
• Slotted precision screwdriver
• Hex wrench (2.5mm)
• Dust-proof goggles
• Dust-proof mask
c CAUTION
The cleaning blow air may be in contact with your face. So, be sure to wear dust-proof goggles and dust-proof mask
before starting the air blow.
4 1 Check the inside of the filter cup. Step 2,3 Removing the filter cup
Check the inside of the cup for oil or water.
If the inside of the cup is contaminated, Bolt
follow the steps below to clean it. Bracket
2 Separate the air and mist filters.

Maintenance
1. Using the hex wrench (2.5), loosen the

bolts.
2. Slide the pin downwards. Remove the
bracket. Separate the air filter and mist
filter.
53431-M9-00
3 Remove the filter cup.

Air filter
Pin
1. Turn the air filter counterclockwise as
shown in the figure at right to pull it
downward. Oil mist filter
2. Put the slotted precision screwdriver in
the groove close to the snap fit of the Air filter
Filter cup
deflector and remove the element
assembly from the filter cup. Remove the air coupler.
Mist filter
Step 3 Removing the element assembly
Turn the filter cup counterclockwise as
shown in the figure at right to pull it Air filter
downward.
Deflector
53432-M9-10
4 Remove the contamination inside

the filter cup. Snap fit
1. Lightly wash the cup with water.
2. Further wash the inside of the cup with
neutral detergent diluted with water.
3. After blowing the air with the air blow Filter cup
tool, wipe away water with a cloth rag.

Slotted precision screwdriver
4-24
5 Remove the filter element. Step 5 Removing filter element
Air filter
Turn the baffle in the direction shown in the
figure at right to remove it from the element
assembly.
Mist filter
Turn the filter element in the direction shown
in the figure at right to remove it.
53433-M9-00
Air filter
6 Check the filter element conditions.

Check the filter element for contamination Baffle
or clogging.
Oil mist filter
If the filter element is contaminated, replace
it with the new filter element stated in the
consumable parts list.
7 Reattach the filter element and

filter cup.
Reattach the filter media and cup in the
reverse order of the removal procedures.
TIP
The manual tightening torque for the cup must be set
to approximately 2.2N·m.
8 Reattach the air coupler.

Connect the air coupler and check that no
4
air is leaking.
Maintenance
4-25
9. How to replace consumable par ts
9.1 Cleaning and replacing the conveyor belts
n Required tools
• Hex wrenches 3mm, 4mm, 5mm
• Paper wipe
• Fine brush
• New conveyor belt
• Square piece of cloth

Step 3 Loosening the belt tensioner bolt
Hex wrenches (5)
2 Open the front safety cover of the

YSi-V. Hex wrenches (4)
3 Loosen the belt.

1. Place a square piece of cloth over the
guide and ball screw.
4 2. While referring to the figure on the right,

loosen the tension pulley with the hex
wrenches (4 and 5) and then slide it fully
along the elongated hole (in the
direction of slackening the belt).
Maintenance
53441-M9-00
Tensioner bolt
4 Detach the belt.
Using the M3 hex wrench, loosen the bolt Step 4 Removing the shaft
securing the belt drive pulley and pull out
the shaft. Then detach the belt from the Pull out the belt from
pulley and take it out through the space this clearance.
between the pulley and the shaft.
53442-M9-00
5 Remove the board clamp board.

Using the hex wrench (3), remove the bolts
(4 locations) that secure the board clamp
board and remove the board clamp board.
53443-M9-00
Drive pulley
Shaft
Step 5 Removing the board clamp board
Board clamp board mounting bolt
Board clamp board
4-26
6 Detach the belt from the conveyor.
7 Clean the conveyor rail.
Use a fine brush or cleaning cloth to clean
the gap between the conveyor rail and
board guide.
8 Attach a new belt. Step 8 Attaching a new belt

1. Temporarily fit a new belt onto the pulley.
2. Reconnect the shaft to the pulley and
tighten the bolt.
3. Tighten the belt tensioner bolt while
applying a proper tension to the belt by
moving the belt tensioner bolt.
53447-M9-00 Span length
138 mm
TIP
Proper belt tension and pulley pitch are as follows:
Tension 150 to 180Hz
Span length 138mm
c CAUTION
The tightening torque for the tension pulley must be set
to 5.5N·m.
4
Tension measurement location
9 Reattach the board clamp board.

