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PA 1309/10 Topaz Service Manual Philips Electronic Manufacturing Technology TRAD DOCUMENT DATA MANUAL TITLE MANUAL NUMBER 5322 871 63606 (01.05) Service Manual Topaz PA NUMBER PA 1309/10 HISTORY ISSUE DATE ORDER NUMBER STATUS RELEASE DOCUMENT 5322 871 63606 REVISION CODE 97.00 First Draft - Replaced - First Issue Update Oct-97 Mar-98 5322 871 63606 5322 871 63606 97.01 98.02 Replaced Replaced DI-CSM-025 DI-CSM-050 Second Issue Update Mar-99 Jan. 2000 5322 871 63606 4022 591 93464 99.03 00.04 Replaced Replaced DI-CSM-076 DI-CSM-105 Third Issue April 2001 5322 871 63606 01.05 Current DI-CSM-138 Preventive and corrective maintenance is reserved for personnel certified by Assembléon. The Philips EMT Customer Support organization has created a series of web pages on the World Wide Web for the use of its internal and external customers. These pages provide a library of information regarding technical aspects of the products sold and supported by Philips EMT organizations around the world. The manuals section is a tool for EMT customers trying to find the part number for the latest documentation currently available. Access to this area is not restricted by a password. It is an on-line reproduction of the manual survey. It has the advantages that it can be updated regularly. The Customer Support website address is: http://www.emt.philips.com/support. © Philips Electronic Manufacturing Technology B.V. All rights reserved. No part of this book may be reproduced in any form, by print, photoprint, microfilm or any other means without the written permission from Philips (Electronic Manufacturing Technology). SAFETY General: For the correct and safe use of the CSM system, it is essential that both OPERATING and SERVICE personnel follow generally accepted safety procedures in addition to the safety precautions specified in these safety and quick reference cards. The operating, service and installation manuals have warning and cautionary statements throughout the whole manuals where applicable. Warnings and cautionary statements and/or symbols are present on the system where applicable. Cautions and marks: REFERENCE Gives useful information related to the mounter operation. NOTE Explains the mounter operation and procedures in a simple and clear manner. CAUTION Gives important information to prevent any damage to the mounter or data. WARNING Gives information of utmost importance in ensuring the safety of the mounter operator, inspector, or service personnel. EMERGENC BUTTON Press the emergency button. REMARK Gives a comment. Training level personnel: Operation, adjustment, maintenance and repair of the CSM system may only be carried out by qualified and trained personnel who are aware of the hazards involved. The following training levels are defined: ■ Operator level: Official Philips training course or training received by a qualified maintenance engineer. ■ User or Supervisor level: Official Philips training at one of the official Philips Training Centres. ■ Maintenance or Service level: Official Philips training at one of the official Philips Training Centres. Safety standards: The safety standard of the CSM system is in accordance with CE directives: ■ Machine directive 89/392/EEC and 91/368/EEC. ■ Low Voltage directive 73/23/EEC. ■ EMC directive 89/336/EEC. Liability: Philips shall not be liable for any costs, damages or personal injuries if the CSM system is not used according to the safety rules given in this paragraph. Detailed information: For more detailed information how to operate and to maintain the CSM machine please refer to the Operating and Service manuals of this system. Location of the Operator manual: The Operator manual MUST BE LOCATED CLOSE to the CSM machine. This enables operators to have easy access to the relevant cards. HOW TO REPORT DOCUMENT IRREGULARITIES We have endeavoured to ensure that the information in this document was correct when published. If, when using this document, errors, omissions or anomalies are discovered, please inform us using the reply-form attached. We thank you for this service, in advance, as it will help us to ensure that you, the customer, receive the highest possible quality of information and service. Manual Title: Service Manual Topaz Manual Number: 5322 871 63606 PA Number: PA 1309/10 Please, don’t forget to fill-in this! Update Code Manual: . ✍ FROM: Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOCUMENT IRREGULARITIES: Page/Paragraph Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Erroneous Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................................................................ ................................................................................................ ................................................................................................ Consequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................................................................ ................................................................................................ ................................................................................................ Suggestion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................................................................ ................................................................................................ ................................................................................................ ................................................................................................ ................................................................................................ TO: Philips Electronic Manufacturing Technology Supply Centre Customer Support P.O. Box 218 Building BAF 2 5600 MD Eindhoven The Netherlands Service Manual Topaz Table of Contents 1. Introduction 1.1. General Introduction 1.2. Chapter Overview 1.3. Safety 1.3.1. General 1.3.2. Basic Rules 1.3.3. Safety Standards 1.3.4. Cautionary Remarks 1.3.5. Warning Stickers 1.3.6. ESD Precaution 1.3.7. Noise Level 1.3.8. Liability 1.3.9. Oil and Greases 1.3.10. Abbreviations 1-1 1-1 1-2 1-4 1-4 1-4 1-4 1-5 1-5 1-7 1-7 1-7 1-8 1-8 2. General and Electrical Block Diagram 2-1 3. System Principles 3.1. Introduction 3.2. Mains Specifications and Connection Schedule 3.3. Air Specifications and Connection 3.4. Interfaces 3.4.1. Bus Definitions 3.4.2. Serial Interface 3.4.3. Line Interconnections 3.5. MCX-Control Unit 3.5.1. MCX-Controller Lay-Out (Second Generation) 3.5.2. System Board 3.5.3. Servo Board 3-1 3-1 3-2 3-5 3-6 3-6 3-6 3-8 3-11 3-11 3-12 3-16 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 1 Table of Contents 3.5.4. Vision Board 3.5.5. Mother Board 3.5.6. Hard- and Floppy-Drives and Flash Disk 3.5.7. Driver Board Assy 3.5.8. D(river) - Power Assy 3.5.9. 5V / 12V Power Supply Assy’s 3.6. LED Driver Board 3.7. I/O - Boards 3.8. Connection-Board 3.8.1. General 3.8.2. 2nd Generation Connection-Board rd 3.8.3. 3 Generation Connection-Board 3.9. Keyboards 3.9.1. PC-Keyboards 3.9.2. Hand Held Keyboard (HHK) 3.10. Monitors 3.10.1. VIOS Monitor 3.10.2. Vision Monitor 3.11. I/O - Signals 3.11.1. VIOS Manual Mode I/O-Monitor 3.11.2. List of OUTPUT Signals (DO’s) 3.11.3. List of INPUT Signals (DI’s) 3-18 3-19 3-20 3-21 3-23 3-23 3-24 3-27 3-32 3-32 3-33 3-35 3-38 3-38 3-38 3-40 3-40 3-40 3-41 3-42 3-43 3-44 4. Power and Safety Circuits 4.1. Introduction 4.2. Safety Circuit 4.2.1. Description 4.2.2. Safety Circuit 4.3. Power Circuits 4.3.1. Description 4.3.2. 5V / 12V Power Supply MCX Box 4.3.3. 24V I/O and Emergency Power Supply (GS21) 4.3.4. D - Power Assembly (282V Power) 4.3.5. Measuring and Adjusting Data 4.3.6. Performance Check and Trouble Shooting 4.3.7. Maintenance Instructions 4-1 4-1 4-1 4-1 4-2 4-5 4-5 4-7 4-9 4-10 4-12 4-13 4-13 5. Vacuum and Pneumatic Systems 5.1. Vacuum Systems 5.1.1. Introduction 5.1.2. Functional Description 5.1.3. Air Supply Unit 5.1.4. Air Pressure Regulator 5.1.5. Pressure-Drop Detection Level 5.1.6. Measurement and Adjusting Vacuum Levels 5.1.7. Performance Check and Trouble Shooting 5.1.8. Maintenance Instructions 5.2. Pneumatic Systems 5.2.1. Introduction 5.2.2. Functional Description 5.2.3. Topaz 5-1 5-1 5-1 5-1 5-2 5-2 5-3 5-4 5-4 5-4 5-5 5-5 5-5 5-5 2 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Table of Contents 5.2.4. Tray Changer (TC) 5.2.5. Tape Feeders 5.2.6. Automatic Tray Stacker 5.2.7. FES/SVS 5.2.8. Measuring and Adjusting 5.2.9. Performance Checks and Trouble Shooting 5.2.10. Maintenance Actions 5.3. Exchanging Head Ejectors, Valves and Base 5.3.1. Exchanging the Head Ejector and/or Valves 5.3.2. Exchanging the Head Up/Down, Slow Valves and Valve Base 5-5 5-5 5-5 5-5 5-6 5-6 5-6 5-7 5-7 5-8 6. PCB Transport Systems 6.1. Introduction 6.2. Conveyor Belt 6.2.1. Adjusting the Conveyor Belt Tension 6.2.2. Adjusting the Carry-In Conveyor Speed 6.3. Main Stopper 6.3.1. Adjusting the Ascent/Descent Speeds of the Main Stopper 6.3.2. PCB Contact Point 6.4. Push-In 6.5. Locate Pin 6.6. Edge Clamp 6.7. Push-Up 6.8. PCB Detection Sensors 6.9. Conveyor Errors 6-1 6-1 6-2 6-2 6-3 6-5 6-5 6-7 6-8 6-10 6-13 6-14 6-16 6-19 7. Component Transport Systems 7.1. Introduction 7.2. Head Assembly 7.2.1. Mechanical Check Head Assembly 7.2.2. Machine Coordinates 7.2.3. Pickup and Mount Vacuum Levels 7.2.4. R-axis Absolute Accuracy Offset 7.2.5. Nozzle Correction 7.2.6. Head Offset 7.3. Nozzle Station 7.3.1. Nozzle Station 7.3.2. Adjusting the Nozzle Sensor Sensitivity 7.3.3. Adjusting the Nozzle Clamp Plate Position 7.3.4. Adjusting the Nozzle Station Coordinates 7.3.5. Nozzle Station Maintenance 7.4. Feeder Plates 7.4.1. Feeder Plate Parallel Adjustment 7.4.2. Feeder Block Positions 7.4.3. Component Pickup Test 7.4.4. Feeder Plate Maintenance 7.5. Component Feeders 7.5.1. Tape Feeders 7.5.2. Minimum Timer / Load Timer / Down Timer 7.5.3. Tape Feeder Maintenance 7-1 7-1 7-1 7-2 7-5 7-9 7-12 7-13 7-14 7-15 7-15 7-16 7-18 7-18 7-20 7-21 7-21 7-22 7-24 7-26 7-27 7-27 7-31 7-32 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 3 Table of Contents 8. Axes Systems 8.1. Introduction 8.2. Machine Reference (Origin) 8.2.1. W-axis Machine Reference 8.2.2. Z-axis Machine Reference 8.2.3. X-axis Machine Reference 8.2.4. Adjusting the Y-axis Machine Reference 8.2.5. R-axis Machine Reference 8.3. Secondary Limits 8.3.1. X-axis Secondary Limits 8.3.2. Y-axis Secondary Limits 8.4. Software Limits 8.4.1. W-axis Software Limits 8.4.2. Z-axis Software Limits 8.4.3. X-axis Software Limits 8.4.4. Y-axis Software Limits 8.4.5. R-axis Software Limits 8.5. Initial Position and Initial Movement 8.5.1. W-axis Initial Position 8.5.2. Adjusting the R-axis Initial Position 8.5.3. Z-axis Initial Movement 8.6. Axes Assembly, Disassembly Adjustments and Maintenance 8.6.1. Adjustment of the X- and Y-motor Encoder Position 8.6.2. Head Replacement 8.6.3. X-axis Assembly 8.6.3.1. X-axis: Replacement X-motor Only 8.6.3.2. X-axis: Ball Screw Replacement 8.6.3.3. X-axis: Linear Guide Replacement 8.6.4. Y-axis Assembly 8.6.4.1. Y-axis: Replacement Y-motor Only 8.6.4.2. Y-axis: Removing Y-axis Ball Screw Generation 2 8.6.4.3. Y-axis: Removing Y-axis Ball Screw Generation 3 8.6.4.4. Y-axis: Installing and Aligning Y-axis Ball Screw Generation 3 8.6.4.5. Y-axis: Pre-tension Adjustment (Generation 3 Y-axis) 8.6.4.6. Y-axis: Linear Guide Replacement 8.6.5. Z-axis Assembly 8.6.6. R-axis Assembly 8-1 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 8-8 8-10 8-11 8-11 8-14 8-16 8-17 8-19 8-20 8-20 8-21 8-22 8-24 8-24 8-25 8-25 8-25 8-26 8-27 8-27 8-27 8-28 8-29 8-30 8-32 8-33 8-34 8-34 9. Vision Systems 9.1. Introduction 9.2. Vision Systems 9.2.1. Pre-Start Operations 9.3. Moving Camera 9.3.1. Adjusting the Focus and Field Of View 9.3.2. Adjusting the Lighting Level of the Moving Camera 9.3.3. Adjusting the Moving Camera Scale 9.4. Single Camera Adjustment 9.4.1. Maximum Component Size and Field Of View 9.4.2. Focus Adjustment 9.4.3. Lighting Level Adjustment 9.4.4. Camera Scale Adjustment 9-1 9-1 9-1 9-2 9-2 9-2 9-3 9-7 9-12 9-12 9-13 9-14 9-16 4 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Table of Contents 9.4.5. Camera Optical Axis Angle Adjustment 9.5. Line Array Camera Adjustment 9.5.1. Maximum Component Size and Field Of View 9.5.2. Adjusting the Focus and Aperture 9.5.3. Adjusting the Lighting Level of the Line Array Camera(s) 9.5.4. Adjusting the Line Array Camera Scale 9.5.5. Adjusting the Dual Recognition Offset 9.5.6. Replacement of the Line Array Camera 9.6. Cleaning the Optical Systems 9.7. Recognition Errors 9.7.1. Chip Components 9.7.2. QFP Components 9-20 9-25 9-25 9-25 9-27 9-28 9-33 9-34 9-35 9-36 9-36 9-37 10. Software Section 10.1. Introduction 10.2. System Software 10.2.1. Operating System 10.2.2. Disk Organization 10.2.3. Installation Disk Contents 10.2.4. VIOS Software Utility 10.2.5. Installation of a New Version VIOS System Software 10.2.6. Backup Creation 10.2.7. VIOS Configuration 10.2.8. Floppy Disk Problems 10.2.9. Flash Disk Problems (Only for Systems with KM5 System Boards) 10.2.10. Hard Disk Problems 10.3. PCB File Handling 10.4. Machine Configuration 10.4.1. Machine Configuration Detailed 10.5. ROM and File Configuration (Version Level) 10.6. System Messages 10.7. Online Commands 10-1 10-1 10-2 10-2 10-2 10-4 10-6 10-13 10-14 10-15 10-16 10-16 10-17 10-20 10-22 10-24 10-28 10-29 10-32 11. Machine Installation and Calibration 11.1. Introduction 11.2. Installation 11.2.1. Installation Position (Work-Area Condition) 11.2.2. Environment 11.2.3. Leveling the System 11.2.4. Removing the Transportation Locks 11.2.5. Monitor and Keyboard Installation 11.2.6. Installation of the Warning Light Tower 11.2.7. Transformer Power Tabs 11.2.8. Air Connection 11.2.9. Power Connection 11.2.10. Switching On the Machine, Verify the Software Version 11.2.11. Vacuum Levels 11.2.12. Warm-up 11.2.13. Camera Check 11.2.14. Acceptance Test 11-1 11-1 11-1 11-3 11-3 11-3 11-4 11-5 11-5 11-5 11-6 11-7 11-8 11-9 11-9 11-10 11-13 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 5 Table of Contents 11.3. Machine Calibration 11.3.1. Back-up 11.3.2. Machine References (Origins) 11.3.3. Machine Limits 11.3.4. Initial Movement Z-axis 11.3.5. Initial Position R-axis 11.3.6. Teach Nozzle Station Positions 11.3.7. W-axis Parallelism 11.3.8. Initial Position W-axis 11.3.9. Vacuum Levels 11.3.10. Moving Camera Adjustment: Focus, Lighting Level, Scale 11.3.11. Single Camera Adjustment: Field Of View, Lighting Level, Focus, Scale 11.3.12. Line Array Camera Adjustment:Lighting Level, Field Of View, Scale, Focus, Optical Axis Alignment 11.3.13. Recognition Speed and Dual Recognition Offset 11.3.14. R-axis Accuracy 11.3.15. Mount Accuracy Calibration (Glass Plate) 11.3.15.1. Introduction 11.3.15.2. Conditions Required 11.3.15.3. Tools Required 11.3.15.4. AUTO MOUNT FEEDBACK (AMF) 11.3.15.5. Program Verification and Setup 11.3.15.6. Adjustment Procedure 11.3.15.7. Mount Calibration 11.3.15.8. Adjustment Steps for Topaz with Only Line Array Camera(s) 11.3.15.9. Adjustment Steps for Topaz with Line Array and Single Camera 11.3.15.10. Viewing the Data Offline 11.3.16. Calibration Feeder Plate 11.3.17. Final Board Accuracy Checks 11.3.18. Back-up 11.4. Procedure How to Run the AMF Program 11.4.1. Making PCB Data for the AMF Program 11.4.2. Mount Information 11.4.3. Component Information 11.4.4. Mark Information 11.4.5. Block Information 11.4.6. Fiducial Information 11.5. Explanation of Various Parameters AMF Program 11.5.1. Camera Scale 11.5.2. Camera Position 11.5.3. Nozzle Correction 11.5.4. Head Down Offset 11.5.5. Head Offset 11.5.6. R-axis Accuracy 11.5.7. Inconsistent Parameter 11.5.8. AMF Program 12. Maintenance 12.1. Introduction 12.2. Oils and Greases 6 11-14 11-17 11-20 11-23 11-25 11-25 11-26 11-28 11-29 11-30 11-31 11-32 11-34 11-35 11-36 11-37 11-37 11-38 11-38 11-39 11-40 11-40 11-47 11-48 11-55 11-64 11-66 11-69 11-70 11-70 11-74 11-75 11-76 11-78 11-78 11-78 11-79 11-79 11-80 11-82 11-83 11-83 11-84 11-84 11-85 12-1 12-1 12-2 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Table of Contents 12.3. Maintenance Checkpoints 12.3.1. FD Drive, Filters and Air Valves 12.3.2. Head Area Checkpoints 12.3.3. X-axis Checkpoints 12.3.4. Y-axis Checkpoints 12.3.5. Conveyor Checkpoints 12.3.6. Feeder Plate Checkpoints 12.3.7. Vision Systems, Camera Lighting Unit 12.3.8. Performance Check and Trouble Shooting 12.4. Overview of Error Messages in VIOS 1.2 12.4.1. L-error Messages 12.4.2. E-error Messages 12.5 Overview of Error Messages in the Vision Monitor 13. Spare Parts List 13.0.1. General Information 13.0.2. Ordering Spare Parts 13.0.3. Regional Stock Keeping 13.0.4. Overview of the Various System Modules 13.0.5. First Aid Spare Parts Kit 13.1. Module 1, System Principles 13.1.1. MCX2 Control Unit 13.1.2. Cover Assemblies 13.1.3. Monitor Assembly 13.2. Module 2, Power and Safety Circuits 13.3. Module 3, Vacuum and Pneumatic Systems 13.4. Module 4, PCB Transport Systems 13.4.1. Conveyor Assembly 13.4.2. Conveyor Auto Width Assembly 13.4.3. Sub-stopper, Main-stopper and Locate Pin Assembly 13.4.4. Edge-clamp and Push-in Assembly 13.4.5. Push-up Pin and Push-up Assembly 13.5. Module 5, Component Transport Systems 13.5.1. Nozzle Station (Option for Standard Topaz) 13.5.2. Nozzle Selection 13.5.3. Head Assembly Part 1: General Parts 13.5.4. Head Assembly Part 2: Head Splines & SIMM-Topaz Head Assembly Spares 13.5.5. Head Assembly Part 3: Z-axis Assembly 13.5.6. Head Assembly Part 4: Valve and Ejector Assy’s 13.5.7. Head Assembly Part 5: R-axis Assembly 13.5.8. Feeder Holder 13.6. Module 6, Axes Systems 13.6.1. X-axis Assembly 13.6.2. Y-axis Assembly 13.6.3. Z-axis Assembly 13.6.4. R-axis Assembly 13.7. Module 7, Vision Systems 13.7.1. Camera Systems 13.7.2. Lighting Systems 13.8. Module 8, Options 13.8.1. Tray Changer 13.8.2. Tape Feeders 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 12-4 12-4 12-9 12-26 12-29 12-32 12-37 12-41 12-44 12-46 12-46 12-52 12-150 13.0-1 13.0-1 13.0-2 13.0-2 13.0-3 13.0-5 13.1-1 13.1-2 13.1-8 13.1-10 13.2-1 13.3-1 13.4-1 13.4-2 13.4-4 13.4-6 13.4-8 13.4-10 13.5-1 13.5-2 13.5-4 13.5-6 13.5-8 13.5-10 13.5-12 13.5-14 13.5-16 13.6-1 13.6-2 13.6-4 13.6-6 13.6-6 13.7-1 13.7-2 13.7-2 13.8-1 13.8-1 13.8-1 7 Table of Contents 13.8.3. Feeder Exchange System (FES) 13.8.4. Set-up Verification System (SVS) 13.8.5. Automatic Tray Stacker (ATS) 13.9. Module 9, Maintenance Tools 13.10. Module 10, Fixation Parts 13.8-1 13.8-1 13.8-1 13.9-1 13.10-1 14. Drawings and Circuit Diagrams 14-1 15. Main Index 15-1 16. Options 16.1. Tray Changer (TC) 16.1.1. Introduction 16.1.2. Specifications 16.2. Auto Tray Stacker (ATS 27) 16.2.1. Introduction 16.2.2. Specifications 16.3. Set-up Verification system (SVS) 16.3.1. Introduction 16.4. Feeder Exchange System (FES) 16.4.1. Introduction 16.4.2. Specifications 16.5. Component Feeders 16.6. Project SIMM Topaz (9466 920 06011) 16-1 16-2 16-2 16-3 16-4 16-4 16-5 16-6 16-6 16-7 16-7 16-8 16-8 16-9 17. Appendix 1: Material Safety Data Sheets 17-1 8 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Introduction CHAPTER 1 1.1. Introduction General Introduction 7KHVHUYLFHPDQXDOGHVFULEHVHOHFWULFDOPHFKDQLFDOVRIWZDUHDQGSQHXPDWLF DVSHFWVRIWKH*(07RSD]V\VWHP7KHUHSDLUSKLORVRSK\RIWKHHOHFWULFSDUWRI WKHPDFKLQHLVEDVHGRQ3&%VZDSSLQJDQGQRWRQFRPSRQHQWOHYHO UHSODFHPHQW7KHUHIRUHRQO\DIXQFWLRQDOGHVFULSWLRQRIHDFK3&%ZLOOEHJLYHQ LQWKLVPDQXDO WARNING Only technical personnel which is trained on the Topaz equipment is allowed to carry out service actions. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 1-1 Introduction 1.2. Chapter Overview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ervice Manual Topaz PA 1309/10 5322 871 63606 01.05 Introduction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ervice Manual Topaz PA 1309/10 1-3 Introduction 1.3. Safety 1.3.1. General 3OHDVHREVHUYHDOOVDIHW\UXOHVDQGFDXWLRQDU\UHPDUNVWRHQVXUHWKDWWKHPDFKLQH LVXVHGLQDVDIHDQGFRUUHFWPDWWHU$OVRSOHDVHEHDULQPLQGWKDWQRWDOOVDIHW\ LWHPVFDQEHOLVWHGLQGHWDLOVRWKDWDQDFFXUDWHMXGJPHQWE\WKHVHUYLFHHQJLQHHU LVHVVHQWLDOLQVHUYLFLQJWKHPDFKLQHVDIHO\ 1.3.2. Basic Rules 7KHIROORZLQJDUHEDVLFVDIHW\UXOHVZKLFKPXVWEHREVHUYHG 7KHSHUVRQZKR·VVHUYLFLQJWKHPDFKLQHPXVWKDYHUHFHLYHGSURSHUWUDLQLQJ WRRSHUDWHVHUYLFHWKHPDFKLQHLQDVDIHDQGFRUUHFWPDQQHU 7KHSRZHUVXSSO\PXVWEHWXUQHG2))ZKHQHYHUWKHPDFKLQHLVLQVSHFWHG SDUWVDUHUHSODFHGRULQWHUQDODGMXVWPHQWVDUHPDGH 'XULQJRSHUDWLRQRIWKHPDFKLQHEHVXUHWRNHHSDOOSDUWVRIWKHERG\VXFK DVWKHKDQGVRUKHDGDZD\IURPWKHPDFKLQH·VPRYLQJSDUWV %HVXUHWRNHHSWKH++.+DQG+HOG.H\ERDUGLQ\RXUKDQGZKHQHYHU ´WHDFKLQJµRUPDNLQJDGMXVWPHQWVWRWKHPDFKLQHVRWKDWLWFDQEHVWRSSHG DWDQ\WLPH %HVXUHWKH´LQWHUORFNµVDIHW\GHYLFHVDUHPDLQWDLQHGLQDQRSHUDEOH FRQGLWLRQVRWKDWLWFDQEHXVHGWRVWRSWKHPDFKLQHDWDQ\WLPH 'RQRWXVHWKHPDFKLQHLQDQHQYLURQPHQWZKHUHIODPPDEOHJDVVHVDUH SUHVHQWRUZKHUHLWLVH[WUHPHO\GLUW\ 1.3.3. Safety Standards 7KHVDIHW\RIWKH&60*(0V\VWHPVLVLQDFFRUGDQFHZLWKIROORZLQJ&( GLUHFWLYHV 0DFKLQHGLUHFWLYH((&DQG((&LQFOXGLQJDPHQGPHQWV /RZ9ROWDJHGLUHFWLYH((&LQFOXGLQJDPHQGPHQWV (0&GLUHFWLYH((&LQFOXGLQJDPHQGPHQWV 1-4 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Introduction 1.3.4. Cautionary Remarks 7KLV0DQXDOXVHVWKHIROORZLQJFDXWLRQDU\UHPDUNV REFERENCE: *LYHVXVHIXOLQIRUPDWLRQUHODWHGWRWKHPDFKLQHRSHUDWLRQ NOTE: ([SODLQVWKHPDFKLQHRSHUDWLRQVDQGSURFHGXUHVLQDVLPSOHDQGFOHDUPDQQHU CAUTION: *LYHVLPSRUWDQWLQIRUPDWLRQWRSUHYHQWDQ\GDPDJHWRWKHPDFKLQHRUGDWD WARNING: *LYHVLQIRUPDWLRQRIXWPRVWLPSRUWDQFHLQHQVXULQJWKHVDIHW\RIWKHRSHUDWRURU VHUYLFHSHUVRQQHO EMERGENCY BUTTON: ,QGLFDWHVWRSUHVVILUVWWKHHPHUJHQF\EXWWRQEHIRUHFRQWLQXH 1.3.5. Warning Stickers 7KLVSDUDJUDSKJLYHVDQRYHUYLHZRIZDUQLQJVWLFNHUVWKDWDUHXVHGWRZDUQWKH RSHUDWRUVDQGVHUYLFHSHRSOHIRUGDQJHURXVVLWXDWLRQV:LWKHYHU\SLFWXUHDVKRUW GHVFULSWLRQLVJLYHQRIWKDWGDQJHURXVVLWXDWLRQ Do not enter Figure 1-1 Do not enter 7KLVVWLFNHUZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUQRWWRHQWHUE\KDQG ,WLVORFDWHGDWWKHHQWUDQFHDQGH[LWFRQYH\RUUDLO 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 1-5 Introduction Electrical shock Figure 1-2 Electrical shock 7KLVVWLFNHUVHHILJXUHZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUIRUHOHFWULFDO VKRFN %HKLQGWKHFRYHUVDUHKLJKHOHFWULFDOYROWDJHVSUHVHQW Low Radiation Figure 1-3 Radiation 7KLVVWLFNHUVHHILJXUHZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUIRUORZUDGLDWLRQ 7KLVVWLFNHULVORFDWHGQHDUE\WKHODVHUWUDQVPLWWHUIRUIHHGHUIORDWLQJGHWHFWLRQ 1-6 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Introduction High temperature Figure 1-4 High temperature 7KLVVWLFNHUVHHILJXUHZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUIRUKLJK WHPSHUDWXUHSUHVHQFH7KLVVWLFNHULVORFDWHGXSRQWKH<PRWRURIWKH7RSD] 1.3.6. ESD Precaution $OO SULQWHG FLUFXLW ERDUGV WKDW DUH SDUW RI WKH &60*(0 PDFKLQHV PXVW EH WUDQVSRUWHGDQGVWRUHGLQ(6'SURWHFWHGEDJV $Q\SHUVRQKDQGOLQJDQ&60*(0SULQWHGFLUFXLWERDUG PXVW DGHTXDWHO\ EH HDUWKHG HJ E\ PHDQV RI D EUDFHOHW ZLWK HDUWK FDEOH WR SUHYHQW GHVWUXFWLYH HOHFWURVWDWLFGLVFKDUJHWKURXJKWKHSULQWHGFLUFXLWERDUG ,Q DUHDV WKDW DUH QRW (6' SURWHFWHG WKH UHPRYDEOH SURWHFWLYH FRYHUV PXVW EH PRXQWHGRQDOOSODFHPHQWPRGXOHV +DQGOLQJRISULQWHGFLUFXLWERDUGVVKRXOGEHUHVWULFWHGDVPXFKDVSRVVLEOH 1.3.7. Noise Level 7KHDYHUDJHQRLVHOHYHORIWKH7RSD]V\VWHPGXULQJSURGXFWLRQLVG%$ 1.3.8. Liability 3KLOLSV VKDOO QRW EH OLDEOH IRU DQ\ FRVWV GDPDJHV RU SHUVRQDO LQMXULHV LI WKH &60*(0V\VWHPLVQRWXVHGDFFRUGLQJWRWKHVDIHW\UXOHVJLYHQLQWKLVPDQXDO 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 1-7 Introduction 1.3.9. Oil and Greases 7KLVVHFWLRQJLYHVPRUHGHWDLOHGLQIRUPDWLRQDERXWRLOVDQGJUHDVHVXVHGLQWKH 7RSD] ,QFKDSWHUDFRPSDWLELOLW\OLVWZLWKDQXPEHURIJUHDVHVWKDWFDQEHXVHGLV JLYHQ )ROORZLQJJUHDVHVDQGRLOVDUHFRYHUHG 12NC no. 5322 390 20159 5322 390 20161 5322 390 20155 5322 390 10144 Supplier NSK NSK AccTech Ausimont Trade name NSK 1 grease Multitemp CRL No3 NSK 2 grease Multitemp PS No2 Molub alloy HP-Alco pad Fomblin Y-VAC3 - Shell Du Pont Alvania grease 2 Krytox GPL-22X GPL-52X General description Grease Grease Grease Cleaning tissues Vacuum grease O-rings and seals Grease Vacuum grease O-rings and seals MSDS no. 07-230 07-300 806H-806 12298 56110-08 DU008134 Table 1-1 Note: Philips will not be responsible for any damage to the machine if other greases and/or oils are used than mentioned above. 1.3.10. Abbreviations 7KLVFKDSWHUGHVFULEHVFRPPRQXVHGDEEUHYLDWLRQVLQWKLVPDQXDOLQDOSKDEHWLF VHTXHQFH 1-8 Abbreviation A AC ASAP ATS Explanation Ampere Alternating current As Soon As Possible Auto Tray Stacker, tray handling device B/W BGA Black and white Ball Grid Array CE CN COB COG CPU CS CSM CSP Comité europièn Connector Chip on board Centre Of Gravity Central processing unit Customer Support Compact Surface Mounter Chip scale package, •BGA Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Introduction 5322 871 63606 01.05 Abbreviation DC DI DI DO DIL Explanation Direct current Document Information Data Input Data Output Dual In Line, chip package EMG ESD Emergency Electro Static Discharge FD FES FV Floppy Disk Feeder exchange system Full Vision GD1 GEM Good Product line : Topaz, Emerald and Sapphire H.H.K. HDD HDLC Hand Held Keyboard Hard Disk Drive High Level Data Link Control; More extensive communication protocol than SDLC IM ISO Installation Manual International Standard Organization LCS Large Component Sequencer, Also called trayfeeder. MTF Manual Tray Feeder OM Operator Manual P1 PA Priority 1 indicator, Philips Article PCP PCS Product Creation Process Philips Consumer Services, worldwide stock for EMT QFP Quad Flat Package SI SDLC SM SOP SVS Service Information Serial Data Link Control; communication protocol with one clock and data line. Service Manual Single Outline Package, Setup Verification System TBD TBW TC TI TPD TSOP To be defined To Be Written Tray Changer, Tray handling device Technical Information Technical Product Documentation Top Single Outline Package, UFOS UM UP URS User Friendly operating System User Manual Under Progress User Requirement Specification VIOS Vision Integrated Operating System Service Manual Topaz PA 1309/10 1-9 Introduction Intentionally left blank. 1 - 10 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 General and Electrical Block Diagram CHAPTER 2 General and Electrical Block Diagram 7KLVFKDSWHUVKRZVERWKJHQHUDODQGHOHFWULFDOEORFNGLDJUDPVRIWKH7RSD] 7KHJHQHUDOEORFNGLDJUDPILJXUHVKRZVWKHPDLQVHFWLRQVRIWKH7RSD] 5HIHUHQFHVDUHPDGHWRWKHFKDSWHUVLQWKLVPDQXDO 7KHHOHFWULFDOEORFNGLDJUDPILJXUHVKRZVDQRYHUYLHZRIWKHPDLQHOHFWULFDO SDUWVRIWKHV\VWHP 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 2-1 General and Electrical Block Diagram VISION SYSTEM Chapt 9 COMPONENT TRANSPORT Chapt 7 SYSTEM AXES SYSTEM Chapt 8 PCB TRANSPORT Chapt 6 SYSTEM MCX CONTROLLER SOFTWARE AIR SUPPLY Chapt 11 POWER SUPPLY Chapt 11 Figure 2-1 2-2 Service Manual Topaz PA 1309/10 Chapt 3 USER Chapt 3 INTERFACE Chapt 10 General block diagram Topaz 5322 871 63606 01.05 General and Electrical Block Diagram * : Flash disk only on new CPU : Located within MCX Controller VGA - Monitor RS - 232 port AT - keyboard Handheld keyb. Power supply 5V, 12V, -12V Power Monitor CPU BOARD - 80486 uP (8 Mb memory) - VGA controller - HDD controller Flash disk* - FDD controller - I/O control HD disk (C) 1.44 Mb (A) 3.5” Floppy I/O -1 Motherboard ISA - bus I/O -2 Encoder signals SDLC SMEMA (FES) FEEDER CONVEYOR EMG. VACUUM UP/DOWN SENSING LY LX LW LZ LH LT I/O - 2 left - side DRIVER - 2 BOARD ASSY Traychanger or ATS SERVO -2 board assy Tray changer or ATS I/O - 1 HEAD I/O Encoder signals (FES) FEEDER CONVEYOR EMG. VACUUM EMERG. CONVEYOR W Z R X Y I/O -2 right side Cam 1, Fid. Cam 2, Single Cam 3, Multi 1 Cam 4, Multi 2 I/O -2 conveyor Tray changer or ATS MAINS POWER + SAFETY CIRCUIT DRIVER - 1 BOARD ASSY VICS 2000 282 VOLT POWER SUPPLY EMG & I/O POWER SUPPLY Figure 2-2 5322 871 63606 01.05 SERVO -1 board assy Service Manual Topaz PA 1309/10 VISION monitor Electrical block diagram Topaz 2-3 General and Electrical Block Diagram Intentionally Left Blank. 2-4 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles CHAPTER 3 3.1. System Principles Introduction 7KLVFKDSWHUGHVFULEHVDOOWKHLQVWDOODWLRQDQGWKH EDVLF V\VWHP SULQFLSOHV RI WKH 723$= 7KH ILUVW SDUW RI WKLV FKDSWHU GHVFULEHV WKH 0DLQV $LU DQG V\VWHP LQVWDOODWLRQ VSHFLILFDWLRQV7KHVHFRQGSDUWGLVFXVVHVWKH&RQWUROXQLW0&;ZLWKWKHUHODWHG 3&%·VWKHWKLUGSDUWJLYHVDRYHUYLHZRIWKHYDULRXV,23&%·V.H\ERDUGVDQG PRQLWRUV7KHODVWSDUWFRYHUVWKH,2VLJQDOVDQGDEULHILQWURGXFWLRQKRZWRXVH WKHYDULRXVDGMXVWPHQWFRPPDQGVDGMXVWPHQWPHWKRGVZKHQGRLQJDPDFKLQH DGMXVWPHQW 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 3-1 System Principles 3.2. Mains Specifications and Connection Schedule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hen connecting the MAINS power, make sure to configure the Mains transformers before. When changing the Mains input voltage, always check first with the Philips service centre. Make sure to take all necessary precautions to avoid dangerous situations. NOTE: For the power connection to the system please refer to “Machine installation: Power connection” in section 11.2.9. For the transformer power tabs see section 11.2.7 as well. 3-2 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles 9 Figure 3.2- 1 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 Tap settings of the mains transformers 3-3 System Principles ,QILJXUHWKHFLUFXLWEUHDNHUER[LVVKRZQZLWKUHPRYHGIURQWFRYHU7KLVER[ ORFDWHVDOOWKHFLUFXLWEUHDNHUVRIWKH7RSD]V\VWHP%HORZDOLVWLVJLYHQRIDOOWKH FLUFXLWEUHDNHUVIXQFWLRQV 4) 4) 4) 4) 4) $ $ $ $ $ 0DLQVFLUFXLWEUHDNHU 0RQLWRUV9*$9LVLRQPRQLWRUV &RQWUROOHUER[DQGSRZHUVXSSO\*6 0RWRUGULYHUV &RQYH\RUPRWRUV ;% 0DLQVLQSXWWHUPLQDO Figure 3.2-2 3-4 Service Manual Topaz PA 1309/10 Circuit breaker box (with removed cover) 5322 871 63606 01.05 System Principles 3.3. 