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6-2

i3070 Series 5i Help

Troubleshooting

System Diagnostics

Diagnostics (dgn) is the main troubleshooting tool. You can use it to check
the hardware configuration, verify performance, and isolate failures to a
field- replaceable unit (FRU). The Diagnostic tests are structured in such a
way that the failing part is usually indicted by the first few test failures.

Some Diagnostic tests require that a Pin Verification Fixture (PVF, part
number E9988- 67901) be installed on the testhead; other tests require that
it not be installed. The Diagnostics program senses whether a fixture is
installed or not and automatically runs the appropriate tests.

Refer to

Diagnostics

in the Medalist i3070 online help for information on

the Diagnostics software package, how to run it, what the tests are and
how to use them for troubleshooting.

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Summary of Contents for Medalist i3070 Series 5i

Page 1: ...Agilent Technologies Medalist i3070 Series 5i Inline ICT System i3070 Series 5i Help...

Page 2: ...with the terms of such license Restricted Rights Legend If software is for use in the performance of a U S Government prime contract or subcontract Software is delivered and licensed as Commercial com...

Page 3: ...70 Series 5i 1 11 2 Touch Panel Functions Modes of Operation 2 2 Maintenance Mode 2 3 Test Settings 2 5 Debug Mode 2 7 3 Test Development Test Development Overview 3 2 Fixturing Guidelines 3 3 Board P...

Page 4: ...r Messages and Remedial Actions 6 4 Sensor Calibration and Troubleshooting 6 8 Calibrating PHS 13 Presser Lower Limit Sensor 6 8 Troubleshooting PHS 1 to PHS 7 6 11 Troubleshooting PHS 12 to PHS 14 PH...

Page 5: ...Belt Movable Side 7 40 Zone 2 Conveyor Belt Fixed Side 7 42 Compression Spring Movable Side 7 44 Compression Spring Fixed Side 7 46 Replacing Conveyor Motors 7 48 Zone 1 Conveyor Motor 7 48 Zone 2 Con...

Page 6: ...vi...

Page 7: ...5i Inline ICT System i3070 Series 5i Help 1 Getting Started Safety Information 1 2 Overview 1 3 System Hardware 1 4 System Software 1 8 Starting the Medalist i3070 Series 5i 1 9 Shutting Down the Meda...

Page 8: ...s equipment without covers may cause electric shock WARNING Moving Parts General Do not touch the equipment while it is running Keep clear of moving machinery WARNING Moving Parts Hand Do not touch th...

Page 9: ...ng multiple boards simultaneously Autodebug Reduces debug time AutoOptimizer Optimizes test times for repeated tests Agilent Utility Card Allows easy plug in of third party test modules for flash prog...

Page 10: ...troller The controller is the computer that controls the test system The controller pod also houses the System Card and DUT power supplies System Card The System Card System card is the conduit for co...

Page 11: ...Getting Started i3070 Series 5i Help 1 5 Figure 1 2 Zone 1 Front View PDU On Off Switch Air Regulator Controller System Card DUT Power Supplies Zone 1 Conveyor Crank for Conveyor Width Adjustment...

Page 12: ...3 Zone 2 Front View Figure 1 4 Rear View Press Assembly PLC Drawer Card Cage Anti Rotation Guide Bar Zone 2 Conveyor Manual Control Panel Electrical Panel PDU MPU Power Outlets Guided Probe Debug Port...

Page 13: ...ntrol Panel Button Switch Description 1 MAINTENANCE KEY SWITCH Off Enable Production Mode On Enable Maintenance Debug Mode allows system to operate with the doors open 2 TOP JIG LOCK Lock the top fixt...

Page 14: ...s LCDTouch Panel Program The LCD touch panel lets you select the mode of operation Select Production mode for production testing Both Debug and Maintenance modes require a password Maintenance mode le...

Page 15: ...he safety relays Open the controller pod cover to access the following switches 3 Turn ON the PDU on off switch that enables power to the testhead 4 Turn ON the DUT power supply 5 Turn ON the controll...

Page 16: ...Default Password Definition and Permissions operator Resetme1 For operators who are using the Operator Interface to test boards tcm Resetme1 For operators who are using BT Basic to test boards user A...

Page 17: ...ware select File Exit 2 Unboot the testhead a Open a Korn Shell window and type dgn at the command line b In the DGN window select Testhead Functs and unboot the testhead using Testhead Power Off 3 Lo...

Page 18: ...1 12 i3070 Series 5i Help Getting Started...