1. Fit the board clamp board to its original
position and secure it temporarily with
the clamp bolts.
Maintenance
2. On the [Unit] – [Conveyor] tab, press the
[Board Clamp] button to raise the board
clamp assembly and tighten the bolts
securely.
c CAUTION
During adjustment, compressed air must be supplied
and the board clamp raised.
0 Check the belt rotating condition.

1. Open the [Unit]-[Conveyor] tab, and
press the [Board Clamp] button again to Step 10 Checking the belt rotating condition
unclamp. At this point, make sure that
the top of the board clamp assembly is
0.5mm lower than the upper surface of
the belt.
2. On the [Unit]-[Conveyor] tab, press the
[Conveyor In] button or [Conveyor Out]
button to turn on the conveyor motor
and check the belt rotation.
0.5 mm
3. If the rotation speed fluctuates or there is
Belt upper surface
slack in the belt, adjust the position of
the tensioner bolt and then check the
rotation again. Board clamp board
Board clamp
53445-M9-00
4-27
9.2 Replacing the UPS (uninterruptible power supply) batter y
The UPS battery used in this equipment will wear down, reaching the end of its service life. The battery service
life and replacement interval differ depending on the usage environment (ambient temperature, etc.).
For detailed information on how to replace the UPS battery, see the user's manual that comes with the UPS.
n NOTE
When you have replaced the UPS battery, write the replacement date on the label affixed to the UPS unit and the left
side of the main switch.
4
Maintenance
4-28
Contents
1. Lubrication points and applicable grease 5-1

1.1 Applicable grease 5-1
1.2 Grease gun 5-1
2. Lubrication of each unit 5-2

2.1 Each axis unit 5-2
2.1.1 X and CZ axis guide and ball screw 5-2
2.1.2 Y axis guide and ball screw 5-3
2.1.3 W axis guide and ball screw 5-4
1. Applicable grease and grease gun
1.1 Applicable grease
When greasing the lubrication points, be sure to use appropriate grease specified by YAMAHA as listed below.
c CAUTION
If grease other than that specified is used, this may cause damage to the YSi-V.
n List of specified grease

Lubrication
Guide Ball screw Remarks
point
X-axis NSL grease NSL grease
Y-axis NSL grease NSL grease
CZ-axis ー NSL grease Option
W-axis NSL grease NSL grease
1.2 Grease gun

Select an appropriate nozzle suitable for the lubrication point from three kinds of nozzles shown below and
attach it to the grease gun to apply the grease. Change the nozzle according to the greasing instructions.
Grease gun
30°-bent type nozzle

Grease gun
Chuck flexible type nozzle

5
Lubrication points
30°
Standard nozzle
Change the
nozzle here.
Outside diameter Outside diameter Outside diameter

of tip: φ5 of tip: φ10 of tip: φ14
53501-M9-00
c CAUTION
Prepare different nozzles by grease. If two or more kinds of grease with different characteristics are mixed in the nozzle
and it is applied, this may cause the YSi-V performance to lower.
5-1
2. Lubrication of each unit
This section explains the lubrication points of each unit, lubrication intervals, and lubrication methods.
2.1 Each axis unit
2.1.1 X and CZ axis guide and ball screw
Lubrication points for X and CZ axes
Grease gun:
X axis ball screw
Grease nipple (large), 1 location
Apply by hand:
CZ axis ball screw
X axis guide
Grease nipple (small), 2 locations
5
Lubrication points
X axis guide
Grease nipple (large), 2 location
53502-M9-00
Unit to be lubricated Lubrication point Interval Lubrication method
X axis ball screw 1 Grease gun with standard nozzle

Once a month
Left side Grease gun: Bend type nozzle
X axis guide 4
Right side Grease gun: Standard nozzle
Once every
CZ axis ball screw 1 Apply grease by hand
3 months
5-2
2.1.2 Y axis guide and ball screw
Lubrication points for Y axis
Grease gun:
Apply by hand:
Rear Y axis ball screw

