CyberOptics SE505 Hardware Manual Download Page 82

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Chapter 4

Replacing Components and Preventive Maintenance

SE505 Hardware Manual

Replacing the Air Regulator

Parts

8011834 Air Regulator

➢

To replace the air regulator

1. Turn off all electrical power to the system. For more information, refer to the section

“

Shutting Down the System

” on page 59.

2. Turn the air shut-off valve to the horizontal position, which is the OFF position.

3. Disconnect the air supply hose from the air supply connector.

4. Unscrew the two screws attached to the cover and remove the safety cover.

5. Unscrew the plastic ring at the top of the air regulator.

Figure 53.

Air Regulator

6. Gently pull the air regulator down to remove it.

7. Using an 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. Turn the knob at the top of the air regulator to turn the air pressure OFF before reconnecting

air.

12. Screw on the plastic ring at the top of the air regulator.

13. Attach the safety cover to the air regulator with the two screws.

14. Reconnect and turn on the air supply.

15. Turn the knob at the top of the air regulator to set the air pressure to 90 psi ± 10 psi.

Air regulator with safety cover

Air regulator without safety cover

screws x 2

safety cover

Plastic ring

Hex nut

Air supply
connector

Air shut-off
valve

Summary of Contents for SE505

Page 1: ...SE505 Hardware Manual ...

Page 2: ... trademarks or registered trademarks in the United States and other countries CyberOptics and SE505 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 a...

Page 3: ...ety Labels 10 Manufacturing Information Conformance 11 2 System Overview 13 SE505 System 14 SE505 Unit 14 SE505 Rear View 16 SE505 Internal Parts 18 Main Electrical Panel 20 Conveyor 22 System Specifications 26 System Requirements 27 Performance Specifications 28 Computer Requirements 28 Dimensions 29 3 Installation 31 Unpacking the SE505 System 32 Choosing a Location 33 Installing the System 34 I...

Page 4: ... Fuses 70 Replacing the Air Regulator 72 Replacing Fans 73 Preventive Maintenance 74 Processor Components 77 Replacing Cards 77 Software Upgrades 78 Restoring system disk using Acronis 79 Preventive Maintenance 96 Conveyor Components 98 Replacing the Conveyor Edge Strip Guides 98 Replacing the Conveyor Clamp Blade 101 Replacing the Conveyor Clamp Air Fittings 103 Replacing the Conveyor Clamp Hall ...

Page 5: ...m 150 Adjusting X axis and Y axis Orthogonality 151 Sensor 152 Sensor Replacement 152 Other Components 155 Replacing the Safety Interlock Switch 155 Replacing Leveling Feet 157 5 Troubleshooting 159 Safety Circuit Block Diagram 160 AC and DC Distribution Block Diagram 161 SMEMA Connector Pinout 162 System Error Messages 163 Solder Paste Failure Causes 164 SOS 166 Index 167 ...

Page 6: ...Contents vi SE505 Hardware Manual ...

Page 7: ...ions SE505 Solder Paste Inspection Software User Guide and Online Help Provides task based step by step procedures and descriptions of the software controls for the Solder Paste Inspection Applications Engineering Interface SPI Systems Inspection User Guide and Online Help Provides task based step by step procedures and descriptions of the software controls for the Solder Paste Inspection Applicat...

Page 8: ...e 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: ...iness 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 Min...

Page 10: ...x SE505 Hardware Manual ...

Page 11: ...CyberOptics Corporation 1 Safety Safety Guidelines 2 Compliance 7 Safety and Conformity Labeling 8 ...

Page 12: ...y interlock mechanisms Do not run the system with panels removed Do not attempt to disassemble or repair any SE505 component without first contacting your CyberOptics representative Use the SE505 system only indoors T o avoid electrical shock always turn off the power using the AC main circuit breaker before servicing the unit Only personnel trained by a CyberOptics representative are recommended ...

Page 13: ... To operate the E Stop 1 Push the red E Stop button to stop the 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 t...

Page 14: ...on which is the OFF position 3 Ensure that all energy sources which could activate the machine must be locked out 4 Insert a padlocking facility into the slot on the AC main circuit breaker CB1 located at the rear of the SE505 See Step 1 in Figure 2 5 Push the latch of the padlocking facility down See Step 2 in Figure 2 6 Attach a padlock or a tag to the padlocking facility See Step 3 in Figure 2 ...

