Chapter 4 - Keysight
Contents
1. 95 5000 0088 MVT TROUBLESHOOTING Monitors are not Operating Are they switched on and plugged in Check MCB Q9 is on for the video monitor and MCB Q10 is on for the text monitor Check cables for tight connections If UPS installed make sure that it s switched on Refer to PC manual for further information PC is not Operating Is it plugged in and switched on Check MCB Q8 is on If UPS installed make sure that it s switched on For further information consult manual Lighting head PSU is not Operating GS 1 and GS 1 only Is it turned on Check MCB Q11 Has the connector to the lighting head become loose Has the connector at the unit become loose Has the bulb blown Is the internal fuse on the unit blown Camera will not Operate Check 12V PSU Check MCB QA is on Check 12V DC at terminal E1 amp E2 Check cable to lighting head Check all connections Check software configuration For further information consult manual 5000 0088 96 TROUBLESHOOTING MVT 5 5 Pneumatics For the locations of terminals relays PLC displays PSUs and MCBs refer to Electrical Schematic Drgs 2005 0117 0118 depending on whether you have a single or dual lane system No Air supply e Check source of air e Check air pressure is set at 5 bar at regulator e Check E stop is not pressed or safety relay is engaged Dump valve will not function Check air pressure is set to 5 bar at regulator2. Clean the PC filter Check operation and direction of motor controller fan 75 5000 0088 MVT MAINTENANCE Check operation and direction of PC fans Inspect and clean camera lens Observe one board cycling through the machine Overall Comments on System Actions Required 1 2 5000 0088 76 MAINTENANCE MVT Site Completion Date System System Serial Type Number Monthly Maintenance Schedule Performed by Good Comments and or Corrective Action Bad if necessary Inspect El Control Panel Inspect mains transformer Clean optical sensors ime Examine cables to PC I Examine cables to the XY table controller Test E Stop and door interlock Test clamping and stop mechanisms Test E Stop reset switch Test System cycle Inspect pneumatic panel Inspect connections to XY table 77 5000 0088 MVT MAINTENANCE FLT eT WA MEN NN pe ie luc NAME EE WA MN RE ic NEN NN NE hae ME EM posee cde Conveyor Inspect conveyor belts Test all sensors Clean belts Examine crown bearings for wear and dirt Pneumatics Check the systems pressure settings Test dump valve Test solenoid valves 5000 0088 78 MAINTENANCE MVT Test airflow to lighting head Test pressure sensor Wipe down the machine panels Clean the PC filter Check direction of motor controller fan Check operation and d
3. 1 Isolate machine from mains supply Take off all side panels and physically check all electrical connections on the machine Main control panel X Y Table PC Motor Controller Pneumatic control panel Transformer if fitted Lighting head power supply unit uuu All connectors 2 Check the insulation resistance of the mains voltage supplies Follow this procedure carefully Only a qualified technician can carry out this test Power off the machine Switch off the main isolator Disconnect the mains plugs to the monitors PC Motor controller and lighting head PSU Disconnect the 220V side of the following PS1 PS2 PS3 and the PLC Leave the loose wires apart and not touching Using an insulation resistance tester NOTE THIS IS 500V DC check between LI and earth There should be a reading of gt 1 M ohm 4 0 4g i Then check between N1 and earth It should have the same reading Check again to ensure all equipment stated above is disconnected 61 5000 0088 MVT MAINTENANCE C Check the reading for cable 14 to earth then cable 13 to earth and finally cable 13 to 14 Again the reading should be 1M ohm This test will give an indication that the insulation resistance of the cables and mains supply to the body of the machine is intact and complies with the relevant standards 3 Open the transformer panel and check the condition of the transformer refer to fig 2 1 Examine it for any of
4. Check emergency stop is off Check for indicator light on valve Check 24V supply at terminals 1 and 2 in the pneumatic panel Stops will not engage Refer to Electrical Schematic Drgs e Check that the Module 3 PLC outputs 10003 rail 1 or 10007 rail 2 is on Check solenoid valve YV2 or YV4 is on Check air supply is on Check dump valve YV1 is energised examining the indicator light Check 24V supply at terminals 3 and 4 in the pneumatic panel Check for kinks in the tubes Clamp will not engage Refer to Electrical Schematic Drgs e Check that the Module 3 PLC output 10004 or 10008 is on Check solenoid valve YV3 is on Check air supply is on Check dump valve YV1 is energised examining the indicator light Check 24V supply at terminals 5 and 6 in the pneumatic panel and at terminals 6 and 10 for conveyor 2 Check for kinks in the tubes e Check PLC input 00001 is on clamping enabled 97 5000 0088 MVT TROUBLESHOOTING No purge on lighting Head e Check air supply at the regulator e Check for kinked tubes e Check for air leaks No purge to X Y table e Check Dump valve e Check air supply at the regulator e Check for kinked tubes e Check for air leaks Laser will not operate SP 2 or No Inspection Signal Check side doors are closed PLC Inputs e 107 OFF e 108 ON e 109 OFF e 1100N Check stops and clamps are on PLC Inputs e 007 ON e 008 OFF e 009 ON e 010 OFF Check E
