CyberOptics SE500ULTRA Hardware Manual Download Page 162

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Chapter 4

Troubleshooting

152

SE500

ULTRA

Hardware Manual

Safety Circuit Block Diagram

SE500ultra DC Distribution

Date: Sept. 06, 12

200

210

220

230

240

250

260

270

280

290

PS2 DC

Distribution

Terminals

750-610

PS3 DC

Distribution

Terminals

143

144
146

8012956

J8
J9

J3
J5

200

201

220

210
211

221

212

222

220

222

221

210

147

8012792

Y Servo Drive

148
149

8012813

Y Servo Drive

177

178
230

8012812

X Servo Drive

231
232
233

8012814

8012816

240

243

250

253

241

244

251

254

242

245

252

AC Dist.

Page 1

8012957

246

247

255

248

24V

750-838

261

263

264

260

262

8012965

8012961

8012962

8012963

8013665

DIO Controller

Power

234

235

S35

S33

S34

S21

S22

S31

S11

S12

Safety

Relay

188

From

K2 Safety
Contactor

Page 1

189

187

186

187

8012959

282

283

284

285

286

287

288

184
185

8012958

8016486

8012967

8012968

8012799

8012970

8012801

204

205

206

207

214

215

216

217

225

226

227

Z Motor

Belt Motor

Width Motor

280

8013777

Middle Man

8012972

8012818

Z Servo

Drive

VP+

201

202

211
212

246
247
248

234
235

281

Middle Man

(Page3)

2002-3217

2002-3201

2002-3217

257

Sig.

2002-3217

258

259

261

To Dio Controller

Conveyor Connector

8012964

8013016

INTERLOCK

E-STOP

295

296

294

297

290
291

8012795

8013018

8013019

8013025

292

293

8012777

8012779

8013217

Misc.

Push Button Panel

SHEET 2 OF 5

FAN

8013362

8012966

8013578

8013579

ER_
LED

282

235

194

CAN ID: 2

CAN ID: 6

CAN ID: 9

PLC (CAN ID: 5)

Modular

Branch

8013370

PUSH
button

modular

branch

8015642

21
31

22
32

194

290
291

8013148

8009605

8013167

8013257

8013259

8013182

8001901

Processor

8012791

AC Dist. Page 1

8013148

AC Dist.

Page 1

J8
J9

J3
J2

Belt

Servo

Drive

VP+

8013148

282

8012796

CyberOptics Corp. Dwg. No. 8020054

Schematic, System, Elec. SE500ultra

Rev C

8016485

8012792

8012778

8012971

8012815

J8
J9

J3
J5

Width
Servo

Drive

VP+

Components connected with dot
line is optional for auto-Width.

2002-3217

256

236

260

267

268

203
208
209

300
301
302

303
304
305

306
307
308

Safety Circuit

Summary of Contents for SE500ULTRA

Page 1: ...SE500ULTRA Hardware Manual ...

Page 2: ...TRA are owned by CyberOptics Corporation Windows owned by Microsoft Corporation Warranty License and Terms of Sale The warranty software license and other terms and conditions of sale covering CyberOptics products are set forth in CyberOptics Standard Terms and Conditions of Sale and License available at www cyberoptics com or by calling CyberOptics at 1 800 526 2540 and requesting a copy Disclaim...

Page 3: ...nstallation 21 Packing the SE500ULTRA 22 Unpacking the SE500ULTRA 25 Choosing a Location 26 Installing the System 27 Installing the Light Pole 27 Positioning Leveling the SE500ULTRA 28 Installing the Sensor 32 Wiring SE500ULTRA for Power 34 Turning on System Power 36 Connecting the Air Supply 37 Connecting SMEMA Cables 38 Connecting to a Network 39 Connecting to an External Device 40 Wago PLC Asse...

Page 4: ...cing the Conveyor Clamp Blade 96 Replacing the Conveyor Clamp Air Fittings 98 Replacing the Conveyor Clamp Hall Effect Switch 99 Replacing the Conveyor Clamp Cylinder 100 Replacing the Conveyor Motors 102 Replacing the Conveyor Belts 104 Replacing the Drive Belts 105 Replacing the Idler Pulleys 107 Replacing the Pulley Drive 109 Replacing the Board Sensors 110 Replacing the Panel Lifter Cylinder a...

Page 5: ...agram 152 AC and DC Distribution Block Diagram 153 SMEMA Connector Pinout 154 System Error Messages 155 Solder Paste Failure Causes 156 SOS 158 5 System Drawings 159 8015066 ASSY MAIN ELECTRICAL PANEL SE500ULTRA 160 Drawing 160 8016704 Conveyor SE500ULTRA 166 Drawing 166 Index 175 ...

Page 6: ...Contents vi SE500ULTRA Hardware Manual ...

Page 7: ...descriptions of the software controls for the Solder Paste Inspection Applications Engineering Interface SE Series Inspection User Guide and Online Help Provides task based step by step procedures and descriptions of the software controls for the Solder Paste Inspection Applications Operator Interface SE Series Solder Paste Inspection Safety User Guide Provides safety guidelines safety symbols and...

Page 8: ...Code City State Province Address Company Name Originator Machine Serial Number Software Version Manual Revision Date Page No or Figure No Suggestion Fax 1 763 542 5100 CyberOptics Corp service cyberoptics com Attn Service Fax or e mail to Check if page is attached Country ...

Page 9: ... business day International Technical Support Center 1 800 526 2540 Fax 1 763 542 5100 Email service cyberoptics com Website www cyberoptics com support If available in your area the toll free number above 1 800 is answered 24 hours a day every day of the week Where toll free access is not available please contact the regional office closest to you North America CyberOptics Corporation Minneapolis...

Page 10: ...x SE500ULTRA Hardware Manual This page is intentionally left blank ...

Page 11: ...CyberOptics Corporation 1 System Overview SE500ULTRA 2 System Specifications 15 Performance Specifications 17 Computer Requirements 17 System Requirements 16 Dimensions 18 ...

Page 12: ...tem s moving parts Green Start Starts the inspection This button is an alternative to using the button in the software Red Stop Stops the inspection This button is an alternative to using the button in the software Yellow E Stop Reset Initializes the system after re engaging the E Stop Yellow Alarm Cancel Clears system alarms This button is an alternative to using the button in the software Emerge...

Page 13: ...ont View Signal light pole Keyboard and trackball tray Flat panel display Safety enclosure hood Leveling feet Air pressure gauge Power Switch ESD wrist strap connection Control panel see below E Stop E Stop Reset Stop Start Control Panel Alarm Cancel ...

Page 14: ...the rear electrical panel and turns off all system power when activated Note Do not obstruct the rear circuit breaker Air Regulator Regulates compressed air for pneumatic control of the conveyor lift and clamp Cooling Fans Draw air out of the system to cool internal electronics Digital Input Output Connector Connection for an external device such as a separate conveyor Ethernet Port Connection to ...

Page 15: ...00ULTRA Figure 2 Rear View Back access cover Air regulator Power access cover COM1 port Ethernet port SMEMA Upstream SMEMA Downstream Digital I O AC circuit breaker Circuit Breaker 1 Power cord strain relief COM2 port Cooling fans ...

Page 16: ...s XP Professional 64 bit platform Conveyor The conveyor brings the panel into the machine clamps it and positions it for inspection During inspection the gantry moves as needed in the X and Y directions and the Z stage adjusts for height while the panel remains stationary The conveyor automatically adjusts to the width of the panel as specified in the SRFF Digital I O Controller The Digital I O co...

Page 17: ...CyberOptics Corporation 7 SE500ULTRA Figure 3 Internal Components Processor PLC Controller Main Electrical panel Gantry Sensor Conveyor ...

Page 18: ...r X Y and Z stages Provide feedback and fine tuning for stage movement Motor Controllers for Conveyor Autowidth and Conveyor Belts 2 Controls belt and autowidth motors for conveyor motion Power Supply 24Vdc 5 Amp 3 5 Amp Provide power and auxiliary power to the sensor and electronics in the system Circuit Breakers CB2 CB3 CB4 CB5 CB6 CB7 CB8 Processor Outlet 6 Amp PS 1 6 Amp PS 2 6 Amp PS 3 6 Amp ...