Page 19: ...2 1 Medalist i3070 Series 5i Inline ICT System i3070 Series 5i Help 2 Touch Panel Functions Modes of Operation 2 2 Maintenance Mode 2 3 Debug Mode 2 7...

Page 20: ...63 Administrators can change the password by pressing Change Password on the password page Table 2 1 Modes of Operation LCD Touch Panel Menus Description Production Mode Start and stop production test...

Page 21: ...es Table 2 2 describes the functions in Maintenance Mode Return to Main Page Next page Previous page Go to the menu for this mode Table 2 2 Maintenance Menu Option Description Zone 1 Zone 2 Scan Drawe...

Page 22: ...t reverse movement of Zone 2 conveyor Stop Stop Zone 2 conveyor Zone 2 Stopper On Move Zone 2 stopper down Off Move Zone 2 stopper up Zone 1 2 FWD Start forward movement of Zone 1 and Zone 2 conveyors...

Page 23: ...xture Unlock Unlock top fixture Presser Presser Up Move the Press up Down Move the Press down Origin Move the Press to origin start position Slow Slow down Press movement Press again to return to norm...

Page 24: ...re triggering an error Recontact Timeout Time in seconds to wait before retest D Stream Timeout Time in seconds to wait for DSB Downstream Busy signal from downstream machine Note Default timeout 300...

Page 25: ...at they are set correctly 1 On the Debug page press Origin to intialize the Press to the start position Then press Next to go to the next page 2 Press a button on the menu to move the Press to the ind...

Page 26: ...2 8 i3070 Series 5i Help Touch Panel Functions...

Page 27: ...3 1 Medalist i3070 Series 5i ICT System i3070 Series 5i Help 3 Test Development Test Development Overview 3 2 Fixturing Guidelines 3 3 Fixture Setup and Debugging 3 15...

Page 28: ...es 5i New IN LINE Keyword In the board file a new keyword is introduced for the Medalist i3070 Series 5i inline fixture Fixture Type IN LINE Fixture Size BANK2 testmain When the IN LINE keyword is use...

Page 29: ...ent task decides the placement of the board on the fixture and creates the fixture files The placement of the board is specified as X and Y offsets from the fixture origin to the board origin and a ro...

Page 30: ...es No probing allowed in this area Components must not be located in or lean into this area Board Length Minimum 50 0 mm 2 36 in Maximum 350 0 mm 13 8 in without top side and dual stage probes Board W...

Page 31: ...Fixture Figure 3 3 Bottom Fixture Specifications Dimensions in mm NOTE All connectors Board Align Board Orientation VTEP and CET control signals should be placed at the front of the fixture for easy...

Page 32: ...ure Maximum Height Figure 3 5 Bottom Fixture Tooling Pin Bushing A The tooling pin bushing should not lean into the conveyor belt area B The bushing should be flush with the probe plate C If any part...

Page 33: ...Test Development i3070 Series 5i Help 3 7 Top Fixture Figure 3 6 Top Fixture Specifications Dimensions in mm...

Page 34: ...0 Series 5i Help Test Development Guide Pin Figure 3 7 Guide Pin Position Center of guide pin to center of guide hole Center of guide pin to front edge of bottom fixture Center of top fixture Dimensio...

Page 35: ...of the PCB must be 184 6 mm 7 27 in after compression regardless of the PCB thickness Figure 3 8 Top Fixture Front View After Compression 2YHUDOO KHLJKW IURP 7RS 3ODWH WR ERWWRP RI 3 PXVW EH PP LQ DI...

Page 36: ...the system can go into Production Auto mode The ID block has three groups of 16 pins arranged in two rows each for a total of 48 pins Table 3 2 shows the pin assignments The first two rows of pins ca...

Page 37: ...2 Signal 405 AF4 Signal 407 AF6 Signal 409 AF8 Signal 411 AF10 Signal 413 Auto GND Signal Com T board orientation Pin 16 Pin 14 Pin 12 Pin 10 Pin 8 Pin 6 Pin 4 Pin 2 Spare Spare Spare J1 10 J1 8 J1 6...

Page 38: ...3 12 i3070 Series 5i Help Test Development Figure 3 10 ID Block Location Dimensions in mm...

Page 39: ...e The transmitter and receiver are aligned with a tooling hole of a correctly positioned and oriented board As the board travels from Zone 1 to Zone 2 it is detected by the stopper sensor When the boa...

Page 40: ...ture connector provided as shown in Figure 3 11 Use Pin 2 and 3 for dry contact voltage free When the board is sitting flat on the support plate all the switches close and provide a short signal to th...

