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Agilent U1840A Medalist sj5000 Automated Optical Inspection System

Hardware Manual

Agilent Technologies

11

Troubleshooting

Troubleshooting the Software

Troubleshooting the System Power

Troubleshooting the 24 V Supply

Troubleshooting the Conveyor

Troubleshooting the Camera

Troubleshooting the Lighting Controller

Troubleshooting the Lighting Tower

Troubleshooting the PC and Monitor

Troubleshooting the Safety Relay

Troubleshooting the XY Table

This chapter is intended to assist you in solving problems that
you may encounter with your system. It provides
troubleshooting information for the failure modes that happen
most frequently and with the greatest effect on productivity,
that is, those that would cause the line to stop.

For the locations of terminals, relays, PLC displays, PSUs and
MCBs, refer to the

Electrical Drawing

document (part number

5186-5861).

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Summary of Contents for U1840A Medalist sj5000

Page 1: ...Agilent Technologies Agilent U1840A Medalist sj5000 Automated Optical Inspection System Hardware Manual...

Page 2: ...ware described in this document are furnished under a license and may be used or copied only in accordance with the terms of such license Restricted Rights Legend If software is for use in the perform...

Page 3: ...ction to the Medalist sj5000 Advantages of the Medalist sj5000 2 2 Post Reflow Inspection 2 3 Camera Navigation 2 4 Parts of the Medalist sj5000 2 5 System Overview 2 5 Front View 2 6 Rear View 2 9 Co...

Page 4: ...st Conveyor Setup Linear Mechanical Setup 6 2 Conveyor Edge Clearance Adjustment 6 3 AWA Mechanical Setup 6 6 AWA Setup and Calibration 6 7 Auto Width Adjust Calibration 6 7 Conveyor Width Adjustment...

Page 5: ...al Com Port Driver 10 2 Download Barcode Reader Setup File 10 3 Set Up Multiple Barcode Readers 10 5 Align Barcode Reader 10 7 Test Barcode Reader Using HyperTerminal 10 8 Configure sj5000 Software 10...

Page 6: ...ubleshooting the Safety Relay 11 18 Troubleshooting the XY Table 11 19 Checking the System 11 20 Troubleshooting 11 38 12 Maintenance Overview 12 2 Weekly Maintenance 12 3 Monthly Maintenance 12 6 Qua...

Page 7: ...Agilent Technologies 1 Safety and Regulatory Information Safety Information 1 2 Electrical Safety 1 6 Physical Safety 1 10 System Warning Caution Labels 1 12 Electrostatic Discharge ESD Precautions 1...

Page 8: ...oduct may be impaired if it is used in a manner not specified in the operation instructions CAUTION A CAUTION notice denotes a hazard It calls attention to an operating procedure practice or the like...

Page 9: ...by a qualified service personnel WARNING The protection provided by the Agilent U1840A Medalist sj5000 system may be impaired if the system is used in a manner not specified by Agilent Table 1 1 Envi...

Page 10: ...potential shock hazard that could result in personal injury Fuses Use only fuses with the required rated current voltage and specified type normal blow time delay Do not use repaired fuses or short c...

Page 11: ...through non conductive flexible conduit such as that used in electrical power distribution Safety Requirements The following is a list of the safety requirements for electrical equipment for measurem...

Page 12: ...y Stop E Stop is designed according to the relevant safety standard It is controlled using a Carlo Gavazzi Class IV safety relay Refer to the hardware manual for E stop locations on the sj5000 The E s...

Page 13: ...troubleshooting or calibration E Stop overrides all modes of operation within the SJ5000 machine When power is removed from the system the E Stop is activated automatically and must be reset on power...

Page 14: ...mechanically and electrically bonded to the machine earth point The bonding wire used is identified by its green and yellow insulation PC Safety The PC s motherboard contains a lithium battery CR2032...

Page 15: ...Safety and Regulatory Information 1 Agilent U1840A Medalist sj5000 Hardware Manual 1 9...

Page 16: ...s of the platform These panels protect the user from electrical and mechanical hazards within the work area The user is to be aware of potential pinch hazards situated at the conveyor entry and exit o...

Page 17: ...as E stop the machine before placing fingers or hands in these areas It should be additionally noted that Agilent recommends that boards should only enter or exit the sj5000 on a conveyor not via hand...

Page 18: ...gh Voltage within General warning label Located inside PC at the lithium battery This indicates you must read the manual before operating the machine Label located on front right side of the hood Movi...

Page 19: ...is actuated Using the maintenance GUI the stops and clamps can be operated therefore be caution as pinch points around clamps can cause injury Warning of high voltage Location Main Filter Main Termin...

Page 20: ...ercised This is to prevent damage to instruments and or test disruption The C tick mark is a registered trademark of the Spectrum Management Agency of Australia This signifies compliance with the Aust...