Page 19: ...A 6 0A 6 0A 6 0A 10 0A 10 0A 10 0A MM PS1 PS2 PS3 K2 K1 TOWER SYSTEM SMEMA Z X Y B Middleman PCB Assembly X Stage Servo Amp Y Stage Servo Amp Z Stage Servo Amp Fixed Rail Motor Belt Motor Controller PS1 3 5 A PS2 5 A PS3 5 A CB2 CB8 Contactor 18 A 24 VDC Coil Safety Relay ...

Page 20: ...ts Motors Provide electro mechanical drive for the conveyor Panel Sensors Entry Exit Sensors located on each end of the conveyor these sensor detect panels entering and exiting the conveyor Sensors work in conjunction with SMEMA to bring boards in Slow Speed Sensor A third sensor detects the panel nearing the inspection position causing the conveyor to slow down for final positioning Board Stop Se...

Page 21: ...anual Adjustment Wheel Board Stop Sensor Panel Detect Sensor Entry Exit Panel Detect Sensor Entry Exit Panel Lifter Top Clamp Slow Speed Sensor Movable Conveyor Rail Fixed Conveyor Rail Note SE500ULTRA does not come with autowidth function as a basic configuration The autowidth function will be available as an option kit Autowidth Motor option kit Board Stop ...

Page 22: ...iagonally and replace the two nuts on the board stop Figure 6 Board Stop Position for Left to Right Configuration 4 Route the cables along the opposite conveyor rail 5 Connect the board stop to the fixed conveyor rail Figure 7 Left to Right Board Flow Configuration i Note Set the ConveyorRightToLeft value using the Configuration Editor The value 0 indicates Left to Right configuration The value 1 ...

Page 23: ...he system type Sensor T ype Ultra Inspection T ype All In One 5 Click OK to complete the configuration setting and close the SE500 System Setup dialog box 6 Start the SPI application 7 In the TEACH file menu choose Open 8 In the Open dialog box navigate to and select the Recipe file you want to use and choose Open Use a certification target provided by CyberOptics 9 Choose TEACH tab 10 In the TEAC...

Page 24: ...rew in the counter clockwise direction Correction Tolerance Turns indicates the specified limits for camera alignment Result indicates if any camera adjustment is required If the radians value is within the Specification no adjustment is needed 16 Repeat step 15 until the camera rotation values are within the specified limits 17 Once the system alignment is complete close the Recipe and reopen it ...

Page 25: ...ard Weight 3 kg 6 6 lbs 5 kg Option Maximum Board Warp 2 of PCB diagonal or a maximum of 6 35 mm 0 25 in total Operational Specifications Conveyor Speed Range 150 450 mm sec 5 9 17 7 in sec Maximum Inspection Area 508 503 mm 20 19 8 in Maximum Pad Size in FOV 15 15 mm 0 6 0 6 in X and Y Pixel Size High speed High resolution 30 µm 1 2 mils 15 µm 0 6 mils Height Resolutiona 0 2 µm 0 008 mils Paste H...

Page 26: ...70 C 4 158 F Altitude Up to 2000 m 6562 ft Insulation Coordination Pollution degree 2 Installation Category overvoltage category Category III Power Requirements Hard wired single phase 100 130 220 240 V 10 50 60 Hz 10 15 amps Permitted Voltage Drops 90 V for 100 130 VAC 200V for 220 240 VAC Peak Operating Current 15 amps 100 V 130 V 10 amps 220V 240 V Compressed Air Requirements 5 6 Kgf cm2 to 7 0...

Page 27: ...ments Y ou can run the T each application on a desktop computer that meets the following minimum requirements Table 8 Desktop Computer Minimum Requirements Processor Intel Pentium 4 processor RAM 256 MB recommended Available Disk Space 1 GB Video card Minimum Recommended 32 MB memory 64 MB memory OpenGL acceleration Monitor Resolution 1024 x 768 24 bit color minimum Operating System Windows XP 64 ...

Page 28: ...Chapter 1 System Overview 18 SE500ULTRA Hardware Manual Dimensions Figure 8 Front View ...

Page 29: ... Corporation 19 Dimensions Figure 9 Side View To achieve the lowest conveyor height configuration of 83 cm to 96 cm 33 inch to 38 inch a customized conversion kit is needed Contact CyberOptics for more information ...

Page 30: ...Chapter 1 System Overview 20 SE500ULTRA Hardware Manual ...

Page 31: ...onnecting the Air Supply 37 Connecting SMEMA Cables 38 Connecting to a Network 39 Connecting to an External Device 40 Wago PLC Assembly 41 Manually Adjusting the Conveyor Width 42 Configuring the Pressure Gauge Display 43 Setting Up System Security 45 Verifying System Accuracy 50 Shutting Down the System 52 Moving the SE500ULTRA System 53 Bypassing the SE500ULTRA System 53 ...

Page 32: ...s a drill with a 13 mm socket attachment hex head bolts a forklift and a pallet jack Capacity of forklift 1060 kg 185 cm To prepare the crate base 1 Prepare the crate base as shown Required Tools Warning Only CyberOptics service personnels shall perform the installation procedures in this Chapter Warning Make sure the SE500ULTRA power and AC main circuit breaker is off before packing Perform visua...

Page 33: ...ing the pallet reach truck 3 Move the machine over the platform Manually raise each of the leveling feet and ensure that it is not touching the crate base Hand tighten the leveling feet 4 Position the machine so that its frame aligns with the platform floaters Slowly lower the machine until it rests on the platform floaters There should be no gap between the machine and the sponge placed at the fr...

Page 34: ...d 3 2 Place the side panel onto the crate and secure with hex head bolts Numbered the panel with numbers 1 and 2 3 Place the other side panel onto the crate and secure with hex head bolts Numbered the panel with numbers 3 and 4 Close the machine ID cover 4 Cover the crate with a top cover and secure with hex head bolts Markings for the Crate 1 Mark the bolts in blue as shown after the crate is rea...

Page 35: ...shown 2 Remove the panel with the label indication from the platform or skid pallet 3 Slide out the remaining crate pocket off the platform 4 Using the drill and socket attachment remove the hex head bolts from the lockdown plate located at each of the leveling feet 5 Remove the packing material moisture barriers desiccant clays and accessories around the unit 6 From the rear of the machine ensure...

Page 36: ... axes before using the machine Figure 10 Transit securing brackets on X Axis Figure 11 Transit securing bracket on Y Axis Choosing a Location The SE500ULTRA must be level and aligned with incoming and outgoing conveyor sections to allow for smooth movement of panels Choose a location for the SE500ULTRA that meets the following requirements System has easy access to power and compressed air Conveyo...

Page 37: ...nut from the light pole and slide it off of the cable 3 Place the light pole in an upright position and insert the threaded end of the pole into the hole on top of the enclosure 4 Tighten the bolt inside the enclosure so that the light pole is firmly attached to the unit 5 Connect the light pole cable to the available cable connector that is tied to the frame 6 Replace the rear panel Figure 12 Lig...

Page 38: ...ng up the front rails of the incoming and outgoing conveyor sections 3 T o adjust the leveling feet loosen the locking nut with a wrench and then turn the adjustment nut T urn the nut clockwise to raise the unit T urn the nut counter clockwise to lower the unit Figure 13 Leveling Foot 4 Use a level or machine height measurements to make sure that the system is level 5 Manually slide a panel throug...

Page 39: ...sition in the line with no access to the side panels remove the front panel from the electronics area and the right panel vertical from the control panel area see Figure 15 on page 30 To remove side panels 1 Loosen the two M5 x 8 screws along the top edge of the panel using a 3 mm allen wrench 2 Lift the upperside panel off the machine 3 Grasp the lower panel underneath the top edge and lift it up...

Page 40: ...ockwise direction to open the swing door 4 Remove the eight M5 screws from the hinge Do not remove the screws attached to the swing door 5 Remove the swing door off the machine 6 Remove the power switch from the machine by removing the attaching screw 7 Loosen and remove four M5 screws from along the inside of the SE500ULTRA frame 8 Lift the right panel off the machine and rest it on the monitor a...

Page 41: ...n the locking nut with a wrench and then turn the adjustment nut T urn the nut clockwise to raise the unit T urn the nut counter clockwise to lower the unit Figure 17 Leveling Foot 8 Use a level or machine height measurements to make sure that the system is level 9 Manually slide a panel through the incoming and outgoing conveyor sections to make sure that the SE500ULTRA conveyor rail is properly ...