Grease nipple
Y axis guide
Grease nipple
Y axis guide
Grease nipple
Lubrication points
53503-M9-00
Guide 4
Once a month Grease gun with standard nozzle
Ball screw 2
5-3
2.1.3 W axis guide and ball screw
Lubrication points for W axis
Grease gun:
Apply by hand:
W axis guide
Grease nipple
W axis ball screw
Hexagon spline
W axis ball screw
53505-M9-00
5
Guide 2 Grease gun: Bend type nozzle
Ball screw 2 Once a year Apply grease by hand
Hexagon spline 1 Apply grease by hand

Lubrication points
5-4
Appendix
Contents
1. Power connection terminals A-1
2. Connection between machines A-2
3. UPS (Uninterruptible Power Supply) A-3

3.1 Safety precaution A-3
3.1.1 Precautions when shipping or exporting the UPS A-3
3.1.2 Disposing of used battery after replacement A-3
3.1.3 Safety precautions A-3
3.2 About the UPS A-5
3.3 Operation and setting A-6
3.3.1 Front panel A-6
3.3.2 Operation during normal operation (power is normal) A-6
3.3.3 Operation during power failure or trouble A-6
3.4 Maintenance A-7
3.4.1 Battery replacement period A-7
3.4.2 Battery replacement A-7
3.4.3 Replacement battery storage A-7
3.5 Troubleshooting A-8
1. Power connection terminals
n Power supply specifications
Model No. YSi-V
Appendix
Power 3-phase AC 200/208/220/240/380/400/416V (±10%)
Frequency 50/60Hz
Power capacity 7.0 KVA
n Power input terminal

The power connection terminals are located behind the lower right panel on the front of the machine. Connect the power
cable leads as shown below to the L1, L2, L3, and earth (PE) on the power terminal block.
Power input terminal

YSi-V
Power input terminal (L1, L2, L3),
Earth terminal (PE)
Main breaker
Clamped at these
two positions
23500-M9-00
n Power cable example
Power cable example
L1 L=350mm
Ring tongue terminal L2
PE L3
Fork tongue terminal
23501-M9-00
c CAUTION
Use a power cable whose conductor cross-section area is greater than 3.3mm2 (AWG12).
w WARNING
To avoid the risk of electrical shock, make sure that the power source is off before connecting the
power cable. Also make sure that the ground cable is securely connected to the machine.
A-1
2. Connection between machines
This inspection machine unloads a board when it receives a conveyance permission signal from the next
process machine, and then sends a conveyance permission signal to the previous process machine to request
another board.
Appendix
The interface connector labeled "NEXT INTERFACE" connects to the next process machine (downstream
machine), and the interface connector labeled "PREVIOUS INTERFACE" connects to the previous process
machine (upstream machine). Both connectors are AMP 206043-1 (14-pin receptacle).
Each connector is installed inside the left and right cover on the lower rear of the machine. For the dual lane,
the connector is provided at two locations of each lane. The connectors are classified into lane 1 and lane 2.
Machine-to-machine connection example
Preceding process machine This machine Next process machine

PNP input
1 1
Input Relay output
2 DC +24V 2
PNP input
3 3
Relay output Input
4 DC +24V 4
5 5
Input
6 6
7 7 Input
8 8
9 9
10 10
11 11
12 12
13 13
14 14
PREVIOUS INTERFACE connector NEXT INTERFACE connector
3 1 3 1
7 4 7 4
11 8 11 8
14 12 14 12
AMP 206043-1 AMP 206043-1

(14-pin receptacle) (14-pin receptacle)
23504-M9-00
n Board transfer signal specifications