Page 21: ...nning Precaution Suggested Solution Anti static flooring Plan to use an anti static floor covering or mats Grounding straps Plan for foot straps in conjunction with anti static flooring and wrist stra...

Page 22: ...oduct label see below indicates that you must not discard this electrical electronic product in domestic household waste Product Category With reference to the equipment types in the WEEE directive An...

Page 23: ...pection 2 3 Camera Navigation 2 4 Parts of the Medalist sj5000 2 5 Power and Communications 2 13 The Medalist sj5000 is designed to accurately measure the position and properties of each placed compon...

Page 24: ...nique This technology allows the AOI system to build a color image by combining a sequence of monochrome images of the PCB when illuminated with light of different red green and blue colors MonoColour...

Page 25: ...By utilizing the latest camera technology high image acquisition speeds are achieved The distortion free lens is complemented by a high precision XY gantry on which the camera lighting assembly is mou...

Page 26: ...he up arrow on the keyboard the camera view moves up on the screen Y axis If you press the right arrow key the camera view moves right on the screen X axis Moving the XY Table Press an arrow key on th...

Page 27: ...he machine The PC is behind the front access door The gantry motor amplifiers are located at the rear of the system in the control panel The standard sj5000 has two amplifiers for the X and Y axes Con...

Page 28: ...6 Agilent U1840A Medalist sj5000 Hardware Manual 2 Introduction to the Medalist sj5000 Front View Figure 2 2 Front view of the sj5000 E Stop button PC access Switch plate Front access door E Stop butt...

Page 29: ...after the mains isolator and residual current circuit beaker RCCB RUN light The ON indicator light for the START switch ES RESET button Resets the safety relay after any E Stop button is pressed or th...

Page 30: ...nd terminated at XB1 on the terminal rail See the Electrical Drawing document for the pin number reference AWA buttons Allow you to manually adjust the distance between the conveyor rails The top whit...

Page 31: ...Introduction to the Medalist sj5000 2 Agilent U1840A Medalist sj5000 Hardware Manual 2 9 Rear View Figure 2 5 Rear view of the sj5000...

Page 32: ...the system electrical controls The control panel is secured behind the rear access panel which is lockable Figure 2 6 shows the main electrical controls on the control panel For more details refer to...

Page 33: ...uction to the Medalist sj5000 2 Agilent U1840A Medalist sj5000 Hardware Manual 2 11 Conveyor The following diagrams show the motor and sensor locations for the conveyor Figure 2 7 Right side of the co...

Page 34: ...2 12 Agilent U1840A Medalist sj5000 Hardware Manual 2 Introduction to the Medalist sj5000 Figure 2 8 Rear of the conveyor...

Page 35: ...earth must be terminated at the earth terminal The earth link wire must have a minimum cross sectional area of 4 mm or 10 AWG An uninterruptible power supply UPS is optional Ensure that the input volt...

Page 36: ...uses pins 3 and 4 The output signals to downstream machines are the Good Board signal for pins 3 and 4 and Bad Board signal for pins 3 and 5 In Figure 2 9 boards are transferred from machine A to B a...

Page 37: ...SMEMA UP connector The downstream cable p n 5186 0615 is connected to the SMEMA DOWN connector These cables need to be routed through the cut out at the base of the system The upstream and downstream...

Page 38: ...1840A Medalist sj5000 Hardware Manual 2 Introduction to the Medalist sj5000 Serial Connection Serial ports are provided for connecting barcode readers They are located inside the sj5000 at the rear to...

Page 39: ...Manual Agilent Technologies 3 Installation Checking the Facilities and Tools 3 2 Unpacking the sj5000 3 2 Moving the sj5000 3 4 Adjusting the Height and Leveling the sj5000 3 6 Mounting the Lighting T...

Page 40: ...wooden pallet with a cardboard box enclosing the system Unpack the sj5000 as follows 1 Check all the Tip n tell indicators and shock sensors Figure 3 1 shows their locations on the box Refer to the de...

Page 41: ...Installation 3 Agilent U1840A Medalist sj5000 Hardware Manual 3 3 Figure 3 1 Locations of indicators and sensors...

Page 42: ...ine with the fixed rails of the input and output conveyors 1 Disconnect the power cord 2 Secure the X and Y axis with shipping clamps 3 Use a hand truck to lift the machine approximately one inch 4 Re...

Page 43: ...s must be followed every time the machine is lifted regardless of whether it is moved from its location WARNING If the machine is being used outside of the production line a conveyor must be fitted bo...

Page 44: ...justed so that the system conveyor height matches that of the input and output conveyors Leveling the sj5000 After adjusting the height level the machine as follows 1 Loosen the feet locking nuts 2 Pl...