Page 42: ...e the sensor onto the plate with three captive M6 x 45 screws using a 5 mm allen wrench Figure 18 Mounting Plate on the Z stage 4 Connect the Illumination Control cable to the connector on the side of the sensor Caution Make sure the SE500ULTRA system power is off before installing the sensor The sensor could be damaged if you connect it to the system when power is on Top mounting pin Bottom mount...

Page 43: ...ing the System 5 Connect the flat white Camera Link cable to the connector on the back of the sensor and tighten the two small screws Figure 19 Sensor Cable Connections Camera Link cable connection Illumination Control cable connection ...

Page 44: ...n relief nut at the bottom of the box Note Make sure the strain relief nut is fully tightened Figure 20 Rear Electrical Panel Caution Before wiring the system make sure that the AC main power supply is turned off and locked off i Note Y ou must have a readily accessible power supply and a protective device in the fixed wiring for the permanently connected SE500ULTRA The power supply wiring and any...

Page 45: ...r c Remove the screwdriver allowing the connector to crimp the conductor d Pull the wire to ensure it is secured 7 Replace the power access cover and secure with four screws Pry open the crimping connector using a screwdriver and insert the conductor Screwdriver Stripped wire NOTE The SE500ULTRA does not comes with power cord PE PE PE N2 L2 PE N1 L1 N L N L GND Power Cord AWG 14 16 Voltage VAC 110...

Page 46: ... the front of the system 4 Release the E Stop button 5 Press the green start button to restart Figure 22 Main AC Circuit Breaker Location i Note The computer will start automatically i Note Do not run any Solder Paste Inspection applications until after the lights on the signal light pole have turned on and then off When you first start the SE500ULTRA the internal processor initializes the system ...

Page 47: ... 6 mm outside diameter x 4 mm inside diameter 3 T urn on power to the system 4 T urn the knob at the top of the air regulator to set the air pressure to 90 10 psi 620 69KPa 5 Observe the air pressure on the gauge located outside the machine near the E Stop button Figure 23 Connecting to the Air Regulator Turn this knob to set air pressure Quick connect fitting Back Electrical Panel i Note The defa...

Page 48: ...ore information refer to Shutting Down the System on page 52 Figure 24 SMEMA Connectors 3 Route the SMEMA cables under the SE500ULTRA unit to the connectors on the rear 4 Connect the upstream cable to the upper connector 5 Connect the downstream cable to the lower connector Downstream SMEMA connector Upstream SMEMA connector Pins Upstream Cable Downstream Cable 1 2 Machine Ready Machine Ready 3 4 ...

Page 49: ...en push the E Stop button on the front of the unit 2 T urn off all electrical power to the system For more information refer to Shutting Down the System on page 52 3 Connect the network cable to the Ethernet connection located on the rear electrical panel Figure 25 Network Connection Configuring the LAN Connection Use the Windows network tools to complete the Ethernet configuration This is typical...

Page 50: ...ectrical power to the system For more information refer to Shutting Down the System on page 52 3 Connect the external device to the digital input output connection on right side of the rear electrical panel Figure 26 Digital Input Output Connector 4 T urn on the power switch on the front of the unit 5 If the E Stop button is pushed in pull it out then press the E Stop Reset button to engage the sy...

Page 51: ...tion including all I O signals and the total current must not exceed 6 3 A max current of this controller In this SPI s WAGO control system it has a limited number of I O modules and the total current consumption is much lower than the maximum current 6 3 A After testing 1 6 A fuse is the best option Figure 27 WAGO PLC Assembly Warning The maximum current of the supply module is 6 3 A When configu...

Page 52: ... adjust conveyor width 1 Open the top cover of the safety enclosure 2 Locate the conveyor adjustment wheel to the left on the front conveyor rail Figure 28 Conveyor Adjustment Wheel 3 T urn the wheel counter clockwise to make the rails wider T urn the dial clockwise to make the rails narrower 4 Close the top cover Press the E Stop Reset button To check conveyor alignment 1 Place a panel on the con...

Page 53: ... shown in the display wait 3 seconds to select the mode 4 When a mode is selected Press to cycle through the options Press to end programming mode To change the Units of Measure 1 Press three times until option 3 appears 2 Wait three seconds to enter mode 3 3 Press to cycle through the options for Pressure Units PA Pascal negative for vacuum sensors PA Pascal bA Bar negative for vacuum sensors bA ...

Page 54: ...1 displayed press to choose Cnp ou1 output 1 Cnp Window Comparator Mode 4 Press to select End To change the display color 1 Press six times until option 6 appears 2 Wait three seconds to enter mode 6 3 Press to cycle through the color options 2 r On Red Off Green 2 9 On Green Off Red 1 r On Red Off Red 1 9 On Green Off Green off T urn off display 4 Press to select End To lock unlock the display co...

Page 55: ...s for all users except for the Security Setup feature Only the Supervisor logon has rights to change the Security Setup by default The default setup also includes an Auto logon feature so that when any of the default system logons are used a separate SE500ULTRA logon is not required If you are logged on as a Supervisor or user with Supervisor rights you can change the security setup at any point t...

Page 56: ...e Local Users and Groups folder 5 Open the Users folder 6 On the Action menu click New User 7 In the New User dialog box type the User ID in the User Name box 8 In the Full Name box type the user s name 9 In the Description box type the name of the group to which the user belongs Supervisor Engineer Lead Operator or Operator 10 In the Password and Confirm Password boxes type the user s network pas...

Page 57: ...and select Properties from the menu 14 In the Properties dialog box click the Member Of tab 15 Click Add 16 In the Select Groups dialog box Enter object names to select box type the name of the Group to which the new user belongs 17 Click Check Names 18 Click OK in the Select Group and Properties dialog boxes ...

Page 58: ...ile Save Allows group members to save changes to the panel SRFF file and the Standard Definition Library DEF file Teach and Solder Paste Inspection SE500ULTRA Inspection Security Secure Assignments Allows group members to change the Secure Area assignments Teach and Solder Paste Inspection Status Bar Units Change Allows group members to change the units using the right click menu in the status bar...

Page 59: ... window without making changes When you click OK your changes are saved to a file named SE500ULTRA sec located in the default security directory The settings in the security file are loaded each time the application starts System Calibration Configuration Allows group members to modify system alignment settings in the configuration editor Solder Paste Inspection System Settings Configuration Allow...

Page 60: ...ges as you use it and keep it free of oils dirt grease and dust CyberOptics Certificate of Traceability CyberOptics provides a certificate of traceability with each certification target The certificate includes the serial number and the certified measurements for the certification target Accuracy High Speed High Resolution Height 10 µm 0 39 mils 5 0 µm 0 20 mils Volume 10 8 AverageMeasuredHeight C...

Page 61: ... o save measurement data for the certification target open the Solder Paste Inspection application On the File Handling tab verify that the Write feature level data files s check box is selected Note This step is only necessary if there is a need to proof that the verification was performed 4 Place the certification tool on the conveyor the same way as a panel 5 On the toolbar click to run the ins...

Page 62: ...he power switch on the front of the unit This removes all power from the system with the exception of the processor power Figure 29 Shutting Down the System To remove power entirely 1 T urn off the power switch on the front of the unit 2 On the rear of the machine turn the AC main circuit breaker to OFF Caution T urning off power at the power switch does not remove power from the processor The AC ...

Page 63: ...trical panel such as the network SMEMA or I O cables if used Bypassing the SE500ULTRA System The SE500ULTRA bypass mode allows panels to run through the machine without inspection In the event of certain hardware failures the system can be temporarily bypassed Failures include processor some of the amplifiers X Y Z axes and width motors To engage bypass mode 1 Push the E Stop button on the front o...

Page 64: ...the bypass switch from NORMAL to BYP ASS Figure 30 Bypassing the System 6 Replace the lower font panel and close the hood 7 Restore system power Bypass switch i Note The conveyor width must be manually adjusted and the E Stop must be released for the system to work Processor is not needed for this operation ...

Page 65: ...Optics Corporation 3 Replacing Components and Preventive Maintenance Maintenance Schedule 56 Main Electrical Panel 57 Processor Components 71 Conveyor Components 93 Gantry Components 124 Other Components 148 ...