Page 15: ...not securely closed or the switch is defeated in another way such as putting the key in the switch all machine motion is disabled To reengage the safety interlock switch 1 Remove the key from the switch if applicable 2 Close the safety enclosure securely 3 Press the yellow E Stop Reset to reengage the system Figure 4 Location of safety interlock switch Caution It is recommended that the machine sh...

Page 16: ...or lights on the SE505 light pole Refer to the Teach Online Help or Solder Paste Inspection Online Help for these procedures Refer to Safety of Machinery EN 60204 1 1998 section 10 3 Indicator lights and displays Table 3 for standard indicator light definitions The lights also indicate that the power up sequence for the system is complete Refer to Turning on System Power on page 43 ...

Page 17: ...ents A1 A2 Table 1 Limits Table 2 Continuous Monitored Operation EN 60204 1 2006 Safety Of Machinery Electrical Equipment Of Machines Part 1 General Requirements EN 954 1 1997 Category 4 Safety Of Machinery Safety related Parts Of Control Systems General Principles For Design ISO 12100 1 2003 Safety Of Machinery Basic Concepts General Principles for Design Part 1 Basic Terminology Methodology ISO ...

Page 18: ...near the conveyor openings and on the front of the machine The label text says WARNING Moving parts can crush and cut Do not operate with guard removed Lockout tagout before servicing Figure 6 Pinch Point Warning Label The pressurized device label is located near the air regulator The maximum air regulator pressure is 100 psi The label text says CAUTION Pressurized device Release air pressure befo...

Page 19: ...s iron steel and nickel Credit cards ATM cards magnetic data carriers wristwatches etc may be damaged when brought too near Figure 9 Magnetic Field Caution Label The power switch caution label is located on the front of the machine next to the power switch The power switch does not remove all power from the system T urn off the AC main circuit breaker at the rear of the machine before servicing th...

Page 20: ... servicing Figure 12 Hazardous Voltage Label The ESD earth ground label is located near the ESD grounding plug on the outside of the system Figure 13 ESD Earth Ground Label The protective earth ground label is located near the PE terminal on the inside of the system at the back electrical panel and gantry grounding plate Figure 14 Protective Earth Ground Label The lockout label is located at the r...

Page 21: ...e with European Conformity CE UL and RoHs requirements In addition a printed EU Declaration of Conformity is shipped with each system If a new copy is required contact CyberOptics Customer Service See T echnical Support on page ix Figure 16 Manufacturing Label SOLDER PASTE INSPECTION SYSTEM Part No Serial No Date Protected by U S 6 115 491 U S 6 385 335 U S 6 549 647 U S 6 557 405 U S 6 593 705 U ...

Page 22: ...Chapter 1 Safety 12 SE505 Hardware Manual Figure 17 Locations of Manufacturing Labels SE505 Rear of Machine SE505 side view of Machine ...

Page 23: ...CyberOptics Corporation 2 System Overview SE505 System 14 System Specifications 26 Performance Specifications 28 Computer Requirements 28 System Requirements 27 Dimensions 29 ...

Page 24: ...ts 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 Emergency Stop E Stop ...

Page 25: ...Front 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 Alarm Cancel Control Panel ...

Page 26: ...rical 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 local area net...

Page 27: ...505 System Figure 19 SE505 Rear View Back access cover Air regulator Cooling fans Power access cover COM1 port Ethernet port SMEMA Upstream SMEMA Downstream Digital I O AC main circuit breaker CB1 Power cord strain relief COM2 port ...

Page 28: ...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 29: ...CyberOptics Corporation 19 SE505 System Figure 20 Internal Components Sensor Main Electrical Panel Conveyor Processor Digital I O Controller Gantry ...

Page 30: ...ages 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 Power Supply 24VDC 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...

Page 31: ... 0A 10 0A 10 0A 10 0A SMEMA SYSTEM TOWER Z W B X MM Y PS1 PS2 PS3 K1 Middleman PCB Assembly X Stage Servo Amp Y Stage Servo Amp Z Stage Servo Amp Conveyor Width Motor Controller 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 32: ...o mechanical drive for the conveyor and for the automatic width adjustment 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 positionin...

Page 33: ...Belt Conveyor Motor Board Stop Conveyor Drive Belt Autowidth Motor Autowidth Drive Belt Conveyor Manual Adjustment Wheel Board Stop Sensor Panel Proximity Sensor Entry Exit Panel Proximity Sensor Entry Exit Panel Lifter Top Clamp Slow Speed Sensor Movable Conveyor Rail Fixed Conveyor Rail ...