5. Inspect and clean camera lens Cycle a PCB through the machine Overall Comments on System Actions Required 1 2 3 5000 0088 82 MAINTENANCE MVT Location Completion Date System System Serial Type Number Yearly Maintenance Schedule Performed Good Comments and or Corrective Action Bad if necessary Inspect El Control Panel Inspect mains transformer Clean optical sensors Examine cables to PC ME Examine cables to the XY table controller Test clamping and stop mechanisms Test E Stop reset switch p Test E Stop and door interlock Check connections to terminals and solenoid valves Inspect connections to pneumatic panel Inspect connections to XY table 83 5000 0088 MVT MAINTENANCE Check connections to control panel WM dM a AI Test system insulation resistance p NE EE reais Eu XYTbe SSS pd MENS N pou WA pem gu i ca NN ud EMEN NE dM MM MEE pone cc Pere NE NEM pors 9 LLL bolts AA BEEN ENS pp Conveyor Examine moving parts 5000 0088 84 MAINTENANCE MVT Inspect conveyor belts Test all sensors Clean belts Examine crown bearings for wear and dirt Lubricate the motor drive shaft Lubricate conveyor linear bearings Inspect electrical connections Check mounting screws E Check motor cable insulation resistance Check the systems pressure settings Test dump valve Test solenoi
6. Position Pre placement in the SMT manufacturing process Facilities Electricity 220V 20A or 110V 40A Air Requirements Clean filtered air at 5 Bar 12 mm input line Operating 10 to 35 degrees C Temperature Physical Characteristics Footprint 1000mm x 1200mm or 1200 mm x 1200 mm Height 1450mm excluding light tree Weight 1500 kg approximate 5000 0088 104 SYSTEM SPECS OMVT 6 3 GS 1 Functional Specifications Software System Operating system User Interface Data Transfer Interfaces Hardware System Computer System Host Communications CAD File Formats Imaging Hardware Camera System X Y Robot System Windows NTTM V4 00 Graphical User Interface with password protected user levels Any ASCII file format via floppy disk or Ethernet TCP IP or MS Network High Speed Pentium II based PC in an industrial rack Thin wire or twisted pair Ethernet supporting TCP IP or MS Network Depending on the inspection application the SJ Series requires CAD from a number of sources Generally these will be Gerber file format or any ASCII based CAD file format such as Fuji etc Filters available for GC Place Unicam FABmaster and CIMbridge 97 PCI Bus framegrabber Camera CCD 1280 x 1024 pixels Electronic Shutter Optics Telecentric gauging lens Field of View 26mm x 20mm a Pixel Size of 20m Illumination Multi layer LED Gantry robot system with linear motors and
7. dual stage Functionality Measurements Board wide X Y and 9 100 2D coverage Per pad X Y Area 10096 2D coverage Height Volume sampled 3D coverage Bridge detection Target Gauging R amp R 2D 15um for X Y Offset lt 10 on pad Capability area with a process width of 20 of the nominal area 3D Heigth 5mm lt 10 on pad volume with a process width of 30 of the nominal volume 5000 0088 108 SYSTEM SPECS MVT Speed 2D 18 cm 2 8 in per second of operation 3D The speed of measurement is dependent on the pad size and is typically 32mm x 4 5mm sec scan for larger pads deposits Ability to inspect multiple uBGA CSP rows in one scan Position Pre placement in the SMT manufacturing process Facilities Electricity 220V 20A or 110V 40A Air Requirements Clean filtered air at 6 Bar 6mm input line Operating 10 to 35 degrees C Temperature Physical Characteristics Footprint 1000mm x 1200mm or 1200 mm x 1200 mm Height 1450mm excluding light tree and monitors Weight 1500 kg approximate 109 5000 0088
8. linear encoders Travel 590mm x 490mm or 490mm x 490mm Velocity x y 1500mm 60 Sec Encoder Resolution 1 25um 105 5000 0088 MVT SYSTEM SPECS Board Clearance e Depends on application Either 28mm as standard or 12mm with low level lighting fitted Conveyor System SMEMA standard conveyor supplied with speed adjustment Position Post Placement Pre Reflow in the SMT Manufacturing Process Enclosure The enclosure is designed to conform to CE Mark standards for electrical and mechanical industrial safety Auto width adjustment available as option Supply Facilities Electricity e 200 240V 25A 100 120V 40A Air Requirements e Clean filtered air at 5 Bar 12 mm or 6mm input line Operating Temperature e 10to35 C Footprint e j000mmx 1200mm or 1200 mm x 1200 mm Height e 450mm excluding light tree and monitors Weight e 1500 kg approximate 5000 0088 106 SYSTEM SPECS OMVT 6 4 SP 2 Functional Specifications Software System Operating system User Interface Vision Algorithms Data Transfer Interfaces Statistical Analysis Hardware System Computer System Host Communications CAD File Formats Imaging Hardware Windows NT V4 00 Graphical User Interface with password protected user levels 2D Sub pixel region boundary analysis for area and offset information 3D Laser triangulation technique employing a proprietary sensin
9. 0108 amp 00110 are on while working on conveyor 2 e To see if sensors are operating examine the indicator light on each sensor check it is set in the right position As per 4 1 above System will not give failed signal to downstream machine Refer to Electrical Schematic Drgs e Check Opto 23 output is pulsed after a PCB has failed inspection e Check that the Module 1 PLC input 00015 is pulsed after the inspection e Check that the Module 1 PLC inputs 00007 amp 00009 are off and 00008 amp 00010 are on Similarly check that inputs 00107 amp 00109 are off and 00108 amp 00110 are on when working on conveyor 2 e To see if sensors are operating examine the indicator light on each sensor check it is set in the right position As per 4 1 above PCB stops at exit Refer to Electrical Schematic Drgs e Check that the Module 1 PLC input 00003 is on e Check SMEMA pins 1 amp 2 are shorted from the SMEMA downstream cable on the next machine 91 5000 0088 MVT TROUBLESHOOTING Conveyor 2 e Check that the Module 2 PLC input 00103 is on e Check SMEMA 2 pins 1 amp 2 are shorted from the SMEMA downstream cable on the next machine PCB will not enter next machine Refer to Electrical Schematic Drgs e Check that the Module 4 PLC output 10104 board available to next machine from rail 1 is on Also check that output 10102 board available to next machine from rail 2 is on e Check pins 3 amp 4 are short