Page 41: ...ture Setup and Debugging Fixture Setup Verify the Fixture Fixture Setup Follow the procedures in this section to set up a new fixture 1 Adjust Conveyor Width 2 Load Bottom Fixture 3 Adjust Board Stopp...

Page 42: ...esthead pod cover 2 On the manual control panel turn the Maintenance Key Switch to ON 3 Insert the crank into the leadscrew Turn the crank to adjust the conveyor to the required width Place a producti...

Page 43: ...Series 5i Help 3 17 Using the Touch Panel 1 Select Maintenance mode on the LCD touch panel and press Width 2 Press Next 3 Enter the board width in mm and then press Go Pos to move the conveyor rail t...

Page 44: ...e the drawer a Select Maintenance mode on the LCD touch panel Press Drawer to go to page 4 b Press Unlock then press UP to move the drawer up 2 Pull the drawer out by its handles 3 Load the bottom fix...

Page 45: ...the board stopper using a production board 1 Turn the Zone 2 board stopper on a On the Maintenance menu select Zone 2 to go to page 2 b Select On for the Zone 2 stopper 2 Place the production board on...

Page 46: ...is correctly positioned and can be guided onto the tooling pins 9 Repeat the process to adjust the placement of the board stopper if necessary to ensure the board is stopped at the correct position 10...

Page 47: ...0 Series 5i Help 3 21 b On the Maintenance menu select Top Jig to go to page 6 and select Lock 11 Go to page 6 Manually jog the Press to check that the board is correctly positioned and can be guided...

Page 48: ...e Standby Pos and Presser Retrieve Pos pages That is keep the factory settings for those positions 4 Begin calibration with the Retest Pos a Press Search Origin to move the Press to the start position...

Page 49: ...on of the Press for removing the fixture or for maintenance The three 75 mm fixture calibration pages below will be followed by similar pages for 85 mm and 100 mm Be sure to use the correct calibratio...

Page 50: ...aintenance Key Switch to OFF 2 Close all the doors and covers 3 Press the Reset button 4 On the LCD touch panel Main page select Production 75mm Jig Long Probe Pos Position where the board is in conta...

Page 51: ...Help 3 25 Verify the Fixture Use Pushbutton Debug to verify the fixture as described in the Medalist i3070 online help Use Debug mode on the touch panel to quickly check the press positions for the fi...

Page 52: ...3 26 i3070 Series 5i Help Test Development...

Page 53: ...4 1 Medalist i3070 Series 5i ICT System i3070 Series 5i Help 4 Production Setup and Testing Production Setup 4 2 Production Testing 4 3...

Page 54: ...model for production 1 Adjust Conveyor Width 2 Load Bottom Fixture 3 Adjust Board Stopper 4 Select Fixture Profile a Select Maintenance mode on the touch panel and enter the password b Press Setting a...

Page 55: ...ler and PLC Settings are verified and the fixture ID is read The Press is initialized On the touch panel Production mode is automatically set to Auto and the system is ready to receive a board and beg...

Page 56: ...4 4 i3070 Series 5i Help Production Setup and Testing...

Page 57: ...5 1 Medalist i3070 Series 5i ICT System i3070 Series 5i Help 5 Maintenance Calibration 5 2 General Cleaning 5 3 Lubrication Procedures 5 4...

Page 58: ...em Calibration In addition to the ASRU calibration a System Calibration Service is available for customers who desire more comprehensive measurements and reporting System Calibration should be perform...

Page 59: ...e system causes a buildup of dirt on pin cards and Mother Cards and clogs air vents in the testhead contributing to system overheating Check and clean these areas as necessary Test fixtures When not u...

Page 60: ...ocks Zone 1 Conveyor Leadscrew and Spline Shaft Zone 1 Conveyor Bevel Gears and Chain Zone 2 Conveyor Runner Blocks Drawer Guide Shafts Testhead Spur Gears Tools and Supplies Brush for greasing parts...

Page 61: ...w Nut 1 Open the Zone 2 door to access the Press The ballscrew and ballscrew nut are found at the side of the Press 2 Use a grease gun to apply a small amount of grease as shown below 3 Close the door...

Page 62: ...ress Linear Shafts The Press has four linear shafts 1 Open the Zone 2 door to access the Press 2 Use a grease gun to apply a small amount of grease to the four linear shafts 3 Close the door Linear Sh...