Page 34: ...nect the board stop to the fixed conveyor rail Figure 24 Left to Right Board Flow Configuration 6 Calibrate the system in either of the following a Set the ConveyorOffsetX and ConveyorOffsetY values manually using the Configuration Editor or b Refer to Aligning the System section of the SE505 Solder Paste Inspection Software User Guide Part Number 8015918 i Note Set the ConveyorRightToLeft value u...

Page 35: ...gistry Editor 3 In the Registry Editor window delete the file LastPatchFile located at My Computer HKEY_LOCAL_MACHINE SOFTWARE CyberOptics SMTSystems Common 4 After the LastPatchFile is deleted the System Setup dialog box automatically pops up during the following SPI software installation 5 Select the appropriate system type conveyor orientation lane configuration and rail configuration 6 Click O...

Page 36: ...arance Topside above belt Bottom side 20 1 mm 0 78 in 25 4 mm 1 0 in Maximum Board Weight 3 kg 6 6 lbs Maximum Board Warp 2 of PCB diagonals 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 Conveyor Adjustment Automatic Maximum Inspection Area 508 503 mm 20 19 5 in Maximum Pad Size in FOV 15 15 mm 0 6 0 6 in Field Of View FOV 32 3...

Page 37: ...rements Humidity Operating Storage 20 80 RH non condensing 10 90 RH non condensing Temperature Operating Ambient Storage 15 35 C 59 95 F 20 70 C 4 158 F Altitude Up to 2000 mm Insulation Coordination Pollution degree 2 Installation Category overvoltage category Category III Power Requirements Hard wired single phase 100 130 220 240 V 50 60 Hz 10 15 amps Permitted Voltage Drops 90 V for 100 130 VAC...

Page 38: ...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 to accommodate quilt image for 20 x 20 in panel Video card Minimum Recommended 32 MB memory 64 MB memory OpenGL acceleration Monitor Resolution 1024 x 768 24 bit color minimum Operatin...

Page 39: ...CyberOptics Corporation 29 Dimensions Dimensions Figure 25 Front View 85cm 34 in 134cm 53 in 100cm 39 in 139cm 55 in 490cm 19 in ...

Page 40: ...E505 Hardware Manual Figure 26 Side View 188cm 74 in 92cm 36 in 127cm 50 in Adjustable 86 104cm 34 41 in T o achieve the lowest conveyor height configuration of 83 cm to 96 cm 33 inch to 38 inch a customized conversion kit is needed ...

Page 41: ...the Air Supply 44 Connecting SMEMA Cables 45 Connecting to a Network 46 Connecting to an External Device 47 Wago PLC Assembly 48 Manually Adjusting the Conveyor Width 49 Configuring the Pressure Gauge Display 50 Setting Up System Security 52 Verifying System Accuracy 57 Shutting Down the System 59 Moving the SE505 System 60 Bypassing the SE505 System 60 ...

Page 42: ...on 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 desiccants and accessories around the unit 6 From the rear of the machine ensure the forklift s forks are supporting both crossbeams ...

Page 43: ...xes before using the machine Figure 27 Transit securing brackets on X Axis Figure 28 Transit securing bracket on Y Axis Choosing a Location The SE505 system must be level and aligned with incoming and outgoing conveyor sections to allow for smooth movement of panels Choose a location for the SE505 that meets the following requirements System has easy access to power and compressed air Conveyor is ...

Page 44: ...ng 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 29 ...

Page 45: ...lining 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 30 Leveling Foot 4 Use a level or machine height measurements to make sure that the system is level 5 Manually slide a panel th...

Page 46: ...y in position 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 32 on page 37 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 lif...

Page 47: ...topped 3 Loosen the two M5 screws along the top edge of the lower front panel 4 Lift the panel off the machine 5 Remove the power switch from the machine by removing the attaching screw 6 Loosen and remove four M5 screws from along the inside of the SE505 frame 7 Lift the right panel off the machine and rest it on the monitor arm Figure 32 Removing Front Panels M5 screws x 4 Power switch M5 screws...

Page 48: ...en 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 34 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 SE505 conveyor rail is properly alig...

Page 49: ...e the sensor onto the plate with three captive M6 x 45 screws using a 5 mm allen wrench Figure 35 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 SE505 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 mounting p...