Page 66: ...g Down the System on page 52 Maintenance Monthly Annually Page Cleaning Rear Fans Every 3 months 67 Cleaning Inside the Enclosure Every 3 months 68 Cleaning Main Electronics Panel Every 3 months 68 Cleaning the Air Regulator Filters Every 3 months 69 Cleaning Inside the Processor Every 3 months 91 Cleaning the Panel Sensors Every 3 months 114 Cleaning the Encoder Strips Every 3 months 134 Checking...

Page 67: ...rs Conveyor Motors Safety Relay and Contactor Middleman PCB Assembly Power Supplies Circuit Breakers Electrical Cables Fuses Air Regulators Warning T o prevent the risk of injury turn the AC main circuit breaker to OFF to shut down all electrical power to the SE500ULTRA before starting any replacement operations For more information refer to the section Shutting Down the System on page 52 ...

Page 68: ...chine frame 5 Identify the part to replace see Figure 32 on page 59 and disconnect the wires from the terminals 6 If present remove attaching screws from the component 7 Insert a flat blade screwdriver underneath the component and press down on the tab to release it from the rail Figure 31 DIN Rail Mounting 8 Hook the component onto the upper edge of the DIN rail and press downward to latch it ont...

Page 69: ... 6 0A 6 0A 6 0A 6 0A 10 0A 10 0A 10 0A MM PS1 PS2 PS3 K2 K1 TOWER SYSTEM SMEMA Z X Y B Middleman PCB Assembly X Stage Servo Amp Y Stage Servo Amp Z Stage Servo Amp Fixed Rail Motor Belt Motor Controller PS1 3 5 A PS2 5 A PS3 5 A Contactor 18 A 24 VDC Coil Safety Relay N PE CB2 CB8 ...

Page 70: ...8013577 8012783 8012788 8012820 8012972 Fix Belt Move Belt Width SMEMA AC2 RS232 COM1 NetWork PE SMEMA AC 8012820 8012975 8013775 8013776 8013777 8013344 AC Y1 Enc CAN X servo FAN X Motor Y Motor Z Motor 8013217 8013025 X Encoder Y Encoder Z Encoder Z Axis Y Enc Hall X Enc Hall Power to Sensor Camera Out AC2 USB USB 8012791 CAN CAN BM KB Mouse SVGA 8013369 8013370 Seq 8 in 8012786 8012786 8009605 ...

Page 71: ...r is off and locked off Use a voltmeter to verify that the power is off 3 Loosen the four screws and remove the Power access cover see Figure 34 on page 62 4 Gently pull out the wires to disconnect the outside line power L and N and the system power Remove and replace the circuit breaker on the DIN rail i Note For Parts Replacement contact CyberOptics for part numbers Warning Hazardous voltages ma...

Page 72: ...e it is secured 6 Place the power access cover back onto the panel and secure in place with four screws 7 T urn the AC main circuit breaker to ON PE PE PE N2 L2 PE N1 L1 N L Power access cover Loosen screws x 4 Strain relief nut AC main circuit breaker CB1 Pry open the crimping connector using a screwdriver and insert the conductor Stripped wire Screwdriver Back Electrical Panel N L GND Power Cord...

Page 73: ...uit breaker to ON i Note For Parts Replacement contact CyberOptics for part numbers Warning Hazardous voltages may be present Make sure that power is disconnected from the mains before replacing the fuse Caution Recommended that only trained service personnels perform this operation Table 11 Fuse Listings Circuit Breaker Rating Purpose CB2 6 0 A To protect the processor outlet CB3 6 0 A To protect...

Page 74: ...TRA Main Electrical Panel 6 0A 6 0A 6 0A 6 0A 10 0A 10 0A 10 0A MM PS1 PS2 PS3 K2 K1 TOWER SYSTEM SMEMA Z X Y B Middleman PCB Assembly X Stage Servo Amp Y Stage Servo Amp Z Stage Servo Amp Fixed Rail Motor Belt Motor Controller PS1 3 5 A PS2 5 A PS3 5 A Contactor 18 A 24 VDC Coil Safety Relay N PE CB2 CB8 ...

Page 75: ...open end wrench loosen the hex nut to remove the shut off valve from the air regulator body 8 Apply teflon tape to the tape threads on the new air regulator 9 Install the shut off valve on the new air regulator Verify that the shut off valve is aligned properly with the air regulator 10 Install the new air regulator 11 T urn the knob at the top of the air regulator to turn the air pressure OFF bef...

Page 76: ...tion Shutting Down the System on page 52 Figure 37 Location of Fans 2 Remove the metal fan guard by removing four M4 x 40 screws on each fan 3 Remove the fan 4 Disconnect the cable from the fan 5 Connect the new fan to the cable Orient the fan so the air flows out of the machine 6 Secure the fan in place with the screws 7 Secure the metal fan guard with four M4 x 40 screws Cooling Fan Back Electri...

Page 77: ...ction Shutting Down the System on page 52 2 Locate the fans on the back electrical panel Figure 38 Rear Fans 3 Using a dry cloth remove any dust covering the fans and wipe off the remaining dust from the outside of the air intakes 4 On the inside check the fans for dust buildup Remove dust buildup using a dry cloth Keep away from the system so the dust will not get into the electronics panel 5 Set...

Page 78: ...trical power to the system For more information refer to the section Shutting Down the System on page 52 2 Open the hood on the SE500ULTRA 3 Make sure all motion has stopped 4 Remove two screws that secure the lower front panel to the machine frame 5 Using clean dry compressed air remove the dust buildup from the main electronics panel Keep away from the system so the dust will not get into the el...

Page 79: ...2 Open the front door of the machine 3 Locate the air regulator inside SE500ULTRA at the lower right side of the machine 4 Close the air shut off valve to release the air pressure 5 Unscrew bowl at the bottom of the regulator and take out the filter 6 Rinse the filter in warm water and let it air dry 7 Replace the filter and bowl at the bottom of the regulator Figure 39 Air Regulator Air shut off ...

Page 80: ...he conveyor and stage movement 2 T wist and pull the E Stop button to disengage then press the yellow E Stop Reset button to restart the system When the E Stop button is pressed or an interlock is broken the E Stop button will light up giving an indication of the machine status After clearing the E Stop button or securing the interlock the light turns off Caution Always press the Emergency Stop bu...

Page 81: ...isconnect any internal cables from the card 10 Remove the screw holding the card to the processor case 11 Gently slide the card out of the processor case 12 Slide the new card into the processor case gently pushing it into place until it seats firmly in the backplane connector 13 Secure the card in place with the screw 14 Reconnect cables to the card 15 Place the processor cover back 16 Tighten th...

Page 82: ...in the DVD R W drive 2 By default the installation setup should auto run by itself If it doesn t navigate to and double click on the Setup exe file located on the Disk 3 Follow the prompts on the screen to install the System Software There is a selection for choosing to install SE500ULTRA configuration 4 After installing the software restart the processor CANOpen Interface card USB Ports Framegrab...

Page 83: ...k itself or from a disk image CD shipped with the system This document provides instructions for both methods Use the Acronis OEM Zone when the operating system does not work properly but the hard drive can be accessed see To Boot from the Hard Drive on page 73 Use the Acronis Boot Disk and the SE500ULTRA Recovery Disk when the hard drive has been replaced or the hard drive cannot be accessed see ...

Page 84: ... Maintenance 74 SE500ULTRA Hardware Manual Backing Up the Computer into DVD Using Acronis 1 Open the Acronis True Image Personal software and click the Backup icon as shown 2 The Create Backup Wizard screen appears as shown Click Next to continue ...

Page 85: ...FS C drive to create the backup copy as shown Click Next to continue 4 Insert a blank DVD into the computer DVD RW drive and select that drive letter and give the filename for the backup image For example E CYBERXXXX where XXXX is the serial number of the machine shown ...

Page 86: ...ions manually option Click Next to continue 6 Click Media Components on the left side of the screen and select Place Acronis True Image full version on media under the General tab This step will ensure that the Acronis software will also be backed up inside the DVD Thus making the DVD a bootable recovery disk ...

Page 87: ...CyberOptics Corporation 77 Processor Components 7 Click Next to continue 8 Make sure all checkboxes are not selected Click Next to continue ...

Page 88: ...ceed to continue 10 The Backup operation is now in progress Do not close the window Recovering the Computer Using Acronis 1 Load the Recovery Image that comes with the SPI machine in to the DVD drive and boot the computer The Acronis loader will start and the first screen is displayed as shown below ...

Page 89: ...CyberOptics Corporation 79 Processor Components 2 Click Acronis True Image Full Version 3 Click Recovery under Pick a Task options and the click Next to continue ...