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MCX-Controller Lay-Out (Second Generation) ,QWKHILJXUHWKHVHFRQGJHQHUDWLRQ0&;FRQWUROOHUER[LVVKRZQ Figure 3.5-1 Second generation MCX-control unit 7DEOHVKRZVWKHFRPSRQHQWVRIWKHFRQWUROOHU,QFKDSWHUDQLQWHUFRQQHFW GLDJUDPFDQEHIRXQGRIDOOWKHLQWHUQDOFRQQHFWLRQVRIWKH0&;FRQWUROXQLW Part no. 1 2 2A 3 3A 4 Description Driver power board Servo assy Servo assy Driver board Driver board System board 5 6 7 8 VICS2000 5V/12V power supply HDD Mother board Remarks 1x 282V power supply 1x servo board 1x servo board for the optional trayfeeder 1x driver board (X,Y,R,Z, W ) 1x driver board for the optional trayfeeder 1x system board equipped with a 40486DX2 CPU, 8 Mb internal memory 1x Vision board 5V, +12V and -12V power supply Hard disk Mother board Table 3.5-1 Controller parts 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 3 - 11 System Principles 3.5.2. System Board 6HFRQGJHQHUDWLRQV\VWHPERDUG 7KHV\VWHPERDUGRIWKH0&;FRQWUROOHULVD';&38EDVHGV\VWHPUXQQLQJ DW0]7KHRQERDUGPHPRU\LV0E\WH$SLJJ\EDFN,2FRQWUROERDUGLVXVHGWR FRQWUROWKH,2FLUFXLWU\7KHERDUGVHHILJXUHKDVWKHIROORZLQJIXQFWLRQV l ,QWHUIDFLQJWRDOORWKHU3&%VFRQQHFWHGWRWKHPRWKHUERDUG l +DUGGLVNLQWHUIDFLQJ l )ORSS\GLVNLQWHUIDFLQJ l 9LGHRLQWHUIDFH9*$ l .HHSVWUDFNRI'DWHDQG7LPH l .H\ERDUGLQWHUIDFH l 6'/&,2LQWHUIDFHFRQWURO To HDD (CN4) To Servo 2 (option) JP1 to JP3 BIOS ROM To Servo 1 JP4 to JP6 Keyboard Floppy disk EMG JP7 underneath the application board RS232 con.1 CN4 (Appl. 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Servo Board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o Driver 1(2) To Vision To Driver Power To Driver 1(2) Good signal To Vision CN7 CN9 CN10 Sticker 1 CN3 CN5 CN8 LED GOOD Sticker 2 Encoder signals CN1 Sticker 3 Encoder signals CN2 S1 S3 CN4 Figure 3.5-5 Servo board 7KHVHUYRERDUGUHFHLYHVFRPPDQGVIURPWKHV\VWHPERDUGYLDWKH,6$EXVFRQQHFWRU &1RQWKHPRWKHUERDUG 3 - 16 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles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achine type → Switch ↓ S1 Bit ↓ 1 2 1-6 S3 Table 3.5-3 Topaz Emerald Sapphire A-table ON OFF ON ON ALL 6 OFF Sapphire B-table ON OFF LCS100 LCS 31 ATS 27 OFF ON Jumpers settings S1 and S3 :LWKWKHVHUYRERDUGDFRXSOHRIVWLFNHUVDUHGHOLYHUHGWKHVHVWLFNHUVVKRXOGEH PRXQWHGDWWKHSRVLWLRQVLQGLFDWHGLQILJXUHDQGDFFRUGLQJWRIROORZLQJWDEOH Machine type → Sticker ↓ Sticker 1 “Servo ..” Sticker 2 “PI ..” Sticker 3 “PI ..” Table 3.5-4 Topaz Emerald Sapphire A-table 1 1 2 1A 1A 2A Sapphire B-table 1B 1B 2B LCS100 LCS 31 ATS 27 2 3 4 Stickers versus machine types 7KHWDEOHEHORZVKRZVLIWKHFRQQHFWRUVLQGLFDWHGLQILJXUHKDYHDFDEOHDWWDFKHG WRDQRWKHUERDUG´&µDVKRUWFRQQHFWRU´6µRUDUHOHIWXQFRQQHFWHG´1&µ Machine type → Connector ↓ CN3 CN5 CN7 CN8 CN9 CN10 Table 3.5-5 5322 871 63606 01.05 Topaz Emerald C C C C C C Sapphire A-table C C C C C C Sapphire B-table C C C C S C LCS100 LCS 31 ATS 27 C C NC NC S NC Connectors versus machine types Service Manual Topaz PA 1309/10 3 - 17 System Principles 3.5.4. Vision Board 7KHYLVLRQERDUGLVWKH9,&6DQGKDQGOHVDOOYLVLRQUHODWHGRSHUDWLRQVH[FHSW ODVHU7KHERDUGOD\RXWLVVKRZQLQILJXUHEHORZ Camera 1 Camera 2 Camera 3 Camera 4 Jumpers F igure 3.5-6 Vision board VICS 2000 7KH9,&6YLVLRQERDUGLVHTXLSSHGZLWKFDPHUDFRQQHFWRUVIURPWRSWR ERWWRPWKH\DUHXVHGDVIROORZV &DPHUD´µ &DPHUD´µ &DPHUD´µ´µ &RQQHFWRUIRUWKHILGXFLDOFDPHUD &RQQHFWRUIRUWKHRSWLRQDOVLQJOHYLHZFDPHUD 7KHFRQQHFWRUVDQGFDQHLWKHUEHXVHGERWKIRUVLQJOH YLHZFDPHUD·VRUERWKIRUPXOWLYLHZFDPHUD·VGHSHQGLQJ RQWKHMXPSHUVHWWLQJV,WLVQRWSRVVLEOHWRXVHHJFDPHUD FRQQHFWLRQIRUDVLQJOHYLHZFDPHUDDQGFDPHUD FRQQHFWLRQIRUDPXOWLYLHZFDPHUD 7KHVHWWLQJVIRUWKHMXPSHUVWRRIWKHYLVLRQERDUGDUH VKRZQLQWKHWDEOHEHORZVHHDOVRILJXUH Camera “3” & “4”: Single-camera Multi-camera Table 3.5-6 Position 2 Camera and jumper settings Position 3 Position 1 Figure 3.5-7 3 - 18 Service Manual Topaz PA 1309/10 Jumpers 1 to 4 : Set jumper to position 1-2 Set jumper to position 2-3 Jumper on position 2-3 Jumper setting 5322 871 63606 01.05 System Principles 3.5.5. Mother Board 7KLVERDUGVHHILJXUHFRQQHFWVWKHYDULRXVERDUGVVXFKDVWKHV\VWHPERDUG VHUYRERDUGDQGYLVLRQERDUGYLDDQ,6$EXV7KHPRWKHUERDUGFRQWDLQVDOVRDQ$& DQG'&SRZHUIDLOXUHGHWHFWLRQIXQFWLRQ7KH$&LQSXWWKH'&9DQGWKH9 9DUHPRQLWRUHG$/('LQGLFDWLRQZLOOVKRZDSRZHUYROWDJHGURSLQVWDQWDQHRXV SRZHUIDLOXUHVDQGHUURUVLQWKH'&SRZHUVXSSO\IRUWKHFRQWUROV\VWHP7DEOH EHORZVKRZVWKHYDULRXVSRVVLELOLWLHV SERVO BOARDS SYSTEM BOARD VISION BOARDS LED 1, 2, 3, 4 CN9: I/O power CN6: 5V IN CN5: 12V IN CN11: AC 12V IN /HJHQGD5→/LWUHG *→/LW JUHHQ ;→1RWOLW Figure 3.5-8 Display LED Specification 200VAC: (VAC) +5VDC: (V1) +12VDC: (V2) -12VDC: (V3) Table 3.5-7 VAC ≥ 180V VAC ≤ 160V V1: ≥ 4.75V V1: < 4,75V V1: < 4.5V 10.8V ≤ V2 ≤ 13.2V 10.8V > V2 > 13.2V V3 < -10.8V V3 > -10.8V CN7: FAN POWER NOT USED SPARE Mother board →QRWGHILQHG -12V (Normally NOTE PWR NG +5V +12V (Normally off) (Normally on) (Normally on) LED 1 X R R LED 2 G X X LED 3 LED 4 G X G X on) Normal AC voltage drop Normal DC 5V Error Normal DC +12V error Normal DC -12V drop Meaning of the LED indicators Remark: It is possible that some mother boards have more connectors, this because some GEM machines need more PCB’s (more axes, etc). 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 3 - 19 System Principles 3.5.6. Hard- and Floppy-Drives and Flash Disk +DUGGLVN ,QV\VWHPVHTXLSSHGZLWKDQROGW\SHV\VWHPERDUGSOHDVHUHIHUWRVHFWLRQWKH KDUGGLVNVHHILJXUHLVORFDWHGDWWKHOHIWVLGHRIWKH0&;FRPSDUWPHQW 7KLVSK\VLFDOO\ODUJHGULYHLVIRUPDWWHGDVD0E\WHGULYHIRUVSHHGUHDVRQV 7KH99SRZHUVXSSO\IRUWKHKDUGGLVNLVFRPLQJIURPWKHPRWKHUERDUGYLD FRQQHFWRU&17KHVLJQDOFDEOHLVFRQQHFWHGWRWKHWRSVLGHRIWKHV\VWHPERDUG LQVLGHWKH0&;FRQWUROOHU Signal connector to system board Power connector +5V, +12V Figure 3.5-9 Hard disk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ote: When inserting or removing a flashdisk the Topaz should be switched off because the disk is not protected against such handling and might get damaged. Be sure to always mount the protective cover over the flash disk after mounting. 3 - 20 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles 3.5.7.Driver Board Assy 7KLVERDUGVHHILJXUHEHORZFDQGULYH$&PRWRUVIRUXSWRD[HV7KH DPRXQWRIPRWRUVXVHGGHSHQGVRQWKHW\SHRIPDFKLQH,QWKH0&;FRQWUROOHUWKH GULYHUERDUGLVDOZD\VXVHGIRUWKHPDLQPDFKLQHZKLOHWKHGULYHUERDUGLV GHGLFDWHGIRURSWLRQVVXFKDVWUD\FKDQJHUDQGDXWRWUD\VWDFNHU$76 282V power connection CN4 CN6 CN1 Power from servo-board CN2 From servo-board PWM/FDB signals CN3 Figure 3.5-10 Driver board 7KHPRWRUGULYHU'&SRZHULV9'&DQGLVVXSSOLHGE\WKH'ULYHUSRZHU VXSSO\YLD&12QWKHGULYHUERDUGWKH9'&LVFRQYHUWHGLQWRDQ$&VLJQDO IRUGULYLQJWKHSKDVH$&PRWRUV7KLVLVGRQHDVVKRZQLQILJXUH U Oscillator 50 kHz V 3 phase AC motor W 12V 282V DC Figure 3.5-11 Power module Driver board principle 1RWHWKDWRQO\WKH;DQG<PRWRUVDUHDFWXDOWKUHHSKDVHPRWRUV 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 3 - 21 System Principles $.+]RVFLOODWRUSRZHUHGDW9DFWLYDWHVHYHU\SRZHUWUDQVLVWRUZKLFK VZLWFKHV9VHTXHQWLDOO\WKXVFUHDWLQJDSKDVH89:$&VLJQDOIRUGULYLQJ WKHPRWRUV 7KH*75*LDQW7UDQVLVWRUPRGXOHZKLFKFRQWUROVWKHFXUUHQWLVORFDWHGDWWKH UHDUVLGHRIWKHGULYHERDUGDQGLVPRXQWHGRQDODUJHKHDWVLQN 7KHPRWRUFXUUHQWRIDPD[LPXPRID[HVLVIHGYLD&1DQGDPD[RID[HVYLD &1WRWKH$&PRWRUV 7KH9±9SRZHUIRUWKHRVFLOODWRUDQGORJLFFLUFXLWU\LVUHFHLYHGIURPVHUYR ERDUGYLD&17KHFXUUHQWRIWKHORJLFSRZHULVFRQWUROOHGE\DQ,30,QWHOOLJHQW 3RZHU0RGXOHZKLFKLVIL[HGRQWKHKHDWVLQN 7KH SXOVH ZLGWK PRGXODWLRQ DQG IHHGEDFN SRZHU IDLOXUH RYHU FXUUHQW HWF VLJQDOV IURPWKHVHUYRERDUGDUHUHFHLYHGYLDFRQQHFWRU&1 Note: It is possible that not fully populated driver-boards are installed. The board only contains the drivers for the axes needed in the system. The not fully populated boards can always be replaced by a fully populated board which are stocked 7KHUH DUH RQO\ WZR YHUVLRQV RI GULYHUERDUGV RQH IRU WKH PDLQ V\VWHPV .- 0([DQGRQHIRUWKHRSWLRQV.-0[VXFKDVWUD\FKDQJHUV/&6 DQGDXWRWUD\VWDFNHUV$76 7KHWDEOHEHORZVKRZVRIWKHYDULRXVGULYHUERDUGVXVHGLQWKH&60)XOO9LVLRQ DQG&60*(0V\VWHPV Factory number KJ0-M5810- xxx -31x, -32x -41x, -42x -51x, -52x, Philips service no. Machine type Remarks 5322 216 04018 5322 216 04262 5322 216 04021 CSM 66, 84, 84V III LCS31, LCS100, ATS27 CSM 66, 84, 84V III -71x, 72x 5322 216 04017 CSM 66, 84, 84V III - A1x, A2x 5322 216 04054 - E2x, 5322 216 04309 Orion, Eclipse-II, Comet-II Topaz, Emerald, Sapphire partly populated board partly populated pcb partly populated, is replaced by 5322-216-04018 partly populated, is replaced by 5322-216-04018 full populated Table 3.5-8 3 - 22 full populated Driver board types Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles 3.5.8. D(river) – Power Assy 7KH'SRZHUDVV\UHFWLILHVWKHSKDVH9$&SRZHUDQGVXSSOLHV9'&WRWKH GULYHU ERDUGV 7KH DVVHPEO\ FRQVLVWV RXW RI WKH 'SRZHUERDUG LWVHOI DQG WKH FDSDFLWRU&$3ZKLFKLVORFDWHGDWWKHULJKWVLGHEDFNFRUQHURIWKH0&;FRQWUROOHU ER[VHHDOVRILJXUHEHORZ )RUPRUHGHWDLOVSOHDVHUHIHUWR FKDSWHUSRZHUVXSSO\V\VWHPV Figure 3.5-12 Driver power board 3.5.9. 5V / 12V Power Supply Assy’s 7KH0&;FRQWUROXQLWKDVRQHSRZHUVXSSO\IRUWKH9'&DQGWKH9'& 7KHSRZHUVXSSO\LVPRXQWHGDWWKHOHIWVLGHLQWKH0&;FRQWUROER[VHHILJ Figure 3.5-13 5V,+12V,-12V Power supply )RUPRUHGHWDLOVSOHDVHUHIHUWRFKDSWHU´SRZHUVXSSO\V\VWHPVµ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 3 - 23 System Principles 3.6. LED Driver Board 7KH/('GULYHUERDUGLVWKHERDUGVHHILJXUHZKLFKFRQWUROVWKHOLJKW LQWHQVLW\RIWKHFRPSRQHQWFDPHUDV7KHUHDUHYDULRXVW\SHVRI/('GULYHUVIRU WKH6DSSKLUHDQG7RSD]V\VWHPVWKHVDPHYHUVLRQLVXVHG7KLV ERDUGFDQKDQGOHWZROLQHVHQVRUPXOWLFDPHUDOLJKWLQJRXWSXWVDQGDUHD&&' FDPHUDVLQJOHFDPHUDOLJKWLQJRXWSXW Light driver signals CN15 CN13 CN11 CN14 CN12 CN10 CN3 Motor encoder Power and control signals CN2 CN1 CN9 CN8 CN7 CN6 CN5 CN4 Lighting sensor signals VR1 VR2 VR3 Multi-cam 2 Coax.light Single camera Not used VR4 VR5 VR6 Multi-cam 1 Non-coax.light Multi-cam 1 Coax.light Multi-cam 2 Non-coax.light Figure 3.6-1 LED driver board (DFKRXWSXWKDVFKDQQHOVHDFKFKDQQHOKDVDEULJKWQHVVDGMXVWPHQW9595 7KHOLQHVHQVRUFKDQQHOVDUHHTXLSSHGZLWKDEULJKWQHVVIHHGEDFNV\VWHP 7KLVPHDQVWKHOLJKWLQJXQLWKDVDVHQVRUZKLFKPHDVXUHVWKHEULJKWQHVVWKHODWWHULV FRPSDUHGZLWKWKHUHIHUHQFHEULJKWQHVVDQGDVDUHVXOWRIWKLVWKHEULJKWQHVV GLIIHUHQFHFRQWUROVWKH/('FXUUHQW,QRUGHUWRSURWHFWWKH/('·VIRUPD[LPXP FXUUHQWWKHERDUGFRQWDLQVDFXUUHQWOLPLWWHUFLUFXLW7KHERDUGDOVRFRQWDLQVD VSHHGIHHGEDFNFLUFXLWU\ZKLFKLVFXUUHQWO\QRWLQXVH 3 - 24 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles 5HPDUNV • 7KHMXPSHUVHWWLQJLVIL[HGDQGLVWKHVDPHIRUERWKWKH6DSSKLUHDQG7RSD] • 7KH/('GULYHUERDUGIRUWKH(PHUDOGLV127FRPSDWLEOHZLWKWKHRQHXVHGLQ WKH6DSSKLUH7RSD]EHFDXVHRIWKHGLIIHUHQFHLQWKHFXUUHQWOLPLWHUV 7KHIROORZLQJWDEOHVKRZVWKHUHODWLRQEHWZHHQWKHVHYHUDOFDPHUDVFRQQHFWRUV SRWHQWLRPHWHUVPD[FXUUHQWVDQGMXPSHUVLQWKHKDUGDQGVRIWZDUH3OHDVHUHIHUWR ILJXUHIRUWKHORFDWLRQRIWKHYDULRXVLWHPV VIOS HARDWARE Vision Board LED driver board LED driver output Light type (note 2) Potentiometer Output connector Sensor connector Sensor jumper Speed jumper SL-bit jumper (note 3) Max current [mA] 3/1/option config/ camera combination 3/2/MCH_DATA/ camera coordinate Table 3.6-1 Camera 1 “Fiducial cam.” - Camera 2 Camera 3 2 A VR3 CN10 CN4 JP9 JP4 JP1 120 Camera 4 3 B VR2 CN11 CN5 JP10 JP4 JP1 120 1 Single camera 1 A VR1 CN12 CN6 JP11 JP6 JP2 90 4 B VR4 CN13 CN7 JP12 JP6 JP2 400 2 Multi camera 2 (note 1) A VR5 CN14 CN8 JP13 JP7 JP3 90 B VR6 CN15 CN9 JP14 JP7 JP3 400 3 Multi camera 1 (note 1) Vision board settings and controls NOTE 1: When the Topaz is only equipped with one multi camera, the camera is defined as multi-camera 1 regardless of the physical position of the camera. If the Topaz is equipped with two multi-cameras the front camera is defined as multi-camera 1 and the rear one as multi-camera 2. NOTE 2: When the table indicates a light type “A” the coaxial light is meant. When referring to the light type “B” the non-coaxial light is meant. Please be aware that the Emerald uses another definition for light type A and B; the B type in the Emerald is the CSP lighting ! NOTE 3: The SL-bit is the Special Light bit setting which is used for switching between the coaxial and non-coaxial light, please refer to the text below. 2Q WKH /(' GULYHUERDUG WKUHH MXPSHUV SURYLGH D VSHFLDO OLJKW ELW VHWWLQJ WKLVVSHFLDOOLJKWELWLVXVHGWRVZLWFKEHWZHHQWKHFRD[LDOOLJKWDQGWKHQRQ FRD[LDOOLJKW$VZHGRQRUPDOO\XVHERWKWRJHWKHUZHGRQRWQHHGWRFKDQJH WKH VHWWLQJV 7DEOH EHORZ VKRZV WKH VHWWLQJV IRU WKHVH MXPSHUV IRU YHULI\LQJSXUSRVHVRQO\ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 3 - 25 System Principles Special light bit OFF ON Table 3.6-2 JP1-3 Light A OFF ON SET Light B ON OFF JP1-3 Light A ON ON REMOVED Light B ON OFF Vision board special light bit settings 2QWKH/('GULYHUERDUGDQXPEHURIMXPSHUVDUHDYDLODEOHZKLFKDUHVHWIURP IDFWRU\7KHWDEOHEHORZVKRZVWKHVHWWLQJRIWKHVHMXPSHUVIRUYHULI\LQJSXUSRVHV RQO\ Jumper No. Setting: JP1 X Jumper No. Setting: JP9 2-3 ´;µ -XPSHUVHW JP2 - JP3 - JP4 X JP5 - JP6 X JP10 2-3 JP11 1-2 JP12 1-2 JP13 1-2 JP14 1-2 ´´ -XPSHUQRWVHW JP7 X JP8 - ´µRU´µLVWKHMXPSHUVHWWLQJUHIHUWRILJXUHIRUDQH[DPSOH Table 3.6-3 Vision board jumper settings $VPHQWLRQHGEHIRUHWKHERDUGLVHTXLSSHGZLWKDVSHHGIHHGEDFNFLUFXLWU\ZKLFKLV FXUUHQWO\QRWLQXVH)RULQIRUPDWLRQDOSXUSRVHVRQO\WKHWDEOHEHORZLQGLFDWHV ZKLFKOLJKWW\SHDQGZKLFKFDPHUDLVHTXLSSHGZLWKWKLVIXQFWLRQDOLW\ Camera No. Light No. Light and feedback control Table 3.6-4 3 - 26 Cam. Light A No 2 Light B No Cam. Light A No 3 Light B Yes Cam. Light A Yes 4 light B Yes Vision board feedback control overview Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles 3.7. I/O - Boards Head I/O-board Right conveyor I/O-board Left conveyor I/O-board Figure 3.7-1 Location of the I/O boards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ervice Manual Topaz PA 1309/10 3 - 27 System Principles 7KH ,2ERDUGV DUH FRPPXQLFDWLQJ ZLWK WKH V\VWHP &38 ERDUG YLD D 6'/& SURWRFRO 7KH ,QWHO PLFURSURFHVVRU RQ WKH GDXJKWHUERDUG LV FRQWUROOLQJ WKLV FRPPXQLFDWLRQ 7KHGDXJKWHUERDUGDOVRFRQWDLQVD520DQGD5$0PHPRU\7KH520PHPRU\ KROGVWKHVRIWZDUHIRUWKHSURFHVVRUWKLVVRIWZDUHLVORDGHGLQWRWKHPHPRU\RI WKLVSURFHVVRUDWVWDUWXS7KHSURFHVVRUXVHVWKH5$0PHPRU\DVDWHPSRUDU\ GDWDVWRUDJH Table 3.7-1 3 4 5 6 7 8 0 0 1 1 0 0 0 1 0 0 0 0 0 1 0 1 Type of board Left/right setting No function No function Terminator use “1” = ON “0” = OFF Terminator use 2 Type of board Dipswitch: Board: I/O-conveyor right I/O-conveyor left Switch functionality 1 Type of board 7KHPRWKHUERDUGRIWKH,2ERDUGFRQWDLQVDFRXSOHRIGLSVZLWFKHVZKLFKIXQFWLRQ ,VGHVFULEHGLQWKHWDEOH I/O-board DIP-switch settings 7KLUGJHQHUDWLRQ,2ERDUGV 7KH ,2ERDUGV RI WKH WKLUG JHQHUDWLRQ WKH VXFFHVVRUV RI WKH VHFRQG JHQHUDWLRQ FRQVLVWDOVRRIDPRWKHUERDUGDQGGDXJKWHUFRUHERDUGZLWKWKHVDPHIXQFWLRQDOLW\ DVWKHVHFRQGJHQHUDWLRQERDUGV 7KH ,QWHO PLFURSURFHVVRU RQ WKH GDXJKWHUERDUG KDV EHHQ UHSODFHG ZLWK WKH +LWDFKL 6+0+] SURFHVVRU WR FRQWURO WKH FRPPXQLFDWLRQ EHWZHHQ V\VWHP ERDUGDQG,2ERDUGV7KHFRPPXQLFDWLQJSURWRFROKDVEHHQFKDQJHGIURP6'/&WR +'/& +LJK /HYHO 'DWD /LQN &RQWURO )RU HVWDEOLVKLQJ WKH +'/& SURWRFRO WKH 6+SURFHVVRU PDNHV XVH RI WKH GHGLFDWHG FRPSRQHQW 6$%1 DOVR ORFDWHG RQWKHGDXJKWHUERDUG 7KHQHZSURFHVVRUUHGXFHVWKH,2VFDQQLQJWLPHWROHVVWKDQPVHFLQVWHDGRIWKH WRPVHFLQWKHVHFRQGJHQHUDWLRQERDUGV 6LPLODU WR WKH VHFRQG JHQHUDWLRQ ,2ERDUGV WKH WKLUG JHQHUDWLRQ GDXJKWHUERDUG SURFHVVRUPDNHVXVHRID520DQG5$0PHPRU\7KH5$0PHPRU\EDVLFDOO\KDV QRW FKDQJHG DQG LV XVHG E\ WKH SURFHVVRU IRU WHPSRUDU\ GDWD VWRUDJH +RZHYHU WKH 520PHPRU\KDVEHHQFKDQJHGWRDIODVK520 7KLV IODVK520 LQ FRPELQDWLRQ ZLWK WKH WKLUGJHQHUDWLRQ V\VWHPERDUG DQG 9,26 VRIWZDUHRUKLJKHUHQDEOHVWKHVRIWZDUHIRUWKH6+SURFHVVRUWREHXSORDGHG IURPWKHV\VWHPXQLWDWVWDUWXS)RUWKLVUHDVRQWKHIODVK520FRQWDLQVDUHDGRQO\ SDUWDQGDUHDGDEOHZULWDEOHSDUW7KHUHDGRQO\SDUWFRQWDLQVVRPHGHGLFDWHGVRIWZDUH QHVVHFDU\ IRU WKH VRIWZDUH GRZQORDG 7KH UHDGDEOHZULWDEOH SDUW LV XVHG IRU WKH VRIWZDUHGRZQORDGIURPWKHV\VWHPXQLW 7KH FRQQHFWRUV RI ERWK WKH VHFRQG DQG WKLUG JHQHUDWLRQ ERDUG DUH IXOO\ FRPSDWLEOH HQDEOLQJXSZDUGVFRPSDWLELOLW\IRUWKH313W\SH,2ERDUGV 3 - 28 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles 7KHERDUGVRIWKHWKLUGJHQHUDWLRQDUHVKRZQLQWKHILJXUHVDQGEHORZ,Q WKHVHILJXUHVWKHORFDWLRQRIWKHLQGLFDWRUVDQGVHWWLQJVDUHKLJKOLJKWHG Flash memory 7 segment LED display 2 stage DIP switch Figure 3.7-2 Flash memory LED-2 6 stage DIP-switch D1 D3 Conveyor I/O-board 7 segment LED display LED-2 2 stage DIP switch Figure 3.7-3 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 Head I/O-board D3 D5 D4 3 - 29 System Principles 7KHJUHHQ/('RQWKHFRUHERDUGDQGWKHJUHHQ/(''RQWKHKHDG,2ERDUG LQGLFDWHDJRRG9VXSSO\ZKHQOLW 7KHVHJPHQWGLVSOD\KDVEHHQDGGHGIRUVHOIGLDJQRVLVSXUSRVHVWKHHUURUFRGHVDUH VKRZQLQWKHWDEOHEHORZ Error code 1 2 3 Table 3.7-2 Meaning Host communication time is over; interruption in communication. Analogue-digital conversion error; I/O-board broken. HDLC controller time is over; I/O-board is broken. Core-board error codes 7KH\HOORZ/(''RQWKHFRQYH\RU,2ERDUGDQG'RQWKHKHDG,2ERDUG LQGLFDWHZKHWKHUWKHUHLVDVHULDOFRPPXQLFDWLRQRUQRWIROORZLQJFRGHVDUHXVHGIRU WKLVFRPPXQLFDWLRQ/('LQGLFDWRU Code Fast flashing On-on-off…on-on-off… On-off…on-off… Table 3.7-3 Meaning Normal operation Host communication time over error, display shows code “1”. +24V line shorted or broken. I/O-board communication indicator 7KHJUHHQ/(''RQWKHFRQYH\RU,2ERDUGDQGWKHJUHHQ/(''RQWKHKHDG ,2ERDUGLQGLFDWHDJRRG9ZKHQOLW 7KHVWDJH',3VZLWFKRQWKHFRQYH\RU,2ERDUGLVQHFHVVDU\WRPDNHWKHERDUG VXLWDEOHIRUHLWKHUWKHOHIWRUULJKWVLGHRUDWUD\IHHGHU7KHWDEOHEHORZVKRZVWKH VHWWLQJV Dipswitch: 1 2 3 4 5 6 Meaning: I/O-conveyor right I/O-conveyor left Trayfeeder 100 Trayfeeder 31 0 0 1 1 1 1 0 0 0 0 1 1 0 1 0 1 0 0 0 1 0 0 0 0 Table 3.7-4 “1” = ON “0” = OFF I/O-board DIP-switch settings 7KHWKLUGJHQHUDWLRQERDUGVKDYHWKHVDPHDPRXQWRI',3VZLWFKHVDVWKHVHFRQG JHQHUDWLRQERDUGVKRZHYHUWKHVZLWFKHVIRUWHUPLQDWRUXVHKDYHEHHQPRYHGWRWKH GDXJKWHUERDUGFRUHERDUGUHIHUWR´VWDJH',3VZLWFKµLQILJXUHVDQG 7KHVHWWLQJVDUHVKRZQLQWKHWDEOHEHORZ Dipswitch: Meaning: I/O-conveyor right, Trayfeeder/ATS I/O-conveyor left Head I/O Table 3.7-5 3 - 30 Sapphire 1 2 0 0 1 0 0 1 Emerald/Topaz 1 2 0 1 1 “1” = ON , enable “0” = OFF, disable 0 1 1 I/O-board DIP-switch terminator settings Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles 7KHVHFRQGJHQHUDWLRQ,2ERDUGVPD\EHUHSODFHGE\WKLUGJHQHUDWLRQ,2ERDUGV ZLWKVRPHUHVWULFWLRQV7DEOHEHORZVKRZVDQRYHUYLHZRIWKH,2ERDUGVDQG WKHPDFKLQHVWKH\FDQEHXVHGLQ Conveyor I/O Head I/O Board types : Suitable for machines (for abreviations see table below) : KG2-M4520-21x (npn) (5322 214 91259) KG2-M4580-00x (pnp) (5322 216 04002) KM5-M4580-00x (pnp) (5322 216 04471) KG2-M4520-11X (npn) (5322 214 91258) KG2-M4570-00X (pnp) (5322 216 04004) KG7-M4520-01X (npn) (5322 214 91374) KG7-M4570-01X (pnp) (5322 216 04001) (1) KM5-M4570-00X (pnp) (5322 216 04313) KM5-M4570-01X (pnp) (5322 216 04469) KM1-M4570-00X (pnp) (5322 216 04083) KV1-M4570-00X (pnp) (5322 216 04628) Abreviation EI EI* EII EM CI CI* CII S O T Table 3.7-6 5322 871 63606 01.05 EI, CI ROM versions (latest version, basic flash ROM indicated with F) : KG2-M45R9-002 n.a. EI*, EII, EM, O, T, CI*, CII, S KG2-M45R9-023 n.a. KM5-M45R9-10X (F) (2) (2) (2) Core board + Mother-board : CI KG2-M45R9-002 KM5-M4560-11X + KM5-M4582-00X n.a. CI*, CII KG2-M45R9-023 n.a. EI KG7-M45R9-00X n.a. EI*, EII, EM KG2-M45R9-023 n.a. S KG2-M45R9-030 n.a. S KM5-M45R9-10X (F) O, T KG2-M45R9-023 KM5-M4560-11X + KM5-M4572-00X n.a. O, T KM5-M45R9-10X (F) EII, O, EM , T , S Meaning Eclipse I Eclipse I-CE Eclipse II Emerald Comet I Comet I-CE Comet II Sapphire Orion Topaz KM5-M4560-110 + KV1-M4572-00X Remarks: Board will be stopped in March 1998 and replaced by KM5-M4570-01X. 2. This board is standard implemented in these machines from December 1998 onwards, for Sapphire from august 1998 onwards. 1. I/O-board versions Service Manual Topaz PA 1309/10 3 - 31 System Principles 3.8. Connection-Board 3.8.1. General 7KHFRQQHFWLRQERDUGLQWHUFRQQHFWVDOOVLJQDOVIURPDQGWRWKHVHQVRUVVZLWFKHV UHOD\VDQGVRPHYDOYHV$OOVLJQDOVZKLFKDUHQRWGLUHFWO\FRQWUROOHGE\WKH0&; FRQWUROOHUDQG,2·VVLJQDOVZKLFKDUHFRQWUROOHGGLUHFWO\E\WKH,2ERDUGVDUHQRW JRLQJYLDWKHFRQQHFWLRQERDUG7KHERDUGLVDOVRGLVWULEXWLQJWKH9'&FRPLQJ IURPWKH*6SRZHUVXSSO\DQGZKLFKLVXVHGIRUWKH,2DQGWKH(0*FLUFXLWV )URP$SULORQZDUGVWKH7RSD]V\VWHPLVHTXLSSHGZLWKWKHW\SHRIFRQQHFWLRQ ERDUGWKDWLVDOVRXVHGLQWKH;VHULHV7RSD]6RWKHQGJHQHUDWLRQFRQQHFWLRQERDUG .80;ZLWKVHUYLFHQRKDVEHHQUHSODFHGE\DQHZ YHUVLRQWKHUGJHQHUDWLRQFRQQHFWLRQERDUG.90;ZLWKVHUYLFHQR Connection-board version KU1-M4550-00X KV7-M4550-11X Table 3.8-1 Generation 2 (old type) 3 (new type) Service number 5322 216 04312 5322 216 04675 Connection-board versions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·VDUHVKRZQ6LQFHWKH3&%LVYHU\LPSRUWDQWIRUWKHVDIHW\ FLUFXLWDQXPEHURI/('·VDUHPRXQWHGRQWKH3&%WRLQGLFDWHWKH(0*VWDWXV)RU PRUHLQIRUPDWLRQRQWKHVH/('·VSOHDVHUHIHUWRFKDSWHU´3RZHUDQG6DIHW\µRIWKLV PDQXDO2QWKHERDUGVVRPHMXPSHUVHWWLQJVFDQEHVHWWRFRQILJXUHWKHV\VWHP GHSHQGLQJRQWKHDGGHGRSWLRQVDQGRUIHDWXUHV 3 - 32 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles nd 3.8.2. 2 Generation Connection-Board 2QWKHERDUGVHOHFWLRQVZLWFKHVDUHDYDLODEOH66DQG6 6DQG6DUHXVHGIRUWKH3&%GLUHFWLRQ6LVXVHGIRUWUD\FKDQJHUSRVLWLRQV 7KHWDEOHVEHORZVKRZWKHVHWWLQJRI6DQG6IRUWKHWUDQVSRUWVHOHFWLRQDQG6IRU WKHWUD\FKDQJHUSRVLWLRQ PCB direction L → R (default) R→L Table 3.8-1 S2 C C S1 and S2 settings Configuration Standard Trayfeeder ATS-27A Table 3.8-2 S1 B A S3 : bit 1 ON ON ON S3 : bit 2 ON OFF OFF S3 : bit 3 ON OFF ON S3 : bit 4 ON ON OFF S3 settings )LJXUHVKRZVWKHORFDWLRQRI6 Figure 3.8-1 Location of S1, S2 and S3 Note 1: The EMG harness of the trayfeeder should be connected to CNF26 and CNF28. Note 2: The speedcontroller connects on SP1, the jumper harness does not connect on CNF2 and CNF3. Note 3: When a special emergency input is added, set bit 3 of S3 to OFF and connect the emergency signal harness to CNF25 (dry contact). 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 3 - 33 System Principles )LJXUHVKRZVWKHFRPSOHWHOD\RXWRIWKHQGJHQHUDWLRQFRQQHFWLRQERDUG Figure 3.8-2 3 - 34 Service Manual Topaz PA 1309/10 nd 2 generation connection-board layout 5322 871 63606 01.05 System Principles rd 3.8.3. 3 Generation Connection-Board 'LSVZLWFKVHWWLQJV :KHQXVLQJWKHUGJHQHUDWLRQFRQQHFWLRQERDUGZLWKIDFWRU\QR.90; LQFRPELQDWLRQZLWKDQH[WHUQDOGHYLFHWKHGLSVZLWFKMXPSHUVHWWLQJVRI6DQG6 KDYHWREHVHWDVIROORZV 7KHVHWWLQJVIRU6DUHDVIROORZ Configuration Standard Table 3.8-3 S3 : bit 1 ON S3 : bit 2 ON S3 : bit 3 ON S3 : bit 4 ON S3 settings ,QVRPHVFKHPDWLFV6KDVMXPSHUVZLWFKHV7KHDGGLWLRQDOMXPSHUVLQWKDWFDVH ELWDQGDUHPHDQWIRUDUHDVHQVRUVHOHFWLRQV7KLVRSWLRQLVQRWXVHGLQWKHFXUUHQW V\VWHPVVRWKHVHELWVDUHDOZD\VVHWWR¶21·ZKLFKPHDQVWKDWWKH(0*FLUFXLW FRQQHFWHGWRWKLVMXPSHUKDVEHHQEULGJHG 7KHVHWWLQJVIRU6DUHDVIROORZ Configuration No trayfeeder 1 LCS 2 ATS27 3 ATS27 Table 3.8-4 5322 871 63606 01.05 S4 : bit 1 ON OFF OFF ON S4 : bit 2 ON ON ON OFF S4 : bit 3 ON ON ON ON S4 : bit 4 ON ON ON ON S4 : bit 5 ON OFF ON ON S4 : bit 6 ON ON ON ON S4 settings Note 1: Connect EMG harness of the tray-feeder to CNF26 (S4-bit1) and CNF28 (S4bit5) (see position A, figure 3.8-3). Note 2: Connect EMG harness of the tray-feeder to CNF26 (S4-bit1) (see position B, figure 3.8-3). Note 3: Connect EMG harness of the tray-feeder to CNF49 (S4-bit2) (see position C, figure 3.8-3). Service Manual Topaz PA 1309/10 3 - 35 System Principles B C $ Front Side Figure 3.8-3 Position of LCS and ATS on main machine 5HPDUN 3UHGHILQHGVHWWLQJVDUHVKRZQLQWDEOH2WKHUVHWWLQJVDUHSRVVLEOHEXWWKHQ GLIIHUHQWFRQQHFWRUVDUHXVHG3OHDVHUHIHUWRWKHLQWHUFRQQHFWDQGVDIHW\GLDJUDPVDQG WKHRYHUYLHZRIWDEOHWR 7KHUHODWLRQEHWZHHQWKH6DQG6GLSVZLWFKHVFRQQHFWRUVDQG/('·VDUHDVIROORZ 6ZLWKGLSVZLWFKHV Bit 1 2 3 4 Connector CNF25 (EMG optional) CNF45 (EMG spare) CNF45 (EMG spare) CNF45 (EMG spare) Table 3.8-5 Signal EMG1 EMG4 EMG5 EMG6 (=8) LED 5 19 20 21 Signal EMG1 EMG3A EMG3B EMG4 EMG5 EMG6 (=8) LED 5 19 20 21 22 23 Signal EMG1F EMG2 EMG2B EMG2C EMG2E EMG3 LED 11 12 14 15 17 18 S3 with 4 dip switches 6ZLWKGLSVZLWFKHV Bit 1 2 3 4 5 6 Connector CNF25 (EMG optional) n.a. only used for area sensor in main machine n.a. only used for area sensor in main machine CNF45 (EMG spare) CNF45 (EMG spare) CNF45 (EMG spare) Table 3.8-6 S3 with 6 dip switches 6GLSVZLWFKHV Bit 1 2 3 4 5 6 Connector CNF26 (TF1 EMG switch) CNF49 (TF4 EMG switch) CNF27 (Cover front 1 TF2) CNF43 (Cover front 2 TF5) CNF28 (Cover rear 1 TF3) CNF44 (Cover rear 2 TF6) Table 3.8-7 3 - 36 S4 dip switches Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles $IWHUVZDSSLQJWKHFRQQHFWLRQERDUG &KHFNDQGRUFKDQJHWKHGLSVZLWFKVHWWLQJVRUKDUQHVVFRQQHFWLRQV &KHFNLIWKH(0*FLUFXLWLVDFWLYDWHGDIWHUSUHVVLQJWKHYDULRXVHPHUJHQF\SXVK EXWWRQVRUZKHQRSHQLQJWKHFRYHUVRIWKHPDLQPDFKLQHDQGLIFRQQHFWHGRQWKH H[WHUQDOGHYLFHV ,QFKDSWHUDUHYLVHGGLDJUDPLVVKRZQRIWKHVLPSOLILHGVDIHW\FLUFXLW,WVKRZVDOOWKH (0*VLJQDOVWRJHWKHUZLWKWKHFRUUHVSRQGLQJ/('·VDQGWKHSRVLWLRQRIWKHMXPSHUV RIWKHGLSVZLWFKHV6DQG6 Figure 3.8-4 5322 871 63606 01.05 rd Connection-board KV7-M4550-11X (3 generation) Service Manual Topaz PA 1309/10 3 - 37 System Principles 3.9. Keyboards 7KHV\VWHPKDVWZRGHYLFHVWRHQWHULQIRUPDWLRQPDQXDOO\DKDQGKHOGNH\ERDUGDQGD 3&NH\ERDUGVHHILJXUH Emergency button Joy stick Full keyboard enable keyswitch Dead man swit ch R ead y Runni ng Stop R un Res et Error cl ear Sel axi s group Ready Hand held keyboard Manu al Joy Speed stick Scree n Esc H elp F9 Axis F10 Tab Ins C trl Del Sh ift Ent er See full keyboard PC keyboard Insert, Delete F9, F10 F1 (Help) Esc 1, 2, 3 ....4 1 2 Q Tab A, B, C ....Z 3 W A S Z Shift 4 E 5 R D X 6 T F C G V Ctrl Figure 3.9-1 7 Y 8 U H B 9 I J N 0 O K P Enter L Shift M Ctrl S D 6245 Topaz key-boards 3.9.1. PC-Keyboard 7KLV NH\ERDUG LV D VWDQGDUG VPDOO YHUVLRQ ZLWKRXW NH\SDG 3&$7 NH\ERDUG DQG LV FRQQHFWHGWRWKHFRQWUROOHUYLDDFRQQHFWRUSOXJRQWKHIURQWVLGHRIWKHV\VWHPERDUGLQ WKH0&;FRQWUROOHU7KLVNH\ERDUGFDQEHXVHGIRUDOOGDWDHQWHULQJDFWLYLWLHVLWFDQEH UHPRYHGIURPWKHPDFKLQHLIRSHUDWRUVDUHQRWDOORZHGWRXVHLW 3.9.2. Hand Held Keyboard (HHK) 7KLVNH\ERDUGLVSHUPDQHQWO\FRQQHFWHGWRWKHV\VWHPYLDDFDEOHHQWHULQJWKH7RSD]DW WKH ULJKW VLGH RI WKH V\VWHP 9LD WKLV NH\ERDUG VLPSOH RSHUDWRU IXQFWLRQV FDQ EH SHUIRUPHGVXFKDV5816723DQG5(6(7 7KH FRQQHFWLRQ EHWZHHQ WKLV NH\ERDUG DQG WKH 0&;FRQWUROOHU FRQVLVW RI IROORZLQJ VLJQDOV n $VHULDOFRPPXQLFDWLRQOLQH56JRLQJWRWKH&01SRUWRQWKHIURQWVLGHRI WKHV\VWHPERDUGLQWKH0&;FRQWUROOHU n 7KH9VXSSOLHGIURPWKHLQWHUFRQQHFWLRQERDUG n (PHUJHQF\VZLWFKDQG5HDG\VZLWFKVLJQDOV n 'HDGPDQSXVKEXWWRQVLJQDO 3 - 38 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles 7KHNH\ERDUGKDVLWVRZQYROWDJHFRQYHUWHU9WR9'&DQGPLFURSURFHVVRUWR FRQWUROWKHNH\IXQFWLRQVDQGWKHVHULDOFRPPXQLFDWLRQZLWKWKH0&;FRQWUROOHU 7KH GHDGPDQ SXVK EXWWRQ LV DGGHG IRU VDIHW\ UHDVRQV WKLV EXWWRQ PXVW EH SUHVVHG FRQWLQXRXVO\LIDVHUYRDFWLRQZKLOHWKHIURQWUHDUVDIHW\FRYHUVDUHRSHQ 7KH++.LVHTXLSSHGZLWKDVRFDOOHG¶IXOONH\ERDUGHQDEOHNH\·WKLVNH\LVFRQQHFWHG WRWKHKDQGKHOGNH\ERDUGE\PHDQVRIDFKDLQ:KHQWKHNH\LVLQVHUWHGLQWKHNH\ VZLWFKRQWKHULJKWIURQWFRYHUWKLVZLOOHQDEOHWKHIXOONH\ERDUG:KHQWKHNH\LVRXW RIWKHNH\VZLWFKQRDFWLRQVDQGFRPPDQGVFDQEHJLYHQIURPWKHIXOONH\ERDUG7KLV SURYLVLRQLVWRFRPSO\WRWKH(XURSHDQVDIHW\UXOHV&( NOTE: If one of the SERVICE KEY-switches (front and/or rear) of the system are activated, there is only a limited function possible with the hand-held key-board. The only actions possible are the joystick and emergency-button actions, all other buttons are disabled because of safety reasons. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 3 - 39 System Principles 3.10. Monitors 7KHV\VWHPKDVWZRPRQLWRUVVHHILJXUHORFDWHGDWWKHWRSRIWKHPDFKLQHRQH 9,26PRQLWRUVHHSDUDJUDSKDQGRQHYLVLRQPRQLWRUVHHSDUDJUDSK %RWKPRQLWRUVFDQEHVKLIWHGWRWKHUHDUVLGHE\URWDWLQJGHJUHHVIRUHDV\XVH VIOS monitor Vision monitor Figure 3.10-1 Topaz monitors 3.10.1. VIOS Monitor 7KH9,26PRQLWRULVDVWDQGDUG3KLOLSV9*$PRQLWRUW\SH,QWKHPRQLWRUJXLGHOLQH ERRNOHW DQ H[SODQDWLRQ LV JLYHQ RI WKH YDULRXV DGMXVWPHQWV DV FRQWUDVW EULJKWQHVV + VKLIW+VL]H9VKLIW9VL]HWUDSH]RLGSLQFKXVLRQURWDWLRQDQGGHJDXVV 3.10.2. Vision Monitor 7KLVPRQLWRULVD%:%ODFNDQG:KLWH3KLOLSVYLGHRPRQLWRUIRUGLVSOD\LQJWKH YLVLRQLQIRUPDWLRQIURPWKHYLVLRQERDUG7KHPRQLWRUFDQEHRUGHUHGYLDWKHUHJXODU FKDQQHOV7KHLPSHGDQFHVZLWFKDWWKHEDFNPXVWEHVHWWRRKP 3 - 40 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles 3.11. I/O - Signals 7KLV SDUDJUDSK ZLOO FRYHU WKH EDVLF LQSXW DQG RXWSXW VLJQDOV ,Q WKH 9,26 PHQX D VFUHHQ,2PRQLWRUVHHILJXUHLVDYDLODEOHWKDWJLYHVLQIRUPDWLRQRIDOOLQSXW DQGRXWSXWVLJQDOV$OOWKH,2VLJQDOVVKRZQDUHWKHDFWXDOUHDOWLPHFRQGLWLRQV7KH ,2PRQLWRU VFUHHQ FRQVLVWV RI VFUHHQV WKH SLFWXUH RQO\ VKRZV ZKLFK FDQ EH DFFHVVHGE\VFUROOLQJXSRUGRZQ7KHOHIWVLGHRIWKHVFUHHQVKRZVWKHRXWSXWPRQLWRU DQGWKHULJKWVLGHRIWKHVFUHHQWKHLQSXWPRQLWRU DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M <<MODE>> 1/MCH_CONFIG 2/MCH_DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT Out Monitor Dialogue box Screen 1 Screen 2 :Select [Enter]:Exec [ESC]:Command Lists TR09 TRAY CHANGER SPARE N A M E OUT Front Fdr data Front Fdr index Signal Tower FORE(M123/LEV) Spare * Spare * Rear Fdr data Rear Fdr index TJ01-08 TJ09-16 TK01-08 TK09-16 TL01-08 TL09-16 TM01-08 TM09-16 N A M E OUT Head Down LED(FID/BACK) Head Sequence Head Sequence Blow Timer Blow Timer Head Vacuum Head Blow * * * * * N A M E Screen 3 TE01-08 TE09-16 TF01-08 TF09-16 TG01-08 TG09-16 TH01-08 TH09-16 N A M E 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 TN01-08 TN09-16 TP01-08 TP09-16 TQ01-08 TQ09-16 TR01-08 TR09-16 Origin/Limit Origin/Limit Spare Spare Conveyor Conveyor Origin/Limit Origin/Limit 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 XY 100 IN * * * * NJ01-08 NJ09-16 NK01-08 NK09-16 NL01-08 NL09-16 * NM01-08 * NM09-16 N A M E OUT Conveyors Conveyors Nzl Clamp/Spare Spare * Tray Changer Tray Changer Tray Changer Tray Changer Selected Arm:MAIN Moving Speed: 0/EXIT 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 IN Spare * Spare * Spare * Spare * Head Lowend * Origin/Limit * Head Pic.Vacuum Head Mnt.Vacuum NE01-08 NE09-16 NF01-08 NF09-16 NG01-08 NG09-16 NH01-08 NH09-16 N A M E IN Nozzle Sensor Nozzle Sensor Spare * Nzl Clamp/Spare Tray Changer Tray Changer Tray Changer Tray Changer NN01-08 NN09-16 NP01-08 NP09-16 NQ01-08 NQ09-16 NR01-08 NR09-16 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000 Current selection Figure 3.11-1 VIOS DI/DO-monitor window $ FRPSOHWH OLVW RI DOO LQSXW DQG RXWSXW VLJQDOV LV JLYHQ RQ WKH QH[W SDJHV 7KH\ DUH VKRZQZLWKWKHGHVFULSWLRQFRQQHFWLRQORFDWLRQDQGUHODWLRQVKLSWRRWKHUVLJQDOV Remarks: T(01) stands for: N(N01) stands for: OUTPUT signal INPUT signal The signal names TN01, TP01, TM09, NQ16, etc. are related to the corresponding labels on the harnesses. The DI/DO lists on the next pages shows this relation. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 3 - 41 System Principles 3.11.1. VIOS Manual Mode I/O-Monitor 2XWSXW0RQLWRU ,QPDQXDOPRGHWKHRXWSXWPRQLWRUFDQEHVHOHFWHGE\DFFHVVLQJWKHIROORZLQJPHQX 23(5$7,2100$18$/'6$9((;,7'287387021,725 %\SODFLQJWKHFXUVRURQWKHGHVLUHGILHOGWKHGHVFULSWLRQRIWKHSDUWLFXODUELWLVVKRZQLQ WKHGLDORJXHER[7KH(17(5!NH\FDQEHXVHGWRWRJJOHDVSHFLILFELWEHWZHHQWKH DFWLYHVWDWH´µDQGWKHQRWDFWLYHVWDWH´µ WARNING ONLY TRAINED CSM SERVICE ENGINEERS ARE ALLOWED TO USE THE INPUT/OUTPUT MONITOR FEATURE !. ACTIVATING MACHINE FUNCTIONS BY MEANS OF THE OUTPUT MONITOR MAY CAUSE DAMAGE TO THE MACHINE IF NOT USED CORRECTLY. The system will not check if an activation of an output signal will cause a dangerous situation. ,QSXW0RQLWRU ,QPDQXDOPRGHWKHLQSXWPRQLWRUFDQEHVHOHFWHGE\DFFHVVLQJWKHIROORZLQJPHQX 23(5$7,2100$18$/'6$9((;,7',1387021,725 %\SODFLQJWKHFXUVRURQWKHGHVLUHGILHOGWKHGHVFULSWLRQRIWKHSDUWLFXODUELWLVVKRZQ LQWKHGLDORJXHER[7KHVHELWVFDQQRWEHPDQLSXODWHGEHFDXVHWKH\DUHLQSXWELWV 3 - 42 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 System Principles 3.11.2. List of OUTPUT Signals (DO’s) )ROORZLQJWDEOHVKRZVDQRYHUYLHZLQDOSKDEHWLFDORUGHURIDOO'DWD 2XWSXWVXVHGLQWKH7RSD]V\VWHP 7KHWDEOHFRPELQHVVLPLODURXWSXWVDVIROORZV 7+ +HDGWRKHDGYDFXXP 7KLVPHDQVRXWSXW7+LVKHDGYDFXXP7+LVKHDGYDFXXPHWF 7( 6SDUH 7KLVPHDQVRXWSXW7(DQG7(DUHVSDUH TA01-16 TB01-16 TC01-16 TD01-16 TE01-8 TE09 TE10+11 TE12 TE13 TE14 TE15 TE16 TF01-8 TF09-13 TF14 TF15 TF16 TG01-8 TG09-11 TG12-14 TG15 TG16 TH01-8 TH09-16 TJ01-8 TJ09-12 TJ13-16 TK01 TK02 TK03 TK04 TK05 TK06 TK07 TK08 TK09 TK10 TK11 TK12 TK13-15 TK16 TL01 TL02 TL03 TL04 TL05 TL06 TL07 Spare Spare Spare Spare Head1 to head8 down Head light1(for moving) on Spare Head 1-2 slow down Head 3-4 slow down Head 5-6 slow down Head 1-8 slow down Head serial cmn ok Head1 to 8 active head-sequence Extended do Head-sequence vac/mnt Head-sequence vac.check Head-sequence start Timer set bit0 to bit7 Timer head-no select bit0 to bit2 Timer port-no select bit0 to bit2 Spare Timer start Head1 to head8 vacuum Head1 to head8 blow F.feeder data1 to data8 F.feeder select1 to select4 Spare Buzzer Blue/yellow lamp White/red lamp Green/green lamp Gate out Spare Cover lock Ba out(smema) Spare Lamp11(single camera 1) on Lamp12(single camera 2) on Lamp13(multi camera) on Brightness1 to brightness3 Spare B.c conveyor on B.c conveyor reverse B.c speed low B.c speed high Front non-stop fdr.carriage up Front non-stop fdr.carriage down Front non-stop fdr.carriage forward Table 3.11-1 5322 871 63606 01.05 TL08 TL09-16 TM01-8 TM09-12 TM13-16 TN01 TN02 TN03 TN04 TN05 TN06 TN07-11 TN12 TN13 TN14 TN15+16 TP01 TP02 TP03+4 TP05 TP06 TP07 TP08 TP09 TP10 TP11 TP12-16 TQ01 TQ02 TQ03 TQ04 TQ05 TQ06+7 TQ08 TQ09 TQ10 TQ11 TQ12 TQ13 TQ14+15 TQ16 TR01-3 TR04-12 TR13 TR14 TR15 TR16 Front non-stop fdr.carriage backward Spare R.feeder data1 to data8 R.feeder select1 to select4 Spare Main stopper Plate push up Locate pin1 Edge clamp Push in Stopper of entrance Spare Conveyor reverse Conveyor on Conveyor speed low Spare Nozzle station up Nozzle station clamp Spare Rear non-stop fdr.carriage up Rear non-stop fdr.carriage down Rear non-stop fdr.carriage forward Rear non-stop fdr.carriage backward Sp. Light (single camera1) up Sp. Light (single camera2) up Sp. Light (single camera3) up Spare Tray changer pallete home Tray changer hook forward Tray changer hook close Tray changer pallete set Tray changer hook backward Tray changer spare Ext.tc conveyor on Ext.tc conveyor reverse Tray changer door1 lock Tray changer door2 lock Tray changer door1 light Tray changer door2 light Tray changer spare Tray changer servo on Ext.tc station1 to station3 vacuum Tray changer spare Ext.tc head vacuum Tray changer spare Ext.tc head down Tray changer spare List of D(ata) O(utputs) used in the Topaz Service Manual Topaz PA 1309/10 3 - 43 System Principles 3.11.3. List of INPUT Signals (DI’s) )ROORZLQJWDEOHVKRZVDQRYHUYLHZLQDOSKDEHWLFDORUGHURIDOO'DWD ,QSXWVXVHGLQWKH7RSD]V\VWHP 7KHWDEOHKDQGOHVVLPLODULQSXWVLQWKHVDPHPDQQHUDVGHVFULEHGIRUWKHRXWSXWV UHIHUWRFKDSWHU NA01-16 NB01-16 NC01-16 ND01-16 NE01-8 NE09-14 NE15 NE16 NF01-16 NG01-8 NG09 NG10 NG11 NG12 NG13+14 NG15 NG16 NH01-8 NH09-16 NJ01 NJ02+3 NJ04 NJ05 NJ06 NJ07 NJ08 NJ09 NJ10 NJ11 NJ12 NJ13 NJ14 NJ15 NJ16 NK01-8 NK09 NK10 NK11 NK12-16 NL01 NL02 NL03 NL04 NL05 NL06 NL07+8 NL09 NL10 NL12 NL13 NL14 NL15 NL16 NM01 Spare Spare Spare Spare Head1 to 8 memory active head-sequence Extended di Head sequence finish Timer busy Spare No 1 to no8 head up/down X-axis origin Spare R-axis origin Nozzle down Spare X-axis over travel Spare Head1 to head8 pick up judgment Head1 to head8 mount judgment Y-axis origin Spare Relay spare Y-axis over travel Spare Front feeder lock 2 Front feeder-carriage lock Invalid fullkey board service key Front feeder lock 1 Front area Gate in Release cover emergency Contactor ok Count reset Can’t use Nozzle 17 to 24 Front non-stop fdr.carriage detect switch Front non-stop fdr.carriage detect upper Front non-stop fdr.carriage detect forward Spare Sub position1 of ent. Conveyor entrance Conveyor exit Sub position2 of ent. Dump station Spare Can’t use Set position Locate pin1 Locate pin2 Spare Rear nozzle station clamp Push up plate fixed Spare Spare Table 3.11-1 3 - 44 NM02 NM03+4 NM05 NM06 NM07 NM08 NM09 NM10 NM11 NM12+13 NM14 NM15 NM16 NN01-16 NP01 NP02 NP03 NP04 NP05 NP06 NP07+8 NP09 NP10 NP11 NP12 NP13+14 NP15 NP16 NQ01 NQ02+3 NQ04 NQ05 NQ06+7 NQ08 NQ09 NQ10 NQ11 NQ12 NQ13 NQ14 NQ15 NQ16 NR01-3 NR04 NR05+6 NR07 NR08 NR09+10 NR11 NR12 NR13 NR14 NR15 NR16 W-axis origin Spare 2nd limit spare Spare Rear feeder lock 2 Rear feeder-carriage lock Air pressure Rear feeder lock 1 Rear area Spare Smema discrimination Smema ba in Spare Nozzle 1 to nozzle 16 Rear non-stop fdr.carriage detect switch Rear non-stop fdr.carriage detect upper Rear non-stop fdr.carriage detect forward Sp. Light (single camera1) up Spare Sp. Light (single camera1) down Can’t use Sp. Light (single camera2) up Sp. Light (single camera2) down Sp. Light (single camera3) up Sp. Light (single camera3) down Front nozzle station clamp Nozzle station up Nozzle station down Tray changer pallet origin Tray changer hook open + close Tray changer pallet set Tray changer relay spare Tray changer spare Tray changer door1 interlock Tray changer door2 interlock Rack1 in(ext.tc),latch open Rack2 in(ext.tc),latch close Ext.tc head beam Ext.tc head vacuum Tray changer spare Ext.tc head lower Tray changer spare Ext.tc station1 to station3 vacuum Tray changer hook safety(zpos) Autotc-s hook forward + backward Tc board discrimination Tray changer +24v ok Tray changer door1 + door2 sw Ext.tc conveyor entrance Ext.tc pcb check position Ext.tc conveyor exit Ext.tc select switch Ext.tc pcb check ok Ext.tc w axis origin List of D(ata) O(utputs) used in the Topaz Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Power and Safety Circuits Power and Safety Circuits CHAPTER 4 4.1. Introduction 7KH7RSD]KDVDQXPEHURIVDIHW\FLUFXLWVDQGSRZHUVXSSOLHV,QWKHILUVWSDUWRI WKLVFKDSWHUWKHVDIHW\FLUFXLWU\ZLOOEHGLVFXVVHGWKHVHFRQGSDUWZLOOKDQGOHWKH YDULRXVSRZHUVXSSOLHVZKLFKDUHXVHGLQWKHV\VWHP'HWDLOHGVFKHPDWLFVFDQEH IRXQGLQFKDSWHURIWKLVPDQXDO 4.2. Safety Circuit 4.2.1. Description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hen working at the systems safety circuit make sure to take all the necessary safety precautions to avoid possible danger. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 4-1 Power and Safety Circuits 4.2.2. Safety Circuit 7KHGHWDLOHGVDIHW\GLDJUDPVRIWKHV\VWHPFDQEHIRXQGLQ&KDSWHU$PRUH VLPSOLILHGGLDJUDPLVVKRZQLQILJXUHDQGILJXUH$OOVLJQDOVIURPDQGWR WKH YDULRXV VZLWFKHV DQG VHQVRUV DUH JRLQJ YLD WKH FRQQHFWLRQERDUG 2Q WKLV FRQQHFWLRQERDUG YDULRXV /('·V DUH PRXQWHG ZKLFK LQGLFDWH WKH VWDWXV RI WKH 2YHU 7UDYHO 27 DQG HPHUJHQF\ (0* VLJQDOV $OVR WKH 9'& IURP WKH *6SRZHUVXSSO\LVGLVWULEXWHGYLDWKLVERDUG )URP$SULORQZDUGVWKH7RSD]V\VWHPLVHTXLSSHGZLWKDUGJHQHUDWLRQ FRQQHFWLRQERDUG7KHQGJHQHUDWLRQFRQQHFWLRQERDUGKDVEHHQUHSODFHGE\ WKLVQHZYHUVLRQ QGJHQHUDWLRQFRQQHFWLRQERDUG.80; Figure 4-1 4-2 Service Manual Topaz PA 1309/10 Safety circuit Topaz 5322 871 63606 01.05 Power and Safety Circuits 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Colour Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Green Green Green Green Green Table 4-1 Mark LED1 LED2 LED3 LED4 LED5 LED6 LED7 LED8 LED9 LED10 LED11 LED12 +24VA +24VB +24S +EMG +24E Condition for LED ON EMG circuit of HEAD I/O-1 board Over Travel is OK EMG circuit of HEAD I/O-2 board Over Travel is OK EMG circuit of CONVEYOR I/O-1 board Over Travel is OK EMG circuit of CONVEYOR I/O-2 board Over Travel is OK EMG circuit of optional EMG and HHK EMG STOP is OK EMG circuit of CONVEYOR I/O-1 board EMG STOP is OK EMG circuit of CONVEYOR I/O-2 board EMG STOP & MCX OK EMG circuit of Tray Changer is OK (NOT for Sapphire) EMG circuit of FRONT cover stop is OK EMG circuit of Tray Changer front cover OK (NOT for Sapphire) EMG circuit of REAR cover stop is OK EMG circuit of Tray Changer rear cover OK (NOT for Sapphire) DC24V input at CNF22 is OK DC24V input at CNF21 is OK Non DC24V input at CNF23 is OK DC24V of EMG safety is OK (only when Servo is switched on) nd Meaning of LED’s on the 2 generation connection-board Note 1: When LED1 to LED4 are ON, and the LED5 to LED12 are OFF, then the HHK EMG STOP (LED5) is NOT GOOD (NG). This means that there is something wrong with the HHK circuitry. Note 2: As can be seen from the diagram figure 4-1, it is only possible to have a cover open at one side at the time. It is also needed to press continuously the dead man push-button in order to keep the servo system active. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 4-3 Power and Safety Circuits QGJHQHUDWLRQFRQQHFWLRQERDUG.90; Figure 4-2 Revised safety circuit Topaz Led no. L Colour 1 Yellow 2 Yellow 3 Yellow 4 Yellow 5 Yellow 6 Yellow 7 Yellow 8 Yellow 9 Yellow 10 Yellow 11 Yellow 12 Yellow 13 Yellow 14 Yellow 15 Yellow 16 Yellow 17 Yellow 18 Yellow 19 Yellow 20 Yellow 21 Yellow Table 4-2 4-4 Mark LED1 LED2 LED3 LED4 LED5 LED6 LED7 LED8 LED9 LED10 LED11 LED12 LED13 LED14 LED15 LED16 LED17 LED18 LED19 LED20 LED21 Condition for LED ON X-1 over travel is OK Not used Y-1 over travel is OK Not used Not used (on) HHK emergency stop is OK Not used Not used (offf) Not used (off) Controller & EMG front/rear is OK Tray feeder emergency stop 1 is OK Tray feeder emergency stop 2 is OK Cover stop of front side is OK Tray feeder cover stop of front side 1 is OK Tray feeder cover stop of front side 2 is OK Cover stop of rear side is OK Tray feeder cover stop of rear side 1 is OK Tray feeder cover stop of rear side 2 is OK Spare 1 emergency circuit is OK Spare 2 emergency circuit is OK Spare 3 emergency circuit is OK rd Meaning of LED’s on the 3 generation connection-board Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Power and Safety Circuits Note 1: When LED1 to LED5 are ON, and the LED6 to LED21 are OFF, then the HHK EMG STOP (LED6) is NOT GOOD (NG). This means that there is something wrong with the HHK circuitry. Note 2: As can be seen from the diagram figure 4-2, it is only possible to have a cover open at one side at the time. It is also needed to press continuously the dead man push-button in order to keep the servo system active. 4.3. Power Circuits 4.3.1. Description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ote: Make sure to set the correct input voltage taps when installing the machine. see chapter 3 , for the correct settings. WARNING Only trained technical personnel is allowed to work in the power section of the machine. Take care to take the necessary actions to avoid dangerous situations. Switch off the mains power when working in the mains power box. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 4-5 Power and Safety Circuits Figure 4-3 4-6 Power rating diagram Topaz system PA1309/10 Figures given are the maximum ratings of the individual items Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Power and Safety Circuits 4.3.2. 5V /12V Power Supply MCX Box ,QWKH0&;FRQWUROOHUD7'.050SRZHUVXSSO\LVXVHGWRVXSSO\9 9 DQG ²9 7KLV SRZHU VXSSO\ LV ORFDWHG DW WKH OHIW VLGH RI WKH 0&; FRQWUROOHU ER[ SOHDVH UHIHU WR ILJXUH 7KH OD\RXW RI WKLV SRZHU VXSSO\ LV VKRZQLQWKHILJXUH MCX-2 controller box TDK MRM270 Figure 4-4 +5/+12/-12V power supply location Jumper input voltage CP1 Input terminal CP2 CP3(115V) (230V) R76 R83 Output voltage adjust trimmer 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 Output terminal CP51 Output terminal CP52 Output terminal R57 W1 Figure 4-5 CP50 R86 PFS signal adjust trimmer Output voltage adjust trimmer Power supply PCB layout 4-7 Power and Safety Circuits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igure 4-6 Jumper setting 7KHIROORZLQJDGMXVWPHQWVFDQEHGRQH 7KH99DGMXVWPHQWLVGRQHE\5DGMXVWWR²99 7KH99DGMXVWPHQWLVGRQHE\5DGMXVWWR99 7KH99DGMXVWPHQWLVGRQHE\5DGMXVWWR99 7KHSRZHUIDLOXUHVLJQDODGMXVWPHQWLVIDFWRU\DGMXVWHG 4-8 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Power and Safety Circuits 4.3.3. 24V I/O and Emergency Power Supply (GS21) 7KH9SRZHUVXSSO\*6LVRIWKHW\SH+<5*1ZKLFKFDQGHOLYHUDQ RXWSXW FXUUHQW RI PD[ $ 7KH $& LQSXW YROWDJH RI WKLV SRZHU VXSSO\ LV IDFWRU\VHWWR9$& $WWKHUHDUVLGHRIWKLVSRZHUVXSSO\WKHRXWSXWYROWDJHFDQEHDGMXVWHGE\PHDQV RI D SRWHQWLRPHWHU 9DGM SOHDVH UHIHU WR ILJXUH $GMXVW WKH YROWDJH WR 9± Figure 4-7 Back GS21 7KH SRZHU VXSSO\ LV ORFDWHG LQ WKH SRZHU ER[ DW WKH UHDU VLGH RI WKH V\VWHP QH[W WR WKH WZR PDLQV WUDQVIRUPHUV 70DQG7& 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 4-9 Power and Safety Circuits D - Power Assembly (282V Power) 7KH'SRZHUDVV\UHFWLILHVWKHSKDVH9$&SRZHUDQGVXSSOLHV9'&WR WKHGULYHUERDUGV7KHDVVHPEO\FRQVLVWVRXWRIWKH'SRZHUERDUGLWVHOIDQGWKH FDSDFLWRU &$3 ZKLFK LV ORFDWHG DW WKH ULJKWVLGH EDFN FRUQHU RI WKH 0&; FRQWUROOHUER[VHHILJXUHEHORZ Fuse 1 200V AC (U) IN 200V AC (V) IN 200V AC (W) IN Fuse FU2 LED 5 LED 4 LED 3 LED 2 LED 1 Jumper 1 282V to Driverboards Cap 1 18V in from trafo CN1 Interlock CN3 EMG CN2 Figure 4-8 D(river) power assy 7KHIROORZLQJFLUFXLWVFDQEHGLVWLQJXLVKHG 9UHIHUHQFHFLUFXLW 7KH UHIHUHQFH FLUFXLW UHFHLYHV D 9$& YROWDJH &1 IURP D VHSDUDWH WUDQV RUPHU LQVLGH WKH 0&; ER[ 7KH 9$& LV SURWHFWHG E\ D IXVH )8 RI $PS $IWHU UHFWLI\LQJ D 9'& YROWDJH LV JHQHUDWHG ZKLFK LV XVHG IRU WKH FRQWUROOLQJFLUFXLWU\7KH/('JUHHQZLOOEHOLWDVORQJDVWKHWHPSHUDWXUHLV 2. 4 - 10 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Power and Safety Circuits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°&/('JUHHQZLOOEH2))ZKLOHDVLJQDOLVVHQWWRWKHVHUYR ERDUG 'ULYHSRZHUFKDUJLQJ $QLQGLFDWLRQ/('LVPDGHWRVHHZKHQWKHFDSDFLWRULVFKDUJLQJXS $VPHQWLRQHGEHIRUHWKH,17(5/2&.FRQQHFWRUZKLFKLVJRLQJWRWKHVHUYR ERDUG WR VZLWFK RII WKH ' SRZHU DQG VWRSV WKH PRWRUV KDV WKH IROORZLQJ VLJQDOV Interlock CN3 INT1 pos.1-2 INT2 pos.3-4 Effect Voltage low Phase loss INT3 pos.5-6 EMG CN2 pos.1-2 Temp./voltage Over flow LED 3 2 4 1 Conditions for close Output over 186V DC 3-phase AC input is active (JP1:1-2) OR only 1-phase AC input is active (JP1:2-3) Temp. is under 65 degrees Celcius AND the ouput is under 414V DC. 3OHDVHUHIHUWR&KDSWHUIRUWKHFLUFXLWGLDJUDPRIWKH'SRZHUDVV\ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 4 - 11 Power and Safety Circuits 4.3.5. Measuring and Adjusting Data 0&;FRQWUROOHUER[ 7KH YROWDJHV LQVLGH WKH 0&; FRQWUROOHU ER[ FDQ EH PHDVXUHG DW WKH PRWKHU ERDUG FRQQHFWRUV &1 DQG QHDU WKH /(' LQGLFDWRUV IROORZ WKH QH[W SURFHGXUHWRGRVR • /RRVHQWKH0&;ER[VRLWFDQVOLGHRXWRIWKHPDFKLQH • /RRVHQWKHWZRWRSFRYHUVFUHZV • 5HPRYHWKHOHIWIURQWFRYHUDWWKHPRWKHUERDUG/('·V • 6RPHFRQQHFWRUVFDQQRZEHVHHQVHHPRWKHUERDUG&KDSWHU • 0HDVXUHDWFRQQHFWRUV&1RU&1EHKLQGWKH/('·VWKHIROORZLQJ YROWDJHV &1 9±9 SLQV &1 9±9 SLQV &1 *1' SLQV &1 9±9 SLQ &1 9±9 SLQV &1 9±9 SLQV &1 *1' SLQV • ,IWKHPHDVXUHGYROWDJHLVQRWZLWKLQWKHDERYHJLYHQVSHF·VWKH\FDQEH DGMXVWHGZLWKWKHSRWHQWLRPHWHUVDVLVLQGLFDWHGLQILJXUH • 5HLQVWDOOWKHIURQWDQGWRSFRYHUDIWHUWKHDGMXVWPHQWLVGRQH • 3XVK0&;FRQWUROOHUER[EDFNLQWRWKHPDFKLQHDQGVHFXUHLW WARNING Make sure to check the +5, +12, and -12 Volt power supplies inside the MCX controller at regular intervals (each 3 months). Especially the +12 and -12 Volts are important for the servo systems because they are used for the IC’s in the servo control circuitry *6²9SRZHUVXSSO\ 7KH YROWDJH RI WKH *6 SRZHU VXSSO\ FDQ EH PHDVXUHG DW WKH SRZHU VXSSO\ WHUPLQDOV&DUU\RXWIROORZLQJDFWLRQV • 2SHQWKHSRZHUER[GRRUVDWWKHUHDUVLGHRIWKHV\VWHP • /RFDWHWKH*6SRZHUVXSSO\DQGPHDVXUHDWWKHWHUPLQDOVWKHIROORZLQJ YROWDJH9±9 • ,IWKHYROWDJHLVQRW2.DGMXVWWKHOHYHOZLWKSRWHQWLRPHWHU59ILJ • &ORVHWKHSRZHUER[GRRUV 4 - 12 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Power and Safety Circuits 4.3.6. Performance Check and Trouble Shooting 1R SHUIRUPDQFH FKHFN LV QHHGHG IRU WKH SRZHU VXSSOLHV RI WKH V\VWHP $OO SRZHUVXSSOLHVKDYHD/('LQGLFDWLRQJUHHQOLJKWZKHQWKHYROWDJHLVRN7KLV FDQEHKDQG\LQFDVHRIWURXEOHVKRRWLQJVRPHSUREOHPV0DNHVXUHWKDWWKH *22'VLJQDO 32:(5 1* LV QRW DFWLYDWHG $OO VHUYR ERDUGV DUH LQWHUFRQQHFWHG ZLWK DQ (0* VLJQDO WKLV VLJQDO JLYHV DQG (0(5*(1&< HUURUZKHQDFWLYH 4.3.7. Maintenance Instructions • &KHFNWKHYROWDJHVRIDOOSRZHUVXSSO\ VHDFKPRQWKVDQGDGMXVWWKHPLI QHFHVVDU\ • &KHFNDQGFOHDQWKHWZRIDQVLQVLGHWKH0&;FRQWUROOHUER[ • &KHFNDOOFDEOLQJDQGKDUQHVVHVIURPDQGWRWKHSRZHUVXSSO\ VFKHFNIRU EDGFRQQHFWLRQVDQGGLVFRORXUHGZLUHV • &KHFNDOOHPHUJHQF\VZLWFKHVDQGKDUQHVVHVHJ(0*FDEOLQJRQWKHLU IXQFWLRQDOLW\ • &KHFNDOOIXVHVLQWKHPDLQVFLUFXLW 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 4 - 13 Power and Safety Circuits Intentionally left blank. 4 - 14 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vacuum and Pneumatic Systems CHAPTER 5 Vacuum and Pneumatic Systems Vacuum Systems Introduction 7KLVFKDSWHUGHVFULEHV WKH YDFXXP V\VWHPV ZKLFK DUH XVHG LQ WKH 7RSD] DQG WKH WUD\FKDQJHU7&+RZWRVHWYDFXXPOHYHOVRIWKHPDFKLQHOLNHSLFNXSYDFXXP PRXQWYDFXXPHWFLVGHVFULEHGLQFKDSWHU´PDFKLQHFDOLEUDWLRQµ Functional Description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´7UDYHUVHUDVV\µ·DQGRQHHMHFWRUYDOYH <9IRUWKHSLFNXSKHDGORFDWHGRQWKHKHDG7KHYDFXXPRQWKHVKXWWOHSDGV FDQEHVZLWFKHGRQYLDWKHYDOYHV75DQG75LWHPLQFKDSWHU7KH YDFXXPRQWKHKHDGFDQEHVZLWFKHGE\VLJQDO75<9 Air switch ON/OFF Figure 5-1 Valves 7KH7RSD]KDVWZRVHSDUDWHDLUSUHVVXUHUHJXODWRUV2QHIRUWKHHMHFWRUVDQGRQHIRU WKHDLUVROHQRLGVRIWKHV\VWHP7KHDLUSUHVVXUHUHJXODWRUIRUWKHYDFXXPOLQHLV ORFDWHGEHKLQGWKHORZHUOHIWSDQHODWWKHOHIWVLGHRIWKHPDFKLQH 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 5-1 Vacuum and Pneumatic Systems Air Supply Unit 7KHDLUVXSSO\XQLWLVORFDWHGLQVLGHWKHORZHUULJKWSDQHORQWKHUHDUVLGHRI WKHPDFKLQHDORQJZLWKDSUHVVXUHUHJXODWRU7KHDLUSUHVVXUHUHJXODWRUPXVW EHVHWFRUUHFWO\LQRUGHUWRSURYLGHRSWLPXPDLUSUHVVXUHIRUWKHYDFXXP HMHFWRUVDQGSQHXPDWLFGHYLFHV%HIRUHPDNLQJWKHVHWWLQJEHVXUHWKDWWKH SUHVVXUHIURPWKHSULPDU\DLUVXSSO\LVEHWZHHQDQG03D Air Pressure Regulator 7KHDLUSUHVVXUHUHJXODWRUFDQEHDGMXVWHGZLWKWKHYDOYHFRQWURONQREDV IROORZV 2SHQWKHORZHUULJKWSDQHORQWKHUHDUVLGHRIWKHPDFKLQH 7KHSUHVVXUHUHJXODWRUYDOYHFRQWURONQREDQGSUHVVXUHPHWHUDUH ORFDWHGLQVLGHWKHSDQHO $GMXVWWKHDLUSUHVVXUH7XUQWKHYDOYHFRQWURONQREVRWKDWWKHDLU SUHVVXUHLVVHWEHWZHHQWR03DWRNJIFP Figure 5-2 Pressure meter WARNING If this pressure setting is not correct, the vacuum ejector cannot function adequately and air cylinders become unstable. Be sure that the pressure is set within the specified range. 5-2 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vacuum and Pneumatic Systems Pressure-Drop Detection Level ,IWKHDLUVXSSO\SUHVVXUHGURSVEHORZWKLVDGMXVWDEOHOHYHOWKHSUHVVXUHGURS GHWHFWLRQVZLWFKWULJJHUVDQHPHUJHQF\VWRSDQGLQKLELWVWKHPRYHPHQWRIDOO D[HV$WWKHVDPHWLPHWKHPHVVDJHEHORZDSSHDUVRQWKHRSHUDWLRQPRQLWRU E 0806 QUICK STOP ACTIVE “NM09 AIR PRESSURE SW”. QUICK STOP FUNCTION for safety is now active. To continue, please check the supplied air 7RDGMXVWWKHVHWWLQJIRUSUHVVXUHGURSGHWHFWLRQSURFHHGDVIROORZV 2SHQWKHORZHUULJKWSDQHORQWKHUHDUVLGHRIWKHPDFKLQH 7KHSUHVVXUHPHWHULVORFDWHGRYHUWKHYDOYHFRQWURONQRE $GMXVWWKHOHYHOIRUSUHVVXUHGURSGHWHFWLRQ - 7XUQWKHDGMXVWPHQWVFUHZLQWKHPHWHUZLWKDVPDOOVORWWHGVFUHZGULYHUVR WKDWWKHQHHGOHUHGLVVHWDWWR03DWRNJIFP Figure 5-3 Air pressure-drop level setting WARNING If this pressure setting is not correct, the vacuum ejector cannot function adequately and air cylinders become unstable. Be sure that the pressure is set within the specified range. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 5-3 Vacuum and Pneumatic Systems Measurement and Adjusting Vacuum Levels 7KHPHDVXUHPHQWRIWKHYDFXXPOHYHOLVGRQHYLDYDFXXPVHQVRUVWUDQVGXFHUV ZKLFKDUHORFDWHGRQWKH,2KHDGDVV\ERDUG(DFKKHDGKDVLWVRZQVHQVRU DQG FDQ EH DGMXVWHG DQG FDOLEUDWHG LQGHSHQGHQW IURP HDFK RWKHU )RU WKH $GMXVWPHQWRIWKHVHQVLQJFLUFXLWSOHDVHUHIHUWRWKHFDOLEUDWLRQFKDSWHU Performance Check and Trouble Shooting ,QRUGHUWRJHWDFRUUHFWYDFXXPOHYHOIURPHDFKHMHFWRUPDNHVXUHWKDWWKHDLU SUHVVXUH LV DW D FRUUHFW OHYHO ! EDU 0DNH DOVR VXUH WKDW WKH KRVHV WR DQG IURPWKHHMHFWRUDUHQRWFRQWDPLQDWHG Maintenance Instructions (DFKHMHFWRUKDVLWVRZQDLUILOWHUZKLFKQHHGVWREHFKHFNHGDWUHJXODULQWHUYDOV +RXUV,IWKHILOWHULVFRQWDPLQDWHGLWLVDGYLVDEOHWRUHSODFHLWE\DQHZ RQH 5-4 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vacuum and Pneumatic Systems Pneumatic Systems Introduction 7KLVFKDSWHUGHVFULEHVWKHHOHFWULFDOLQWHUIDFHRIWKHSQHXPDWLFV\VWHPLQWKH 7RSD]DQG7UD\&KDQJHU Functional Description 7KH7RSD]FRQWDLQVDQXPEHURISQHXPDWLFVROHQRLGYDOYHVDQGF\OLQGHUV7KH DLU VROHQRLG YDOYHV FRQWURO WKH DLU IORZ WR FHUWDLQ DLU SUHVVXUH OLQHV 7KH SQHXPDWLFGULYHQF\OLQGHUVDUHXVHGIRUWKHORFDWHSLQVSXVKXSSLQVSXVKLQ HGJHFODPSVDQGKHDGGRZQPRYHPHQW 7KHDLUVROHQRLGYDOYHVDUHFRQWUROOHGHOHFWULFDOO\E\D9VLJQDOFRPLQJIURP WKH ,2ERDUGV 7KH DLU F\OLQGHUV DUH DFWLYDWHG E\ DLU SUHVVXUH ZKLFK DUH FRQWUROOHGE\HOHFWULFDOVROHQRLGV7KHSQHXPDWLFF\OLQGHUVDUHFRQWUROOHGE\DLU VROHQRLGYDOYHV Topaz 7KHDLUVROHQRLGYDOYHVDUHFRQWUROOHGE\WKH,2ERDUGVLQVLGHWKHPDFKLQH ,QFKDSWHUWKHLQWHUFRQQHFWLRQVDUHVKRZQEHWZHHQWKHFRQYH\RU,2 VDQG WKHYDULRXVYDOYHV Tray Changer (TC) 7KHDLUVROHQRLGYDOYHVRIWKH7UD\&KDQJHUDUHFRQWUROOHGE\WKH,2FRQYH\RU ERDUGLQVLGHWKH7UD\FKDQJHU)RUWKHFRQQHFWLRQVEHWZHHQWKH,2ERDUGDQG WKH YDULRXV VROHQRLGV SOHDVH UHIHU WR WKH RYHUDOO 7& LQWHUFRQQHFW GLDJUDP LQ FKDSWHU 7KH DLU SUHVVXUH IRU WKH 7UD\ &KDQJHU DLU YDOYHV LV VXSSOLHG YLD WKH PDLQ PDFKLQH Tape Feeders 7KH WDSH IHHGHUV GR QRW KDYH DLU VROHQRLGV YDOYHV VR WKH\ GR QRW FRQWDLQ HOHFWULFDOFRQQHFWLRQV Automatic Tray Stacker 7KHDXWRPDWLFWUD\VWDFNHUVGRKDYHDLUYDOYHVZKLFKDUHVXSSOLHGYLDWKHPDLQ PDFKLQHDVZHOODVWKHHOHFWULFDOVLJQDOVUHTXLUHG FES/SVS 7KHFRPSUHVVHGDLUXVHGLQWKH)(6DQG696V\VWHPVDUHVXSSOLHGYLDWKH PDFKLQHFRQQHFWHGYLDWKHLQWHUIDFHER[ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 5-5 Vacuum and Pneumatic Systems Measuring and Adjusting &KHFNDQGLIQHFHVVDU\DGMXVWDWUHJXODULQWHUYDOVTXDUWHUO\WKHYROWVZKLFK LVXVHGWRFRQWUROWKHYDULRXVYDOYHVRIWKHSQHXPDWLFV\VWHP 7KHWZRSRZHUVXSSO\ V*6DQG*6DUHORFDWHGDWWKHOHIWORZHUUHDUVLGH RIWKHV\VWHP Performance Checks and Trouble Shooting 1RVSHFLILFDFWLRQVDUHGRQHIRUWKHSHUIRUPDQFHFKHFN,IVRPHYDOYHVDUHQRW ZRUNLQJSOHDVHILUVWFKHFNWKHYROWSRZHUVXSSO\WKHQFKHFNLIWKH,2VLJQDO LV RN FKHFN WKLV E\ DFWLYDWLQJ PDQXDOO\ WKH ,2 VLJQDO YLD WKH PDQXDO ,2 VHWWLQJVFUHHQ Maintenance Actions 1RVSHFLILFPDLQWHQDQFHDFWLRQVEHVLGHVWKH9FKHFNLQJDUHQHFHVVDU\ 5-6 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vacuum and Pneumatic Systems Exchanging Head Ejectors, Valves and Base 7KLVFKDSWHUGHVFULEHVKRZWRUHSODFHWKHKHDGHMHFWRUVDQGYDOYHV Exchanging the Head Ejector and/or Valves %ORZRIIYDOYHUHSODFHPHQW 7RUHSODFHWKHEORZRIIYDOYHVRQWRSRIWKHHMHFWRULQWKHKHDGDVV\UHIHUWR ILJXUHDQGSURFHHGDVIROORZV /RRVHQWKHWZRVFUHZVRQWRSRIWKHYDOYH 5HPRYHWKHYDOYHLQWKHGLUHFWLRQRIWKHDUURZ ,QVWDOOWKHQHZYDOYHDQGWDNHFDUHDERXWWKHGLUHFWLRQRIWKHJDVNHW 7LJKWHQWKHWZRVFUHZVZLWKDWRUTXHRI1FP ´%ORZRIIµ Figure 5-4 Ejector and Valves (MHFWRUUHSODFHPHQW 7RUHSODFHWKHHMHFWRULWVHOIUHIHUWRILJXUHDQGSURFHHGDVIROORZV 5HPRYHWKHYDOYHRQWRSRIWKHHMHFWRUE\IROORZLQJVWHSVDQGRIWKH SUHYLRXVSURFHGXUH´9DOYHUHSODFHPHQWµ 5HPRYHWKHWZRVFUHZVKROGLQJWKHHMHFWRUWRWKHHMHFWRUEDVHHQGEORFN 5HPRYHWKHHMHFWRUE\PRYLQJLWLQWKHGLUHFWLRQRIWKHDUURZ ,QVWDOOWKHQHZHMHFWRUDQGWDNHFDUHDERXWWKHGLUHFWLRQRIWKHJDVNHW 7LJKWHQWKHWZRVFUHZVZLWKDWRUTXHRI1FP 0RXQWWKHYDOYHRQWRSRIWKHHMHFWRUE\IROORZLQJVWHSVDQGRIWKH SUHYLRXVSURFHGXUH´9DOYHUHSODFHPHQWµ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 5-7 Vacuum and Pneumatic Systems %DVHUHSODFHPHQW 7RUHSODFHWKHEDVHRIWKHHMHFWRULWVHOIUHIHUWRILJXUHDQGSURFHHGDVIROORZV /RRVHQWKHWZRVFUHZVLQWKHOHIWRUULJKWHQGEORFN 5HPRYHWKHDSSOLFDEOHHQGEORFNDQGHMHFWRUEDVH 5HPRYHWKHYDOYHDQGHMHFWRURQWRSRIWKHHMHFWRUEDVHRUHQGEORFNE\ IROORZLQJVWHSVWRRIWKHSURFHGXUH´(MHFWRUUHSODFHPHQWµ ,QVWDOOWKHUHPRYHGHMHFWRUDQGYDOYHRQWRWKHQHZHMHFWRUEDVHE\IROORZLQJ VWHSVWRRIWKHSURFHGXUH´(MHFWRUUHSODFHPHQWµ ,QVWDOOWKHHMHFWRUEDVHDQGHQGEORFNZKLOHWDNLQJFDUHRIWKH2ULQJ 7LJKWHQWKHEROWVZLWKDWRUTXHRI1FP REMARK: If there is a need to replace the end-blocks separate code numbers are available in the spare parts list. CAUTION 1. 2. 3. Disconnect the power and air supply prior to replacing the valves. Confirm the torque of each removed bolt prior to reconnecting air and power. Too much torque may damage the plastic ejector base ! Exchanging the Head Up/Down, Slow Valves and Valve Base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´8S'RZQYDOYHUHSODFHPHQWµDQG´6ORZYDOYHUHSODFHPHQWµ 5-8 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vacuum and Pneumatic Systems ,QVWDOOWKHUHPRYHGYDOYHVRQWRWKHQHZYDOYHEDVHE\IROORZLQJVWHSVDQG WKHSURFHGXUHV´8S'RZQYDOYHUHSODFHPHQWµDQG´6ORZYDOYH UHSODFHPHQWµ ,QVWDOOWKHYDOYHEDVHDQGHQGEORFNVZKLOHWDNLQJFDUHRIWKH2ULQJV 7LJKWHQWKHEROWVZLWKDWRUTXHRI1FP ´8S'RZQµ ´6ORZµ Figure 5-5 REMARK: Head valves If there is a need to replace the end-blocks separate code numbers are available in the spare parts list. CAUTION 1. 2. 5322 871 63606 01.05 Disconnect the power and air supply prior to replacing the valves. Confirm the torque of each removed bolt prior to reconnecting air and power. Service Manual Topaz PA 1309/10 5-9 Vacuum and Pneumatic Systems Intentionally Left Blank. 5 - 10 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 PCB Transport Systems CHAPTER 6 6.1. PCB Transport Systems Introduction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igure 6-1 5322 871 63606 01.05 PCB transport system (top view) Service Manual Topaz PA 1309/10 6-1 PCB Transport Systems 6.2. Conveyor Belt 7KHFRQYH\RUEHOWWUDQVSRUWVWKH3&%·VE\EHOWLQIRUPRXQWLQJDQGRXW ZKHQUHPRXQWHGWKH7RSD]2QDVWDQGDUGPDFKLQH3&% VDUH FRQYH\HGLQWKHOHIWWRULJKWGLUHFWLRQZKLOHWKHFRQYH\RUZLGWKLV DGMXVWHGE\VOLGLQJWKHUHDUUDLOWKHIURQWUDLOLVIL[HG7KHVHVSHFLILFDWLRQV FDQQRWEHFKDQJHGDIWHUWKHPDFKLQHKDVEHHQVKLSSHG Adjusting the Conveyor Belt Tension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igure 6-2 6-2 Service Manual Topaz PA 1309/10 Adjusting the conveyor belt tension 5322 871 63606 01.05 PCB Transport Systems Adjusting the Carry-In Conveyor Speed 7KHFRQYH\RUVSHHGYDULHVDFFRUGLQJWRWKHIUHTXHQF\RIWKHSRZHUVXSSO\ DQGWKHZHLJKWRIWKH3&%VRQWKHFRQYH\RU<RXFDQDGMXVWWKHFDUU\LQ FRQYH\RUVSHHGVE\XVLQJWKHWZRDGMXVWLQJVFUHZVORFDWHGLQVLGHWKHORZHU ULJKWSDQHORQWKHIURQWVLGH 7KHFDUU\LQFRQYH\RUPRYHVDWWZRVSHHGVDKLJKVSHHG+IRUUHGXFLQJ WKHWUDQVIHUWLPHRI3&%VDQGDORZVSHHG/IRUPLQLPL]LQJLPSDFW ZKHQWKH3&%KLWVWKHHQWUDQFHRUPDLQVWRSSHU7RDGMXVWWKHVHVSHHGV SUHSDUHW\SLFDO3&%VDQGXVHWKHSURFHGXUHEHORZ Figure 6-3 Carry-in conveyor speed adjusting screws $GMXVWWKHFRQYH\RUZLGWKDFFRUGLQJWRWKHVL]HRIWKH3&%7RDGMXVW WKHFRQYH\RUZLGWKWKH&RQYH\RU8QLWXWLOLW\LQWKH'DWD0DQDJHU ZLOOEHFRQYHQLHQW,I\RXUPDFKLQHLVQRWHTXLSSHGZLWKDQDXWR FRQYH\RUZLGWKDGMXVWLQJIXQFWLRQDGMXVWPDQXDOO\ 2SHQWKHRXWSXWPRQLWRUVFUHHQDQGWXUQRQWKHFRQYH\RUVHHILJXUH 6HOHFW0$,17(0!!!0$18$/!!&',63/$< (;,7!^&287387021,725`DQGSUHVVWKH>(17(5@NH\ - 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71 &219(<2521 - 3UHVVWKH>(17(5@NH\WRWXUQRQWKHFRQYH\RU7KHRXWSXW PRQLWRUGLJLWUHDGVLIWKHFRQYH\RULVRQDQGLILWLVRII Out Monitor [↑↓←→] : Select [Enter] : Exec Selected Arm : MAIN [ESC] : Command Lists Moving Speed : XY 100 TN13 CONVEYOR ON OFF NAME Conveyors Figure 6-4 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 0 / ON OUT 1 NAME IN TN09-16 00001000 Output monitor screen, activate conveyor 6-3 PCB Transport Systems :KLOHUXQQLQJWKHFRQYH\RUVZLWFKWKHVSHHGDVIROORZVILJXUH 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71&219(<25 63(('/2: - 3UHVVWKH>(17(5@NH\WRVZLWFKWKHFRQYH\RUVSHHG7KHRXWSXW PRQLWRUGLJLWUHDGVZKHQWKHFRQYH\RULVDWORZVSHHGDQGUHDGV ZKHQLWLVDWKLJKVSHHG Out Monitor [↑↓←→] : Select [Enter] : Exec Selected Arm : MAIN [ESC] : Command Lists Moving Speed : 100 XY TN14 CONVEYOR SPEED LOW 0 / LOW HIGH ( NAME Conveyors = 0 / OUT TN09-16 1 = 1) NAME IN 00001100 Figure 6-5 monitor screen, conveyor speed Output 4) $GMXVWWKHKLJKVSHHGZKLOHUXQQLQJWKHFRQYH\RUDWKLJKVSHHGDGMXVW 7KHVSHHGE\WXUQLQJWKH+VFUHZ'RQRWVHWWKHVSHHGWRRKLJKDV WKLVPD\KDPSHUVZLWFKLQJUHVSRQVH3RVLWLRQWKH+VFUHZDWDSRLQW VOLJKWO\VORZHUWKDQWKHPD[LPXPVSHHG 5) 5DLVHWKHHQWUDQFHVWRSSHUE\VHOHFWLQJ0$,17(0!!! 0$18$/!!&',63/$<(;,7!^&287387 021,725`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ervice Manual Topaz PA 1309/10 5322 871 63606 01.05 PCB Transport Systems 6.3. Main Stopper :KHQWKHFRQYH\RUEHOWWUDQVSRUWVD3&%LQWRWKH7RSD]WKHPDLQ VWRSSHUZLOOVWRSWKH3&%DWWKHPRXQWLQJSRVLWLRQ7KHDVFHQWGHVFHQW VSHHGVRIWKHPDLQVWRSSHUDQGWKH3&%FRQWDFWSRLQWFDQEHDGMXVWHG SOHDVHUHIHUWRILJXUHEHORZ Rear right side of the Topaz Figure 6-6 Main stopper and air solenoid valve Adjusting the Ascent/Descent Speeds of the Main Stopper 2SHQWKHRXWSXWPRQLWRUVFUHHQDQGRSHUDWHWKHPDLQVWRSSHUILJ 6HOHFW0$,17(0!!!0$18$/!!&',63/$< (;,7!^&287387021,725`DQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWRVHWWKHFXUVRUDW710$,167233(5 3UHVVWKH>(17(5@NH\WRDOWHUQDWHO\UDLVHDQGORZHUWKHPDLQVWRSSHU 7KHRXWSXWPRQLWRUGLJLWUHDGVZKHQWKHPDLQVWRSSHULVWKHUDLVHG SRVLWLRQDQGUHDGVZKHQLWLVDWWKHORZHUHGSRVLWLRQ Figure 6-7 5322 871 63606 01.05 Output monitor screen, activate main stopper Service Manual Topaz PA 1309/10 6-5 PCB Transport Systems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igure 6-8 6-6 Service Manual Topaz PA 1309/10 Main stopper exploded view 5322 871 63606 01.05 PCB Transport Systems PCB Contact Point 7KHVWRSSHURIWKHPDLQVWRSSHULVDVWHHO´ZDVKHUµ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`XWLOLW\RUWKH RXWSXWPRQLWRULQWKH0DQXDOPRGH 3UHVVWKHHPHUJHQF\VWRSEXWWRQVHWWKH3&%LQWKHPRXQWLQJ SRVLWLRQ3ODFHWKH3&%DJDLQVWWKHPDLQVWRSSHUDQGGHWHUPLQHWKH RIIVHWEHWZHHQWKH3&%SRVLWLRQLQJKROHDQGWKHIL[HGORFDWHSLQ /RRVHQWKHEROWVHFXULQJWKHVWRSSHUE\XVLQJWKHKH[ZUHQFKORRVHQ WKHEROWEXWGRQRWUHPRYHLWWRDOORZWXUQLQJRIWKHVWRSSHU $GMXVWWKHRULHQWDWLRQRIWKHVWRSSHUE\VOLJKWO\URWDWLQJWKHVWRSSHUVR WKDWWKHORFDWHSLQFDQH[DFWO\EHDOLJQHGZLWKWKH3&%SRVLWLRQLQJ KROH 5HWLJKWHQWKHEROWWRVHFXUHWKHVWRSSHU Figure 6-9 Adjusting the PCB contact point CAUTION When you use PCBs having typical positioning holes, you must return the above adjustment to the original setting. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 6-7 PCB Transport Systems 6.4. Push-In 7KHSXVKLQPHFKDQLVPSUHVVHVWKH3&%DJDLQVWWKHPDLQVWRSSHU VHFXULQJLWLQWKHSRVLWLRQIRUPRXQWLQJ7RDGMXVWWKHVSHHGVRIWKHSXVK LQPHFKDQLVPSURFHHGDVIROORZVUHIHUWRILJXUH Rear right side of the Topaz Figure 6-10 Push in and air solenoid valve 2SHQWKHRXWSXWPRQLWRUVFUHHQVHHILJXUHDQGRSHUDWHWKH SXVKLQPHFKDQLVP 6HOHFW0$,17(0!!!0$18$/!!&',63/$< (;,7!^&287387021,725`DQGSUHVVWKH>(17(5@ NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71386+,1 3UHVVWKH>(17(5@NH\WRDOWHUQDWHO\FORVHDQGUHOHDVHWKHSXVKLQ PHFKDQLVP7KHRXWSXWPRQLWRUGLJLWUHDGVZKHQWKHSXVKLQ PHFKDQLVPLVDFWLYHDQGUHDGVZKHQLWLVUHOHDVHG Figure 6-11 Ouput monitor screen, activate push in &KHFNWKHSUHVVLQDQGUHOHDVHVSHHGV%RWKVSHHGVVKRXOGEHDURXQG RQHVHFRQGWKHVSHHGDWZKLFKSUHPRXQWHGFRPSRQHQWVRQWKH3&% ZLOOQRWVKLIW 6-8 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 PCB Transport Systems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igure 6-12 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 Exploded view Push-in 6-9 PCB Transport Systems 6.5. Locate Pin 7ZRORFDWHSLQVDUHDYDLODEOHDORQJWKHFRQYH\RUUDLORQHIL[HGDQGRQH PRYDEOH7KHVHSLQVHQJDJHZLWKWKHSRVLWLRQLQJKROHVRIWKH3&%WR VHFXUHLWLQSODFHUHDG\IRUPRXQWLQJ7RDGMXVWWKHDVFHQWGHVFHQWVSHHGV RIWKHORFDWHSLQVSURFHHGDVIROORZVSOHDVHUHIHUWRILJXUHDQG Figure 6-13 Locate pin arrangement Rear right side of the Topaz Figure 6-14 6 - 10 Service Manual Topaz PA 1309/10 Locate pin and air solenoid valve 5322 871 63606 01.05 PCB Transport Systems 2SHQWKHRXWSXWPRQLWRUVFUHHQILJXUHDQGRSHUDWHWKHORFDWH SLQV6HOHFW 0$,17(0!!!0$18$/!!&',63/$<(;,7! ^&287387021,725`DQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71/2&$7( 3,1 3UHVVWKH>(17(5@NH\WRDOWHUQDWHO\UDLVHDQGORZHUWKHORFDWHSLQV 7KHRXWSXWPRQLWRUGLJLWUHDGVZKHQWKHORFDWHSLQVDUHDWWKH UDLVHGSRVLWLRQDQGUHDGVZKHQWKH\DUHDWWKHORZHUHGSRVLWLRQ Figure 6-15 Output monitor, activate locate pins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ervice Manual Topaz PA 1309/10 6 - 11 PCB Transport Systems ,IWKLVPHWKRGZRUNVWKHUHZLOOSUREDEO\EHDSUREOHPZLWKWKHHOHFWULF FLUFXLWIRUWKHDLUVROHQRLGYDOYH&KHFNWKHIROORZLQJSRLQWV (OHFWURPDJQHWLFFRLOEUHDNDJH /RRVHKDUQHVVFRQQHFWRUV 7URXEOHZLWKWKH'&9VXSSO\ ,2ERDUGRXWSXWHUURUVHWF ,ISUHVVLQJWKHPDQXDOEXWWRQGRHVQRWDOORZQRUPDORSHUDWLRQWKHUHLVD SUREOHPZLWKWKHDLUVXSSO\DLUSLSLQJRUSLSHWWHYDOYHVGDPDJHFORJJLQJ DQGDGKHVLRQRIIRUHLJQPDWWHU&KHFNWKHDLUVXSSO\OLQHRIWKHORFDWH SLQV)RUDQ\UHSODFHPHQWRIWKHORFDWHSLQSOHDVHUHIHUWRILJXUH Figure 6-16 6 - 12 Service Manual Topaz PA 1309/10 Exploded view Locate pin assembly 5322 871 63606 01.05 PCB Transport Systems 6.6. Edge Clamp $QRWKHU3&%FODPSLQJPHWKRGLVWKHXVHRIWKHHGJHFODPSF\OLQGHUV ZKHQHYHUWKHORFDWHSLQVFDQQRWEHXVHGWKHHGJHFODPSF\OLQGHUVFDQEH XVHGWRSUHVVWKH3&%DJDLQVWWKHIURQWFRQYH\RUUDLODQGVRIL[LWWRWKH PRXQWLQJSRVLWLRQ 7KHHGJHFODPSF\OLQGHUVGRQRWKDYHDQ\DGMXVWPHQWSRVVLELOLWLHV2I FRXUVHWKHHGJHFODPSVFDQEHDFWLYDWHGE\PHDQVRIWKHRXWSXWPRQLWRU 71SOHDVHUHIHUWRILJXUH )RUWKHDQ\UHSODFHPHQWVRIWKHHGJHFODPSDVVHPEO\SOHDVHUHIHUWRWKH ILJXUH 71 Rear right side of the Topaz Figure 6-17 Figure 6-18 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 Air solenoid rear right side of Topaz Exploded view edge clamp assembly 6 - 13 PCB Transport Systems 6.7. Push-Up 7KHSXVKXSSODWHLVORFDWHGGLUHFWO\XQGHUQHDWKWKHFRPSRQHQWPRXQ WLQJSRVLWLRQ7KHVXSSRUWSLQVDWWDFKHGE\PDJQHWVRQWKHVXUIDFHRIWKH SXVKXSSODWHVXSSRUWWKH3&%GXULQJWKHPRXQWLQJSURFHVV7KH3&% ZLOOEHSXVKHGDJDLQVWWKHWRSVLGHRIWKHFRQYH\RUUDLOSOHDVHUHIHUWR ILJXUH7RDGMXVWWKHDVFHQWGHVFHQWVSHHGVRIWKHSXVKXSSODWH SURFHHGDVIROORZV Rear right side of the Topaz Figure 6-19 Push-up and air solenoid valve 2SHQWKHRXWSXWPRQLWRUVFUHHQDQGRSHUDWHWKHSXVKXSSODWH 6HOHFW0$,17(0!!!0$18$/!!&',63/$< (;,7!^&287387021,725`DQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71386+83 3UHVVWKH>(17(5@NH\WRDOWHUQDWHO\UDLVHDQGORZHUWKHSXVKXS SODWH7KHRXWSXWPRQLWRUGLJLWUHDGVZKHQWKHSXVKXSSODWHLV DWWKHUDLVHGSRVLWLRQDQGUHDGVZKHQLWLVDWWKHORZHUHG SRVLWLRQ Figure 6-19a 6 - 14 Service Manual Topaz PA 1309/10 PCB supporter pins 5322 871 63606 01.05 PCB Transport Systems Figure 6-20 Output monitor, activate push-up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hen you set the push-up pins on the push-up plate, make sure that the push-up pins do not interfere with the conveyor rails and edge clamp cylinder. ,ISUHVVLQJWKHPDQXDOEXWWRQGRHVQRWDOORZIRUQRUPDORSHUDWLRQWKHUH LVDQRWKHUSUREOHPZLWKWKHDLUVXSSO\DLUSLSLQJDQGSLSHWWHYDOYHV GDPDJHFORJJLQJDQGDGKHVLRQRIIRUHLJQPDWWHU&KHFNWKHDLUVXSSO\ OLQHRIWKHSXVKXSSODWH)RUDQ\UHSODFHPHQWVRQWKHSXVKXSDVV\UHIHU FKDSWHU 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 6 - 15 PCB Transport Systems 6.8. PCB Detection Sensors ,QWKHFRQYH\RUDVV\WKHUHDUHILYH3&%GHWHFWLRQVHQVRUVDUUDQJHGDORQJ WKHIURQWUDLORIWKHFRQYH\RU7KHVHQVRUVHDFKKDYH/('VPRXQWHGRQ WKHVLGHZKLFKDUHQRUPDOO\OLW:KHQWKHVHQVRUGHWHFWVWKHSUHVHQFHRID 3&%WKH/('WXUQVRIISOHDVHUHIHUWRILJXUH SQ53 SQ54 SQ57 SQ51 SQ52 PCB SQ52 SQ51 SQ54 SQ57 SQ53 PCB Figure 6-21 PCB detection sensors 7KHWDEOHEHORZVKRZVWKH3&%GHWHFWLRQVHQVRUVWKHLUIXQFWLRQ DQGWKHLUORFDWLRQ7KHVHQVRUFRGHFDQEHXVHGWRWUDFNWKHVHQVRUVLQWKH GLDJUDPVRIFKDSWHU7KHVLJQLVWKHVRIWZDUHFRGHZKLFKLVXVHGIRU LQVWDQFHLQWKH','2VFUHHQRIWKHVRIWZDUH Sensor SQ51 SQ52 SQ53 SQ54 SQ57 Location Entrance stopper 1 Sign NL01 Conveyor entrance Conveyor exit Entrance stopper 2 PCB securing position NL02 NL04 NL03 NL09 Remarks Stopper for decelerating transport. PCB detection. - Table 6.8-1 6 - 16 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 PCB Transport Systems 7KHVHQVRUVPD\QRWGHWHFWD3&%VHHILJXUHGXHWRVXFKIDFWRUVDV WKHRULHQWDWLRQGLVWDQFHDQGDQJOHDWZKLFKLWLVDWWDFKHG7KHVHQVRUV PD\DOVREHDIIHFWHGE\VWURQJH[WUDQHRXVOLJKWH[FHVVLYHGXVWDQGWKH VKDSHKROHRUQRWFKDQGFRORURIWKH3&%8VLQJ3&%VRQZKLFK\RX DFWXDOO\PRXQWFRPSRQHQWVFKHFNWKDWWKHVHQVRUVFDQGHWHFWWKHP UHOLDEO\ Figure 6-22 PCB sensors detection errors 3UHSDUHWKH3&%\RXZLOODFWXDOO\XVHIRUFRPSRQHQWPRXQWLQJ $GMXVWWKHFRQYH\RUZLGWKDFFRUGLQJWRWKHVL]HRIWKH3&% 7RDGMXVWWKHFRQYH\RUZLGWK\RXFDQXVHWKH&RQYH\RU8QLWXWLOLW\LQ WKH'DWD0DQDJHU,I\RXUPDFKLQHLVQRWHTXLSSHGZLWKDQDXWR FRQYH\RUZLGWKDGMIXQFWLRQDGMXVWPDQXDOO\ 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGSDFHWKH3&%RQWKHFRQYH\RU 2SHQWKHLQSXWPRQLWRUDQGFKHFNWKHGHWHFWLRQVWDWXVILJXUH 6HOHFW0$,17(0!!!0$18$/!!&',63/$<(;,7 !^&,1387021,725`DQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71WR71 7KHLQSXWPRQLWRUGLJLWUHDGVZKHQWKH3&%LVGHWHFWHGDQGUHDGV ZKHQQRWGHWHFWHG&KHFNWKDWWKHGLJLWRIHDFKVHQVRUUHDGV $OVRFKHFNWKDWWKHGHWHFWLRQVWDWXVRIWKHVHQVRU641/GRHV QRWYDU\HYHQLIWKHORFDWHSLQVDQGSXVKXSSODWHDUHUDLVHG In Monitor [↑↓←→] : Select [Enter] : Exec Selected Arm : MAIN [ESC] : Command Lists Moving Speed : 100 XY NL09 SET POSITION DETECT NAME OUT 1 NAME Conveyor Figure 6-23 IN NL09-16 10000000 Input monitor 3ODFHD3&%RYHUHDFKVHQVRUDORQJWKHFRQYH\RUDQGFKHFNLIWKHDUH 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 6 - 17 PCB Transport Systems 2.7RVHFXUHWKH3&%LQWKHPRXQWLQJSRVLWLRQRYHUWKHVHQVRU 64WKH&RQYH\RU8QLWXWLOLW\ZLOOEHFRQYHQLHQW ,IQHFHVVDU\DGMXVWWKHSRVLWLRQRIWKH3&%GHWHFWLRQVHQVRU/RRVHQ WKHVFUHZVVHFXULQJWKHVHQVRUDQGDGMXVWWKHSRVLWLRQRULHQWDWLRQRU DQJOHDWZKLFKLWLVDWWDFKHG 5HPRYHWKH3&%IURPWKHFRQYH\RU Figure 6-24 6 - 18 Service Manual Topaz PA 1309/10 Adjusting the position of the PCB detection sensor 5322 871 63606 01.05 PCB Transport Systems 6.9. Conveyor Errors 7KHWDEOHVKRZVVRPHSRVVLEOHFRQYH\RUSUREOHPV\PSWRPVWKDW PD\RFFXU 6\PWRP 3RVVLEOHFDXVHV &RUUHFWLYHDFWLRQ The PCB hits hard against the main stopper. The soft stop function is defect or adjusted incorrectly. The PCB does not reach the main stopper at all. The soft stop function takes too much effect. A PCB transfer error (PCB installation error) occurs when a thick PCB is conveyed. The locate pin will not rise adequately for a thick PCB or a PCB having a small reference hole, so the sensor remians off. The sensor at the PCB installation position is faulty, or the PCB has a cutpout area just above the sensor so the sensor cannot detect the PCB. Open the front lower right panel of the machine, you will see the two adjustment scres for the conveyor speed, adjust the L-screw to the left slightly to reduce the conveyor speed. Open the front lower right panel of the machine, you will see the two adjustment scres for the conveyor speed, adjust the L-screw to the right slightly to increase the conveyor speed. Loosen the screw for the locate pin sensor and slightly lower its position. Then check that the sensor turns on when the PCB is secured in place. After the PCB has been conveyed in the mounting position the pins will not rise to secure the PCB (the conveyor keeps turning). Table 6.9-1 5322 871 63606 01.05 Check the sensor operation in the manual mode (input monitor). If the sensor is defect, replace it. If the sensitivity is too low adjust the height of the sensor. Possible conveyor problem symptoms Service Manual Topaz PA 1309/10 6 - 19 PCB Transport Systems Intentionally left blank. 6 - 20 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems CHAPTER 7 7.1. Component Transport Systems Introduction 7KLVFKDSWHUGHVFULEHVWKHFRPSRQHQWWUDQVSRUWV\VWHPWKDWLVUHVSRQVLEOHIRUIHHGLQJ DQGRUWUDQVSRUWLQJFRPSRQHQWV. 7.2. Head Assembly 7KHKHDGDVVHPEO\ILJXUHRIWKH723$=FRQVLVWVRIHLJKWLQOLQHKHDGV7KLV FKDSWHUGHVFULEHVKRZWRFKHFNDGMXVWDQGRSWLPL]HDLUGULYHQPHFKDQLFDO PRYHPHQWVYDFXXPJHQHUDWLRQDQGPDFKLQHGDWDUHODWHGWRWKHKHDGDVVHPEO\VHH WKHWDEOHEHORZ Head descent movement Head lower end detection Vacuum generation Vacuum sensor function Machine coordinates (position) Pick and mount vacuum levels R-axis absolute accuracy offset* Nozzle correction* Head offset* Check that each head descends smoothly Check that the lower end is correctly detected when each head descends. Check that the vacuum ejector provides adequate vacuum levels. Check that the vacuum sensor display levels are correct. These coordinates include the stand-by point for the head and discard point for components The reference vacuum pressure (suction) is used to determine whether each head has picked up or mounted a component. Angular offset for the R-axis that rotates each nozzle shaft. This is used to correct an off-center nozzle shaft when it rotates by 180 degrees. The position of the heads related to fiducial camera 7KHVHSDUDPHWHUVDUHDXWRPDWLFDOO\FRUUHFWHGZKHQ\RXSHUIRUPPRXQWIHHGEDFN GHVFULEHGODWHULQFKDSWHU´0DFKLQH,QVWDOODWLRQDQG&DOLEUDWLRQµ Figure 7-1 5322 871 63606 01.05 Topaz head assembly Service Manual Topaz PA 1309/10 7- 1 Component Transport Systems 7.2.1. Mechanical Check Head Assembly 7KLVFKDSWHUGHVFULEHVKRZWRFKHFNWKHDLUGULYHQPHFKDQLFDOPRYHPHQWV DQGYDFXXPJHQHUDWLRQLQWKHKHDGDVVHPEO\ &KHFNLQJWKHDVFHQWGHVFHQWPRYHPHQW )LUVWPDNHVXUHWRWKHKHDGLVLQVXFKDSRVLWLRQWKDWLWFDQQRWKLWDQ\WKLQJ ZKHQORZHUHG/RZHUWKHKHDGDVIROORZV - 2SHQWKHRXWSXWPRQLWRUZLWK&RXWSXWPRQLWRU!DQGVHOHFWWKH WDUJHWKHDG7(WR7(ZLWKWKHFXUVRU - 3UHVVWKHHQWHUNH\WRORZHUWKHWDUJHWKHDGWKHRXWSXWPRQLWRUSRVLWLRQ UHDGV´µZKHQORZHUHGDQG´µZKHQWKHKHDGLVUDLVHG &KHFNLQJWKHORZHUHQGGHWHFWLRQVHQVRU - :KLOHWKHKHDGLVORZHUHGPRYHWKHFXUVRUZLWKWKH7$%NH\WRWKHLQSXW VFUHHQDQGPRYHWKHFXUVRUWRWKHKHDGXSGRZQVHQVRULQSXW1*WR 1* - &KHFNWKHVWDWXVRIWKHLQSXW - :KHQWKHKHDGLVORZHUHGRXWSXW µµWKHLQSXWPRQLWRUVKRXOGUHDG ´µ7KHRSSRVLWHVLWXDWLRQLVYDOLGZKHQWKHKHDGLVUDLVHG Note1: The head end-lower sensor that are used are of the type “normally closed” For safety reasons. When a sensor wire breaks the machine will detect a head in the lower position and will stop immediately. Note2: If the head does not move normally during the above testing, check the operation of the head manually as follows; - Press the emergency button. - Press the manual button (red button on top of the air valve) of the air valve that is the most close to the nozzles by means of a narrow screw driver. When the head lowers in this situation the circuitry that should operate the valve is defect. Points to check are following; - Damaged valve - Loose harness connectors, - DC24V power supply - I/O-board etc. - 7-2 When performing manual operation does not move the head down there is a problem with the pneumatic installation. Check following; Air supply Air filters Air piping Air valves Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems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´·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ervice Manual Topaz PA 1309/10 7- 3 Component Transport Systems &KHFNLQJWKHYDFXXPVHQVRUIXQFWLRQ 7RFKHFNWKHYDFXXPVHQVRUIXQFWLRQRIWKHGHVLUHGKHDGE\IROORZLQJ SURFHGXUH 3UHVVWKHHPHUJHQF\VWRSEXWWRQ 2SHQWKHRXWSXWPRQLWRUVFUHHQDQGVHOHFWWKHWDUJHWKHDG 6HOHFW&287387021,725!DQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\WROLQHXSWKHFXUVRUZLWK7++($' 9$&880RUDQ\RWKHUKHDG7+WR7+ 3UHVVWKH>(17(5@NH\WRJHQHUDWHWKHYDFXXPLQWKHVHOHFWHGKHDG 7KHRXWSXWPRQLWRUGLJLWFKDQJHVWR´·ZKHQWKHYDFXXPHMHFWRULV RQ 6HOHFW0$18$/!$9$&8806(1625!DQGSUHVVWKH >(17(5@NH\ 7KHFXUUHQWYDFXXPOHYHOVRIDOOKHDGVDUHGLVSOD\HGRQWKHRSHUDWLRQ PRQLWRU <COMMAND_LIST> A/CHANGE_CONDITION VACUUM SENSOR LEVEL MINIMUM HEAD CURRENT MAXIMUM 137 187 3 A1 135 186 2 A2 Figure 7-2 Vacuum level display &KHFNWKHYDFXXPVHQVRUIXQFWLRQ 0DNHVXUHWKDWWKHYDFXXPOHYHOEDUJUDSKDQGQXPHULFDOYDOXHRQWKH RIWKHVHOHFWHGKHDGFKDQJHVZKHQ\RXSODFH\RXUILQJHURYHUWKHQR]]OH WLSRSHQLQJDQGWKHQUHPRYHLW7KHYDFXXPOHYHOLQFUHDVHVZKHQWKH QR]]OHWLSRSHQLQJLVFORVHG 5HWXUQWRRXWSXWPRQLWRUVFUHHQDQGWXUQRIIWKHYDFXXP &KHFNWKDWWKHFXUVRULVRQWKHWDUJHWKHDGLQWKH+HDG9DFXXPFROXPQ RQWKHRXWSXWPRQLWRUDQGSUHVVWKH>(17(5@NH\WRWXUQRIIWKH YDFXXP 7-4 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems 7.2.2. Machine Coordinates :KHQ\RXVHOHFW0$,17(0!!!0&+B$'-867!!% 6$9(48,7!^%$'-8677$5*(7`3RVLWLRQDQGSUHVVWKH >(17(5@NH\WKHIROORZLQJGLVSOD\DSSHDUVVKRZLQJWKHSRVLWLRQRIHDFK SDUWYHUVXVWKHRULJLQDQGRWKHUEDVLFSDUDPHWHUVHWWLQJV7KLVVHFWLRQ GHVFULEHVKRZWRVHWWKHPRVWLPSRUWDQWSDUDPHWHUV Figure 7-3 Machine coordinates editing screen A) Fine angle :KHQ),1(PRGHLVVHOHFWHGWRUHFRJQL]HD4)3ZLWKWKHVLQJOHYLVLRQ FDPHUDWKH),1(DQJOHSDUDPHWHUGHWHUPLQHVKRZDFFXUDWHO\WKHUHFRJQLWLRQ DQJOHVKRXOGEHFRQYHUJHGDGMXVWHGWRWKHVSHFLILHGDQJOH7KLVSDUDPHWHU FDQEHRUGHJUHHV:HUHFRPPHQGVHWWLQJWRWKH PLQLPXPYDOXHRIIRUDGMXVWPHQWDQGWRRUIRUDFWXDO PRXQWLQJRSHUDWLRQWDNHVPRUHWLPH8VHWKH>,16@^'(/@RU >63$&(@NH\WRPDNHDVHOHFWLRQ NOTE: The smaller the setting of this parameter, the higher the recognition angle accuracy. However, the recognition time will be longer affecting the cycle time, or there may be occasions when the component is dumped without being converged to the specified angle. B) Multi camera )RUWKHPXOWLFDPHUDIROORZLQJSDUDPHWHUVDUHIRUHVHHQ - 0XOWLFDPHUD´<µ 7KLVSDUDPHWHUUHIOHFWVWKHVSHHGLQPLOOLPHWHUVSHUVHFRQGDWZKLFKWKH KHDGDVVHPEO\WUDYHOVRYHUWKHPXOWLFDPHUDGXULQJFRPSRQHQW UHFRJQLWLRQ6HWWKLVSDUDPHWHUWR´µWKLVYDOXHLVDQRSWLPXPVRGR QRWFKDQJHWKLVYDOXH - 0XOWLFDPHUD´=µDQG´5µ 7KHVHVHWWLQJVDUHIRUFRUUHFWLQJWKHDQJXODUVKLIWRIWKHPXOWLYLVLRQ FDPHUDYHUVXVWKHPRXQWHUD[LV7KH´=µFROXPQLVIRUWKHRSWLRQDO PXOWLFDPHUDZKLOHWKH´5µFROXPQLVXVHGIRUWKHVWDQGDUGPXOWL FDPHUD3OHDVHVHWWKLVYDOXHWR´µ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 5 Component Transport Systems C) Locate pin 7KLVVHWWLQJLVWKHUHIHUHQFHSRVLWLRQZKHQWKH3&%LVVHFXUHGLQWKH PRXQWLQJSRVLWLRQRQWKHFRQYH\RU7KLVSRVLWLRQLVDOVRUHIHUUHGWRDVWKH 3&%RULJLQ:KHQVHWWLQJWKLVORFDWHSLQSRVLWLRQXVHIROORZLQJSURFHGXUH - 2SHQWKHSRVLWLRQVVFUHHQE\$VHOHFWWDUJHW!´SRVLWLRQµDQGSUHVV (QWHU - /LQHXSWKHFXUVRUZLWKWKH´;µRU´<µYDOXHLQWKH´ORFDWHSLQURZµ - 3UHVV)DQGVHWWKHWHDFKLQJFRQGLWLRQVVHOHFWWKHFDPHUDDVWKH WHDFKLQJXQLWDWDVORZVSHHGHJDQGSUHVVHQWHUDJDLQ - 0RYHWKHKHDGDERYHWKHIL[HGORFDWHSLQE\PHDQVRIWKHMR\VWLFN$OLJQ WKHFURVVFXUVRULQFHQWHURIWKHORFDWHSLQ - 3HUIRUPWHDFKLQJRIWKHORFDWHSLQE\SUHVVLQJWKH)NH\WZLFHWRHQWHU WKH;FRRUGLQDWHSHUIRUPWKHVDPHIRUWKH<FRRUGLQDWH - 6DYHWKHVHWWLQJVE\SUHVVLQJ(6&DQGVHOHFW%VDYHGDWD!RU% VDYHTXLW! D) Edge clamp :KHQWKHHGJHFODPSVDUHXVHGWRVHFXUHD3&%RQWKHFRQYH\RULQVWHDGRI XVLQJWKHORFDWHSLQVWKH3&%SRVLWLRQPD\VKLIWVOLJKWO\UHODWLYHWRWKHSRVLWLRQ GHWHUPLQHGE\WKHSLQV,IDVKLIWLQPLOOLPHWHUVLVIRXQGVXEWUDFWLWIURPWKH ORFDWHSLQFRRUGLQDWHVDQGHQWHUWKLVFRRUGLQDWHLQWKHHGJHFODPSSDUDPHWHUV 1RUPDOO\WKHVDPHSDUDPHWHUVDVWKHORFDWHSLQVDUHHQWHUHGLQKHUH E) Wait point 3UH&RQGLWLRQ2ULJLQWKHPDFKLQH :KHQ WKH PDFKLQH LV LGOH ZDLWLQJ IRU QHZ 3&%V WKH KHDGV ZLOO PRYH WR D :DLW3RVLWLRQ7KLVSRVLWLRQFDQDWDQ\OG ;<SRVLWLRQEXWWDNHFDUHRIWKH IROORZLQJQRWHV n 6HQVRUSRVLWLRQVWKH\PLJKWDFFLGHQWDOO\EHDFWLYDWHG n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´SRVLWLRQµ - 3RVLWLRQWKHFXUVRURQWKH;FROXPQRIWKH,ZDLWSRVLWLRQDQGSUHVV )WZLFH'RWKHVDPHIRUWKH<YDOXH - 6DYHWKHVHWWLQJVE\SUHVVLQJ(6&DQGVHOHFWLQJVDYHGDWD 7-6 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems F) Discard point 7KLVLVWKHSRVLWLRQDWZKLFKWKHKHDGGLVFDUGVDFRPSRQHQW7\SLFDOGLVFDUG SRLQWFRRUGLQDWHVDUHHQWHUHGSULRUWRVKLSPHQW 6LQFHLWLVQRWQHFHVVDU\WRORZHUWKHQR]]OHZKHQGLVFDUGLQJDFRPSRQHQW WKH=FRRUGLQDWHLVXVXDOO\VHWWR7RFKDQJHWKHGLVFDUGSRLQW;< FRRUGLQDWHVXVHWKHVDPHSURFHGXUHDVIRUVHWWLQJWKHZDLWSRLQW0DNHVXUH WKDWWKHKHDGDVVHPEO\ZLOOQRWEHGHWHFWHGE\D3&%VHQVRU9HULI\WKDWZKHQ DFRPSRQHQWLVGLVFDUGHGWKHGLVFDUGHGFRPSRQHQWZLOOQRWLQWHUIHUHZLWKWKH 3&%WUDQVSRUWDVV\FDPHUDRUVHQVRUV 7KH´)HHGHUFROXPQLQGLFDWHVWKHGXUDWLRQIRUZKLFKWKHDLUEORZWXUQVRQWR GLVFDUGDFRPSRQHQWLQPLOOLVHFRQGV7KLVYDOXHLVVHWW\SLFDOO\WRWR PVHF G) PCB/Fix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·3RVLWLRQDQGSUHVVWKH>(17(5@ NH\ 3UHVVWKH>)@NH\WZLFHWRSHUIRUPWHDFKLQJIRUWKH=FRRUGLQDWH 3UHVVWKH>(6&@NH\WKHQVHOHFW%6$9('$7$!RU%6$9( 48,7!DQGSUHVVWKH>(17(5@NH\ NOTE: It is also possible to teach the height on the fixed conveyor rail surface, which is basically the same height as the PCB surface. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 7 Component Transport Systems H) Dual recognition offset 7KLVSDUDPHWHULVXVHGWREHDEOHWRJRIURPOHIWWRULJKWDQGWKHRSSRVLWHZD\ RYHUWKHPXOWLFDPHUDVWKLVLVVHWGXULQJDGMXVWLQJRIWKHFDPHUDV I) Simultaneous pickup area 7KLVSDUDPHWHULVXVHGWRGHWHUPLQHZKHWKHUPXOWLSOHKHDGVFDQSLFNXS FRPSRQHQWVVLPXOWDQHRXVO\(DFKFROXPQUHVSHFWLYHO\VKRZVWKHDOORZDEOH UDQJHVRISLFNXSSRVLWLRQV;<5=WKDWSHUPLWVLPXOWDQHRXVSLFNXSIURP GLIIHUHQWFRPSRQHQWIHHGHUV7\SLFDOO\;<DQG=VKRXOGEHVHWWRPPDQG WKH5WRGHJUHH J) QFP clearance ,IDODUJHLPSDFWLVDSSOLHGWRD4)3DWWKHLQVWDQWZKHQDKHDGORZHUVWRSLFN RUPRXQWLWWKHOHDGVRIWKH4)3LQTXHVWLRQVDUHOLNHO\WREHQW7RDYRLGWKLV WKHVRIWODQGLQJSLFNXSRUPRXQWLQJLVXVHIXO7KLVSDUDPHWHUVSHFLILHVWKH= VWURNHWRSHUIRUPWKHVRIWODQGLQJDQGLVW\SLFDOO\VHWWRPP:KHQ´µ LVHQWHUHGWKHVRIWODQGLQJLVQRWSHUIRUPHG K) CngTimer/Speed 7KHYDOXHLQWKH´;µFROXPQLVWKHWLPHGXUDWLRQIRUZKLFKDKHDGVWD\VDW WKHORZHUHQGSRVLWLRQZKHQFKDQJLQJDQR]]OH8QLWVDUHPLOOLVHFRQGV$ W\SLFDOVHWWLQJLVDURXQGPVHF,IDQR]]OHFKDQJHLVXQVXFFHVVIXOWU\ HQWHULQJDVOLJKWO\ODUJHUYDOXH$YDOXHRIDVORQJDVRQHVHFRQGPVHF FDQEHVHW 7KHYDOXHLQWKH´<µFROXPQLVWKHUHODWLYHDVFHQWDQGGHVFHQWVSHHGIRUWKH KHDGGXULQJQR]]OHFKDQJH7KLVLVQRUPDOO\VHWWR,IDQR]]OHFKDQJHLV XQVXFFHVVIXOWU\GHFUHDVLQJWKLVYDOXHVOLJKWO\ L) Retry limit 7KLVLVWKHPD[LPXPQXPEHURIUHWULHVWKDWWKHPRXQWHULVDOORZHGWRUHWU\ SLFNLQJRUUHFRJQL]LQJDIWHUZKHQDQHUURURFFXUV7KLVSDUDPHWHUFDQEHDQ\ YDOXHIURPWR8VHWKHVSDFHLQVHUWDQGGHOHWHNH\·VWRFKDQJHWKH VHWWLQJ:KHQ\RXGRQRWZDQWWRDOORZUHWULHVVHWWKLVSDUDPHWHUWR12 5(75<7KHQXPEHURIUHWULHVFDQDOVREHVSHFLILHGIRUHDFKFRPSRQHQWWR EHPRXQWHG,QWKHVHFDVHVWKHUHWU\LVSHUIRUPHGDQXPEHURIWLPHVXSWRD PLQLPXPVHWWLQJ M) Dump point 7KLVSDUDPHWHUGHVFULEHVZKHUHDFRPSRQHQWWKDWIDLOHGWKHUHFRJQLWLRQ VKRXOGEHGXPSHG N) Moving height 7KLV SDUDPHWHU LV LQYDOLG LQ WKH 7RSD] VXUIDFH PRXQWHU DQG VKRXOG EH VHW WR ´µ 7-8 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems 7.2.3. Pickup and Mount Vacuum Levels 3UH&RQGLWLRQV 1RQH 7KHYDFXXPSUHVVXUHWRSLFNXSDFRPSRQHQWLVDQDORJXHGHWHFWHGDQGGLJLWDOO\ UHSUHVHQWHGE\DVFDOHRIWR7KHFXUUHQWOHYHOVDUHVKRZQLQWKHIROORZLQJ VFUHHQ 0&+B'$7$!$ 6(/(&7 7$5*(7! ´9DFXXP OHYHOµ DQG SUHVV(QWHU6HHILJXUH Editing Head No. Head 1 Head 2 Head 3 Head 4 Head 5 Head 6 Head 7 Head 8 Object Low level 141 137 10 10 10 10 10 10 Vacuum Level High level 160 162 150 150 150 150 150 150 Figure 7-4 Current vacuum levels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ick level adjustment: :KHQDQR]]OHGHVFHQGVDQGSLFNVDFRPSRQHQWQRDLULVDOORZHGWRHQWHUWKH QR]]OH VR WKH YDFXXP VHQVRU GHWHFWV DQ LQFUHDVHG YDFXXP :KHQ WKLV OHYHO EHFRPHVKLJKHUWKDQWKHSUHVHWSLFNXSYDFXXPOHYHOWKHPDFKLQHDVVXPHVWKH QR]]OHKDVSLFNHGXSDFRPSRQHQW 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 9 Component Transport Systems 7KH SLFNXS YDFXXP OHYHO VKRXOG EH SUHVHW IRU HDFK KHDG IRU D OHYHO WKDW LV VOLJKWO\KLJKHURIIVHWLVWKDQWKHPLQLPXPYDFXXPOHYHOPDLQWDLQHGZKHQ WKHQR]]OHLVRSHQQRFRPSRQHQWDWWKHQR]]OH 3UHVVWKHHPHUJHQF\EXWWRQDQGDWWDFKQR]]OHWRDOOKHDGV &DQFHOWKHHPHUJHQF\VWRSDQGSUHVVWKHUHDG\EXWWRQ ([HFXWH WKH YDFXXP OHYHO XWLOLW\ E\ VHOHFWLQJ PHQX 0$,17(0 0&+B$'-867%$'-8677$5*(7DQGVHOHFW 9DFXXP/HYHO 6HH ILJXUH 7RDGMXVWWKHPDFKLQHORZOHYHOVHOHFWWKH´$//µDQG´3LFNµIURPWKH PHQX7KH $OO FKRLFHZLOODOORZWKHDGMXVWPHQWRIDOOKHDGVDWWKHVDPH WLPH7KH .H\,Q RSWLRQZLOOSURPSWWKHXVHUWRVHOHFWDQ\RIWKHHLJKW KHDGV 5)$IWHUWKHDERYHFKRLFHVKDYHEHHQPDGH9,26SURPSWVWKHXVHUWRLQSXWD YDFXXPRIIVHW7KLVLVWRFUHDWHDVDIHZRUNLQJUDQJH*HQHUDOO\DQ RIIVHW RI LV D FRUUHFW YDOXH +RZHYHU ZKHQ XVLQJ QR]]OH VPDOO FRPSRQHQWV FKDQJLQJ WKH RIIVHW IURP WR ZLOO LQFUHDVH WKH YDFXXXP UDQJH 7KLV ZLOO DOORZ D EHWWHU GLVWLQFWLRQ EHWZHHQ DQ RSHQ DQG D FORVHG QR]]OH(QWHUWKLVYDOXHDQGSUHVV <ENTER>. See figure 7-5 3UHVVHQWHUWRVWDUWWKHPHDVXUHPHQWWKHSLFNXSYDFXXPOHYHOLVPHDVXUHG IRUWRVHFRQGVWKHQWKHUHVXOWVDUHGLVSOD\HG 7KHSLFNXSOHYHOZLOOEHPHDVXUHGIRUWRVHFRQGV$IWHUWKDWWKH UHVXOWVZLOOEHGLVSOD\HG6HHDOVRILJXUH7-5. 6HOHFW%6DYH'$7$!RU%VDYHTXLW!DQGSUHVVHQWHU <<<APPLICATION>>>1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH-ADJUST 4/MANUAL 0/EXIT <COMMAND_LIST> A/CHANGE-CONDTION B/SAVE & QUIT C/DISPLAY & EXIT B1 ADJUST TARTET Object Vacuum Level Head ALL Key in Target Pick Mount <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT A441 Please input the offset value of the vacuum level. Picking level used is higher than open level by offset. Mounting vacuum level is • • • Offset 5 A443 It will measure the vacuum level when picking. This adjustment requires a nozzle or no nozzle on the head with no component attached. Press the EMG • • • A444 <<Measuring!!>> New it is measuring vacuum level. It takes 20 sec. • • • A445 <<Result>> The following data is the result of the adjustment of the vacuum level when picking and mounting. • • • 1 Level XXX Max. XXX Current XXX Result XXX Figure 7-5 7 - 10 2 XXX XXX XXX XXX 3 0 0 0 0 4 0 0 0 0 5 0 0 0 0 6 0 0 0 0 7 0 0 0 0 8 0 0 0 0 Vacuum results Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems B) Mount level adjustment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´$//µDQG´PRXQWµ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bject Vacuum Level Head ALL Key in Target Pick Mount <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH-ADJUST 4/MANUAL 0/EXIT A441 Please input the offset value of the vacuum level. Picking vacuum level is higher than open level by offset. Mounting vacuum level is • • • A442 It will measure the vacuum level when mounting. This adjustment requires a nozzle and a component • • • A444 <<Measuring!!>> New it is measuring vacuum level. It takes 20 sec. • • • A445 <<Result>> The following data is the result of the adjustment of the vacuum level when picking and mounting. • • • 1 Level XXX Min. XXX Current XXX Result XXX 5322 871 63606 01.05 2 XXX XXX XXX XXX 3 0 0 0 0 Service Manual Topaz PA 1309/10 4 0 0 0 0 5 0 0 0 0 6 0 0 0 0 7 0 0 0 0 8 0 0 0 0 7- 11 Component Transport Systems Figure 7-6 7.2.4. Vacuum results R-axis Absolute Accuracy Offset 7KLVLVWKHDQJXODURIIVHWIRUWKH5D[LVWKDWURWDWHVHDFKQR]]OHVKDIWWRPRXQW WKHFRPSRQHQW:KHQ\RXVHOHFW$VHOHFWWDUJHW!´5D[LVDFFXUDF\µ (QWHUWKHFXUUHQWRIIVHWVHWWLQJVIRUWKHPRXQWLQJDQJOHVDQG² DUHGLVSOD\HGDVVKRZQEHORZ <<<APPLICAITON>>> <<MODE>> 2/MCH_DATA 3/MAINTE/M Editing Head No. Head 1 Head 2 Head 3 Head 4 Head 5 Head 6 Head 7 Head 8 Object 0deg. 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 180deg. 90deg. 0.07 0.00 0.20 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 R Axis Accuracy -90deg. 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Figure 7-7 Note These off-sets are automatically corrected when you execute the mount feedback (Vision). Since the position at “0-degree” is used as a reference, it is always set to “0.00” 7RGHWHUPLQHWKHVHRIIVHWVXVHWKH5D[LVDFFXUDF\URXWLQHLQWKHPDLQWHQDQFH PDQDJHU7KHPDFKLQHDXWRPDWLFDOO\HYDOXDWHVWKHVHRIIVHWVHWWLQJVE\ UHFRJQL]LQJWKHFRPSRQHQWWKDWDKHDGSLFNVXSZKLOHURWDWLQJWKHQR]]OH VKDIWDWWKHIRXUDQJOHV 7ZRVLWXDWLRQVFDQEHGLVWLQJXLVKHG 7 - 12 - 7RSD]ZLWKRQO\WKHPXOWLFDPHUDLQVWDOOHG :KHQWKHPXOWLFDPHUDZLWKWKHUHIHUHQFHPRXQWLQJDQJOHVSHFLILHGDW GHJUHHVLVXVHGPRXQWLQJVDWDQG²PLJKWGHYLDWHVOLJKWO\ 7KLVGHYLDWLRQRURIIVHWFDQEHFRUUHFWHGZLWKWKH5D[LVDFFXUDF\ FRPPDQGLQZKLFKWKHPXOWLFDPHUDUHFRJQL]HVD4)3FRPSRQHQWDW WKHIRXUPRXQWLQJDQJOHVWRGHWHUPLQHWKHRIIVHWZLWKUHVSHFWWRWKH UHFRJQLWLRQUHVXOWDWGHJUHHV6LQFHWKHGHJUHHSDUDPHWHULVXVHGDVD UHIHUHQFHLWLVVHWWRGHJUHHV - 7RSD]ZLWKDQRSWLRQDOVLQJOHFDPHUDLQVWDOOHG :KHQDVLQJOHFDPHUDZLWKWKHUHIHUHQFHPRXQWLQJDQJOHVSHFLILHGDW GHJUHHVLVXVHGPRXQWLQJVDWDQG²PLJKWGHYLDWHVOLJKWO\7KLV GHYLDWLRQRURIIVHWFDQEHFRUUHFWHGZLWKWKH5D[LVDFFXUDF\FRPPDQG LQZKLFKWKHPXOWLFDPHUDUHFRJQL]HVD4)3FRPSRQHQWDWWKHIRXU PRXQWLQJDQJOHVWRGHWHUPLQHWKHRIIVHWZLWKUHVSHFWWRWKHUHFRJQLWLRQ UHVXOWDWGHJUHHV6LQFHWKHGHJUHHSDUDPHWHULVXVHGDVDUHIHUHQFH LWLVVHWWRGHJUHHV Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems Note The R-table will always show the 90 degree as a reference, so the value in this table is always 0.00. In case the multi-camera is used as a reference internally a calculation is carried out to get the correction for the other angles 90, -90 and 180 degrees. Preparing the component and nozzle 3UHSDUHD4)3FRPSRQHQWWREHXVHGDVDUHIHUHQFH3UHIHUDEO\DODUJHSRSXODU 4)3RINQRZQVL]HZKLFKLVUHJLVWHUHGLQWKHFRPSRQHQWGDWDEDVH ([DPSOHLV4)33/3UHVVWKHHPHUJHQF\EXWWRQDQGDWWDFKD4)3 QR]]OHW\SHWRHDFKKHDG Calibrating the R-axis accuracy )ROORZWKHSURFHGXUHEHORZ - &DQFHOWKHHPHUJHQF\VWRSDQGVHOHFW%DGMXVWWDUJHW!´5D[LVDFFXUDF\µ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ozzle Correction 7KLVSDUDPHWHULVXVHGWRFRUUHFWDQRIIFHQWHUQR]]OHVKDIWZKHQLWURWDWHVE\ GHJUHHV:KHQ\RXVHOHFW0&+B'$7$!!$0&+B'$7$! ^$6(/(&77$5*(7`µ1R]]OH&RUUHFWLRQµDQGSUHVVWKH>(17(5@ NH\WKHFXUUHQWVHWWLQJIRUWKLVRIIVHWLVGLVSOD\HG <<<APPLICATION>>> <<MODE>> 2/MCH_DATA Editing Head No. Atbl Head 1 Atbl Head 2 Atbl Head 3 Atbl Head 4 3/MAINTE/M Object X -0.03 0.00 0.00 0.00 NozzleCorrection Y 0.03 0.00 0.00 0.00 Figure 7-8 Note This offset is automatically corrected when you execute mount feedback (Vision). 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 13 Component Transport Systems 7.2.6. Head Offset 7KLVLVWKHSRVLWLRQRI+HDGVUHODWHGWR+HDG:KHQ\RXVHOHFW 0&+B'$7$!!!$0&+B'$7$!!^$6(/(&77$5*(7` !µ+HDG2IIVHWµDQGSUHVVWKH>(17(5@NH\WKHFXUUHQWVHWWLQJIRUWKLV RIIVHWLVGLVSOD\HG <<<APPLICATION>>> <<MODE>> 2/MCH_DATA 3/MAINTE/M Editing Object Head No. Head 1 Head 2 HeadType AutoNzlChg. AutoNzlChg. Head 7 Head 8 None None X 0.00 25.00 Y 0.00 12.00 Z 0.00 0.95 nozzle TYPE-31 TYPE-32 0.00 0.00 0.00 0.00 0.00 0.00 TYPE-31 TYPE-31 Head Offset Figure 7-9 Note This offset is automatically corrected when you execute mount feedback. Since the position of Head 1 is used as a reference, this is always set to “0.00”. 7 - 14 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems 7.3. Nozzle Station 7.3.1. Nozzle Station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igure 7-10 5322 871 63606 01.05 Nozzle station, positions and sensors Service Manual Topaz PA 1309/10 7- 15 Component Transport Systems 7.3.2. Adjusting the Nozzle Sensor Sensitivity (DFKQR]]OHKROGHULQWKHQR]]OHVWDWLRQKDVDVHQVRUWKDWGHWHFWVWKHSUHVHQFH RIWKHQR]]OHDOORZLQJWKHPDFKLQHWRLGHQWLI\ZKLFKW\SHRIQR]]OHLV FXUUHQWO\DWWDFKHGWRHDFKKHDG7KHQR]]OHVHQVRULVVHSDUDWHGIURPLWV DPSOLILHUXQLWZKLFKLVLQVWDOOHGLQVLGHWKHPDFKLQHMXVWEHKLQGWKHOHIWVLGH RIWKHIURQWIHHGHUSODWH6LQFHDJDLQFRQWUROLVSURYLGHGRQWKHDPSOLILHUWKH QR]]OHVHQVRUVHQVLWLYLW\FDQEHFKHFNHGDQGDGMXVWHGLIQHFHVVDU\DVGHVFULEHG EHORZ Figure 7-11 Nozzle sensor amplifier 2SHQWKHRXWSXWPRQLWRUDQGUHOHDVHWKHQR]]OHFODPSSODWH 6HOHFW0$,17(0!!!0$18$/!!&',63/$<(;,7! ^&287387021,725`DQGSUHVVWKH>(17(5@NH\ /LQHXSWKHFXUVRUZLWK´73µ)521712==/(67$7,21 &/$03 3UHVVWKH>(17(5@NH\WRRSHQWKHFODPSSODWH 7KHRXWSXWPRQLWRUGLJLWUHDGV´µZKHQWKHFODPSSODWHLVFXUUHQWO\ FORVHGDQGUHDGV´µZKHQLWLVRSHQHG Out Monitor [↑↓←→] : Select [Enter] : Exec Selected Arm : MAIN [ESC] : Command Lists Moving Speed : 100 XY TP02 FRONT NOZZLE STATION CLAMP 0 / OPEN 1 1 / NP14= 0) NAME OUT Nzl Clamp/Spare TP01-08 Figure 7-12 7 - 16 CLAMP (NP14= NAME IN Nzl Clamp/Spare NP09-16 01000000 00000100 Nozzle clamp in output monitor Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGLQVHUWDQR]]OHLQWRWKHQR]]OHKROGHU \RXZDQWWRFKHFN 2SHQWKHLQSXWPRQLWRUDQGVHOHFWWKHFRUUHFWQR]]OHVHQVRU 3UHVVWKH>7$%@NH\WRPRYHWKHFXUVRULQWRWKHLQSXWPRQLWRUZLQGRZ /LQHXSWKHFXUVRUZLWKWKHGLJLWIRUWKHFRUUHVSRQGLQJVHQVRUIURP DPRQJ ´11µWR´11µVHHILJXUH In Monitor [↑↓←→] : Select [Enter] : Exec Selected Arm : MAIN [ESC] : Command Lists Moving Speed : 100 XY NN06 NOZZLE 6 SENSOR NAME Figure 7-13 OUT NAME IN Nozzle Sensor NN01-08 00000100 Nozzle Sensor NN09-16 00000000 Nozzle sensors in input monitor 7RPDWFKWKHQR]]OHKROGHU1RRUQR]]OHVWDWLRQ1RDQGWKHVHQVRU LQSXWGLVSOD\FRGHVHHILJXUH &KHFNWKHLQSXWVWDWXVRIWKHVHOHFWHGVHQVRU 7KHGLJLWUHDGV´µZKHQWKHQR]]OHLVVWRUHGLQWKHKROGHUEXWUHDGV´µ ZKHQLWLVQRW,IWKHGLJLWUHDGV´µWKHDPSOLILHUJDLQIRUWKHQR]]OH VHQVRULVWRRORZ*UDGXDOO\WXUQWKHJDLQFRQWURORIWKHDPSOLILHU FORFNZLVHXQWLOWKHGLJLWUHDGV´µ 7DNHWKHQR]]OHRXWRIWKHKROGHUDQGFKHFNWKHLQSXWVWDWXV &KHFNLIWKHGLJLWKDVFKDQJHGWR´µ,IQRWWKHDPSOLILHUJDLQLVVHWWRR KLJK7XUQEDFNWKHJDLQFRQWURORIWKHDPSOLILHUVOLJKWO\WRWKHOHIWVRWKDW WKHGLJLWUHDGV´µ Caution Do not change the amplifier’s MODE selector setting. With this setting, the red and green LED’s of the amplifier are both lit when the nozzle is in the holder, and only the green LED is lit when not in the holder. If this detection still occurs even after you have adjusted the amplifier gain, the position of the nozzle sensor is probably incorrect. Loosen the set screw located on the bottom of the nozzle station and make adjustment to the sensor position. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 17 Component Transport Systems 7.3.3. Adjusting the Nozzle Clamp Plate Position 7KHQR]]OHFODPSSODWHLVORFDWHGRQWKHWRSVXUIDFHRIWKHQR]]OHVWDWLRQ,W RSHQVWRDOORZDKHDGWRH[WUDFWDQR]]OHIURPWKHQR]]OHVWDWLRQRUFORVHVWR ORFNDQR]]OHLQSODFHDQGH[WUDFWLWIURPWKHKHDG 7KHQR]]OHFODPSSODWHRSHQVDQGFORVHVE\PHDQVRIDQDLUF\OLQGHUZKLOHWKH SRVLWLRQRIWKHSODWHDLUF\OLQGHULVGHWHFWHGE\DVHQVRU,IWKHSRVLWLRQLV QRWFRUUHFWWURXEOHPD\RFFXUGXULQJWKHQR]]OHFKDQJH,IQHVVHFDU\DGMXVW WKHFODPSSODWHDVIROORZV - - 2SHQWKHFODPSSODWHE\DFWLYDWLQJ73)URQWQR]]OHVWDWLRQFODPSLQ WKHRXWSXWPRQLWRU$´µPHDQVWKHFODPSLVRSHQ 3UHVVWKHHPHUJHQF\EXWWRQDQGORRVHQWKHFODPSSODWHEROWVVHHILJXUH $GMXVWWKHSRVLWLRQRIWKHFODPSE\XVLQJWKHSOD\RIWKHPRXQWLQJKROHV 7KHSRVLWLRQLVFRUUHFWZKHQWKHDSHUWXUHRIHDFKQR]]OHVWDWLRQLVH[DFWO\ DOLJQHGZLWKWKHKROHVLQWKHFODPSSODWH 7LJKWHQWKHEROWVLQWKHFODPSSODWH &KHFNWKHVWDWXVRIWKHFODPSSODWHVHQVRUVDVLQIROORZLQJWDEOH Output TP02 = 0 (clamp) TP02 = 1 (open) 7.3.4. Input NP13 = 0 NP14 = 1 NP13 = 1 NP14 = 0 Adjusting the Nozzle Station Coordinates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´73µ)521712==/(67$7,21&/$03 3UHVVWKH>(17(5@NH\WRRSHQWKHFODPSSODWH 7KHRXWSXWPRQLWRUGLJLWUHDGV´µZKHQWKHSODWHLVRSHQHGDQGUHDGV ´µZKHQLWLVFORVHG 7 - 18 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems Out Monitor [↑↓←→] : Select [Enter] : Exec Selected Arm : MAIN [ESC] : Command Lists Moving Speed : 100 XY TP02 FRONT NOZZLE STATION CLAMP CLAMP 0 / OPEN 1 (NP14= 1 / NP14= 0) NAME OUT Nzl Clamp/Spare TP01-08 NAME IN Nzl Clamp/Spare NP09-16 01000000 00000100 Figure 7-14 6HOHFWWKHD[LVWRGLVSOD\WKHFRRUGLQDWHVRQWKHPRQLWRU 3UHVVWKH>6(/$;,6@NH\RIWKH++.WRVHOHFWWKHD[LV´0$,1;<µ 5DLVHWKHQR]]OHVWDWLRQLQWKHPDQXDOVFUHHQ 3UHVVWKHHPHUJHQF\VWRSEXWWRQ $WWDFKD7\SHQR]]OHWR+HDGE\KDQG 7\SHQR]]OHLVXVHGRQO\IRU+HDG 0RYHWKHKHDGDVVHPEO\E\KDQGWRRYHUWKHQR]]OHVWDWLRQ 0RYHWKHKHDGDVVHPEO\VRWKDWWKHQR]]OHWLSLVSRVLWLRQHGGLUHFWO\DERYH 1R]]OH6WDWLRQ Caution When moving the head assembly, do not push on the camera or head shaft. The settings for the coordinates may become unreliable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eference Turning the coupling assembly located between the motor and the ball screw allows for easy minute movement of the X-axis and Y-axis. For the vertical movement of the Z-axis, it is advisable to gently press the metallic plate (lower limit detection dog) downwards or pull upwards attached to the nozzle shaft. &KHFNWKH;<=DQG5FRRUGLQDWHV0DNHDQRWHRIWKHUHDGLQJV GLVSOD\HGRQWKHERWWRPRIWKHRXWSXWPRQLWRUVFUHHQ 2SHQWKHQR]]OHVWDWLRQFRRUGLQDWHVVFUHHQ 6HOHFW$^$6(/(&77$5*(7`µ1R]]OH6WDWLRQµDQGSUHVV WKH>(17(5@NH\ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 19 Component Transport Systems (QWHUWKH;<=DQG5FRRUGLQDWHV (QWHUWKH;<=DQG5 FRRUGLQDWHV\RXPDGHDQRWHRILQ6WHSDORQJWKH´1]O6WDWLRQµURZ Editing Object Nozzle Station Nzl.Station No. Nzl. Station 1 Nzl. Station 2 Nzl. Station 3 Nzl. Station 4 Nzl. Station 5 Nzl. Station 6 Nzl. Station 7 X 13.78 20.13 -29.50 19.44 -29.50 6.75 -43.50 Y 57.33 32.33 19.00 5.72 -6.00 39.40 34.00 Z 74.62 74.54 69.0 74.63 69.00 76.64 69.00 R -59.44 -57.95 -57.21 -59.71 -57.21 -57.97 -18.36 Nzl.Type TYPE-34 TYPE-3F TYPE-33 TYPE-3F TYPE-3F TYPE-3F TYPE-3F HeadNo. Head1 Head1 Head1 Head1 Head1 Head2 Head2 Nzl. Station 14 Nzl. Station 15 Nzl. Station 16 31.21 31.16 -43.50 23.41 11.07 -6.00 72.08 71.99 69.00 -18.39 -18.51 -18.36 TYPE-31 TYPE-31 TYPE-32 Head2 Head1 Head1 Figure 7-15 Nozzle station coordinates screen 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^$6$9(48,7`RU^$6$9(`DQG SUHVVWKH>(17(5@NH\ 7RTXLWZLWKRXWVDYLQJVHOHFW^$$%25748,7`DQGSUHVVWKH >(17(5@NH\ &DQFHOHPHUJHQF\VWRS(QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRS EXWWRQDQGSUHVVWKH>5($'<@EXWWRQRIWKH++. &KHFNWKDWWKHQR]]OHFDQEHH[FKDQJHGVPRRWKO\ 7RFKHFNXVHWKH^$&+$1*(12==/(`FRPPDQGLQWKH0DFKLQH $GMXVWPRGH Note When you need to adjust other nozzle stations, use the same procedure described above. Be careful to use the correct head specified for each nozzle station The list of nozzle location and type can be found in figure 7-15. 7.3.5. Nozzle Station Maintenance &KHFNDWDUHJXODULQWHUYDOTXDUWHUO\WKHIROORZLQJIXQFWLRQVRIWKHQR]]OH VWDWLRQ í í í 7 - 20 &KHFNLIWKHQR]]OHVDUHJRLQJVPRRWKO\LQDQGRXWRIWKHQR]]OHKROGHU )RUDUHDGMXVWPHQWVHHWKHSUHYLRXVSDUDJUDSKVRIWKLVFKDSWHU &KHFNLIWKHVHQVLQJRIWKHQR]]OHLVGRQHLQDSURSHUZD\8VHWKH DGMXVWPHQWGHVFULEHGLQWKHSUHYLRXVSDUDJUDSKVWRFRUUHFWWKLV &KHFNIRUZHDUDQGGHEULVLQDQGDURXQGWKHQR]]OHVWDWLRQ&OHDQWKH VWDWLRQDQGDSSO\DOLWWOHJUHDVHRQWKHPRYLQJVXUIDFHVRIWKHFODPS SODWH Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems 7.4. Feeder Plates 7KLVVHFWLRQGHVFULEHVKRZWRDGMXVWWKHSRVLWLRQRIWKHIHHGHUSODWHVDQGWKHLU PDFKLQHGDWDLQRUGHUWKDWHDFKKHDGSURSHUO\SLFNVXSDFRPSRQHQW$OVR H[SODLQHGDUHDGMXVWPHQWVWRIHHGSLWFKRIWDSHIHHGHUV&RUUHFWDGMXVWPHQWRI WKHIHHGHUSODWHVLVHVVHQWLDOWRWKHSURSHUZRUNLQJRIWKHV\VWHP,PSURSHU DGMXVWPHQWZLOOUHGXFHWKHFRPSRQHQWSLFNXSUDWHRIHDFKKHDG7KHVHFRQG SDUWRIWKLVFKDSWHUH[SODLQVKRZWRDGMXVWWKHIHHGSLWFKDQGVSHHGRIWKHWDSH IHHGHUV 7.4.1. Feeder Plate Parallel Adjustment 7KHIHHGHUSODWHLVVHFXUHGWRWKHIHHGHUEDVHRIWKHPDLQXQLWE\EROWV8QGHU QRUPDOZRUNLQJFRQGLWLRQVWKHIHHGHUSODWHZLOOQRWUHTXLUHSDUDOOHO DGMXVWPHQW+RZHYHULI\RXQHHGWRUHPRXQWWKHIHHGHUSODWHIRUVRPH UHDVRQVILUVWPDNHWKHSDUDOOHODGMXVWPHQWDVIROORZV)LQHDGMXVWPHQWVWR IHHGHUSRVLWLRQVZLOOEHSHUIRUPHGLQWKHQH[WVHFWLRQ7HDFKLQJWKH IHHGHUEORFNSRVLWLRQV0RXQWWZRIHHGHUEDUDGMXVWPHQWEORFNVRQWKH IHHGHUEDUDWWKHHQGDQGEHJLQQLQJ Figure 7-16 Feeder plates (top view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ervice Manual Topaz PA 1309/10 7- 21 Component Transport Systems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eeder Block Positions 2QHDFKRIWKHWZRIHHGHUSODWHVIHHGHUVHWSRVLWLRQVSLFNXSSRVLWLRQV DUHSURYLGHG7KHVHSLFNXSSRVLWLRQVDUHGLYLGHGLQWRVHYHQIHHGHUEORFNVSHU SODWHDVVKRZQEHORZ(DFKIHHGHUEORFNLVFRPSULVHGRIHLJKWIHHGHU SRVLWLRQVH[FHSWWKHULJKWPRVWIHHGHUEORFN3)3)RQHDFKSODWHZKLFK FRQVLVWVRIWZRIHHGHUSRVLWLRQV7KHILUVWIHHGHUVHWSRVLWLRQRIHDFKIHHGHU EORFNLVVSHFLILHGDVDUHIHUHQFHSRVLWLRQ7KHUHIRUHIHHGHUVHWSRVLWLRQVRI 1RDQGRQWKHIURQWSODWHDQG1R DQGRQWKHUHDUSODWHDUHXVHGDVUHIHUHQFHSRVLWLRQV Figure 7-17 7 - 22 Feeder block arrangement Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems CAUTION Due to the configuration design of the Topaz head assembly, the feeder set positions that can be actually accessed by each head are limited to No. 1 to 47 on the front side and No. 104 to 150 on the rear side (94 positions in total). Accordingly, to teach the reference position No. 101, use No. 104 instead and add 48.00mm to the X coordinate determined. (One pitch of the feeder set positions equals to 16.00mm.) The Y coordinate will be the same as feeder position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`)HHGHU3ODWH2IIVHWDQGSUHVV WKH>(17(5@NH\ <<<APPLICATION>>>1/OPERATION/M 2/DATA/M 3/MAINTE/M <<MODE>> 1/MCH-CONFIG 2/MCH_DATA <COMMAND_LIST> A/MCH_DATA A1 SELECT TARGET Object FeederPlateOffset <<<APPLICATION>>>1/OPERATION/M 2/DATA/M 3/MAINTE/M <<MODE>> 1/MCH-CONFIG 2/MCH_DATA Editing Plate No. FeederPlate FeederPlate FeederPlate FeederPlate FeederPlate Object 1 2 3 4 5 X 51.50 179.50 307.50 435.50 563.50 Figure 7-18 FeederPlateOffset Y 3.53 3.51 3.35 3.51 3.53 Feeder plate offset editing screen /LQHXSWKHFXUVRUZLWKWKH;FROXPQRIWKHIHHGHUEORFN\RXDUH WHDFKLQJ 3UHVVWKH>)@NH\7KHPHQXZLQGRZIRUVHOHFWLQJWHDFKLQJFRQGLWLRQV WKHQDSSHDUV 6HWWHDFKLQJFRQGLWLRQV 6HOHFWWKHWHDFKLQJXQLWDQGSUHVVWKH>(17(5@NH\ 7KHKHDG1R\RXDUHXVLQJIRUWHDFKLQJPXVWEHVHOHFWHG 6HOHFWDQ\VSHHGIURP6SHHGWR6SHHGDQGSUHVV>(17(5@ 3UHVVWKH>)@NH\WZLFHWRSHUIRUPWHDFKLQJ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 23 Component Transport Systems 7KH;FRRUGLQDWHYDOXHRIWKHUHIHUHQFHIHHGHUSRVLWLRQLVHQWHUHG 7KHQOLQHXSWKHFXUVRUZLWKWKH<FROXPQ 3UHVVWKH>)@NH\WZLFHWRSHUIRUPWHDFKLQJ 7KH<FRRUGLQDWHYDOXHRIWKHUHIHUHQFHIHHGHUSRVLWLRQLVHQWHUHG 5HSHDWWKHSURFHVVIRURWKHUUHIHUHQFHIHHGHUSRVLWLRQV8VHWKHDERYH VWHSVLQVWDOOLQJWKHVDPHWDSHIHHGHULQHDFKUHIHUHQFHIHHGHUSRVLWLRQ 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^$6$9(48,7`RU^$6$9(`DQG SUHVVWKH>(17(5@NH\7RTXLWZLWKRXWVDYLQJVHOHFW ^$$%257(;,7`DQGSUHVVWKH>(17(5@NH\ 3HUIRUPWKHFRPSRQHQWSLFNXSWHVWWRFKHFNWKHVHWWLQJV7KLVWHVW VKRXOGEHSHUIRUPHGIRUDOOUHIHUHQFHIHHGHUSRVLWLRQV5HIHUWRWKHQH[W VHFWLRQ&RPSRQHQWSLFNXSWHVW,IDQ\RIIVHWLVIRXQGFRUUHFWLW RQWKHIHHGHUSODWHRIIVHWVFUHHQ 7.4.3. Component Pickup Test 7RFKHFNFRPSRQHQWSLFNXSSRVLWLRQRUSLFNXSIXQFWLRQ\RXFDQXVHWKH FRPSRQHQWSLFNXSWHVWFRPPDQG,QVWDOOLQDGYDQFHDWDSHIHHGHULQWKH IHHGHUVHWSRVLWLRQZKHUH\RXZDQWWRSHUIRUPWKHFRPSRQHQWSLFNXSWHVW,W·V UHFRPPHQGHGWRSHUIRUPWKHWHVWZLWKWKHVPDOOHVWDYDLODEOHFRPSRQHQW 5HIHUDOVRWRILJXUHVDQG ([HFXWHWKHFRPSRQHQWSLFNXSWHVW 6HOHFW$^$3,&.&20321(17`DQGSUHVVWKH>(17(5@NH\ (QWHUWKHGDWDEDVH1RRIWKHFRPSRQHQWDQGSUHVV>(17(5@ (QWHUWKHKHDG1RDQGSUHVVWKH>(17(5@NH\6SHFLI\WKHKHDG1R IRUZKLFK\RXZDQWWRSHUIRUPWKHFRPSRQHQWSLFNXSWHVW (QWHUWKHIHHGHUVHW1RDQGSUHVVWKH>(17(5@NH\6SHFLI\WKHIHHGHU VHW1RDWZKLFK\RXKDYHLQVWDOOHGWKHWDSHIHHGHULQ6WHS (QVXUHVDIHW\WKHQSUHVVWKH>(17(5@NH\DJDLQ 7KHKHDGDVVHPEO\VWDUWVWRPRYHDQGWKHVSHFLILHGKHDGSLFNVXSD FRPSRQHQWIURPWKHIHHGHU &KHFNWKHFRPSRQHQWSLFNXSSRVLWLRQ /RRNDWWKHSRVLWLRQRIWKHQR]]OHWLSUHODWLYHWRWKHFRPSRQHQW ,IDQ\RIIVHWLVIRXQGLQWKH;DQG<GLUHFWLRQVHQWHUWKHRIIVHWRQWKH IHHGHUSODWHRIIVHWHGLWLQJVFUHHQDVH[SODLQHGLQWKHSUHYLRXVVHFWLRQ WHDFKLQJWKHUHIHUHQFHIHHGHUEORFNSRVLWLRQV 'XPSWKHFRPSRQHQW 6HOHFW^$'803&20321(17`DQGSUHVVWKH>(17(5@NH\ (QVXUHVDIHW\WKHQSUHVVWKH>(17(5@NH\ 7KHKHDGPRYHVWRWKHGLVFDUGSRLQWDQGGXPSVWKHFRPSRQHQW DXWRPDWLFDOO\ 7 - 24 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems <<<APPLICATION>>>1/OPERATION/M 2/DATA/M 3/MAINTE/M <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH_ADJUST <COMMAND_LIST> A/UTILITY A3 PICK COMPONENT <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH_ADJUST A461 Please input the data base number which has already prepared. After input, please press the [ENTER] key. Database No. 1 A463 It will pick one component. An nozzle type used by this is Type 11 Please input the head number. Head No. 1 A462 As a Tape feeder is specified by this component, the machine can pick component automatically. Please type feeder position number. Feeder Set No. 1 A303 CAUTION!! The axes will move. After confirming safety, please press the [ENTER] key. A394 <<<Picking!!>>> Now it is picking up the specified component automatically. To pause, press [ESC] key. Figure 7-19 Component pickup Figure 7-20 Offset of the nozzle and center position of the component Note In both the X and Y directions, if the nozzle tip is shifted to the machine origin side with respect to the center of the component, then this is a plus offset. If shifted in the opposite side, this is a minus offset. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 25 Component Transport Systems 7.4.4. Feeder Plate Maintenance &KHFNRQDZHHNO\EDVLVWKHZHDURIWKHIHHGHUSODWH5HSODFHWKHDLUMRLQWLI ZHDULVQRWLFHGRULIDLUOHDNDJHLVQRWLFHG$OVRDPDOIXQFWLRQIHHGHUFDQEH FDXVHGE\DEDGDLUVXSSO\RUEDGFRXSOLQJ&OHDQWKHLQQHUSDUWRIWKHDLU FRXSOLQJDQGDSSO\OLWWOHJUHDVHRQWKHLQQHUSDFNLQJRIWKHDLUMRLQW &KHFNWKHIHHGHUDOLJQPHQWHYHU\WKUHHPRQWKV3URFHHGZLWKWKHGHVFULSWLRQ JLYHQLQWKHSUHYLRXVSDUDJUDSKLIQHHGHG 7 - 26 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems 7.5. Component Feeders 7KLVVHFWLRQH[SODLQVKRZWRDGMXVWWKHIHHGSLWFKDQGVSHHGRIWDSHIHHGHUV DQGPXOWLVWLFNIHHGHUVWKDWFRQWLQXRXVO\VXSSO\FRPSRQHQWVIRUPRXQWLQJ 5HIHUWRWKH&60*(0)HHGHU0DQXDOIRUPRUH LQIRUPDWLRQDERXWWDSHIHHGHUV&EXONIHHGHUVDQGLQWHOOLJHQWWDSH IHHGHUV 7.5.1. Tape Feeders )RUVWDEOHDQGDFFXUDWHFRPSRQHQWIHHGLQJWKHIROORZLQJLWHPVPXVWEH DGMXVWHGFRUUHFWO\. Adjustment item Feed pitch Tape feeder type All feeder except 8mm and 32 mm tape feeder 16 mm, 24 mm, 32 mm and 44 mm tape feeders 8 mm and 12 mm tape feeders 32 and 44 emboss tape feeders Feeder speed Tape peeling load Lock lever position Figure 7-21 Tape feeder pitch 7KHVSDFLQJEHWZHHQFRPSRQHQWVRQWKHWDSHDOVRNQRZQDVWKHSLWFKGLIIHUV GHSHQGLQJRQW\SHRIFRPSRQHQWV7KHWDSHIHHGSLWFKRQWKHWDSHIHHGHUPXVW WKHUHIRUHEHVHWWRPDWFKWKHFRPSRQHQWSLWFK7KHWDEOHEHORZVKRZVIHHGSLWFKHV DYDLODEOHIRUHDFKW\SHRIIHHGHU Tape Feeder ( Model No. ) 4 8mm tape feeder for 1005 chip ( PL-082 ) 2, 4 12mm tape feeder ( PL-12 ) 4, 8 16mm tape feeder ( PL-16 ) 4, 8, 12, 16 24mm tape feeder ( PL-24 ) 4, 8, 12, 16 32mm tape feeder ( PL-32) 12, 16, 20, 24, 28, 32, 36 44mm tape feeder ( PL-44 ) 12, 16, 20, 24, 28, 32, 36 32mm adhensive tape feeder ( PL-N32 ) 12 Figure 7-22 5322 871 63606 01.05 Pitch ( m/m ) 8mm tape feeder ( PL-084 ) Tape feeder pitch Service Manual Topaz PA 1309/10 7- 27 Component Transport Systems 8mm (for 0402 chip) and 12mm tape feeders 7RFKDQJHWKHWDSHIHHGSLWFKVHWWLQJPRGLI\WKHSRVLWLRQRIWKHDLUF\OLQGHU RQWKHWDSHIHHGHUDVGHVFULEHGEHORZ /RRVHQWKHWZRVFUHZVIRUWKHDLUF\OLQGHU ,QVHUWWKHWZRVFUHZVLQWRWKHRWKHUSDLURIKROHV 8VHQXPEHUKROHVIRUPPSLWFKDQGQXPEHUKROHVIRUPPSLWFK FKLS 7LJKWHQWKHVFUHZVWRVHFXUHWKHDLUF\OLQGHU 7 - 28 Figure 7-23 8mm (0402 chip) tape feeder Figure 7-24 12mm tape feeder Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems 16mm, 24mm, 32mm, 44mm tape feeders /RRVHQWKHWZRVFUHZVRQWKHDLUF\OLQGHUKROGHUSODWH )LWWKHVPDOOSLQLQWRWKHGHVLUHGQRWFKLQWKHKROGHUSODWH 7KHQXPEHUVPDUNHGRQWKHKROGHUSODWHLQGLFDWHVWKHDFWXDOIHHGSLWFKHV LQPLOOLPHWHUV 7LJKWHQWKHVFUHZVWRVHFXUHWKHDLUF\OLQGHU Figure 7-25 16mm, 24mm, 32mm, 44mm tape feeders Feeder speed (for 12 LP, 16, 24, 32 and 44mm tape feeders) 7KHVSHHGDGMXVWHUOLQNHGWRWKHDLUF\OLQGHURIWKHWDSHIHHGHUDOORZV\RXWR YDU\WKHVSHHGDWZKLFKWKHFRPSRQHQWVDUHGHOLYHUHG7XUQWKHDGMXVWHUNQRE WRWKHOHIWWRLQFUHDVHWKHVSHHGDQGWXUQLWWRWKHULJKWWRUHGXFHWKHVSHHG 7KHRSWLPXPVSHHGGLIIHUVGHSHQGLQJRQWKHFRPSRQHQWDQGWDSH,IWKH VSHHGLVVHWWRRIDVWFRPSRQHQWVPD\EHVNLSSHGRUEHFRPHMDPPHGRUWKH WDSHPD\FRPHRIIWKHWDSHJXLGHVSURFNHWSUHYHQWLQJWKHFRPSRQHQWVIURP EHLQJIHGFRUUHFWO\,QVXFKFDVHVWKHVSHHGVKRXOGEHUHGXFHG Figure 7-26 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 29 Component Transport Systems Changing the tape peeling load D7DSHSHHOLQJORDGIRUPPDQGPPWDSHIHHGHUV 7KHWRSWDSDQGFDUULHUWDSRIDWDSHUHHODUHJOXHGZLWKDGKHVLYH,IWKLV DGKHVLYHLVWRRVWURQJWKHWRSWDSHPD\QRWSHHODZD\IURPWKHFDUULHUWDSHDW SURSHUWLPLQJLQSDUWLFXODUSDSHUWDSH 7RLQFUHDVHWKHWDSHSHHOLQJORDGVHWWKHVSULQJVKRZQLQWKHGUDZLQJRQWKH XSSHUVXSSRUWSLQ Figure 7-27 $GMXVWLQJ/RFNOHYHUIRUPPDQGPPHPERVVWDSHIHHGHUV ,IWKHUHLVDJDSEHWZHHQWKHWDSHJXLGHDQGWKHORFNOHYHUWKHWDSHJXLGHPD\ ZRUNORRVHDQGLQKLELWSURSHUIHHGLQJRIWKHFRPSRQHQWV7RSUHYHQWWKLV DGMXVWWKHORFNOHYHUDVIROORZV 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGDWWDFKWKHWDSHIHHGHUWRWKHIHHGHU SODWH /RRVHQWKHWZRVFUHZVVHFXULQJWKHORFNOHYHU%HFDUHIXOQRWWRUHPRYH WKHVFUHZDWWKLVSRLQW $GMXVWSODWHV$DQG%VRWKDWWKHWDSHJXLGHDQGWKHORFNOHYHUWRXFK 5HWLJKWHQWKHVFUHZV Figure 7-28 7 - 30 Adjusting the lock lever position Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems 7.5.2. Minimum Timer / Load Timer / Down Timer :KHQDKHDGPRYHVGRZQWRWKHFRPSRQHQWSLFNXSSRVLWLRQWKHIHHGHU·VDLU F\OLQGHUVKDIWLVSXVKHGRXWWRRSHQWKHVKXWWHUWKHF\OLQGHULVRQ :KHQWKHKHDGPRYHVXSWKHVKDIWUHWXUQVWKHF\OLQGHULVRIIDQGWKHQH[W FRPSRQHQWLVGHOLYHUHGWRWKHSLFNXSSRVLWLRQ,IWKLVRQRIIWLPLQJLVQRW FRUUHFWFRPSRQHQWGHOLYHU\HUURUVPD\RFFXU7RDYRLGWKLVSUREOHPWKH PLQLPXPWLPHUDQGORDGWLPHUPXVWEHDGMXVWHGFRUUHFWO\ 7RFKHFNWKHPLQLPXPWLPHUDQGORDGWLPHUVHWWLQJVVHOHFW 0$,17(0!!!0&+B&21),*!!$0&+B&21),*!^$ )(('(563(&,1)`DQGSUHVVWKH>(17(5@NH\7KHVFUHHQDSSHDUVDV VKRZQEHORZ DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M <<MODE>> 1/MCH_CONFIG 2/MCH_DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT PNEUMATIC Type FeederType LeftWidt RightWid PickPos Min.Time LoadTime DownTime 8mmTape 7.80 8.00 0.00 0 0 0 8mm1005cmp 7.80 8.00 0.00 0 20 40 12mmEmboss 14.50 11.20 0.00 10 30 0 16mmEmboss 16.50 13.20 0.00 10 50 0 24mmEmboss 20.50 17.20 0.00 10 50 0 32mmTape 25.00 21.90 0.00 15 50 0 32mmEmboss 24.70 22.50 0.00 50 100 0 44mmEmboss 30.70 28.50 0.00 50 100 0 56mmEmboss 42.50 34.50 0.00 50 100 0 MultiStick 39.80 87.00 0.00 0 140 0 Fix.TF 0.00 0.00 0.00 0 0 0 Figure 7-29 0/EXIT Sequence TapeType TapeType TapeType TapeType TapeType TapeType TapeType TapeType TapeType StickTyp TrayType Feeder plate spec information screen Minimum timer 7KHPLQLPXPWLPHULVWKHWLPHGXULQJZKLFKWKHDLUF\OLQGHULVNHSWRQVR WKDWWKHQR]]OHLQWKHORZHUHGSRVLWLRQFDQSLFNXSDFRPSRQHQWZLWKRXWIDLO 7KHWLPHLVH[SUHVVHGLQKXQGUHGWKVRIDVHFRQG Load timer 7KHORDGWLPHULVWKHWLPHIURPZKLFKWKHDLUF\OLQGHULVWXUQHGRIIXQWLOWKH QH[WFRPSRQHQWLVVHFXUHO\GHOLYHUHGWRWKHSLFNXSSRVLWLRQ7KLVLVH[SUHVVHG LQKXQGUHGWKVRIDVHFRQG. Down timer 7LPHWKDWPXVWEHDOORZHGEHWZHHQWKHIHHGHUVKXWWHURSHQLQJDQGWKHKHDG EHLQJORZHUHGRQWRWKHFRPSRQHQWLQWKRXVDQGWKRIDVHFRQG Caution: This information is set at the factory prior to shipment. It is unlikely that you will need to change it. If, however, this information needs to be adjusted, enter the optimum settings on this screen while checking for feeder operation. To save the new settings, select {A0/EXIT} and press the [ENTER] key. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 31 Component Transport Systems 7.5.3. Tape Feeder Maintenance Introduction 7KHWDSHIHHGHUVFRPSO\WRWKH(,$VWDQGDUG7KHIROORZLQJWDSHIHHGHUV DUHDYDLODEOH 3$ 3$ 3$ 3$ 3$ 3$ 3$ 3$ 3$ PP7DSH)HHGHUPPSLWFK5HHO PP7DSH)HHGHUPPSLWFK5HHO PP7DSH)HHGHUPPSLWFK5HHO PP7DSH)HHGHU5HHO PP7DSH)HHGHU5HHO PP7DSH)HHGHU PP7DSH)HHGHU PP7DSH)HHGHU PP7DSH)HHGHU Adjustment 7DSH IHHGHU DGMXVWPHQW PP WR PP RQO\ FDQ EH GRQH ZLWK WKH 2SWLFDO 7DSH)HHGHU$GMXVWPHQW7RRO$XVHUPDQXDOLVLQFOXGHGZLWKWKLVWRRO7KH WRROFDQEHRUGHUHGZLWK3$ 7 - 32 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems Preventive Maintenance for tape feeders a) Preventive Maintenance Schedule Item every feeder change Tape waste Daily Weekly Monthly > 1/2 million > 2 million indexes indexes clean Cleanliness check Tape path clean Transport assy clean Top cover assy clean Moving parts lubricate Top foil wheel Bottom surface replace check Figure 7-30 Preventive Maintenance Schedule b) Recommended Materials: 5HFRPPHQGHG(TXLSPHQWDQG0DWHULDOVIRU&OHDQLQJDQG/XEULFDWLQJ 9DFXXPFOHDQHUIRUPDLQWHQDQFHFORVHWRWKH7RSD] &RPSUHVVHGDLUJXQIRUPDLQWHQDQFHLQZRUNVKRS 3DLURIWZHH]HUV 6PDOOEUXVKHV 4WLSV /LQWIUHHWLVVXHSDSHU ,VRSURSDQRO /LJKWPDFKLQHRLOHJ6KHOO7HOOXV 6FUHZGULYHU3KLOLSVQR IHHOHUJDXJHVRIPPWKLFN 6HDOORFNDJHQW/RFNWLWH 3XQFKPD[LPDOGLDPPP $OOHQNH\PP 6FUHZGULYHU7RUFQR7 +DPPHUVPDOO 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 33 Component Transport Systems c) Checking the Cleanliness )UHTXHQF\ :HHNO\ 5HTXLUHGWLPH KUSHUIHHGHU 3URFHGXUH &KHFN WKH ZKROH WDSH SDWK IRU FRQWDPLQDWLRQ DQG FOHDQ LW LI QHFHVVDU\ ZLWK D OLQWIUHH WLVVXH SDSHU EUXVKHVRU4WLSVPRLVWHQHGLQLVRSURSDQRO &OHDQ WKH IHHGHU ZLWK FRPSUHVVHG DLU RU ZLWK D YDFXXPFOHDQHUWRUHPRYHDOOGXVW d) Tape Path Cleaning )UHTXHQF\ GDLO\ 5HTXLUHGWLPH KUSHUIHHGHU 3URFHGXUH &KHFN LI WKHUH LV DQ\ WDSH VHGLPHQW DGKHVLYH RU FRPSRQHQW GHEULV DGKHULQJ WR WKH WDSH WUDYHOOLQJ VXUIDFH 6SHFLDO DWWHQWLRQ PXVW EH JLYHQ WR WKH WDSH SDWK DUHD XQGHUQHDWK WKH WRS FRYHU SODWH &OHDQ LI QHFHVVDU\ ZLWK WKH UHFRPPHQGHG HTXLSPHQW DQG PDWHULDOV e) Tape Transport Cleaning )UHTXHQF\ GDLO\ 5HTXLUHGWLPH KUSHUIHHGHU 3URFHGXUH &KHFN LI WKHUH LV DQ\ GLUW RQ WKH VSURFNHWV RI WKH VSURFNHW ZKHHO RQ WKH WZR SDZOV WKH SDZO ZKHHO DQGLQEHWZHHQWKHZKHHOV &OHDQLIQHFHVVDU\ZLWKWKHUHFRPPHQGHGHTXLSPHQWDQGPDWHULDOV1HYHUXVHD VROYHQWRWKHUZLVHWKHJUHDVHLQVLGHWKHWUDQVSRUWDVV\ZLOOEHGLVVROYHG f) Top Cover Plate cleaning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ervice Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems Figure 7-31 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 CSM top cover plate 7- 35 Component Transport Systems g) Top Cover Plate replacement (see fig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emark: If the spring (12) is deformed, the complete top-cover plate must be replaced (assembly). The spring is good if the spring ends face each other 180 degrees ± 10 degrees (visual inspection). h) Replace Gear Wheel (Small) )UHTXHQF\ (YHU\PLOOLRQLQGH[HV 5HTXLUHGWLPH PLQXWHV 5HTXLUHG0DWHULDO ['ULYHWRSIRLOZKHHO 3URFHGXUH /RRVHQ WKH FRXQWHUVXQN VFUHZ DQG UHPRYH WKH IODQJH DQG JHDU ZKHHO E\ XVLQJD3KLOLSVVFUHZGULYHUQR 0RXQWDQHZJHDUZKHHOLQWKHUHYHUVHGLUHFWLRQ0DNHVXUHWKDWWKHJHDU ZKHHOPRYHVIUHHO\LIWXUQLQJLWFORFNZLVHVHHDUURZ Figure 7-32 7 - 36 Replacing of the gear wheel (small) Service Manual Topaz PA 1309/10 [SD-2355.WPG] 5322 871 63606 01.05 Component Transport Systems i) Bottom Surface )UHTXHQF\ 5HTXLUHGWLPH (YHU\IHHGHUFKDQJH KUSHUIHHGHU Procedure: Check if the bottom surface of the feeder is clean and free of mechanical damage. &OHDQLIQHFHVVDU\ZLWKWKHUHFRPPHQGHGHTXLSPHQWDQGPDWHULDOV j) Lubrication )UHTXHQF\ 5HTXLUHGWLPH (YHU\LQGH[HV KUSHUIHHGHU 3URFHGXUH &OHDQWKHSRLQWVWKDWKDYHWREHOXEULFDWHGILJDQGUHPRYHDOOGXVW E\XVLQJDYDFXXPFOHDQHU &OHDQDQGUHPRYHLIQHFHVVDU\ROGRLODQGGXVWZLWKDOLQWIUHHWLVVXHSDSHU EUXVKHV RU 4WLSV PRLVWHQHG LQ GHQDWXUHG LVRSURS\O PHWK\O DOFRKRO KDVWREHSXUFKDVHGORFDOO\ Remark: The fig. 7-33 shows the mechanical feeder and not the FV feeder. This is of no importance because most of the lubrication points are the same. WARNING WHEN USING DENATURED ISOPROPYL OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS: a) KEEP CONTAINER CLOSED TIGHT WHEN NOT USED. b) KEEP AWAY FROM INFLAMMABLE SOURCES - NO SMOKING. c) HARMFUL IF INHALED OR SWALLOWED. d) HIGHLY INFLAMMABLE. e) AVOID CONTACT WITH THE SKIN. f) DO NOT EMPTY INTO DRAINS. $GGRLOEHWZHHQWKHSDUWVDVVKRZQE\DUURZVLQILJXUH /XEULFDQW7HOOXVIURP6KHOOKDVWREHSXUFKDVHGORFDOO\ 5RWDWHRUPRYHWKHSDUWVVHYHUDOWLPHVVRWKDWWKHOXEULFDQWFDQVSUHDG Note: The amount of lubrication oil should be a single drop supplied with a small screw driver or needle pin (has to be purchased locally). After lubrication, wipe off excessive oil to avoid contamination. Use only the type of lubricant that is mentioned above. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 37 Component Transport Systems [SD-2354A.WPG] [SD-2354B.WPG] Figure 7-33 7 - 38 Lubrication of the rotating and moving parts (figures show mech. feeders) Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Component Transport Systems Trouble shooting Symptom description Automatic refire level to high (number of re-pick actions) Possible cause Solution Tape out of specification (diam. sprocket holes 1.6 mm max, play component in pocket 0.5 mm max) Replace tape Feeder not placed correctly Feeder interface damaged Tape or cover tape path not correct or obstructed Speed air-cylinder too low Clean feeder-bar Clean feeder bottom Send feeder back for repair Correct path and/or remove obstructions Index mechanism polluted Check adjustment Feeder does not index correctly Clamping lever of feeder to the left presses against index mechanism Index mechanism damaged Clean index mechanism Tighten clamping lever to the feeder body Cover plate not completely closed Cover plate damaged Send feeder back for repair Index force extremely high Remove obstructing components Spring (left-pulley) broken/absent Replace cover plate Spring (top-foil) broken/absent Lubricate rotating parts Replace Replace 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 7- 39 Component Transport Systems Symptom description Possible cause Solution (continue) Feeder does not index correctly Spring (set-up) broken/absent Replace Pick position wrong See index problems Check pick position with Tape Feeder Adjustment Tool PA 2849/10 Cover tape does not peel back from carrier tape Tape not inserted correctly Tape stuck between wheels Insert tape according instructions Insert tape again, make sure the scrapers are close to the wheels and the double guiding is straight Replace spring Spring (left pulley) broken/absent Replace spring Spring (top-foil) broken/absent Replace spring Spring (set-up) broken/absent Reel/tape stuck Check for obstructions Replace small wheel Top foil wheel (small) rotates during upward stroke Set up spring incorrect mounted Check if the spring is set onto the correct fixing pin Cover tape does not peel back from the carrier tape at the appropriate timing (specially paper tape) 7 - 40 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems CHAPTER 8 8.1. Axes Systems Introduction 7KLVFKDSWHUGHVFULEHVWKHD[HVV\VWHPVRIWKH7RSD] 7KHPHFKDQLFDOPRYHPHQWRIWKH723$=V\VWHPVLVFRQWUROOHGE\WKHILYH D[HVGHVFULEHGLQWDEOHEHORZ Axis Function Power drive method W axis Adjust the width of the conveyor that carries in or out a PCB Moves the nozzle shafts of heads 1 to 8 simultaneously in vertical direction. Moves the head assembly in parallel with the PCB transfer direction(right to left and left to right as viewed from the front of the machine) Moves the head assy forwards and backwards as viewed from the front of the machine Rotates the nozzle shaft of the head 1-8. AC motor/ ball screw Z axis X axis Y axis R axis Table 8-1 AC motor/ ball screw AC motor/ ball screw AC motor/ ball screw AC motor/ belt drive Axes overview 7RSUHVHUYHWKHUHSHDWDELOLW\RID[LVPRYHPHQWDQGPRXQWLQJDFFXUDF\WKH IROORZLQJSDUDPHWHUVPXVWEHVHWFRUUHFWO\ Parameter Machine reference Secondary limit Software limit Initial position Initial movement Table 8-2 Axis W, Z, X, Y, R X, Y W, Z, X, Y, R W, R Z Adjustment parameters of moving axes WARNING MAKE SURE TO TAKE ALL NECESSARY SAFETY PRECAUTIONS WHEN DOING MECHANICAL ACTIONS AT THE SYSTEM. ALWAYS SWITCH OFF THE MACHINE IF MECHANICAL ASSEMBLY OR DISASSEMBLY ACTIONS ARE CARRIED OUT. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 8-1 Axes Systems 8.2. Machine Reference (Origin) 7KHEXLOWLQPRWRUHQFRGHURIHDFKD[LVLVVXHVD´µSXOVHHDFKWLPHRQHWXUQ LVFRPSOHWH :KHQUHWXUQWRRULJLQLVSHUIRUPHGWKHUHZLOOEHDGLIIHUHQFHLQGLVWDQFH EHWZHHQWKHSRVLWLRQZKHUHWKHRULJLQVLJQDOLVGHWHFWHGDQGWKHSRLQWDW ZKLFKWKHQH[WHQFRGHU´µSXOVHLVUHFHLYHGWKHRULJLQSRVLWLRQDFWXDOO\VHW 7KLVLVFDOOHGWKHPDFKLQHUHIHUHQFHDQGLVXVXDOO\H[SUHVVHGLQSHUFHQWDJHV ZLWKEHLQJHTXDOWRRQHIXOOWXUQRIWKHPRWRU Figure 8-1 Machine reference &KHFNWKHPDFKLQHUHIHUHQFHVHWWLQJV 0RYHWKHFXUVRUWR0$,17(0!!!0$18$/!! %$8720$7,&B029(!^%,1,76(59225,*,1`DQGSUHVVWKH >6+,)7@>(17(5@NH\ 7KHPDFKLQHUHIHUHQFHRIHDFKD[LVDSSHDUVRQWKHRSHUDWLRQPRQLWRUDIWHUWKH UHWXUQWRRULJLQKDVEHHQSHUIRUPHG Figure 8-2 8-2 Machine reference display Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems 8.2.1. W-axis Machine Reference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igure 8-3 Adjusting the W-axis machine reference Note: The machine reference will be adjusted to about 20% for every 1mm movement of the origin dog. Be sure to slide the dog slightly (a maximum of 2.5mm). If you slide it too far, a “0” pulse in a different cycle may be received, causing the origin position to shift 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 8-3 Axes Systems 8.2.2. Z-axis Machine Reference 7KH=D[LVYHUWLFDOO\PRYHVWKHKHDGDVVHPEO\E\EDOOVFUHZ:KHQUHWXUQWR RULJLQLVSHUIRUPHGWKH=D[LVWUDYHOVDWORZVSHHGXSDJDLQVWWKHXSSHUHQG DQGWKHUHVXOWLQJH[FHVVLYHPRWRUFXUUHQWLVGHWHFWHGDVDQRULJLQVLJQDOWKHQ WKHRULJLQLVVHWDWWKHSRVLWLRQRIWKHSUHFHGLQJHQFRGHU´µSXOVHDVWKH PRWRUUHYHUVHVVOLJKWO\7KHUHLVQRRULJLQVHQVRUDQGRULJLQGRJ7RDGMXVW WKH=D[LVPDFKLQHUHIHUHQFHIROORZWKHVHVWHSV 3UHVVWKHHPHUJHQF\VWRSEXWWRQ /RRVHQWKHEROWVHFXULQJWKHFRXSOLQJRQWKH=D[LVEDOOVFUHZVLGHUHIHU WRILJXUHEHORZ $GMXVWWKHPDFKLQHUHIHUHQFHURWDWHWKHEDOOVFUHZWRDGMXVWWKHPDFKLQH UHIHUHQFHDVIROORZV - 7RLQFUHDVHWKHPDFKLQHUHIHUHQFHURWDWHLQGLUHFWLRQ$GRZQ - 7RGHFUHDVHWKHPDFKLQHUHIHUHQFHURWDWHLQGLUHFWLRQ%XS 5HWLJKWHQWKHEROWWRVHFXUHWKHFRXSOLQJDIWHUWKHPDFKLQHUHIHUHQFHLV VHWZLWKLQWKHWROHUDQFHUDQJH Figure 8-4 Adjusting the Z-axis machine reference Note: A 1mm movement of the Z-axis is equal to 25% of the machine reference. Do not allow the Z-axis to move more than 2mm. If you move too far, a “0” pulse in a different cycle may be received, causing the origin to shift. Do not allow the shaft to turn during adjustment. 8-4 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems 8.2.3. X-axis Machine Reference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igure 8-5 Adjusting the X-axis machine reference Note: The machine reference will be adjusted to about 10% for every 2mm of movement of the origin dog. Be sure to slide the dog slightly (a maximum of 10mm). If you slide it too far, a “0” pulse in a different cycle may be received, causing the origin position to shift. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 8-5 Axes Systems 8.2.4. Adjusting the Y-axis Machine Reference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igure 8-6 Adjusting the Y-axis machine reference Note: The machine reference will be adjusted about 10% for every 2mm movement of the origin dog. Be sure to slide the dog slightly (a maximum of 10mm). If you slide it too far, a “0” pulse in a different cycle may be received, causing the origin position to shift 8-6 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems 8.2.5. R-axis Machine Reference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igure 8-7 Adjusting the R-axis machine reference Note: Be sure to turn the dog ring slightly, if you turn it too far a “0” pulse in a different cycle may be received, causing the origin to shift. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 8-7 Axes Systems 8.3. Secondary Limits :KHQWKHKHDGDVVHPEO\UXQVLQWRWKHVHFRQGDU\OLPLWDUHDRYHUWKHVRIWZDUH OLPLWWKHVHUYRFRQWUROLPPHGLDWHO\VWRSVWRDYRLGFROOLGLQJZLWKWKH PHFKDQLFDOKDUGVWRSSHU$OLJKWLPSDFWPD\RFFXUKRZHYHUGHSHQGLQJ RQWKHUXQQLQJVSHHG 7KHVHFRQGDU\OLPLWDUHDLVSURYLGHGIRUWKH;DQG<D[HVDQGFDQEH DGMXVWHGE\VOLGLQJWKHSRVLWLRQRIWKHVHFRQGDU\OLPLWGRJORFDWHGDWWKHERWK HQGVRIWKHPRYHPHQWUDQJH 8.3.1. X-axis Secondary Limits 8VXDOO\WKH;D[LVVHFRQGDU\OLPLWVDUHVHWWRDSRLQWPPLQVLGHWKH PHFKDQLFDOVWRSSHUKDUGOLPLWVHHILJXUH 6HOHFWWKHD[LV6SHFLI\LQDGYDQFHWKHD[LVZKRVHFRRUGLQDWHVQHHGWREH GLVSOD\HGLQ6WHS7RVSHFLI\WKHD[LVVHOHFW0$,17(0!!! 0$18$/!!$&+$1*(B&21',7,21!^$6(/(&7 $;(6`µ0$,1;<µDQGSUHVVWKH>(17(5@NH\ 3UHVVWKHHPHUJHQF\VWRSEXWWRQWKHQORRVHQWKHVFUHZVIRUWKHVHFRQGDU\ OLPLWGRJ7KHVHFRQGDU\OLPLWGRJVDUHORFDWHGDWERWKHQGVRIWKH; D[LV6OLJKWO\ORRVHQWKHVFUHZVVRWKDW\RXFDQMXVWVOLGHWKHGRJ'RQRW UHPRYH Figure 8-8 8-8 X-axis secondary limit dog 0RYHWKHKHDGDVVHPEO\WRWKHHQGRIWKHD[LV 0RYHWKHKHDGDVVHPEO\E\KDQGXQWLOLWPDNHVFRQWDFWZLWKWKH PHFKDQLFDOVWRSSHUIRUWKHVHFRQGDU\OLPLWGRJZLWKWKHEROWORRVHQHG 7KHEOLQNLQJPHVVDJH´(0(5*(1&<672321µLQGLFDWHGRQWKH ORZHUOHIWRIWKHRSHUDWLRQPRQLWRUZLOOFKDQJHWR´QG/,0,729(5µ Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems 4. 