10. 80mm or 590mm x 480mm 3D Travel 440mm x 410mm or 540 x 410mm Velocity x y 1 5 3 0m Sec Encoder Resolution 1 25um Top side 15mm Bottom side 30mm 10mm close to clamp blades 4 7mm component clearance along edge of PCB SMEMA standard conveyor supplied as standard with manual width and speed adjustment Bottom up clamping knife edge with centre post support and vacuum leveling to an overall board flatness of gt 100um gt The enclosure is designed to conform to CE Mark standards for electrical and mechanical industrial safety UL approval by Q1 2000 Bar code reader Auto width adjust GC Place software Dual lane and dual stage Functionality Measurements Board wide X Y and 9 100 2D coverage Per pad X Y Area 10096 2D coverage Height Volume sampled 3D coverage Bridge detection Target Gauging R amp R 2D 15um for X Y Offset lt 10 on pad Capability area with a process width of 20 of the nominal area 3D lt 10 on fine pitch solder paste height of 200um with a process width of 50um lt 10 on pad volume with a process width of 30 of the nominal area 103 5000 0088 MVT SYSTEM SPECS Speed 2D 18 cm 2 8 in per second of operation 3D The speed of measurement is dependent on the pad size and is typically 8 x 3mm per second for fine pitch and 16 x 3 mm per larger pads deposits Ability to inspect multiple uBGA CSP rows in one scan
11. MAINTENANCE MVT Chapter 4 Maintenance Chapter Contents 4 1 Introduction eere teer tito ooo eene er oboe na o o eene roseo ere rep 58 4 2 Electrical Maintenance cccccsccssscsssssssssssccessssseees 58 4 3 X Y Table Maintenance erroe eee eee eene eee ettn nane e tao 63 4 4 Conveyor Maintenance eee eee ee e eee eee eee te sten seen ns 66 4 5 Pneumatic Maintemanc cccccccccscscscsssssscssccsccsssssees 67 4 6 SP 2 Additions cccdsssscvsscescecscccdsosscasecoovsssosossceseossesees 69 4 7 General Maintenance cccccccccccsssssecscssccssssssssecsccsessssess 73 Appendix I Requirements Listing sssseeseeseese 73 Appendix II Maintenance Checklists 74 Summary This chapter describes a maintenance schedule for the inspection system Where possible it refers to the electrical schematic drawing numbers that describe the circuits involved They are contained in a 57 5000 0088 MVT MAINTENANCE separate document This schedule must be strictly adhered to and be performed only by qualified personnel 4 1 Introduction Maintenance is divided into weekly monthly quarterly and yearly schedules It is also divided into five main sections each covering an area on the machine These areas are as follows e Electrical Maintenance e X Y table Maintenance e Conveyor Maintenance e P
12. al Schematic Drgs e Check 24V supply across the relay terminals A1 A2 e Check emergency stop and door interlock is functioning correctly This can be done by checking the continuity across terminals 35 and 36 for circuit no 1 and across 37 and 38 for circuit no 2 There are three indicator lights on the safety relay The top light represents power on and the bottom ones represent circuit no 1 and circuit no 2 respectively When the three lights are on this means that the relay is functioning correctly e Check that all contacts and terminations are intact e Check the software key press Opto 19 activates reset circuit see is it being pulsed e Check reset circuit activated by the hardware push button that shorts out terminals B39 and B40 on the control panel e Ifthe emergency stop is on and there is no indication on the monitor screen check Opto 4 X Y table motor controller not Operating e Is MCB Q7 on e Is the local on off switch in the on position e Is there an emergency stop condition Examine the three indicator lights on the safety relay e Are the safety circuit contacts functioning correctly To do this disconnect cable SLC24 going into the motor controller There are three pairs of pins With the emergency stop off check that the continuity between these pins are Pins 2 and 10 Pins 11 and 12 Pins 13 and 14 e Check all cables are tight and in position e For further information consult Aerotech manual
13. anism back SQ4 OFF SQ5 ON gt Stop mechanism up SQ6 ON SQ7 OFF gt Stop mechanism down SQ6 OFF SQ7 ON If the system has up lift clamping then follow this sequence C Clamp mechanism up SQ4 ON SQ5 OFF C Clamp mechanism down SQ4 OFF SQ5 ON gt Stop mechanism up SQ6 ON SQ7 OFF gt Stop mechanism down SQ6 OFF SQ7 ON Release the E Stop and press the reset switch 5000 0088 MVT MAINTENANCE Figure 4 1 The System Conveyor Schematic 13 Cycle a board through the machine and watch its operation for any faults Monthly 1 Carry out weekly routine 2 Open the pneumatic panel and check the terminals and solenoid valves connections refer to fig 4 4 Quarterly 1 Carry out monthly routine 2 When inspecting the control panel check the tightness of the connections at random The following points below Changing the lighting head fluorescent tube only applies to the GS 1 system 3 Change the lighting head fluorescent tube life span of bulb is 2000hrs To replace the bulb do the following gt Open main window and remove the push on bulb cable C Release the 2 x M3 grub screws clamping the metal bulb end 5000 0088 60 MAINTENANCE MVT gt Gently pull the bulb downwards away from the bulb holder to remove bulb from bulb clips C Reverse this procedure to install new bulb Caution The bulb may still be hot Allow 15 minutes cool down time before removing it Yearly