· PREVIOUS INTERFACE · NEXT INTERFACE
Pin No. Signal specifications Pin No. Signal specifications
1 Board transfer permit 1 Board transfer permit
2 Board transfer permit COM 2 Board transfer permit COM
3 Board transfer request 3 Board transfer request
4 Board transfer request COM 4 Board transfer request COM
5 Inspection result OK (pass)
6 Inspection result OK (pass) COM
7 Inspection result NG (fail)
8 Inspection result NG (fail) COM
A-2
3. UPS (Uninterruptible Power Supply)
3.1 Safety precaution
Appendix
3.1.1 Precautions when shipping or exporting the UPS
When shipping the machine equipped with a UPS, always remove the UPS from the machine and carefully
pack it in a separate box.
Take appropriate measures so that the UPS storage temperature does not exceed the rated range (-15 to +50°C).
If the storage temperature exceeds +50°C, the UPS might malfunction or dilute sulfuric acid might leak from
the UPS battery.
When the UPS is left stored for more than three months, the UPS battery may become unusable. Be sure to
recharge the UPS battery once every three months unless the machine has been installed shortly after shipping.
The UPS used at this time for YAMAHA machines does not fall under the Export Trade Control Ordinance.
3.1.2 Disposing of used batter y after replacement

This UPS uses a lead battery, so do not discard it as incombustible waste. Dispose of it properly in compliance
with legal regulations in your country. If any point is unclear about the disposal method, please consult our
sales office or representative.
3.1.3 Safety precautions

When using the UPS, take the following precautions to ensure safety. Failure to follow these safety precautions
may result in serious accidents.
n Do not connect any other than the specified unit to the UPS output receptacle.
Increased load capacity may shorten the UPS backup time or prevent the UPS from providing sufficient backup power if
an overload occurs or cause the YSi-V power to turn off. For details, refer to the instruction manual that comes with the
UPS.
n Immediately replace the batter y when no longer usable.
Dilute sulfuric acid may leak out from the UPS battery if used when worn down, causing smoke or fire.
n Do not disassemble, repair and modify the UPS except when replacing the batter y.
Electrical shock or fire may result.
n Do not touch the UPS batter y if fluid is leaking out of the inside.
Loss of eyesight or burns may result, if battery fluid gets in eyes or comes in contact with skin. Immediately wash
liberally with pure water and consult a physician for proper treatment.
n If unusual sounds, odor or smoke is coming out from the UPS, or if batter y fluid leaks out,
immediately turn off the YSi-V power switch and the UPS power switch.
Continuous operation under such conditions may cause fire. If this happens, immediately turn off the YSi-V power switch
and also all breakers located inside the rear panel of the YSi-V. Then turn off the UPS power switch.
After checking no power is supplied to the YSi-V and UPS, contact our sales office or representative..
n Securely ground the UPS during recharging.
When recharging a UPS which is being stored, always connect the UPS to the ground pin of the AC input plug.
n Install the UPS facing correctly in the YSi-V.
Battery fluid may leak out if the UPS is installed facing the wrong way.
n Do not block the air intake and outlet vents on the UPS.
Blocking the air vents causes the internal temperature to rise excessively, resulting in malfunctions, breakdowns or fire.
n Do not use the UPS in locations at high temperatures above 40°C.
The UPS battery may wear down quickly or cause fire. This may also cause breakdown or malfunction.
A-3
n Avoid installing or storing the UPS in the following locations.
· Airtight locations or locations where inflammable gases or corrosive gases are present.
· Outdoor locations
· Dusty locations
Using in the above locations may cause fire and must be avoided.
Appendix
n Do not get the UPS wet and do not splash with water.
Electrical shock or fire may result.
n Do not short the UPS batter y terminals.
Burns or fire may result. Use caution even when handling a used battery since electrical energy still remains inside the
battery.
n Do not throw the batter y into fire or do not destroy the batter y.
The battery may explode or the internal dilute sulfuric acid might leak out.
n When recharging the UPS batter y during storage, always connect to the power outlet of the
specified AC power voltage (50/60Hz).
Connecting to a power outlet of different AC voltage may cause fire.
n Do not insert a metallic object into the power output connector.
Electrical shock may result.
n Do not insert the AC input plug into the power output connector.
The UPS may be damaged.
A-4
3.2 About the UPS
The YSi series uses a UPS (BY50FW) made by OMRON. It is not possible for this manual to include all
information on the UPS. For more detailed information, refer to the instruction manual that comes with the
UPS.
n UPS installation position
Appendix
When you open the front lower cover of the YSi-V, you will see the UPS installed upright in the right position.
UPS installation position
UPS
Open the YSi-V front cover.
23505-M9-00
n Prevents the user data corruption