Page 45: ...unted on the roof of the sj5000 1 Feed the cable through the mounting hole on the roof and fit the light tower with the three screws provided and a 2 5 mm Allen key 2 Ensure that the 22 mm nut is tigh...

Page 46: ...3 Place the mounting pole through the keyboard tray mount clamp and then into the monitor keyboard mount arm 4 Tighten the keyboard tray in place 5 Secure the mounting pole by tightening the screw in...

Page 47: ...em in place with the cable ties provided Do not secure the cables too tightly Ensure there is enough slack so that the monitor keyboard arm can be adjusted without straining the cables 2 Feed the moni...

Page 48: ...nnector to be used will depend on the requirements of the factory in which the sj5000 is being installed 1 Route the mains cable from the mains isolator following the cleats provided 2 Feed the cable...

Page 49: ...ilent U1840A Medalist sj5000 Hardware Manual 3 11 Earth Cable Connection The earth cable is connected to the earth terminal block as shown below WARNING The mains connection should only be done by qua...

Page 50: ...3 12 Agilent U1840A Medalist sj5000 Hardware Manual 3 Installation...

Page 51: ...on System Hardware Manual Agilent Technologies 4 Starting Up the Medalist sj5000 Before Powering Up 4 2 Powering Up the sj5000 for the First Time 4 3 Powering Up From the Mains Off Position 4 4 Poweri...

Page 52: ...then remove the rear access panel 2 Measure the voltage between live phase 1 and neutral phase 2 at the mains isolator The voltage should be 100 to 120 VAC or 200 V to 240 VAC 3 Ensure the system is...

Page 53: ...o move over its entire envelope before continuing You can manually move it around its enclosure 7 Ensure that the conveyor is free from obstruction 8 Ensure that the MAINT SWITCH is in the O position...

Page 54: ...move any tools or equipment that may hinder the table as it moves inside the enclosure 3 Ensure that the rear access panel is locked in position and turn the mains isolator to the ON position 4 Ensure...

Page 55: ...s the Machine Not Busy signal It is possible to configure the system to trigger the reader first and await a good read before sending Machine Not Busy this would typically be used when integrating wit...

Page 56: ...or and the conveyor starts running The board transfers to the Exit sensor The sj5000 signals the inspection result to the downstream machine via SMEMA pins 3 and 4 closed Good Board Available 3 and 5...

Page 57: ...Changing the Conveyor Rail Width Sensors and Flags 5 2 Manual Width Adjust 5 3 Auto Width Adjust 5 4 This chapter describes how to manually and automatically change the distance between the conveyor r...

Page 58: ...e three sensors has a corresponding flag mounted on the moving rail of the conveyor The sensors are installed so that each sensor is triggered when the rails reach a maximum or minimum distance apart...

Page 59: ...are no boards in the sj5000 2 Ensure the E Stop circuit has been reset 3 To narrow the distance between the rails press the top white button AWA OUT Hold the button for at least one second to activat...

Page 60: ...if any boards remain in the machine 6 In the Auto Width Adjust window Figure 5 3 click the Jog Out and Jog In buttons to adjust the distance between the conveyor rails The Auto Width Adjust Window To...

Page 61: ...t or in Each click moves the rails by the selected pulse increment 0 5 mm 1 mm or 10 mm Hold down the Jog Out Jog In buttons for continuous movement of the conveyor rails AWA PLX Control Select this o...

Page 62: ...Rail Width Calibration When you click Calibrate instructions for calibration appear in the following window NOTE Make sure the rails are parallel and the distance between the fixed and moving rails is...

Page 63: ...Technologies 6 Auto Width Adjust Conveyor Setup Linear Mechanical Setup 6 2 AWA Setup and Calibration 6 7 General Conveyor Checks 6 12 Board Sensor Checks 6 13 AWA Conveyor Component Alignment 6 15 Cl...

Page 64: ...ake the necessary adjustments 1 Use the steel ruler to measure the distance from the inside of the linear rail to the outside of the black lip where the outer clamp edge ends This distance must be les...

Page 65: ...1 mm for the clamp If trying to reduce the edge clearance any further consider carefully how much of the belt is left to carry the PCB Care should also be taken to set the top and bottom side edge cl...

Page 66: ...e screws along the linear rail Use care when loosening the screws as they may be very tight It may help to add a drop of oil or anti seizure solution Adjust the distance to 2 5 mm along the whole leng...

Page 67: ...e screws along the finger clamp 8 Re check the full edge clearance by measuring the distance from the inside of the linear rail to the outside edge of the clamp 9 Ensure that all clamps are straight p...

Page 68: ...aximum and minimum sensors and set them up according to the factory default Figure 6 1 shows the sensor distances to be set Use a steel ruler to measure from the base to the sensor edge If the measure...

Page 69: ...late the sensor triggering You will need another person check the PLC inputs on the control panel in the rear of the machine Verify that the PLC input LED turns on and off as you activate and deactiva...