14. ays PSUs and MCBs refer to Electrical Schematic Drgs 2005 0117 0118 depending on whether you have a single or dual lane system Power failure or no power response Is the main supply connected Is the main isolator in the ON position Are the main circuit breakers in the ON position Is the Power On light illuminated Is the key switch in the ON position Check MCB Q15 is on Is the mains contact energised Check the supply voltage at the main terminals Mains transformer is not working Check MCB Q2 is on Check main MCB Ql is on Ensure there is the customer selected voltage at terminals L1 and N1 Ensure there is 230V at terminals L2 and N2 Check transformer resistance 21 ohm at terminals L1 and N1 WARNING ENSURE MACHINE IS FIRST ISOLATED FROM MAINS SUPPLY Check transformer resistance 21 ohm at terminals L2 and N2 WARNING ENSURE MACHINE IS FIRST ISOLATED FROM MAINS SUPPLY Check cables and terminals at transformer are intact 5000 0088 88 TROUBLESHOOTING MVT 5 2 Conveyor For the locations of terminals relays PLC displays PSUs and MCBs refer to Electrical Schematic Drgs 2005 0117 0118 depending on whether you have a single or dual lane system Conveyor will not run Refer to Electrical Schematic Drgs Check that the conveyor is not obstructed Check MCB Q14 is on Check emergency stop is in the off position Examine the three indicator lights on the relay e Chec
15. d valves Test airflow to lighting head Test pressure sensor Check air purge motors replace main air filter 85 5000 0088 MVT MAINTENANCE Wipe down the machine panels Clean the PC filter Check direction of motor controller fan Check operation and direction of PC fans Inspect and clean camera lens a Observe one board cycling through the machine Overall Comments on System Actions Required 1 2 3 5000 0088 86 TROUBLESHOOTING MVT Chapter 5 Troubleshooting Guide Chapter Contents S1 System POWEL aa 88 TO CONVEY OF EAT TE 89 5 3 PCB Inspection Sequence ssss0esses0eeseesoesoeee 90 5 4 Other Electrical cscssssscssccecsssccssescssessssenesesssseneee 94 5 5 Pneumatics ssis rsss seen essen enne oa stantes enne tastes senses sous 97 Summary The Troubleshooting Guide is intended to assist the user to solve problems that they may encounter with their system It describes the sequence to follow when the system does not function within normal operating parameters We have concentrated on the failure modes that happen most frequently and with the greatest effect to productivity IE those that would cause the line to stop Use this manual in conjunction with the electrical drawings issued with the document pack 87 5000 0088 MVT TROUBLESHOOTING 5 1 System Power For the locations of terminals relays PLC displ
16. e controller 63 check the integrity of the connectors at random 5000 0088 MVT MAINTENANCE s F 5 3 V P Ea T a4 In Fig 4 2 X Y gantry schematic WARNING Failure to lubricate the stage at quarterly intervals invalidates all warranties Quarterly 1 2 E A ad a Carry out Monthly routine b Carry out the following procedure for lubricating and cleaning of the stage Turn off controller and activate the E Stop Drive the stage to one end of its travel Open door and remove side panels Remove any accumulated dust or debris from inside of the assembly 5000 0088 64 MAINTENANCE MVT 7 Vacuum clean the base of the table 8 Remove any dirty or dried lubricant from the bearing guides Figure 4 2 D Use a clean cloth with along the rails to clean the bearing guides A cotton swab soaked in solvent will suffice to remove stubborn debris 9 After the solvent has evaporated if used apply a thin continuous film of lubricant to the bearing guides A good quality natural bristle artist s brush is an excellent applicator for this 10 Lubricate the four LMG bearing trucks on each stage Figure 4 2 A See note on lubricant overleaf Use a grease gun with a grease nipple type UU or SS Figure 4 2 F 11 Refit all panels and close the door 12 Restore power to the machine Yearly Carry out quarterly routine Ta
17. eck that the Module 3 PLC output 10009 is on e Check Opto 0 is on e Check stops are in up position and that the Module 1 PLC input 00009 is on e Check clamp is in on position and that the Module 1 PLC input 00007 is on e To see if sensors are operating examine the indicator light on each sensor Check it is set in the right position Stop UP input 00009 Stop DOWN input 00010 Clamping ON input 00007 Clamping OFF input 00008 e Check that conveyor motor is not running No Module 3 PLC output 10000 on the PLC Check that the Module 3 PLC outputs 10009 amp 10010 are on Check Optos 1 amp 2 are on Check stops are in up position The Module 2 PLC input 00109 is on Check clamp is in on position The Module 2 PLC input 00107 is on 5000 0088 90 TROUBLESHOOTING MVT e To see if sensors are operating examine the indicator light on each sensor check it is set in the right position Stop UP input 00109 Stop DOWN input 00110 Clamping ON input 00107 Clamping OFF input 00108 e Check that conveyor motor is not running No Module 3 output 10005 on the PLC System will not release board Downstream Refer to Electrical Schematic Drgs e Check Opto 20 output is pulsed after the inspection e Check that the Module 1 PLC input 00011 is pulsed after the inspection e Check that the Module 1 PLC inputs 00007 amp 00009 are off and 00008 amp 00010 are on Also check that Module 2 inputs 00107 amp 00109 are off and 0
