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Topaz Service Manual - PCB Technology Elbląg

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1. e towards the front rail Y positive movement DW Placing a shim below the screw will tilt camera Away from the front rail negative movement O 2 1 4 P di Rotate the adater plate against the d camera for large movements m d Rotate the adapter plate on the camera C lt 4 stand for small movements ae Figure 9 27 Service Manual Topaz 5322 871 63606 9 24 1309 10 01 05 Vision Systems 9 5 Line Array Camera Adjustment This section describes the calibration of the line array camera s 9 5 Maximum Component Size and Field Of View This procedure explains how to adjust the maximum component size Field Of View The field of view is everything the camera can recognize see on its focal plane The maximum component is always smaller than the Field Of View and is the FOV minus the deviation of the lens border so the size within the FOV in which a component can be recognized without problems Measure the Field Of View by means of a plastic ruler Attach the ruler in such a way that the ruler is visible in X direction East West direction on the screen as the X direction is a fixed value of 58 59 The Field Of view depends on the height of the line array camera as well as the used lens and extension ring Adjust the FOV to 33mm 9 5 2 Adjusting the Focus and Aperture To adjust the focus and aperture a special focus adjuster tool 5322 395 10275 is
2. lt lt lt APPLICATION gt gt gt 2 DATA M 63706408 tif lt lt MODE gt gt 3 DATA BASE OBJ COMPONENT DATABASE VISION No COMPONENT NAME COMMENT Edit Term Change this value to 9 99 1 Alignment Type QFP d 2 Lighting Level 10 3 Comp Threshold 30 4 Comp Tolerance 1 30 200 Search Area mm 9 99 6 Sample_QFP100 P0 65 example data 572500050 USER ITEMS igure 9 22 Edit search area 6 Save the edited data Press the ESC key twice then select 0 5 amp EXIT and press the ENTER key Adjustment of the camera scale When the preparation is complete use the following procedure to calibrate the scale of the single vision camera 1 Execute the SingleCam Scale utility Select lt lt lt 3 MAINTE M gt gt gt lt lt 3 MCH_ADJUST gt gt lt B SAVE amp QUIT gt BI ADJUST SingleCam Scale and press the ENTER key Select SingleCam 1 and press the ENTER key If you have added an optional vision camera select SingleCam 2 to adjust it EO NOTE Camera scale adjustment on a camera using side illumination need to be run with a part that uses the fore lighting system If a part cannot recognized check the Single Cam Scale levels MCH_DATA Vision Parameter The following numbers should be close to what the scale adjustment will find if the field of view is set correctly Max component size X 32mm 77 5 77 Le
3. 01 16 5 01 16 5 01 16 5 NDOI 16 Spare 01 8 Head to 8 memory active head sequence 09 14 Extended di NEI5 Head sequence finish NEI6 Timer busy 01 16 5 01 8 to no8 head up down NG09 X axis origin NGIO Spare NGII R axis origin NGI2 Nozzle down NGI3 14 Spare NGI5 X axis over travel NGI6 Spare 01 8 Head to head8 pick up judgment 09 16 Head to head8 mount judgment NJO Y axis origin NJO2 3 Spare 04 Relay spare 05 Y axis over travel NJO6 Spare 07 Front feeder lock 2 NJO8 Front feeder carriage lock 09 Invalid fullkey board service key NJIO Front feeder lock I Front area NJI2 Gate in NJI3 Release cover emergency NJI4 Contactor ok NJI5 Count reset NJI6 Can t use NKOI 8 Nozzle 17 to 24 NKO9 Front non stop fdr carriage detect switch NKIO Front non stop fdr carriage detect upper NKI I Front non stop fdr carriage detect forward NKI2 16 Spare Sub position of ent NL02 Conveyor entrance NL03 Conveyor exit NL04 Sub position2 of ent NL05 Dump station NL06 Spare NL07 8 Can t use NL09 Set position NLIO Locate pinl NLI2 Locate pin2 NLI3 Spare NLI4 Rear nozzle station clamp NLI5 Push up plate fixed NLI6 Spare 01 5 Table 3 11 1 3 44 Service Manual Topaz PA 1309 10 NM02 W axis origin NM03 4 Spare 05 2nd limit spare 06 5 NM07 Rear feeder lock 2 NMO08 Rear feeder carriage loc
4. 5 SI SDLC SM SOP SVS TBD TBW TC TI TPD TSOP UFOS UM UP URS VIOS Explanation Direct current Document Information Data Input Data Output Dual In Line chip package Emergency Electro Static Discharge Floppy Disk Feeder exchange system Full Vision Good Product line Topaz Emerald and Sapphire Hand Held Keyboard Hard Disk Drive High Level Data Link Control More extensive communication protocol than SDLC Installation Manual International Standard Organization Large Component Sequencer Also called trayfeeder Manual Tray Feeder Operator Manual Priority indicator Philips Article Product Creation Process Philips Consumer Services worldwide stock for EMT Quad Flat Package Service Information Serial Data Link Control communication protocol with one clock and data line Service Manual Single Outline Package Setup Verification System To be defined To Be Written Tray Changer Tray handling device Technical Information Technical Product Documentation Top Single Outline Package User Friendly operating System User Manual Under Progress User Requirement Specification Vision Integrated Operating System 5322 871 63606 01 05 PA 1309 10 Service Manual Topaz Introduction Intentionally left blank Service Manual Topaz PA 1309 10 5322 871 63606 01 05 General and Electrical Block Diagram CH
5. TAE Tus ENVIRONMENT User sub directry Work sub directry 1 TITLE OPTION SWITCHES Dsleep SLEEP NoServo ACTIVE WithServo EMUL Emulate Nsleep SLEEP NoVision ACTIVE WithVision Isleep SLEEP NolOcard ACTIVE WithIOcard PART OnlyBasicIO EP EP Csleep SLE oCOMI1 ACTIVE WithCOM1 Ysleep SLE Fixed ACTIVE Variable 0 BitO SkipBackupCheck Bitl WithDRDOS Bit2 QuickStart L8 Protrction 0 RUNNING 2 OPERATION 4 MAINTE L8 ALL A0 20 XC7000 XD2 Figure 10 2 6 5322 871 63606 Service Manual Topaz 10 15 01 05 PA 1309 10 Software Section 10 2 8 10 2 9 Floppy Disk Problems The floppy drive inside the Topaz is a standard 3 5 1 4Mbyte floppy drive which uses the standard IBM formatted 3 5 diskettes 720Kbytes or 1 4Mbytes If the VIOS system has problems when reading from or writing to the floppy drive perform the following actions Check the floppy diskette by checking it at another PC can it be read and or written If the diskette is OK at the PC format the floppy diskette on the Topaz system and check if this is OK Then try to write read to from the diskette If it is still not possible to read or write check the connections to the drive and check the 5 and
6. xnsesuo Figure 6 20 Output monitor activate push up 2 Check the ascent and descent speeds Both speeds should be around one second the speed at which components pre mounted on the PCB will not shift 3 Press the emergency stop button then adjust the ascent descent speeds Turning the speed adjuster knob for orange tube adjusts the ascent speed and turning the speed adjuster knob for black tube adjusts the descent speed 4 Check the input status from the upper limit sensor Pressing the TAB key allows the cursor jump to NL10 on the right hand input monitor screen When the upper limit sensor is properly attached the input monitor digit for NL10 reads as follows 1 when the push up plate is at the raised position 0 when the push up plate is at the lowered position If the push up plate does not move normally in Step 1 manually check the operation without using the output monitor as follows Press the emergency stop button Press the manual button of the air solenoid valve marked 02 with a narrow screwdriver or similar tool having a pointed tip to raise the push up plate If this method works there will probably be a problem with the electric circuit for the air solenoid valve Check the following points Electromagnetic coil breakage Loose harness connectors Trouble with the DC24V supply I O board output errors etc CAUTION When you set the push up pins on the pu
7. DIP switch settings 0 0 0 0 The third generation boards have the same amount of DIP switches as the second generation boards however the switches for terminator use have been moved to the daughter board core board refer to 2 stage DIP switch in figures 3 7 1 and 3 7 2 The settings are shown in the table below Sapphire 1 enable 0 OFF disable o left 0 0 Head I O IP actes of Table 3 7 5 DIP switch terminator settings Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 y o Head I O System Principles The second generation I O boards may be replaced by third generation I O boards with some restrictions Table 3 7 6 below shows an overview of the I O boards and the machines they can be used in Board types Suitable for machines for abreviations see table below Core board Mother board ROM versions latest version basic flash ROM indicated with F KG2 M4520 21x npn El 5322 214 91259 KG2 M4580 00x pnp 5322 216 04002 KM5 M4580 00x pnp EM 5322 216 04471 EI Ell EM O T CI CII S KG2 M45R9 002 KG2 M45R9 023 KG2 M4520 I1X npn CI 5322 214 91258 KG2 M4570 00X pnp Cr CII 53
8. PWRNG 5V DV 42 Normal Normal NOTE ecification_ on on TENENTE 200VAC gt 180 x Normal AC VAC VAC lt 160V R voltage drop 5VDC VI gt 4 75 Normal DC VI lt 4 75 x 5 VI lt 45V R x Error I2VDC 10 8V lt V2 lt 13 2V Normal DC V2 10 8V gt V2 13 2V G 2V error I2VDC V3 lt 10 8V G Normal DC V3 V3 gt 10 8V x 12V drop Table 3 5 7 Meaning of the LED indicators Remark Itis possible that some mother boards have more connectors this because some GEM machines need more PCB s more axes etc 5322 871 63606 Service Manual Topaz 3 19 01 05 PA 1309 10 4 3 5 6 System Principles Hard and Floppy Drives and Flash Disk Hard disk In systems equipped with an old type system board please refer to section 3 5 2 the hard disk see figure 3 5 9 is located at the left side of the MCX compartment This physically large drive is formatted as a 40 Mbyte drive for speed reasons The 5V 12V power supply for the hard disk is coming from the mother board via connector CN9 The signal cable is connected to the top side of the system board inside the MCX controller Signal connector to system board Power connector 45V 12V Figure 3 5 9 Hard disk Floppy disk The 1 4 Mbyte floppy drive is located in the service panel behin
9. Figure 6 15 Output monitor activate locate pins 2 Check the ascent and descent speeds Both speeds should be around one second the speed at which pre mounted components on the PCB do not shift 3 Press the emergency stop button then adjust the ascent descent speeds Turning the speed adjuster knob for the orange tube adjusts the ascent speed and turning the speed adjuster knob for the black tube adjusts the descent speed 4 Check the input status from the upper limit sensor Pressing the TAB key allows the cursor jump to NL11 on the right hand input monitor screen When the upper limit sensor is properly attached the input monitor digit for reads as follows 1 when the locate pins are at the raised position 0 when the locates pins are at the lowered position If the locate pins do not work normally in Step 1 manually check the operation without using the output monitor as follows Press the emergency stop button Press the manual button of the air solenoid valve marked TN03 with a narrow screwdriver or similar tool having a pointed tip to raise the locate pins 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 6 11 PCB Transport Systems If this method works there will probably be a problem with the electric circuit for the air solenoid valve Check the following points Electromagnetic coil breakage Loose harness connectors Trouble with the DC24V supply I O board output error
10. The following disks are required when upgrading the VIOS software to a higher level e SYSTEM 1 DISK upgrade disk e SYSTEM 2 DISK upgrade disk e SYSTEM 3 DISK upgrade disk e SOFTWARE UTILITY DISK see remark in step 4 e SYSTEM DATA DISK System data and backup disk Proceed with the following actions Step 1 Shut down the VIOS software and turn off power this for the monkeys among us Step 2 Switch the machine and press a key within 6 sec Now the VIOS SOFTWARE UTILITY will start Step 3 Enter the password of protection level 8 and the main menu of the VIOS SOFTWARE UTILITY will appear Step 4 Select 4 VIOS software utility installation and follow the instructions on the screen Remark The steps 4 7 are only needed if the version up contains a new version software utility disk but it is advised to do these steps always Step 5 Remove the VIOS software utility floppy out of the floppy drive and switch off power Step 6 Switch on the machine and press a key within 6 sec Now the VIOS SOFTWARE UTILITY will start Step 7 Enter the password of protection level 8 and the main menu of the VIOS SOFTWARE UTILITY will appear Step 8 Select 2 Version up of VIOS soft and press the ENTER key Follow the instructions on the screen Insert a blank formatted disk in the floppy drive as the system will ask for it to create a system data back up Copy SYSTEM 1 DISK Copy SYSTEM 2 DISK SYST
11. NLO2 53 onveyor exit NL04 SQ54 Entrance stopper 2 NL03 PCB detection SQ57 PCB securing position NLO9 Table 6 8 1 Service Manual Topaz 6 16 PA 1309 10 5322 871 63606 01 05 PCB Transport Systems The sensors may not detect a PCB see figure 6 22 due to such factors as the orientation distance and angle at which it is attached The sensors may also be affected by strong extraneous light excessive dust and the shape hole or notch and color of the PCB Using PCBs on which you actually mount components check that the sensors can detect them reliably Figure 6 22 sensors detection errors 1 Prepare the PCB you will actually use for component mounting 2 Adjust the conveyor width according to the size of the PCB To adjust the conveyor width you can use the Conveyor Unit utility in the Data Manager If your machine is not equipped with an auto conveyor width adj function adjust manually 3 Press the emergency stop button and pace the PCB on the conveyor 4 Open the input monitor and check the detection status figure 6 23 Select lt lt lt 3 MAINTE M gt gt gt lt lt 4 MANUAL gt gt lt C DISPLAY amp EXIT gt C2 INPUT MONITOR and press the ENTER key Use the arrow keys to line up the cursor with NOI to TNO9 The input monitor digit reads 1 when the PCB is detected and reads 0 when not detected Check that the digit of each sensor
12. 31 Head 2 AutoNzIChg 25 00 12 00 0 95 TYPE 32 Head 7 None 0 00 000 0 00 TYPE 31 Head 8 None 0 00 0 00 0 00 TYPE 31 Figure 7 9 Note This offset is automatically corrected when you execute mount feedback Since the position of Head is used as a reference this is always set to 0 00 Service Manual Topaz 7 14 PA 1309 10 5322 871 63606 01 05 Component Transport Systems 7 3 Nozzle Station 7 3 1 Nozzle Station The nozzle station of the Topaz can hold a total of 12 nozzles 11 standard nozzles and 1 optional nozzle Automatic nozzle change can be performed with heads 1 3 5 and 7 Nozzle change on heads 2 4 6 and 8 has to be done manually but are normally equipped with a type 31 nozzle To perform a smooth nozzle change the following items should be adjusted correctly Nozzle clamp plate position Amplifier gain for nozzle sensor UH L 34 NNOI Nozzle station coordinates Figure 7 10 shows the nozzle station and the station nozzle 8 H1 31 NNO8 positions 2 H 1 32 NNO2 9 H5 31 NN09 3 H3 31 NN03 Example 1 H1 34 NNO1 means Station 1 10 H5 32NNIO 4 3 32 04 Used by head 1 Equipped with type 34 nozzle LUHZI3INNII 5 7 32 05 Nozzle sensor input NNO1 TR 12 7 35 12 3 5 SPARE NNO6 STATION 12 STATION 7 7 1 33 07 Nozzle station Nozzle sensor Clamp plate Clamp plate bolts Figure 7 10 Nozzle station positions and sensor
13. REGIS MADE IN JAPAN 87 2 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 System Principles The green LED on the core board and the green LED D3 on the head I O board indicate a good 5V supply when lit The 7 segment display has been added for self diagnosis purposes the error codes are shown in the table below Error code Meaning Host communication time is over interruption in communication 2 Analogue digital conversion error l O board broken 3 HDLC controller time is over l O board is broken Table 3 7 2 Core board error codes The yellow LED D1 on the conveyor I O board and D5 on the head I O board indicate whether there is a serial communication or not following codes are used for this communication LED indicator Code T Meaning EN Fast flashing Normal operation On on off Host communication time over error display shows code 1 On off on off 24V line shorted or broken Table 3 7 3 O board communication indicator The green LED D3 on the conveyor I O board and the green LED D4 on the head I O board indicate a good 24V when lit The 6 stage DIP switch on the conveyor I O board is necessary to make the board suitable for either the left or right side or a trayfeeder The table below shows the settings ON 0 OFF l O conveyor right l O conveyor left Trayfeeder 100 Trayfeeder 31 Table 3 7 4
