ZM500 Screw Tightening and Removal Machine Video Guide: 19 Tutorials

Five phases, step by step

Follow the five phases in order. Each video entry lists the procedure shown in that installment, followed by the notes stated in the source video.

Phase 1 — Installation and machine overview

Power, signal and air connections, the vibrating disk feeder, the pneumatic clamps, the CCD camera and the control panel.

Video 1 — Hardware tour: power, signal cables, air, feeder and control panel (9:40)

Key moments: 00:00 Power cord and signal cable connection · 00:19 Connect signal wires to screw feeder · 01:56 Air pressure input hose connection · 02:34 Screw feeder controller voltage and frequency · 04:16 Turn on machine main power

• Connect the AC 220V power cord and identify the 3-core signal cable, the handle signal cable and the video cable of the monitor.
• Wire the three signal groups to the feeder and the machine exactly as shown – they are keyed, so plug them in following the socket direction.
• Connect the air supply at the main inlet, check the barometer and route the two air tubes to the machine.
• Fill the vibrating disk with screws and confirm the screw travels down the delivery tube, through the sensor, to the head.
• Learn the control panel: motor test, reset, stop, start (press once to run, twice to pause) and the air-blow switch.
• Swap the nozzle to the screw-removal part when the job needs screws out instead of in.

Note: The vibrating disk controller is set at the factory. Only the voltage (U) and frequency (F) may be adjusted – do not touch anything else on that controller (see video 9).

Note: Press Reset after power-on so the alarm clears and the head returns to origin, and press Reset again before switching the power off.

Video 9 — Hardware recap: feeder controller, clamps, camera and driver motor (8:12)

Key moments: 01:37 Change the display language · 02:09 Start wiring at the back panel · 02:22 Connect the main air inlet hose · 03:27 Adjust the vibrating disk controller (U/F) · 04:25 Clamp cylinder on LED module

• Identify the independent indicator-light socket and plug it in following the socket direction.
• Follow the screw delivery tube from the vibrating disk, through the sensor, down to the head.
• Check the main air inlet and the barometer, and confirm both air tubes are connected at the machine side.
• On the vibrating disk controller, adjust only U (voltage) and F (frequency) – the factory setting is already correct for the screws supplied.
• Check the clamp cylinders and the red support blocks that hold the LED module flat.
• Adjust the CCD camera focus and check the driver motor and the air tube that feeds the sensor.

Note: The air tube must pass through the sensor before it reaches the head – if it is routed outside the sensor, the machine cannot see the screw arriving.

Note: Voltage and frequency on the feeder controller were set before shipment; changing them is the most common cause of screws no longer feeding evenly.

Phase 2 — Fixture, controller language and the first program

Switch the controller to English, set the default parameters, adapt the fixture to the module size and create a named program.

Video 2 — Switch the controller to English and set the first program parameters (9:25)

Key moments: 00:06 Open Menu 4 for language setup · 00:29 Switch controller to English language · 04:37 Enter 1 to clamp the product · 05:14 Align red cursor to screw hole center · 05:49 Record first coordinate with Location key

• Press Stop and Menu 1 together to open Menu 4, page through to page 4 and select option 6 to change the language.
• Enter 2 for English – the interface switches immediately – then press Back.
• Create a new program, switch the input method with the # key and type the product or module name.
• Enter the default parameters (safety height, locking cycle, dwell time, XYZ speeds) as shown on screen.
• Clamp the product from Menu 3, page 2, option 7 (control output) and set the clamp output to 1 – the cylinder closes at once; 0 releases it.
• Press Reset after power-on before running, so the head is homed and the alarm is cleared.

Note: Entering the language menu is the same key combination on every ZM500: Stop + Menu 1, then Menu 4.

Note: The product must be clamped before you teach any coordinate, otherwise every position you record is wrong.

Video 3 — Adapt the fixture to the LED module size and create a named program (12:13)

Key moments: 00:06 Loosen screws to move cylinder fixture · 02:18 Open Menu 3 to clamp module · 03:41 Start creating a new program · 05:22 Switch input method for program name · 07:57 Set follow-up length to zero

• Loosen the two clamp screws and slide the cylinder fixture to suit the module – the platform accepts up to 500 × 500 mm.
• Reposition the red support blocks so the module sits flat and is supported under the screw area.
• Place the LED module against the baffle in the lower-right corner, keep hands clear, then clamp from the controller.
• Create the program and type the name. The controller has no decimal point key – replace the dot with a space (for example P3 84).
• Accept the generated default parameters, but set the fourth one manually as shown in the video.
• Compare every default value on screen with the values in these videos before you run the program.