Page 50: ...ardware Manual 5 Connect the flat white Camera Link cable to the connector on the back of the sensor and tighten the two small screws Figure 36 Sensor Cable Connections Camera Link cable connection Illumination Control cable connection ...

Page 51: ...Note Make sure the strain relief nut is fully tightened Figure 37 Rear Electrical Panel 4 Feed the incoming power lines through the strain relief connector 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 SE505 system...

Page 52: ... of the wire into the connector 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 SE505 does not comes with power cord PE PE PE N2 L2 PE N1 L1 N L N blue L brown GND ...

Page 53: ...tch on the front of the system 4 Release the E Stop button 5 Press the green start button to restart Figure 39 AC Main Circuit Breaker CB1 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 SE505 system the internal processor initializes...

Page 54: ...ide 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 40 Connecting to the Air Regulator Turn this knob to set air pressure Quick connect fitting Back Electrical Panel i Note The default settin...

Page 55: ...e information refer to Shutting Down the System on page 59 Figure 41 SMEMA Connectors 3 Route the SMEMA cables under the SE505 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 3 4 Board Available Board...

Page 56: ...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 59 3 Connect the network cable to the Ethernet connection located on the rear electrical panel Figure 42 Network Connection Configuring the LAN Connection Use the Windows network tools to complete the Ethernet configuration This is typical...

Page 57: ...electrical power to the system For more information refer to Shutting Down the System on page 59 3 Connect the external device to the digital input output connection on right side of the rear electrical panel Figure 43 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 ...

Page 58: ...ption 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 44 WAGO PLC Assembly Warning The maximum current of the supply module is 6 3 A When config...

Page 59: ...ed To 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 45 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 th...

Page 60: ... 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 Bar H9 mm...

Page 61: ...ith ou1 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 disp...

Page 62: ...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 SE505 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 to allow access ...

Page 63: ...sers 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 password 11 Click to clear the User must change...

Page 64: ...operties 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 65: ...ows group members to save changes to the panel SRFF file and the Standard Definition Library DEF file Teach and Solder Paste Inspection SE505 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 Solder Paste Ins...

Page 66: ...window without making changes When you click OK your changes are saved to a file named SE505 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 Allows grou...

Page 67: ...s 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 15 µm 0 59 mils 8 0 µm 0 31 mils Volume 10 10 AverageMeasuredHeight Certi...

Page 68: ...3 T 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 ...

Page 69: ...h on the front of the unit This removes all power from the system with the exception of the processor power Figure 46 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 main circuit b...

Page 70: ...cables if used Bypassing the SE505 System The SE505 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 of the unit 2 T urn off all electrical power to the syste...

Page 71: ...ssing the System 6 Replace the lower font panel and close the hood 7 Restore system power Bypass switch Safety Interlock 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 72: ...Chapter 3 Installation 62 SE505 Hardware Manual ...

Page 73: ...Optics Corporation 4 Replacing Components and Preventive Maintenance Maintenance Schedule 64 Main Electrical Panel 65 Processor Components 77 Conveyor Components 98 Gantry Components 132 Other Components 155 ...

Page 74: ...fer to the section Shutting Down the System on page 59 Maintenance Monthly Annually Page Cleaning Rear Fans Every 3 months 74 Clean Inside of the Enclosure Every 3 months 75 Clean the Main Electrical Panel Every 3 months 75 Clean the Air Regulator Filters Every 3 months 76 Clean Inside of the Processor Every 3 months 96 Cleaning the Panel Sensors Every 3 months 122 Cleaning the Encoder Strips Ever...

Page 75: ...lectrical panel by removing two screws that secure the lower front panel to the machine frame 5 Identify the part to replace see Figure 49 on page 66 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 48 DIN Rail Mounting 8 Hook th...

Page 76: ...city Use a ground strap when handling the board to prevent damage to sensitive components SMEMA SYSTEM TOWER Z W B X MM Y PS1 PS2 PS3 K1 6 0A 6 0A 6 0A 6 0A 10 0A 10 0A 10 0A Middleman PCB Assembly X Stage Servo Amp Y Stage Servo Amp Z Stage Servo Amp Conveyor Width Motor Controller 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 CB...

Page 77: ...013775 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 8013220 AC PC 8013220 AC LCD 8013220 AC PC 8013220 AC 8013355 8012783 USB Power Switch Cable Trunking 8013365 PE Cable trun...