18. ed on SMEMA downstream socket PCB will not stop for inspection Refer to Electrical Schematic Drgs e Check the pass through switch is in the inspect position e Check the computer software is not in pass through e Check Opto 21 is on when the machine is in inspect mode Conveyor 1 e Check that the Module 1 PLC input 00012 is on e Check that the Module 1 PLC input 00005 is working by placing an object over the sensor and checking the input Ensure that the sensor is not positioned too far from the bottom off the board Conveyor 2 e Check that the Module 2 PLC input 00100 is on e Check that the Module 3 PLC sensor input 00105 is working by placing an object over the sensor and checking the input Ensure that the sensor is not positioned too far from the bottom off the board System will not release board to rework station Refer to Electrical Schematic Drgs e Check Opto 22 is pulsed when the board is released to the rework e Check that the Module 1 PLC input 00013 is pulsed e Check relay KAI is energised Examine its indicator light e Check emergency stop is off by examining the three indicator lights on the safety relay 5000 0088 92 TROUBLESHOOTING MVT e Check that the Module 1 PLC inputs 00007 amp 00009 are off and 00008 and 00010 are on e To see if sensors are operating examine the indicator light on each sensor Check that it is set to the correct position Stop UP input 00009 Stop DOWN inpu
19. enoid fA Solenoid y i si ai a amp Fig 4 4 Pneumatic Drawer Monthly 1 Operate the E Stop to ensure that the dump valve is operating correctly Manually operate the control solenoid valves and ensure that the stops and the clamping if installed are operating correctly Ensure that they are not sticking 3 Check the air purge to the lighting head 4 Ensure the pressure switch is operating if installed by removing the air from the system the PC should indicate this on the monitor Yearly Carry out the monthly routine as above 2 Ensure the lighting head restrictor is set to the desired airflow 3 Ensure the air purge to the X Y table is operating and that the restrictor is fully open 4 Replace the main air filter by removing the half panel above the transformer guard Ensure that the main air supply is isolated from the machine prior to replacing filter refer to fig 2 1 5000 0088 68 MAINTENANCE MVT 4 6 SP 2 Additions Pneumatics Wiring Figure 4 6 shows the pneumatic diagram for the Entry Exit doors on the SP 2 system e The doors remain open by default preventing operation of the laser If there is a loss of air pressure the doors will close slowly under their own weight with no danger of pinching or cutting e The flow control on the door open supply is set to ensure smooth low impact opening of the shields e The Pressure Regulator on the door close supply is set to a very low p
20. g system Any ASCII file format via floppy disk or Ethernet TCP IP or MS Network Mean std deviation Cp K CpK Pareto control charts based on the X Y theta area height or volume High Speed Pentium HI based PC with flat screen monitor Thin wire or twisted pair Ethernet supporting TCP IP or MS Network Gerber file format conversion with GC Place software PCI Bus framestore 2D Camera System Camera Large area CCD camera Electronic Shutter Optics Telecentric gauging lens Field of View 32 mm x 25mm Pixel Size 25um LEDs x 2 Lighting Ultra bright 3D Camera System High speed sensor system 107 5000 0088 MVT SYSTEM SPECS X Y Robot System Board Clearance Conveyor System Clamping System Enclosure Optional extras Gantry robot system with linear motors and linear encoders 2D Travel 490mm x 480mm or 590mm x 480mm 3D Travel 440mm x 410mm or 540 x 410mm Velocity x y 1 5 3 0m Sec Encoder Resolution 1 25um Top amp Bottom side 15mm Base Clearance 2 5mm 4 7mm SMEMA standard conveyor supplied as standard with manual width and speed adjustment Bottom up clamping knife edge with centre post support and vacuum leveling to an overall board flatness of 100um The enclosure is designed to conform to CE Mark standards for electrical and mechanical industrial safety Bar code reader Auto width adjust GC Place software Dual lane and
21. h MVT RS1 upstream from system e Check that the Module 4 PLC output 10102 is on e Check pins 1 amp 7 are shorted on the SMEMA upstream socket 5 4 Other Electrical For the locations of terminals relays PLC displays PSUs and MCBs refer to Electrical Schematic Drgs 2005 0117 0118 depending on whether you have a single or dual lane system Lighting tree will not operate Refer to Electrical Schematic Drgs e sit plugged in Check bulbs and sounder Check Optos 15 to 18 for relevant light or sounder Check Opto configuration on PC software refer to user manual Check connector is intact and undamaged NO 24V supply Refer to Electrical Schematic Drgs e Check 24V supply PSI looks at the indicator light e Check MCB Q3 is on e Check MCB Q16 is on 24V control MCB NO PLC inputs or outputs Refer to Electrical Schematic Drgs e Check power to PLC MCB Q6 Look at its power indication light e Check 24V supply on PLC is functioning Look at its input indication lights e Check that PLC modules are clipped together properly e Make sure that the PLC run light is on 5000 0088 94 TROUBLESHOOTING MVT Opto board not functioning Refer to Electrical Schematic Drgs e Check 5V PSU examining its indication light Check MCB Q5 is on Check Opto cable to PC has not come loose or is damaged in any way Check Opto card in PC is seated and functioning Safety relay will not reset Refer to Electric