14. indicated on the lower left of the operation monitor will change to 2nd LIMIT OVER Service Manual Topaz 5322 871 63606 8 8 PA 1309 10 01 05 Axes Systems Move back the head assembly to 1 00mm inside the mechanical stopper do this open the output monitor screen or input monitor screen and while observing the X co ordinate value indicated on the bottom of the operation monitor stop the head at a position approximately 1 00 mm from the mechanical stopper i e from the hard limit This position is the secondary limit of the X axis Make a Note of the X axis co ordinates displayed on the monitor This is used as a reference for the X axis software limit settings Adjust the position of the secondary limit dog With the head assembly left at the position of Step 4 slide the position of the secondary limit dog so that the secondary limit sensor just detects it Find the optimum posi tion while checking the sensor detection LED or reading the blinking message on the lower left of the operation monitor see figure 8 9 L013 2nd LIMIT OVER Figure 8 9 Secondary limit over display screen Re tighten the screws of the secondary limit dog Use the same procedure from Steps 4 to 6 for the other secondary limit After the adjustment is complete move the head assembly by hand to within the allowable movement range 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 8 9 Axes Systems
15. A303 CAUTION The axes will move A426 Please put the specified PCB at the mounting Figure 9 2 Moving camera light adjustment procedure Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Vision Systems 3 Enter the width of the PCB and press the ENTER key Enter the width millimetres of the PCB used in this adjustment 4 Ensure safety then press the ENTER key again The W axis moves to set the specified conveyor width 5 Press emergency button set the PCB amp light adjuster plate Align the locate pins with the centre of the positioning holes of the PCB Then place the light adjuster plate in the centre of the PCB with the two tone surface facing up 6 Adjust the conveyor unit Adjust the positions of the locate pin and push up pins to match the PCB 7 Cancel emergency stop Ensure safety then release the emergency stop button and press the READY button of the HHK 8 Press the ENTER key The locate pins and push up pins rise to secure the PCB and the head assembly moves to over the PCB The teaching screen for the light adjuster plate then appears 70043306 01 eps A655 lt lt lt Teaching gt gt gt Please position the cross hair cursor over the Light Adjuster Figure 9 3 Adjusting light intensity 9 Adjust the camera position While manipulating the HHK joystick adjust the position of the moving camera so that the light grey area on th
16. gt E B6 INIT SERVO ORIGIN and press the SHIFT ENTER key The machine reference of each axis appears on the operation monitor after the return to origin has been performed Machine reference display 50543602 00 Machine Reference Hit Any Key X 49 Y 52 22 53 R1 53 R2 4876 Figure 8 2 Machine reference display Service Manual Topaz 5322 871 63606 8 2 PA 1309 10 01 05 Axes Systems XW 8 2 1 W axis Machine Reference The W axis is driven by ball screw at a lead of 5 00mm per turn of the motor The conveyor width is adjusted by sliding the rear rail The front rail is fixed The origin signal is output when the origin sensor which is located near the inner end of the W axis ball screw has detected the origin dog attached to the movable rail Use the following procedure to adjust the machine reference This is not needed for machines designed for manual adjustment of conveyor width 1 Press the emergency stop button Adjust the machine reference as follows 3 Loosen the bolt securing the origin dog and slide it slightly To increase the machine reference Slide the dog in the width enlarging direction To decrease the machine reference Slide the dog in the width reducing direction 4 Re ghten the bolt to secure the origin dog after the machine reference is set within the tolerance range f2 Origin sensor 1 Origin dog A Movable rail Ball screw Figure 8 3
17. soren 8 L j x gt Jj WT REL E EET eri d 3015 Figure 3 7 2 Flash Conveyor l O board 7 segment LED display memory sd 53 si Q Era isi i den 5 o STOTT 23505500000 i baee l EL ens El no SALISVBA 25L P mp2 y INN d RPS RPS 2 SRF TN YAMANA MOTOR 2 17 57 5 BADE Js JAPAN E dio ooooco NM lu 00560605 r7 200000000 567550005 COO OG OOS ope a LA mes FAUCI 005555 9000000000000000v 000000000 1000000000 200000000 E un OCHO Ed _ E annann 00000000 Exc 055909522009209 ER t ioQOoOoOooODOOOODOOON ar 555590090999999 s 000000000000000 05050000000000000 Figure 3 7 3 Head l O board D4 ERACO 1 8 ERAON 9 15 Y 00000000 1999 1 5895989399985 5506060000000 B
18. 7 2 3 1 2 1 2 Not applicable Table 3 5 2 Overview system boards Notes 1 VIOS VI 1or later needs 8Mbytes 2 From December 1998 onwards 3 Size is different between KJO 10x and 00x 4 With system board KM5 M4210 01X 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 3 15 3 16 3 5 3 System Principles Servo Board This board see figure 3 5 5 controls the AC motor driver circuitry The servo 1 board always controls the driver 1 board both boards are dedicated for the main machine The servo 2 board is optional and controls the driver 2 board both boards are dedicated for options such as traychangers and auto tray stackers The servo board receives its power 5V 12V 12V via the ISA bus of the mother board This power is forwarded to the driver board via connector CN10 to feed the logic circuitry on the driver board The powerfail signal is connected to the D river power board via connector CN9 The Good 2 signal is connected to the servo board via connector CN5 To 1 2 E Power T 1 2 T ron od signal Vision CN7 Sticker 1 LED GOOD Encoder signals CN1 Sticker 1 Encoder signals CN2 The servo board receives commands from the system board via the ISA bus connector CN4 on the mother board Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles The pulse width m
19. ES R 96 02 26 INS Zu BIRA 96502526 NOO gt 50 Heus 62 02 25 NO1 HOC PIG Bx 95 02 26 RE 96 02 26 96 02 28 96 02 25 STATUS 965025216 KG2 42MO 009 gt SUB_DIR lt 96 02 26 KG2 42T0 009 SUB DIR 96 02 26 KG2 4289 005 476 93 03 06 KG2 4288 007 Gio 5 05 2 KG2 58D9 010 ILS 5 105102 KG7 44D0 146 HS si Lisl KG7 44D1 146 Qo O2 17 AUTOEXEC BAT 9 95 00 26 FTABLE BIN 955095016 ECL92 EXE 09 COM92 ICG 4026 96 02 26 ECL92 ICO 4026 96 02 26 MCXCONF NEW 299 9 5 05 SERIAL STS WE QZ O9 19 MCXCONF SYS BES iL 422 s V 621 e UJ UJ UJ UU UJ DU UJ UJ UJ DU UJ PGM gt 50 P BASE gt 50 RAMD gt SU STATUS gt SU KG2 42M0 gt SU lt 96 02 26 KG2 42T0 PSUBIDTRE 96 02 26 KG2 4289 476 93 03 06 KG2 4288 Suo 95 05 24 KG2 58D9 AGH OGM IS OS 52 KG7 44D0 OO MES Kd Aa LAVAGE AUC c N OY O1 Figure 10 4 Dos files 10 20 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section The 1 directory first of all has the two following files USER ED All Machine equipment OPTION USER HD All Machine parameters DATA A backup of these files on the SYSTEM DATA DISK should always be present in the neighbourhood of the machine See figure10
20. Mov Cam Scale lt lt MODE gt gt 3 MCH ADJUST A420 This procedure adjusts the vertical Y and horizontal X scales of the moving camera A fiducial mark is meeded for this adjustment Recommended is an easy recognizable Mark No 153 A422 Please input the PCB width mm which you want o use and confirm if the PCB uses the fiducial hat is described in the used mark database number PCB width mm 128 A423 By moving the axes the fiducial mark will be recognized in three steps Please input the allowed moving distance 1 lt gt mm The unit of Distance mm 10 20 A303 CAUTION The axes will move After confirming safety please press the ENTER key A426 Please set the specified PCB on the mount position When using your hands you must first press the EMG STOP button After the board is inserted on the Figure 9 10 Moving scale adjustment Enter the mark database No and press the ENTER key Here enter the database No of the mark on the PCB you are using Check or enter the width of the PCB and press the ENTER key 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 9 Vision Systems The width of the Phillips board is 136mm and of the glass PCB130mm Confirm that Distance mm 10 15 is displayed and press ENTER Normally a movement distance of 15
21. PA 1309 10 Service Manual Philips s Electronic Manufacturing S D f i LI p Technology DOCUMENT DATA MANUAL TITLE MANUAL NUMBER PA NUMBER Service Manual Topaz 5322871 63606 01 05 PA 1309 10 HISTORY ORDER REVISION RELEASE Issue DATE NUMBER CODE SIUS DOCUMENT First Draft 5322 871 63606 97 00 Replaced First Issue Oct 97 5322 871 63606 97 01 Replaced DI CSM 025 Update Mar 98 5322 871 63606 98 02 Replaced DI CSM 050 Second Issue Mar 99 5322 871 63606 99 03 Replaced DI CSM 076 Update Jan 2000 4022 591 93464 00 04 Replaced DI CSM 105 Third Issue April 2001 5322 871 63606 01 05 Current DI CSM 138 Preventive and corrective maintenance is reserved for personnel certified by Assembl on The Philips EMT Customer Support organization has created a series of web pages the World Wide Web for the use of its internal and external customers These pages provide a library of information regarding technical aspects of the products sold and supported by Philips EMT organizations around the world The manuals section is a tool for EMT customers trying to find the part number for the latest documentation currently available Access to this area is not restricted by a password It is an on line reproduction of the manual survey has the advantages that it can be updated regularly The Customer Support website address is http
22. 0 Switch MS 60 functionality S g g c c c 5 2 G oO c qua 8 8 833 5 5 5 59 S E 9 5 B 2 E E x 9 9 9 9 s Z Z Table 3 7 1 DIP switch settings Third generation I O boards The I O boards of the third generation the successors of the second generation consist also of a mother board and daughter core board with the same functionality as the second generation boards The Intel 8344 microprocessor on the daughter board has been replaced with the Hitachi SH7021 20MHz processor to control the communication between system board and I O boards T he communicating protocol has been changed from SDLC to HDLC High Level Data Link Control For establishing the HDLC protocol the SH7021 processor makes use of the dedicated component SAB82526N also located on the daughter board The new processor reduces the I O scanning time to less than 1msec instead of the 3 to msec in the second generation boards Similar to the second generation I O boards the third generation daughter board processor makes use of a ROM and RAM memory The RAM memory basically has not changed and is used by the processor for temporary data storage However the ROM memory has been changed to flash ROM This flash ROM in combination with the third generation system board and VIOS 1 2 software or higher enables the so
23. Figure 9 38 Multi camera 2 Camera stay 4 2 Nri _ 80 CO Adjusting cam coor X Camera stand Adjusting cam coor Y insert a shim 12 When the calibration is complete dump the component Press the lt Enter gt key to dump the component automatically If you want to quit without dumping press the lt Esc gt key and follow the message on the operation monitor 13 Save the calibrated data Select lt B2 Save data gt or lt BO Save amp Quit gt and press the lt Enter gt key to quit without saving select B3 or B7 14 Return the edited data to the original setting Return the edited data to the original setting as nessecary If you want to keep this edited data it is advisable to enter a proper comment Service Manual Topaz 5322 871 63606 9 32 PA 1309 10 01 05 Vision Systems 9 5 5 Adjusting the Dual Recognition Offset The line array camera can recognize components travelling from left to right and right to left This recognition offset between the both directions is indicated by the parameter DualRec Offset in the position parameters and must be adjusted correctly for accurate mounting It is recommended that you use a SOP such as those used in camera scale adjustment l Attach an SOP to head 1 Press the emergency button and attach an SOP nozzle type 32 to head 1 Cancel emergency Ensure safety and release the emergency button and press Ready Execute th
24. 009 Ext tc conveyor reverse 09 5 TQIO Tray changer door lock TKIO single camera 1 on TQII Tray changer door2 lock TKII Lampl2 single camera 2 on TOI2 Tray changer door light TKI2 Lamp l3 multi camera on TQI3 Tray changer door light TK13 15 Brightness to brightness3 TOI4 15 Tray changer spare 6 5 16 Tray changer servo 01 TROI 3 Ext tc station to station3 vacuum TLO2 B c conveyor reverse 04 12 Tray changer spare TLO3 B c speed low TRI3 Ext tc head vacuum TLO4 B c speed high TRI4 Tray changer spare TLOS Front non stop fdr carriage up TRIS Ext tc head down TLO6 Front non stop fdr carriage down TRI6 Tray changer spare TL07 Front non stop fdr carriage forward Table 3 11 1 List of D ata O utputs used in the Topaz 5322 871 63606 Service Manual Topaz 3 43 01 05 PA 1309 10 System Principles 3 11 3 List of INPUT Signals DI s Following table 3 11 2 shows an overview in alphabetical order of all D ata I nputs used in the Topaz system The table handles similar inputs in the same manner as described for the outputs refer to chapter 3 11 2
25. 1 Caution Do not change the amplifier s MODE selector setting With this setting the red and green LED s of the amplifier are both lit when the nozzle is in the holder and only the green LED is lit when not in the holder If this detection still occurs even after you have adjusted the amplifier gain the position of the nozzle sensor is probably incorrect Loosen the set screw located on the bottom of the nozzle station and make adjustment to the sensor position 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 7 17 Component Transport Systems 7 3 3 Adjusting the Nozzle Clamp Plate Position The nozzle clamp plate is located on the top surface of the nozzle station It opens to allow a head to extract a nozzle from the nozzle station or closes to lock a nozzle in place and extract it from the head The nozzle clamp plate opens and closes by means of an air cylinder while the position of the plate air cylinder is detected by a sensor If the position is not correct trouble may occur during the nozzle change If nessecary adjust the clamp plate as follows Open the clamp plate by activating TP02 Front nozzle station clamp in the output monitor 1 means the clamp is open Press the emergency button and loosen the clamp plate bolts see figure 7 3 1 Adjust the position of the clamp by using the play of the mounting holes The position is correct when the aperture of each nozzle station is exactly ali
26. 2 4258 00 2 4259 005 KG7 44D0 237 KG7 44D1 237 KJ0 58D9 044 KM5 58D9 007 VIOS EXE CONVERT exe BRAND sys DESCRIPTION Dos command interpreter Installation batch program DOS internal command VIOS Device driver Batch file needed at software update Command interpreter back up config file Start up Configuration file back up start up file Start up file VIOS configuration file Y2K patch Ini file Extract command file Document description Status file File table for the action specs hidden Sequence Program IPL Sequence program OS I O communication software OS I O communication software IPL VISION program will be down loaded during start up VISION program Servo program will be down loaded during start up Main VIOS executable program Brand name selection The files above are the most important files of the root directory of the system which uses the MS DOS 6 2 system 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 Software Section 10 2 3 Installation Disk Contents With the system there will be a set of 5 diskettes supplied 1 SYSTEM DISK 1 2 SYSTEM DISK 2 3 SYSTEM DISK 3 4 SYSTEM DATA 5 VIOS SOFTWARE UTILITY SYSTEM 1 2 and 3 diskettes contain the VIOS program utilities component and mark database VIOS SOFTWARE UTILITY disk contains various utilities of the machine The SYSTEM DATA disk contains a back up of the MACHINE data Static compon