Page 90: ... Preventive Maintenance 80 SE500ULTRA Hardware Manual 4 The Restore Data Wizard welcome screen appears Click Next to continue 5 Navigate to the CD drive and select the TIB file that is the factory default recovery image for the machine ...

Page 91: ...ftware will prompt you to select a partition or disk to restore Y ou must select ONL Y NTSC C and click Next to continue 7 The Acronis software will prompt you to resize the recovered partition Select No I do not want to resize partitions and click Next to continue ...

Page 92: ...reventive Maintenance 82 SE500ULTRA Hardware Manual 8 Select NTFS C ONLY when the Acronis software prompts you to select a target partition for the restore 9 In the Restored Partition T ype screen select Active and click Next to continue ...

Page 93: ...oration 83 Processor Components 10 The Acronis software will prompt you to if you intend to restore another partition Select No I do not and click Next to continue 11 In the Restore Operation Options screen click Next ...

Page 94: ...eventive Maintenance 84 SE500ULTRA Hardware Manual 12 The Acronis software will prompt you that it is ready to recover the image to the target partition Click Proceed 13 The Recovery process has now begun Do not cancel or close the window ...

Page 95: ... Processor Components Backing Up the Disk Image to Acronis Secure Zone 1 Open the Acronis True Image Personal software and click the Backup icon as shown 2 The Create Backup Wizard screen appears as shown Click Next to continue ...

Page 96: ...eplacing Components and Preventive Maintenance 86 SE500ULTRA Hardware Manual 3 Select ONLY the NTFS C drive to create the backup copy Click Next to continue 4 Select Acronis Secure Zone and click Next to continue ...

Page 97: ...ion 87 Processor Components 5 Select Use default options option Click Next to continue 6 Click Media components on the left side of the screen and select Place Acronis True Image full version on media under the General tab ...

Page 98: ...8 SE500ULTRA Hardware Manual 7 Click Additional Settings on the left side of the screen and select Place Acronis True Image full version on media under the General tab Make sure the check boxes are not selected and click OK to continue 8 Click Next to continue ...

Page 99: ...CyberOptics Corporation 89 Processor Components 9 Click Proceed to continue 10 The Backup operation is in progress Do not close the window ...

Page 100: ... files SPI exe config Inspection Results folder 1 Insert a writable CD in the DVD R W drive 2 Use the Windows Explorer to copy the files to the CD 3 For the writable drive Windows displays a temporary area where the files are held before they are copied to the CD Verify that the files and folders that you intend to copy to the CD appear under Files Ready to be Written to the CD 4 Under CD Writing ...

Page 101: ...in cables connected to the rear 7 T urn the AC power switch at the rear of the processor to OFF 8 Disconnect cables from the rear of the processor taking note as to the correct connections 9 Remove the processor cover 10 Use a dry cloth to clean the dust buildup out of the processor and keep away from the system so dust will not be blown into the electronics panel 11 Replace the processor cover 12...

Page 102: ...r front panel to the machine frame 5 Lift the air filter up and out from the front of the processor Figure 42 Processor Air Filter 6 Using clean dry compressed air to remove the dust buildup from the air filter Keep away from the system so the dust will not be blown into the electronics panel 7 Replace the air filter in the front of the processor 8 Replace the lower font panel 9 Close the SE500ULT...

Page 103: ... guide 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Open the hood Caution T urn the AC main circuit breaker to OFF to shut down all electrical power to the SE500ULTRA unit before replacing any parts or components For more information refer to the section Shutting Down the System on page 52 Warning Make sure the AC ma...

Page 104: ...e left hand lock plate in a counter clockwise direction Figure 43 Lock Plates at front clamp assembly 5 Loosen the two screws located at the blade holder using Allen key No 2 5 Figure 44 Screws at blade holder 6 Loosen the two springs attached at the using Long Nose pliers Be careful not to loose the springs Keep the springs away in a safe place Figure 45 Springs at blade holder Right hand lock pl...

Page 105: ...at the front clamp assembly in a counter clockwise direction T urn the left hand lock plate in a clockwise direction 12 Apply threadlocking to the screws after unlocking to ensure the rigidity of the clamp assembly 13 Using steps 10 11 of the procedure for replacing the conveyor belt Refer to the section Replacing the Conveyor Belts on page 104 To replace the edge guide at rear clamp assembly 1 Re...

Page 106: ...Hammer Threadlock Sealant Loctite No 2163 or equivalent To replace the conveyor clamp blade 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Remove all the M4 screws on the top of the blade holder Figure 47 Blade Holder and clamp blade 3 Remove and replace the old clamp blade with a new one 4 Measure the distance gap bet...

Page 107: ...nter clockwise direction This will allow the clamp blade to slide forward backward 2 Lower down the blade holder into the clamping position Slide the clamp blade until the gap between the top guide and clamp blade is approximately 2 5 3 mm 3 Tighten all the five blade mounting screws 4 T est the clamper movement for up down binding and interference ...

Page 108: ... to the horizontal position 3 Disconnect the air hose from the air fitting assembly 4 Disconnect the air fitting assembly from the side of the conveyor clamp cylinder 5 Connect the fitting parts elbow exhaust port and reducer creating an air fitting assembly Figure 49 Conveyor Clamp Air Connections 6 Wrap teflon tape twice around the brass end of the reducer leaving the first thread exposed 7 Atta...

Page 109: ...er Figure 50 Conveyor Clamp Hall Effect Switch 4 Remove the screw from the top of the conveyor clamp cylinder using a 5 16 inch hex wrench Support the clamp surrounding the screw with a inch wrench to avoid bending the shoulder screw 5 Flip the conveyor clamp cylinder away from the conveyor rail 6 Slide the switch out of the groove on the side of the cylinder 7 Unscrew the switch cable connector 8...

Page 110: ...on line Parts Conveyor Clamp Cylinder 8000517 T eflon Tape To replace the conveyor clamp cylinder 1 T urn off the air supply by turning the air shut off valve to the horizontal position Figure 51 Air Shut Off Valve 2 Disconnect the two air fitting assemblies from the side of the conveyor clamp cylinder Note Mark the connection placement for each of the assemblies Figure 52 Conveyor Clamp Cylinder ...

Page 111: ...inder and reattach the screw to the cylinder using adequate amount of threadlocking sealant on the screw 10 Reattach the hall effect switch if removed in step 6 Use the measurements taken in step 5 to attach the switch as near the same position as possible 11 Wrap teflon tape twice around the brass ends of the air fitting assemblies leaving the first thread exposed 12 Attach the air fitting assemb...

Page 112: ... DC Brushless Motor Tools Allen Key No 2 5 To replace the conveyor motors 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Use steps 1 9 of the procedure for removing the conveyor belt Refer to the section Replacing the Conveyor Belts on page 104 3 Loosen the mounting screws from the motor Figure 53 Conveyor Motor 4 Remo...

Page 113: ...ng Allen key No 2 5 Figure 56 Drive pulley 8 Remove the drive motor and install with a new drive motor 9 Transfer the drive pulley to a new motor and tighten it then replace it at the bracket and tighten back with screws 10 Repeat step 10 11 for replacing the conveyor belt Refer to the section Replacing the Conveyor Belts on page 104 11 Reverse the process to reassemble ...

Page 114: ...ting Down the System on page 52 4 Open the front cover from the machine 5 Loosen the Idler pulley No 2 by using the No 3 Allen Key at the setscrew 6 Slide the Idler pulley towards the motor direction in order to relieve the belt tension Figure 57 Conveyor Belt Replacement 7 Loosen the belt from the drive pulley first followed by the sequence pulley No 3 5 8 Make sure the belt is loosen from the bo...

Page 115: ... Autowidth Timing belt Manual width drive belt Required Tools No 3 Allen key No 2 Allen key To replace the manual width drive belt 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Loosen the screw from the wheel plate by using Allen key No 4 Figure 58 Wheel Plate 3 Push the wheel plate towards to cylinder direction in or...

Page 116: ...60 Shaft Guide and Drive Pulleys 5 Remove the timing belt from the motor drive pulley Figure 61 Timing Belt and Pulley 6 Replace with a new timing belt 7 Thread the timing belt onto the motor drive pulley 8 Replace the drive pulley and shaft guide and tighten with screws at 6kgf 9 Push the wheel plate in order to tighten the tension from the timing belt 10 Tighten the wheel plate with screws ...