22. ight e 1500 kg approximate 101 5000 0088 MVT SYSTEM SPECS 6 2 SP 1 Functional Specifications Software System Operating system User Interface Vision Algorithms Data Transfer Interfaces Statistical Analysis Hardware System Computer System Host Communications CAD File Formats Imaging Hardware Windows NT V4 00 Graphical User Interface with password protected user levels 2D Sub pixel region boundary analysis for area and offset information 3D Laser triangulation technique employing a proprietary sensing system Any ASCII file format via floppy disk or Ethernet TCP IP or MS Network Mean std deviation Cp K CpK Pareto control charts based on the X Y theta area height or volume High Speed Pentium HI based PC with flat screen monitor Thin wire or twisted pair Ethernet supporting TCP IP or MS Network Gerber file format conversion with GC Place software PCI Bus framestore 2D Camera System Camera Large area CCD camera Electronic Shutter Optics Telecentric gauging lens Field of View 25 mm x 25mm Pixel Size 25um Lighting LED lighting head x 2 3D Camera System High speed sensor system 5000 0088 102 SYSTEM SPECS MVT X Y Robot System Board Clearance Conveyor System Clamping System Enclosure Optional extras Gantry robot system with linear motors and linear encoders 2D Travel 490mm x 4
23. irection of PC fans Inspect and clean camera lens Cycle a PCB through the machine Overall Comments on System Actions Required 1 2 3 79 5000 0088 MVT MAINTENANCE Site Completion Date System System Serial Type Number Quarterly Maintenance Schedule Performed by Inspect El Control Panel Inspect mains transformer Clean optical sensors Examine cables to PC UN Examine cables to the XY table controller Inspect connections to XY table BE Test E Stop and door interlock Test clamping and stop mechanisms Test E Stop reset switch Test System cycle Inspect pneumatic panel 5000 0088 80 MAINTENANCE MVT Check Connections in control panel X Y Table Examine X Y table motion Examine cabling Inspect bearings E ee LN E eee NE ss eA NINE Ecole MM a E MN LI d Conveyor Examine moving parts Inspect conveyor belts Test all sensors Clean belts Examine crown bearings for wear and dirt Lubricate motor drive shaft Lubricate conveyor linear bearings Pneumatics 81 5000 0088 MVT MAINTENANCE Check the systems pressure settings Test dump valve Test solenoid valves Test airflow to lighting head Test pressure sensor General Wipe down the machine panels Clean the PC filter Check operation and direction of motor controller fan Check operation and direction of PC fans
24. k VRI rail 1 or VR2 rail 2 is not turned to zero Conveyor 1 e Check that the Module 3 PLC output 10000 is on e Check relay KAT is energised by examining its indicator light Conveyor 2 e Check that the Module 3 PLC output 10005 is on e Check relay KAS is energised by examining its indicator light Conveyor will not run no output from PLC e Referto Electrical Schematic Drgs e Check that the Module 1 PLC input 00002 was pulsed e Check that the Module 1 PLC inputs 00007 amp 00009 are off and 00008 amp 00010 are on e To see if sensors are operating look at the indicator light on each sensor check it is set in the correct position Stop UP input 00009 Stop DOWN input 00010 Clamping ON input 00007 Clamping OFF input 00008 e Check that the Module 2 PLC input 00102 was pulsed e Also check that the Module 2 PLC inputs 00107 amp 00109 are off and 00108 amp 00110 are on 89 5000 0088 MVT TROUBLESHOOTING e To see if sensors are operating look at the indicator light on each sensor check it is set in the correct position Stop UP input 00109 Stop DOWN input 00110 Clamping ON input 00107 Clamping OFF input 00108 5 3 PCB Inspection Sequence For the locations of terminals relays PLC displays PSUs and MCBs refer to Electrical Schematic Drgs 2005 0117 0118 depending on whether you have a single or dual lane system System will not inspect Refer to Electrical Schematic Drgs e Ch
25. ke off the cover of the controller and check the interior for loose connections Ensure that the internal fan is functioning 3 Using an 8mm Allen key ensures that the securing bolts on the table have not become loose Tighten to 35 Nm 310 Ibf inch Important notes on lubrication Be sure to use a clean dry soft lint free cloth for cleaning Take the time to inspect the linear motor drives for wear and signs of damage Further disassembly of the stage is NOT recommended since proper setting and calibration can only be carried out at the factory Recommended Lubricants 1 2 65 Dow Corning s Molykote 44 is recommended Only use lithium based grease 5000 0088 MVT MAINTENANCE 4 4 Conveyor Maintenance General Warnings NEVER clean with a compressed air stream It may cause dirt etc to get lodged into the motor shaft Use a vacuum cleaner to remove loose dust or dirt NEVER disassemble the motor Boardin Position Sensor Board Clamps radierts 4 100 conveyor Speed Controller Board Stops Fixed Rail Exit Sensor iB E i Conveyor Speed Adjustable Adjustable Fig 4 3 Conveyor Components Weekly 1 Check the function of the sensors by placing a sample board over them Look at the indicator light on each of the sensors 2 Check soundness of all motor housings 3 Lubricate belt motor drive shaft DO NOT leave shaft dripping with oil a light coating is all that i