Page 70: ...s triggered Measure and take note of the conveyor width 8 Adjust the rail inwards by hand until the Right Min sensor is triggered Measure and take note of the conveyor width Make sure that the differe...

Page 71: ...s triggered then the rail will move out 50 mm and then commence homing When homing the adjustable rail moves in until it triggers the Left Min sensor It will then look for the Right Min sensor If it i...

Page 72: ...and press Enter Click Move to move the conveyor rail in or out to the required width Every time the AWA is accessed the conveyor will automatically home itself for the first move and then move to the...

Page 73: ...e Required Width field The conveyor should first home and then move to 150 mm 9 Using Vernier calipers check that the width of the conveyor is 150 mm 0 5 mm at both ends To test the Stop function do t...

Page 74: ...ce mode no power or control is given to the gantry or conveyor belt motors to safeguard personnel carrying out maintenance and calibration on the system 1 Remove any boards from the conveyor and make...

Page 75: ...the ON position and push the E Stop button the sequence is not important 3 Open the front access door 4 Locate the Entry sensor This depends on the conveyor direction left to right or right to left i...

Page 76: ...this procedure for the Exit sensor and the In Position sensor 10 When finished push a board over each sensor and check PLC input from the control panel NOTE Do not move the gantry using the cables ass...

Page 77: ...anual 6 15 AWA Conveyor Component Alignment In order to achieve smooth operation during stopping and clamping the stopping and clamping mechanism must be correctly assembled and aligned Figure 6 2 Cla...

Page 78: ...s length when a production board is clamped 1 Activate Maintenance mode and manually insert the test board onto the clamping location 2 Click the clamps Up button in the Maintenance window to clamp th...

Page 79: ...are Manual 6 17 Use caution when adjusting the Clamp Home sensor Setting it too high may cause the clamp plate stepper motor CAM to overshoot 5 Repeat the above steps for all three locations on the cl...

Page 80: ...Conveyor Setup Conveyor Speed Adjustment The speed of the conveyor can be adjusted by turning a potentiometer POT on the PLC The POT is located behind the cover marked Peripheral in the control panel...

Page 81: ...eed to be dismantled and swapped The following shows the default left to right configuration for the clamps To change to a right to left configuration follow these steps 1 Remove 16 screws from the li...

Page 82: ...Width Adjust Conveyor Setup 6 Move the clamp plates up firmly against the top finger clamps and tight all the screws 7 Adjust the Clamp Home sensor to ensure the clamps are able to home properly see C...

Page 83: ...nt U1840A Medalist sj5000 Automated Optical Inspection System Hardware Manual Agilent Technologies 7 Camera and Lighting Calibration Camera Calibration 7 2 Lighting Calibration 7 9 Lens Foreign Body C...

Page 84: ...ent of the lens so that a sharp clear image can be acquired by the camera See Focusing the Camera Scaling using the Auto scale procedure to automatically determine the optical pixel size of the camera...

Page 85: ...Solder Joints which consists of the 70 and 60 degree rings 5 Open the front access door 6 Drag the E Stop alarm window to one side so that the camera display is visible 7 Turn the MAINT SWITCH on the...

Page 86: ...ens and tighten all screws associated with the camera 14 Turn the MAINT SWITCH back to the OFF position This automatically closes the Maintenance window 15 Close the front access door and clear the E...

Page 87: ...ware Manual 7 5 Setting the Lens Aperture To set the camera lens aperture to F stop 5 6 do the following 1 Unlock the lens aperture The lock switch is located at the side of the aperture window 2 Turn...

Page 88: ...er the camera re focus and then perform auto scaling 1 Load a board in the sj5000 2 Pick a fiducial on the board whose presence score is above 900 Refer to the Engineering Manual for details on fiduci...

Page 89: ...pped moving from the Tools menu click the Interface folder and click the System Information icon 6 Verify the values for pixel size 19 microns 1 micron for the sj5000 and field of view in the System I...

Page 90: ...Raising or Lowering the Camera 1 Loosen the lens locking clamp to allow the camera lens to move 2 Hold the camera and loosen the four screws shown below This allows you to adjust the camera by slidin...

Page 91: ...n as close as possible to the target mean The new calculated means are referred to as Achieved Means and are displayed in the Calibrated Means column in the Lighting Controller window The procedures f...

Page 92: ...A 4 column is sent to the lighting controller Each lighting ring has a maximum current in addition the current that may be sent to the lighting controller must not exceed 4000 mA 2 Ensure that the cur...

Page 93: ...on 7 Agilent U1840A Medalist sj5000 Hardware Manual 7 11 4 When changes have been made to the lighting intensities you will be prompted to save the new current values Click Yes to display a summary of...