The UPS prevents the user data from being damaged even if power is suddenly shut off by power failure or other
accidents. Normally, the system area of the hard disk in the YSi-V is protected by a write filter so that the data in the
system area is not damaged even if power is suddenly shut off by power failure or other accidents. However, the data
area of the hard disk used to store the user board data (inspection programs) are not protected, so the board data might
be damaged if a power failure occurs. (Even in this case, the board data can be recovered if a backup copy of board data
was made.)
If the power to the machine equipped with a UPS is shut off by power failure, the UPS provides backup power to the
control box and the monitor. This allows you to shut down the machine safely and correctly without damaging the user
board data.
n What UPS backs up

One UPS is needed to provide backup power to one YSi-V. The UPS is connected to the secondary of the control
transformer and provides backup power to the control box.
c CAUTION
In YSi-V equipped with a UPS, the control power is still supplied even in the event of power failure or even after the
main power switch is turned off. Therefore, turn off the UPS power switch when performing maintenance work, etc.
A-5
3.3 Operation and setting
3.3.1 Front panel

The USP front panel is shown below.
Appendix
Front panel
"Beep Stop / Test" switch "Battery Replacement" indicator lamp
"Power" switch
Digital "Status" display
23A02-K1-00
3.3.2 Operation during normal operation (power is normal)

No special operations are required as long as the UPS operates normally. Use the YSi-V power switch to turn
the YSi-V on and off, just as operating a YSi-V not equipped with a UPS.
3.3.3 Operation during power failure or trouble

If trouble occurs with the power supply due to a power failure or other reasons, the UPS detects the error and
automatically starts providing backup power. At the same time, the YSi-V application software receives the
error signal from the UPS and sets the YSi-V to emergency stop. The backup state is then maintained for 1
minute while waiting for the power to be restored.
When the power is restored:

Take out the board and then resume inspection.
If the power does not recover when 1 minute has passed after a power failure:
The YSi-V automatically starts shutting down the YSi software. To protect the hard disk during this shutdown
process, the data that was being edited is not saved. After AC power is restored, the YSi-V automatically turns
on and restarts YSi software.
A-6
3.4 Maintenance
The UPS battery will wear down, reaching the end of its service life after the UPS has been operated for a long
time. When the battery is low, the UPS backup time during power failures becomes short and in worst cases
the battery dies before the machine shutdown process is finished. To prevent this, the UPS battery must be
replaced periodically.
Appendix
The UPS itself will also gradually wear down after extended operation time and must be replaced when the end
of its service life is reached.
3.4.1 Batter y replacement period

If the auto battery test or the self-diagnostic test results in any of the following, see “5. Troubleshooting”.
· The “Status” display flashes.
· The “Battery replacement” indicator lamp flashes.
· The “Beep” sound goes off.
n Auto batter y test function
This test checks once per 4 weeks whether the battery needs to be replaced and whether the internal circuit is operating
normally.
n Self-diagnostic test
Press the "Beep Stop / Test" switch on the UPS for at least 0.5 seconds and then release it. A self-diagnostic test will be
run.
n Expected UPS batter y life
Average ambient temperature Expected battery life Replacement period
20°C 4 to 5 years 4 to 5 years after starting use
20°C 2 to 2.5 years 2.5 years after starting use
3.4.2 Batter y replacement

When replacing the UPS battery, refer to the instruction manual that comes with the UPS. A Phillips
screwdriver is required to replace the battery.
n NOTE
After replacing the UPS battery, write the date you replaced the battery on the labels which are stuck to the UPS and
the left side of the main switch.
3.4.3 Replacement batter y storage