Page 78: ...that AC main power 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 51 on page 69 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 Haza...

Page 79: ...imp the conductor d Pull the wire to ensure 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 Screwdrive...

Page 80: ...ing refer to Table 11 4 T urn the AC main circuit 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 pro...

Page 81: ...WER Z W B X MM Y PS1 PS2 PS3 K1 6 0A 6 0A 6 0A 6 0A 10 0A 10 0A 10 0A Middleman PCB Assembly X Stage Servo Amp Y Stage Servo Amp Z Stage Servo Amp Conveyor Width Motor Controller 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 Fuses ...

Page 82: ...it 7 Using an 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 pr...

Page 83: ...n Shutting Down the System on page 59 Figure 54 Location of Fans 2 Remove the metal fan guard by removing four M4 x 40 screws 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 Fans Back Electrical Panel ...

Page 84: ...refer to the section Shutting Down the System on page 59 2 Locate the fans on the back electrical panel Figure 55 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 electron...

Page 85: ...o the system For more information refer to the section Shutting Down the System on page 59 2 Open the hood on the SE505 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 electronics panel 6 R...

Page 86: ...System on page 59 2 Open the front door of the machine 3 Locate the air regulator inside SE505 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 56 Air Regulator ...

Page 87: ...ons on the rear of the processor 7 Remove processor cover by sliding the cover plate back toward the rear connectors 8 Disconnect any internal cables from the card 9 Remove the screw holding the card to the processor case 10 Gently slide the card out of the processor case 11 Slide the new card into the processor case gently pushing it into place until it seats firmly in the backplane connector 12 ...

Page 88: ...stallation 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 During installation there will be an option for users to configure the machine accordingly i e SE505 configuration 4 After installing the software restart the computer CANOpen Interface card USB Ports Frame...

Page 89: ...f 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 79 Use the Acronis Boot Disk and the SE505 Recovery Disk when the hard drive has been replaced or the hard drive cannot be accessed see To Boot from...

Page 90: ...ive Maintenance 80 SE505 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 91: ...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 92: ...s 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 93: ...CyberOptics Corporation 83 Processor Components 7 Click Next to continue 8 Make sure all checkboxes are not selected Click Next to continue ...

Page 94: ...Chapter 4 Replacing Components and Preventive Maintenance 84 SE505 Hardware Manual 9 Click Proceed to continue 10 The Backup operation is now in progress Do not close the window ...

Page 95: ...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 2 Click Acronis True Image Full Version 3 Click Recovery under Pick a Task options and the click Next to continue ...

Page 96: ...and Preventive Maintenance 86 SE505 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 97: ...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 98: ...d Preventive Maintenance 88 SE505 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 99: ...oration 89 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 100: ... Preventive Maintenance 90 SE505 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 101: ... 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 102: ...4 Replacing Components and Preventive Maintenance 92 SE505 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 103: ...ion 93 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 104: ...e 94 SE505 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 105: ...CyberOptics Corporation 95 Processor Components 9 Click Proceed to continue 10 The Backup operation is in progress Do not close the window ...

Page 106: ...rn off all electrical power to the system For more information refer to the section Shutting Down the System on page 59 2 Open the hood on the SE505 3 Make sure all motion has stopped 4 Remove two screws that secure the lower front panel to the machine frame 5 Remove two screws at the top of the processor that secure it to the machine frame 6 Gently slide the processor part way out of the machine ...

Page 107: ... the machine frame 5 Lift the air filter up and out from the front of the processor Figure 58 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 SE505 hood Warning Make ...

Page 108: ...Wrench size 7 mm Threadlocking sealant Long Nose pliers To replace the conveyor edge guide 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 59 2 Open the hood Caution T urn the AC main circuit breaker to OFF to shut down all electrical power to the SE505 unit before replacing any parts or components For more information refer...

Page 109: ...e in a counter clockwise direction Figure 59 Lock Plates at front clamp assembly 5 Loosen the two screws located at the blade holder using Allen key No 2 5 Figure 60 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 61 Springs at blade holder Right hand lock plate Left hand lock pl...

Page 110: ...ight hand lock plate 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 Use steps 1 8 of the procedure for replacing the conveyor belt Refer to the section Replacing the Conveyor Belts on page 111 Replacing the edge guide at rear cla...

Page 111: ...4 Allen Key Ball Pein 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 59 2 Remove all the M4 screws on the top of the blade holder Figure 63 Blade Holder and clamp blade 3 Remove and replace the old clamp blade with a new one 4 Measur...