Page 94: ...g Controller under the Camera folder 3 Click Set Location The system turns the LEDs on and displays the following instruction 4 Jog the camera as instructed and click Set 5 Click Yes to confirm The sy...

Page 95: ...og file CalibrationResults log and perform the auto calibration again Calibration on Location The following procedure performs automatic calibration at a specific location 1 From the Tools menu click...

Page 96: ...o activate a lighting ring select the check box next to its name The following details are shown for each ring mA 4 When a lighting ring is enabled this current is sent to the lighting controller Each...

Page 97: ...g Records the brightness of each of the lighting rings in the intensity log file Focus Allows you focus the camera with the front access door open An E Stop alarm window will be visible and a Focus Ca...

Page 98: ...oCalibrationResults log Contains lighting auto calibration results and other useful information such as current outputs sent to the lighting rings Located in C cpi log Lighting Ring Image over Grey Ar...

Page 99: ...og the camera over it 2 Set the aperture to F16 3 If some dirt can be seen on the scre0en jog the camera slightly to the left or right If the dirt is still in the same position on the screen then eith...

Page 100: ...7 18 Agilent U1840A Medalist sj5000 Hardware Manual 7 Camera and Lighting Calibration...

Page 101: ...8 1 Agilent U1840A Medalist sj5000 Automated Optical Inspection System Hardware Manual Agilent Technologies 8 Camera and Lighting Controller Testing Camera Testing 8 2 Lighting Controller Testing 8 5...

Page 102: ...a Testing To test the Dalsa camera follow the steps below 1 Click Start Programs Matrox Imaging Intellicam Intellicam 2 Click the Board icon on the toolbar to display the following dialog box 3 Under...

Page 103: ...Manual 8 3 4 Click the Open icon on the toolbar to open the file SOLIOS_4M60_10CONTINUOUS DCF located in the C cpi data folder 5 Click the Camera tab and click Continuous Safe Grab The window that ap...

Page 104: ...steps to check the camera settings 1 In Windows Explorer navigate to C cpi plc terminal and double click terminal exe 2 From the Terminal window open dalsa trm 3 Type GCP in the command line 4 Check...

Page 105: ...1 From the Terminal window open slc800 new trm 2 Click Settings Communications Make sure the settings are as follows then click OK 3 Click MAX CURR 1 4 and check that the feedback is as follows 1MC400...

Page 106: ...ing The Terminal window should now show the following 6 Click Level 1 to display the Level 2 window 7 Click MAX CURR 5 8 and check that the feedback is as follows 5MC4000 6MC4000 7MC4000 8MC4000 8 Cli...

Page 107: ...0 M 11 Type in the following 4SS469 5SS469 6SS469 7SS469 12 Click Read and check that the feedback is as follows RYSC R1SC857 0 3757 R2SC957 0 3757 R3SC22257 0 37 57 R4SC2457 469 3757 R5SC2557 469 375...

Page 108: ...triggered on and off Click this Check that feedback shows this 90 Ring 01FF F The red 90 degree ring in the lighting head should turn on 70 Ring 02FF 0 The red 70 degree ring should turn on and the 90...

Page 109: ...F The blue 45c degree ring should turn on and the 45b degree ring turn off 45d Ring 08FF 6 The red 45d degree ring should turn on and the 45c degree ring turn off Click this Check that feedback shows...

Page 110: ...vel 4 which returns you to the level 1 window 18 Click off and check that the feedback reads 0000 0 At this point none of the LEDs should be on The lighting controller is now fully tested 19 Close the...

Page 111: ...his chapter describes the procedure for downloading PLC programs from a PC to the Medalist sj5000 The procedure applies to both the sj5000 Single Lane and sj5000 Dual Lane Both systems use the Omron C...

Page 112: ...n 6 1 installed The download procedure is as follows 1 Connect a USB cable between the PC and the USB port of the PLC 2 Launch CX Programmer version 6 1 3 Click File Open to open c cpi data PLC sj5000...

Page 113: ...t all items Programs Settings Symbols Comments and Program Index b Select Transfer files of all tasks c Do not select Exclude Port Serial 1 2 of PLC Settings from the transfer target 7 Click Yes in th...

Page 114: ...control panel move PLC dip switch 4 on This sets the PLC serial communications protocol to Auto 3 Launch CX Programmer version 6 1 4 Click File Open to open c cpi data PLC sj5000 cxt 5 In the left pa...

Page 115: ...t the following and then click OK a Select all items Programs Settings Symbols Comments and Program Index b Select Transfer files of all tasks c Do NOT select Exclude Port Serial 1 2 of PLC Settings f...

Page 116: ...al or Single Lane Operation To select dual lane operation simply move PLC dip switch 6 to the on position and press the PLC RESET button on the front of the machine To revert to single lane operation...