When the replacement battery has been stored for a long time, it must be recharged periodically. This is
because the battery gradually discharges if left stored without being recharged and will finally reach a level
where recharging is impossible.
c CAUTION
When you store a UPS battery as a spare, connect the "AC input" plug into a power outlet once every 3 months for 12
hours or more in order to recharge the UPS. Avoid storing the UPS battery in locations subject to high temperatures.
Store it at room temperature.
A-7
3.5 Troubleshooting
The UPS shows the status on the digital display and sounds a beep to alert you of an error or problem. See
the table below ("Meaning of beeps and displays") for information on alarms and UPS operation status and
their solutions.
Appendix
n To stop the beep
To stop the beep sound triggered by an error or problem, press the "Beep Stop / Test" button.
If another error or problem occurs, then a beep will sound regardless of whether the previous peep was stopped with this
button.
n Meaning of beeps and displays
Displays and beeps during normal operation : Blinking
Battery
Status
No. replacement Beep Output Charging Description Solution
display
indicator lamp
No AC power input
1 None OFF OFF –
Operation stopped
AC power is input
2 None OFF ON –
Power switch “OFF”
Power switch “ON”

3 None ON ON –
Operating normally
Displays and beeps while testing
OFF
4 None ON Self-diagnostic test in progress –
Discharging
OFF
5 None ON Auto battery test in progress –
Discharging
Displays and beeps during power failure or AC input error
Backup is operating due to power Perform shutdown

Intermittent
OFF failure or AC input error. The operations for the
6 4-second ON
Discharging battery will be depleted if backup connected devices
intervals
operation continues. and stop them.
Intermittent (Same as above.)

OFF
7 1-second ON Battery level is low, so output will (Same as above.)
Discharging
intervals stop soon.
Battery is dead, so output stopped.

OFF
8 None OFF (This is displayed only for a few Charge the battery.
Discharging
seconds.)
Use within the input

AC input voltage or frequency is
voltage/frequency
9 None OFF (ON) too high (over)
range described in
the specifications.
AC input voltage or frequency is

10 None OFF (ON) too low (under) (Same as above.)
A-8
Displays and beeps when equipment failure has occurred
Battery
Status
No. replacement Beep Output Charging Description Solution
display
indicator lamp
There are too many connected Reduce the number
Appendix
Intermittent devices and the rated capacity is of connected
ON or
11 0.5-second ON exceeded. If this status continues devices until the
discharging
intervals for 5 minutes or more, the status display appears as
No. 12 occurs and output stops. in status No. 3.
Turn OFF this unit

and all connected
Stopped due to excess connection
devices. Reduce
capacity. If the connection capacity
ON or the number of
12 Continuous OFF exceeds 120%, this status
discharging connected devices,
immediately occurs without
and then turn ON
entering the status No. 11.
this unit and the
connected devices.
Check that the AC

ON or Output stopped due to short-circuit with input of connected
13 Continuous OFF
discharging the connected devices. devices is not short-
circuited.
Turn OFF this unit

and all connected
devices. Then, turn
the power switch
back ON for this
unit only. If the
14 Continuous OFF – Stopped because of failure. display does not
change, there is a
problem with the
UPS.
Contact our sales
office or
representative.
Stopped because of excessive

15 Continuous OFF – (Same as above.)
output voltage (over).
Stopped because of insufficient

output voltage (under).
Stopped because of excessive

battery charge voltage (over).
Stopped because of insufficient

battery charge voltage (under).
Stopped because of abnormal

internal temperature.
Displays and beeps for batter y replacement
Charge the battery.

You can replace the
Intermittent weak battery with a
The battery test detected a weak
20 2-second ON ON separately
battery.
intervals purchased
replacement battery
as needed.
A-9
Index
Monthly 4-10
Replacing the conveyor belts 4-26
INDEX
Three-month inspection 4-17
Weekly inspection 4-9
Safety instructions Maintenance list 4-4