26. lution and lint free cloth Ensure that the lens is securely in place while doing this Appendix I Requirements Listing 1 wani EGG SOW ut Set of Metric Hexagonal Allen keys 1 5 2 2 5 3 4 4 5 5 5 5 6 7 8 9 10 Set of insulated slotted screwdrivers 2 8 4 0 5 5 and 6 5 Pistol grease gun Natural Bristle artist s brush Lint free cloth Anti static cleaning spray Dow Corning Molykote 44 grease Fast dry precision cleaner solvent RS 203 0716 Aerosol optical instrument cleaner RS 217 3857 Megger BM101 4 Insulation resistance tester Flow rate sensor 73 5000 0088 MVT MAINTENANCE Appendix Il Maintenance Checklists Site Completion Date System System Serial Type Number Weekly Maintenance Schedule Performed by Good Comments and or Corrective Bad Actions if necessary Electrical m p CEDENS e idi RR RN Kaa WA panier Mmmm o XY table controller Xy o o o to XY gantry e a interlock Sop mchana stop mechanisms poc Test System Cycle 5000 0088 74 MAINTENANCE MVT X Y Table Examine X Y table motion Examine cabling Inspect bearings Inspect magnet platten Inspect encoder Inspect limit switches Conveyor Examine moving parts Inspect conveyor belts Test all sensors Clean belts Pneumatics Check the systems pressure settings General Wipe down the machine panels
27. mergency Stop Circuit 5000 0088 98 SYSTEM SPECS OMVT Chapter 6 System Specifications Chapter Contents 6 1 SJ 10 Functional Specifications 100 6 2 SP 1 Functional Specifications 102 6 3 GS 1 Functional Specifications eere 105 6 4 SP 2 Functional Specifications 107 Summary This chapter is intended to outline the systems specifications It includes the physical specs like footprint and electrical and pneumatic inputs as well as the software operating system These are accurate at the time of printing and are liable to change We recommend that you consult with the Functional Specifications for each system for the most up to date set of specifications 99 5000 0088 MVT SYSTEM SPECS 6 1 SJ 10 Functional Specifications Software System Operating system User Interface Data Transfer Interfaces Hardware System Computer System Host Communications CAD File Formats Imaging Hardware Camera System X Y Robot System Windows NT V4 00 Graphical User Interface with password protected user levels Any ASCII file format via floppy disk or Ethernet TCP IP or MS Network High Speed Pentium II based PC in an industrial rack Thin wire or twisted pair Ethernet supporting TCP IP or MS Network Depending on the inspection applicati
28. neumatic Maintenance e General Maintenance WARNING Maintenance must only be carried out by trained personnel 4 2 Electrical Maintenance Weekly 1 Visually inspect the electrical control panel by turning off the machine at the ON OFF switch and putting the isolator handle in the OFF position Open the back door Make sure the computer has been shutdown correctly before this is done 2 Inspect all electrical equipment on the machine for damaged contacts exposed wire cores and frayed insulation 3 Ensure there are no items in front of the transformer panel i e Check that the vent is kept clear of obstruction refer to fig 2 1 4 Clean the optical sensors with a dry cloth 5000 0088 58 MAINTENANCE 10 11 12 59 MVT Pull out the PC drawer and check the cables going into the PC ensure that they have not become loose by trying to push them in Pull out the motor controller drawer and check the cables going into the motor controller ensure that they have not become loose Inspect the X Y Table and check all cables and connectors Power back up the machine Operate the E Stop and open front window Ensure that both of these mechanisms effectively stop the machine Operate the clamping and the stopping mechanisms by manually moving the piston heads Examine the indicator LED s on the sensors to ensure that they are operating properly gt Clamp mechanism forward SQ4 ON SQ5 OFF gt Clamp mech
29. on the SJ Series requires CAD from a number of sources Generally these will be Gerber file for paste inspection format or any ASCII based CAD file format such as Fuji etc Filters available for GC Place Unicam FABmaster and CIMbridge 97 PCI Bus framegrabber Camera CCD 1280 x 1024 pixels Electronic Shutter Optics Telecentric gauging lens Field of View 26mm x 20mm a Pixel Size of 20pm Illumination Multi layer LED Gantry robot system with linear motors and linear encoders Travel 590mm x 490mm or 490mm x 490mm Velocity x y 1500mm 60 Sec Encoder Resolution 1 25um 5000 0088 100 SYSTEM SPECS MVT Board Clearance e Depends on application Either 28mm as standard or 12mm with low level lighting fitted Conveyor System e SMEMA standard conveyor supplied with speed adjustment Position e Depends on application e Post Oven Post Wave with h w modifications e Pre Oven e Pre placement in the SMT manufacturing process Enclosure e The enclosure is designed to conform to CE Mark standards for electrical and mechanical industrial safety Auto width adjustment available as option Supply Facilities Electricity e 210 240V 25A 100 120V 40A Air Requirements e Clean filtered air at 5 Bar 12 mm or 6mm input line Operating Temperature e 10to35 C Footprint e j000mmx 1200mm or 1200 mm x 1200 mm Height e 450mm excluding light tree and monitors We
30. ont door is opened IRE BLACK Figure 4 7 SP 2 Extra Wiring Schematic WIRE I c KS1 935 CH2 54 LASER CLASS 3 Al GND SV DC LASER 5000 0088 MVT MAINTENANCE e The side door inputs are fed into the PLC which closes the side doors when a board is in position and then turns on the laser When the inspection is finished the doors are opened and the laser is switched off The SP 2 system then waits for the next board PLC Inputs for SP 2 Doors TERMINAL STRIP C 24V DC GND Do hb Z B c26 rece g B c2s Sole SQ13 SQ14 XB C34 Ay XB C35 Ay XB C36 a a rl 4 e Y AD ya x cf E P23 Oe gar Hie F3 XE Kor 00107 00109 00110 w w ww w w a a a he ue mo Xo x e Ex E e a e ul D Ped S On AGS uo bz RU BI u5 zu 36 Sag 3 sca A20 ann avo B x Y D x auc awa aie auc Lot Lion uo wag uo wee uae wee Yaa via ia vja Figure 4 8 SP 2 PLC Inputs for doors schematic 5000 0088 72 MAINTENANCE MVT 4 7 General Maintenance Weekly 1 3 en Clean down the machine panels Clean the PC filter if fitted Check fan on the motor controller you should hear this fan running when the drawer is pulled fully out Check PC power supply fan is running Open the PC drawer and feel the air intake at the power supply Check PC CPU fan is running if fitted Clean camera lens Only use a proper lens cleaning so