Page 117: ...System Hardware Manual Agilent Technologies 10 Setting Up Barcode Readers Microscan MS 4 USB Barcode Reader 10 2 Microscan MS 820 Serial Barcode Reader 10 10 Handheld Barcode Reader 10 15 WARNING Bar...

Page 118: ...e installation software should be launched automatically 2 Click ESP Software 3 Click Current Version ESP Software 4 Follow the instruction on the screen to complete the installation Install USB to Se...

Page 119: ...following example the MS 4 barcode reader appears as COM7 4 Note down the COM port number of each barcode reader connected to the sj5000 Download Barcode Reader Setup File Use the Microscan ESP softw...

Page 120: ...gain to connect to the MS 4 barcode reader click Yes 6 Select RS232 protocol 7 Select the COM port that you noted in the previous procedure and click Connect 8 Click Send Recv Send to Reader Send and...

Page 121: ...s described below Make sure all barcode readers are properly connected to the USB ports before proceeding 1 Launch the Microscan ESP software 2 Select the barcode reader model MS 4 and click OK 3 When...

Page 122: ...rcode reader connected the preamble is set to 0 For subsequent barcode readers this header should be a running number starting with 1 for the second barcode reader 9 Type in the correct number in the...

Page 123: ...SP software which provides a real time visual environment for barcode alignment 1 Load a board with a barcode in the desired location for barcode detection 2 Launch the Microscan ESP software and go i...

Page 124: ...3 Type in the Terminal window This command causes the barcode reader to scan for a valid barcode and either return a barcode string or a no read Configure sj5000 Software Once the barcode readers have...

Page 125: ...he Serial Port list as follows click the button select the COM port and click OK 3 If it is necessary to configure the Read Trigger string type it in the Read Trigger field For the Microscan USB barco...

Page 126: ...o the MS 820 barcode reader Plug the trigger cable into the XS 42 port on the breakout box Program the Barcode Reader Install the software as described in Install Microscan ESP Software and do the fol...

Page 127: ...ely trigger the conveyor entry sensor b Scan a barcode and the decoded barcode text should appear in the Terminal window 9 Close the ESP software and launch the sj5000 software 10 From the Tools menu...

Page 128: ...he master barcode reader with header 00 820DL01 esp is the slave barcode reader with header 01 Program the Barcode Readers Each barcode reader can only be programmed from port XP 40 on the breakout bo...

Page 129: ...save this to slave barcode reader 12 Plug the master barcode reader to the XP 40 port and the slave barcode reader to the XP 41 port on the breakout box 13 To test both barcode readers click Terminal...

Page 130: ...c tab and click Read a Use the master barcode reader to scan a barcode b Use the slave barcode reader to scan a barcode The barcode text should be displayed with a 01 prefix 19 Place a board in the sj...

Page 131: ...e USB port on the PC The barcode reader will flash on and off and then emit three beeps 4 Install the USB to Serial driver a Insert the Trendnet TU S9 Software Installation CD into the drive b Browse...

Page 132: ...logy GS 1 Barcode b Ensure that Intermec appears in the Data column for both Active and Type string names c Double click the Barcode folder and then click Intermec d Ensure that the Dword named Lines...

Page 133: ...eader is connected 2 Open the Device Manager by clicking Start Control Panel System Hardware Device Manager 3 Look under Ports to find the USB to Serial port as shown below Program the Barcode Reader...

Page 134: ...10 18 Agilent U1840A Medalist sj5000 Hardware Manual 10 Setting Up Barcode Readers...

Page 135: ...5 Troubleshooting the Lighting Tower 11 16 Troubleshooting the PC and Monitor 11 17 Troubleshooting the Safety Relay 11 18 Troubleshooting the XY Table 11 19 This chapter is intended to assist you in...

Page 136: ...ode reader is working Do not stare into the barcode reader observe the manufacturer s warning Typically the reader is working if a red laser line is present Verify that the barcode reader is connected...

Page 137: ...ftware crashes and will not restart If the sj5000 software crashed and will not restart when you try to launch it again from the desktop icon do the following Verify that the sj5000 software has compl...

Page 138: ...is could be any database but c cpi data vispcad may be the safest If the program runs fine then try reloading the original database and rerun the program If the program crashes in a similar place it i...

Page 139: ...ng JointMVC or JointSLA When tuning an s type device Make sure the lead length and location are correct Shift the joint position light blue box away from the end of the lead The blue box should be pos...

Page 140: ...n RCBO in the on position Is the RUN indicator light illuminated Is the START key switch in the ON position Check that Q2 24 V PSU is on Check Q3 and Q4 24 V DC are on Check the supply voltage at the...

Page 141: ...ill not align properly Conveyor will not load a board The SMEMA cable may not connected Check the connection at the upstream conveyor and the back of the sj5000 The sj5000 may believe there is a board...