Page 117: ...he rail 2 Make sure the clamp blade at the rails are in the OPEN position 3 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 4 Open the front cover from the machine 5 Loosen the setscrew using Allen Key No 2 5 Figure 62 Idler Pulley And Front Conveyor Belt 6 Remove the Idler pulley from the rail and replace 7 Do not loosen t...

Page 118: ...is starting to strengthen Figure 63 Idler 2 Make a line marking by using the ruler in line with the slot nut Figure 64 Slot nut 3 Place a ruler in line with the marking initial marking from Figure 64 from the ruler reading measure the distance length at 22 mm Figure 65 Marking with ruler 4 Mark a line with the ruler as shown in Figure 65 and start to push the Idler forward until it reaches the 22 ...

Page 119: ...Idler pulley towards the motor direction in order to relieve the belt tension 7 Remove the belt from the pulley drive first followed by the sequence with pulley No 3 5 8 T urn the pulley drive setscrew facing to the bracket motor M4 screw hole and use the No 2 5 Allen Key to loosen the two setscrews 9 Remove the pulley drive from the bracket motor 10 Replace a new pulley drive fixed it to the moto...

Page 120: ...ll electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Remove the two mounting screws and sensor slide bracket on the board sensor as shown in Figure 67 3 Clip the cable ties to free the board sensor cable from the conveyor 4 Disconnect board sensor cable and remove the board sensor 5 Attach new board sensor to the sensor bracket and secur...

Page 121: ...CyberOptics Corporation 111 Conveyor Components Figure 67 Board Sensors on Conveyor Handwheel Mounting screws Board sensor Sensor bracket Board sensor ...

Page 122: ...in production line Parts Panel Lifter Cylinder Required Tools No 3 Allen Key No 4 Allen Key Screwdriver To replace the panel lifter cylinder and inductive sensor 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Open the cover 3 Make sure all motion has stopped 4 Remove the centre lifter plate 5 Remove the four screws on ...

Page 123: ...the 7 mm spanner T urn in a clockwise direction 9 Use Allen key No 2 5 to release the cylinder from the cylinder plate Remove the cylinder and replace with a new cylinder 10 Reverse the process to reassemble Lock nut i Note For more information on system alignment refer to Aligning the System section of the SE Series Solder Paste Inspection Software User Guide Part Number 8020277 ...

Page 124: ...s stopped 4 Use a dry soft cloth with household glass cleaner 5 Gently wipe the panel sensors lenses Figure 68 Conveyor Panel Sensors Warning Make sure the system power is turned off before working inside the hood Gantry motion can pinch or sever objects in its path i Note Do not use solvents or abrasives to clean the panel sensor lenses Board Stop Sensor Panel Detect Sensor Entry Exit Panel Detec...

Page 125: ...o change the position of the mechanical board stop 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Make sure the machine is OFF and the rails are in HOME position 3 Unscrew the two thumb screws Figure 69 Stopper Sensor Bracket Thumb screws 4 Remove the stopper sensor bracket from the conveyor Re tightened the thumb scre...

Page 126: ...ULTRA Hardware Manual 6 Use a cutter to cut the cable tie Figure 71 Stopper Cable tie Figure 72 Stopper Sensor Bracket dismantled from the conveyor 7 Take out the stop spacer from the cylinder by using the Allen key No 2 5 Figure 73 Stop Spacer Cutter Allen Key No 2 5 ...

Page 127: ...ing cylinder from stopper bracket Figure 75 Cylinder dismantled from the stopper bracket 9 Re assemble the cylinder on the bracket using Allen key No 2 5 Apply adequate amount of Loctite before tightening Figure 76 Stopper bracket assembly in the opposite side Allen Key No 2 5 M3 Bolts i Note Ensure the stopper bracket is turned to the opposite side and apply Loctite before tightening ...

Page 128: ...cylinder top edge Apply loctite to the bolts Figure 77 Stop spacer assembly 11 Prepare the left side conveyor with two thumb screws two slot nuts and one cable mount fixed up as shown in Figure 78 Figure 78 Left side conveyor rail assembly 12 Mount the completed stopper bracket assembly to the left side conveyor rail Tighten with wing nut Figure 79 Mounting stopper bracket assembly Slot nuts x 2 T...

Page 129: ...op spacer and Top cap Figure 81 Relocation of mechanical board stop completed 14 Tidy the cable routing with cable tie onto the cable mount Figure 82 Cable Routings 15 Reset the conveyor offset after the relocation of the mechanical board stop is completed For more information refer to the section To reset the conveyor offset settings on page 123 Top Cap Stop spacer ...

Page 130: ... Manual To relocate the Slow Down Sensor 1 Loosen the slot nut as shown in Figure 83 to adjust the slow down sensor position Figure 83 Slow Down Sensor Location 2 Use a cutter to cut the cable tie Figure 84 Cable Tie 3 Disconnect the connector Figure 85 Connector Slot Nut Connector ...

Page 131: ...Components 4 Re route the existing wiring route Figure 86 Re routing the wiring 5 Move the slow down sensor from left hand side to right hand side Figure 87 Moving slow down sensor 6 Re connect the connector Figure 88 Re connect Connector ...

Page 132: ...Set the distance of 52 mm by using a steel ruler or a 52 mm plate between the slow down sensor and the stopper spacer Once the distance is set secure the position with Allen key No 3 Figure 89 Setting Distance for slow down sensor Figure 90 Relocation of slow down sensor completed 52 mm plate ...

Page 133: ...ttings 1 Run SystemSetup exe In the System Setup dialog choose the appropriate system type conveyor orientation lane configuration and rail configuration 2 Select the desired fudicial 3 Run the Inspection 4 Conveyor offsets are automatically saved no manual adjustments are needed ...

Page 134: ...uction line This section shows the procedure performed when the machine is not in production line Parts Forcer Required Tools 1 4 mm spacer Threadlock Sealant Caution T urn the AC main circuit breaker to OFF to shut down all electrical power to the SE500ULTRA unit before replacing any parts or components For more information refer to the section Shutting Down the System on page 52 i Note For Parts...

Page 135: ...o the system For more information refer to the section Shutting Down the System on page 52 2 Remove the forcer and hall sensor connectors 3 Remove all the cable ties 4 Remove all the screws 5 Remove the forcer and the hall sensor screws Cable ties Forcer and hall sensor connectors cables Forcer and hall sensor ...

Page 136: ...hten the forcer with the screws removed in step 3 Tighten the screws after applying adequate amount of threadlocking sealant 8 Replace back the forcer hall sensors connectors and cables 9 Check the air gap between the hall sensor and the stator with a 1 4 mm spacer The air gap must be maintained at a 1 4 mm gap width Contact CyberOptics for the part number of the spacer X axis Forcer and hall sens...

Page 137: ... stator 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Prepare two ironless containers as shown 3 Slide out the first piece of stator at the edge of the stage and place it in one of the ironless container 4 Move the carrier to the other end of the stage i Note For Parts Replacement contact CyberOptics for part numbers ...

Page 138: ...ng torque of 110 kgf cm after apply adequate amount of threadlocking sealant 9 Install the middle stator Tighten with screws using a tightening torque of 110 kgf cm after applying adequate amount of threadlocking sealant 10 Lastly install the first stator Tighten with screws using a tightening torque of 110 kgf cm after adequate amount of applying threadlocking sealant The direction of the stators...

Page 139: ...CyberOptics Corporation 129 Gantry Components 11 Be sure to keep the stator s S mark connecting to the N mark of the neighboring stator S mark N mark Stator ...

Page 140: ...ction line Parts X Axis To replace the X Axis of the gantry 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Remove the screws attached to the grounding board 3 Remove the screws attached on the base of the cable chain and cable chain bracket 4 Remove the D Sub connectors i Note For Parts Replacement contact CyberOptics ...

Page 141: ... 5 Remove all the screws attached to the right endplate 6 Remove the encoder grounding cable and D sub connector 7 Remove all the screws attached to the left endplate screws screws screws Grounding Cable D sub connector screws screws screws screw ...

Page 142: ...es 12 Replace the Y axis stator 13 Tighten the left endplate with screws 14 Reconnect the encoder grounding cable and D sub connector 15 Tighten the right endplate with screws 16 Reconnect the cable chain 17 Reattach and tighten the grounding board with screws Left Side endplate screw Right Side endplate screw X axis i Note For more information on system alignment refer to Aligning the System sect...