Page 112: ...tion 1 Loosen the clamp blade by turning the screw in a counter 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 0 6 1 0 mm 3 Tighten all the five blade mounting screws 4 T est the clamper movement for up down binding and i...

Page 113: ... 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 65 Conveyor Clamp Air Connections 6 Wrap teflon tape twice around the brass end of the reducer leaving the first thread exposed 7 Attach ...

Page 114: ... the conveyor clamp cylinder Figure 66 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 th...

Page 115: ...arts 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 67 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 68 Conveyor Clamp Cylinder i Note Fo...

Page 116: ...cylinder 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 ass...

Page 117: ...ools 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 59 2 Use steps 1 9 of the procedure for removing the conveyor belt Refer to the section Replacing the Conveyor Belts on page 111 3 Loosen the mounting screws from the motor Figure 70 Conveyor Motor 4 Remove the grounding cabl...

Page 118: ...ulley drive by using Allen key No 2 5 Figure 73 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 111 11 Reverse the process to reassemble ...

Page 119: ...ne is not in the production line Parts DC Brushless Motor Required Tools No 3 Allen key No 2 Allen key No 8 Spanner To replace the Autowidth Motor 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 59 2 Open the hood 3 Make sure all motion has stopped 4 Loosen the four nuts by using spanner No 8 5 Remove the two screws by using...

Page 120: ... belt from the pulley 7 Remove the whole unit of the motor plate with the motor 8 Completely remove the screw from the motor 9 Replace with a new motor and tighten back the motor to the gear box with motor plate as shown 10 Push the motor plate away from the width adjust direction in order to give tension to the timing belt 11 Tighten the motor with the four nuts and two screws ...

Page 121: ...on page 59 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 74 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 both ends 9 Remove the ...

Page 122: ...arts Autowidth Timing belt Manual width drive belt Required Tools No 3 Allen key No 2 Allen key To replace the autowidth 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 59 2 Perform step 1 6 for removing the auto width motor Refer to the section Replacing the Autowidth Motor on page 109 3 Loosen the three screws f...

Page 123: ...dth Adjust 9 Tighten with screws at 6kgf 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 59 2 Loosen the screw from the wheel plate by using Allen key No 4 Figure 75 Wheel Plate 3 Push the wheel plate towards to cylinder direction in order to loosen the tension from the timing belt Figu...

Page 124: ... Shaft Guide and Drive Pulleys 5 Remove the timing belt from the motor drive pulley Figure 78 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 125: ...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 59 4 Open the front cover from the machine 5 Loosen the setscrew using Allen Key No 2 5 Figure 79 Idler Pulley And Front Conveyor Belt 6 Remove the Idler pulley from the rail and replace 7 Do not loosen t...

Page 126: ...starting to strengthen Figure 80 Idler 2 Make a line marking by using the ruler in line with the slot nut Figure 81 Slot nut 3 Place a ruler in line with the marking initial marking from Figure 81 from the ruler reading measure the distance length at 22 mm Figure 82 Marking with ruler 4 Mark a line with the ruler as shown in Figure 82 and start to push the Idler forward until it reaches the 22 mm ...

Page 127: ...ler 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 motor ...

Page 128: ...l electrical power to the system For more information refer to the section Shutting Down the System on page 59 2 Remove the four mounting screws and sensor slide bracket on the board sensor as shown in Figure 84 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 129: ...CyberOptics Corporation 119 Conveyor Components Figure 84 Board Sensors on Conveyor Handwheel Mounting screws Board sensor Sensor bracket Board sensor ...

Page 130: ...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 59 2 Open the cover 3 Make sure all motion has stopped 4 Remove the centre lifter plate 5 Remove the four screws on the...

Page 131: ...h 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 SE505 Solder Paste Inspection Software User Guide Part Number 8015918 ...

Page 132: ...Down the System on page 59 2 Open the SE505 hood 3 Make sure all motion has stopped 4 Use a dry soft cloth with household glass cleaner 5 Gently wipe the panel sensors lenses Figure 85 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 ...

Page 133: ...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 59 2 Make sure the machine is OFF and the rails are in HOME position 3 Unscrew the two thumb screws Figure 86 Stopper Sensor Bracket Thumb screws 4 Remove the stopper sensor bracket from the conveyor Re tightened the thumb scre...