0RYHEDFNWKHKHDGDVVHPEO\WRPPLQVLGHWKHPHFKDQLFDOVWRSSHU 7RGRWKLVRSHQWKHRXWSXWPRQLWRUVFUHHQRULQSXWPRQLWRUVFUHHQ DQGZKLOHREVHUYLQJWKH;FRRUGLQDWHYDOXHLQGLFDWHGRQWKHERWWRPRI WKHRSHUDWLRQPRQLWRUVWRSWKHKHDGDWDSRVLWLRQDSSUR[LPDWHO\ PPIURPWKHPHFKDQLFDOVWRSSHULHIURPWKHKDUGOLPLW7KLV SRVLWLRQLVWKHVHFRQGDU\OLPLWRIWKH;D[LV Note: Make a Note of the X-axis co-ordinates displayed on the monitor. This is used as a reference for the X-axis software limit settings. $GMXVWWKHSRVLWLRQRIWKHVHFRQGDU\OLPLWGRJ:LWKWKHKHDGDVVHPEO\ OHIWDWWKHSRVLWLRQRI6WHSVOLGHWKHSRVLWLRQRIWKHVHFRQGDU\OLPLWGRJ VRWKDWWKHVHFRQGDU\OLPLWVHQVRUMXVWGHWHFWVLW)LQGWKHRSWLPXPSRVL WLRQZKLOHFKHFNLQJWKHVHQVRUGHWHFWLRQ/('RUUHDGLQJWKHEOLQNLQJ PHVVDJHRQWKHORZHUOHIWRIWKHRSHUDWLRQPRQLWRUVHHILJXUH L013: 2nd LIMIT OVER! Figure 8-9 “Secondary limit over” display screen 5HWLJKWHQWKHVFUHZVRIWKHVHFRQGDU\OLPLWGRJ 8VHWKHVDPHSURFHGXUHIURP6WHSVWRIRUWKHRWKHUVHFRQGDU\OLPLW $IWHUWKHDGMXVWPHQWLVFRPSOHWHPRYHWKHKHDGDVVHPEO\E\KDQGWR ZLWKLQWKHDOORZDEOHPRYHPHQWUDQJH 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 8-9 Axes Systems 8.3.2. Y-axis Secondary Limits 7KH<D[LVVHFRQGDU\OLPLWVDUHVHWWRDSSUR[LPDWHO\PPLQVLGHWKH PHFKDQLFDOVWRSSHUKDUGOLPLW6LQFHWKLVDGMXVWPHQWSURFHGXUHLVH[DFWO\ WKHVDPHDVIRUWKH;D[LVUHIHUWRWKHSUHYLRXVVHFWLRQ7KHORFDWLRQVRI WKH<D[LVVHFRQGDU\OLPLWGRJVDUHVKRZQEHORZ Figure 8-10 Y-axis secondary limit dogs Note: To make settings for the Y-axis secondary limits, use the same procedure as for the X-axis except that you move the head assembly to a point 2.00mm inside the mechanical stopper in Step 5. 8 - 10 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems 8.4. 8.4.1. Software Limits :KHQDQD[LVPRYHVWRDWDUJHWSRVLWLRQWKHVRIWZDUHOLPLWLVXVHGWRUHVWULFW PRYHPHQWWRDYRLGLQWHUIHULQJZLWKWKHPHFKDQLFDOVWRSSHUVORFDWHGDWWKH ERWKHQGVRIWKHD[LV,IWKHWDUJHWSRVLWLRQH[FHHGVWKHVRIWZDUHOLPLWWKH HUURUPHVVDJH´$;,662)7/,0,729(5µDSSHDUVDQGD[LVPRYHPHQWLV SURKLELWHG,QWKH0DQXDOPRGH\RXFDQXVHWKHMR\VWLFNRQWKH++. ZLWKLQWKHVRIWZDUHOLPLWUDQJH W-axis Software Limits 7KH:D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRPPLQVLGHWKHPHFKDQLFDO VWRSSHUIRUERWKWKH´SOXVµVLGHZLGWKHQODUJLQJGLUHFWLRQDQGWKH´PLQXVµ VLGHZLGWKUHGXFLQJGLUHFWLRQ :KHQWKHVRIWZDUHOLPLWVHWWLQJVDUHFRUUHFWWKLVPHHWVWKHVSHFLILFDWLRQVIRU WKHPLQLPXPPPDQGPD[LPXPPPZLGWKVRI3&%VWKDW FDQEHWUDQVIHUUHG A: Structural movable range B: Allowable movement range C: “plus” side software limit (rear) D: Origin position E: “minus” side software limit (front) F: Mechanical limit F 3.00mm C D B A E 3.00mm F Figure 8-11 W-axis movement range 7RVHWWKH:D[LVVRIWZDUHOLPLWIROORZWKHVHVWHSV 6HOHFWWKH:D[LVWRVHWWKHVRIWZDUHOLPLW 6HOHFW0$,17(0!!!0$18$/!!$&+$1*(&21',7 ,21 !^$6(/(&7$;(6`µ:0$,1µDQGSUHVVWKH>(17(5@NH\ 0DQLSXODWHWKHMR\VWLFNRQWKH++.WRPRYHWKH:D[LVFRQYH\RU ZLGWK7RVHWWKH´SOXVµVLGHVRIWZDUHOLPLWPRYHWKHD[LVLQWKHZLGWK HQODUJLQJGLUHFWLRQ7RVHWWKH´PLQXVµVLGHPRYHWKHD[LVLQWKHZLGWK UHGXFLQJGLUHFWLRQ Note: Tilting the joystick on the HHK to the right you reduces the width, and tilting it to the left you enlarges the width. Set the conveyor width to a maximum or minimum as long as the movable rail does not make contact with the mechanical stopper. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 8 - 11 Axes Systems Figure 8-12 W-axis pulley 6HWWHDFKLQJFRQGLWLRQVDVIROORZV 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%&21',7,212)7&+`DQGSUHVV>(17(5@ 6HOHFW´7($&+81,76(/µDQGSUHVVWKH>(17(5@NH\ 6HOHFWDQ\RI´&DPHUDµ´+HDGµRU´+HDGµ 6HOHFW´63(('6(/(&7µ6HOHFWDQ\VSHHGIURPWR <<<APPLICATION>>> <<MODE>> <COMMAND_LIST> 3/MAINTE/M 3/MCH_ADJUST B/SAVE & QUIT B4 CONDITION OF TCH TEACH-UNIT SEL. Camera Head 1 Head 2 SPEED SELECT. Speed1= Speed2= Speed3= Speed4= Speed5= 100 80 60 40 20 3UHVVWKHHPHUJHQF\VWRSEXWWRQWKHQPRYHWKHFRQYH\RUUDLO7XUQWKH :D[LVSXOOH\E\KDQGXQWLOWKHPRYDEOHUDLOPDNHVFRQWDFWZLWKWKH PHFKDQLFDOVWRSSHU:KHQWKHPRYDEOHUDLOLVSRVLWLRQHGLQFRQWDFWZLWK WKHPHFKDQLFDOVWRSSHUWKHPD[LPXPFRQYH\RUZLGWKLVDSSUR[ PPDQGWKHPLQLPXPZLGWKLVDSSUR[PP&KHFNWKHZLGWKE\ PHDVXULQJZLWKDVTXDUHRUWDSHPHDVXUH 3HUIRUPWHDFKLQJDWWKHSRVLWLRQLQFRQWDFWZLWKWKHPHFKDQLFDOVWRSSHU 6HOHFW0&+B$'-867!!%6$9(48,7!^%$'-867 7$5*(7`µ6RIW/LPLWµDQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK´GLUHFWµRU´GLUHFWµ RIWKHFRQYH\RUZLGWKEHLQJDGMXVWHG7KHFXUVRUVKRXOGEH SRVLWLRQHGRQWKH´GLUHFWµ\RXPRYHGWKH D[LVLQ6WHS 3. 3UHVVWKH>)@NH\WZLFHWRSHUIRUPWHDFKLQJ 7KHQXPHULFDOYDOXHRIWKHSDUDPHWHUWKDWWKHFXUVRULVRQFKDQJHV 8 - 12 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems Editing Axis W/MAIN Figure 8-13 Object +direct. 3.70 -direct. -350.00 Init.Pos Software Limit Init.Mov -408.00 W-axis software setting screen (QWHUWKHVRIWZDUHOLPLW 6XEWUDFWPPIURPWKHPHFKDQLFDOOLPLWRQWKH´SOXVµVLGHRUDGG PPWRWKHPHFKDQLFDOOLPLWRQWKH´PLQXVµVLGH7KLVYDOXH\RX KDYHMXVWHQWHUHGLVWKHVRIWZDUHOLPLW 5HWXUQWKHFRQYH\RUZLGWKWRZLWKLQWKHVRIWZDUHOLPLW 7XUQWKHSXOOH\E\KDQGWRUHWXUQWKHFRQYH\RUZLGWK &DQFHOHPHUJHQF\VWRS (QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH >5($'<@EXWWRQRIWKH++. 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVVWKH>(17(5@NH\ 7RTXLWZLWKRXWVDYLQJVHOHFW^%5(&29(5$'-867`RU ^%48,7`DQGSUHVVWKH>(17(5@NH\ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 8 - 13 Axes Systems 8.4.2. Z-axis Software Limits 7KH=D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRPPLQVLGHWKHPHFKDQLFDO VWRSSHUIRUERWKWKH´SOXVµVLGHORZHUGLUHFWLRQDQGWKH´PLQXVµVLGH XSSHUGLUHFWLRQ 7KH´SOXVµVLGHPXVWEHVHWDWDSRVLWLRQZKHUHQR]]OHFKDQJHLVQRW GLVWXUEHGDQGWKH´PLQXVµVLGHDWDSRVLWLRQZKHUHWKHQR]]OHVGRQRW LQWHUIHUHZLWKWKHEDFNOLJKWXQLW A: Structural movable range B: Allowable movement range C: “plus” side software limit D: Origin position E: “minus” side software limit F: Mechanical limit E 1.00 C B A D 1.00 F Figure 8-14 Z-axis movement 7RVHWWKH=D[LVVRIWZDUHOLPLWIROORZWKHVHVWHSV 8 - 14 1) 6HWWHDFKLQJFRQGLWLRQV 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%&21',7,212)7&+`DQGSUHVVWKH>(17(5@NH\ 6HOHFW´7($&+81,76(/µDQGSUHVVWKH>(17(5@NH\ 6HOHFWDQ\RI´&DPHUDµ´+HDGµRU´+HDGµ 3. 6HOHFW´63(('6(/(&7µ6HOHFWDQ\VSHHGIURPWR5. 2) 3UHVVWKHHPHUJHQF\VWRSEXWWRQWKHQPRYHWKH=D[LV 5DLVHRUORZHUWKH=D[LVE\KDQGXQWLOWKHPDNHVFRQWDFWZLWKWKH PHFKDQLFDOVWRSSHU5DLVHWKH=D[LVWRDGMXVWWKH´PLQXVµVLGHZKLOH ORZHULWWRDGMXVWWKH´SOXVµVLGH 3) 3HUIRUPWHDFKLQJDWWKHSRVLWLRQLQFRQWDFWZLWKWKHPHFKDQLFDOVWRSSHU 6HOHFW0&+B$'-867!!%6$9(48,7!^%$'-867 7$5*(7`µ6RIW/LPLWµDQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK´=0$,1µIRUWKH =D[LVRU´=0$,1µIRUWKH=D[LV7KHFXUVRUVKRXOGEH SRVLWLRQHGRQ´GLUHFWµ\RXKDYHPRYHGLQ6WHS Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems 3. 3UHVVWKH>)@NH\WZLFHWRSHUIRUPWHDFKLQJ7KHQXPHULFDOYDOXH RIWKHSDUDPHWHUWKDWWKHFXUVRULVRQFKDQJHV 7KLVYDOXHLVWKHPHFKDQLFDOOLPLWKDUGOLPLW Editing Axis Object +direct. -direct. Init.Pos Init.Mov 22.90 23.00 0.16 0.05 0.00 0.00 18.72 18.00 Z1/MAIN Z2/MAIN Figure 8-15 5322 871 63606 01.05 Software Limit Z-axis software setting screen 4) (QWHUWKHVRIWZDUHOLPLW 6XEWUDFWPPIURPWKHPHFKDQLFDOOLPLWRQWKH´SOXVµVLGHRUDGG PPWRWKHPHFKDQLFDOOLPLWRQWKH´PLQXVµVLGH7KLVYDOXH\RX KDYH MXVWHQWHUHGLVWKHVRIWZDUHOLPLW 5) 5HWXUQWKH=D[LVE\KDQGWRZLWKLQWKHVRIWZDUHOLPLW 6) &DQFHOHPHUJHQF\VWRS(QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRS EXWWRQDQGSUHVVWKH>5($'<@EXWWRQRIWKH++. 7) 6DYHWKHVHWWLQJV3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU ^%6$9(48,7`DQGSUHVVWKH>(17(5@NH\7RTXLWZLWKRXW VDYLQJVHOHFW^%5(&29(5$'-867`RU^%48,7`DQGSUHVVWKH >(17(5@ Service Manual Topaz PA 1309/10 8 - 15 Axes Systems 8.4.3. X-axis Software Limits 7KH;D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRPPLQVLGHWKHVHFRQGDU\OLPLW IRUERWKWKH´SOXVµVLGHULJKWGLUHFWLRQDQGWKH´PLQXVµVLGHOHIWGLUHFWLRQ A 1 1 1 1 B F D C Mechanical stopper Mechanical stopper A: Structural movable range B: Allowable movement range C: Software limit D: Secondary limit E: Origin position F: Mechanical limit C D F E Figure 8-16 X-axis movement range Note: To set the X-axis software limit, use the X-axis secondary limit values you have made a note when adjusting the secondary limits. 2SHQWKHVRIWZDUHOLPLWVFUHHQ 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%$'-8677$5*(7`µ6RIWZDUH/LPLWµDQGSUHVVWKH >(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK´GLUHFWµRU´GLUHFWµ LQWKH´;0$,1µURZ Editing Axis X/MAIN Object +direct. 666.42 Figure 8-17 8 - 16 Service Manual Topaz PA 1309/10 -direct. Init.Pos Software Limit Init.Mov -16.38 X-axis software limit setting screen 5322 871 63606 01.05 Axes Systems (QWHUWKHVRIWZDUHOLPLW 2QWKH´SOXVµVLGHHQWHUDYDOXH\RXKDYHVXEWUDFWHGPPIURPWKH VHFRQGDU\OLPLWRURQWKH´PLQXVµVLGHDYDOXH\RXKDYHDGGHGPP WRWKHVHFRQGDU\OLPLW 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVVWKH>(17(5@NH\7RTXLWZLWKRXWVDYLQJVHOHFW ^%5(&29(5$'-867`RU^%48,7`DQGSUHVVWKH>(17(5@NH\ 8.4.4. Y-axis Software Limits $VZLWKWKH;D[LVWKH<D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRPPLQVLGH WKHVHFRQGDU\OLPLWIRUERWKWKH´SOXVµVLGHULJKWGLUHFWLRQDQGWKH´PLQXVµ VLGHOHIWGLUHFWLRQ Figure 8-18 Y-axis movement range Note: To set the Y-axis software limit, use the Y-axis secondary limit values you have made a note when adjusting the secondary limits. 5322 871 63606 01.05 1) 2SHQWKHVRIWZDUHOLPLWVFUHHQ 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%DGMXVWWDUJHW`µ6RIWZDUH/LPLWµDQGSUHVV>(17(5@ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK´GLUHFWµRU´GLUHFWµ LQWKH´<0$,1µURZ 2) (QWHUWKHVRIWZDUHOLPLW 2QWKH´SOXVµVLGHHQWHUDYDOXH\RXKDYHVXEWUDFWHGPPIURPWKH VHFRQGDU\OLPLWRURQWKH´PLQXVµVLGHDYDOXH\RXKDYHDGGHGPP WRWKHVHFRQGDU\OLPLW Service Manual Topaz PA 1309/10 8 - 17 Axes Systems Editing Axis Y/MAIN Figure 8-19 3) 8 - 18 Object +direct. 699.00 -direct. Init.Pos Software Limit Init.Mov -11.86 Y-axis software limit setting screen 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVVWKH>(17(5@NH\ 7RTXLWZLWKRXWVDYLQJVHOHFW^%5(&29(5$'-867`RU ^%48,7`DQGSUHVVWKH>(17(5@NH\ Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems 8.4.5. R-axis Software Limits 7KH5D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRDIL[HGYDOXHRIRQWKH ´PLQXVµVLGHFORFNZLVHDQGWRDIL[HGYDOXHRIRQWKH´SOXVµVLGH FRXQWHUFORFNZLVH 2) 2SHQWKHVRIWZDUHOLPLWVFUHHQ 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%$'-8677$5*(7`µ6RIWZDUH/LPLWµDQGSUHVVWKH >(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK´GLUHFWµRU´GLUHFWµ LQWKH´50$,1µRU´50$,1URZ\RXZDQWWRDGMXVW (QWHUWKHVRIWZDUHOLPLW (QWHUIRUWKHVRIWZDUHOLPLWRQWKH´SOXVµVLGHZKLOHRQ WKH´PLQXVµVLGH Editing Axis 12 R-NO1 13 R-NO2 Figure 8-20 5322 871 63606 01.05 Object +direct. 360.00 360.00 -direct. -360.00 -360.00 Init.Pos Software Limit Init.Mov 80.00 -80.50 R-axis software setting screen 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVV>(17(5@NH\ 7RTXLWZLWKRXWVDYLQJVHOHFW^%5(&29(5$'-867`RU ^%48,7`DQGSUHVVWKH>(17(5@NH\ Service Manual Topaz PA 1309/10 8 - 19 Axes Systems 8.5. Initial Position and Initial Movement 7KLVVHFWLRQH[SODLQVKRZWRDGMXVWWKH:D[LVDQG5D[LVLQLWLDOSRVLWLRQDQG =D[LVLQLWLDOPRYHPHQW 8.5.1. W-axis Initial Position 7KH:D[LVLQLWLDOSRVLWLRQLVWKHGLVWDQFHEHWZHHQWKHFRQYH\RUUDLOVZKHQ WKH:D[LVLVLQWKHUHWXUQWRRULJLQSRVLWLRQH[SUHVVHGDVDPLQXVYDOXH 7RVHWWKH:D[LVLQLWLDOSRVLWLRQIROORZWKHVHVWHSV 3HUIRUPUHWXUQWRRULJLQ 3UHVVWKHHPHUJHQF\VWRSEXWWRQ 'HWHUPLQHWKHLQLWLDOSRVLWLRQ 0HDVXUHWKHFRQYH\RUZLGWK:GLVWDQFHEHWZHHQWKHIL[HGDQGWKH PRYDEOHUDLO 6XEWUDFWPPIURPWKLVZLGWKDVDFOHDUDQFHPDUJLQDQGWKHQSUHIL[ D´PLQXVµVLJQWRWKLVYDOXH7KLVLVWKH:D[LVLQLWLDOSRVLWLRQ Figure 8-21 8 - 20 Conveyor width measurement and initial position (QWHUWKHLQLWLDOSRVLWLRQ 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%$'-8677$5*(7`µ6RIW/LPLWµDQGSUHVVWKH >(17(5@ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK´,QLW3RVµLQWKH ´:0$,1µURZ 8VHWKHQXPHULFNH\VWRHQWHUWKHLQLWLDOSRVLWLRQYDOXHGHWHUPLQHG LQWKHSUHYLRXVVWHS &DQFHOWKHHPHUJHQF\VWRS (QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH >5($'<@EXWWRQRIWKH++. 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVVWKH>(17(5@NH\7RTXLWZLWKRXWVDYLQJVHOHFW ^%5(&29(5$'-867`RU^%48,7`DQGSUHVVWKH>(17(5@NH\ Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems Editing Axis W/MAIN Figure 8-22 8.5.2. Object +direct. 3.70 -direct. -350.00 Init.Pos Software Limit Init.Mov -408.00 W-axis initial position setting screen Adjusting the R-axis Initial Position 1R]]OHVVXFKDV7\SHKDYHDQRULHQWDWLRQ6LQFHFRPSRQHQWVDUHXVXDOO\ SLFNHGDWGHJUHHWKH5D[LVLQLWLDOSRVLWLRQPXVWEHDGMXVWHGVRWKDWWKHVH QR]]OHVDUHDOLJQHGZLWKWKHGLUHFWLRQRIFRPSRQHQWVWKHQR]]OHKROGHU VOHDI VSULQJVDUHVHWSDUDOOHOZLWKWKH;D[LV 5322 871 63606 01.05 ([HFXWHWKH´&+$1*(12==/(µFRPPDQGWRDWWDFKDQR]]OHIRU H[DPSOH7\SHWRDKHDG 3UHVVWKHHPHUJHQF\VWRSEXWWRQ &KHFNWKDWWKHQR]]OHKROGHU VOHDIVSULQJVDUHVHWSDUDOOHOZLWKWKH; D[LV,IQRWSDUDOOHOZLWKWKH;D[LVDGMXVWE\URWDWLQJWKHQR]]OHVKDIW 0RYLQJWKH5D[LVEHOWE\KDQGDOORZVHDV\DGMXVWPHQW 6HWWHDFKLQJFRQGLWLRQV 3UHVVWKHHPHUJHQF\EXWWRQ $WWDFKDW\SHQR]]OHWRKHDG &KHFNWKDWWKHQR]]OHKROGHU·VOHDIVSULQJVDUHVHWSDUDOOHOZLWKWKH; D[LVLIQRWURWDWHWKH5D[LVXQWLOWKH\GR 6HWWHDFKLQJFRQGLWLRQVE\VHOHFWLQJ%!DQGSUHVV(17(5 3HUIRUPWHDFKLQJIRUWKH5D[LVLQLWLDOSRVLWLRQ6HOHFW%! ´6RIWOLPLWµDQGSUHVV(17(58VHWKHDUURZNH\VWROLQHXSWKH FXUVRUZLWKWKH´LQLWSRVµRIWKH´5PDLQµURZDQGSUHVV)WZLFH WRSHUIRUPWHDFKLQJ 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\VHOHFW^%6$9('$7$`RU^%6$9( 48,7` DQGSUHVVWKH>(17(5@NH\7RTXLWZLWKRXWVDYLQJVHOHFW ^%5(&29(5$'-867`RU^%48,7`DQGSUHVVWKH>(17(5@ NH\ Service Manual Topaz PA 1309/10 8 - 21 Axes Systems Editing Axis R1/MAIN R2/MAIN Figure 8-23 8.5.3. Object +direct. 360.00 360.00 -direct. -360.00 -360.00 Init.Pos Software Limit Init.Mov 138.00 138.00 R-axis initial position setting screen Z-axis Initial Movement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´+HDG´DQGSUHVVWKH>(17(5@NH\ 6HOHFWDQ\VSHHGIURPWRDQGSUHVVWKH>(17(5@ 8 - 22 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems 3HUIRUPWHDFKLQJIRUWKH=D[LVLQLWLDOPRYHPHQW 6HOHFW%6$9(48,7!%µ6RIW/LPLWµDQGSUHVV>(17(5@ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK´,QLW0RYµLQWKH ´=0$,1µURZ 3UHVVWKH>)@NH\WZLFHWRSHUIRUPWHDFKLQJ 7KHQXPHULFDOYDOXHRIWKHSDUDPHWHUWKDWWKHFXUVRULVRQFKDQJHV 1H[WHQWHUWKHLQLWLDOPRYHPHQWIRU+HDG=D[LV (QWHUWKHVDPHYDOXHDVIRU+HDGIRU´,QLW0RYµLQWKH´=0$,1µ URZ &DQFHOHPHUJHQF\VWRS (QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH >5($'<@EXWWRQRIWKH++. Editing Axis Object +direct. -direct. Init.Pos Init.Mov 21.90 -1.90 0.00 20.72 Z1/MAIN Figure 8-24 Software Limit Software setting screen (for initial movement) 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVV>(17(5@NH\7RTXLWZLWKRXWVDYLQJVHOHFW ^%5(&29(5$'-867`RU^%48,7`DQGSUHVVWKH>(17(5@NH\ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 8 - 23 Axes Systems 8.6. Axes Assembly, Disassembly, Adjustments and Maintenance 7KLVVHFWLRQGHVFULEHVWKHDVVHPEO\GLVDVVHPEO\DQGDGMXVWPHQWVRIWKHYDULRXV D[HVV\VWHPVLQWKH7RSD] WARNING MAKE SURE TO TAKE ALL THE NECESSARY SAFETY PRECAUTIONS WHEN DOING MECHANICAL ACTIONS AT THE SYSTEM. ALWAYS SWITCH OFF THE MACHINE IF MECHANICAL ASSEMBLY OR DISASSEMBLY ACTIONS ARE CARRIED OUT. 8.6.1. Adjustment of the X- and Y-motor Encoder Position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´5HDG\µNH\RQWKH++.ZKLOHVWLOODWWKHDERYH;DQG<SRVLWLRQV 7KLVZLOOEORFNWKHSRVLWLRQVRIWKH;<PRWRUHQFRGHU 0RYHWKHKHDGDVVHPEO\WRWKHH[DFWFRUUHFWSRVLWLRQVE\KDQGORRNDWWKH YLVLRQPRQLWRU 5HWLJKWHQWKHVFUHZVRQWKHPRWRUFRXSOLQJ 3RLQWPRYHWRWKHQRWHGSRVLWLRQVDJDLQMXVWWREHVXUH 3HUIRUPLQLWVHUYRRULJLQ &KHFNIRUYDOXHVDQGUHDGMXVWLIQHFHVVDU\ 8 - 24 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems 8.6.2. Head Replacement 'LVDVVHPEOHWKHKHDGDVGHVFULEHGEHORZVHHILJXUH 0DNHVXUHWRNQRZWKHVWDWXVRIWKHV\VWHPLQDGYDQFHRIWKLVUHSODFHPHQW 6ZLWFKRIIWKHV\VWHP &XWORVVDOWKHWLHZUDSVELQGLQJWKHFDEOHVDQGKRVHVWRWKHKHDGXQLW 5HPRYHWKHWZRRUDQJHDLUKRVHV 5HPRYHDOOFDEOLQJFRQQHFWLQJWKHKHDGDVVHPEO\WRWKH;EHDP)ROORZLQJ FDEOHVDUHWREHUHPRYHGIURPFRQQHFWRUSODWHLWHPLQILJXUH 9DFXXPVHQVRUKDUQHVV 5PRWRUDQGHQFRGHUFDEOH $OOFDEOHVDVKHDGEORZRIIYDFXXPGRZQVORZGRZQGRZQVHQVRU (DUWKFDEOHDQGILGXFLDOFDPHUDFDEOHVDVZHOODVWKHRYHUDOOKHDGGRZQ VHQVRUFDEOLQJ 5HPRYHWKHFRPSOHWHKHDGDVV\E\UHPRYLQJWKHEROWVLWHPLQILJXUH 7KHKHDGLVDWWDFKHGWRSODWHLWHPLQILJXUHE\PHDQVRI ILWWLQJSLQV $VVHPEOLQJLVGRQHLQUHYHUVHRUGHU 8.6.3. X-axis Assembly 7KHPHFKDQLFDODVVHPEO\RIWKH;D[LVLVVKRZQLQILJXUH 8.6.3.1. X-axis: Replacement X-motor Only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ervice Manual Topaz PA 1309/10 8 - 25 Axes Systems 8.6.3.2. X-axis: Ball Screw Replacement 5HSODFLQJ WKH ;D[LV EDOO VFUHZ LV GRQH DV GHVFULEHG EHORZ 6HH IRU UHIHUHQFH ILJXUH 'RNOTUHPRYHWKH;PRWRU 'HWHUPLQHWKH;DQG<SRVLWLRQVE\SHUIRUPLQJWKHILUVWSDUWRIWKH DGMXVWPHQWSURFHGXUHRIWKH;PRWRUHQFRGHUSRVLWLRQEHIRUHUHPRYLQJWKH ;D[LVEDOOVFUHZ6HHVHFWLRQ 6ZLWFKRIIWKHPDFKLQH4XLWWKH9,26VRIWZDUHRSHUDWLRQDQGWXUQRIIWKH PDLQVZLWFKRIWKHPDFKLQH 5HPRYHWKHKHDGDVVHPEO\DVGHVFULEHGLQVHFWLRQ 5HPRYHWKHWZRJUHHQEROWVRIWKHJUHHQFRXSOLQJ Figure 8-25 X-axis ball screw 5HPRYHWKHIRXUEROWVILUPO\WLJKWHQHGRIWKHVXSSRUWXQLWDWWKHULJKW KDQGVLGH 'RNOTUHPRYHWKHKROGHUVDQG 5HPRYHWKHIRXUEROWVWKDWVHFXUHWKHEDOOVFUHZQXWKROGHUWRWKHKHDG KROGHUXQLW0RYHWKHKHDGKROGHUXQLWWRWKHOHIWDQGWKHEDOOVFUHZQXW KROGHUWRWKHULJKW *HQWO\ PRYH WKH EDOO VFUHZ WR WKH OHIW WR IUHH WKH VXSSRUW XQLW IURP WKH ;PRWRUKROGHU 5HPRYHWKHFLUFOLSDQGWKHEHDULQJRIWKHVXSSRUWXQLWRQWKHOHIWVLGH 1RZJHQWO\WDNHRXWWKHFRPSOHWHEDOOVFUHZDVVHPEO\ 'RNOTUHPRYHWKHLWHPVDQG 8 - 26 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems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axis: Linear Guide Replacement 8.6.4. 5HSODFLQJWKH;D[LVOLQHDUJXLGHVLVGRQHDVGHVFULEHGEHORZ6HHIRUUHIHUHQFH ILJXUH 5HPRYHWKHKHDGDVVHPEO\DVGHVFULEHGLQVHFWLRQ )URPWKHJXLGHWKDWPXVWEHUHSODFHGGLVFRQQHFWWKHJXLGHEHDULQJVIURPWKH KHDGKROGHUXQLWE\UHPRYLQJWKHEROWV 5HPRYH WKH JXLGH IURP WKH ;D[LV EHDP E\ UHPRYLQJ WKH EROWV KROGLQJ WKH JXLGH 5HSODFH WKH JXLGH DQG DVVHPEOH LQ UHYHUVH RUGHU 'XULQJ DVVHPEOLQJ WKH GLVWDQFHEHWZHHQWKHWZRJXLGHVLVIL[HGWRPP7KHERWWRPDQGWRSOLQHDU JXLGHDUHSDUDOOHOWRHDFKRWKHUZLWKQRWROHUDQFH Y-axis Assembly 7KHPHFKDQLFDODVVHPEO\RIWKH<D[LVLVVKRZQLQILJXUH 8.6.4.1. Y-axis: Replacement Y-motor Only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ervice Manual Topaz PA 1309/10 8 - 27 Axes Systems 8.6.4.2. Y-axis: Removing Y-axis Ball Screw Generation 2 5HPRYLQJDQGJHQHUDWLRQ<D[LVEDOOVFUHZLVGRQHDVGHVFULEHGEHORZ6HHIRU UHIHUHQFHILJXUH 'RNOTUHPRYHWKH<PRWRU 'HWHUPLQHWKH;DQG<SRVLWLRQVE\SHUIRUPLQJWKHILUVWSDUWRIWKH DGMXVWPHQWSURFHGXUHRIWKH<PRWRUHQFRGHUSRVLWLRQEHIRUHUHPRYLQJWKH <D[LVEDOOVFUHZ6HHVHFWLRQ 6ZLWFKRIIWKHPDFKLQH4XLWWKH9,26VRIWZDUHRSHUDWLRQDQGWXUQRIIWKH PDLQVZLWFKRIWKHPDFKLQH 5HPRYHWKHVXSSRUWXQLWEHDULQJ&LQWKHEDFNRIWKHPDFKLQH 5HPRYHWKHFRYHUDQGWKHORFNQXWZDWFKIRUWKH´FRSSHUFKLSµ ZKLFKLVXQGHUWKHVHWVFUHZ 5HPRYHWKHWKUHHVSULQJFRQHGGLVNV 5HPRYHWKHVOHHYHEHDULQJDQGWKHWKUXVWEHDULQJ 5HPRYHWKHIRXUKH[DJRQEROWVDQGWKHEHDULQJKROGHU 5HPRYHWKHFLUFOLSDQGWKHVXSSRUWXQLWEHDULQJ& Do NOT remove the Y-axis bearing holder (6). 7KHEDOOVFUHZLVQRZIUHHRQRQHVLGH Figure 8-26 8 - 28 Y-axis ball screw generation 2 5HPRYHWKHEDOOVFUHZ 0RYHWKHURERWDUPEDFNZDUGVQHDUWKH<D[LVEHDULQJKROGHU 5HPRYHWKHWZRKH[DJRQEROWVRIWKHJUHHQFRXSOLQJ 5HPRYHWKHIRXUKH[DJRQEROWV%WKDWVHFXUHWKHVXSSRUWXQLW$ Do NOT remove the Y-axis motor holder (5). 5HPRYHWKHIRXUKH[DJRQEROWVIURPWKHEDOOVFUHZZKLFKDUHPRXQWHG LQWKH<D[LVQXWKROGHU 1RZJHQWO\WDNHRXWWKHFRPSOHWHEDOOVFUHZ 5HPRYHWKHORFNQXWDQGVXSSRUWXQLW$ &RQWLQXHZLWKLQVWDOOLQJDQGDOLJQLQJWKHQHZ<D[LVEDOOVFUHZJHQHUDWLRQ VHHVHFWLRQ Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems 8.6.4.3. Y-axis: Removing Y-axis Ball Screw Generation 3 5HPRYLQJDUGJHQHUDWLRQ<D[LVEDOOVFUHZLVGRQHDVLVGHVFULEHGEHORZ6HH IRUUHIHUHQFHILJXUH 'RNOTUHPRYHWKH<PRWRU 'HWHUPLQHWKH;DQG<SRVLWLRQVE\SHUIRUPLQJWKHILUVWSDUWRIWKH DGMXVWPHQWSURFHGXUHRIWKH<PRWRUHQFRGHUSRVLWLRQEHIRUHUHPRYLQJWKH <D[LVEDOOVFUHZ6HHVHFWLRQ 6ZLWFKRIIWKHPDFKLQH4XLWWKH9,26VRIWZDUHRSHUDWLRQDQGWXUQRIIWKH PDLQVZLWFKRIWKHPDFKLQH 5HPRYHWKHVXSSRUWXQLWEHDULQJ&LQWKHEDFNRIWKHPDFKLQH 5HPRYHWKHORFNQXWZDWFKIRUWKH´FRSSHUFKLSµZKLFKLVXQGHUWKH VHWVFUHZ 5HPRYHWKHWKUHHVSULQJFRQHGGLVNV 5HPRYHWKHWKUXVWEHDULQJ 5HPRYHWKHIRXUKH[DJRQEROWVDQGWKHEHDULQJKROGHU 5HPRYHWKHFLUFOLSDQGWKHVXSSRUWXQLWEHDULQJ& Do NOT remove the Y-axis bearing holder (6). 7KHEDOOVFUHZLVQRZIUHHRQRQHVLGH Figure 8-27 5322 871 63606 01.05 Y-axis ball screw generation 3 5HPRYHWKHEDOOVFUHZ 0RYHWKHURERWDUPEDFNZDUGVQHDUWKH<D[LVEHDULQJKROGHU 5HPRYHWKHWZRKH[DJRQEROWVRIWKHJUHHQFRXSOLQJ 5HPRYHWKHIRXUKH[DJRQEROWV%WKDWVHFXUHWKHVXSSRUWXQLW$ Do NOT remove the Y-axis motor holder (5). 5HPRYHWKHIRXUKH[DJRQEROWVIURPWKHEDOOVFUHZZKLFKDUHPRXQWHG LQWKH<D[LVQXWKROGHU 1RZJHQWO\WDNHRXWWKHFRPSOHWHEDOOVFUHZ 5HPRYHWKHORFNQXWDQGVXSSRUWXQLW$ &RQWLQXHZLWKLQVWDOOLQJDQGDOLJQLQJWKHQHZ<D[LVEDOOVFUHZJHQHUDWLRQ VHHVHFWLRQ Service Manual Topaz PA 1309/10 8 - 29 Axes Systems 8.6.4.4. Y-axis: Installing and Aligning Y-axis Ball Screw Generation 3 )RUUHSODFLQJDUGJHQHUDWLRQ<D[LVEDOOVFUHZDUHSODFHPHQWNLWLVDYDLODEOH :KHQDQGJHQHUDWLRQ<D[LVEDOOVFUHZLVUHSODFHGIRUDUGJHQHUDWLRQ<D[LV EDOOVFUHZRUGHULQJDJUHDVHQLSSOHLQDGGLWLRQWRWKHUHSODFHPHQWNLWLV UHFRPPHQGHG 6HHIRUUHIHUHQFHILJXUHVDQG &KHFNWKHSDUWVRIWKHUHSODFHPHQWNLWOLVWHGLQWDEOH Item Service number (12NC) Complete replacement kit: 3 8-27 5322 816 11327 4A/B/C 8-27 5322 520 40305 20 8-27/28 5322 816 11298 25 8-27/28 5322 816 11296 26 8-27/28 5322 816 11297 27 8-27/28 5322 816 11292 31 8-28 5322 526 10729 Table 8-3 Description Qty Ball screw Support unit Bearing holder Thrust bearing Spring coned disk Lock nut Grease nipple 1 1 1 1 3 1 2 Y-axis ball screw replacement kit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igure 8-28 8 - 30 Figure Replacement of generation 2 ball screw for generation 3 ball screw Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems Difference generation 2 and generation 3. nd rd The difference between the 2 and 3 generation ball screw assembly is found in the Bearing holder (34), Sleeve bearing (32) and thrust bearing(36). In the 3rd generation these have been changed for a new Bearing holder (20) and new Thrust bearing (25) only. See figure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igure 8-29 5322 871 63606 01.05 alignment tool of the Y-axis ball screw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ervice Manual Topaz PA 1309/10 8 - 31 Axes Systems 8.6.4.5. Y-axis: Pre-tension Adjustment (Generation 3 Y-axis) 7KH<D[LVEDOOVFUHZKDVWKUHHVSULQJFRQHGGLVNVZKLFKFRQWUROWKHWHQVLRQRI WKH<D[LVPRYHPHQW6HHIRUUHIHUHQFHILJXUH 0DNHVXUHWKHVXUIDFHRIWKHJXLGHVDQGEDOOVFUHZLVIUHHRIGLUWDQGRYHUGXH JUHDVH 0DNHVXUHWKHVSULQJFRQHGGLVNVDUHWLJKWHQHGVRWKH\MXVWWRXFKHDFKRWKHU RQO\ $SSO\RQHVKRUWWXUQGHJUHHVWRWKHORFNQXW)LJE\KDQG RQO\VHHILJXUH Figure 8-30 Adjusting the pre-tension 0RYHWKH<D[LVE\XVHRIDQ\XWLOLW\SURJUDP 2QO\WLJKWHQWKHORFNQXWVOLJKWO\PRUHLIWKHD[LVPDNHVQRLVHSUHVV(0* VZLWFKILUVW 0D[SUHWHQVLRQDGMXVWPHQWLVOHVVWKDQGHJUHHVWXUQ 7LJKWHQWKHVHWVFUHZZDWFKIRUWKHFRSSHUFKLSRIWKHORFNQXWVHHILJXUH Set screw Copper chip Lock nut Figure 8-31 8 - 32 Lock nut set &KHFNLIDOOEROWVRIWKH<D[LVDUHWLJKWHQHGZHOO Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems 8.6.4.6. Y-axis: Linear Guide Replacement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ervice Manual Topaz PA 1309/10 8 - 33 Axes Systems 8.6.5. Z-axis Assembly 7KHPHFKDQLFDODVVHPEO\RIWKH=D[LVLVGHWDLOHGLQILJXUH Z-axis: Z-Motor replacement 5HSODFHWKH=PRWRUE\SURFHGLQJDVIROORZV 5HPRYHWKHKHDGDVVHPEO\DVGHVFULEHGLQWKHEHJLQQLQJRIWKLVVHFWLRQWKLVLV QRW DEVROXWHO\ QHFHVVDU\ EXW HDV\ ,I WKH KHDG LV QRW UHPRYHG PDNH VXUH WR GLVFRQQHFWWKHPRWRUDQGHQFRGHUFDEOHIURPFRQQHFWRUSODWHLWHPLQILJXUH 5HPRYHWKHPRWRUE\ORRVHQLQJWKHIRXUVFUHZVLWHPKROGLQJLWWREUDFNHW $VVHPEOHLQUHYHUVHRUGHU Z-axis: Z-bearing replacement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axis Assembly 7KHPHFKDQLFDODVVHPEO\RIWKH5$[HVRIWKH7RSD]LVVKRZQLQILJXUH 7KH7RSD]XVHVDEHOWGULYHZKLOHWKHHQFRGHUDSDUWLVRIWKH5PRWRUDVVHPEO\ R-Axis: Replacing the Nozzle Holder 1) 2) 3) 8 - 34 5HPRYHWKHOHDIVSULQJVLWHPE\PHDQVRIVFUHZWDNHFDUHQRWWRORRVH WKHZDVKHULWHP 5HPRYHWKHSLQLWHP·LQILJXUHD7KHSLQKDVWREHGULYHQRXWRIWKH KROHEHIRUHUHSODFLQJWKHQR]]OHKROGHULVSRVVLEOH7KHEHVWZD\WRGRWKLVWR PDNHVXUHWKHVSOLQHLVVXSSRUWHGDWWKHUHDUVLGHDQGE\XVLQJDVPDOOSLQWR GULYHWKHSLQRXWRIWKHVKDIW 5HDVVHPEOHWKHQHZQR]]OHKROGHUDQGOHDIVSULQJVLQWKHUHYHUVHZD\ &KHFNWKHOHDIVSULQJVLIWKH\FDQKROGWKHQR]]OHZHOOLIQRWUHSODFHWKHVSULQJV Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Axes Systems R-axis: Replacing the Spline Shaft 5HSODFHPHQWRIWKHVSOLQHVKDIWLVGRQHDVIROORZV 5HPRYH WKH KHDG DVVHPEO\ IURP WKH PDFKLQH DV GHVFULEHG LQ WKH SUHYLRXV VHFWLRQ /RRVHQEHOWLWHPDQGUHPRYHWKHEROWV5HPRYHLWHPVDQG ORRVHQFLUFOLS7KHVSOLQHVKDIWFDQQRZEHUHPRYHG 5HDVVVHPEOHLQWKHUHYHUVHRUGHU 1) 2) 3) R-axis: Replacing and Maintaining the Piston and Plugs Assy’s 7KLVSDUWGHVFULEHVKRZWRUHSODFHSDUWVRIWKHSLVWRQDQGSOXJVDVV\·VDVZHOO DVZKDWKDVWREHGRQHWRPDLQWDLQWKHP 1) 2) 3) 4) 5) 6) 5322 871 63606 01.05 7KHSLVWRQDVV\RIKHDGLVGLIIHUHQWIURPKHDGVWREXWWKHPDLQWHQDQFH DFWLRQVDUHVLPLODUIRUERWK'LVDVVHPEOLQJLVGRQHDVIROORZV 'LVDVVHPEOLQJWKHSLVWRQDVV\LVGRQHE\UHPRYLQJWKHSOXJDVV\LWHP $OODVV\·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ervice Manual Topaz PA 1309/10 8 - 35 Axes Systems Intentionally left blank. 8 - 36 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems CHAPTER 9 Vision Systems 9.1. Introduction 7KLVFKDSWHUGHVFULEHVWKHYLVLRQV\VWHPVWKDWDUHXVHGLQWKH7RSD] 9.2. Vision Systems 7KHVWDQGDUGPRGHORI7RSD]XVHVIROORZLQJFDPHUDUHFRJQLWLRQHTXLSPHQW l $PRYLQJFDPHUDWRUHFRJQLVHWKH3&%ILGXFLDOPDUNVWREHDEOHWRFRUUHFW IRUDQ\VKLIWVLQWKH3&%OD\RXW l 2QHLQWKHIURQWRUWZRVHFRQGDWWKHEDFNOLQHDUVHQVRUFDPHUDV\VWHPV DOVRUHIHUUHGWRDVPXOWLFDPHUD7KLVFDPHUDLVXVHGWRUHFRJQLVH FRPSRQHQWVDVFKLSVHWF7KHFDPHUDXVHVDRQHOLQH&&'WRUHDGRQHOLQH RIWKHSLFWXUHDWDWLPHWKHSLFWXUHRIWKHFRPSRQHQWLVEXLOGE\IO\LQJ RYHUWKHFDPHUDZLWKDVSHFLILHGVSHHGDQGVWRULQJOLQHE\OLQHLQPHPRU\ l 2QH&&'FDPHUDDOVRUHIHUUHGWRDVWKHVLQJOHYLVLRQFDPHUDWRUHFRJQLVH FRPSRQHQWDV4)3HWF 7KLVVHFWLRQGHVFULEHVKRZWRDGMXVWWKHYLVLRQV\VWHP$OODGMXVWPHQWLWHPVFDQ EHDGMXVWHGZLWKWKHXWLOLWLHVLQWKH0DFKLQH$GMXVWPRGHRIWKHPDLQWHQDQFH 0DQDJHU %HDZDUHWKDWWKHVHFRQGPXOWLFDPHUDZKLFKLVDQRSWLRQUHGXFHVWKH PD[LPXP3&%ZLGWKIURPPPWRPP Figure 9-1 5322 871 63606 01.05 Vision Systems of the Topaz Service Manual Topaz PA 1309/10 9- 1 Vision Systems 9.2.1. Pre-Start Operations 3ULRUWRWKHFDPHUDDGMXVWPHQWVHVSHFLDOO\WKHVLQJOHDQGPXOWLFDPHUD DGMXVWPHQWVLWLVZLVHWRSHUIRUPRQHRUPRUHRIWKHIROORZLQJSUHVWDUW RSHUDWLRQV l ,ID)(6LVLQVWDOOHGWRIURQWRIWKHV\VWHPUHPRYHWKH)(6FDUULDJHWR HQDEOHHDV\DFFHVVWRWKHPXOWLDQGLILQVWDOOHGDOVRWKHVLQJOHYLVLRQ FDPHUD ,ID)(6LVLQVWDOOHGDWWKHEDFNVLGHRIWKHV\VWHPUHPRYHWKH)(6FDUULDJH LIDQRSWLRQDOVHFRQGPXOWLFDPHUDLVLQVWDOOHG l ,I12)(6LVLQVWDOOHGDWWKHIURQWRIWKHV\VWHPUHPRYHWKHWDSHZDVWH JXLGHRIWKHIURQWIHHGHUEDUWRHQDEOHHDVLHUDFFHVVWRWKHFDPHUD·VDWWKH IURQW ,IWKHRSWLRQDOVHFRQGPXOWLFDPHUDLVLQVWDOOHGDWWKHEDFNRIWKHV\VWHP WKDQUHPRYHWKHWDSHZDVWHJXLGHDOVRIURPWKHUHDUIHHGHUEDU 9.3. Moving Camera 7KHPRYLQJFDPHUDLVORFDWHGLQWKHKHDGDVVHPEO\DQGXVHGWRUHFRJQLVH3&% ILGXFLDOPDUNVDQGSHUIRUPWHDFKLQJ7KHOLJKWLQJOHYHODQGWKHVFDOHRIWKH PRYLQJFDPHUDFDQEHDGMXVWHG 9.3.1. Adjusting the Focus and Field Of View )RFXVLQJWKHPRYLQJFDPHUDLVDIDLUO\VLPSOHSURFHVV:KLOHORRNLQJDW VRPHWKLQJRQWKH3&%WKDWSURYLGHVJRRGFRQWUDVWVLPSO\PRYHWKHFDPHUDXS RUGRZQDVQHFHVVDU\WRREWDLQWKHVKDUSHVWSLFWXUH2QHWKLQJWRNHHSLQPLQG ZKLOHPRYLQJWKHFDPHUDLVWRNHHSLWVWUDLJKWKDVDGLUHFWLPSDFWRQWKHVFDOH SURFHGXUH NOTE: You may use a fiducial for focus, however, any thing on the board that provides good contrast and detail will work (i.e. any writing or etchings on the board). 6\QRSVLV )L[DERDUGLQSODFHWKDWKDVDJRRGFOHDUILGXFLDO*RWRWKHGDWDEDVHDQG SHUIRUPDQ)IXQFWLRQ8VHWKH´7HDFK0DUNµVHFWLRQWRPRYHWKHFDPHUD RYHUWKHILGXFLDODQGWKHQPRYHWKHFDPHUDXSRUGRZQDVQHFHVVDU\WRREWDLQ WKHVKDUSHVWSLFWXUH'RQ·WIRUJHWWRNHHSWKHFDPHUDVWUDLJKW $GMXVWLQJWKHIRFXV 6HWXSWKHWUDQVSRUWVHFWLRQWRUHFHLYHWKH3&%WREHXVHGIRUWKLVVHFWLRQXVHD 3&%WKDWKDVDUHIOHFWLYHILGXFLDOGRQ WXVHWKHJODVVSODWH7KLVLVWKHVDPHDVD SURGXFWFKDQJHRYHUZLWKRXWWKHIHHGHUV *RWRWKH'DWDEDVH'$7$0→'$7$%$6(→0$5.'% 0RYHWKHFXUVRUWRDQ\OLQHFRQWDLQLQJDILGXFLDODQGSUHVV)\RXZRQ·W DFWXDOO\XVHWKHZKROH)IXQFWLRQ 9-2 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems 7KHFXUVRUZLOOEHRQWKH´),;3&%µOLQH3UHVV(QWHU,IWKHERDUGLVDOUHDG\ IL[HGLQSRVLWLRQPRYHWKHFXUVRUWR´5(7851µDQGSUHVV(QWHU,IWKHERDUG LVQRWLQSODFHIL[LWLQSODFHDWWKLVWLPHWKHQJRWR´5(7851µDQGSUHVV (QWHU 0RYHWKHFXUVRUWR´7($&+0$5.µ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djusting the Lighting Level of the Moving Camera )RUDFFXUDWHUHFRJQLWLRQRI3&%ILGXFLDOPDUNVWKHOLJKWLQJOHYHORIWKH PRYLQJFDPHUDPXVWEHRSWLPLVHG7RPDNHWKHDGMXVWPHQWDQRSWLRQDO FXVWRPWRROOLJKWDGMXVWHUSODWHVKRXOGEHXVHG NOTE: If fiducial lighting unit has 1 dial and three potentiometers, and you have a light adjuster tool (part number 5322 395 10274) you should use the special tool option in Moving Camera Light. This will take you through adjusting the individual light of the moving camera. Inner Light, Outer Light, and Coaxial, with each dial position being set for each position. Ensure to reset the Dial position to 0 so all light types will be available to the machine. When using the light adjuster tool, ensure that the lighter side of the tool is in full view of the camera when setting the lighting level. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 3 Vision Systems 7KLVDXWRPDWHGSURFHGXUHFKHFNVWKHEULJKWQHVVRIWKH/('OLJKWVIRUWKH PRYLQJFDPHUD7RGRWKLV\RXZLOOQHHGWRIL[DERDUGLQSRVLWLRQWKDWKDVD FOHDQILGXFLDO,WLVSUHIHUUHGWRXVHDFLUFOHRIDWOHDVWPP 7KHUHLVDGLUHFWUHODWLRQVKLSEHWZHHQWKH7KUHVKROGYDOXHRIWKHPDUNDQGWKH OHYHORIOLJKWWKHPDFKLQHZLOODFFHSWDV´2.µ%HIRUHSHUIRUPLQJWKLV SURFHGXUHLWLVUHFRPPHQGHGWRJRWRWKHGDWDEDVHZKHUHWKLVPDUNUHVLGHVDQG ILQGRXWZKDWWKH7KUHVKROGYDOXHLVVHHVHFWLRQ$→IRU GLUHFWLRQVKRZWRJHWWKHUH2QFHLQWKHGDWDEDVHSUHVVWKH)NH\XQWLOWKH ´9LVLRQ,QIRµVXEZLQGRZLVGLVSOD\HG,QWKLVVXEZLQGRZLVWKH7KUHVKROG YDOXH7KHOLJKWLQJOHYHOQHHGHGWRSURGXFHDQ´$YHUDJH*UD\/HYHOWKDWLV ´2.µLVYHU\FORVHWRWKLVOHYHO 1. Prepare the light adjuster plate. 3UHSDUHWKHOLJKWDGMXVWHUSODWHDQGDSURSHU3&%RQZKLFKWKHOLJKW DGMXVWHUFDQEHSODFHG3&%ILGXFLDOPDUNVDUHQRWQHFHVVDU\ 2. Execute the “Mov.Cam. Light” command. 6HOHFW%$'-8677$5*(7!