Note: The maximum product size for the ZM500 is L500 × W500 mm; the cylinder fixture can be moved anywhere inside that envelope.

Note: If the module is not flat before clamping, coordinates taken afterwards will be off by the amount the module is tilted.

Video 10 — Prepare screw removal: clamp, change the nozzle and start a program (8:20)

Key moments: 00:06 Start removing screws from plate · 00:53 Adjust fixture with cylinder clamped · 03:59 Begin nozzle change for screw removal · 06:06 Install air tube before removing screws · 07:24 Switch input method to type product name

• Demonstrate removal on a plate, then put the clamp cylinder back and re-adjust the support base.
• Clamp first and only then position the cylinder: enter the control output menu (fifth input), change 0 to 1 to clamp, and move the cylinder until it holds the product.
• Confirm the module is flat – no bending, no deformation, no tilt – before programming.
• Press and take off the nozzle, fit the screw-removal part, loosen the screw at the holder and tighten the new part in place.
• Install the air tube needed for removal, then start a new program: press # to open the file screen, build a new file and type the product name.
• Check the default parameters before running the removal program.

Note: If the removal part does not seat, loosen the small screw on the holder rather than forcing the part – forcing it deforms the bit.

Note: Adjusting the cylinder after clamping is what keeps the product from moving while the screws are backed out.

Phase 3 — Teaching coordinates, calibration and bulk copy

Find each screw hole through the CCD camera, record it with the handle, copy identical hole patterns in bulk, then calibrate the camera against the head.

Video 4 — Programming part 1: clamp the module and teach each screw hole with the CCD camera (17:07)

Key moments: 00:32 Release cylinder clamp with reset · 01:55 Change option 5 value to clamp · 02:53 Insert screw removal command · 09:07 Center cursor on first screw hole · 14:00 Recheck and correct stored coordinates

• Press Reset to release the clamps when you need to change the product, then re-clamp the new module.
• With the program open, move X and Y with the handle keys and switch to slow speed as you approach the hole.
• Bring the red crosshair to the exact centre of the screw hole in the camera image (adjust the focus if the image is blurry).
• Press 1 once to record that position – pressing 1 twice records the same hole twice and corrupts the program.
• Continue hole by hole until the whole pattern is recorded, then press Location to correct any coordinate that has drifted.
• Run one screw in single step to confirm the positions before running the whole program.

Note: If the coordinates of a hole are offset, the screw cannot be assembled or removed properly – the crosshair must be in the centre of the hole, not at its edge.

Note: For LED modules, remove or lift the mask when it hides the holes; video 5 shows the shortcut of teaching from a module that already has screws in it.

Video 5 — Fast programming: copy one screw pattern onto the identical section (8:02)

Key moments: 00:43 Introduce the copy coordinate method · 02:14 Move CCD to first lower screw hole · 04:00 Press 1 to select copy option · 05:59 Copy upper coordinates below line 39 · 07:09 Recenter each copied screw coordinate

• Teach the first section of the pattern normally, or teach from a finished module so the holes are easy to see.
• Open the coordinate menu and pick the copy function (the menu offers copy, delete, move and coordinate offset).
• Select the first and last coordinate of the source block, then choose the destination serial number for the copy.
• Do not copy onto an existing serial number – that overwrites it; always pick the next free number.
• Check every copied hole in the camera and press Location to nudge any that are not exactly centred.
• Save the program and run a single-step test before automatic run.

Note: Bulk copy only works when the second area has the same hole spacing as the first – irregular patterns must be taught hole by hole (video 13).

Note: Even a correct copy needs a visual check: one offset hole is one screw that will not go in.