27. 8 3 2 Y axis Secondary Limits The Y axis secondary limits are set to approximately 2 00mm inside the mechanical stopper hard limit Since this adjustment procedure is exactly the same as for the X axis refer to the previous section 8 3 2 The locations of the Y axis secondary limit dogs are shown below Y axis guide X axis ball screw Secondary limit dogs Figure 8 10 Y axis secondary limit dogs y Note To make settings for the Y axis secondary limits use the same procedure as for the X axis except that you move the head assembly to a point 2 00mm inside the mechanical stopper in Step 5 Service Manual Topaz 5322 871 63606 8 10 PA 1309 10 01 05 Axes Systems 8 4 8 4 1 Software Limits When an axis moves to a target position the software limit is used to restrict movement to avoid interfering with the mechanical stoppers located at the both ends of the axis If the target position exceeds the software limit the error message AXIS SOFT LIMIT OVER appears and axis movement is prohibited In the Manual mode you can use the joystick on the HHK within the software limit range W axis Software Limits The W axis software limit should be set to 3 00mm inside the mechanical stopper for both the plus side width enlarging direction and the minus side width reducing direction When the software limit settings are correct this meets the specifications for the minimum 50 00mm and maxim
28. Description In the Topaz two transformers are used to supply power to the various parts of the machine TC11 and 11 Refer to chapter 14 for the complete power circuit diagram Transformer TC11 is used for the logic circuits and converts the 3 phase input voltage to a 2 phase 200 220V supply voltage T C11 uses following taps Tap U10 220 volts this voltage is used for the two monitors via QF21 2A Make sure to set the correct tap 100V or 220 V when installing the monitors Tap U20 200 volts this voltage is via QF22 5A used for the GS21 power supply which feeds the I O and EMG circuitry It is also used for the circuit logic in the MCX controller Transformer TM11 supplies the motor drivers boards and converts the voltage level but keeps it a 3 phase supply voltage The output of the TM11 transformer is 3 phase 200V and is fed via QF31 10A and the emergency power relays KM11 and 12 to the 282V D river power supply in the MCX controller Also the conveyor belt motors and the connection board are fed via QF32 2A by this transformer The Power supply unit GS21 supplies 24V to the I O and emergency circuits in the Topaz GS21 is located next to the transformers TM11 and TC11 in the power box at the back of the Topaz For more information about this power supply please refer to chapter 4 5 4 Note Make sure to set the correct input voltage taps when installing the machine see chapter 3 for the c
29. Figure 3 5 10 Driver board The motor driver DC power is 282VDC and is supplied by the D river power supply via CN4 On the driver board the 282V DC is converted into an AC signal for driving the 3 phase AC motors This is done as shown in figure 3 5 11 Oscillator 50 kHz AC motor Figure 3 5 11 Driver board principle Note that only the X and Y motors are actual three phase motors 5322 871 63606 Service Manual Topaz 3 21 01 05 PA 1309 10 Note System Principles 50KHz oscillator powered at 12V activates every power transistor which switches 282V sequentially thus creating a 3 phase U V W AC signal for driving the motors The GTR Giant Transistor module which controls the current is located at the rear side of the drive board and is mounted on a large heat sink The motor current of a maximum of 4 axes is fed via CN2 and a max of 3 axes via CN3 to the AC motors The 5V amp 12 power for the oscillator and logic circuitry is received from servo board via CN6 The current of the logic power is controlled by an IPM Intelligent Power Module which is fixed on the heat sink The pulse width modulation and feedback power failure over current etc signals from the servo board are received via connector It is possible that not fully populated driver boards are installed The board only contains the drivers for the axes needed in the system The not fully populated boards ca
30. List of D ata O utputs used in the Topaz 5322 871 63606 01 05 Power and Safety Circuits CHAPTER 4 Power and Safety Circuits 41 Introduction The Topaz has a number of safety circuits and power supplies In the first part of this chapter the safety circuitry will be discussed the second part will handle the various power supplies which are used in the system Detailed schematics can be found in chapter 14 of this manual 4 2 Safety Circuit 4 2 1 Description The safety interlock circuit of the Topaz consists out of a number of switches and relays contacts These switches or contacts are activated during an unsafe situation of the machine Examples are open covers over travel low voltages low air over current activation of the EMG switches Figure 4 1shows the safety circuit diagram with the various safety switches and relays contacts On the next page a simplified drawing is made of this circuit The following situations can activate an emergency situation which causes an immediate stop of all movements inside the machine Opening of one of the covers during running of the machine The over travel OT signal indicates a movement of one of the axes beyond the soft limit range Low air pressure Activation of one of the EMERGENCY switches which are located at the front and the rear side of the machine and at the hand held key board Feeder floating signal if installed indicating a wrongly ins
31. Step 7 Remove the floppy disk from the drive label it with the correct information name time stamp machine type etc and store it away on a save place Step 8 Select 1 to start the VIOS software 10 14 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section 10 2 7 VIOS Configuration The VIOS configuration file is located in the ROOT directory on the C drive and is called MCXCONF SYS This file see fig 10 2 6 is very important for the VIOS system If not OK the VIOS software will not start up MCX CONFIGRATION ZOSTAN TITLE ROM a SYS KG2 M42R9 002 SYS BIOS DRDOS HED KG7 M45R9 000 IO bd head if CNV KG2 M45R9 002 IO bd conveyor P amp P KG2 M45R9 002 IO bd YTF100 wf YPU KG2 M51R9 003 YPU e SOFT KM1 42E0 012 MAIN ExeFile KG7R EXE rd KG2 42T0 012 MCH TYPE TxtFile TYPEN KG2 42M0 012 MESSAGE Ext N S TSI KG7 44D0 237 VISION HexFile TMSLIBIN OUT KG2 4288 00A IO OS BinFile 83440S BI rd KG2 4289 005 IO IPL HexFile 83441PL HEX 5 4258 001 IO HexFile OS amp IPL HEX KG2 58D9 044 SERVO HexFile SRV HEX KJ0 58D9 044 SERVO HexFile SRV HEX KM5 58D9 007 SERVO HexFile SRV HEX SS prc eI pole 5 5 255225255
32. www emt philips com support Philips Electronic Manufacturing Technology B V All rights reserved No part of this book may be reproduced in any form by print photoprint microfilm or any other means without the written permission from Philips Electronic Manufacturing Technology SAFETY General For the correct and safe use of the CSM system it is essential that both OPERATING and SERVICE personnel follow generally accepted safety procedures in addition to the safety precautions specified in these safety and quick reference cards The operating service and installation manuals have warning and cautionary statements throughout the whole man uals where applicable Warnings and cautionary statements and or symbols are present on the system where applicable Cautions and marks REFERENCE Gives useful information related to the mounter operation v NOTE Explains the mounter operation and procedures in a simple and clear manner s ds Qe CAUTION Gives important information to prevent any damage to the mounter or data WARNING Gives information of utmost importance in ensuring the safety of the mounter operator inspector or service personnel gt gt EMERGENC BUTTON Press the emergency button REMARK Gives a comment amp S Training level personnel Operation adjustment maintenance and repair of the CSM system may only be carried out by qualified and trained per
33. Remove the support unit bearing 4C in the back of the machine Remove the cover 33 and the lock nut 27 watch for the copper chip which is under the set screw Remove the three spring coned disks 35 Remove the sleeve bearing 32 and the thrust bearing 36 Remove the four hexagon bolts 30 and the bearing holder 34 Remove the circlip and the support unit bearing 4C Do NOT remove the Y axis bearing holder 6 T he ball screw 3 is now free on one side 30 36 6 N ONES 4C 2 27 S lt 3235 l 34 Figure 8 26 ball screw generation 2 Remove the ball screw Move the robot arm backwards near the Y axis bearing holder 6 Remove the two hexagon bolts of the green coupling 22 Remove the four hexagon bolts 4B that secure the support unit 4A Do NOT remove the Y axis motor holder 5 Remove the four hexagon bolts 29 from the ball screw which are mounted in the Y axis nut holder 7 Now gently take out the complete ball screw Remove the lock nut and support unit 4A Continue with installing and aligning the new Y axis ball screw generation 3 see section 8 6 4 4 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Axes Systems 8 6 4 3 Y axis Removing Y axis Ball Screw Generation 3 Removing 3 generation Y axis ball screw is done as is described below See for reference figure 8 27 Do NOT remove the Y motor Determine th
34. To quit without saving select B3 RECOVER ADJUST or B7 QUIT and press the ENTER key At the completion of a scale adjustment the following parameters are given It is important to execute the utility 2 or 3 times before relying on this data DISTANCE 5 The component movement distance specified during the adjustment SCALE X 83 33 Pixel value in microns SCALE Y 83 97 Pixel value in microns CAM POS X 0 00 Indicates the distance the center of the camera was moved from the last recorded position in Machine Data CAM POS Y 0 00 Indicates the distance the center of the camera was moved from the last recorded position in Machine Data CAM POS R 0 56 The current rotational position of the camera Not to exceed 1 degree RATE 9955 The Ratio of X to Y pixel measurement Camera Optical Axis Angle Adjustment Introduction The Camera optical axes angle adjustment is a procedure that allows for the measurement of the relationship between the cameras optical axis and the Z axis movement of the head or Spine assembly It can be used on the Topaz with an additional single camera This relationship plays an important role in the placement accuracy between QFP and Fine Mode and becomes more significant when 2 or more single cameras are used Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Vision Systems Current software revisions do not allow for independent Offsets settings for each camera This limi
35. cable Determines the Badmark usage Only Orion Topaz and Comet Only Orion Topaz and Comet Determines the function of Alt Comp only VIOS version gt V1 xx Determines the function of the retry action 10 24 Service Manual Topaz PA 1309 10 5322 871 63606 01 05 Software Section Parameter Selection 7 Production Log Use None Machine config RECOGNITION 1 Laser Alignment None Exist 2 Camera Combin 1 Single view 1 amp 2 Single view Description Records the machine logging and errors during running Version 1 Do not select Do not select Do not select 1 2823 Single view Do not select 1 Single 3 Multi 3 Multi view Do not select Possible for Topaz 1 amp 2 Single 3 Multi Do not select 2 amp 3 Multi Possible for Topaz 1 Single 28 amp 3 Multi Possible for Topaz 4 Cameral Spec Back light Fore light For amp back light 5 Camera2Spec Back light Fore light fore amp back light 6 Camera3Spec Back light Fore light fore amp back 7 Multi Detection With Calib Standard Adjust model Adjust mode 2 8 MarkLightingControl None Exist Machine config CONVEYOR 1 Edge Clamp Exist None 2 Conveyor Width Axis Exist None Camera 1 is a backlight type camera Camera 1 is a reflective type camera Camera 1 can handle both Camera 2 is a backlight type camera Camera 2 is a reflective type camera Camera 2 can handle both Camera 3 is a ba
36. 1 Second generation MCX control unit Table 3 5 1 shows the components of the controller In chapter 14 an interconnect diagram can be found of all the internal connections of the MCX control unit ETT Description Remarks Driver power board 282V power supply 2 Servo assy Ix servo board 2A Servo assy Ix servo board for the optional trayfeeder 3 Driver board Ix driver board X Y R Z W 3A Driver board Ix driver board for the optional trayfeeder 4 System board Ix system board equipped with a 40486DX2 CPU 8 Mb internal memory 5 VICS2000 Ix Vision board 6 5V I2V power supply 5V 12 and 12V power supply 7 HDD Hard disk 8 Mother board Mother board Table 3 5 1 Controller parts 5322 871 63606 Service Manual Topaz 3 11 01 05 PA 1309 10 3 12 System Principles 3 5 2 System Board Second generation system board The system board of the MCX controller is 80486 DX2 CPU based system running at 66Mz The on board memory is 8Mbyte A piggy back I O control board is used to control the I O circuitry The board see figure 3 5 2 has the following functions Interfacing to all other PCBs connected to the motherboard Hard disk interfacing Floppy disk interfacing Video interface VGA Keeps track of Date and Time Keyboard interface SDLC I O1 2 interface control To HDD 4 3 Servo 2 option JP1 to JP3 JP4 to JP6 To Servo 1 Keyboard Floppy dis
37. 10 01 05 Axes Systems 8 2 5 R axis Machine Reference The R axis performs the rotation of each nozzle The origin sensor is attached to the lower part of each head The origin dog is the head of a screw inserted into the dog ring located at the lower part of the nozzle shaft When the origin sensor has detected the origin dog an origin signal is output To adjust the R axis machine reference follow these steps see figure 8 7 l Press the emergency stop button 2 Loosen the set screw for the dog ring Look at the lower part of the head assembly there is a dog ring attached to each nozzle shaft Use a hex wrench to loosen the set screw for the dog ring you want to adjust Do not remove 3 adjust the machine reference slightly turn the dog ring To increase the machine reference Turn clockwise topview To decrease the machine reference Turn counter clockwise topview 4 Re tighten the set screw to secure the dog ring Make sure that the machine reference is set within the tolerance range Y N o y j Dog ring R axis origin sensor R axis dog ring Screw Figure 8 7 Adjusting the R axis machine reference 2 vl Note Be sure to turn the dog ring slightly if you turn it too far a 0 pulse a different cycle may be received causing the origin to shift 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 8 7 Axes Systems 8 3 Seco
38. 11 3 5 2 System Board 3 12 3 5 3 Servo Board 3 16 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 Table of Contents 3 5 4 Vision Board 3 18 3 5 5 Mother Board 3 19 3 5 6 Hard and Floppy Drives and Flash Disk 3 20 3 5 7 Driver Board Assy 3 21 3 5 8 D river Power Assy 3 23 3 5 9 5 12 Power Supply Assy s 3 23 3 6 LED Driver Board 3 24 3 7 Boards 3 27 3 8 Connection Board 3 32 3 8 1 General 3 32 3 82 2 Generation Connection Board 3 33 3 8 3 3 Generation Connection Board 3 35 3 9 Keyboards 3 38 3 9 1 PC Keyboards 3 38 3 9 2 Hand Held Keyboard HHK 3 38 3 10 Monitors 3 40 3 10 1 VIOS Monitor 3 40 3 10 2 Vision Monitor 3 40 3 11 Signals 3 41 3 11 1 VIOS Manual Mode 3 42 3 11 2 List of OUTPUT Signals DO s 3 43 3 11 3 List of INPUT Signals DI s 3 44 4 Power and Safety Circuits 4 41 Introduction 4 1 42 Safety Circuit 4 4 2 1 Description 4 4 2 2 Safety Circuit 4 2 4 3 Power Circuits 4 5 4 3 1 Description 4 5 4 3 2 5V 12V Power Supply MCX Box 4 7 4 3 3 24V I O and Emergency Power Supply GS21 4 9 4 3 4 D Power Assembly 282V Power 4 10 4 3 5 Measuring and Adjusting Data 4 12 4 3 6 Performance Check and Trouble Shooting 4 13 4 3 7 Maintenance Instructions 4 13 5 Vacuum and Pneumatic Systems 5 5 1 Vacuum Systems 5 5 1 1 Introduction 5 1 5 1 2 Functional Description 5 5 1 3 Air Supply Unit 5 2 5 1 4 Air Pressure