Page 63: ...with two runner blocks along each rail 1 Open the Zone 2 door to access the Press 2 Use a grease gun to apply a small amount of grease to the four runner blocks at the front 3 Open the rear doors to...

Page 64: ...Conveyor Leadscrew and Spline Shaft 1 Open the Zone 1 door to access the Zone 1 conveyor assembly 2 Use a brush to lightly apply grease to the two leadscrews and the spline shaft 3 Close the door Zone...

Page 65: ...r to access the Zone 1 conveyor assembly 2 Remove three screws to remove the rear cover of the assembly 3 Use a brush to lightly apply grease to the two bevel gears and the chain 4 Replace the rear co...

Page 66: ...ntal runner blocks and four vertical runner blocks 1 Open the rear doors to access the Zone 2 conveyor assembly 2 Use a grease gun to apply a small amount of grease to the runner blocks 3 Close the re...

Page 67: ...r guide shafts at the corners 1 Remove the testhead pod cover to access the guide shafts of the drawer assembly 2 Use a brush to lightly apply grease to the two guide shafts at the front 3 Open the re...

Page 68: ...Accessing the Testhead to pull out the testhead 2 Remove six screws around the spur gear cover 3 Use a brush to lightly apply grease to the two spur gears 4 Replace the guide bar on the testhead and...

Page 69: ...6 1 Medalist i3070 Series 5i ICT System i3070 Series 5i Help 6 Troubleshooting System Diagnostics 6 2 General System Troubleshooting 6 3 Sensor Calibration and Troubleshooting 6 8...

Page 70: ...usually indicted by the first few test failures Some Diagnostic tests require that a Pin Verification Fixture PVF part number E9988 67901 be installed on the testhead other tests require that it not...

Page 71: ...ons Green On System is in Auto mode Amber On System has stopped System is in Maintenance mode or Debug mode Flashing Error during Maintenance mode Downstream Not Ready timeout Red On Emergency Stop ac...

Page 72: ...if needed 4 Replace the Down reed switch if faulty 1 Check that the air supply is turned on 2 Check the Zone 2 stopper cylinder and replace if faulty 3 Check the Up reed switch for the Zone 2 stopper...

Page 73: ...rly Check the Bottom Jig Fully In Detect sensor PHS 11 Ensure that the drawer is pushed all the way into the system Check the Engine Fully In Detect sensor PHS 9 Ensure that the testhead is pushed all...

Page 74: ...n the bottom fixture is locked Repalce if faulty 1 Check that the air supply is turned on 2 Check the bottom fixture s clamping cylinders and replace if faulty 3 Check the bottom fixture clamp s unloc...

Page 75: ...Check the front hook sensor PHS 17 See Sensor Troubleshooting Disengage the rear safety hook Check the rear hook sensor PHS 16 See Sensor Troubleshooting A board was removed when the system is runnin...

Page 76: ...ed by the Presser Lower Limit Sensor PHS13 see Figure 6 5 for the location It must allow the Press to move down sufficiently for the probes to contact the board during testing but if it is set too low...

Page 77: ...s are contacting the board 6 If the lower limit sensor is too low Loosen the two screws securing the sensor bracket Figure 6 1 7 Adjust the position of the lower limit sensor a Slide the sensor slowly...

Page 78: ...8 Test the sensor positioning a On the LCD Touch Panel press and hold UP to move the Press up b Press and hold Down to move the Press down until the probes are contacting the board Check that the lowe...

Page 79: ...t respond Check the sensor response after each step and continue only if the sensor fails to respond 1 Adjust the sensor sensitivity by turning the control clockwise or anti clockwise 2 Check the conn...

Page 80: ...heck fails check the cables and connectors Troubleshooting PHS 12 to PHS 14 PHS 24 to PHS 26 See Figure 6 5 on page 6 17 for the location of the sensors See Figure 6 5 for the location of the sensors...

Page 81: ...rigger the sensor again and check if the PLC responds through the PLC I O indicator If the PLC responds it was likely an intermittent failure and no further action is needed 2 If the PLC does not resp...

Page 82: ...ensor response after each step and continue only if the sensor fails to respond 1 Check the connectors and ensure there is power to the sensor 2 Replace the sensor If the sensor responds 1 Trigger the...

Page 83: ...e Bar Detect Sensor PHS 19 306 Conveyor Right Limit Sensor Dark on PHS 25 400 Conveyor Origin Sensor Dark on PHS 24 315 Conveyor Left Limit Sensor Dark on PHS 26 401 Zone 1 Stopper Up SV1 1010 RS1 108...