Page 143: ...section Shutting Down the System on page 52 2 Remove the cable ties and screws 3 Remove the encoder and replace with a new encoder 4 T urn on all electrical power to the system For more information refer to the section Shutting Down the System on page 52 5 After replacing the new encoder check the encoder signal for green light ON 6 Pay attention to the cable paths and configuration 7 Perform enco...

Page 144: ...ation refer to the section Shutting Down the System on page 52 2 Open the SE500ULTRA hood 3 Make sure all motion has stopped 4 Locate the encoder strips on the X and Y axes 5 Remove any coarse or abrasive particles with clean dry compressed air Warning Make sure the system power is turned off and locked off before working inside the hood Gantry motion can pinch or sever objects in its path Caution...

Page 145: ...ectrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Remove all screws on both sides of the stage 3 Remove the side plate 4 Loosen the screw on the encoder bracket and remove the encoder 5 Remove the encoder strip Side plate Encoder bracket ...

Page 146: ... with the standard tool by pasting the strip onto the gantry Contact CyberOptics for the part number of the standard tooling kit 7 Perform encoder read head adjustment after replacing the encoder strip Refer to steps 6 10 on Adjusting the Encoder Read Head on page 137 for the procedures Standard Tooling kit Encoder Strip ...

Page 147: ...mation refer to the section Shutting Down the System on page 52 2 Open the SE500ULTRA hood 3 Make sure all motion has stopped 4 Locate the encoders to be replaced on the X axis and Y axis 5 Loosen the two screws as shown in Figure 91 Figure 91 Encoder carrier screws 6 Insert a RENISHAW 0 8mm spacer between the read head and the scale Contact CyberOptics for the part number of the REINSHAW spacer 7...

Page 148: ...he required air gap can be achieved and the green LED light should be ON 10 Slightly move the carrier and make sure that the green light is ON during the whole travel 11 Inspect if there is any contamination on the scale If there is contamination clean with wiper Carrier Caution Do not clean contamination with alcohol ...

Page 149: ...mation refer to the section Shutting Down the System on page 52 2 Open the top cover of the safety enclosure 3 Locate the grease fittings attached to the red blocks on each stage as shown in Figure 92 Each stage X and Y has four grease fittings two on the front and two on the rear Figure 92 Grease Fittings 4 Using a grease gun with a tapered nozzle fitting pump grease into each fitting until greas...

Page 150: ...hole in the center of the sensor mounting plate as shown in Figure 93 Figure 93 Z axis Leadscrew 6 Move the Z stage up and down manually by turning the knob underneath the Z stage 7 Slide the sensor onto the bottom pin of the mounting plate 8 Pivot the sensor to align with the top pin of the mounting plate 9 Secure the sensor to the mounting plate by tightening the three captive screws 10 Reconnec...

Page 151: ...tion line This section shows the procedure performed when the machine is not in production line To adjust the X axis parallelism 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Set a target within 5 μm for the reference guideway 3 Set a target within 5 μm for the following guideway Target set within 5 µm Target within 5...

Page 152: ...h access to the left right of the machine in production line This section shows the procedure performed when the machine is not in production line To adjust the Y axis parallelism 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Remove the right or left side carrier 3 Set at target within 5 μm for the reference guideway ...

Page 153: ...on shows the procedures performed when the machine is not in the production line To adjust the X axis and Y axis orthogonality 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 52 2 Place the square granite ruler and indicators Contact CyberOptics for the part number of the granite ruler and indicator Target within 5 µm Granit...

Page 154: ... Replacing Components and Preventive Maintenance 144 SE500ULTRA Hardware Manual 3 Make Y axis as the reference 4 Set a target within 5μm and adjust the X Axis Y Indicators screw adjustment Target set within 5µm ...

Page 155: ...Down the System on page 52 2 Open the SE500ULTRA hood 3 Loosen the two screws from the Camera Link connector on the back of the sensor 4 Disconnect the Camera Link cable from the connector on the back of the sensor 5 Disconnect the Illumination Control Cable from the connector on the side of the sensor 6 Remove the three captive M6 x 45 screws using a 5 mm allen wrench 7 Remove the sensor from the...

Page 156: ...146 SE500ULTRA Hardware Manual Figure 94 Mounting Plate on the Z Stage Figure 95 Sensor Cable Connections Top mounting pin Bottom mounting pin Z Stage Captive screw Captive screw Captive screw Camera Link cable connection Illumination Control cable connection ...

Page 157: ...e rotated If this value is positive turn the screw in the clockwise direction Else turn the screw in the counter clockwise direction Correction Tolerance Turns indicates the specified limits for camera alignment Result indicates if any camera adjustment is required If the radians value is within the Specification no adjustment is needed 6 Repeat step 5 until the camera rotation values are within t...

Page 158: ...rical power to the system For more information refer to the section Shutting Down the System on page 52 2 Open the SE500ULTRA hood 3 Make sure all motion has stopped 4 Remove three screws to take off the cover to the safety interlock switch Figure 96 Safety Interlock Switch Access 5 Disconnect the six wires in the box 6 Remove the strain relief nut and pull the cable out of the switch Caution T ur...

Page 159: ...97 Safety Interlock Switch To align safety interlock switch 1 Press the green ON button to turn on system power 2 Close the hood to make sure the pin is lined up with the safety interlock switch socket T o check the alignment Re engage the E Stop Observe the safety circuit relays inside the electronics panel The LEDs should be turned on 3 Adjust the switch for correct alignment and tighten the mou...

Page 160: ...t secure the plate and foot assembly to the frame 3 Replace the damaged leveling foot 4 Reassemble the foot assembly onto the frame 5 Repeat steps 1 4 as required to replace the other leveling feet 6 Adjust the leveling feet as needed to align the SE500ULTRA with the conveyors For more information refer to the section Positioning Leveling the SE500ULTRA on page 28 for details Figure 98 Leveling Fo...

Page 161: ...erOptics Corporation 4 Troubleshooting Safety Circuit Block Diagram 152 AC and DC Distribution Block Diagram 153 SMEMA Connector Pinout 154 System Error Messages 155 Solder Paste Failure Causes 156 SOS 158 ...

Page 162: ... Motor 280 8013777 Middle Man 8012972 8012818 Z Servo Drive PE M1 M2 M3 VP PR PE J4 201 202 202 211 212 246 247 248 234 235 281 Middle Man Page3 2002 3217 2002 3217 2002 3217 2002 3217 2002 3201 2002 3217 2002 3217 2002 3217 257 PE PE PE PE PE Sig 2002 3217 PE PE PE WH 258 259 261 To Dio Controller Conveyor Connector 8012964 8013016 INTERLOCK E STOP 2B 295 296 294 297 290 291 8012795 8013018 80130...

Page 163: ...CyberOptics Corporation 153 AC and DC Distribution Block Diagram AC and DC Distribution Block Diagram ...

Page 164: ...TRA to communicate with the upstream and downstream conveyors For more information about SMEMA cables refer to Connecting SMEMA Cables on page 38 SMEMA Connector Pin Upstream Cable Downstream Cable 1 2 Machine Ready Machine Ready 3 4 Board Available Board Available 7 8 Failed Board Available Failed Board Available ...

Page 165: ...rectory This log file provides sufficient information to diagnose the problem or report the problem to CyberOptics Service and Support for further analysis Y ou can configure the logging options under T ools Options Advanced tab to record additional information in the MachineControl log file See the Solder Paste Inspection Online Help for details on the different logging options System Error Messa...

Page 166: ...Contamination on board Localized issue usually on one board Contamination under Stencil Localized issue usually on repeated boards Damaged Squegee blades Check blades for damage Bridging Lack of Support while printing Board flexes while pressed on when locked in print position Contamination on board or stencil Localized issue Print gap too large Tap on stencil with board in position stencil should...

Page 167: ...using scooping Look at shape if center is lower with no dog ears then pressure too high Dirty stencil causing poor release Jagged edges poorly defined print Old paste Paste clumps will not move smoothly Smeared paste Look for evidence that board was hit Low Volume High Height Dirty Stencil causing poor release Jagged edges poorly defined print Stencil aperture ratio poor Look for apetures that wil...