Video 6 — Calibrate the CCD camera against the head (7:42)

Key moments: 01:00 Open Menu 4 for calibration · 01:45 Calibrate camera to head distance · 04:39 Drill marker with both buttons · 05:58 Locate drilled marker with CCD · 07:15 Press Enter to confirm calibration

• Open Menu 4 (Stop + Menu 1), go to page 2, option 4 for the CCD camera settings and press Enter.
• Start the calibration, then jog the head over the calibration surface and switch to slow speed.
• Lower Z until the nozzle just touches the surface of the red support block – contact only, do not press down.
• Confirm that height, then move X and Y until the red cursor sits in the centre of the hole in the camera view.
• Press Enter on the handle and wait for the confirmation prompt, then exit the menu.
• Re-check one taught coordinate afterwards to confirm the offset has been corrected.

Note: Re-calibrate whenever the camera has been removed or knocked, when the nozzle has been changed, or when the assembly position looks inaccurate – the whole purpose of the calibration is to re-establish the camera-to-head distance.

Note: A bent or deformed nozzle bit also needs calibration after replacement.

Video 11 — Teach coordinates with the handle: speeds, crosshair and the record key (15:16)

Key moments: 00:01 Begin teaching screw coordinates · 00:38 Adjust camera focus for clear view · 01:11 Switch slow speed near screw hole · 01:52 Record first coordinate with key 1 · 13:01 Insert screw removal instruction

• Move X and Y with the handle keys and read the current speed at the top of the screen.
• Switch between fast, medium and slow with the speed key; approach the hole fast, then switch to slow for the last few millimetres.
• Align the centre of the red crosshair with the centre of the screw hole in the camera image.
• Press 1 exactly once to record that coordinate, then move to the next hole.
• Adjust the camera focus with the lens ring whenever the image is blurry – focusing is faster than re-teaching a hole.
• Repeat for every hole; test one screw before running the whole program.

Note: Pressing 1 multiple times in a row records duplicate coordinates – one press, one hole.

Note: The same coordinate procedure is used for assembly and for removal; the mode is set later in the parameters, not while teaching.

Video 13 — Record all hole coordinates and bulk-copy a block to the next section (11:09)

Key moments: 01:03 Press 1 to record coordinate · 02:54 Demonstrate batch copying screw coordinates · 03:50 Choose copy option in menu 1 · 05:48 Realign copied coordinates to screw centers · 07:59 Demonstrate wrong operation duplicating coordinates

• Centre the crosshair in the hole and press 1 once per hole to record each coordinate.
• Open the copy function, select the start coordinate (for example 008) and the end coordinate (for example 029).
• Choose the destination serial number – the next free one (030), never an existing number, because that overwrites the source.
• Confirm the copy and check the numbering that the controller generates.
• Inspect every copied position in the camera and correct the ones that are not exactly centred.
• Adjust the Z-axis height for the copied range afterwards if the second area sits at a different height.

Note: Bulk copy is invalid for irregular hole patterns – if the spacing differs, teach the holes individually.

Note: When you copy, verify that the destination spacing matches the source spacing before you accept it.

Phase 4 — Height, depth and torque parameters, then run

Set the Z-axis height, choose depth mode or torque mode, set the drill-bit service-life limit, check the default parameters and run the program – including how to skip a screw after an alarm.

Video 7 — Set the Z-axis assembly height and choose depth mode or torque mode (10:49)

Key moments: 00:22 Slowly lower Z axis to surface · 02:27 Bulk edit all Z axis heights · 04:02 Select depth mode in Menu 4 · 06:00 Restart machine to apply mode · 07:45 Start torque value at 0.03

• After all coordinates are taught, move the head above the LED module and lower Z slowly.
• Use depth mode: bring the white press (the guide foot next to the driver bit) just onto the LED module surface.
• Record that Z height – this is the assembly height for the screws in this program.
• In Menu 4, page 1, item 4, select depth mode, then set item 7 (intelligent batch settings) and enter 0 to switch the intelligent batch off.
• If you use torque mode instead, the intelligent batch function is enabled and depth mode is off – video 18 shows that setup.
• After any restart, wait more than ten seconds before switching the power back on, then press Reset so the head homes.

Note: Depth mode stops the driver when the sensor detects the telescopic column; torque mode stops it when the set torque is reached. Never mix the two settings within one program.

Note: The white press must only touch the LED surface – pressing it down changes the height you just recorded.