Page 84: ...nt Safety Hook Detect Sensor PHS 17 100 Table 6 4 Motors and Controls Motor Control ID Presser Servo Motor M1 Zone 1 Motor M2 Zone 2 DC Motor M3 M4 Lighting LT1 Tester Self test not used PB2 102 1001...

Page 85: ...stem Figure 6 6 Press and Conveyor Sensors 3 6 3 6 69 69 3 6 3 6 3 6 3 6 3 6 69 69 3 6 ELW 7RS LJ QSXW 0 0 0 0 7 3 6 3 6 3 6 3 6 69 69 3 6 3 6 3 6 3 6 3 6 3 6 3UR LPLW VHQVRU LIIXVH VHQVRU 6ROHQRLG YD...

Page 86: ...Press Sensors Zone 1 Inlet Sensor PHS 1 Zone 1 Stopper Sensor PHS 2 Zone 1 Exit Sensor PHS 3 Rear Safety Hook Detect Sensor PHS 16 Front Safety Hook Detect Sensor PHS 17 Upper Limit Sensor PHS 12 Home...

Page 87: ...19 Figure 6 8 Zone 2 Sensors Right Limit Sensor PHS 25 Origin Sensor PHS 24 Left Limit Sensor PHS 26 Conveyor Conveyor Conveyor Zone 2 Inlet Sensor PHS 4 Zone 2 Stopper Slow Sensor PHS 5 Zone 2 Stoppe...

Page 88: ...6 20 i3070 Series 5i Help Troubleshooting...

Page 89: ...8 Replacing Runner Blocks 7 10 Replacing Module Power Unit MPU 7 21 Installing DUT Power Supply 7 23 Replacing Servo Motor 7 27 Replacing Press Components 7 31 Replacing Zone 1 Conveyor Belt 7 35 Repl...

Page 90: ...he Zone 2 door and pull out the drawer to remove the bottom fixture d Push the drawer back into place 2 Turn off the PDU on off switch 3 Unlock and remove the testhead pod cover See Figure 7 1 for the...

Page 91: ...Series 5i Help 7 3 6 Use the hand crank to rotate the testhead The direction depends on the part being replaced Figure 7 1 Accessing the Testhead Hand Crank Handle Guide Bar Latch Star Knob Install h...

Page 92: ...7 4 i3070 Series 5i Help Replacement Procedures Figure 7 2 Stowing the guide bar Guide Bar...

Page 93: ...the testhead 120 degrees until the blower door is facing you Figure 7 3 3 Release the latches and open the blower door Figure 7 3 Accessing the Cards 4 It may be necessary to remove cables from the AS...

Page 94: ...or but do not force the card since it can damage the connector 4 Reconnect cables as needed To prevent electrostatic discharge ESD from damaging sensitive components on module slot cards wear a tested...

Page 95: ...replacing a Module Control Card update the hardware address in the system software before booting the testhead otherwise there will be boot errors 8 Close and secure the blower door 9 Rotate the test...

Page 96: ...ables 2 Open the controller pod door 3 Remove the four dress screws securing the i System Card Assembly and remove the assembly Installation 1 Slide the new i System Card Assembly along the support ra...

Page 97: ...Replacement Procedures i3070 Series 5i Help 7 9 3 Open the rear door to reconnect the cables to the i System card To Module 3 To Module 2...

Page 98: ...wn Zone 2 Conveyor Runner Block Width Adjustment Testhead Runner Blocks There are two guide rails on each side of the testhead with two runner blocks on each guide rail The runner blocks are accessed...

Page 99: ...ing the runner block to be replaced Slide the runner block out along the guide rail Installation 5 Slide the new runner block along the guide rail into the system Align the mounting holes and secure w...

Page 100: ...of the system Figure 7 6 Front Runner Blocks for Press Removal Follow this procedure to replace a lower runner block Power must be connected to begin this procedure 1 Select Maintenance mode on the LC...

Page 101: ...e PDU on off switch Front Hook Locked Rear Hook Locked 4 Remove the lower runner block to be replaced a Remove two screws below the runner block stopper and remove the stopper b Remove four screws sec...

Page 102: ...res Installation 1 Slide the new runner block up the guide rail Align the screw mounting holes and secure with the four screws 2 Install the runner block stopper and secure with the two screws 3 Unloc...

Page 103: ...connected to begin this procedure 1 Select Maintenance mode on the LCD touch panel a Press Presser to go to page 6 b Press Origin to move the Press to its origin position c Then press and hold Down to...