Cautions during power outage iv Maintenance tools 4-6
Cautions regarding ferromagnetic fields iv Manual contents i
CE marking i Contents of each chapter iii
Components and materials to be used x Page layout iv
Handling batteries ix Using this manual i
Handling grease and oil ix Marker pen 1-7
Handling heavy objects ix
Marking unit 1-7
Handling solvents vii
O
Handling the laser viii
Lock out the main switch and the air supply/ Operation
exhaust switch iii Daily operation flow 3-1
Muzzle plate vi Ending 2-3
Operator and service personnel iii Pre-operation inspection 2-2
Safety ii Return-to-origin 2-2
Safety message and categories xi Selecting a board 3-3
Typical warning text xii Starting 2-2
Warning labels xv Option units 1-7

P
3D projector 1-9 Power connection terminals 1-3,A-1
4D angular camera 1-10 Pressure gauge 1-2
A pressure regulator 1-2
Alarm buzzer 1-1 R

Axis configuration 1-5 [READY] button 1-1
C Required tools 4-8
Connection between machines A-2 S

Consumable parts 4-5 Safety cover 1-1
Conveyor unit 1-4 Signal light (signal tower) 1-1
Conveyor unit setup 3-4 T

E Three-dimensional measurement 1-9
Emergency stop button 1-1 U

Canceling emergency stop 2-1 UPS
Error Replacing the UPS battery 4-28
Clearing an error 2-1 UPS (uninterruptible power supply) 1-3,A-3
H USB port 1-2
High-speed dual lane 1-11 W
I Warm-up operation 3-2
Inspection program 3-3 Warranty ii
L Y
Laser height sensor 1-8 YSi-V main unit 1-1
Lubrication of each unit 5-2
M
Machine-to-machine connection
connectors 1-3
Main switch 1-2,2-2
Maintenance 4-2
Air filter 4-24
Ball screws and guides 4-11
Board sensor 4-9
Camera lighting unit 4-16
Importance of periodic inspections and
cleaning 4-3
S-1
Operator’s Manual June 2017
Version 2.10

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High-speed High-precision Hybrid AOI

1.1 To ensure safety

1.1.1 Defining safety

1.1.2 Causes of injuries and accidents

1.2 Using safety gear

1.3.2 Restricting machine operation with passwords

Air supply / exhaust switch

OFF position OFF position

• Do not turn off the air during operation.

1.5 Cautions during power outage

1.6 Cautions regarding ferromagnetic fields

1.7 Handling the internal tape cutter

Prevention of hand entry

Dummy feeder (Wide-size)

Dummy feeder (8mm-size)

Prevention of hand entry

Upper muzzle plate

Board conveyance plane

Lower muzzle plate

Upper clearance Lower clearance Remarks

YS100, YS88 8.0 to 38.5mm 1.0 to 31.0mm

YS12, YS12P, YS12F, YS24,

YSM40/YSM40R 0 to 44.0mm 0 to 39.0mm

Z:LEX(YSM20/YSM20W) 0 to 36.0mm 4 to 40.0mm

YSM10 0 to 44.0mm 4 to 40.0mm From board conveyor plane

YC8 13.4 to 80.4mm 4.6 to 39.2mm

YSB55w 0 to 10mm 6mm (fixed)

YSP 0 to 6.6mm 0 to 26.4mm

YSi-V 0 to 48.0mm 0 to 102mm

To prevent accidents caused by solvents

1.11 Handling the laser

Knowledge and information about laser

To prevent accidents caused by laser

Cautions on handling grease and oil

1.13 Handling batteries

Cautions on handling batteries

1.14 Handling heavy objects

Cautions on handling heavy objects

2. Do not use the material whose function is impaired by heating.

n Safety alert symbols and signal words

2.2.1 Safety instruction

3.1.1 Warning label format

Warning label format

WARNING Signal word panel

Mark and pictogram

3.1.2 Meaning of marks

Mark and pictogram

Warning mark Prohibition mark Instruction mark

WARNING WARNING WARNING

Meaning of the above

3.2.1 Handling safety covers

Electrical shock hazard

To prevent the electric shock or damage.

Example for machines that must be connected to 200 VAC

■ Left of main switch

■ Panels inner side

■ UPS unit inside rear cover

■ Behind rear door

Before using the YSi-V

3. Contents of each chapter iii

Chapter 1 Part names and functions

2. Conveyor unit 1-4

3. Axis configuration 1-5