Video 8 — Run the program, and skip a screw after a depth alarm (13:33)

Key moments: 01:18 Open page 2 option 7 in menu 3 · 01:37 Set option five to 1 for cylinder clamp · 02:20 Switch camera motion to drill motion · 04:37 Read sensor light to find drill stop · 07:32 Rotate telescopic ruler to set tightening depth

• Confirm the depth-mode parameters and the camera on/off setting (Menu 4, page 2, option 4 – enter 1 to enable the camera).
• Teach the remaining screw positions and save the program.
• Run one screw in single step to confirm height and torque before automatic run.
• Press Start to begin automatic run; press it twice to pause if you need to inspect a screw.
• If the machine stops with a depth abnormality, press Start once to skip that screw and continue with the rest of the pattern.
• When the alarm is a screw fault, clear the screw at the head first, then use the motor test switch to resume.

Note: A depth abnormality means the screw was not tightened to the set depth – the machine stops rather than driving it further. Skipping is safe for that one screw, but mark it for re-check.

Note: Do not leave a skipped screw unrecorded: the customer-facing board must not ship with a loose screw.

Video 12 — Drill-bit service-life limit, motor test and CCD reference point (13:23)

Key moments: 00:00 Set drill bit service life limit · 05:27 Open menu 4 with stop plus menu 1 · 06:25 Select depth mode by entering 1 · 08:36 Adjust torque value in option four · 09:52 Power off after torque parameter setting

• Open the bit-life setting (bit service life) and enter the number of cycles you allow for the bit – for example 1,000.
• When the counter is reached the machine alarms so you inspect the bit; if the bit is still good, raise the limit.
• After clearing a screw-feed alarm, use the motor test switch to resume; use Start only when you merely want to continue.
• If the machine reports a slipping screw that has already been driven, press Start – do not use motor test.
• Turn torque-mode checks on: after a torque-mode run, verify the driven screw height meets the requirement.
• Set the CCD point function in Menu 4, page 2, option 4 – choose whether the camera or the nozzle is the reference position.

Note: The bit-life counter is a reminder, not a measurement: the machine cannot see wear. Inspect the bit when it alarms.

Note: Choosing the wrong reference (camera versus nozzle) is a common reason taught coordinates suddenly land off-centre.

Video 17 — Default parameter reference: assembly versus removal (3:01)

Key moments: 00:08 Set follow-up speed parameter · 00:51 Turn on screw detection setting · 01:22 Close locks screws, open removes · 02:32 Raise removal height to 15 or 20 · 02:49 Enable screw removal switch

• Work through the assembly parameters: follow-up speed, torque switch detection and screw detection (keep screw detection on).
• Check the head movement speed and the height parameter above the screw hole.
• Set the screw-removal mode: 0 (off) to assemble screws, 1 (open) to remove them.
• Review the removal parameters – they are their own set, not a copy of the assembly set.
• Set the removal height so the head does not touch the product; raise it to 15 or 20 if it does.
• If you are new to the machine, enter these values exactly as shown before you experiment.

Note: The removal switch must be entered as 1 to remove screws and 0 to drive them – a wrong value is the usual reason a removal run does nothing.

Note: Check the removal height against the product before every removal run: too low and the head hits the module.

Video 18 — Torque-mode assembly: telescopic column and torque value (4:40)

Key moments: 00:00 Screw telescopic column out of sensor · 00:53 Select 0 for torque mode · 01:15 Open intelligent batch settings option 7 · 02:32 Lower torque parameter to 0.04 · 03:33 Press OK to save parameters

• Screw the telescopic column down to the bottom so the sensor cannot sense it; in torque mode the sensor must not stop the driver.
• Press the re-lock button and check that the Z-axis head lowers without the sensor being triggered.
• Open Menu 4 (Stop + Menu 1), then function 4 on page 1 for the electric driver (torque) parameters.
• Start from a small torque (the video starts at 0.04) and drive one screw.
• If the screw is not tight, raise the torque step by step (the video works up to 0.45) and test again.
• Save the parameter after every accepted change – unsaved values revert.

Note: 0.15 N·m is already a high value for these screws; work up from a low torque instead of starting high.

Note: In torque mode the depth sensor must stay untriggered, otherwise the machine stops before the torque is reached.

Phase 5 — Screw removal, re-locking and screw-size changeover

Change the head for removal, run removal from the cursor, re-lock the screws afterwards, switch a removal program back to assembly and rebuild coordinates after a fixture change.