Page 104: ...ock stopper and secure with the two screws 4 Move the two set collars back into position 30 mm to 50 mm from the end of the shaft Tighten the screws on the set collars 5 Close all doors covers 4 Remov...

Page 105: ...ctions in Zone 2 Conveyor Motor Movable Side to remove the conveyor motor 2 Remove the right side cover 3 To remove the runner block a Remove two screws to release the runner block from the conveyor b...

Page 106: ...e the runner block off the guide rail Installation 1 Slide the new runner block onto the guide rail 2 Reinstall the guide rail in the system 3 Secure the runner block to the conveyor with two screws 4...

Page 107: ...he right side cover 2 Remove the movable rail assembly a Remove six screws securing one side of the rail assembly b Do the same on the other side and remove the rail assembly The guide rail can now be...

Page 108: ...he new runner block onto the guide rail 2 Reinstall the guide rail in the system Secure with 10 screws 3 Secure the movable guide holder four screws to the guide rail 4 Reinstall the movable rail asse...

Page 109: ...testhead 90 degrees until the MPUs are facing up 3 Disconnect the MPU cable from the motherboard and disconnect the power cable 4 Use an Allen key to remove the screws holding the MPU to the support...

Page 110: ...2 Connect the MPU cable to the motherboard Be sure to align the connectors properly 3 Plug in the power cable 4 Rotate the testhead back into position and stow the hand crank Replace the guide bar an...

Page 111: ...Power Supply in Controller Pod Installation 1 Open the controller pod door 2 Slide the DUT power supply along the support rails into the system 3 Secure it with four dress screws i System Card Dress...

Page 112: ...round cable at the back of the DUT power supply 5 Connect the cables F G H and J 6 Tidy the unused cables K and L and secure with cable ties 7 If two DUT power supplies are installed connect the GPIB...

Page 113: ...power supply to the PDU outlet box Set the GPIB address 1 On the front panel of the DUT Power Supply press the Menu button 2 Press to select System then press Sel to select IO 3 Press Sel to select GP...

Page 114: ...config files Example 7 1 bank 2 module 2 supplies ps6751 5 to 8 asru channels 1 to 4 supplies hp6634 19 asru channels 5 supplies hp6634 20 asru channels 6 ports ext3 ext4 end module module 3 supplies...

Page 115: ...w Power must be connected to begin this procedure 1 Select Maintenance mode on the LCD touch panel a Press Presser to go to page 6 b Press Origin to move the Press to its origin position c Press and h...

Page 116: ...3 Open the rear door 4 Loosen the two screws on the set collar and push the set collar against the linear bearing Tighten the screws on the set collar Do the same for the other set collar Linear Beari...

Page 117: ...Zone 2 door and remove the side cover 2 Remove the Press servo motor a Loosen the screw that secures the coupling to the motor shaft b Unplug the electrical connectors c Remove four screws securing t...

Page 118: ...it to go into the coupling Secure the motor with the four screws 4 Plug in the electrical connectors 5 Tighten the screw on the coupling Reposition Set Collars 6 Loosen the screws on the set collars a...

Page 119: ...apered roller bearing on either side of the bearing block Coupling Tools required Metric Allen key Philips screwdriver Flat screwdriver Diagonal cutter C spanner Remove the fixture before replacing pa...

Page 120: ...or 3 Loosen the screw securing the coupling to the ballscrew Then loosen the locknuts 4 Remove four screws securing the bearing block 5 Remove six screws securing the ballscrew collar The collar and b...

Page 121: ...or shaft The coupling can now be removed Replace with a new coupling and tighten the screw to secure it to the servo motor shaft 8 Insert the ballscrew through the collar and bearing block ensuring th...

Page 122: ...knuts and the screw on the coupling Reposition Set Collars 11 Loosen the screws on the set collars and move them back into position 30 mm to 50 mm from the end of the shaft Tighten the screws on the s...

Page 123: ...onveyor Belt Movable Side Removal 1 Open the Zone 1 door to access the access the Zone 1 conveyor assembly 2 Loosen the screw on the tensioner bearing to release tension on the belt 3 Slide the tensio...

Page 124: ...7 36 i3070 Series 5i Help Installation 1 Install the new belt 2 Slide the tensioner bearing in the direction shown and tighten the screw 3 Close the door Tensioner Bearing Belt...

Page 125: ...1 door to access the access the Zone 1 conveyor assembly 2 Loosen the screw on the tensioner bearing to release tension on the belt 3 Slide the tensioner bearing in the direction shown and release the...