39. 2 Check the press in and release speeds Both speeds should be around one second the speed at which pre mounted components on the PCB will not shift Service Manual Topaz PA 1309 10 5322 871 63606 01 05 PCB Transport Systems 3 Press the emergency stop button then adjust the press in release speeds Turning the speed adjuster knob for orange tube adjusts the press in speed and turning the speed adjuster knob for black tube adjusts the release speed If the push in mechanism does not work normally in Step 1 manually check the operation without using the output monitor proceed as follows Press the emergency stop button Press the manual button of the air solenoid valve marked 02 with a narrow screwdriver or similar tool having a pointed tip to make the push in mechanism active If this method works there will probably be a problem with the electric circuit for the air solenoid valve Check the following points Electromagnetic coil breakage Loose harness connectors Trouble with the DC24V supply I O board output errors etc If pressing the manual button does not allow normal operation there is another problem with the air supply air piping and pipette valves damage clogging and adhesion of foreign matter Check the air supply line of the push in mechanism For any replacements of the push in assembly please refer to the figure 6 12 Figure 6 12 Exploded view Push in 5322 871 63606 Ser
40. 21 Vision Systems Line Array Camera Unlike the single camera the line array camera does not require an external program The standard camera scale utility available in Machine Adjust is used The head assembly is raised and lowered during the utility The component is measured at several angles and positions above the camera The results are displayed in a table at the completion of the scale measurement This table contains the camera scale rate and head delta information The camera s position and angle are indicated by the camera delta or camera correction information CAM COR Required Tools and Supplies 1 Square shaped QFP recommended for single camera alignment 2 Thin shims ranging from 0 05mm to 0 2mm 3 Allen wrenches Single Camera Adjustment The following steps will guide you through the COM utility Preliminary steps 1 Loading Utilities Check if the REC COM pgm is available in the c PGM directory If not use the SHELL manager to copy the COM utility to the c PGM directory 2 Component Preparation In the Philips DataBase select or create the vision file you wish to use Use a square component like the QFP48 or glass QFP2S If using the glass 25 from the Glass Adjustment kit set the Multi Detection to Adjust Mode 2 F6 Adjust the component and record the components lighting level 3 Set the Search area to 9 99 REC COM 1 Program Execution a Execute the COM
41. 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 7 1 Component Transport Systems 7 2 1 Mechanical Check Head Assembly This chapter describes how to check the air driven mechanical movements and vacuum generation in the head assembly Checking the ascent descent movement First make sure to the head is in such a position that it cannot hit anything when lowered Lower the head as follows Open the output monitor with lt 3 4 C1 output monitor and select the target head 01 to 08 with the cursor Press the enter key to lower the target head the output monitor position reads 1 when lowered and 0 when the head is raised Checking the lower end detection sensor While the head is lowered move the cursor with the TAB key to the input screen and move the cursor to the head up down sensor input NGO1 to NG08 Check the status of the input When the head is lowered output 1 the input monitor should read 1 The opposite situation is valid when the head is raised Notel The head end lower sensor that are used are of the type normally closed For safety reasons When a sensor wire breaks the machine will detect a head in the lower position and will stop immediately Note2 If the head does not move normally during the above testing check the operation of the head manually as follows Press the emergency button Press the manual button red button on top of the air valve of the air valve that i
42. 90 degree parameter is used a s a reference it is set to 0 00 degrees Service Manual Topaz 5322 871 63606 7 12 PA 1309 10 01 05 Component Transport Systems 7 2 5 Note The R table will always show the 90 degree as a reference so the value in this table is always 0 00 In case the multi camera is used as a reference internally a calculation is carried out to get the correction for the other angles 90 90 and 180 degrees Preparing the component and nozzle Prepare a QFP component to be used as a reference Preferably a large popular QFP of known size which is registered in the component database Example is QFP 100 P0 65 7L Press the emergency button and attach a QFP nozzle type 33 to each head Calibrating the R axis accuracy Follow the procedure below Cancel the emergency stop and select lt 3 3 B1 adjust target accuracy and press Enter Enter the head number and press Enter Enter the component database number of the component you prepared and press Enter Enter the feeder set number where you can easily attach the QFP manually to the nozzle and press the Enter key Press the emergency button and attach the QFP by hand to the head to be adjusted The QFP should be aligned with the long side parallel to the conveyor Cancel emergency ready and press Enter The head will move to the camera and recognise the QFP at each angle the results are displayed on the right side of the s
43. A MCH_CONFIG A5 FEEDER SPEC INF and press the ENTER key The screen appears as shown below DATA non lt lt lt APPLICATION gt gt gt 1 OPERATION M 2 DATA M 3 MAINTE M 4 SHELL M 0 lt lt MODE gt gt 1 MCH_CONFIG 2 MCH_DATA 3 MCH_ADJUST 4 MANUAL 0 EXIT PNEUMATIC Type FeederType LeftWidt RightWid PickPos Min Time LoadTime DownTime Sequence 8mmTape 7 80 8 00 00 0 0 TapeType 8mm1005cmp 7 80 8 00 00 0 20 TapeType 12mmEmboss 14 50 die 20 00 10 30 TapeType 16mmEmboss L650 5240 00 10 50 TapeType 24mmEmboss 2855500 220 00 10 50 TapeType 32mmTape 25 00 2190 00 15 50 32mmEmboss 24 70 22790 n 50 100 TapeType 44mmEmboss 30 70 28 50 E 50 100 TapeType 56mmEmboss 42 50 34 50 E 50 100 TapeType MultiStick 92480 87 00 5 0 140 StickTyp 0 00 0 00 b 0 0 TrayType Figure 7 29 Feeder plate spec information screen Minimum timer The minimum timer is the time during which the air cylinder is kept on so that the nozzle in the lowered position can pick up a component without fail The time is expressed in hundredths of a second Load timer The load timer is the time from which the air cylinder is turned off until the next component is securely delivered to the pickup position This is expressed in hundredths of a second Down timer Time that must be allowed between the feeder shutter opening and the head being lowered onto the component in thousandth of a second 0 2000 Caution This in
44. Adjusting the W axis machine reference Note The machine reference will be adjusted to about 2076 for every Imm movement of the origin dog Be sure to slide the dog slightly a maximum of 2 5mm If you slide it too far a 0 pulse in a different cycle may be received causing the origin position to shift 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 8 3 Axes Systems 8 22 Z axis Machine Reference The Z axis vertically moves the head assembly by ball screw When return to origin is performed the Z axis travels at low speed up against the upper end and the resulting excessive motor current is detected as an origin signal then the origin is set at the position of the preceding encoder 0 pulse as the motor reverses slightly There is no origin sensor and origin dog To adjust the Z axis machine reference follow these steps 1 Press the emergency stop button Loosen the bolt securing the coupling on the Z axis ball screw side refer to figure 8 4 below 3 Adjust the machine reference rotate the ball screw to adjust the machine reference as follows To increase the machine reference rotate in direction A down To decrease the machine reference rotate in direction B up 4 Retighten the bolt to secure the coupling after the machine reference is set within the tolerance range Z axis motor Coupling Z axis ball screw Figure 8 4 Adjusting the Z axis machine reference Note Imm movement of the
45. EMG STOP LED5 is NOT GOOD This means that there is something wrong with the HHK circuitry 0 Note 2 As can be seen from the diagram figure 4 it is only possible to have a cover open at 0 one side at the time It is also needed to press continuously the dead man push button in order to keep the servo system active 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 4 3 Power and Safety Circuits 374 generation connection board KV7 M 550 11X Safetyl jpg Emg sw Emg sw Emg HHK Rear Front X OT Wil YOT W 12 C am m OT OT2 OT3 OT4 OT5 Em EmglA 1B Emg 1C Emg 1D u 1 B 15 16 L8 is Emg MCX Controller KM 10 M Emg 1E Safety circuit simplified L10 S 1 EMG TF1 LCS ATS Emg 1F h GS 21 L11 45 EMG TF2 LCS ATS 24 Emg yo Cover sw front Emg 2A 113 Cover sw 1 Front Emg 8 Emg 9 y Cover sw TF2 Front Emg 2C Emg 8 Emg 7 L15 Service key Ir rear tr Cover sw TF1 Rear NICE Emg 6 Emg 5 4 e ue x 9 Emg 2E D oos Ema Figure 4 2 Revised safety circuit Topaz pian Clo Mari Conon LED ON Yellow LEDI 1 over travel is OK Yellow LED2 Not used 3 Yellow LED3 Y I over travel is OK 4 Yellow LED4 Not used 5 Yellow LED5 Not used on 6 Yellow LED6 HHK emergency stop is OK 7 Yellow LED7
46. FeederPlateOffset Plate No Y FeederPlate 1 51 50 3 53 FeederPlate 2 179 50 3 51 FeederPlate 307 50 3 35 FeederPlate 4 435 50 3 51 FeederPlate 5 563 50 3 53 Figure 7 18 Feeder plate offset editing screen 7 Lineup the cursor with the X column of the feeder block you are teaching 8 Press the F10 key The menu window for selecting teaching conditions then appears 9 Setteaching conditions 1 Select the teaching unit and press the ENTER key The head No you are using for teaching must be selected 2 Select any speed from Speed 1 to Speed 5 and press ENTER 10 Press the F10 key twice to perform teaching 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 7 23 Component Transport Systems 11 Press the F10 key twice to perform teaching 13 14 15 The X coordinate value of the reference feeder position is entered Then line up the cursor with the Y column The Y coordinate value of the reference feeder position is entered Repeat the process for other reference feeder positions Use the above steps installing the same tape feeder in each reference feeder position Save the settings Press the ESC key then select 0 5 amp QUIT or A2 SAVE and press the ENTER key To quit without saving select A7 ABORT amp EXIT and press the ENTER key Perform the component pickup test to check the settings This test should be performed for al
47. General Please observe all safety rules and cautionary remarks to ensure that the machine is used in a safe and correct matter Also please bear in mind that not all safety items can be listed in detail so that an accurate judgment by the service engineer is essential in servicing the machine safely Basic Rules The following are basic safety rules which must be observed 1 person who s servicing the machine must have received proper training to operate service the machine in a safe and correct manner 2 The power supply must be turned OFF whenever the machine is inspected parts are replaced or internal adjustments are made 3 During operation of the machine be sure to keep all parts of the body such as the hands or head away from the machine s moving parts 4 Be sure to keep the HHK Hand Held Keyboard in your hand whenever teaching or making adjustments to the machine so that it can be stopped at any time 5 Besure the interlock safety devices are maintained in an operable condition so that it can be used to stop the machine at any time 6 Do notuse the machine in an environment where flammable gasses are present or where it is extremely dirty Safety Standards The safety of the CSM GEM systems is in accordance with following CE directives Machine directive 89 392 EEC and 91 368 EEC including amendments Low Voltage directive 73 23 EEC including amendments EMC directive 89 336 EEC including
48. OFF THE MACHINE IF MECHANICAL ASSEMBLY OR DISASSEMBLY ACTIONS ARE CARRIED OUT 8 6 1 7 8 9 Adjustment of the X and Y motor Encoder Position Action before changing the X or Y axis or X or Y motor Perform init servo origin For reference point use a mark seal sticker with an accurate sign cross hair corner etc Put it on the middle of the front conveyor rail Perform teaching of a dedicated point with the moving camera Switch on Head light 1 09 Note the X and Y positions e g X 424 29 177 43 Action after changing the X or Y axis or X or Y motor Perform init servo origin Switch on the light of the moving camera 09 in lt 3 4 C display amp exit C1 gt output monitor Point move to the above noted positions Press the EMG switch Loosen the screws on the X Y motor coupling Push the Ready key on the HHK while still at the above X and Y positions This will block the positions of the X Y motor encoder Move the head assembly to the exact correct positions by hand look at the vision monitor Re tighten the screws on the motor coupling Point move to the noted positions again just to be sure Perform init servo origin 10 Check for 5096 values and readjust if necessary Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Axes Systems 8 6 2 Head Replacement Disassemble the head as described below see figure 13 5 3 Make sure to know the sta
49. Principles 2 os O JP1 3 SET jP1 3 REMOVED LightA or OFF oN or ON OFF Table 3 6 2 Vision board special light bit settings On the LED driver board a number of jumpers are available which are set from factory The table below shows the setting of these jumpers for verifying purposes only Jumper No EN jes LE ps X X Jumper set Setting 23 23 Setting BAL dme ape r6 2 3 or 1 2 is E mS ETE em to em 3 5 Pe an NETUS sanie not set Table 3 6 3 Vision board jumper settings As mentioned before the board is equipped with a speed feedback circuitry which is currently not in use For informational purposes only the table below indicates which light type and which camera is equipped with this functionality Camera No 2 3 4 Light No LightA Light B Light A LightB Light A lightB Light and feedback control No No Yes Yes Yes Table 3 6 4 Vision board feedback control overview Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles Boards Head l O board Left conveyor Right conveyor l O board Figure 3 7 1 Location of the I O boards The Topaz is equipped with three I O boards one he
50. ROM TYPE CURRENT ROM HEAD I O ROM CONVEYOR A I O ROM CONVEYOR B I O ROM Ext TC I O ROM SYSTEM ROM HHK ROM Figure 10 9 ROM IC version The screen in Fig 10 10 shows an example of the file configuration file version of the system Ifa file has not the correct level it will be shown in red It is necessary that all files have the correct level to avoid problems The screen in fig 10 10 shows an example of the various files with their level Depending on the VIOS version the file versions will change accordingly DATA non lt lt lt APPLICATION gt gt gt 1 OPERATION M 2 DATA M 3 MAINTE M 4 SHELL M 0 lt lt MODE gt gt 1 MCH CONFIG 2 DATA 3 MCH ADJUST 4 MANUAL 0 FILES amp DIRECTORY REQUEST VERSION STATUS MACHINE TYPE PATH KG2 42T0 011NN MESSAGE FILE PATH KG2 42M0 011NN APL EXE FILE 5 42 0 011 VISION HEX FILE KG7 44D0 208 IO OS BIN FILE KG2 4288 00A IO IPL HEX FILE KG2 4289 005 SEQUENCE HEX FILE DC SERVO HEX FILE AC SERVO HEX FILE 5 5809 900 Figure 10 10 File configuration 10 28 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section 10 6 System Messages This chapter gives a list of the system messages of the VIOS operating system The screens below are valid for the 0 9x software and higher In screen 4 SHELL M 2 DISK MAINTENANCE sub dir KG7 42 0 009 a list is shown of the contents of this sub directory see fig 10 11 With mov
51. Reel tape stuck Top foil wheel small rotates during upward stroke Set up spring incorrect mounted Replace Check pick position with Tape Feeder Adjustment Tool PA 2849 10 Insert tape according instructions Insert tape again make sure the scrapers are close to the wheels and the double guiding is straight Replace spring Replace spring Replace spring Check for obstructions Replace small wheel Check if the spring is set onto the correct fixing pin Service Manual Topaz PA 1309 10 5322 871 63606 01 05 Axes Systems CHAPTER 8 Axes Systems 8 1 Introduction This chapter describes the axes systems of the Topaz The mechanical movement of the TOPAZ systems is controlled by the five axes described in table 8 1 below W axis Adjust the width of the conveyor that carries AC motor ball screw in or out a PCB Z axis Moves the nozzle shafts of heads to 8 AC motor ball screw simultaneously in vertical direction PCB transfer direction right to left and left to right as viewed from the front of the machine X axis Moves the head assembly in parallel with the AC motor ball screw Y axis Moves the head assy forwards and backwards AC motor ball screw as viewed from the front of the machine R axis Rotates the nozzle shaft of the head 1 8 AC motor belt drive Table 8 Axes overview To preserve the repeatab