Video 14 — Set the Z-axis height, then run screw removal from the cursor (6:09)

Key moments: 00:09 Set Z-axis coordinates for assembly · 02:27 Enter Z-axis height value 68.6 mm · 03:11 Test one screw in single-step mode · 04:32 Set max lock time to 0.5 for removal · 05:30 Run from cursor to remove remaining screws

• With all coordinates in the controller, lower Z slowly and note the height at which the nozzle just touches the LED module surface.
• Enter that Z value for the coordinate range: select the start and end serial numbers, then type the Z height (the video shows 68.6 mm on screen).
• Confirm all screws in the range share the same Z height before running.
• Do not start removal immediately – check the head, the product and the clamps first.
• Open Menu 2, page 2, option 3 (run from the cursor) and press OK to let the machine remove all screws behind the current position.
• Watch the first few screws, then let the cycle finish.

Note: The nozzle should hang slightly above the LED surface, not press on it – the driver still has travel when it comes down.

Note: Run from cursor continues from the current coordinate, so a wrong cursor position means the machine starts at the wrong screw.

Video 15 — Re-lock after removal, and change feeder parts for a different screw size (9:00)

Key moments: 00:09 Swap the nozzle · 00:42 Lift fixture and insert the drill · 01:42 Replace the screw conveyor air tube · 05:34 Replace feeder parts for new screw size · 07:30 Install M1.0 screw track

• After removal, fit the assembly nozzle and the driver bit again, then lower the fixture and insert the bit.
• Match the feeder parts to the screw: M0.8 screws need the M0.8 parts, M1.0 screws the M1.0 parts – the nozzle can drive and remove, so it is the better choice for mixed work.
• To go from M1.7 to M1.0, replace the three feeder components and the corresponding driver bit.
• Push each air tube down to the bottom of its fitting – press the white buckle first so the tube seats fully.
• Loosen the fixing screw before inserting a tube that will not go in, then tighten it again.
• Check the spacing between the three feeder components: too wide or too narrow and the screws will jam.

Note: An air tube that is not pushed to the bottom is a classic cause of screws failing to reach the head.

Note: Changing the screw size means changing feeder parts and bit together – a mismatched bit damages both the screw head and the bit.

Video 16 — Convert a removal program back to assembly (15:49)

Key moments: 00:07 Change locking time to 1.5 seconds · 01:15 Turn off screw-removal mode · 03:56 Copy the program to the controller · 07:33 Enter Z-axis height 60.8 · 14:46 Run from cursor for remaining screws

• Open the program parameters and set the locking (tightening) time – the video uses 1.5 – and leave the remaining values as they are.
• Turn the screw-removal setting off: select off and enter 0.
• Enable screw detection on the coordinate you are working with (serial 004 in the video).
• Set the Z-axis assembly height in Menu 1, page 1, item 2, and check the clearance at the head.
• Keep the gap at the head small – the nozzle must contact the LED surface when the head comes down.
• Open Menu 2, page 2, option 3 (run from the cursor) to complete all remaining screws from the current position.

Note: Assembly and removal share the coordinate list but not the timing: the removal time and the locking time are set separately.

Note: Do not move the clamp cylinder up and down too fast – it shifts the product and the taught coordinates no longer fit.

Video 19 — Rebuild coordinates after a fixture change and continue the run (13:22)

Key moments: 00:15 Disable screw-removal mode · 00:48 Coordinates shifted after fixture added · 02:18 Select option 9 to teach offset · 09:12 Increase torque from 0.04 to 0.045 · 12:45 Run from cursor to finish assembly

• Exit the Menu 4 parameters and switch the screw-removal mode off (enter 0) before working on assembly coordinates.
• Move the head to a taught coordinate and check the crosshair against the screw: after a fixture change the coordinates no longer match.
• Rebuild the coordinate list for the new fixture position, or re-teach the affected positions and copy the repeating block.
• Set the Z-axis height for the range in Menu 1, page 1, option 2 (item 5), selecting the start and end serial numbers.
• Check the head gap – about one millimetre is the reference shown in the video.
• Open Menu 2, page 2, option 3 (run from the cursor) to continue assembly from the new position.

Note: Adding or moving the fixture changes the product position, so previously taught coordinates are no longer valid – re-teach rather than adjust one hole.

Note: A single-step test at the first screw confirms the rebuilt program before the automatic run.