Page 126: ...7 38 i3070 Series 5i Help Installation 1 Install the new belt 2 Slide the tensioner bearing in the direction shown and tighten the screw 3 Close the door Tensioner Bearing Belt...

Page 127: ...i3070 Series 5i Help 7 39 Replacing Zone 2 Conveyor Belt Spring Zone 2 Conveyor Belt Movable Side Zone 2 Conveyor Belt Fixed Side Compression Spring Movable Side Compression Spring Fixed Side...

Page 128: ...e Zone 2 door to access the Zone 2 conveyor assembly 2 Loosen the screw on the tensioner bearing to release tension on the belt 3 Slide the tensioner bearing in the direction shown and release the bel...

Page 129: ...i3070 Series 5i Help 7 41 Installation 4 Install the new belt Slide the tensioner bearing in the direction shown and tighten the screw 5 Close the door Belt Tensioner Bearing...

Page 130: ...Zone 2 door to access the Zone 2 conveyor assembly 2 Loosen the screw on the tensioner bearing to release tension on the belt 3 Slide the tensioner bearing in the direction shown and release the belt...

Page 131: ...i3070 Series 5i Help 7 43 Installation 1 Install the new belt Slide the tensioner bearing in the direction shown and tighten the screw 2 Close the door Belt Tensioner Bearing...

Page 132: ...movable side Removal 1 Remove the right side cover 2 Remove the movable rail assembly a Remove six screws securing one side of the rail assembly b Do the same on the other side and remove the rail ass...

Page 133: ...Insert the spring guide and new spring 2 Reinstall the movable rail assembly On each side tighten the four screws at the base and make sure the rail assembly is properly aligned before tightening the...

Page 134: ...springs for the Zone 2 conveyor fixed side Removal 1 Remove the right side cover 2 Remove the fixed rail assembly a Remove two screws securing one side of the rail assembly b Do the same on the other...

Page 135: ...late spring and spring guide can now be removed Installation 1 Assemble the new spring spring guide and support plate Secure the support plate to the rail assembly with four screws 2 Secure the spring...

Page 136: ...Motor Zone 2 Conveyor Motor Movable Side Zone 2 Conveyor Motor Fixed Side Zone 1 Conveyor Motor Removal 1 Open the rear door to access the Zone 1 conveyor assembly 2 Remove three screws to remove the...

Page 137: ...e conveyor motor to the bracket Installation 1 Install the new conveyor motor on the bracket a Align the mounting holes and secure with the four screws b Insert the bevel gear and tighten the setscrew...

Page 138: ...n the two setscrews that mount the pulley on the conveyor motor and remove the pulley Installation 1 Install the pulley and tighten the setscrews Ensure that the pulley is properly aligned 2 Align the...

Page 139: ...and remove the pulley 3 Remove the four mounting screws securing the conveyor motor Installation 4 Align the mounting holes and secure the new conveyor motor with four screws 5 Insert the pulley and...

Page 140: ...7 52 i3070 Series 5i Help...

Page 141: ...Touch Panel Firmware 8 5 Back Up LCD Touch Panel Firmware 8 6 If a firmware update is available the files must be copied to a memory card for transfer to the Medalist i3070 Series 5i PLC Use a Compact...

Page 142: ...2 Turn off the power to the PLC by switching off MCB4 Main Circuit Breaker 4 which is found on the electrical panel 3 Open the cover of the memory card slot on the PLC and insert the memory card into...

Page 143: ...the DIP switches 5 Turn on DIP switch 2 and 7 6 Switch on MCB4 The program is automatically downloaded to the PLC 7 Wait for the BUSY and MCPWR lights to go off then turn the PLC power off 8 Turn off...

Page 144: ...ry card into the slot 3 Open the cover above the memory slot to access the DIP switches 4 Turn on DIP switch 7 5 Press and hold the MCPWR button until the BUSY light starts blinking 6 Wait for the BUS...

Page 145: ...re 1 Copy the entire folder gt_data containing the firmware update to an SD card 2 Open the Zone 2 door Insert the SD card into the card slot 3 On the Setting Mode page select SD GT 4 Select the folde...

Page 146: ...l Firmware 1 Open the Zone 2 door Insert the SD card into the card slot 2 On the Setting Mode page press Manual to switch to Automatic mode 3 To back up the firmware select GT SD 4 Enter a filename fo...

Page 147: ...9 1 Medalist i3070 Series 5i ICT System i3070 Series 5i Help Appendix Parts List 9 2 Electrical Diagrams 9 5...