52. Regulator 5 2 5 1 5 Pressure Drop Detection Level 5 3 5 1 6 Measurement and Adjusting Vacuum Levels 5 4 5 1 7 Performance Check and Trouble Shooting 5 4 5 1 8 Maintenance Instructions 5 4 5 2 Pneumatic Systems 5 5 5 2 1 Introduction 5 5 5 2 2 Functional Description 5 5 5 2 3 Topaz 5 5 Service Manual Topaz 5322 871 63606 2 PA 1309 10 01 05 Table of Contents 5 24 Tray Changer TC 5 5 5 2 5 Tape Feeders 5 5 5 2 6 Automatic Tray Stacker 5 5 5 2 7 5 5 5 5 5 5 2 8 Measuring and Adjusting 5 6 5 29 Performance Checks and Trouble Shooting 5 6 5 2 10 Maintenance Actions 5 6 5 3 Exchanging Head Ejectors Valves and Base 5 7 5 3 1 Exchanging the Head Ejector and or Valves 5 7 5 3 2 Exchanging the Head Up Down Slow Valves and Valve Base 5 8 6 Transport Systems 6 1 6 1 Introduction 6 1 6 2 Conveyor Belt 6 2 6 2 1 Adjusting the Conveyor Belt Tension 6 2 6 2 2 Adjusting the Carry In Conveyor Speed 6 3 6 3 Main Stopper 6 5 6 3 1 Adjusting the Ascent Descent Speeds of the Main Stopper 6 5 6 3 2 Contact Point 6 7 6 4 Push In 6 8 6 5 Locate Pin 6 10 6 6 Edge Clamp 6 13 6 7 Push Up 6 14 6 8 PCB Detection Sensors 6 16 6 9 Conveyor Errors 6 19 7 Component Transport Systems 7 1 7 1 Introduction 7 1 7 2 Head Assembly 7 1 72 1 Mechanical Check Head Assembly 7 2 7 22 Machine Coordinates 7 5 7 2 3 Pickup and Mount Vacuum Levels 7 9 7 2 4 R axis Absolute Accuracy Offset 7 12 7 2 5 Nozzle Co
53. Service Manual Topaz 5322 871 63606 9 12 PA 1309 10 01 05 Vision Systems 9 4 2 NOTE Focus Adjustment To adjust the focus the special focus adjuster tool can be used The focus adjuster 5322 395 10275 is also used to adjust the cameras of the Orion Topaz or Sapphire Prepare a component in the component database so that the focus adjuster can be picked up with nozzle type 33or 34 Make sure the component thickness Z 0 and that the component focus adjuster is recognised at the correct camera Set the focus ring on the lens to the 0 5 position before adjusting the focus The Focus adjustment tool can only be used with a Fore lighting system Set the Alignment Module to Fore Dress F6 adjust assist Mark the nozzle position with a permanent marker onto the pick up surface of the focus adjuster tool see figure 9 16 This ensures that the tool is attached to head 1 at a fixed position Pick up the focus adjuster tool as shown in figure 9 16 Mark position Figure 9 16 Focus adjuster tool direction Adjust the focus by shifting the camera up or down see figure 9 17 At the level 3 position of the focus adjuster tool the focus must be optimal The machine will take in to account the Z height of the component and will subtract that number from the Camera Z co ordinate Figure 9 17 Nozzle back plate sides visible The bottom of the component will always be recognised at the same Z
54. WITH THE SKIN f DO NOT EMPTY INTO DRAINS Add oil between the parts as shown by arrows in figure 7 33 Lubricant Tellus 32 from Shell has to be purchased locally Rotate or move the parts several times so that the lubricant can spread Note The amount of lubrication oil should be a single drop supplied with a small screw driver or needle pin has to be purchased locally After lubrication wipe off excessive oil to avoid contamination Use only the type of lubricant that is mentioned above 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 7 37 Component Transport Systems Lubricate between the sprocket wheel ring and lever as well between the ratchet wheel and lever Ratchet wheel n Sprocket wheel Lubricating points Lubricating points Lever Jg View according B Lubricate between the rings and lever Lever Lubricating point View according SD 2354A WPG Lubricating points SD 23548 WPG Figure 7 33 Lubrication of the rotating and moving parts figures show mech feeders Service Manual Topaz 5322 871 63606 7 38 PA 1309 10 01 05 Component Transport Systems Trouble shooting Symptom description Possible cause Solution Automatic refire level to high number of re pick actions Feeder does not index correctly Tape out of
55. also distributing the 24VDC coming from the GS21 power supply and which is used for the I O and the EMG circuits From April 2000 onwards the Topaz system is equipped with the type of connection board that is also used in the X series Topaz So the a generation connection board KU1 M4550 00X with service no 5322 216 04312 has been replaced by a new version the 24 generation connection board KV7 M4550 11X with service no 5322 216 04675 Connection board version Generation Service number KUI M4550 00X 2 oldtyp 532221604312 KV7 M4550 11X 3 newtype 532221604675 Table 3 8 1 Connection board versions The differences between the KV7 M4550 11X board 34 generation and the older KU1 M4550 00X board 274 generation are 1 The 3 generation board contains more LED indicators 2 LEDS red for EMG indications 14 LEDS green for the various 24V power sources 2 At the 3 generation board only one 24V input connection CNF21 is used This means that the connector going to CNF22 on the z d generation connection board is not used anymore and can be stowed away in the cable duct 3 The 3 generation board contains automatic fuses These fuses protect the various 24V powers sources The fuses are of a type which trip above a certain current and restores it self after power is disconnected In chapter 14 a detailed logic diagram is shown of both boards and on the next pages the layout of both PCB s a
56. and mark data CAUTION Before re writing the software or hard disk always check if there is a system back up on disk It is strongly recommended to make a back up via the VIOS SOFTWARE UTILITY immediate after the system is unpacked and set up Keep this back up on a safe place away from the machine The back up can be done via the VIOS SOFTWARE UTILITY See for this procedure paragraph 10 3 2 of this chapter The SYSTEM disks 1 2 and 3 containing the files INSI LZH INS2 LZH and INS3 LZH which are compressed by means of the LHA command These files are the complete VIOS operating system and database which must be de compressed via the same LHA command The UPDATE bat and related files will take care of this extraction 5322 871 63606 01 05 Service Manual Topaz 10 5 PA 1309 10 Software Section 10 2 4 VIOS Software Utility This section describes how to start up the VIOS software utility for machines As soon as the MS DOS 6 2 system is loaded the system will wait for 6 sec before continuing with the VIOS boot up During that period the following message is shown Now Loading VIOS SOFTWARE UTILITY If you hit any key VIOS SOFTWARE UTILITY will start If you don t hit any key this mode will finish after 6 sec and machine continues to start up If a key is pressed during these 6 seconds the system will go into the software utility screen The following procedure has to be followed Type in
57. as follows Scale_y 83 97 To save the result in memory press the ENTER key Cam posx 0 00 the results are Cam posy 0 00 Cam posr 180 19 Rate 0 9923 Figure 9 25 Scale parameters 9 Press the ENTER key to save the calibrated results Press the ESC key if you want to discard the results 10 Note the camera position XY in the results When the Cam posx and Cam posy values are nearly zero 0 00 0 01 the calibration is satisfactory Press the ESC key to advance to the next Step If the Cam posx and values are too far from zero there is likely an error in the calibration Press the ENTER key to retry calibrating 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 19 Vision Systems cy NOTE 9 4 5 Verify the Cam posx and Cam posy values to be 0 00 by running the scale utility again One of the most important items of camera scale is that these values go to zero and are stabile If the position move by 05 or more with each run of scale then a mechanical problem exists loose elements in the lens or lens that is loose on the camera 11 When the calibration is complete dump the component Press the ENTER key to dump the component automatically If you want to quit without dumping press the ESC key and follow the message on the operation monitor 12 Save the calibration data Select B2 SAVE DATA or BO SAVE amp QUIT and press the ENTER key
58. assy Top cover assy Moving parts Top foil wheel Bottom surface check lubricate replace Figure 7 30 Preventive Maintenance Schedule b Recommended Materials Recommended Equipment and Materials for Cleaning and Lubricating Vacuum cleaner for maintenance close to the Topaz Compressed air gun for maintenance in workshop Pair of tweezers Small brushes Q tips Lint free tissue paper Isopropanol Light machine oil e g Shell Tellus 32 Screwdriver Philips no 00 2 feeler gauges of 0 05 mm thick Seal lock agent 063 Locktite 603 Punch maximal diam 2 mm Allen key 1 5 mm Screwdriver Torc no T10 Hammer small 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 7 33 Component Transport Systems c Checking the Cleanliness Frequency Weekly Required time 0 1 hr per feeder Procedure Check the whole tape path for contamination and clean it if necessary with a lint free tissue paper brushes or Q tips moistened in isopropanol Clean the feeder with compressed air or with a vacuum cleaner to remove all dust d Tape Path Cleaning Frequency daily Required time 0 1 hr per feeder Procedure Check if there is any tape sediment adhesive or component debris adhering to the tape travelling surface Special attention must be given to the tape path area underneath the top cover plate Clean if necessary with the recommended equipment and mate
59. be found that they together form data of one PCB Those files are C FILE ID Contains the name and run condition FILE BD Contains the PCB mount data FILE FD Contains the component and vision info FILE MD Contains all Mark information FILE PD Contains the production history An example is shown in figure 10 6 10 4 Machine Configuration The machine configuration list is located in the application MAINTENANCE MANAGER A1 OPTION CONFIG Depending on the configuration of the system it is possible to disable or enable parts and options of the machine see fig 10 7 DATA non 1 lt lt lt APPLICATION gt gt gt 1 OPERATION M 2 DATA M 3 MAINTE M 4 SHELL M 0 lt lt MODE gt gt 1 MCH CONFIG 2 MCH_DATA 3 MCH_ADJUST 4 MANUAL 0 EXIT lt COMMAND_LIST gt A MCH_CFG OPTION CONFIG HEAD SPEC INF FEEDER BASE INF NOZZLE SPEC INF FEEDER SPEC INF ROM CONFIG FILE CONFIG EXIT Figure 10 7 Maintenance manager 10 22 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section In figure 10 8 the machine configurations is shown of the VIOS V1 2x version There are a number of options and features that are not used in the Topaz REMARK the VIOS operating system is also used in other mounters By means of the INS and DEL key it is possible to enable or disable a certain option m M DATA non lt lt lt APPLICATION gt gt gt 1 O
60. by scrolling up or down The left side of the screen shows the output monitor and the right side of the screen the input monitor DATA non lt lt lt APPLICATION gt gt gt 1 OPERATION M 2 DATA M 3 MAINTE M 4 SHELL M 0 lt lt MODE gt gt 1 CONFIG 2 DATA 3 ADJUST 4 MANUAL 0 EXIT Out Monitor Select Enter Exec Selected Arm MAIN LESC Command sts Moving Speed Dialogue box R09 TRAY CHANGER S NAME OUT NAME IN Front Fdr data 201 08 00000000 Origin Limit NJO1 08 00000000 Front Fdr index TJ09 16 00000000 Origin Limit NJ09 16 00000000 Screen 1 Signal Tower TK01 08 00000000 Spare NK01 08 00000000 FORE M123 LEV TK09 16 00000000 Spare NK09 16 00000000 Spare TL01 08 00000000 Conveyor 101 08 00000000 Spare TL09 16 00000000 Conveyor NL09 16 00000000 Rear Fdr data TMO1 08 00000000 Origin Limit NMO1 08 00000000 Rear Fdr index 09 16 00000000 Origin Limit 09 16 00000000 NAME OUT NAME Head Down 01 08 00000000 Spare 00000000 LED FID BACK 09 16 00000000 Spare 00000000 Head Sequence TF01 08 00000000 Spare F 00000000 Screen 2 Head Sequence TF09 16 00000000 Spare F 00000000 Blow Timer TG01 08 00000000 Head Lowend 00000000 Blow Timer TG09 16 00000000 Origin Limit 00000000 Head Vacuum TH01 08 00000000 ead Pic Vacuum 00000000 Head Blow TH09 16 00000000 ead Mnt Vacuum 00000000 NAME OUT Conveyors 00000000 ozzle Sensor 00000000 Conveyors TN09 16 00000000 ozzle
61. components such as QFP s the lighting level and the scale of the single vision camera fixed camera must be adjusted correctly The single vision camera scale represents an actual measurement in units of microns equivalent to one pixel For accurate recognition of components this scale must be adjusted correctly To make the adjustment you will need a of known size Preparation for the single vision camera scale First check the current settings of the single vision camera scale 1 Select 3 2 A MCH_DATA gt A1 SELECT TARGET Vision Parameter and press the ENTER key 2 Check the settings of SingleCAM scale When you execute the single camera scale utility the X and Y values microns will be adjusted lt lt MODE gt gt 3 MCH_ADJUST A377 Camera 1 lt lt lt Result gt gt gt Distance 5 00 The results of calculating the scales of the single Scale_x 83 33 vision camera are as follows Scale_y 83 97 To save the result in memory press the ENTER key Cam posx 0 00 the results Cam posy 0 00 Cam posr 7180 19 Rate 0 9923 Figure 9 21 scale parameters 3 Prepare a QFP component to be used Use a relatively large often used component of known size which is registered in the component database If you use a component not registered in the database it must be registered first vl 2 TY NOTE Use of a component is recommended sin
62. digit reads 1 when the entrance stopper is at the raised position and reads 0 when it is at the lowered position 6 Adjust the low speed while running the conveyor at low speed and carrying in a PCB adjust the speed by turning the L screw Position the L screw so that PCBs are not subjected to a strong impact when they hit the entrance stopper 7 Check for switching from high to low speed while carrying in a PCB check that the conveyor speed smoothly changes from high to low speed 5322 871 63606 Service Manual Topaz 01 05 6 4 PA 1309 10 PCB Transport Systems 6 3 Main Stopper When the conveyor belt transports a PCB into the Topaz the main stopper will stop the PCB at the mounting position The ascent descent speeds of the main stopper and the PCB contact point can be adjusted please refer to figure 6 6 below Manual button mmm 14 TN0 Ascent speed adjuster Orange tube Black tube Descent speed adjuster Rear right side of the Topaz Figure 6 6 Main stopper and air solenoid valve 6 3 1 Adjusting the Ascent Descent Speeds of the Main Stopper 1 Open the output monitor screen and operate the mainstopper fig 6 7 Select lt lt lt 3 MAINTE M gt gt gt lt lt 4 MANUAL gt gt lt C DISPLAY amp EXIT CI OUTPUT MONITOR and press the ENTER key Use the arrow keys to set the cursor at 01 MAIN STOPPER Press the ENTER key to alternately rai
63. does not work normally check the operation without using the output monitor as described below Press the emergency stop button Press the manual button of the air valve use screwdriver or a similar tool When this method works the electric circuit for the air valve is probably defective Check the following points connector misconnection electro magnetic coil breakage loose harness connectors trouble with the DC24V supply I O board output errors etc Whenever pressing the manual button does not allow normal operation there is a problem with the air supply air piping and pipette valves damage clogging and adhesion of foreign matter Check the vacuum ejector air supply line Check for air leakage drop in vacuum in each head by connecting a vacuum gauge with air tube to the type 32 nozzle Measure the vacuum intensity mmHg the vacuum intensity is satisfactory when 500 mmHg or higher If the vacuum intensity measured with the vacuum gauge is lower than 500mmHg the vacuum generation line nozzle shaft air hose etc may be clogged If no clogging is observed the vacuum ejector causes the problem 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 7 3 Component Transport Systems Checking the vacuum sensor function To check the vacuum sensor function of the desired head by following procedure 1 Press the emergency stop button 2 Open the output monitor screen and select the target he