µ0RY&DP/LJKWµDQGSUHVVWKH >(17(5@NH\ 6HOHFW'LDOVFUHZV 6HOHFW8VHIRUWKHVSHFLDOWRRO <<<APPLICATION>>> <<MODE>> <COMMAND_LIST> 3/MAINTE/M 3/MCH_ADJUST B/SAVE B1 ADJUST TARGET Object Mov.Cam.Light A650 This procedure adjusts the light intensity of the moving camera. The way of . . . LED Type 0 Dial + 2 screws 1 Dial + 3 screws A651 Please select whether you will use a Light Adjuster (special adjustment . . . Special Tool Use Not Use A653 This adjustment requires placing . . . PCBwidth(mm) 128 A303 CAUTION! The axes will move. A426 Please put the specified PCB at the mounting . . . Figure 9-2 9-4 Moving camera light adjustment procedure Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems 3. Enter the width of the PCB and press the [ENTER] key. (QWHUWKHZLGWKPLOOLPHWUHVRIWKH3&%XVHGLQWKLVDGMXVWPHQW 4. Ensure safety, then press the [ENTER] key again. 7KH:D[LVPRYHVWRVHWWKHVSHFLILHGFRQYH\RUZLGWK 5. Press emergency button, set the PCB & light adjuster plate. $OLJQWKHORFDWHSLQVZLWKWKHFHQWUHRIWKHSRVLWLRQLQJKROHVRIWKH3&% 7KHQSODFHWKHOLJKWDGMXVWHUSODWHLQWKHFHQWUHRIWKH3&%ZLWKWKHWZR WRQHVXUIDFHIDFLQJXS 6. Adjust the conveyor unit. $GMXVWWKHSRVLWLRQVRIWKHORFDWHSLQDQGSXVKXSSLQVWRPDWFKWKH3&% 7. Cancel emergency stop. (QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH >5($'<@EXWWRQRIWKH++. 8. Press the [ENTER] key. 7KHORFDWHSLQVDQGSXVKXSSLQVULVHWRVHFXUHWKH3&%DQGWKHKHDG DVVHPEO\PRYHVWRRYHUWKH3&%7KHWHDFKLQJVFUHHQIRUWKHOLJKWDGMXVWHU SODWHWKHQDSSHDUV HSV A655 <<<Teaching>>> Please position the cross hair cursor over the Light Adjuster … Figure 9-3 Adjusting light intensity 9. Adjust the camera position. :KLOHPDQLSXODWLQJWKH++.MR\VWLFNDGMXVWWKHSRVLWLRQRIWKHPRYLQJ FDPHUDVRWKDWWKHOLJKWJUH\DUHDRQWKHOLJKWDGMXVWHUSODWHLVGLVSOD\HGRYHU WKHHQWLUHILHOGRIYLHZ OK Figure 9-4 NG Position the light adjuster tool 10. Adjust the camera lighting level according to the messages. 7KHPRYLQJFDPHUDOLJKWLQJSDWWHUQLVGLYLGHGLQWRDWULSOHULQJHGDUHD RXWHULQQHUDQGFRD[LDO 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 5 Vision Systems $GMXVWWKHOLJKWLQJOHYHOIRUHDFKSDWWHUQE\XVLQJWKH/('WULPPHUVDQG VHOHFWLQJWKHOLJKWLQJSDWWHUQZLWKWKHURWDU\VZLWFK7KUHH/('WULPPHUV DUHORFDWHGRQWKHVLGHRIWKHPRYLQJFDPHUDOLJKWXQLWIRUDGMXVWPHQWRI WKHRXWHULQQHUDQGFRD[LDODUHDV7KHOLJKWOHYHOLQFUHDVHVE\WXUQLQJWKH WULPPHUWRWKHULJKWFORFNZLVHDQGGHFUHDVHVE\WXUQLQJLWWRWKHOHIW $GMXVWHDFKWULPPHUVRWKDWWKH´$YH*UD\/HYHOYDOXHGLVSOD\HGDWWKH XSSHUULJKWRIWKHRSHUDWLRQPRQLWRUPDWFKHVWKHRSWLPXPOHYHOLQGLFDWHG LQWKHWDEOHEHORZ A657 In this type of LED light, turning the dial next to 3 screws enables outer, inner and … A658 Please adjust the light intensity of outer LED by turning … A659 Please adjust the light intensity of inner LED by turning the screw in the middle of 3 screws. until … A660 Please adjust the light intensity of coaxial LED by turning … Figure 9-5 Calibration procedure Figure 9-6 Fiducial light adjustment Inner Rotary SW Outer Middle (coaxial) Optimum level 0 ❍ ❍ Normal lighting pattern ❍ ❍ 1 ❍ 2 ❍ 3 ❍ 4 ❍ 5 ❍ – ❍ 50±5 ❍ 7 Figure 9-7 9-6 – 50±5 ❍ 6 – 20±5 – Optimum level settings Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems 11. Return the rotary switch to "0". :KHQDGMXVWPHQWRIHDFKOLJKWLQJSDWWHUQLVFRPSOHWHVHWWKHURWDU\ VZLWFKWRDOO/('·VWXUQHGRQ 12. Press the [ESC] key to quit the adjustment. 7KHORFDWHSLQVDQGSXVKXSSLQVDUHDXWRPDWLFDOO\UHOHDVHG$IWHUSUHVVLQJ WKHHPHUJHQF\VWRSEXWWRQUHPRYHWKH3&%7KHUHLVQRPDFKLQHGDWDWR EHVDYHGLQWKLVDGMXVWPHQW 9.3.3. Adjusting the Moving Camera Scale 7KHPRYLQJFDPHUDVFDOHLVDYLVLRQSDUDPHWHUUHSUHVHQWLQJDPHDVXUHPHQW HTXLYDOHQWWRRQHSL[HO7KLVVFDOHPXVWEHDGMXVWHGFRUUHFWO\IRUDFFXUDWH UHFRJQLWLRQRI3&%ILGXFLDOPDUNV7RPDNHWKHDGMXVWPHQW\RXZLOOQHHGD 3&%KDYLQJDILGXFLDOPDUNRINQRZQVL]H 1) Preparing the PCB (normal PCB) 3UHSDUHD3&%KDYLQJDSUHFLVHILGXFLDOPDUNWKDWLVUHJLVWHUHGLQWKH GDWDEDVH:KHQ\RXXVHD3&%KDYLQJDPDUNQRWUHJLVWHUHGLQWKH GDWDEDVHLWPXVWEHUHJLVWHUHG NOTE: Use of a circular mark is recommended since circular marks are generally superior in dimensional precision to other marks. Use of a 1mm diameter circular mark that faithfully reflects light is especially preferred. (A doughnut shape is not suited for use in this adjustment.) Check the registration in the mark database. 7RRSHQWKHPDUNGDWDEDVHVHOHFW'$7$%$6(!$ &20321(170$5.'%!0$5.'$7$%$6(DQGSUHVVWKH >(17(5@NH\ &KHFNIRUWKHUHJLVWUDWLRQGDWD&KHFNLQSDUWLFXODUWKDWWKHPDUNVL]H RIWKH3&%H[DFWO\PDWFKHVWKHUHJLVWUDWLRQGDWD0DUN2XW6L]H&KHFN DOVRWKDWWKH6HDUFK$UHDSDUDPHWHULQWKH9LVLRQ,QIRVXEZLQGRZLV RUODUJHUQRWWRRODUJHEXWDOVRQRWVPDOOHUWKDQ Sub-window <<<APPLICATION>>> <<MODE>> OBJ : MARK No. 151 2/DATA/M 3/DATABASE DATABASE MARK NAME Mark size Info. COMMENT Edit Term Mark OutSize : : mm 1.0 CIRCLE_1.0_Cu Vision Info. Figure 9-8 Edit Term : Search Area : 4:00 Mark data base Open the Adjust Assist. to check that the mark is clearly recognized. 7KH$GMXVW$VVLVWDQWVFUHHQDSSHDUVE\SUHVVLQJWKH>)@NH\ Secure the PCB on the conveyor by means of the FIX PCB command. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 7 Vision Systems $GMXVWWKHFRQYH\RUXQLWDFFRUGLQJWRWKHVL]HRIWKH3&%\RXDUHJRLQJWR XVH$IWHUSUHVVLQJWKHHPHUJHQF\VWRSEXWWRQPDNHQHFHVVDU\DGMXVWPHQWV WRWKHORFDWHSLQVDQGSXVKXSSLQV7KHWHVWERDUG&7LVPP ZLGH Execute the VISION TEST command. :KHQQRHUURUVRFFXUWKHFXUUHQWSDUDPHWHUVHWWLQJVDUHDSSURSULDWH $GYDQFHWRWKHPRYLQJFDPHUDVFDOHDGMXVWPHQWLQWKHQH[WVHFWLRQ,IDQ HUURURFFXUVDGMXVWWKHPRYLQJFDPHUDOLJKWLQJSDWWHUQDQGRUPDUN LQIRUPDWLRQSDUDPHWHUVDVQHFHVVDU\)RUPRUHGHWDLOVRQWKHSDUDPHWHU VHWWLQJVUHIHUWRWKHPRXQWHURSHUDWLRQPDQXDO 2) Preparing the PCB (glass PCB) :KHQXVLQJDJODVV3&%VSHFLDOO\WDLORUHGIRUFDPHUDVFDOHDGMXVWPHQW IROORZWKHVHVWHSV Prepare a glass PCB which is set in the jig. $JODVV3&%ZLWKLQ3$VHWZLWKWKHMLJGHVLJQHGIRUWKLV DGMXVWPHQWLVDYDLODEOHIURP3+,/,36'RQRWUHPRYHWKH3&%IURPWKHMLJ GXULQJDGMXVWPHQW Register the mark on the PCB in the mark database. 2SHQWKHPDUNLQIRUPDWLRQVFUHHQ 6HOHFW'6:,7&+3&%'$7$!$0)B4)30DUN,QIR DQGSUHVVWKH>(17(5@NH\ &KHFNWKDWWKHGDWDEDVH1XPEHURIWKH1RPDUNGDWDLV 3UHVVWKH>(6&@NH\VHOHFWWKH%6(7)520'$7$%$6(! FRPPDQGZLWKWKHDUURZNH\VDQGSUHVVWKH>6+,)7@>(17(5@NH\V $QDOHUWPHVVDJHDSSHDUVEXWSURFHHGDVLQGLFDWHGWRH[HFXWHWKLV FRPPDQG Sub-window <<<APPLICATION>>> <<MODE>> OBJ : MARK No. 151 2/DATA/M 3/DATABASE DATABASE MARK NAME Mark size Info. COMMENT Edit Term Mark OutSize : : mm 1.0 CIRCLE_1.0_Cu Vision Info. Figure 9-9 Edit Term : Search Area : 4:00 Mark info screen Check for the registration data in the mark database. 2SHQWKHPDUNGDWDEDVH6HOHFW'$7$%$6(!$ &20321(170$5.'%!0$5.'$7$%$6(DQGSUHVVWKH >(17(5@NH\WRRSHQWKHPDUNGDWDEDVH 3UHVVWKH>)@NH\DQGWKHQ>(6&@NH\7KH&+$1*(326,7,21ER[ DSSHDUVVRHQWHUDQGSUHVVWKH>(17(5@NH\ &KHFNWKDWWKHGDWDLVHQWHUHGLQ1R Change the moving camera lighting setting. 6HWWKHPRYLQJFDPHUDURWDU\VZLWFKWRVRWKDWWKHOLJKWLQJLVRSWLPL]HG IRUUHFRJQL]LQJWKHJODVV3&% 9-8 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems Check that the mark is clearly recognized in the Adjust Assistant. 7KH$GMXVW$VVLVWDQWVFUHHQDSSHDUVE\SUHVVLQJWKH>)@NH\ Secure the PCB on the conveyor with the FIX PCB command. )RU&219(<25:,'7+HQWHU7KHQSUHVVWKHHPHUJHQF\VWRS EXWWRQDQGPDNHQHFHVVDU\DGMXVWPHQWVWRWKHORFDWHSLQVDQGSXVKXSSLQV Execute the VISION TEST command. :KHQQRHUURUVRFFXUWKHFXUUHQWSDUDPHWHUVHWWLQJVDUHDSSURSULDWH $GYDQFHWRWKHPRYLQJFDPHUDVFDOHDGMXVWPHQWLQWKHQH[WVHFWLRQ,IDQ HUURURFFXUVDGMXVWWKHPDUNLQIRUPDWLRQSDUDPHWHUVDVQHFHVVDU\)RUPRUH GHWDLOVRQWKHSDUDPHWHUVHWWLQJVUHIHUWRWKHPRXQWHURSHUDWLRQPDQXDO 3) Adjusting the moving camera scale :KHQ\RXKDYHSUHSDUHGWKH3&%XVHWKHIROORZLQJVWHSVWRFDOLEUDWHWKH PRYLQJFDPHUDVFDOH Execute the “Mov.Cam. Scale” command 6HOHFW%$'-8677$5*(7!µ0RY&DP6FDOHµDQGSUHVVWKH >(17(5@NH\ <<<APPLICATION>>>1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH-ADJUST 4/MANUAL 0/EXIT <COMMAND_LIST> A/CHANGE-CONDTION B/SAVE & QUIT C/DISPLAY & EXIT B1 ADJUST TARGET Object Mov.Cam. Scale <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH-ADJUST 4/MANUAL 0/EXIT A420 This procedure adjusts the vertical (Y) and horizontal (X) scales of the moving camera. A fiducial mark is meeded for this adjustment. Recommended is an easy recognizable · · · Mark No. 153 A422 Please input the PCB width (mm) which you want to use and confirm if the PCB uses the fiducial that is described in the used mark database number. · · · PCB width (mm) 128 A423 By moving the axes, the fiducial mark will be recognized in three steps. Please input the allowed moving distance : 1 ↔ 3 (mm). The unit of · · · Distance (mm/10) 20 A303 CAUTION!! The axes will move. After confirming safety, please press the [ENTER] key. A426 Please set the specified PCB on the mount position. When using your hands, you must first press the EMG STOP button. After the board is inserted on the · · · Figure 9-10 Moving scale adjustment Enter the mark database No. and press the [ENTER] key. +HUHHQWHUWKHGDWDEDVH1RRIWKHPDUNRQWKH3&%\RXDUHXVLQJ Check or enter the width of the PCB and press the [ENTER] key. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 9 Vision Systems 7KHZLGWKRIWKH3KLOOLSVERDUGLVPPDQGRIWKHJODVV3&%PP Confirm that “Distance (mm/10) 15” is displayed, and press [ENTER]. 1RUPDOO\DPRYHPHQWGLVWDQFHRI´µLQWHQWKVRIDPLOOLPHWHULV UHFRPPHQGHG Ensure safety, then press the [ENTER] key again. 7KH:D[LVPRYHVWRVHWWKHVSHFLILHGFRQYH\RUZLGWK:KHQ\RXKDYH DOUHDG\DGMXVWHGWKHFRQYH\RUZLGWKIRUSHUIRUPLQJWKH$GMXVW$VVLVWDQWLQ WKHSUHYLRXVVHFWLRQWKH:D[LVGRHVQRWPRYH Press the emergency stop button, then set the PCB in position. :KHQWKH3&%KDVDOUHDG\EHHQVHWRQWKHFRQYH\RUVNLSWKLVVWHS Cancel emergency stop. ,I\RXKDYHVHWHPHUJHQF\VWRSLQ6WHSUHOHDVHWKHHPHUJHQF\VWRSEXWWRQ DQGSUHVVWKH>5($'<@EXWWRQRQWKH++. Ensure safety, then press the [ENTER] key. 7KHORFDWHSLQVDQGSXVKXSSLQVULVHWRVHFXUHWKH3&%DQGWKHKHDG DVVHPEO\PRYHVWRRYHUWKH3&%7KHWHDFKLQJVFUHHQIRUWKHILGXFLDOPDUN SRVLWLRQWKHQDSSHDUV 3/MCH-ADJUST <<MODE>> A427 <<<Moving!!>>> Now it is fixing the PCB and moving the axes. To quit, please press the [ESC] key. A428 <<<Teaching>>> Please set the fiducial mark on the center cross cursor of the monitor by using the joy stick. After teaching, please press the [ENTER] key. To quit, please press the [ESC] key. Figure 9-11 Teaching fiducials Position the fiducial mark in the center of the screen. 0DQLSXODWHWKH++.MR\VWLFNWRDOLJQWKHPDUNZLWKWKHFURVVFXUVRULQWKH FHQWHURIWKHVFUHHQ Figure 9-12 9 - 10 Mark info screen Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems Press the [ENTER] key to start calibration. 7KHPRYLQJFDPHUDPRYHVLQERWK;DQG<GLUHFWLRQV 7KHDPRXQWRIPRYHPHQWRQWKHYLVLRQPRQLWRULVFDOLEUDWHGDQGWKH UHVXOWVDUHWKHQGLVSOD\HGRQWKHVFUHHQ 3/MCH_ADJUST <<MODE>> A431 <<<RESULT>>> The following data is the result of the adsjustment of the moving camera scales. To save the result in memory, press the [ENTER] key (contents are not saved on disk). To abandon, press the [ESC] key. Figure 9-13 Scale_x Scale_y Angle = = = xx.xx yy.yy rr.rr Start calibration 7KHFRUUHFWYDOXHVIRUWKHPRYLQJFDPHUDDUHDVVKRZQLQWDEOH Average FOV 4.8mm Table 9-1 Scale range of X and Y value 10.5 ±0.2 (µm/pixel) X/Y scale ratio Angle R 1.00 ±0.01 0° ±0.5° Moving camera ,IWKHVFDOHYDOXHLVQRWZLWKLQOLPLWVPRYHWKHFDPHUDXSRUGRZQDQG DGMXVWWKHFDPHUDVFDOHDJDLQ ,IWKHURWDWLRQLVRIIURWDWHWKHFDPHUDDQGDGMXVWWKHFDPHUDVFDOHDJDLQ Press the [ENTER] key to save the calibrated results. 3UHVVWKH>(6&@NH\LI\RXZDQWWRFDQFHOWKHUHVXOWV Save the calibration settings. 6HOHFW%6$9('$7$!RU%6$9(48,7!DQGSUHVVWKH>(17(5@ NH\7RTXLWZLWKRXWVDYLQJVHOHFW%5(&29(5$'-867!RU% 48,7!DQGSUHVVWKH>(17(5@NH\ Press the emergency stop button, then remove the PCB. %HIRUHUHPRYLQJWKH3&%WKHFODPSLQJPXVWEHUHPRYHGWKLVFDQEHGRQH E\PHDQVRIWKH'2VFUHHQ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 11 Vision Systems 9.4. Single Camera Adjustment 7KLVVHFWLRQGHVFULEHVWKHFDOLEUDWLRQRIWKHVLQJOHFDPHUD,IQRWLQVWDOOHGWKDQ VNLSWKLVVHFWLRQ 9.4.1. Maximum Component Size and Field Of View 7KLVSURFHGXUHH[SODLQVKRZWRDGMXVWWKHPD[LPXPFRPSRQHQWVL]H7KH PD[LPXPFRPSRQHQWVL]HLVGLUHFWO\UHODWHGWRWKH)LHOG2I9LHZ)RUWKH7RSD] WKHUHFRPPHQGHG)LHOG2I9LHZLVPPRUODUJHUWKHPD[LPXPFRPSRQHQWLV PPVTXDUH 7RDGMXVWXVHDWUDQVSDUHQWUXOHUVKHHWWLSFRS\RQDFRS\PDFKLQHDUXOHURQD WUDQVSDUHQWVKHHW 6HWWKHIRFXVULQJLQWKHPLGGOHSRVLWLRQ 6HOHFWWKHDGMXVWDVVLVWDQW)!NH\SLFNXSWKHUXOHUVKHHWDQGEULQJLWDERYH WKHVLQJOHFDPHUDRQZKLFK\RXZDQWWRDGMXVWWKHDSHUWXUH$GMXVWWKH)LHOG2I 9LHZVL]HE\VKLIWLQJWKHFDPHUDXSRUGRZQ Figure 9-14 Ruler sheet on the vision monitor NOTE: Adjusting the Field Of View too large may give problems with the nozzle back plate. If you can see two stripes on the screen as shown in the figure 9-15 below please readjust again. White stripes next to the nozzle back plate may influent the recognition of components in a negative way. nozzle back plate Figure 9-15 9 - 12 Nozzle back plate sides visible Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems 9.4.2. Focus Adjustment 7R DGMXVW WKH IRFXV WKH VSHFLDO IRFXV DGMXVWHU WRRO FDQ EH XVHG 7KH IRFXV DGMXVWHU LV DOVR XVHG WR DGMXVW WKH FDPHUDV RI WKH 2ULRQ 7RSD]RU6DSSKLUH • 3UHSDUHDFRPSRQHQWLQWKHFRPSRQHQWGDWDEDVHVRWKDWWKHIRFXVDGMXVWHU FDQ EH SLFNHG XS ZLWK QR]]OH W\SH RU 0DNH VXUH WKH FRPSRQHQW WKLFNQHVV= DQGWKDWWKHFRPSRQHQWIRFXVDGMXVWHULVUHFRJQLVHGDWWKH FRUUHFWFDPHUD • 6HW WKH IRFXV ULQJ RQ WKH OHQV WR WKH ´ µ SRVLWLRQ EHIRUH DGMXVWLQJ WKH IRFXV NOTE: The Focus adjustment tool can only be used with a Fore lighting system. Set the Alignment Module to Fore. • 3UHVV)DGMXVWDVVLVW • 0DUNWKHQR]]OHSRVLWLRQZLWKDSHUPDQHQWPDUNHURQWRWKHSLFNXSVXUIDFH RI WKH IRFXV DGMXVWHU WRRO VHH ILJXUH 7KLV HQVXUHV WKDW WKH WRRO LV DWWDFKHGWRKHDGDWDIL[HGSRVLWLRQ • 3LFNXSWKHIRFXVDGMXVWHUWRRODVVKRZQLQILJXUH Figure 9-16 Focus adjuster tool direction $GMXVWWKHIRFXVE\VKLIWLQJWKHFDPHUD XSRUGRZQVHHILJXUH $W WKH OHYHO SRVLWLRQ RI WKH IRFXV DGMXVWHUWRROWKHIRFXVPXVWEHRSWLPDO 7KHPDFKLQHZLOOWDNHLQWRDFFRXQWWKH =KHLJKW RI WKH FRPSRQHQW DQG ZLOO VXEWUDFWWKDWQXPEHUIURPWKH&DPHUD =FRRUGLQDWH Figure 9-17 Nozzle back plate sides visible 7KH ERWWRP RI WKH FRPSRQHQW ZLOO DOZD\V EH UHFRJQLVHG DW WKH VDPH = SRVLWLRQ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 13 Vision Systems 7KH IRFXV DGMXVWPHQW LQIOXHQFHV WKH PD[LPXP FRPSRQHQW VL]H DGMXVWPHQW VRWDNHFDUHRIWKDWDQGILQGWKHRSWLPXPYDOXHIRUERWKIRFXVDQGPD[LPXP FRPSRQHQW NOTE: The focus must be adjusted by moving the camera up or down, not by turning the focus ring. Only use the focus ring adjustment if no good results can be obtained. This because it is a very precise adjustment. Figure 9-18 9.4.3. Nozzle back plate sides visible Lighting Level Adjustment 7KLV VHFWLRQ GHVFULEHV KRZ WR DGMXVW WKH OLJKWLQJ OHYHO RI WKH 6LQJOH YLVLRQ FDPHUD 7KLV FDQ EH GRQH LQ WZR GLIIHUHQW ZD\V SURFHHG DV LQGLFDWHG LQ IROORZLQJVWHSV 7KH OHQV DSHUWXUH VHWWLQJ GLDSKUDJP RI WKH VLQJOH FDPHUD LV FRUUHFWHG DXWRPDWLFDOO\ LQ VRIWZDUH ZKLOH GRLQJ WKH IRUH OLJKW DGMXVWPHQW 7KH DSHUWXUH ULQJ RQ WKH OHQV RI WKH VLQJOH FDPHUD PXVW EH VHW LQEHWZHHQ SRVLWLRQ´)µDQG´)µ ([HFXWHWKH´6LQJOH&DP/LJKWµXWLOLW\DVIROORZV l 6HOHFW%$GMXVWWDUJHW6LQJOH&DP/LJKW!DQGSUHVV(QWHU! l (QWHU WKH GDWDEDVH QXPEHU RI WKH FRPSRQHQW \RX DUH XVLQJ IRU WKLV DGMXVWPHQW DQG SUHVV (QWHU! ,I \RX KDYH DGGHG DQ RSWLRQDO KLJK SUHFLVLRQYLVLRQFDPHUDVHOHFW´6LQJOH&DPµWRDGMXVWLW l (QWHU WKH IHHGHU VHW QXPEHU DQG SUHVV WKH (QWHU! NH\ :KHQ WKH VHOHFWHGFRPSRQHQWLVUHJLVWHUHGDVDWUD\FRPSRQHQWWKLVGLDORJER[ GRHVQRWDSSHDU 9 - 14 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems R IVE DR 1 Figure 9-19 Led driver board (QVXUHVDIHW\WKHQSUHVVWKH(QWHU!NH\DJDLQ 7KH KHDG DVVHPEO\ PRYHV WR DERYH WKH VLQJOH YLVLRQ FDPHUD DQG PHDVXUHPHQWRIEULJKWQHVVDURXQGWKHQR]]OHZLOOVWDUW $GMXVWWKHVLQJOH YLVLRQ FDPHUD OLJKWLQJ OHYHO ZLWK SRWPHWHU 95 RQ WKH /('GULYHUERDUGVHFRQGSRWHQWLRPHWHUIURPWKHERWWRPDWWKHULJKWVLGH RI WKH 0&; FRQWUROOHU $GMXVW WKH ´$YH*UD\/HYHO RQ WKH XSSHU ULJKW FRUQHURIWKHVFUHHQWR,IWKLVYDOXHFDQQRWEHUHDFKHGSOHDVHDGMXVW WKHDSHUWXUHULQJDOLWWOHDQGWU\DJDLQ 3UHVV(VF!RU(QWHU!WRTXLWWKHDGMXVWPHQW7KHUHLVQRPDFKLQHGDWDWR EHVDYHGLQWKLVDGMXVWPHQW 2SWLRQDODGMXVWPHQWPHWKRG 6HOHFW%6LQJOH&DPHUDOLJKWLQJ6LQJOH&DPHUD)URQWOLJKW! )ROORZWKHH[SODQDWLRQRQWKH9,26 PRQLWRUDQGDGMXVWWKH/('GULYHU ERDUGSRWHQWLRPHWHU95 8VHWKH/LJKWDGMXVWHUWRRO $GMXVWWKHSRWHQWLRPHWHUVRWKDW WKHERUGHUEHWZHHQGDUNDQG EULJKWLVRQHIXOOVFDOHOHYHOV VHHILJ Full Scale Figure 9-20 NOTE: 5322 871 63606 01.05 Forelight adjustment Finish the adjustment within 30 seconds because the lighting level becomes lower and lower. Check the gap between dark and bright, not the absolute value. Service Manual Topaz PA 1309/10 9- 15 Vision Systems 9.4.4. Camera Scale Adjustment )RUDFFXUDWHUHFRJQLWLRQRIFRPSRQHQWVVXFKDV4)3·VWKHOLJKWLQJOHYHODQG WKHVFDOHRIWKHVLQJOHYLVLRQFDPHUDIL[HGFDPHUDPXVWEHDGMXVWHGFRUUHFWO\ 7KHVLQJOHYLVLRQFDPHUDVFDOHUHSUHVHQWVDQDFWXDOPHDVXUHPHQWLQXQLWVRI PLFURQVHTXLYDOHQWWRRQHSL[HO)RUDFFXUDWHUHFRJQLWLRQRIFRPSRQHQWVWKLV VFDOHPXVWEHDGMXVWHGFRUUHFWO\7RPDNHWKHDGMXVWPHQW\RXZLOOQHHGD4)3 RINQRZQVL]H Preparation for the single vision camera scale )LUVWFKHFNWKHFXUUHQWVHWWLQJVRIWKHVLQJOHYLVLRQFDPHUDVFDOH 6HOHFW$0&+B'$7$!^$6(/(&7TARGET} /"Vision Parameter" and press the [ENTER] key. &KHFNWKHVHWWLQJVRI6LQJOH&$0VFDOH :KHQ\RXH[HFXWHWKHVLQJOHFDPHUDVFDOHXWLOLW\WKH;DQG<YDOXHV PLFURQVZLOOEHDGMXVWHG <<MODE>> 3/MCH_ADJUST A377 <<<Result>>> The results of calculating the scales of the single vision camera are as follows. To save the result in memory, press the [ENTER] key (the results are . . . Figure 9-21 Camera = 1 Distance = 5.00 Scale_x = 83.33 Scale_y = 83.97 Cam.posx = 0.00 Cam.posy = 0.00 Cam.posr =180.19 =0.9923 Rate Camera scale parameters 3UHSDUHD4)3FRPSRQHQWWREHXVHG 8VHDUHODWLYHO\ODUJHRIWHQXVHGFRPSRQHQWRINQRZQVL]HZKLFKLV UHJLVWHUHGLQWKHFRPSRQHQWGDWDEDVH,I\RXXVHDFRPSRQHQWQRW UHJLVWHUHGLQWKHGDWDEDVHLWPXVWEHUHJLVWHUHGILUVW NOTE: Use of a QFP component is recommended since QFP’s are generally superior in dimensional precision to other components, PHILIPS recommends using QFP components registered in the database, e.a."No.766; QFP100-P0.6525.7L" or "No.767; QFP100-P0.65-24.7L". You can also use the inner QFP 68 of the glass calibration set (PA 1912/00) but this can give problems with the outer glass QFP208 . &KHFNWKHUHJLVWUDWLRQGDWDLQWKHFRPSRQHQWGDWDEDVH • 7RRSHQWKHFRPSRQHQWGDWDEDVHVHOHFW'$7$0!!! '$7$%$6(!$',63/$<!^$&20321(170$5.'%` &20321(17'$7$%$6(DQGSUHVVWKH>(17(5@NH\ • &KHFNWKHUHJLVWUDWLRQGDWDRIWKHVHOHFWHG4)3 ,QSDUWLFXODUFKHFNWKDWWKHFRPSRQHQWVL]HH[DFWO\PDWFKHVWKH UHJLVWUDWLRQGDWD,IQRWWKHDGMXVWPHQWZLOOEHDERUWHG (GLW6HDUFK$UHDPPLQWKHFRPSRQHQWGDWD 'DWDUHJLVWHUHGLQWKHGDWDEDVHDVDQXPEHUODUJHUWKDQ1RFDQQRWEH HGLWHGGXHWRZULWHSURWHFWLRQ0DNHDFRS\RIWKHGDWDDVDQXPEHUVPDOOHU 9 - 16 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems WKDQ1RWKHQHGLWWKLVGDWD)RULQVWDQFHWKHIROORZLQJVWHSVDUH H[SODLQHGLQFDVHVZKHUHDFRS\LVPDGHRQWRUHJLVWUDWLRQ1R • 2SHQWKHVXEVFUHHQ9LVLRQIRUWKHFRPSRQHQWRIUHJLVWUDWLRQ1R • (GLWWKHGDWDRQ6HDUFK$UHDPP • 8VHWKHQXPHULFNH\VWRVHWWKHQRUPDOYDOXHWR PD[LPXPVHWWLQJ7KLVLVIRURIIFHQWHUSLFNXSRIWKH4)3WREH SHUIRUPHGODWHU F igure 9-22 Edit search area 6DYHWKHHGLWHGGDWD 3UHVVWKH>(6&@NH\WZLFHWKHQVHOHFW^&6$9((;,7`DQGSUHVVWKH >(17(5@NH\ $GMXVWPHQWRIWKHFDPHUDVFDOH :KHQWKHSUHSDUDWLRQLVFRPSOHWHXVHWKHIROORZLQJSURFHGXUHWRFDOLEUDWHWKH VFDOHRIWKHVLQJOHYLVLRQFDPHUD ([HFXWHWKH6LQJOH&DP6FDOHXWLOLW\ 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%$'-8677$5*(7`6LQJOH&DP6FDOHDQGSUHVVWKH >(17(5@NH\ 6HOHFW6LQJOH&DPDQGSUHVVWKH>(17(5@NH\,I\RX KDYHDGGHGDQRSWLRQDOYLVLRQFDPHUDVHOHFW6LQJOH&DPWRDGMXVWLW NOTE: Camera scale adjustment on a camera using side illumination need to be run with a part that uses the fore lighting system. If a part cannot be recognized, check the Single Cam. Scale levels in [MCH_DATA]→Vision Parameter. The following numbers should be close to what the scale adjustment will find if the field of view is set correctly. Max component size 32mm Table 9-2 Scale adjustments 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 X 77.5 Y 77 Lens Lens 16 9- 17 Vision Systems Figure 9-23 Procedure of scale adjustment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ervice Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems Figure 9-24 CAUTION When you use a rectangular QFP, align the long side in parallel with the X-axis. :KHQWKH4)3KDVEHHQDWWDFKHGSUHVVWKH>(17(5@NH\ &DQFHOHPHUJHQF\VWRS 5HOHDVHWKHHPHUJHQF\EXWWRQDQGSUHVVWKH>5($'<@EXWWRQRIWKH++. (QVXUHVDIHW\WKHQSUHVVWKH>(17(5@NH\DJDLQ +HDGPRYHVWRDERYHWKHVLQJOHYLVLRQFDPHUDDQGWKH4)3LVGLVSOD\HG RQWKHYLVLRQPRQLWRU7KHQR]]OHURWDWHVVRWKDWWKHFDPHUDVFDOHSRVLWLRQ DQGDQJOHDUHFDOLEUDWHGILYHWLPHV7KHUHVXOWVDUHGLVSOD\HGLQWKHXSSHU ULJKWFRUQHURIWKH9,26PRQLWRU <<MODE>> 3/MCH_ADJUST A377 <<<Result>>> The results of calculating the scales of the single vision camera are as follows. To save the result in memory, press the [ENTER] key (the results are . . . Figure 9-25 Camera = 1 Distance = 5.00 Scale_x = 83.33 Scale_y = 83.97 Cam.posx = 0.00 Cam.posy = 0.00 Cam.posr =180.19 =0.9923 Rate Scale parameters 3UHVVWKH>(17(5@NH\WRVDYHWKHFDOLEUDWHGUHVXOWV 3UHVVWKH>(6&@NH\LI\RXZDQWWRGLVFDUGWKHUHVXOWV 1RWHWKHFDPHUDSRVLWLRQ;<LQWKHUHVXOWV :KHQWKH&DPSRV[DQG&DPSRV\YDOXHVDUHQHDUO\]HUR WKHFDOLEUDWLRQLVVDWLVIDFWRU\3UHVVWKH>(6&@NH\WRDGYDQFHWRWKHQH[W 6WHS ,IWKH&DPSRV[DQG&DPSRV\YDOXHVDUHWRRIDUIURP]HURWKHUHLV OLNHO\DQHUURULQWKHFDOLEUDWLRQ3UHVVWKH>(17(5@NH\WRUHWU\FDOLEUDWLQJ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 19 Vision Systems Verify the Cam.posx and Cam.posy values to be 0.00 by running the scale utility again. One of the most important items of camera scale is that these values go to zero and are stabile. If the position move by .05 or more with each run of scale then a mechanical problem exists (loose elements in the lens or lens that is loose on the camera). NOTE: :KHQWKHFDOLEUDWLRQLVFRPSOHWHGXPSWKHFRPSRQHQW 3UHVVWKH>(17(5@NH\WRGXPSWKHFRPSRQHQWDXWRPDWLFDOO\ ,I\RXZDQWWRTXLWZLWKRXWGXPSLQJSUHVVWKH>(6&@NH\DQGIROORZWKH PHVVDJHRQWKHRSHUDWLRQPRQLWRU 6DYHWKHFDOLEUDWLRQGDWD 6HOHFW^%6$9('$7$`RU^%6$9(48,7`DQGSUHVVWKH>(17(5@ NH\7RTXLWZLWKRXWVDYLQJVHOHFW^%5(&29(5$'-867`RU ^%48,7`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amera Optical Axis Angle Adjustment Introduction 7KH&DPHUDRSWLFDOD[HVDQJOHDGMXVWPHQWLVDSURFHGXUHWKDWDOORZVIRUWKH PHDVXUHPHQWRIWKHUHODWLRQVKLSEHWZHHQWKHFDPHUDVRSWLFDOD[LVDQGWKH= D[LVPRYHPHQWRIWKHKHDGRU6SLQHDVVHPEO\,WFDQEHXVHGRQWKH7RSD]ZLWK DQDGGLWLRQDOVLQJOHFDPHUD 7KLVUHODWLRQVKLSSOD\VDQLPSRUWDQWUROHLQWKHSODFHPHQWDFFXUDF\EHWZHHQ 4)3DQG)LQH0RGHDQGEHFRPHVPRUHVLJQLILFDQWZKHQRUPRUHVLQJOH FDPHUDVDUHXVHG 9 - 20 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems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easurement Principles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ingle Camera )RUWKHVLQJOHYLVLRQFDPHUDWKHSURJUDP5(&B&20SJPLVXVHG7KLV SURJUDPLVVLPLODUWRWKH$XWR0RXQWIHHGEDFNURXWLQHVDQGLVH[HFXWHGLQWKH VDPHPDQQHU8QOLNHWKHVWDQGDUG$0)SURJUDPVWKHFDPHUDXWLOLW\ZLOOQRW HIIHFWWKHPDFKLQH·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ervice Manual Topaz PA 1309/10 9- 21 Vision Systems Line Array Camera 8QOLNHWKHVLQJOHFDPHUDWKHOLQHDUUD\FDPHUDGRHVQRWUHTXLUHDQH[WHUQDO SURJUDP7KHVWDQGDUGFDPHUDVFDOHXWLOLW\DYDLODEOHLQ>0DFKLQH$GMXVW@LV XVHG7KHKHDGDVVHPEO\LVUDLVHGDQGORZHUHGGXULQJWKHXWLOLW\7KH FRPSRQHQWLVPHDVXUHGDWVHYHUDODQJOHVDQGSRVLWLRQVDERYHWKHFDPHUD7KH UHVXOWVDUHGLVSOD\HGLQDWDEOHDWWKHFRPSOHWLRQRIWKHVFDOHPHDVXUHPHQW7KLV WDEOHFRQWDLQVWKHFDPHUDVFDOHUDWHDQGKHDGGHOWDLQIRUPDWLRQ7KHFDPHUD·V SRVLWLRQDQGDQJOHDUHLQGLFDWHGE\WKHFDPHUDGHOWDRUFDPHUDFRUUHFWLRQ LQIRUPDWLRQ&$0&25 Required Tools and Supplies 6TXDUHVKDSHG4)3UHFRPPHQGHGIRUVLQJOHFDPHUDDOLJQPHQW 7KLQVKLPVUDQJLQJIURPPPWRPP $OOHQZUHQFKHV Single Camera Adjustment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´0DFKLQH&RQILJµDQGVHOHFW&175/(17(5! F 6HOHFW&KDQJH3URJUDPDQGILOHQDPH G 6HOHFW)WRLQLWLDWH7KHSURJUDPZLOOQHHGDERXWVHFRQGVWRORDG 6HOHFW0DFKLQHW\SH 7RSD] (PHUDOG(FOLSVH 6HOHFW3LFNXSFRPSRQHQW 6HOHFW&DPHUD3RVLWLRQ &RPSRQHQW'%QR 'DWD%DVHQXPEHU &RPSRQHQW'%QR &RPSRQHQW+HLJKW &RPSRQHQW= $GGPPLI\RXDUHXVLQJDW\SHQR]]OH /LJKWLQJ/HYHO /HYHOIURPFRPSRQHQWYLVLRQILOH +RZPDQ\7LPHV 1XPEHURIWLPHVWRUHFRJQL]HWKH FRPSRQHQWDWDOODQJOHVDWHYHU\= UHIHUHQFHSRVLWLRQLVVXIILFLHQWLI\RX KDYHDOOGD\ 9 - 22 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems $GMXVW&RPSRQHQW5 6HOHFW12\HVZLOOFDXVHD)LQHPRGHW\SH RIDGMXVWPHQW7KHFRPSRQHQW VDQJOHZLOO EHYHULILHGDQGFRUUHFWHGSULRUWRHDFK;< PHDVXUHPHQW 6HOHFW² 'RQRWIRUJHWWKHGHFLPDOSRLQW 6HOHFW 'RQRWIRUJHWWKHGHFLPDOSRLQW LVUHFRPPHQGHG +HLJKW5DQJHIURP +HLJKW5DQJHWR +RZPDQ\6WHSV $VWKHSURJUDPUXQVWKHKHDGVWDUWVLQWKHWRSPRVWSRVLWLRQDQGPRYHVGRZQ WKURXJKRXWWKHFDPHUD·VILHOGRIYLHZ ,IWKHYLVLRQV\VWHPIDLOVWRUHFRJQL]HWKHFRPSRQHQWWRRPDQ\WLPHVWKH SURJUDPZLOOGLVSOD\WKH6RIW/LPLW2YHU(UURUPHVVDJH,IWKLVRFFXUV9HULI\ WKH6HDUFKDUHDLVDQGFRPSRQHQWIRFXVLVJRRG Evaluating the Results $IWHUWKHSURJUDPFRPSOHWHVWKHPHDVXUHPHQWDWDEOHRIUHVXOWVZLOOEH GLVSOD\HGRQWKH9,26PRQLWRU 7KHGDWDLQWKHWDEOHLVSUHVHQWHGLQDIRUPDWWKDWUHSUHVHQWVDGRZQZDUG PRYHPHQWRIWKHVSOLQHEHJLQQLQJDWPPDERYHWKHUHFRJQLWLRQKHLJKWWRD SRLQWPPEHORZ,QWKLVWDEOHWKHWRWDOGHYLDWLRQIRUHDFKD[LVVKRXOGQRW H[FHHGPLFURQVPP ([DPSOHRIWKHUHVXOWVWDEOH REC.Height = REC.Height = REC.Height = REC.Height = REC.Height = -2.0 -1.6 0.0 1.6 2.0 Camera Pos Camera Pos Camera Pos Camera Pos Camera Pos X = 320.467 X = 320.463 X = 320.460 X = 320.457 X = 320.452 Y = 140.295 Y = 140.287 Y = 140.281 Y = 140.273 Y = 140.266 Figure 9-26 ,IWKHGHYLDWLRQH[FHHGVPPSHUPPLWLVUHFRPPHQGHGWKDW\RXVDYHWKH GDWDWRDIORSS\DQGXVHWKH([FHO7HPSODWHWRGHWHUPLQHWKHFDPHUDSRVLWLRQ $V\RXPDNHDGMXVWPHQWVWKHWHPSODWHZLOOSURYLGHKLVWRU\GDWDWKDWLVYHU\ XVHIXOWRYLVXDOO\LQWHUSUHWWKHDPRXQWDQGGLUHFWLRQRIFRUUHFWLRQ\LHOGHGE\ HDFKDGMXVWPHQW 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 23 Vision Systems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ometimes it can be the case that the bolts (M3x10) holding the lighting unit are too long and as such protruding through the camera stand pressing against the camera bracket. This can cause a tilted camera body. Adding some washers between the bolt and camera stand can prevent it. Placing a shim above the screw will tilt camera towards the front rail. =Y positive movement. Placing a shim below the screw will tilt camera Away from the front rail. =Y negative movement. Rotate the adater plate against the camera for large movements. Rotate the adapter plate on the camera stand for small movements. Figure 9-27 9 - 24 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems 9.5. Line Array Camera Adjustment 7KLVVHFWLRQGHVFULEHVWKHFDOLEUDWLRQRIWKHOLQHDUUD\FDPHUDV 9.5.1. Maximum Component Size and Field Of View 7KLVSURFHGXUHH[SODLQVKRZWRDGMXVWWKHPD[LPXPFRPSRQHQWVL]H)LHOG2I 9LHZ7KHILHOGRIYLHZLVHYHU\WKLQJWKHFDPHUDFDQUHFRJQL]H´VHHµRQLWVIRFDO SODQH7KHPD[LPXPFRPSRQHQWLVDOZD\VVPDOOHUWKDQWKH)LHOG2I9LHZDQGLV WKH)29PLQXVWKHGHYLDWLRQRIWKHOHQVERUGHUVRWKHVL]HZLWKLQWKH)29LQ ZKLFKDFRPSRQHQWFDQEHUHFRJQL]HGZLWKRXWSUREOHPV 0HDVXUHWKH)LHOG2I9LHZE\PHDQVRIDSODVWLFUXOHU$WWDFKWKHUXOHULQVXFKD ZD\WKDWWKHUXOHULVYLVLEOHLQ;GLUHFWLRQ(DVW:HVWGLUHFWLRQRQWKHVFUHHQDV WKH;GLUHFWLRQLVDIL[HGYDOXHRI7KH)LHOG2IYLHZGHSHQGVRQWKHKHLJKW RIWKHOLQHDUUD\FDPHUDDVZHOODVWKHXVHGOHQVDQGH[WHQVLRQULQJ$GMXVWWKH )29WRPP 9.5.2. Adjusting the Focus and Aperture 7RDGMXVWWKHIRFXVDQGDSHUWXUHDVSHFLDOIRFXVDGMXVWHUWRRO LVQHFHVVDU\)ROORZWKHVWHSVEHORZ 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGSUHSDUHIRUDGMXVWPHQW l /RRVHQWKHVHWVFUHZVRIWKHDSHUWXUHULQJDQGOHQVKROGHU l 3UHSDUHWKHOLJKWDGMXVWHUWRRO Focus ring Aperture ring Knurled ring (complete lens) Figure 9-28 ([HFXWHWKHOLQHDUUD\FDPHUD´)RFXVDQG,ULVµFRPPDQG l 6HOHFW%$GMXVWWDUJHW0XOWLFDPHUD)RFXV,ULV!DQGSUHVVWKH (QWHU!NH\ l 6HOHFW´8VHµIRUWKHVSHFLDOWRRO l 6HOHFWWKHFDPHUDWREHDGMXVWHG $WWDFKWKHIRFXVDGMXVWHUWRROWRKHDGDVIROORZV l $WWDFKDW\SHQR]]OHWRKHDG LIGRQHE\KDQGSUHVVWKH HPHUJHQF\EXWWRQSULRUWRWKLV DFWLRQ l &KHFNWKDWWKHHPHUJHQF\ EXWWRQLVSUHVVHG Figure 9-29 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 25 Vision Systems 4. &DQFHOWKHHPHUJHQF\VWRS (QVXUHVDIHW\UHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH5HDG\! EXWWRQRQWKH+DQGKHOGNH\ERDUG 5. (QVXUHVDIHW\DQGSUHVVWKH(QWHU!NH\DJDLQ 7KHKHDGDVVHPEO\PRYHVDQGSDVVHVUHSHDWHGO\RYHUWKHOLQHDUUD\FDPHUD ZKLOHWKHLPDJHRIWKHIRFXVDGMXVWHUWRRODQGLWVLQWHQVLW\SURILOHLV GLVSOD\HGRQWKHYLVLRQPRQLWRU 6. $GMXVWWKH)RFXVDQGDSHUWXUH %\URWDWLQJWKHDSHUWXUHDQGIRFXVE\PHDQVRIWKHOHQVKROGHUWKHRSWLPXP LPDJHLQDVFDOHUDQJHRI²WRDVVKRZQLQWKHILJXUHPXVWEHIRXQG LEVEL:80 Figure 9-30 2QHZD\RISHUIRUPLQJWKLVDGMXVWPHQWLVIROORZLQJ l 2SHQWKHDSHUWXUHIRUPD[LPXPOLJKWZLWKDPLQLPXPGHSWKRIILHOG ERWWRPOHQVULQJDQGVHWWKHIRFXVULQJXSSHUOHQVULQJWR²<RX ZLOORQO\VHHRQHSHHNRQWKHVFUHHQURWDWHWROHQVKROGHUFRPSOHWH OHQVXSGRZQWRVKLIWWKLVSHHNWRWKH´µYDOXHRQWKHDGMXVWHUWRRO l $GMXVWWKHDSHUWXUHFORVHLWWRLQFUHDVHWKHGHSWKRIILHOGWRWKHVFDOH YDOXHRI²WRRQWKHDGMXVWHUWRRO l ,ILWLVQRWSRVVLEOHWRDGMXVWLWLQWKLVZD\WKHFDXVHPD\EHWKH DPRXQWRIOLJKWPLJKWZKLFKLVWRRPXFKRUWRRORZ7U\FORVLQJWKH DSHUWXUHDOLWWOHRULIWKLVZLOOQRWZRUNLQFUHDVHWKHOLJKWLQJLQWHQVLW\ RQWKH/('GULYHUERDUGVHHQH[WSDUDJUDSK l ,QFDVHRIWZROLQHDUUD\FDPHUDVWU\WRREWDLQWKHVDPHOLJKWLQJOHYHO RQERWKIURQWDQGUHDUFDPHUD WARNING The head assembly passes repeatedly over the multi-vision camera during the adjustment. Be extremely careful not to touch the head with your body ! 7. 9 - 26 3UHVVWKH(QWHU!RUWKH(VF!NH\ZKHQWKHDGMXVWPHQWLVFRPSOHWH )ROORZWKHPHVVDJHVGLVSOD\HGRQWKHRSHUDWLRQPRQLWRU7KHUHLVQR PDFKLQHGDWDWKDWQHHGVWREHVDYHGDIWHUWKLVDGMXVWPHQW Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems 8. 9.5.3. 7LJKWHQWKHVHWVFUHZV l 3UHVVHPHUJHQF\DQGUHPRYHWKHDGMXVWHUWRROIURPKHDG l 7LJKWHQWKHVFUHZVQRWWRRWLJKWRIWKHDSHUWXUHDQGOHQVKROGHU 5HFKHFNWKHIRFXVDIWHUWLJKWHQLQJ Adjusting the Lighting Level of the Line Array Camera(s) 7RDGMXVWWKHOLJKWLQJOHYHORIWKHOLQHDUUD\FDPHUDV\RXZLOOQHHGWKHVSHFLDO OLJKWDGMXVWHUSODWH7KHOLJKWLQJOHYHOLVDGMXVWHGRQWKH /('GULYHUERDUGORFDWHGRQWKHOHIWVLGHRIWKH0&;FRQWUROOHUZKLOHDQ LPDJHLVGLVSOD\HGRQWKHPRQLWRUSURFHHGDVIROORZV ([HFXWHWKH´0XOWLFDPHUD%ULJKWQHVVOHYHOµ l ([HFXWHWKHPXOWLFDPHUD%$GMXVWWDUJHW0XOWLFDPHUD %ULJKWQHVV!DQGSUHVVWKH(QWHU!NH\ l 6HOHFW´JRLQJRQDQGRIIµIURPWKH/('W\SHER[ l 6HOHFW´8VHµIURPWKHVSHFLDOWRROER[ l 6HOHFWWKHFDPHUDWREHDGMXVWHG 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGDWWDFKWKHOLJKWDGMXVWHUSODWHWRKHDG $WWDFKWKHOLJKWDGMXVWHUSODWHWRKHDGZLWKWKHWZRWRQHVXUIDFHIDFLQJ GRZQ2ULHQWDWLRQRIWKHOLJKWDGMXVWHUSODWHPXVWEHVXFKWKDWWKH ERXQGDU\OLQHEHWZHHQWKHWZRWRQHVLVVHWKRUL]RQWDORQWKHVFUHHQ Figure 9-31 &DQFHOWKHHPHUJHQF\VWRS (QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH5HDG\! EXWWRQRQWKH++. (QVXUHVDIHW\WKHQSUHVVWKH(QWHU!NH\DJDLQ7KHKHDGDVVHPEO\PRYHV UHSHDWHGO\RYHUWKHPXOWLYLHZFDPHUDZKLOHWKHLPDJHRIWKHOLJKWDGMXVWHU SODWHLVGLVSOD\HGRQWKHYLVLRQPRQLWRU OHYHOV Full Scale Figure 9-32 $GMXVWWKHQRQFRD[LDOOLJKWOHYHO 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 27 Vision Systems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f the average light level cannot be set to 30 the lens aperture may be incorrect. Readjust the lens aperture as explained in previous sections. 