31. ressure 0 2 0 3 MPA maximum to provide the minimum force required to assist the doors closing under their own weight Blue Tube Rear of Manifold Additional Solenoid Flow Control Blue Tubing Figure 4 5 SP 2 Pneumatic drawer 69 5000 0088 MVT MAINTENANCE I 1 PA i4 Y 6 4 T E 6 4 YL 4 Y 3 l I I 1 6 6 Y 1 hr AI AANA A as E E TTA RE za f I ps 6 6 Y La I ji I cn i pd 0000 0 0 0 1 1 1 1 1 10000 mtm mimm e 6 ED i I te emp BUE AB piue PIT A TR RRIP res Figure 4 6 SP 2 Pneumatic Wiring Schematic e The Regulator should not be adjusted except by qualified personnel as an increase in air pressure could result in injury due to the greater closing force of the doors 5000 0088 70 MAINTENANCE SP 2 Extra Wiring Figure 4 7 shows the extra wiring installed for an SP 2 system 71 MVT YV7 is the solenoid valve for the vacuum pump when YV7 is energized the vacuum switches on and holds the board flat The laser is energized when the doors are all closed see fig 4 8 The laser is also on the Emergency Stop circuit which will shut down the laser in the event of an E Stop or when the fr
32. s needed 4 Lubricate conveyor support rods DO NOT apply excessive oil a light coating is all that is needed 5 Wipe off edge belts with recommended cleaning agent 409 spray cleaner n alternative is to use alcohol or equivalent 5000 0088 66 MAINTENANCE MVT Monthly 1 Carry out the weekly maintenance routine in full 2 Examine crown toothed bearings for sticking or wobble Ensure all bearings are free running and belt tension is adequate 3 Ensure that conveyor belts are not twisted on either rail Yearly 1 Carry out monthly maintenance routine in full 2 Check the electrical connections at the conveyor motor and in junction box C Make sure all connections are intact and securely fitted 3 Check all mounting screws and hardware on the machine 4 Systematically check all nuts bolts and screws on rails lifting mechanism air cylinders bearings and mountings for all hardware 5 Check for insulation resistance of the motor gt 10 M Ohms using a 500V DC insulation resistance tester WARNING Isolate the machine and disconnect the conveyor motor from the supply at junction box c before doing insulation resistance test 4 5 Pneumatic Maintenance Weekly Check the air pressure of the following Main pressure regulator 5 Bar C Pressure sensor 3 Bar 67 5000 0088 MVT MAINTENANCE Air tubes to AY table Air Tube to Camera ETA Pressure Pressure Air tube to Sol
33. t 00010 Clamping ON input 00007 Clamping OFF input 00008 PCB will not enter upstream single rail machine Refer to Electrical Schematic Drgs e Check the Module 4 PLC output 10103 It indicates that a board has failed inspection e Check pins 3 amp 8 are shorted on SMEMA downstream socket PCB will not slow down on exit Refer to Electrical Schematic Drgs e For conveyor 1 check that relay KA is energised by examining its indicator light Relay KAG corresponds to conveyor 2 e Check that the Module 3 PLC output 10001 is on Similarly check output 10006 for conveyor 2 e Check that the Module 1 input 00000 slow on exit is enabled on PLC e Check the resistance is respectively 3k3 and 15k ohms across terminals D1 amp D2 and D2 amp D3 Repeat for rail 2 with the same resistors 3k3 between D4 amp D5 and 15k between D5 amp D6 ENSURE THAT ALL POWER HAS BEEN REMOVED FROM THE SYSTEM BEFORE PERFORMING THIS TEST Next PCB will not enter rework station Refer to Electrical Schematic Drgs Note Only used with MVT RS 1 upstream from system e Check that the Module 4 PLC output 10101 is pulsed when PCB is finished inspection e Check pins 1 amp 6 are shorted on SMEMA upstream socket when inspection is complete 93 5000 0088 MVT TROUBLESHOOTING PCB will not enter system from rework station e Only available on single rail conveyor Refer to Electrical Schematic Drgs Note Only used wit
34. the following Discoloured blistered or cracked transformer coating Cable and crimp integrity Broken or chipped terminals Excessive blackening of transformer guard Check all terminal connections on the machine and complete the monthly routine 0 Uuu Check DC power supply unit outputs 5000 0088 62 MAINTENANCE MVT 4 3 X Y Table Maintenance Weekly 1 Power down the machine and switch off the X Y stage at the controller Inspect the X Y table by moving the stage manually from one end of the axis travel to the other This will also redistribute the lubricant and extend the stage life 3 Check that all cables on the stage are free and not obstructing its movement 4 Ensure the bearings are kept free from dust loose particles and moisture Fig 4 2 D 5 Ensure the magnetic platens are free from debris Fig 4 2 E 6 Run the machine and press the E Stop to ensure that it operates as normal 7 Visually examine the encoder Fig 4 2 C on each axis to ensure that there are no scratches grease or dirt If some grease or dirt needs to be removed do this with a very fine lint free cloth only Take care not to scratch gold foil as this will greatly affect the table s accuracy 8 Check the small home marker contacts and end limits are intact Figure 4 2 C B Ensure that they are free from dirt and grease Monthly 1 Carry out weekly routine 2 When inspecting the connections on the stage and at th
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