64. ejector cannot function adequately and air cylinders become unstable Be sure that the pressure is set within the specified WARNING range Service Manual Topaz 5322 871 63606 5 2 PA 1309 10 01 05 Vacuum and Pneumatic Systems 5 1 5 Pressure Drop Detection Level If the air supply pressure drops below this adjustable level the pressure drop detection switch triggers an emergency stop and inhibits the movement of all axes At the same time the message below appears on the operation monitor E 0806 QUICK STOP ACTIVE 09 AIR PRESSURE SW QUICK STOP FUNCTION for safety is now active To continue please check the supplied air To adjust the setting for pressure drop detection proceed as follows Open the lower right panel on the rear side of the machine The pressure meter is located over the valve control knob Adjust the level for pressure drop detection Turn the adjustment screw in the meter with a small slotted screwdriver so that the needle red is set at 0 4 to 0 45 MPa 4 to 4 5 kgf cm2 Pressure meter Adjustment screw for pressure drop detection level setting 9 SNNT Y V KY Wy BO Valve contro knob Figure 5 3 Air pressure drop level setting If this range and air cylinders become unstable Be sure that the pressure is set within the specified WARNING pressure setting is not correct the vacuum ejector cannot fun
65. feeder so the shaft 6 and the top cover plate can be removed Mount the new top cover plate spring at the same position and make sure that the spring end falls into the slit of the shaft Also pay attention that the lever 9 is pulled away Slide lip 2 to the most forward position so that the sprocket lip falls into the correct slit Rotate the shaft against the spring force clock wise 180 degrees 10 degrees or 1 2 stroke This guarantees that the slit in the shaft stands in horizontal position Secure the shaft with the socket set screw During rotation of the shaft push the cover plate with a small force onto the body Check the functioning of the cover plate before tape reel loading Make sure that the clamp lever 9 and the top cover plate are not scoring or catching the surfaces below to maintain freedom or movement Also the total width of the feeder front of the 8 mm feeders should not exceed 16 mm The total width of the feeder front of the 12 mm mechanical air driven feeders and the 16 mm air feeder should not exceed 20 mm Remark If the spring 12 is deformed the complete top cover plate must be replaced assembly The spring is good if the spring ends face each other 180 degrees 10 degrees visual inspection h Replace Gear Wheel Small Frequency Every 2 million indexes Required time 10 minutes Required Material 1 Drive top foil wheel 5322 522 33367 Procedure Loosen the countersunk scre
66. feeders Lock lever position 32 and 44 emboss tape feeders Figure 7 21 Tape feeder pitch The spacing between components on the tape also known as the pitch differs depending on type of components The tape feed pitch on the tape feeder must therefore be set to match the component pitch The table below shows feed pitches available for each type of feeder Tape Feeder Model No Pitch m m 8mm tape feeder PL 084 4 8mm tape feeder for 1005 chip PL 082 2 4 12mm tape feeder PL 12 4 8 16mm tape feeder PL 16 4 8 12 16 24mm tape feeder PL 24 4 8 12 16 32mm tape feeder PL 32 12 16 20 24 28 32 36 44mm tape feeder PL 44 12 16 20 24 28 32 36 32mm adhensive tape feeder PL N32 12 Figure 7 22 Tape feeder pitch 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 7 27 Component Transport Systems 8mm for 0402 chip and 12mm tape feeders To change the tape feed pitch setting modify the position of the air cylinder on the tape feeder as described below 1 Loosen the two screws for the air cylinder 2 Insert the two screws into the other pair of holes Use number 1 holes for 4mm pitch and number 2 holes for 2mmpitch 1005 chip 3 Tighten the screws to secure the air cylinder 1 4mm pitch 2 2mm pitch 1 8mm pitch 2 4mm pitch Figure 7 24 12mm tape feeder Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Com
67. following display appears showing the position of each part versus the origin and other basic parameter settings This section describes how to set the most important parameters a Tye x Y Y z 8 Feeder FINE angle 0 03 Multi camera Intermit 900 00 0 00 0 00 Locate pin 77 27 195 76 9 00 Edge Clamp 195 76 0 00 Wait point 344 29 430 84 4 0 00 Discard point 115 14 76 45 PCB Fix TF 16 95 Dual Rec Offset 0 76 0 00 0 01 Sumul pickarea 0 20 0 20 1 00 clearance 4 00 CngTimer Speed 100 00 100 00 Retry Limit 14 Dump stn point 0 00 0 00 0 00 Dump stn timer 0 00 0 00 0 00 Moving height Figure 7 3 Machine coordinates editing screen A Fine angle When FINE mode is selected to recognize a QFP with the single vision camera the FINE angle parameter determines how accurately the recognition angle should be converged adjusted to the specified angle This parameter can be 0 01 0 02 0 03 or 0 04 degrees We recommend setting to the minimum value of 0 01 for adjustment and to 0 02 or 0 03 for actual mounting operation 0 01 takes more time Use the INS DEL or SPACE key to make a selection N 0 NOTE The smaller the setting of this parameter the higher the recognition angle accuracy However the recognition time will be longer affecting the cycle time or there may be occasions when the component is dumped without being converged to the specified angle B Multi camera For the multi
68. gt lt lt 3 MCH_ADJUST gt gt lt B SAVE amp QUIT gt B1 ADJUST TARGET Software Limit and press the ENTER key 2 Use the arrow keys to line up the cursor with direct or direct in the RI MAIN or R2 MAIN row you want to adjust 2 Enter the software limit Enter 360 00 for the software limit on the plus side while 360 00 on the minus side Editing Object Software Limit Axis direct direct Init Pos Init Mov 12 R NO1 360 00 80 00 13 R NO2 360 00 360 00 80 50 Figure 8 20 R axis software setting screen 3 Save the settings Press the ESC key then select B2 SAVE DATA or BO SAVE amp QUIT and press ENTER key To quit without saving select B3 RECOVER ADJUST or B7 QUIT and press the ENTER key 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 8 19 Axes Systems 8 5 8 5 1 Initial Position and Initial Movement This section explains how to adjust the W axis and R axis initial position and Z axis initial movement W axis Initial Position The W axis initial position is the distance between the conveyor rails when the W axis is in the return to origin position expressed as a minus value To set the W axis initial position follow these steps 1 Perform return to origin 2 Press the emergency stop button 3 Determine the initial position 1 Measure th
69. i 49 0 Nem D 5322 464 10347 5322 530 10439 O RING END BLOCK BOLT Rcommended torque 147 0 Ncm Ejector replacement To replace the ejector itself refer to figure 5 4 and proceed as follows 1 D Woes Remove the valve on top of the ejector by following steps 1 and 2 of the previous procedure Valve replacement Remove the two screws holding the ejector to the ejector base end block Remove the ejector by moving it in the direction of the arrow Install the new ejector and take care about the direction of the gasket Tighten the two screws with a torque of 49 0 Ncm Mount the valve on top of the ejector by following steps 3 and 4 of the previous procedure Valve replacement 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 Vacuum and Pneumatic Systems Base replacement To replace the base of the ejector itself refer to figure 5 4 and proceed as follows 1 Loosen the two screws in the left or right end block 2 Remove the applicable end block and ejector base 3 Remove the valve and ejector on top of the ejector base or end block by following steps 1 to 3 of the procedure Ejector replacement 4 Install the removed ejector and valve onto the new ejector base by following steps 4 to 6 of the procedure Ejector replacement 5 Install the ejector base and end block while taking care of the O ring 6 Tighten the bolts with a torque of 147 0 Ncm REMARK If
70. limit values you have made a note when adjusting the secondary limits 1 Open the software limit screen 1 Select lt lt lt 3 MAINTE M gt gt gt lt lt 3 MCH_ADJUST gt gt lt B SAVE amp QUIT gt B1 adjust target Software Limit and press ENTER 2 Use the arrow keys to line up the cursor with direct or direct in the Y MAIN row 2 Enter the software limit On the plus side enter a value you have subtracted 1 00mm from the secondary limit or on the minus side a value you have added 1 00mm to the secondary limit 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 8 17 Axes Systems Editing Object Software Limit Axis direct direct Init Pos Init Mov Y MAIN i 11 86 Figure 8 19 Y axis software limit setting screen 3 Save the settings Press the ESC key then select B2 SAVE DATA or BO SAVE amp QUIT and press the ENTER key To quit without saving select B3 RECOVER ADJUST or B7 QUIT and press the ENTER key 8 18 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Axes Systems 8 4 5 R axis Software Limits The R axis software limit should be set to a fixed value of 360 00 on the minus side clockwise and to a fixed value of 360 00 on the plus side counter clockwise 1 Open the software limit screen 1 Select lt lt lt 3 MAINTE M gt gt
71. necessary Follow the steps below 1 Press the emergency stop button and prepare for adjustment e Loosen the set screws of the aperture ring and lens holder Prepare the light adjuster tool Focus ring Aperture ring Knurled ring complete lens Figure 9 28 2 Execute the line array camera Focus and Iris command e Select lt 3 3 B1 Adjust target Multi camera Focus amp Iris and press the Enter key e Select Use for the special tool e Select the camera to be adjusted 3 Attach the focus adjuster tool to head 1 as follows Attach a type 33 nozzle to head 1 if done by hand press the emergency button prior to this action Check that the emergency button is pressed Figure 9 29 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 25 Vision Systems 4 Cancel the emergency stop Ensure safety release the emergency stop button and press the Ready button on the Hand held keyboard 5 Ensure safety and press the Enter key again The head assembly moves and passes repeatedly over the line array camera while the image of the focus adjuster tool and its intensity profile is displayed on the vision monitor 6 Adjust the Focus and aperture By rotating the aperture and focus by means of the lens holder the optimum image in a scale range of 1 to 6 as shown in the figure must be found Figure 9 30 One way of performing this adjustment is following e Open
72. open level by offset Mounting vacuum level is Offset 5 A443 It will measure the vacuum level when picking This adjustment requires a nozzle or no nozzle on the head with no component attached Press the EMG lt lt Measuring gt gt New it is measuring vacuum level It takes 20 A445 lt lt Result gt gt The following data is the result of the adjustment of the vacuum level when picking and mounting A444 1 2 3 Level XXX 0 0 Current XXX 0 Result XXX XXX 0 cocoon ooooo Figure 7 5 Vacuum results Service Manual Topaz 5322 871 63606 7 10 PA 1309 10 01 05 Component Transport Systems B Mount level adjustment When a nozzle descends to mount a component onto the PCB the vacuum pressure at the nozzle is instantaneously inverted to a positive pressure so the detected value of the vacuum sensor decreases When this level becomes lower than the preset mount vacuum level the machine assumes the component has been separated from the nozzle and mounted onto the PCB The mount vacuum level should be preset for each of the eight heads at a slightly lower offset is 5 value than the maximum vacuum level when the nozzle opening is sealed 1 Go to menu MAINTE M MCH ADJUST B1 ADJUST TARGET and select Vacuum Level S
73. position 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 9 13 Vision Systems The focus adjustment influences the maximum component size adjustment so take care of that and find the optimum value for both focus and maximum component NOTE The focus must be adjusted by moving the camera up or down not by turning the focus ring Only use the focus ring adjustment if no good results can be obtained This because it is a very precise adjustment Figure 9 18 Nozzle back plate sides visible 9 4 3 Lighting Level Adjustment This section describes how to adjust the lighting level of the Single vision camera This can be done in two different ways proceed as indicated in following steps 1 The lens aperture setting diaphragm of the single camera is corrected automatically in software while doing the fore light adjustment The aperture ring on the lens of the single camera must be set in between position F2 and F 2 Execute the SingleCam Light utility as follows e Select lt 3 3 B1 Adjust target SingleCam Light and press Enter e Enter the database number of the component you are using for this adjustment and press Enter If you have added an optional high precision vision camera select SingleCam2 to adjust it e Enter the feeder set number and press the Enter key When the selected component is registered as a tray component this dialog box does not appear Ser
74. primary side ee m 2 P 1 ERKKI 9 099 DOGS GC XS OGIO 0000000001060 PAZ e OR KK Voltage Supply 416 KXOIOKOXOKOXC or imate or inen ide CERK E PX OOOO KY OKOKO OXON PS b 5575559 905666666 666 PLKK 2 CES ee X GC X TETELE 19 Figure 3 2 settings of the mains transformers 5322 871 63606 Service Manual Topaz 3 3 01 05 PA 1309 10 System Principles In figure 3 2 2 the circuit breaker box is shown with removed front cover This box locates all the circuit breakers of the Topaz system Below a list is given of all the circuit breakers functions 11 13 Mains circuit breaker QF21 2A Monitors VGA 4 Vision monitors QF22 5A Controller box and power supply 6521 QF31 10A Motor drivers QF32 2A Conveyor motors XB11 Mains input terminal QF11 13A es 21 QF22 2A 5A Ly E QF31 QF32 L1L2L3PE E XB11 Figure 3 2 2 Circuit breaker box with removed cover Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 3 3 System Principles Air Specifications and Connection Th
75. process The PCB will be pushed against the top side of the conveyor rail please refer to figure 6 19 To adjust the ascent descent speeds of the push up plate proceed as follows Ascent speed adjuster Black tube Push up pin and air solenoid valve a Rear right side of the Topaz Figure 6 19 Push up and air solenoid valve 1 Open the output monitor screen and operate the push up plate 1 Select lt lt lt 3 MAINTE M gt gt gt lt lt 4 MANUAL gt gt lt C DISPLAY amp EXIT gt C1 OUTPUT MONITOR and press the ENTER key Use the arrow keys to line up the cursor with TN02 PUSH UP Press the ENTER key to alternately raise and lower the push up plate The output monitor digit reads 1 when the push up plate is at the raised position and reads 0 when it is at the lowered position support plate 4 Pin shaft Conveyor frame Wing nut Magnet Figure 6 9 supporter pins Service Manual Topaz 5322 871 63606 6 14 PA 1309 10 01 05 PCB Transport Systems Out Monitor 4 4 Select Enter Exec Selected Arn MAIN XY ESC Command Lists Moving Spead 100 TNO2 PUSH UP DOWN 0 UP 1 0 0 NL10 1 NAME zusuauuxutumsen Raden Conveyors ssmouvecesvsxus o m m aas hnasesuen emneono cvaxesun exunsuxusnsunm senxuama suxcoxasasemn sxs 01000000
76. settings VIOS version 1 2 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 10 23 Software Section 10 4 1 Machine Configuration Detailed Default selections are marked with an asterisk if no default is defined then the setting depends on the machine configuration more choices applicable in that case Some differences can noticed between both VIOS versions indicated where needed Machine config BASIC CONF Parameter Selection 1 Message Japanese English 2 Simple Edition Primal Items Full Items 3 RS232C CMU Ignore Normal WithCMU Report 4 Sub Mach Type 5 100 SM100 IISP Machine config SOFTWARE 1 Online Optimize Exist None 2 Badmark function Normal 3 Badmark Distinction Normal Reverse No limit Limited 4 Air Consumption 5 Alternate Component WithConfirm WithEmpthyMes Continue 6 Retry Sequence ReworkCycle GroupRetry SkipRetry Description Not English Not Japanese special other language do not select if special language is not installed Some component parameters are not shown All component information is shown No communication Standard communication As with Normal but condition reports are send as well for PCS software For Topaz For SIMM topaz Simple optimiser during running No optimizer used during running Normal use of badmark Transmit CMU To transmit to a external PC for data sharing via a RS232