3UHVVWKH(QWHURU(VFNH\ZKHQWKHDGMXVWPHQWLVFRPSOHWH )ROORZWKHPHVVDJHVGLVSOD\HGRQWKHPRQLWRUWKHUHLVQRPDFKLQHGDWDWR EHVDYHG 9.5.4. Adjusting the Line Array Camera Scale 7KHOLQHDUUD\FDPHUDVFDOHUHSUHVHQWVDQDFWXDOPHDVXUHPHQWLQPLFURQV HTXLYDOHQWWRRQHSL[HO7KLVVFDOHPXVWEHFDOLEUDWHGFRUUHFWO\IRUDFFXUDWH UHFRJQLWLRQRIFRPSRQHQWV 7RFDOLEUDWHWKHFDPHUDVFDOH\RXZLOOQHHGD623RINQRZQVL]H:KHQ\RX H[HFXWHWKHDGMXVWPHQWXWLOLW\GHVFULEHGEHORZWKHVFDOHLVFDOLEUDWHG DXWRPDWLFDOO\DQGDWWKHVDPHWLPHWKH;<SRVLWLRQVDQGLQVWDOODWLRQDQJOH5RI WKHOLQHDUUD\FDPHUDDQGLQWKH´&DPHUD&RRUGLQDWHµPDFKLQHGDWDDUH DGMXVWHGDOVR Setting up for the line array camera %HIRUH\RXEHJLQWKHFDOLEUDWLRQFKHFNWKHFXUUHQWFDPHUDVFDOHVHWWLQJVDQG SUHSDUHWKHFRPSRQHQWDQGQR]]OHDVGHVFULEHGEHORZ 9 - 28 &KHFNWKHFXUUHQWVHWWLQJVRIWKHFDPHUDVFDOH l 6HOHFW$6HOHFWWDUJHW9LVLRQSDUDPHWHU!DQGSUHVV(QWHU! l &KHFNWKHVHWWLQJVRIWKH0XOWLFDPRUVFDOH:KHQ\RXH[HFXWH WKH´0XOWLFDPHUDFDPHUDVFDOHµFRPPDQGH[SODLQHGODWHUWKH;< YDOXHVZLOOEHFDOLEUDWHG Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems <<<APPLICATION>>> 3/MAINTE/M <<MODE>> 2/MCH_DATA Editing Object Object X Y M-CAM 1 Delta pos. A 60.03 70.05 Z Vision Parameter R Figure 9-33 3UHSDUHDFRPSRQHQWWREHXVHGDVDUHIHUHQFH 8VHDUHODWLYHO\ODUJHSRSXODU4)3RINQRZQVL]HZKLFKLVUHJLVWHUHGLQWKH FRPSRQHQWGDWDEDVH,I\RXKDYHQR623DYDLODEOH\RXFDQXVHFKLS FDSDFLWRUVVXFKDVD&LI\RXXVHDFRPSRQHQWWKDWLVQRWUHJLVWHUHG LQWKHGDWDEDVHLWPXVWEHUHJLVWHUHG (GLW´VHDUFKDUHDPPµLQWKHFRPSRQHQWGDWD 'DWDUHJLVWHUHGLQWKHGDWDEDVHDVDQXPEHUODUJHUWKDQFDQQRWEH HGLWHGGXHWRZULWHSURWHFWLRQ0DNHDFRS\RIWKHGDWDDVDQXPEHU VPDOOHUWKDQDQGHGLWWKLVGDWD)ROORZLQJLVDQH[DPSOHRIWKLV l 2SHQWKH9LVLRQVXEZLQGRZRIWKHFRPSRQHQWUHJLVWUDWLRQ1R l (GLWWKH6HDUFKDUHDSDUDPHWHU8VHWKHQXPEHUNH\·VWRFKDQJHWKH QRUPDOYDOXHWRPD[VHWWLQJ7KLVLVWRHQDEOHRIIFHQWHUSLFNXS RIWKH623WREHSHUIRUPHGODWHURQ l 6HWWKHWUD\IHHGHUSDUDPHWHULQWKH8VHU,WHPZLQGRZWR´7UD\µ7KH VXEZLQGRZVZLWFKHVE\SUHVVLQJWKH)NH\ 6DYHWKHHGLWHGGDWD3UHVVWKH´(VFµNH\WZLFHWKHQVHOHFW&6DYH ([LW!DQGSUHVVWKH(QWHU!NH\ 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGDWWDFKDQR]]OHWRKHDG $WWDFKDQR]]OHIRU623W\SHWRKHDG ([HFXWHWKHDGMXVWDVVLVWDQWWRFKHFNWKDWWKHFRPSRQHQWLVUHFRJQL]HG )RUGHWDLOVRQWKHDGMXVWDVVLVWDQWUHIHUWRWKHXVHUPDQXDOLIQHFHVVDU\ LQFUHDVHWKHVHDUFKDUHDYDOXH Adjusting the line array camera scale :KHQWKHSUHSDUDWLRQLVFRPSOHWHDGMXVWWKHVFDOHRIWKHOLQHDUUD\FDPHUDZLWK WKHSURFHGXUHEHORZ &DQFHOWKHHPHUJHQF\VWRS (QVXUHVDIHW\DQGUHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVV5HDG\!RQ WKH++. ([HFXWHWKH´0XOWLFDPHUDµFRPPDQG l 6HOHFW%DGMXVWWDUJHW0XOWLFDPµ!DQGSUHVV(QWHU! l 6HOHFW´FDPHUDVFDOHµDQGSUHVV(QWHU! l 6HOHFWWKHFDPHUDWREHDGMXVWHGDQGSUHVV(QWHU! &RQILUPWKDW´'LVWDQFHPPµLVGLVSOD\HGDQGSUHVV(QWHU! 1RUPDOO\DPRYLQJGLVWDQFHRIPPLVUHFRPPHQGHG (QWHUWKHFRPSRQHQWGDWDEDVH1RDQGSUHVVWKH(QWHU!NH\ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 29 Vision Systems (QWHUWKHGDWDEDVHQRRIWKHFRPSRQHQW\RXKDYHSUHSDUHG A540 To return to the command menu ... Distance (mm) 5 A461 Enter the component database number ... Database No. 6 A466 The specified component uses ... A303 CAUTION! The axes will move. A373 Please pick up the specified component with the specified head, or ... Figure 9-34 (QVXUHVDIHW\DQGSUHVVWKH(QWHU!NH\WZLFH 7KHKHDGDVVHPEO\PRYHVWRDSRLQWZKHUHKHDGLVUHDG\WRSLFNXSD FRPSRQHQW 3UHVVWKHHPHUJHQF\VWRSEXWWRQWKHQDWWDFKWKHFRPSRQHQWWRKHDG $WWDFKWKHFRPSRQHQWWRWKHQR]]OHRIKHDGZLWKWKHFRPSRQHQWFHQWHU VOLJKWO\VKLIWHG Figure 9-35 CAUTION When using a SOP component, attach it to the nozzle with the component center slightly shifted. Align the long side parallel to the X-axis. 9 - 30 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems :KHQWKHFRPSRQHQWKDVEHHQDWWDFKHGSUHVVWKH(QWHU!NH\ &DQFHOWKHHPHUJHQF\VWRS 5HOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH5HDG\!EXWWRQRIWKH++. (QVXUHVDIHW\DQGSUHVV(QWHU!DJDLQ 7KHKHDGDVVHPEO\SDVVHVUHSHDWHGO\RYHUWKHOLQHDUUD\FDPHUDDQGWKH FDPHUDVFDOHLVFDOLEUDWHG7KHUHVXOWVDUHWKHQGLVSOD\HGRQWKHXSSHU ULJKWRIWKHRSHUDWLRQPRQLWRU <<<APPLICATION>>> <MODE>> 3/MAINTE/M 3/MCH_ADJUST A542 <<<Result>>> The results of calculating the scales of the multi-vision camera are as follows. ……… Camera = 1 Distance = 5.00 Scale_x = 58.59 Scale_y = 73.28 Cam.posx =328.96 Cam.posy =111.88 Cam.posr = 0.03 = 0.00 Div_x = 0.43 Div_y Cam.corx = -1.80 Cam.cory = 1.48 =0.5969 Rat Figure 9-36 3UHVVWKH(QWHU!NH\WRVDYHWKHFDOLEUDWHGUHVXOWV 3UHVVWKH(VF!NH\LI\RXZDQWWRFDQFHOWKHUHVXOWV7KHQSURFHHGWRWKH QH[WVWHSWRFDOLEUDWHWKHVFDOHRIWKHOLQHDUUD\FDPHUD:KHQ\RXU PDFKLQHLVQRWHTXLSSHGZLWKDOLQHDUUD\FDPHUDDGYDQFHWRVWHS 1H[WFDOLEUDWHWKHVFDOHRIWKHVHFRQGRSWLRQDOOLQHDUUD\FDPHUD :LWKWKHFRPSRQHQWVWLOOSLFNHGXSE\KDQGH[HFXWHWKH´0XOWL&DPHUDµ FRPPDQGDJDLQDVLQVWHSDQGVHOHFW´0XOWL&DPµ NOTE: In case of two line array cameras the difference in Cam Co-ordinate X and Y parameters between the two cameras should be within “10”. If this difference exceeds “10” an error message window appears as shown below. The advise is to make fine adjustments to the installation of camera 2 as described below, the procedure to adjust the camera optical axis might also be very useful to check in this case, see the end of this chapter. <<MODE>> 3/MCH_ADJUST A711 MultiCam2 Position Error Position(angle) of MltCam2 is not correct. Please adjust position of MltCam2 as difference between [MltCam1 Cam.cor] and [MltCam Cam.cor] is less than "10.0". Adjusting method is shown in next display. Please press [Enter] key. A712 Adjusting Method of MltCam2 When you see the machine from front, 1.if you tilt MltCam to right direction, value of [Cam.cor X] is decreasing. 2.if you tilt MltCam to front direction, value of [Cam.cor Y] is decreasing. (Caution) Please move only Mltcam2. Please don't move MltCam1. Please press [Enter] key to stop this adjustment. Cam. cor X MaltCam1 : -18.61 MaltCam2 : 0.00 Cam. cor X MaltCam1 : -18.61 MaltCam2 : 0.00 Figure 9-37 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 31 Vision Systems l 7RDGMXVWWKH&DPFRRUG;ORRVHQWKHEROWVHFXULQJWKHFDPHUDVWD\WR WKHFDPHUDVWDQGWKHQPDNHWKHILQHDGMXVWPHQWVWRWKHFDPHUD LQVWDOODWLRQDQJOH5HWLJKWHQWKHEROWWRVHFXUHWKHFDPHUD l 7RDGMXVWWKH&DPFRRUG<ORRVHQWKHEROWVVHFXULQJWKHFDPHUDVWD\ DQGLQVHUWDVKLPRIPPEHWZHHQWKHVWD\DQGFDPHUD7KHQ UHWLJKWHQWKHEROWVWRVHFXUHWKHFDPHUD,QHLWKHUFDVHDGMXVWWKH FDPHUDLQVWDOODWLRQLQWKH$GLUHFWLRQZKHQLQFUHDVLQJWKH&DPFRRUG ;<YDOXHVDQGLQ%GLUHFWLRQZKHQUHGXFLQJWKHP Figure 9-38 Multi-camera 2 Camera stay Adjusting cam coor. X A Camera stand B Adjusting cam coor. Y (insert a shim) :KHQWKHFDOLEUDWLRQLVFRPSOHWHGXPSWKHFRPSRQHQW 3UHVVWKH(QWHU!NH\WRGXPSWKHFRPSRQHQWDXWRPDWLFDOO\ ,I\RXZDQWWRTXLWZLWKRXWGXPSLQJSUHVVWKH(VF!NH\DQGIROORZWKH PHVVDJHRQWKHRSHUDWLRQPRQLWRU 6DYHWKHFDOLEUDWHGGDWD 6HOHFW%6DYHGDWD!RU%6DYH4XLW!DQGSUHVVWKH(QWHU!NH\ WRTXLWZLWKRXWVDYLQJVHOHFW%RU% 5HWXUQWKHHGLWHGGDWDWRWKHRULJLQDOVHWWLQJ 5HWXUQWKHHGLWHGGDWDWRWKHRULJLQDOVHWWLQJDVQHVVHFDU\,I\RXZDQWWR NHHSWKLVHGLWHGGDWDLWLVDGYLVDEOHWRHQWHUDSURSHUFRPPHQW 9 - 32 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems 9.5.5. Adjusting the Dual Recognition Offset 7KHOLQHDUUD\FDPHUDFDQUHFRJQL]HFRPSRQHQWVWUDYHOOLQJIURPOHIWWRULJKW DQGULJKWWROHIW7KLVUHFRJQLWLRQRIIVHWEHWZHHQWKHERWKGLUHFWLRQVLV LQGLFDWHGE\WKHSDUDPHWHU´'XDO5HF2IIVHWµLQWKHSRVLWLRQSDUDPHWHUVDQG PXVWEHDGMXVWHGFRUUHFWO\IRUDFFXUDWHPRXQWLQJ,WLVUHFRPPHQGHGWKDW\RX XVHD623VXFKDVWKRVHXVHGLQFDPHUDVFDOHDGMXVWPHQW $WWDFKDQ623WRKHDG 3UHVVWKHHPHUJHQF\EXWWRQDQGDWWDFKDQ623QR]]OHW\SHWRKHDG &DQFHOHPHUJHQF\ (QVXUHVDIHW\DQGUHOHDVHWKHHPHUJHQF\EXWWRQDQGSUHVV5HDG\! ([HFXWHWKH0XOWLFDPHUDXWLOLW\ l 6HOHFW%DGMXVWWDUJHWPXOWLFDPHUDµDQGSUHVVWKH(QWHU!NH\ l 6HOHFW´'XDOUHF2IIVHWµDQGSUHVVWKH(QWHU!NH\ l 6HOHFW´0XOWLFDPµDQGSUHVV(QWHU! ,I\RXUPDFKLQHLVHTXLSSHGZLWKDQRSWLRQDOPXOWLYLVLRQFDPHUDDQG \RXDUHPDNLQJDGMXVWPHQWVWRLWVHOHFWWKHFRUUHFWFDPHUDQXPEHU (QWHUWKHFRPSRQHQWGDWDEDVHQRDQGSUHVV(QWHU! +HUHHQWHUWKHGDWDEDVHQXPEHURIWKH4)3\RXKDYHSUHSDUHG (QVXUHVDIHW\DQGSUHVV(QWHU!WZLFH 7KHKHDGDVVHPEO\PRYHVWRDSRLQWZKHUHKHDGLVUHDG\WRSLFNXSWKH FRPSRQHQW 3UHVVHPHUJHQF\DQDWWDFKDQ623WRKHDGE\KDQG :KHQXVLQJDUHFWDQJXODU623DOLJQWKHORQJVLGHLQSDUDOOHOZLWKWKH ;D[LV:KHQWKH623KDVEHHQDWWDFKHGSUHVV(QWHU! Figure 9-37 &DQFHOHPHUJHQF\ 5HOHDVHWKHHPHUJHQF\EXWWRQDQGSUHVVWKH5HDG\!EXWWRQRQWKHKDQG KHOGNH\ERDUG (QVXUHVDIHW\DQGSUHVV(QWHU!DJDLQ 7KHKHDGDVVHPEO\SDVVHVUHSHDWHGO\RYHUWKHPXOWLFDPHUDDQGWKHGXDO UHFRJQLWLRQRIIVHWLVPHDVXUHG7KHUHVXOWVDUHGLVSOD\HGLQWKHXSSHUULJKW FRUQHURIWKHRSHUDWLRQPRQLWRU 3UHVV(QWHU!NH\WRVDYHWKHUHVXOWV 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 33 Vision Systems 3UHVV(VF!LI\RXZDQWWRFDQFHOWKHUHVXOWV :KHQWKHPHDVXUHPHQWLVFRPSOHWHGXPSWKHFRPSRQHQW 6DYHWKHUHVXOWV 6HOHFW%6DYHGDWD!RU%6DYHDQG4XLW!DQGSUHVV(QWHU! 4XLWZLWKRXWVDYLQJE\PHDQVRI%RU% 9.5.6. Replacement of the Line Array Camera :KHQUHSODFLQJDQHZOLQHDUUD\FDPHUDLQWRWKHV\VWHPRQHVKRXOGWDNHFDUHWKH FDPHUDLVPRXQWHGFRUUHFWO\)LJXUHVKRZVWKHZD\WKHFDPHUDVVKRXOGEH PRXQWHGLQWRWKHV\VWHPVHHQIURPWKHIURQWVLGHRIWKHV\VWHP Figure 9-38 Multi-camera 1 and 2 positions )RUERWKWKHIURQWDQGUHDUOLQHDUUD\FDPHUDWKHOLQHDUUD\FDPHUDLVWKHVDPH 7KHGLIIHUHQFHLVWKHZD\RIPRXQWLQJWKHEUDFNHWLWHPRQWRWKHFDPHUD)RU WKHIURQWOLQHDUUD\FDPHUDWKLVLVWKHSRVLWLRQLQGLFDWHG ZLWK WKH ´)µ ZKLOH LWHPVKRXOGEHPRXQWHGDWSRVLWLRQ´5µIRUOLQHDUUD\FDPHUD7KHULJKWVLGH RI ILJXUH VKRZV WKH H[DFW PRXQWLQJ SRVLWLRQV QRWH WKDW ERWK FDPHUDV DUH PRXQWHGZLWKWKHFDPHUDFDEOHSRLQWLQJWRWKHOHIW ,QWKLVZD\WKHUHDUVLGHOLQHDUUD\FDPHUDLVURWDWHGGHJUHHVZLWKUHVSHFWWR WKHIURQWVLGHOLQHDUUD\FDPHUD :KHQLQVWDOOLQJDVHFRQGFDPHUDLQWRWKHV\VWHPEHVXUHWRVHWWKHNQXUOHGULQJRI WKHFRPSOHWHOHQVLQLWVPLGGOHSRVLWLRQDVWKLVHQDEOHVEHWWHUDGMXVWPHQW 9 - 34 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems 9.6. Cleaning the Optical Systems 7KHRSWLFDOV\VWHPVRIWKH7RSD]PXVWEHFOHDQHGSHULRGLFDOO\:KHQPDNLQJ DGMXVWPHQWVWRWKHFDPHUD·VPDNHVXUHWRUHPRYHDQ\GXVWDQGGHEULVLQ DGYDQFH 7RFOHDQWKHRSWLFDOV\VWHPVXVHDFOHDQLQJVWLFNVXSSOLHGZLWKWKHPDFKLQHRU FRWWRQVZDEVOLJKWO\PRLVWHQHGZLWKHWK\ODOFRKRODQGZLSHWKHVXUIDFHRIWKH OHQV'RQRWXVHRUJDQLFVROYHQWVIRUFOHDQLQJ Figure 9-39 CAUTION Do not apply excessive force to the cameras while cleaning, this may cause the calibration parameters to be unreliable. Be sure to press emergency prior to cleaning ! 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 35 Vision Systems 9.7. Recognition Errors 7KLVFKDSWHUGHVFULEHVVRPHUHFRJQLWLRQHUURUVWKDWPLJKWRFFXU 9.7.1. Chip Components Symptom Recognition error frequently occurs with almost all components Recognition error frequently occurs with specific components Possible cause Dust or dirt on the camera lens. Corrective action Whip the lens surface with its special cleaner. The shape data in the component information width is not correct, or the nozzle is picking up the component by the edge. Recognition error frequently occurs with a specific head, specific components cannot be recognized The buffing part of the nozzle does not move smoothly, or dirt is on the nozzle tip. Check the shape data and make adjustments by using the adjust assistant. If the pickup position is off center of the component check the tape feeder for operation. Generate a negative pressure for all heads in the manual mode and move the nozzles. The shape data in the component information is not properly supplied. If any incorrect value is entered for the shape data the component is supplied in a wrong direction, this also results in recognition errors. For components to be supplied laterally specify 0 degree in the database. While specifying 90 degrees for lengthwise supply. Table 9-3 9 - 36 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Vision Systems 9.7.2. QFP Components Symptom Possible cause Corrective action Recognition error frequently occurs. Incorrect data is entered for the Component Information. Recognition error frequently occurs. (QFP is not displayed on the vision monitor.) Check the "Feeder Pos_X/Y" and "X/YIf the component has deviated from the center CompPitch" values in the Component of pickup position, it may Information, and make the corrections. shift from the center of the monitor, resulting in a recognition error. Components cannot be recognized. The direction supplying the component is not correct. (If the supply direction is wrong, the number of leads is switched between the length and width sides, causing a recognition error even if the SHAPE data is correct.) Check the data on the Component Information, and perform "PARAM. SEARCH" in the Adjust Assistant. Component supply data is created for the database, with the lateral supply as standard. Therefore, when the component is to be supplied in a lengthwise direction, enter "90 degrees (-90 degrees)" for the "Pick Angle" parameter in the Component Information. Table 9-4 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 9- 37 Vision Systems Intentionally left blank. 9 - 38 Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Software Section Software Section CHAPTER 10 10.1. Introduction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ervice Manual Topaz PA 1309/10 10-1 Software Section 10.2. System Software 10.2.1. Operating System 7KH',6.RSHUDWLQJV\VWHPZKLFKLVXVHGE\WKHV\VWHPLVWKH06'26YHUVLRQ 7KHRSHUDWLQJV\VWHPLVLQVWDOOHGDWWKHIDFWRU\RQWKHKDUGGLVNGULYH&WRJHWKHU ZLWKWKH9,26VRIWZDUHSDFNDJH 7KHFRQWHQWVRIWKHURRWGLUHFWRU\RIGULYH&LVOLVWHGLQSDUDJUDSK 10.2.2. Disk Organization 7KHKDUGGLVNLVEDVLFDOO\RUJDQLVHGDVLVVKRZQEHORZ 5227 &? 68% ',5(&725<V (;3/$,1$7,21 '26 ,16 .*7 .*0 3B%$6( &RQWDLQVWKHVWDQGDUG'26FRPPDQGV &RQWDLQVVRPHXWLOLWLHVOLNH021,725WRDGMXVW9,26PRQLWRU &RQWDLQVDOOPDFKLQHSDUDPHWHUWDEOHV &RQWDLQVDOOWH[WPHVVDJHVXVHGLQWKH9,26VFUHHQV 7KH 3%$6( LV WKH (XURSHDQ86$ GDWDEDVH LW FRQWDLQV +,''(1ILOHVZLWKWKHEDVLF3&%FRPSRQHQWPDUNHUDQG,' LQIRUPDWLRQ·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ervice Manual Topaz PA 1309/10 5322 871 63606 01.05 Software Section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ervice Manual Topaz PA 1309/10 10-3 Software Section 10.2.3. Installation Disk Contents :LWKWKHV\VWHPWKHUHZLOOEHDVHWRIGLVNHWWHVVXSSOLHG 6<67(0',6. 6<67(0',6. 6<67(0',6. 6<67(0'$7$ 9,2662)7:$5(87,/,7< 7KH6<67(0DQGGLVNHWWHVFRQWDLQWKH9,26SURJUDPXWLOLWLHVFRPSRQHQWDQG PDUNGDWDEDVH 7KH9,2662)7:$5(87,/,7<GLVNFRQWDLQVYDULRXVXWLOLWLHVRIWKHPDFKLQH 7KH 6<67(0 '$7$ GLVN FRQWDLQV D EDFN XS RI WKH 0$&+,1( GDWD 6WDWLF FRPSRQHQWGDWDEDVHDQG&RPSRQHQW0DUNGDWDEDVH $QH[DPSOHRIWKHFRQWHQWVRIWKHIORSSLHVLVVKRZQLQWKHQH[WVFUHHQV SYSTEM – 1 SM100 .001 1 07-23-97 INFDSK .V12 381 11-29-95 INS1 .LZH 1.114.237 21-12-98 07:33 12:06 08:55 SYSTEM – 2 SM100 .002 INFDSK .V12 INS2 .LZH 1 07-23-97 56 11-29-95 995.318 21-12-98 07:33 12:05 04:54 SYSTEM - 3 SM100 INFDSK INS3. VERSION .003 .V12 .LZH .STS 1 56 781.441 6 07-23-97 11-29-95 21-12-98 12-14-96 07:33 12:05 04:55 11:47 SYSTEM - DATA NO0 >SUB_DIR< NO1 >SUB_DIR< FTABLE .BIN 740 INFDSK .V12 56 DATABASE .LZH 29730 MCXCONF .SYS 2110 SM100 .DAT 1 98-06-17 98-06-17 06-09-98 11-29-95 06-11-98 05-29-98 07-23-98 15:58 15:58 08:33 12:06 04:59 01:10 VIOS SOFTWARE UTILITY DISK Name Ext INST486 LZH UPDATE BAT COMMAND.COM LHA DOC LHA EXE HDDCHK EXE Figure 10.1 10-4 Size 333812 478 58886 27059 34445 113005 Date 12-21-98 11-04-98 12-06-93 7-20-91 7-20-91 12-22-97 Time 8:15p 8:19p 6:20a 2:13a 2:13a 11:17a Contents of installation disks Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Software Section 7KH 6<67(0 '$7$ GLVN LV YHU\ LPSRUWDQW EHFDXVH LW FRQWDLQV WKH 0$&+,1( 3$5$0(7(5 ILOHV 86(5(' DQG 86(5+' LQ WKH 1R 'LUHFWRU\ 7KH 86(5(' FRQWDLQV WKH PDFKLQH FRQILJXUDWLRQ (TXLSPHQW 'DWD DQG WKH 86(5+' DOO WKH PDFKLQH SDUDPHWHUV +DUGZDUH 'DWD $QRWKHU LPSRUWDQW ILOH LV WKH '$7$%$6(/=+7KLVILOHFRQWDLQVWKHFRPSUHVVHGFRPSRQHQWDQGPDUNGDWD CAUTION Before re-writing the software or hard disk always check if there is a system back up on disk. It is strongly recommended to make a back up via the VIOS SOFTWARE UTILITY immediate after the system is unpacked and set-up. Keep this back up on a safe place away from the machine. 7KHEDFNXSFDQEHGRQHYLDWKH9,2662)7:$5(87,/,7<6HHIRUWKLVSURFHGXUH SDUDJUDSKRIWKLVFKDSWHU 7KH 6<67(0 GLVNV DQG FRQWDLQLQJ WKH ILOHV ,16/=+ ,16/=+ DQG ,16/=+ZKLFKDUHFRPSUHVVHGE\PHDQVRIWKH/+$FRPPDQG7KHVHILOHVDUHWKH FRPSOHWH 9,26 RSHUDWLQJ V\VWHP DQG GDWDEDVH ZKLFK PXVW EH GHFRPSUHVVHG YLD WKH VDPH/+$FRPPDQG7KH83'$7(EDWDQGUHODWHGILOHVZLOOWDNHFDUHRIWKLVH[WUDFWLRQ 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 10-5 Software Section 10.2.4. VIOS Software Utility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ervice Manual Topaz PA 1309/10 5322 871 63606 01.05 Software Section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his command can be dangerous because it initialises all machine data on the hard disk. Use this command only in case the machine data is corrupted or out of date or if there are hard disk problems. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 10-7 Software Section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ervice Manual Topaz PA 1309/10 5322 871 63606 01.05 Software Section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ervice Manual Topaz PA 1309/10 10-9 Software Section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ervice Manual Topaz PA 1309/10 5322 871 63606 01.05 Software Section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PCB File Handling 7KLVFKDSWHUGHVFULEHVWKHLVVXHVUHODWHGWRWKH3&%ILOHVRI9,26 ,Q WKH >6+(//0@>'$7$B),/(B01*@ WKH 3&% ILOHV RQ WKH GLVN DUH VKRZQ 6HH ILJXUHD7KHILOHQDPHGHVFULSWLRQVDUHVWRUHGLQDKLGGHQILOHQDPHG)7$%/(%,1 7KHQDPHVWKDWFDQEHJLYHQWRHDFK3&%PD\FRQVLVWRIFRQVHFXWLYHFKDUDFWHUVQR VSDFLQJ DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M <<MODE>> 1/DATA_FILE_MNG 2/DISK_MAINTENANCE 3/VIOS_DIC 0/EXIT <VIOS PCB> /Drv:C Vios Pcb Name STATIC_COMPONENTS___ CONVEYOR ANC_TEST PALLET_80 ADJUST_CHIP OFFSET CUK_92001_1 CUK_93001_0 ECLIPSE MFB_CHIP Date Time 94-07-16 93-12-06 94-02-12 94-02-12 95-08-11 95-08-11 94-01-10 94-02-12 95-08-11 95-08-09 07:58 11:04 10:01 09:25 13:46 13:47 18:05 09:18 13:48 13:38 Figure 10.3 <VIOS PCB> /Drv:C Vios Pcb Name STATIC_COMPONENTS___ CONVEYOR ANC_TEST PALLET_80 ADJUST_CHIP OFFSET CUK_92001_1 CUK_93001_0 ECLIPSE MFB_CHIP Date Time 94-07-16 93-12-06 94-02-12 94-02-12 95-08-11 95-08-11 94-01-10 94-02-12 95-08-11 95-08-09 07:58 11:04 10:01 09:25 13:46 13:47 18:05 09:18 13:48 13:38 PCB file names DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M <<MODE>> 1/DATA_FILE_MNG 2/DISK_MAINTENANCE 3/VIOS_DIC 0/EXIT DIRECTORY C:\ECL92 Name Ext Size Date .. D_BASE FONT INS NO0 NO1 PGM P_BASE RAMD STATUS KG2-42M0 KG2-42T0 KG2-42S9 KG2-42S8 KG2-58D9 KG7-44D0 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 93-03-06 95-05-24 95-05-12 95-11-08 009 009 005 007 010 146 >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< 476 8191 46706 555410 Figure 10.4 10-20 Service Manual Topaz PA 1309/10 0/EXIT Time 15:15 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 08:57 12:10 12:11 18:09 0/EXIT DIRECTORY C:\ECL92 Name Ext Size Date STATUS KG2-42M0 KG2-42T0 KG2-42S9 KG2-42S8 KG2-58D9 KG7-44D0 KG7-44D1 AUTOEXEC FTABLE ECL92 COM92 ECL92 MCXCONF SERIAL MCXCONF 96-02-26 96-02-26 96-02-26 93-03-06 95-05-24 95-05-12 95-11-08 95-02-17 96-02-26 95-09-06 95-11-09 96-02-26 96-02-26 95-11-08 92-09-19 95-12-18 009 009 005 007 010 146 146 BAT BIN EXE ICO ICO NEW STS SYS >SUB_DIR< >SUB_DIR< >SUB_DIR< 476 8191 46706 555410 1082 97 308 1584018 4026 4026 2499 785 2493 Time 15:16 15:16 15:16 08:57 12:10 12:11 18:09 17:11 15:36 19:07 14:58 15:23 15:30 20:37 10:51 16:16 Dos files 5322 871 63606 01.05 Software Section 7KH&?12GLUHFWRU\ILUVWRIDOOKDVWKHWZRIROORZLQJILOHV 86(5(' 86(5+' $OO0DFKLQHHTXLSPHQW237,21B&)* $OO0DFKLQHSDUDPHWHUV0&+B'$7$ $EDFNXSRIWKHVHILOHVRQWKH´6<67(0'$7$',6.µVKRXOGDOZD\VEHSUHVHQWLQWKH QHLJKERXUKRRGRIWKHPDFKLQH6HHILJXUH DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M <<MODE>> 1/DATA_FILE_MNG 2/DISK_MAINTENANCE 3/VIOS_DIC 0/EXIT DIRECTORY C:\orn\NO1 Name Ext Size Date .. @00101 @00201 @00901 USER @00101 @00201 @00901 USER @00101 @00901 @00201 @00901 @00101 @00201 @00901 96-02-26 93-09-24 93-12-06 94-10-18 95-12-18 93-09-24 93-12-06 95-08-11 95-12-08 93-09-24 94-07-16 93-12-06 94-09-22 93-09-24 93-12-06 94-09-22 BD BD *BD ED FD FD *FD HD ID *PD ID *ID MD MD *MD >SUB_DIR< 1000 1050 19450 152 0 0 57036 11800 0 4257 152 152 0 0 130 Time 15:16 09:53 11:04 17:35 15:54 10:23 11:04 13:48 15:09 11:29 07:58 11:04 11:20 10:23 11:04 11:41 DIRECTORY C:\orn Name Ext Size .. D_BASE FONT INS NO0 NO1 PGM P_BASE RAMD STATUS KG2-42M0 KG2-42T0 KG2-42S9 KG2-42S8 KG2-58D9 KG7-44D0 009 009 005 007 010 146 >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< 476 8191 46706 555410 0/EXIT Date Time 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 93-03-06 95-05-24 95-05-12 95-11-08 15:15 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 08:57 12:10 12:11 18:09 Figure 10.5 DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M <<MODE>> 1/DATA_FILE_MNG 2/DISK_MAINTENANCE 3/VIOS_DIC 0/EXIT DIRECTORY C:\orn\NO1 Name Ext Size Date .. @00101 @00201 @00901 USER @00101 @00201 @00901 USER @00101 @00901 @00201 @00901 @00101 @00201 @00901 96-02-26 93-09-24 93-12-06 94-10-18 95-12-18 93-09-24 93-12-06 95-08-11 95-12-08 93-09-24 94-07-16 93-12-06 94-09-22 93-09-24 93-12-06 94-09-22 BD BD *BD ED FD FD *FD HD ID *PD ID *ID MD MD *MD >SUB_DIR< 1000 1050 19450 152 0 0 57036 11800 0 4257 152 152 0 0 130 Time 15:16 09:53 11:04 17:35 15:54 10:23 11:04 13:48 15:09 11:29 07:58 11:04 11:20 10:23 11:04 11:41 DIRECTORY C:\orn Name Ext Size .. D_BASE FONT INS NO0 NO1 PGM P_BASE RAMD STATUS KG2-42M0 KG2-42T0 KG2-42S9 KG2-42S8 KG2-58D9 KG7-44D0 009 009 005 007 010 146 >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< >SUB_DIR< 476 8191 46706 555410 0/EXIT Date Time 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 96-02-26 93-03-06 95-05-24 95-05-12 95-11-08 15:15 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 15:16 08:57 12:10 12:11 18:09 Figure 10.6. 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 10-21 Software Section ,QWKHVDPH&?12GLUHFWRU\FRPELQDWLRQRIILOHVFDQEHIRXQGWKDWWKH\WRJHWKHUIRUP GDWDRIRQH3&%7KRVHILOHVDUH #>),/(@,' #>),/(@%' #>),/(@)' #>),/(@0' #>),/(@3' &RQWDLQVWKH3&%QDPHDQGUXQFRQGLWLRQ &RQWDLQVWKH3&%PRXQWGDWD &RQWDLQVWKHFRPSRQHQWDQGYLVLRQLQIR &RQWDLQVDOO0DUNLQIRUPDWLRQ &RQWDLQVWKHSURGXFWLRQKLVWRU\ $QH[DPSOHLVVKRZQLQILJXUH 10.4. Machine Configuration 7KHPDFKLQHFRQILJXUDWLRQOLVWLVORFDWHGLQWKHDSSOLFDWLRQ0$,17(1$1&( 0$1$*(5$237,21&21),*'HSHQGLQJRQWKHFRQILJXUDWLRQRIWKHV\VWHPLWLV SRVVLEOHWRGLVDEOHRUHQDEOHSDUWVDQGRSWLRQVRIWKHPDFKLQHVHHILJ DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M <<MODE>> 1/MCH_CONFIG 2/MCH_DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT <COMMAND_LIST> A/MCH_CFG A1 A2 A3 A4 A5 A6 A7 A0 OPTION CONFIG. HEAD SPEC.INF. FEEDER BASE INF. NOZZLE SPEC.INF. FEEDER SPEC.INF. ROM CONFIG. FILE CONFIG. EXIT Figure 10.7 10-22 0/EXIT Service Manual Topaz PA 1309/10 Maintenance manager 5322 871 63606 01.05 Software Section ,QILJXUHWKHPDFKLQHFRQILJXUDWLRQVLVVKRZQRIWKH9,269[YHUVLRQ7KHUHDUH DQXPEHURIRSWLRQVDQGIHDWXUHVWKDWDUHQRWXVHGLQWKH7RSD]5(0$5.WKH9,26 RSHUDWLQJV\VWHPLVDOVRXVHGLQRWKHUPRXQWHUV %\PHDQVRIWKH,16DQG'(/NH\LWLVSRVVLEOHWRHQDEOHRUGLVDEOHDFHUWDLQRSWLRQ ---------------------------DATA[non ]--------------------------<<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/MCH_CONFIG 2/MCH_DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT +------------------------------------------------------------------------------+ ¦OPTION CONFIG. ¦ ¦ Serial:KM1-632312 M.type:SM100-1/2 ¦ ¦ ¦ • • /BASIC CONF./ Message English • Simple Edition Full Itms • • RS232C CMU Normal • • Sub Machine Type SM100-2 • • /SOFTWARE/ Online Optimization None • • Badmark Function Normal • • Badmark Distinction Normal • • Air Consumption No Limit. • • Alternate Component WithConfirm. • • Retry Sequence GroupRetry • • Production Log Use • • /RECOGNITION/ Laser Alignment Exist • • Camera Combination 1&2:Single View • • Camera1 Spec. Fore&Back Light • • Camera2 Spec. Fore&Back Light • • • Camera3 Spec. Fore&Back Light • • Multi Detection Standard • • MarkLightingControl Exist • • /CONVEYOR/ Edge Clamp Exist • • Conveyor Width Axis Normal • • Conveyor Direction R -> L • • Conveyor Spec. Line • • Conveyor Width Exist • • Precede Pick None • • /BUFFER CONV/ Buffer Conveyor A-TYPE • • Buffer Conv. W Axis Reverse • • /TRAY CHANGE/ Tray Changer Ext.TC-A • • Ext.TC Trv. Axis Normal • • • Ext.TC Access Table A table • • /OPTIONS/ Nozzle Changer Exist • • Slide Feeder Bar None • • Co-Planarity Sensor None • • Dump Station None • • Dispense Head None • • Disp. Head R Sensor Single • • Dot Station None • • RS232C extension None • •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Figure 10.8 5322 871 63606 01.05 Configuration settings VIOS version V1.2x Service Manual Topaz PA 1309/10 10-23 Software Section 10.4.1. 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ROM and File Configuration (Version Level) 7KHVFUHHQLQILJLVVKRZLQJWKHYHUVLRQRIWKHYDULRXV520·VXVHGLQWKHV\VWHP DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M <<MODE>> 1/MCH_CONFIG 2/MCH_DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT ROM TYPE 0/EXIT CURRENT ROM HEAD-I/O-ROM CONVEYOR(A)-I/O-ROM CONVEYOR(B)-I/O-ROM Ext.TC-I/O-ROM SYSTEM-ROM HHK-ROM Figure 10.9 ROM IC version 7KHVFUHHQLQ)LJVKRZVDQH[DPSOHRIWKHILOHFRQILJXUDWLRQILOHYHUVLRQRIWKH V\VWHP,IDILOHKDVQRWWKHFRUUHFWOHYHOLWZLOOEHVKRZQLQUHG,WLVQHFHVVDU\WKDWDOOILOHV KDYHWKHFRUUHFWOHYHOWRDYRLGSUREOHPV7KHVFUHHQLQILJVKRZVDQH[DPSOHRIWKH YDULRXVILOHVZLWKWKHLUOHYHO'HSHQGLQJRQWKH9,26YHUVLRQWKHILOHYHUVLRQVZLOOFKDQJH DFFRUGLQJO\ DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M <<MODE>> 1/MCH_CONFIG 2/MCH_DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT FILES & DIRECTORY MACHINE-TYPE-PATH MESSAGE-FILE-PATH APL-EXE.FILE VISION-HEX.FILE IO(OS)BIN.FILE IO(IPL)HEX.FILE SEQUENCE-HEX.FILE DC-SERVO-HEX.FILE AC-SERVO-HEX.FILE Figure 10.10 10-28 REQUEST VERSION KG2-42T0.011\\ KG2-42M0.011\\ KM5-42E0-011 KG7-44D0.208 KG2-42S8.00A KG2-42S9.005 KM5-58D9.900 0/EXIT STATUS OK OK OK OK OK OK OK File configuration Service Manual Topaz PA 1309/10 5322 871 63606 01.05 Software Section 10.6. System Messages 7KLVFKDSWHUJLYHVDOLVWRIWKHV\VWHPPHVVDJHVRIWKH9,26RSHUDWLQJV\VWHP7KHVFUHHQV EHORZDUHYDOLGIRUWKH[VRIWZDUHDQGKLJKHU,QVFUHHQ6+(//0',6. 0$,17(1$1&(VXEGLU.*B0DOLVWLVVKRZQRIWKHFRQWHQWVRIWKLVVXE GLUHFWRU\VHHILJ:LWKPRYLQJWKHKLJKOLJKWHGEDUWRDILOHDQGSUHVVLQJ>)@LWLV SRVVLEOHWRYLHZWKHFRQWHQWVRIWKLVILOH7KHPRVWLPSRUWDQWILOHVDUHGLVSOD\HGLQEROW DQGDUH (550(6B(7;7VHHILJ +/30(6B(7;7VHHILJ ,700(6B(7;7VHHILJ 02'0(6B(7;7VHHILJ 33(55B(7;7VHHILJ 9,60(6B(7;7VHHILJ DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/DATA_FILE_MNG 2/DISK_MAINTENANCE 3/VIOS_DIC 0/EXIT DIRECTORY C:\KG7-42M0.009 Name Ext Size Date ERRMES_E TXT 110282 95-11-09 ERRMES_J TXT 98592 95-11-09 ERRMES_S TXT 93584 96-02-29 HLPMES_E TXT 432420 95-11-09 HLPMES_J TXT 379910 95-11-09 HLPMES_S TXT 337020 96-02-29 ITMMES_E TXT 33961 95-11-09 ITMMES_J TXT 35227 95-11-09 ITMMES_S TXT 34076 96-02-29 LASERPOS TXT 213 96-02-29 MODMES_E TXT 17373 95-11-09 MODMES_J TXT 16734 95-11-09 MODMES_S TXT 16639 96-02-29 Figure 10.11 Time 15:35 15:35 14:55 15:35 15:35 14:57 15:35 15:35 14:57 14:57 15:35 15:35 14:57 DIRECTORY C:\ECL92\KG7-42M0.009 Name Ext Size Date QWORDS_S TXT 2859 96-02-29 SBMMES_E TXT 23530 95-11-09 SBMMES_J TXT 22763 95-11-09 SBMMES_S TXT 22314 96-02-29 SPEED5 TXT 252 96-02-29 TITLE_X TXT 47897 95-11-09 TKNSCD TXT 177 95-11-09 TKNSYM TXT 2235 95-11-09 UFOSBRD TXT 297 95-11-09 UFOSFD2 TXT 57 95-11-09 UFOSFDR TXT 248 95-11-09 UFOSMCH TXT 1868 95-11-09 UFOSVIS TXT 816 95-11-09 Time 14:58 15:35 15:35 14:58 14:59 15:35 15:35 15:35 15:35 15:35 15:35 15:35 15:35 C:\KG7-42M0.009 7KHB(7;7ILOHVFRQWDLQVWKH(QJOLVKWH[WILOHV7KHB-7;7ILOHVFRQWDLQVWKH-DSDQHVH WH[WILOHV$QGWKHB67;7 ILOHV FRQWDLQV WKH WH[W ILOHV IRU D VSHFLDO ODQJXDJH HD )UHQFK *HUPDQLIDYDLODEOH$OOWKHVHWH[WILOHVFDQRQO\EHYLHZHGLQWKH9,26VRIWZDUH 5322 871 63606 01.05 Service Manual Topaz PA 1309/10 10-29 Software Section (550(6B(W[W ,QILJDVPDOOSDUWRIWKH(UURUOLVWLVVKRZQ #0000 Detection succeeded. The corrected data is now effective. S50xX /0000/E #0001 CORRECTION DATA ERROR Only 1 Lead detected. $5022 /0000/E #0002 CORRECTION DATA ERROR Correction data is not loaded. Or it diversifies. $5022 /0000/E #0003 COMPONENT DETECTION ERROR Figure 10.12 ERROR_E.TXT +/30(6B(W[W 7KLVILOHFRQWDLQVWKHKHOSPHVVDJHVZKLFKLVVKRZQZLWKWKH>)@NH\ILJ #0000 YOU CAN PUT 74 CHARACTERS PER 1 LINE, 19 LINES PER 1 PAGE. USE ’,’ AND ’.’ FOR INTEGRITY. THIS IS A TEXT FILE FOR ONLINE-HELP MESSAGES. IF YOU PUSH THE [F1] KEY, YOU WILL GET AN EXPLANATION AND PUSH ANY KEY TO CLEAR THE EXPLANATION. THIS MESSAGE IS NO.0 $37 /0000/E #0001 1/OPERATION/M <<<OPERATION MANAGER>>> supports daily production. MODE RUNNING :Production, Warming Up [CTRL] + [F1] PRD.DATA :PCB data modification [CTRL] + [F2] PRD.HISTORY :See production history [CTRL] + [F3] Figure 10.13 10-30 Service Manual Topaz PA 1309/10 HLPMES_E.TXT 5322 871 63606 01.05 Software Section 0260(6B(W[W 7KLVILOHFRQWDLQVWKHWH[WILOHVIRUHDFKPRGHILJ #0010 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT --------------- » ----------------- <<<OPERATION MANAGER>>> supports daily production. MODE RUNNING :Production, Warming Up PRD.DATA :PCB data modification PRD.HISTORY:See production history MANUAL :Manual operating Figure 10.14 MODMES_E.TXT 9,60(6B(W[W 7KLVILOHFRQWDLQVDOOWKHYLVLRQWH[WILOHV #0000 Component was detected successfully Position and angle data is available $57XX /0000/E #0001 Component detection Error: (1) - Only 1 Lead detected. $57XX /0000/E #0002 Calculation Error: (2) Calibration data is not ready to read $57XX /0000/E #0003 Component detection Error: (3) Failed to detect component Figure 10.17 5322 871 63606 01.05 VISMES_E.TXT Service Manual Topaz PA 1309/10 10-31 Software Section 10.7. Online Commands 2QOLQHFRPPDQGVDUHXVHGWRFRQWUROWKH7RSD]IURPD3& ([SHULHQFHVLQSURJUDPPLQJDUHUHTXLUHG $SURJUDPWKDWPDNHVIXOOXVHRIWKHVHLQVWUXFWLRQVLVWKH3KLOLSV3URGXFWLRQ&RQWURO 6RIWZDUHDQGFDQEHRUGHUHGYLDUHJXODUFKDQQHOV 7KHVHWRIRQOLQHFRPPDQGVZLOOQRWEHSULQWHGLQWKLVPDQXDOEXWDUHDYDLODEOHRQ VSHFLDOUHTXHVWDW3KLOLSV(LQGKRYHQ 10-32 Service Manual Topaz PA 1309/10 5322 871 63606 01.05