Page 142: ...eam SMEMA cable does not meet Agilent requirements For older systems the cable must have an additional pin 8 and for newer systems additional pin 5 for relaying the bad board signal Verify that relays...

Page 143: ...occurs when the fiducial appearance has changed See Fiducial Setup in the Engineering Manual In some instances this could be a hardware setup issue where the board is not reaching the stops or is ove...

Page 144: ...ower to P404 stepper driver Check that Q2 Q3 and Q4 are on Check that KA4 on a single rail is on to energize all motors Check whether it is the PLC that is not allowing the move The PLC may not allow...

Page 145: ...align properly Perform AWA calibration Check that the left minimum sensor and the right alignment sensor are in line This can be done by measuring and comparing the distance from the sensor to the st...

Page 146: ...s Check that the cables part numbers 5186 5778 and 5186 6325 are connected from the camera to the Frame Grabber Check for 12 V DC on pins 4 and 16 on the cable p n 5186 6324 connected to the lighting...

Page 147: ...tion Lighting controller will not work Check that MCB Q3 and Q4 are on Check that the 24 V DC power supply is on Check that the LED on the lighting controller is on Images seem darker than normal Ligh...

Page 148: ...the lighting controller Verify that unified_ligt_map txt SLC800LightingValues xml SLC800Initialisation xml and LightingControllerIntensityTargets xml are present and not corrupted Replace any missing...

Page 149: ...the lighting controller is not working Check that the lighting controller is enabled in the Windows registry 1 Click Start Run type regedit in the command line and click OK 2 Go to HKEY_LOCAL_MACHINE...

Page 150: ...k that the lighting tower is plugged in 2 From the Tools menu click the Machine IO folder 3 Activate all the lights select any green amber or red light and press the space bar to activate it Press the...

Page 151: ...Console to view a report on the hard drives If a hard disk has failed contact Agilent Support to get a new hard disk To remove a failed hard disk open the PC cover remove the power and SATA connectors...

Page 152: ...ing the continuity across terminals Check S11 and S12 for continuity Check S21 and S22 for continuity Check the three indicator lights on the safety relay If the three lights are on the relay is funct...

Page 153: ...additional troubleshooting information are provided in this section Checking the System Check the Hardware Download Parameters to MEI Card and Drives Move the Axis Troubleshooting Troubleshooting the...

Page 154: ...Parameters to MEI Card and Drives Move the Axis Check the Hardware 1 Reset the E Stop circuit 2 Remove the rear access panel On the control panel make sure that Q7 Q8 and Q9 for Z axis if used are swi...

Page 155: ...ohms Mb and Mc 2 ohms If the resistance is greater it means there is a wire break somewhere 7 Note that the E Stop should be off 8 If everything is OK close the cover to the Kollmorgen drives and tur...

Page 156: ...orgen drive This cable gives feedback on the Halls and also on the gantry as it moves along the encoder strip Again both drives should have this cable 11 At the back of the PC check that a SyncNet cab...

Page 157: ...type connector in C4 as shown below The bottom SyncNet cable should be connected to the top connector in C4 on the drive 2 Axis 1 or Y Axis 13 An easy way to find faults on the SyncNet cabling is by l...

Page 158: ...11 Troubleshooting Download Parameters to MEI Card and Drives Make sure all hardware is checked and present before performing the following procedure 1 In Windows Explorer locate the folder c cpi dat...

Page 159: ...controller card and both the X and Y axes have to be downloaded manually 4 Download the parameters as follows a Select Start All Programs Accessories Command Prompt b Type the following at the comman...

Page 160: ...for the X axis and press Enter cddriveconfig save node 0 file c cpi data mei x txt g To save for the Y axis cddriveconfig save node 1 file c cpi data mei y txt 5 To save the parameters to the Motion...

Page 161: ...sj5000 Hardware Manual 11 27 b In the configuration window that appears select the Controller tab Then click Controller 0 and click Add All Sub Objects Click OK c You should see the following Click O...

Page 162: ...downloaded before continuing Launch MoCon for the following procedures On the toolbar of the MoCon window the following buttons will be used C Controller Summary S Motion Supervisor Summary F Filter S...

Page 163: ...r 0 c On the Config tab make sure the Sample Rate is set to 8000 If it is not the SJ5000 xmp file has to be downloaded follow the instructions in Download Parameters to MEI Card and Drives to do so 2...

Page 164: ...f the encoders on both axes are reading correctly then the following should happen As the X axis Axis 0 in MoCon is moved away from the front of the system the numbers highlighted above should decreas...

Page 165: ...n The encoder phase should be reversed for all motors see the Motor Summary window d Make sure the both axes are in the middle of the machine Close the front access door and reset the E Stop circuit e...

Page 166: ...All Algorithms is selected and that the values are the same as shown below 4 On the MoCon toolbar click the S button a On the MS tab make sure both MS 0 Controller 0 and MS 1 Controller 0 appear in t...