77. specification diam sprocket holes 1 6 mm max play component in pocket 0 5 mm max Feeder not placed correctly Feeder interface damaged Tape or cover tape path not correct or obstructed Speed air cylinder too low Index mechanism polluted Clamping lever of feeder to the left presses against index mechanism Index mechanism damaged Cover plate not completely closed Cover plate damaged Index force extremely high Spring left pulley broken absent Spring top foil broken absent Replace tape Clean feeder bar Clean feeder bottom Send feeder back for repair Correct path and or remove obstructions Check adjustment Clean index mechanism Tighten clamping lever to the feeder body Send feeder back for repair Remove obstructing components Replace cover plate Lubricate rotating parts Replace Replace 5322 871 63606 Service Manual Topaz PA 1309 10 7 39 Component Transport Systems Symptom description Possible cause Solution continue Feeder does not index correctly Pick position wrong Cover tape does not peel back from carrier tape Cover tape does not peel back from the carrier tape at the appropriate timing specially paper tape Spring set up broken absent See index problems Tape not inserted correctly Tape stuck between wheels Spring left pulley broken absent Spring top foil broken absent Spring set up broken absent
78. the Focus and Aperture 9 25 9 5 3 Adjusting the Lighting Level of the Line Array Camera s 9 27 9 5 4 Adjusting the Line Array Camera Scale 9 28 9 5 5 Adjusting the Dual Recognition Offset 9 33 9 5 6 Replacement of the Line Array Camera 9 34 9 6 Cleaning the Optical Systems 9 35 9 7 Recognition Errors 9 36 9 7 1 Chip Components 9 36 9 7 2 QFP Components 9 37 10 Software Section 10 1 10 1 Introduction 10 1 10 2 System Software 10 2 10 2 1 Operating System 10 2 10 2 2 Disk Organization 10 2 10 2 3 Installation Disk Contents 10 4 10 2 4 VIOS Software Utility 10 6 10 2 5 Installation of a New Version VIOS System Software 10 13 10 2 6 Backup Creation 10 14 10 2 7 VIOS Configuration 10 15 10 2 8 Floppy Disk Problems 10 16 10 2 9 Flash Disk Problems Only for Systems with KM5 System Boards 10 16 10 2 10 Hard Disk Problems 10 17 10 3 File Handling 10 20 10 4 Machine Configuration 10 22 10 4 1 Machine Configuration Detailed 10 24 10 5 ROM and File Configuration Version Level 10 28 10 6 System Messages 10 29 10 7 Online Commands 10 32 Machine Installation and Calibration 11 1 Introduction 11 1 11 2 Installation 11 1 11 2 1 Installation Position Work Area Condition 11 3 11 2 2 Environment 11 3 11 2 3 Leveling the System 11 3 11 2 4 Removing the Transportation Locks 11 4 11 2 5 Monitor and Keyboard Installation 11 5 11 2 6 Installation of the Warning Light Tower 11 5 11 2 7 Transfo
79. the PCB layout e One in the front or two second at the back linear sensor camera systems also referred to as multi camera This camera is used to recognise components as chips etc T he camera uses a one line CCD to read one line of the picture at a time the picture of the component is build by flying over the camera with a specified speed and storing line by line in memory One camera also referred to as the single vision camera to recognise component etc This section describes how to adjust the vision system All adjustment items can be adjusted with the utilities in the Machine Adjust mode of the maintenance Manager Be aware that the second multi camera which is an option reduces the maximum PCB width from 407mm to 305mm d on 10943100 00 Head assembly Moving camera camera Single vision camera Figure 9 Vision Systems of the Topaz 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 Vision Systems pa ay 9 2 1 9 3 9 3 1 Pre Start Operations Prior to the camera adjustments especially the single and multi camera adjustments it is wise to perform one or more of the following pre start operations e Ifa FES is installed to front of the system remove the FES carriage to enable easy access to the multi and if installed also the single vision camera If a FES is installed at the backside of the system remove the FES carriage if an optional second
80. the aperture for maximum light with a minimum depth of field bottom lens ring and set the focus ring upper lens ring to 0 5 You will only see one peek on the screen rotate to lens holder complete lens up down to shift this peek to the 3 value on the adjuster tool e Adjust the aperture close it to increase the depth of field to the scale value of 1 to on the adjuster tool e fit is not possible to adjust it in this way the cause may be the amount of light might which is too much or too low Try closing the aperture a little or if this will not work increase the lighting intensity on the LED driver board see next paragraph e Incase of two line array cameras try to obtain the same lighting level on both front and rear camera WARNING The head assembly passes repeatedly over the multi vision camera during the adjustment Be extremely careful not to touch the head with your body 7 Press the Enter or the Esc key when the adjustment is complete Follow the messages displayed on the operation monitor There is no machine data that needs to be saved after this adjustment Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Vision Systems 9 5 3 8 Tighten the set screws Press emergency and remove the adjuster tool from head 1 e Tighten the screws not too tight of the aperture and lens holder Recheck the focus after tightening Adjusting the Lighting Level of the Line A
81. the password for level 8 after the message is displayed and press the Enter key Use the up down key to select the language and press Enter Then the main menu of the VIOS Software Utility appears with the following selections Starting Up Machine VIOS Soft Version Up System Data Utility VIOS SOFTWARE UTILITY Installation Change of Protect Level Database Utility Production History Utility Disk Utility VIOS Special Command S9 ONY RS EA qs These 9 selections will be discussed in the next paragraphs Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section 3 1 Starting Up Machine This command starts up the machine in the normal way Remark This command is only available for VIOS releases from V1 20 software onwards 3 2 VIOS Software Version Up This command execute the version up of VIOS V1 2x software using SYSTEM 1 DISK until SYSTEM 3 DISK see paragraph 10 2 5 3 8 System Data Utility MAIN MENU 1 Starting Up Machine 2 VIOS 8 Syst 4 VIO SUB MENU 5 Chan 2 System Data Installation B Data 3 Return to MAIN MENU Prod 8 Disk Utility 3 VIOS Special Command System Data Backup This command saves machine data into SYSTEM DATA DISK After the changing of option configuration database machine data etc use this command to save the newest information onto the floppy disk System Data Installation This command executes the initial installa
82. the position for mounting adjust the speeds of the push in mechanism proceed as follows refer to figure 6 10 fi fet Manual button Press in speed adjuster Orange tube Black tube Release speed adjuster Rear right side of the Topaz Figure 6 10 Push in and air solenoid valve 1 Open the output monitor screen see figure 6 11 and operate the push in mechanism Select lt lt 3 MAINTE M gt gt gt lt lt 4 MANUAL gt gt lt C DISPLAY amp EXIT gt C1 OUTPUT MONITOR and press the ENTER key Use the arrow keys to line up the cursor with N05 PUSH IN Press the ENTER key to alternately close and release the push in mechanism The output monitor digit reads 1 when the push in mechanism is active and reads 0 when it is released Tle 4 Select Enter Exec ESC Command Lists TNO3 LOCATE PIN DOWN 111 Selected Arn MAIN XY Moving Speed 100 Out Monitor 0 UP O NUM 1 ACHES READS EAT xt ziau 00100000 ITI sxscwmusausTzuu ssnecaw Conveyors 4e esenene censoxsse kowsemuonosann umssem ichs MAxO EHVAS ETT w eraorvasen Figure 6 11 o ssh usu sranesa EETETETT sasaszssasas asansene ansasen monitor screen activate push
83. to C A by using ctrl Pgup Pgdwn f remove floppy disk g Esc and press F10 to save and exit h System asks Write to CMOS and exit y n Answer enter i Turn off power j Turn on power And after boot up the screen will show the C prompt k Insert the VIOS SOFTWARE UTILITY disk into the floppy drive 1 At the C prompt type ASUPDATE and press the ENTER key m After copying some files the message turn off power will be displayed Turn off power and remove the floppy disk from the drive n Turn on power and after loading DOS a message will appear on the screen for 6 sec Please input password and hit the ENTER key Enter specialist and press the ENTER key o Select 2 VIOS Soft version up and press the ENTER key p Follow the instructions on the screen SYSTEM 1 DISK SYSTEM 2 DISK SYSTEM 3 DISK q Select 3 System Data utility and select System Data installation r Insert the SYSTEM DATA DISK which contains the latest machine data for that machine into the floppy drive and press Enter key s After copying of the machine data files is finished remove the floppy disk t Select 1 starting up machine and press the Enter key The system will now start up the VIOS system 5322 871 63606 Service Manual Topaz 10 19 01 05 PA 1309 10 Software Section 10 3 PCB File Handling This chapter describes the issues
84. 0 8 Head 0 00 0 00 0 00 0 00 Figure 7 7 Note These off sets are automatically corrected when you execute the mount feedback Vision Since the position at O degree is used as a reference it is always set to 0 00 determine these offsets use the R axis accuracy routine in the maintenance manager The machine automatically evaluates these offset settings by recognizing the component that a head picks up while rotating the nozzle shaft at the four angles Two situations be distinguished Topaz with only the multi camera installed When the multi camera with the reference mounting angle specified at 0 degrees is used mountings at 90 180 and 90 might deviate slightly This deviation or offset can be corrected with the R axis accuracy command in which the multi camera recognizes a QFP component at the four mounting angles to determine the offset with respect to the recognition result at 0 degrees Since the 0 degree parameter is used a s a reference it is set to 0 00 degrees Topaz with an optional single camera installed When a single camera with the reference mounting angle specified at 90 degrees is used mountings at 0 180 and 90 might deviate slightly This deviation or offset can be corrected with the R axis accuracy command in which the multi camera recognizes a QFP component at the four mounting angles to determine the offset with respect to the recognition result at 90 degrees Since the
85. 01 05 Axes Systems 6 Perform teaching for the Z axis initial movement Select lt 3 B SAVE amp QUIT gt B1 Soft Limit and press ENTER 1 7 Next enter the initial movement for Head 2 Z2 axis Use the arrow keys to line up the cursor with Init Mov in the Z1 MAIN row Press the F10 key twice to perform teaching The numerical value of the parameter that the cursor is on changes Enter the same value as for Head 1 for Init Mov in the Z2 MAIN row 8 Cancel emergency stop Ensure safety then release the emergency stop button and press the READY button of the HHK Editing Object Software Limit Axis direct Init Pos Init Mov Z1 MAIN Figure 8 24 Software setting screen for initial movement 9 Save the settings Press the ESC key then select B2 SAVE DATA or BO SAVE amp QUIT and press ENTER key To quit without saving select B3 RECOVER ADJUST or B7 QUIT and press the ENTER key 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 8 23 Axes Systems 8 6 Axes Assembly Disassembly Adjustments and Maintenance This section describes the assembly disassembly and adjustments of the various axes systems in the Topaz WARNING MAKE SURE TO TAKE ALL THE NECESSARY SAFETY PRECAUTIONS WHEN DOING MECHANICAL ACTIONS AT THE SYSTEM ALWAYS SWITCH
86. 12V power Swap the floppy drive if the connections and voltages are OK Flash Disk Problems Only for Systems with KM5 System Boards Systems delivered after November 1998 are equipped with the new system board which do not have a hard disk anymore These systems are equipped with a so called FLASH disk which is mounted onto the SYSTEM PCB The disk is treated as a normal IDE drive of 40 Mb It is also possible to have 85 Mb disks installed The disk when ordering at PCS Philips EMT warehouse are normally already formatted with the MS DOS6 2 system This means that no installation of the DOS system is needed when ordering the 12 NC Code number If there are problems with the disk use the same procedures as described for the hard disk to check format and install the MS DOS and the Application software The only difference is the way to enter the BIOS set up This can be done by pressing the F10 key After doing so locate the boot disk selection and change it manually from C to A Remember to set it back after the action is completed To install the new MS DOS 6 2 system insert the hard disk maintenance disk No in the floppy drive and reboot the system Continue with step 3 in section 10 2 10 Remark It is NOT possible to use both Flash and Hard disk at the same time this because the 80486DX 4 100MHz card PC does not allow both disks simultaneous For this reason there is not HD connector available on the new system boar
87. 13 6 6 13 6 4 R axis Assembly 13 6 6 13 7 Module 7 Vision Systems 13 7 1 13 7 1 Camera Systems 13 7 2 13 7 2 Lighting Systems 13 7 2 13 8 Module 8 Options 13 8 1 13 8 1 Tray Changer 13 8 1 13 8 2 Tape Feeders 13 8 1 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 Table of Contents 13 8 3 Feeder Exchange System FES 13 8 4 Set up Verification System SVS 13 8 5 Automatic Tray Stacker ATS 13 9 Module 9 Maintenance Tools 13 10 Module 10 Fixation Parts 14 Drawings and Circuit Diagrams 15 Main Index 16 Options 16 1 Tray Changer TC 16 1 1 Introduction 16 1 2 Specifications 16 2 Auto Tray Stacker ATS 27 16 2 1 Introduction 16 2 2 Specifications 16 3 Set up Verification system SVS 16 3 1 Introduction 16 4 Feeder Exchange System FES 16 4 1 Introduction 16 4 2 Specifications 16 5 Component Feeders 16 6 Project SIMM Topaz 9466 920 06011 17 Appendix 1 Material Safety Data Sheets 13 8 1 13 8 1 13 8 1 13 9 1 13 10 1 14 1 15 1 16 1 16 2 16 2 16 3 16 4 16 4 16 5 16 6 16 6 16 7 16 7 16 8 16 8 16 9 17 1 Service Manual Topaz 8 PA 1309 10 5322 871 63606 01 05 Introduction CHAPTER Introduction l l General Introduction The service manual describes electrical mechanical software and pneumatic aspects of the GEM Topaz system The repair philosophy of the electric part of the machine is based on PCB swapping and not on com
88. 177 2235 ZO 577 248 1868 816 955 95 09 019 96502529 96502529 SU e 95 e 95 gu 95 OS 9 509 9 agy 09 09 Time 01 O1 oss oo 59 895 RSS 258 859 b INS 855 35 395 185 3 5 RSS The _E TXT files contains the English text files The J TXT files contains the Japanese text files And the _S TXT files contains the text files for a special language ea French German if available All these text files can only be viewed in the VIOS software 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 10 29 Software Section ERRMES E txt In fig 10 12 a small part of the Error list is shown 30000 Detection succeeded The corrected data is now effective S50xX 0000 E 0001 CORRECTION DATA ERROR Only 1 Lead detected 5022 0000 E 0002 CORRECTION DATA ERROR Correction data is not loaded Or it diversifies 5022 0000 E 0003 COMPONENT DETECTION ERROR Figure 10 12 ERROR HLPMES F txt This file contains the help messages which is shown with the F1 key fig 10 13 0000 YOU CAN PUT 74 CHARACTERS PER 1 LINE 19 LINES PER 1 PAGE DINI I ORSSINIBGESDYS THIS IS A TEXT FILE FOR ONLINE HELP MESSAGES IF YOU PUSH THE F1 KEY YOU WILL GET AN EXPLANATION AND PUSH ANY KEY TO CLEAR THE EXPLANATION THIS MESSAGE IS 0 639 0000 0001 1 OPERATION M lt lt lt OPER
89. 2 46 12 4 2 E error Messages 12 52 12 5 Overview of Error Messages in the Vision Monitor 12 150 13 Spare Parts List 13 0 1 13 0 1 General Information 13 0 1 13 0 2 Ordering Spare Parts 13 0 2 13 0 3 Regional Stock Keeping 13 0 2 13 0 4 Overview of the Various System Modules 13 0 3 13 0 5 First Aid Spare Parts Kit 13 0 5 13 1 Module System Principles 13 1 1 13 1 1 MCX2 Control Unit 13 1 2 13 1 2 Cover Assemblies 13 1 8 13 1 3 Monitor Assembly 13 1 10 13 2 Module 2 Power and Safety Circuits 13 2 1 13 3 Module 3 Vacuum and Pneumatic Systems 13 3 1 13 4 Module 4 Transport Systems 13 4 1 13 4 1 Conveyor Assembly 13 4 2 13 4 2 Conveyor Auto Width Assembly 13 4 4 13 4 3 Sub stopper Main stopper and Locate Pin Assembly 13 4 6 13 4 4 Edge clamp and Push in Assembly 13 4 8 13 4 5 Push up Pin and Push up Assembly 13 4 10 13 5 Module 5 Component Transport Systems 13 5 1 13 5 1 Nozzle Station Option for Standard Topaz 13 5 2 13 5 2 Nozzle Selection 13 5 4 13 5 3 Head Assembly Part General Parts 13 5 6 13 5 4 Head Assembly Part 2 Head Splines amp SIMM Topaz Head Assembly Spares 13 5 8 13 5 5 Head Assembly Part 3 Z axis Assembly 13 5 10 13 5 6 Head Assembly Part 4 Valve and Ejector Assy s 13 5 12 13 5 7 Head Assembly Part 5 R axis Assembly 13 5 14 13 5 8 Feeder Holder 13 5 16 13 6 Module 6 Axes Systems 13 6 1 13 6 1 X axis Assembly 13 6 2 13 6 2 Y axis Assembly 13 6 4 13 6 3 Z axis Assembly