Page 134: ...505 Hardware Manual 6 Use a cutter to cut the cable tie Figure 88 Stopper Cable tie Figure 89 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 90 Stop Spacer Cutter Allen Key No 2 5 ...

Page 135: ...ing cylinder from stopper bracket Figure 92 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 93 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 136: ...inder top edge Apply loctite to the bolts Figure 94 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 95 Figure 95 Left side conveyor rail assembly 12 Mount the completed stopper bracket assembly to the left side conveyor rail Tighten with wing nut Figure 96 Mounting stopper bracket assembly Slot nuts x 2 Thum...

Page 137: ...op spacer and Top cap Figure 98 Relocation of mechanical board stop completed 14 Tidy the cable routing with cable tie onto the cable mount Figure 99 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 131 Top Cap Stop spacer ...

Page 138: ...ual To relocate the Slow Down Sensor 1 Loosen the slot nut as shown in Figure 100 to adjust the slow down sensor position Figure 100 Slow Down Sensor Location 2 Use a cutter to cut the cable tie Figure 101 Cable Tie 3 Disconnect the connector Figure 102 Connector Slot Nut Connector ...

Page 139: ...omponents 4 Re route the existing wiring route Figure 103 Re routing the wiring 5 Move the slow down sensor from left hand side to right hand side Figure 104 Moving slow down sensor 6 Re connect the connector Figure 105 Re connect Connector ...

Page 140: ...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 106 Setting Distance for slow down sensor Figure 107 Relocation of slow down sensor completed 52 mm plate ...

Page 141: ...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 142: ...uction line This section shows the procedure performed when the machine is not in production line Parts Forcer Required Tools 1 4mm spacer Threadlock Sealant Caution T urn the AC main circuit breaker to OFF to shut down all electrical power to the SE505 unit before replacing any parts or components For more information refer to the section Shutting Down the System on page 59 i Note For Parts Repla...

Page 143: ...o the system For more information refer to the section Shutting Down the System on page 59 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 144: ...n 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 sensor ...

Page 145: ...tor 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 59 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 Caut...

Page 146: ...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 mu...

Page 147: ...CyberOptics Corporation 137 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 148: ...ot in the production 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 59 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 i Note For Parts Replacement contact CyberOptics for part number...

Page 149: ...cs Corporation 139 Gantry Components 4 Remove the D Sub connectors 5 Remove all the screws attached to the right endplate 6 Remove the encoder grounding cable and D sub connector Grounding Cable D sub connector ...

Page 150: ...e two endplates 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 screws screws screws screw Left Side endplate screw Right Side endplate screw X axis i Note For more information on system ali...

Page 151: ...section Shutting Down the System on page 59 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 59 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 152: ... 4 Locate the encoder strips on the X and Y axes 5 Remove any coarse or abrasive particles with clean dry compressed air To replace the encoder strips 1 T urn off all electrical power to the system For more information refer to the section Shutting Down the System on page 59 2 Remove all screws on both sides of the stage 3 Remove the side plate Warning Make sure the system power is turned off and ...

Page 153: ...CyberOptics Corporation 143 Gantry Components 4 Loosen the screw on the encoder bracket and remove the encoder 5 Remove the encoder strip Encoder Bracket ...

Page 154: ...th 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 145 for the procedures Standard Tooling kit Encoder Strip ...

Page 155: ...ormation refer to the section Shutting Down the System on page 59 2 Open the SE505 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 108 Figure 108 Encoder carrier screws 6 Insert a RENISHAW 0 8 mm spacer between the read head and the scale Contact CyberOptics for the part number of the REINSHAW spacer 7...

Page 156: ...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 157: ...ation refer to the section Shutting Down the System on page 59 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 109 Each stage X and Y has four grease fittings two on the front and two on the rear Figure 109 Grease Fittings 4 Using a grease gun with a tapered nozzle fitting pump grease into each fitting until grea...

Page 158: ... in the center of the sensor mounting plate as shown in Figure 110 Figure 110 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 Reconnect ...

Page 159: ...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 59 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 160: ...ne 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 59 2 Remove the right or left side carrier 3 Set at target within 5 μm for the reference guideway 4 Set a target within 5 μm for the foll...

Page 161: ...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 59 2 Place the square granite ruler and indicators Contact CyberOptics for the part number of the granite ruler and indicator 3 Make Y axis as the reference 4 Set a target within 5 μm and adjust the X Axis Granite Ruler Indicators Y In...