Page 167: ...ach axis is Idle If you do not see the window below go to the next step c If you see the following window instead the grayed out MS1 column indicates that MS0 is controlling both axes The axes should...

Page 168: ...sure both Motor 0 Controller 0 and Motor 1 Controller 0 appear in the Object List Click OK b In the Motor Summary window select the Config tab Select the Reversed option for Encoder Phase as shown be...

Page 169: ...n the drive should show 2 This means that the drive has enabled correctly 7 Go to the MS Summary window On the Actions tab click the Move to Further button The axis should move in a positive direction...

Page 170: ...than click Move to Further 9 If the axes are moving it means the system is ready for inspection Disable the Repeat Mode disable the motors disable Amp Enable in the Motor Summary window and close the...

Page 171: ...ller 0 and select Remove Axis From List c Click Yes to confirm the removal d The Object Explorer will show that Axis 1 Controller 0 is no longer under the control of MS0 4 Now map Axis 1 Controller 0...

Page 172: ...ng software startup The Anorad gantry has protective metal casings that cover the magnets If the metal plate is damaged there is a possibility that a magnet could be cracked or damaged which would pre...

Page 173: ...n Check that the 24 V power supply is on Check that contactors KS2 and KS3 are at the ON position Gantry makes strange noise Launch the MoCon software In the Controller Summary window select the Confi...

Page 174: ...otes on where are they connected to d Physically swap the drives and connect the cables again e Power up the machine reset the E Stop circuit and start the sj5000 software f If the error is reported o...

Page 175: ...xcessive Position Deviation Communication Interface Overload fan malfunction power stage failure Excessive deceleration rate Power stage surge current Feedback signal through C8 not correctly detected...

Page 176: ...11 42 Agilent U1840A Medalist sj5000 Hardware Manual 11 Troubleshooting...

Page 177: ...Medalist sj5000 Automated Optical Inspection System Hardware Manual Agilent Technologies 12 Maintenance Overview 12 2 Weekly Maintenance 12 3 Monthly Maintenance 12 6 Quarterly Maintenance 12 8 Yearl...

Page 178: ...electrical drawing numbers are provided where possible Important Notes on Lubricants Be sure to use a clean dry soft lint free cloth for cleaning any dirt or dried lubricant from the linear rails Only...

Page 179: ...bstructed throughout its full range of movement on both X and Y axes Test the E Stop circuit by opening and closing the front access door Reset the E Stop circuit using the ES Reset button at the fron...

Page 180: ...up the machine Check the function of the conveyor sensors see Figure 12 2 by placing a sample board over them Look at the indicator light on each of the sensors Move the lighting head over each senso...

Page 181: ...Maintenance 12 Agilent U1840A Medalist sj5000 Hardware Manual 12 5 Figure 12 2 Sensors on the conveyor...

Page 182: ...owing checks Turn off the sj5000 using the START key switch and turn the mains isolator to the OFF position Open the rear access panel and visually inspect the electrical control panel Inspect all ele...

Page 183: ...When inspecting the connections on the gantry stage and at the controller check the integrity of the connectors at random Ensure that all conveyor bearings are free running and that belt tension is t...

Page 184: ...e of the table Remove any dirty or dried lubricant from the bearing guides Using a clean cloth wipe along the rails to clean the bearing guides A cotton swab soaked in a general purpose white spirit w...

Page 185: ...ies with the relevant standards a Power off the machine b Switch off the mains isolator c Disconnect the power plugs for the monitor PC UPS if used and camera d Disconnect all AC power for the DC powe...

Page 186: ...s on the machine Check the electrical connections at the conveyor motors Make sure all connections are intact and securely fitted Check all mounting screws and hardware on the machine Systematically c...

Page 187: ...es A System Specifications Software specifications A 2 Hardware specifications A 2 Supply facilities specifications A 3 Physical dimensions A 3 Note that the system specifications may change during th...

Page 188: ...CPU 1 GB memory 250 GB hard drive Host Communications Twisted pair Ethernet supporting TCP IP or MS Network CAD Translation Tool CAMCAD Imaging Hardware Matrox Solios Frame Grabber Camera System DALSA...

Page 189: ...is available as standard Table A 3 Supply facilities specifications Item Specification Electricity 100 120 V 200 240 V 50 60 Hz Main protection to system is 16 Amps Normal Running Current 100 120 V 2...

Page 190: ...A 4 Agilent U1840A Medalist sj5000 Hardware Manual A System Specifications...

Page 191: ...5000 Automated Optical Inspection System Hardware Manual Agilent Technologies B Reference Documents The following reference documents are provided with the Medalist sj5000 Site Preparation Manual Oper...

Page 192: ...B 2 Agilent U1840A Medalist sj5000 Hardware Manual B Reference Documents...

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