Page 148: ...LT L1670 2 Zone 2 Conveyor Rail Assy 5186 2230 Reed Switch_24VDC 100VAC 2 Zone 2 Conveyor Rail Assy 0960 3187 Sensor Background suppression w 2m fixed Cable 4 Zone 2 Conveyor Rail Assy 0950 5621 Power...

Page 149: ...utput Unit Relay Contact 16 Outputs 3 Electrical Panel PLC 0960 3188 Serial Communications Unit with two RS 232C ports 1 Electrical Panel PLC 9135 6165 Filter Line Module 60Hz MAX 520VAC 16A Panel mou...

Page 150: ...el 24VDC 3130 1520 Switch Guard push Button rectangular 1 Interface Panel 24VDC 3101 4359 Switch push Button emergency stop Pushlock Pull Turn Reset Red 1 Interface Panel 24VDC 3100 3744 Switch Rotary...

Page 151: ...9 1 Medalist i3070 Series 5i ICT System i3070 Series 5i Help Appendix Electrical Diagrams 9 2...

Page 152: ...1 Pneumatic 2 Pneumatic 3 PLC Input Unit Channel 0 PLC Input Unit Channel 1 PLC Input Unit Channel 2 PLC Input Unit Channel 3 PLC Input Unit Channel 4 PLC Output Unit Channel 10 PLC Output Unit Chann...

Page 153: ...i3070 Series 5i Help 9 3 Figure 9 1 Sensor Layout 1...

Page 154: ...9 4 i3070 Series 5i Help Figure 9 2 Sensor Layout 2...

Page 155: ...i3070 Series 5i Help 9 5 Figure 9 3 Sensor Layout 3...

Page 156: ...9 6 i3070 Series 5i Help Figure 9 4 Sensor Layout 4...

Page 157: ...i3070 Series 5i Help 9 7 Figure 9 5 Power Circuit 1...

Page 158: ...9 8 i3070 Series 5i Help Figure 9 6 Power Circuit 2...

Page 159: ...i3070 Series 5i Help 9 9 Figure 9 7 Power Circuit 3...

Page 160: ...9 10 i3070 Series 5i Help Figure 9 8 Power Circuit 4...

Page 161: ...i3070 Series 5i Help 9 11 Figure 9 9 Power Circuit 5...

Page 162: ...9 12 i3070 Series 5i Help Figure 9 10 Pneumatic 1...

Page 163: ...i3070 Series 5i Help 9 13 Figure 9 11 Pneumatic 2...

Page 164: ...9 14 i3070 Series 5i Help Figure 9 12 Pneumatic 3...

Page 165: ...i3070 Series 5i Help 9 15 Figure 9 13 PLC Input Unit Channel 0...

Page 166: ...9 16 i3070 Series 5i Help Figure 9 14 PLC Input Unit Channel 1...

Page 167: ...i3070 Series 5i Help 9 17 Figure 9 15 PLC Input Unit Channel 2...

Page 168: ...9 18 i3070 Series 5i Help Figure 9 16 PLC Input Unit Channel 3...

Page 169: ...i3070 Series 5i Help 9 19 Figure 9 17 PLC Input Unit Channel 4...

Page 170: ...9 20 i3070 Series 5i Help Figure 9 18 PLC Output Unit Channel 10...

Page 171: ...i3070 Series 5i Help 9 21 Figure 9 19 PLC Output Unit Channel 11...

Page 172: ...9 22 i3070 Series 5i Help Figure 9 20 PLC Output Unit Channel 12...

Page 173: ...i3070 Series 5i Help 9 23 Figure 9 21 Motor and Communication...

Page 174: ...9 24 i3070 Series 5i Help Figure 9 22 PLC to PC Interface...

Page 175: ...i3070 Series 5i Help 9 25 Figure 9 23 Interfacinng Cables...

Page 176: ...9 26 i3070 Series 5i Help Figure 9 24 SMEMA Communication...

Page 177: ...i3070 Series 5i Help 9 27 Figure 9 25 Touch Panel...

Page 178: ...9 28 i3070 Series 5i Help Figure 9 26 Servo Motor...

Page 179: ...i3070 Series 5i Help 9 29 Figure 9 27 Servo Pin Connection...

Page 180: ...9 30 i3070 Series 5i Help Figure 9 28 Analog Card Interface...

Page 181: ...i3070 Series 5i Help 9 31 Figure 9 29 Stepper Motor...

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