Page 162: ... to the section Shutting Down the System on page 59 2 Open the SE505 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...

Page 163: ...or Figure 111 Mounting Plate on the Z Stage Figure 112 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 164: ...anual To check rotational alignment This procedures are done after the replacement of the sensor 1 Select the desired fudicial 2 Run the inspection 3 Go to T ools System Alignment Camera Rotation 4 The Result field in the System Alignment dialog indicates if adjustment is needed ...

Page 165: ...n off all electrical power to the system For more information refer to the section Shutting Down the System on page 59 2 Open the SE505 hood 3 Make sure all motion has stopped 4 Remove the screws to take off the cover to the safety interlock switch Figure 113 Safety Interlock Switch Access 5 Disconnect the six wires in the box Caution T urn the AC main circuit breaker to OFF to shut down all elect...

Page 166: ...all the cover onto the safety interlock switch Figure 114 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 Adju...

Page 167: ...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 SE505 with the conveyors For more information refer to the section Positioning Leveling the SE505 System on page 35 for details Figure 115 Leveling Foot Locking nut Adjustment...

Page 168: ...Chapter 4 Replacing Components and Preventive Maintenance 158 SE505 Hardware Manual ...

Page 169: ...erOptics Corporation 5 Troubleshooting Safety Circuit Block Diagram 160 AC and DC Distribution Block Diagram 161 SMEMA Connector Pinout 162 System Error Messages 163 Solder Paste Failure Causes 164 SOS 166 ...

Page 170: ... RQWDFWRU 3DJH 5 3 0RWRU HOW 0RWRU LGWK 0RWRU 0LGGOH 0DQ 6HUYR ULYH 3 0 0 0 93 35 3 0LGGOH 0DQ 3DJH 3 3 3 3 3 3 3 3 3 7R LR RQWUROOHU RQYH RU RQQHFWRU 17 5 2 6723 6 0LVF 6 3XVK XWWRQ 3DQHO SHEET 2 OF 5 1 1 5B 1 1 1 3 1 0RGXODU UDQFK 386 EXWWRQ PRGXODU EUDQFK 3URFHVVRU LVW 3DJH LVW 3DJH HOW 6HUYR ULYH 3 0 0 0 93 35 3 3 EHU2SWLFV RUS ZJ 1R 6FKHPDWLF 6 VWHP OHF 6 6 6 FS 6 5HY LGWK 6HUYR ULYH 3 0 0 0 ...

Page 171: ...CyberOptics Corporation 161 AC and DC Distribution Block Diagram AC and DC Distribution Block Diagram SE505 AC DC Power Distribution ...

Page 172: ...ommunicate with the upstream and downstream conveyors For more information about SMEMA cables refer to Connecting SMEMA Cables on page 45 SMEMA Connector Pin Upstream Cable Downstream Cable 1 2 Machine Ready 3 4 Board Available Board Available 7 8 Failed Board Available Failed Board Available 1 3 4 7 8 11 12 14 2 ...

Page 173: ...irectory 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 Mess...

Page 174: ...ntamination 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 b...

Page 175: ...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 176: ... 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 s...

Page 177: ...replacing 68 Circuit breakers description 20 Cleaning inside enclosure 75 main electronics panel 75 rear fan 74 Computer requirements 28 Connecting air supply 44 power 41 signal light pole 34 SMEMA cables 45 to network 46 Contacting CyberOptics ix Control buttons description 14 Controlling access setting up security 52 Conveyor adding a separate conveyor 47 adjusting width 49 description 18 manual...

Page 178: ...ling feet adjusting 35 38 description 14 location 15 repair 157 Lockout SE505 4 M Main Electrical Panel Main 65 Main electrical panel description 18 Maintenance preventive 74 Mechanical board stop description 22 Middleman PCB assembly description 20 Monitor description 14 location 15 Motor controller description 20 Motor conveyor replacing 107 Motors drive description 22 Movable rail motor control...

Page 179: ...curity setup 52 Sensor description 18 installation 39 Sensors panel description 22 Serial connector 16 Service email ix Servo amps description 20 Shutting down the system 59 Signal light pole attaching to system 34 description 14 indicator lights 6 location 15 SMEMA connector description 16 location 17 pinout 162 SMEMA connecting cables 45 Software Upgrades 78 SOS Application 164 Specifications pe...

Page 180: ...Index 170 SE505 Hardware Manual ...

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