Page 168: ...nu 2 In the Open dialog box navigate to and select the SRFF you want to use and click Open 3 On the Tools menu point to Maintenance and then click S O S 4 The files are automatically saved in the Output Folder specified To change the Output Folder 1 On the Tools menu select Options 2 Select the File Handling tab 3 In the Output Folder area click Browse 4 Navigate to the folder in which you want to...

Page 169: ...Chapter 5 System Drawings SE500ULTRA Hardware Manual 159 5 System Drawings 8015066 ASSY MAIN ELECTRICAL PANEL SE500ULTRA 160 8016704 Conveyor SE500ULTRA 166 ...

Page 170: ...Chapter 5 System Drawings 160 CyberOptics Corporation 8015066 ASSY MAIN ELECTRICAL PANEL SE500ULTRA Drawing Figure 99 8015066 ASSY MAIN ELECTRICAL PANEL SE500ULTRA Sheet 1 of 6 ...

Page 171: ...Chapter 5 System Drawings SE500ULTRA Hardware Manual 161 Figure 100 8015066 ASSY MAIN ELECTRICAL PANEL SE500ULTRA Sheet 2 of 6 ...

Page 172: ...Chapter 5 System Drawings 162 CyberOptics Corporation Figure 101 8015066 ASSY MAIN ELECTRICAL PANEL SE500ULTRA Sheet 3 of 6 ...

Page 173: ...Chapter 5 System Drawings SE500ULTRA Hardware Manual 163 Figure 102 8015066 ASSY MAIN ELECTRICAL PANEL SE500ULTRA Sheet 4 of 6 ...

Page 174: ...Chapter 5 System Drawings 164 CyberOptics Corporation Figure 103 8015066 ASSY MAIN ELECTRICAL PANEL SE500ULTRA Sheet 5 of 6 ...

Page 175: ...E500ULTRA Hardware Manual 165 Figure 104 8015066 ASSY MAIN ELECTRICAL PANEL SE500ULTRA Sheet 6 of 6 Note The part numbers that are appended with ITEM for example 2X 8019437_ITEM10 are not FRU parts and are not sold by CyberOptics ...

Page 176: ...LTRA Drawing Figure 105 8016704 Conveyor SE500ULTRA Sheet 1 of 8 8016704 Conveyor for SE500CP and SE500ULTRA 18 Sep 2013 Spare Part Location Map 3 15 5 4 2 6 11 4 10 9 15 16 13 18 20 1 12 21 17 22 26 27 28 29 14 14 23 7 39 19 31 24 24 38 25 8 44 45 46 47 52 55 56 57 59 58 53 29 ...

Page 177: ... Number 1 Motor Wire Harness FIXED RAIL M1 1 pc unit 8014333 2 Motor Wire Harness WIDTH MOTOR WM 1 pc unit 8014337 3 Proximity sensor with wire Assy E2E X4MD1 wire code WH 1 pc unit 8014304 4 Idec sensor with wire Assy SA1E GP1 2M wire code 4A 4C 12A 12C 4 pcs unit 8014305 5 Idler Pulley Assy 12 pcs unit 8014342 6 Gearhead 1 5 8H5FBN SE 350 Belt Auto Width common SE 500 2 pcs unit 8014346 7 DC Bru...

Page 178: ...d Valve SY3103120 5LZD C4 Q 3 pcs unit 8014349 9 Timing belt Width Adjust 10W T5 900L 1 pc unit 8014350 10 Timing belt Auto Width Adjust Motor 10W T5 275L 1 pc unit 8014352 11 Timing belt Hand Wheel Adjust 10W T5 400L 1 pc unit 8015981 12 Timing belt Drive pulley 10W T5 220L 1 pc unit 8015982 13 Edge Belt ENI 5P 2 pcs unit 8014302 14 In Output Block RH 2 pc unit 8015953 15 In Output Block LH 2 pc ...

Page 179: ...der Clamp Blade CDQSD16 10D A93LS 2 pcs unit 8014957 19 Cylinder Lifter CDQ2A20 30D A73 1 pc unit 8014579 20 Cylinder Board Stop CDQMB12 30 A93LS 1 pc unit 8014580 21 Stop Spacer Block 1 pc unit 8014582 22 Stopper Cylinder Mount 1 pc unit 8014584 23 Auto Width Adjust Fitting Kit Include Timing pulley 5200509 Timing pulley 5067280 Timing belt 5064434 1 set unit 8014586 24 Leadscrew Length 637mm 2 p...

Page 180: ...t Fitting Kit KQ2U04 00 AS1001F 04 Note W O tubing 1 set unit 8014602 28 Handwheel Include Handwheel 5202507 Spacer 5202508 Timing Pulley 5202856 Washer 5201089 1 pc unit 8015958 29 Drive Pulley 2 pcs unit 8015959 30 Lift Down Sensor Wire Harness 1 pc unit 8014603 31 Board Stop Sensor C W Cylinder Proximity Wire Harness 1 pc unit 8014625 32 Left Side Panel Sensor Wire Harness 1 pc unit 8014605 33 ...

Page 181: ...14610 36 Clamp Front Up Down Proximity Sensor Wire Harness 1 pc unit 8014612 37 Auto Width Home Sensor Wire Harness 1 pc unit 8014614 38 Air Manifold Wire Harness SY100 30 4A 3 pcs unit 8014616 39 Shoulder Bolt Dia 6 x 10L 2 pcs unit 8014618 40 Tubing TUD425B 20 Black 20 meter 80914619 41 Lift Proximity sensor 150mm D A73 wire code 6A 1 pc unit 8014627 42 Clamp Proximity sensor 150mm D A93L wire c...

Page 182: ... 12 UUN 4 pc unit 8016299 46 Support Plate 1 pc unit 8019008 47 Yoke Plate 2 pcs unit 8016824 48 Supernut 2 pcs unit 8016825 49 Flange Bearing F688AZZ 4 pcs unit 8016826 50 Linear Bushing LM12L UU 2 pcs unit 8016820 51 Flange Bearing F696ZZ 2 pcs unit 8016828 52 Cylinder Joint 2 pcs unit 8016829 53 Bearing Holder Assy Kit Include Bearing Holder 5204800 Deep Groove Ball Bearing 5069159 Lock Nut 520...

Page 183: ...ing on stock level CyberOpticsSP_V2_20101228 No Description Use Quantity CyberOptics Part Number 54 Width Adjust Assy Kit Include Linear Bushing 5204111 Supernut Plate 5065098 Supernut 5069012 Yoke Plate 5202464revB Customize item 8016306 55 Conveyor Drive Support Plate 1 pc unit 8017479 56 Conveyor Width Shaft 1 pc unit 8017465 57 Conveyor Support Bush 1 pc unit 8017480 58 Insert plate oil bronze...

Page 184: ...Chapter 5 System Drawings 174 CyberOptics Corporation ...

Page 185: ...rive description 10 motor controller description 8 Board clamp description 10 Board stop mechanical description 10 Bypassing system 53 C Cables Replacing 60 Certification tool 50 Changing mechanical board stop position 115 slow down sensor position 120 Choosing installation location 26 Circuit breaker description 8 replacing 61 Clamp Blade replacing 96 Cleaning air regulator filters 69 encoder str...

Page 186: ...onveyor 40 F Failure Causes solder paste 156 Fans replacing 66 Fixed rail motor controller description 8 Fuses replacing 63 G Gantry description 6 encoder strips cleaning 134 encoder adjusting 137 encoder replacing 133 forcer replacing 124 location 7 lubricating 139 stator replacing 127 x axis replacing 130 H Hall effect switch replacing 99 I I O channel indicators 154 Indicators smema I O 154 Ind...

Page 187: ...nductive sensors 112 panel sensors 110 processor components 71 pulleys 107 safety interlock switch 148 sensor 145 x axis 130 replacing X Axis 130 Replacing Cards 71 Replacing the Conveyor Belts 104 Requirements computer 17 system 16 Restoring system disk using Acronis 73 S Safety circuit block diagram 152 Safety contactor description 8 Safety enclosure location 3 Safety Interlocks aligning switch ...

Page 188: ... Verifying system accuracy 50 W WAGO PLC assembly 41 Website ix Wiring the system 34 X X Axis parallelism adjusting 141 X Stage servo amp description 8 Y Y Axis parallelism adjusting 142 Y Stage servo amp description 8 Z Z Stage lubricating lead screw 140 Z Stage servo amp description 8 ...

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CyberOptics SE500ULTRA, Hardware Manual

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