90. 22 216 04004 KG7 M4520 01X npn 5322 214 91374 KG7 M4570 01X pnp 5322 216 04001 KM5 M4570 00X pnp S 5322 216 04313 5 4570 01 pnp S 5322 216 04469 1 4570 00 pnp O T 5322 216 04083 4570 00 pnp O T 5322 216 04628 EI EM CT US 5 45 9 10 F KM5 M4560 11X KM5 M4582 00X KG2 M45R9 002 n a KG2 M45R9 023 n a KG7 M45R9 00X n a KG2 M45R9 023 n a KG2 M45R9 030 n a 5 45 9 10 F KM5 M4560 11X KM5 M4572 00X KG2 M45R9 023 n a KM5 M45R9 10X F KM5 M4560 110 4572 00 El Eclipse Eclipse Ell Eclipse EM Emerald Cl Comet Comet Cll Comet Il S Sapphire Orion T Topaz Table 3 7 6 versions Remarks 1 Board will be stopped in March 1998 and replaced by KM5 M4570 01 X 2 This board is standard implemented in these machines from December 1998 onwards for Sapphire from august 1998 onwards 5322 871 63606 Service Manual Topaz PA 1309 10 3 8 3 8 1 System Principles Connection Board General The connection board interconnects all signals from and to the sensors switches relays and some valves All signals which are not directly controlled by the MCX controller and I O s signals which are controlled directly by the I O boards are not going via the connection board The board is
91. 3 pin female This is the connector for incoming PCB request signals from the machine in the next process the pinning of this connector is as follows pin 1 signal NJ15 Count reset signal pin 2 signal NJ12 Gate in signal input pin 3 signal 24C OV Ground shared by 15 and NJ12 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles Gate in signal input This signal is received from the machine in the subsequent process When there is conductivity between 2 3 closed the system judges that a request for a PCB loading has been made When mounting has finished the is ejected Count reset signal This signal resets the counter for the max number of PCB s If 1 3 become conductive closed the PCB counter is reset The output from the subsequent process should be handled as relay contact points dry contact point no voltage output In figure 3 4 3 the gate in connection is shown MAIN UNIT Count Reset NJ15 GATE IN NJ12 Machinery lh GND 0V subsequent processes Figure 3 4 3 Gate in connection IN WPG MAIN UNIT Not connected TK05 GHD Machinery in previous process Figure 3 4 4 Gate out connection OUT WPG e out connector output This is the connector for PCB request signals sent to the machine in the previous process the pinning of this conne
92. 5 DATA non lt lt lt APPLICATION gt gt gt 1 OPERATION M 2 DATA M 3 MAINTE M 4 SHELL M 0 lt lt MODE gt gt 1 DATA FILE MNG 2 DISK_MAINTENANCE 3 VIOS DIC 0 DIRECTORY C NornNNOl DIRECTORY Cs V OE Name Ext Size Date Time Name Ext Size Date Time FSR jones 95 02 26 1155116 ae gt SUB_D 96 02 26 15g LOOO BSI OQ ZH 09552 D_BASE gt SU 96502726 TOSO FONT gt 50 D GIG UO AS OM 4 UTOR ESSE INS gt SU OE i52 917 16 355857 NOO gt SU 960226 0 OEEO 3109275 NO1 gt SU 96 02 26 PGM gt 50 965025626 SVOE 95 965 1 3 48 P BASE gt 50 96502 2 i309 95 12 09 15500 RAMD gt 50 96 02 26 0 93 09 24 3 29 STATUS gt SU DOLI 7 1 1 0 i di 800101 800201 800901 USER 800101 800201 800901 USER 800101 800901 800201 800901 800101 800201 800901 CE NA do MEO PG Ore a8 KG2 42M0 gt SU 6 100 26 50 92 12 1056 04 KG2 42T0 2S8UB 96702729 dL SO 212 820 KG2 4289 9 2 0 3 016 0 93 09 24 32 3 KG2 4288 2 OQ 92 12 40 04 KG2 58D9 0505 12 22510 LA 2 141 KG7 44D0 OEIL 4019 UJ UJ UJ UU UJ DU UJ UJ UU UJ CJ e UU dues ui qo Mew ur a er ur quos Ts wr MT Figure 10 5 DATA non lt lt lt APPLICATION gt gt gt 1 OPERATION M 2 DATA M 3 MAINTE M 4
93. AINTE M ADJUST B1 ADJUST TARGET and select Vacuum Level See figure 7 5 4 To adjust the machine low level select the ALL and Pick from the menu The choice will allow the adjustment of all heads at the same time The Key In option will prompt the user to select any of the eight heads 5 After the above choices have been made VIOS prompts the user to input a vacuum offset This is to create a safe 10096 working range Generally an offset of 5 is a correct value However when using nozzle 31 small components changing the offset from 5 to 0 will increase the vacuuum range This will allow a better distinction between an open and a closed nozzle Enter this value and press ENTER See figure 7 5 6 Press enter to start the measurement the pickup vacuum level is measured for 8 to 20 seconds then the results are displayed 7 The pick up level will be measured for 8 to 20 seconds After that the results will be displayed See also figure 7 5 8 Select B2 Save DATA or BO save amp quit and press enter lt lt lt APPLICATION gt gt gt 3 MAINTE M lt lt MODE gt gt 3 MCH ADJUST COMMAND LIST B SAVE amp QUIT B1 ADJUST TARTET Object Head Target Vacuum Level 6 4 442 4 4 lt lt MODE gt gt 3 MCH_ADJUST A441 Please input the offset value of the vacuum level Picking level used is higher than
94. APTER 2 General and Electrical Block Diagram This chapter shows both general and electrical block diagrams of the Topaz The general block diagram figure 2 1 shows the main sections of the Topaz References are made to the chapters in this manual The electrical block diagram figure 2 2 shows an overview of the main electrical parts of the system 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 2 1 General and Electrical Block Diagram VISION SYSTEM Chapt 9 COMPONENT TRANSPORT SYSTEM Chapt7 AXES SYSTEM 8 PCB TRANSPORT SYSTEM Chapt 6 MCX CONTROLLER USER Chapt3 Chapt 3 INTERFACE SOFTWARE Chapt 10 SUPPLY Chapt 11 POWER SUPPLY Chapt 11 gt 20 Figure 2 1 General block diagram Topaz Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 General and Electrical Block Diagram HD disk C FES FEEDER CONVEYOR EMG VACUUM UP DOWN SENSING FES FEEDER CONVEYOR EMG 1 44 A qT 3 5 Floppy VGA Monitor Handheld keyb CPU BOARD VGA controller HDD controller FDD controller control 1 SDLC I O 2 left side 1 HEAD I O VO 2rightside VACUUM EMERG 4 CONVEYOR I O 2 conveyor Tray changeror ATS MAINS POWER SAFETY CIRCUIT 282 VOLT POWER SUPPLY EMG amp I O POWER SUPPLY Flash disk only on new CPU Located within MCX Contro
95. ATION MANAGER gt gt gt supports daily production MODE RUNNING Production Warming Up ae nib PRD DATA PCB data modification 621 PRD HISTORY 5 production history Figure 10 13 HLPMES 10 30 Service Manual Topaz PA 1309 10 5322 871 63606 01 05 Software Section MOSMES_E ext This file contains the text files for each mode fig 10 14 0010 1 OPERATION M 2 DATA M 3 MAINTE M 4 SHELL M 0 EXIT lt lt lt gt gt gt supports daily production MODE RUNNING Production Warming Up PRD DATA PCB data modification PRD HISTORY See production history MANUAL Manual operating Figure 10 14 MODMES VISMES E txt This file contains all the vision text files 0000 Component was detected successfully Position and angle data is available 57XX 0000 E 0001 Component detection Error 1 Only 1 Lead detected 57XX 0000 E 0002 CaTeulat Iiom Errors 2 Calibration data is not ready to read 57XX 0000 0003 Component detection Error 3 Failed to detect component Figure 10 17 VISMES 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 10 31 Software Section 10 7 Online Commands Online commands are used to control the Topaz from a PC Experiences in programming are required program that makes full use of these instructions is the Phil
96. B that has a reflective fiducial don t use the glass plate This is the same asa product change over with out the feeders Go to the Database 2 DATA M3 DATABASE MARK D B Move the cursor to any line containing a fiducial and press F6 you won t actually use the whole F6 function Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Vision Systems 4 The cursor will be on the FIX PCB line Press Enter If the board is already fixed in position move the cursor to RETURN and press Enter If the board is not in place fix it in place at this time then go to RETURN and press Enter 5 Move the cursor to TEACH MARK and press Enter 6 Use the joystick to move the camera over the fiducial or object to be used to set the focus 7 To adjust the focus a Remove the plastic cover on the head assembly b Loosen the two screws that allow movement of the camera up and down c Move the camera up or down as necessary to obtain the sharpest picture while keeping the camera straight d Retighten the screws and replace the plastic cover when the image is in focus Adjusting the Field Of View 1 Insert a PCB and clamp it manually e g with use of the DO screen 2 Puta plastic ruler onto the PCB surface in such a way that the ruler appears vertical onto the vision screen 3 Check the Field Of View it is 4 8mm average 4 Ifthe Field Of View is way out than the camera should be move up and down u
97. B transport system transports the PCB into the mounting area and secures it onto the mounting position The PCB transport system shown in figure 6 1 below consists of The conveyor belt to transport the PCB to the mount position The main stopper to stop the PCB at the mounting position The push in to set the PCB at mount position The locate pins 2 to fix the PCB by means of holes in the PCB The edge clamp cylinders 2 to fix the PCB whenever the locate pins cannot be used The push up plate with push up pins to support the PCB during mounting Sensors to detect the PCB at different positions on the transport system The PCB flow direction of european systems is most common from left to right in asian countries the right to left PCB flow is most common For the electrical connections of these items we refer to the overall interconnection diagram in chapter 14 of this manual The mechanical items and the dismantling of those items are explained in the next chapters Each item of the transport system is arranged along the conveyor rails as shown in figure 6 1 below The air solenoid valve of each item is located inside the lower right panel on the rear side of the machine lt Sensor 5 T ush In Ly lt 3 Locate Locate Pin Figure 6 transport system top view 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 6 1 PCB Transport Systems 6 2 Conveyor Belt The conveyor belt tran
98. EM 3 DISK Step 9 when the upgrade is completed the following message will appear on the screen 5322 871 63606 Service Manual Topaz 10 13 01 05 PA 1309 10 Software Section 10 2 6 Version up Finished successfully hit any key Step 10 Select 3 System Data utility and select System data backup then press the ENTER key Insert the SYSTEM DATA DISK in the floppy drive and hit any key Follow the instructions on the screen Step 11 Select 1 to start the VIOS software Backup Creation It can be useful and save to make at regular times back ups of the system data f i after a recalibration or new component mark data From version V1 23 onwards the installation procedure takes care of a back up before the new installation starts In order to make a back up of the machine data follow the next steps Step 1 Shut down the VIOS and turn off power Step 2 Turn on power and after a moment a screen will appear that the machine will start after 6 sec press any key within 6 sec after this message to enter the VIOS SOFTWARE UTILITY Step 3 Enter the password specialist and the main menu of the VIOS SOFTWARE UTILITY will appear Step 4 Select 3 System Data Utility and hit the ENTER key Step 5 Select 1 system Data backup and follow the instructions on the screen Step 6 When the backup is completed the following message will appear on the screen Backup data finished successfully Hit any key
99. FRONT OT2 OT3 OT4 0 5 EMG _ 2 PLZ RELAY CONTROLLER SAFETY CRCUIT SIMPLIFED ECLIPSE II ORION EMGS DEAD MAN SWITCH EMG6 SERVICE KEY REAR READY Sw EMG7 Figure 4 Safety circuit Topaz EMG8 COVER SWITCH Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Power and Safety Circuits Colour Mark Condition for LED ON LEDI EMG circuit of HEAD l O I board Over Travel is OK LED2 EMG circuit of HEAD 2 board Over Travel is OK LED3 EMG circuit of CONVEYOR l O I board Over Travel is OK LED4 EMG circuit of CONVEYOR I O 2 board Over Travel is OK LEDS EMG circuit of optional EMG and HHK EMG STOP is OK LED6 EMG circuit of CONVEYOR l O I board EMG STOP is OK LED7 EMG circuit of CONVEYOR I O 2 board EMG STOP amp MCX OK LED8 EMG circuit of Tray Changer is OK NOT for Sapphire LED9 EMG circuit of FRONT cover stop is OK LEDIO EMG circuit of Tray Changer front cover OK NOT for Sapphire LEDII EMG circuit of REAR cover stop is LEDI2 EMG circuit of Tray Changer rear cover OK NOT for Sapphire 24VA DC24V input at CNF22 is OK 24VB DC24V input at CNF2I is OK 245 Non DC24V input at CNF23 is OK 24E DC24V of EMG safety is OK only when Servo is switched on Table 4 1 Meaning of LED s on the 2 generation connection board Not EOS Note I When LEDI to LED4 are ON and the LED5 to LEDI2 are OFF then the HHK
100. MEANS OF THE OUTPUT MONITOR MAY CAUSE DAMAGE TO THE MACHINE IF NOT USED CORRECTLY The system will not check if an activation of an output signal will cause a dangerous situation Input Monitor In manual mode the input monitor can be selected by accessing the following menu 1 OPERATION M 4 MANUAL D SAVE amp EXIT D1 INPUT MONITOR By placing the cursor on the desired field the description of the particular bit is shown in the dialogue box These bits cannot be manipulated because they are input bits Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles 3 11 2 List of OUTPUT Signals DO s Following table 3 11 1 shows an overview in alphabetical order of all D ata O utputs used in the Topaz system The table combines similar outputs as follows 01 8 Headl to head8 vacuum This means output THO01 is head 1 vacuum THO02 is head 2 vacuum etc 10 11 Spare This means output 10 and are spare 01 16 5 TLO8 Front non stop fdr carriage backward TBOI 16 Spare TLO9 16 Spare TCOI 16 Spare 01 8 R feeder data8 TDOI 16 Spare 09 12 R feeder select to select4 01 8 Headl to head8 down 16 5 09 Head lightl for moving on TNOI Main s
101. Not used 8 Yellow LED8 Not used offf 9 Yellow LED9 Not used off 10 Yellow LEDIO Controller amp EMG front rear is OK E Yellow LEDII Tray feeder emergency stop is OK MP Yellow LEDI2 Tray feeder emergency stop 2 is OK 13 Yellow LEDI3 Cover stop of front side is OK 14 Yellow LEDI4 Tray feeder cover stop of front side is OK 15 Yellow LEDIS Tray feeder cover stop of front side 2 is OK l6 Yellow LEDI6 Cover stop of rear side is OK 7 Yellow LEDI7 Tray feeder cover stop of rear side is OK 18 Yellow LEDI8 Tray feeder cover stop of rear side 2 is OK 19 Yellow LEDI9 Spare emergency circuit is OK 20 Yellow LED20 Spare 2 emergency circuit is OK 21 Yellow LED21 Spare 3 emergency circuit is OK Table 4 2 Meaning of LED s on the 37 generation connection board Service Manual Topaz 5322 871 63606 4 4 PA 1309 10 01 05 Power and Safety Circuits M 1 0 DT 2 M vl EX T Note Note 2 4 3 4 3 1 When LEDI to LED5 are and the LED6 to LED21 are OFF then the HHK EMG STOP LED6 is NOT GOOD NG This means that there is something wrong with the HHK circuitry As can be seen from the diagram figure 4 2 it is only possible to have a cover open at one side at the time It is also needed to press continuously the dead man push button in order to keep the servo system active Power Circuits
102. ONFIG For example if the Tray Changer LCS had been removed without changing the Tray Changer option into NON in 3 1 A1 OPTION gt the machine will hang up until the Tray Changer option is changed into NON using this command D Copy of Machine Data This command installs the machine data using the SYSTEM DATA DISK CAUTION This command is dangerous because the machine data is initialized Use this command only when the hard disk in the machine has problems 5322 871 63606 Service Manual Topaz 10 11 01 05 PA 1309 10 Software Section E Read version I O board This command read the version of I O board F Update I O hex I O board This command installs software onto the I O board The command can only be used on system boards which have a Flash memory 5 type CAUTION Normally these 2 commands are not used These commands requires the VIOS BOARD UTILITY INSTALLATION DISK for its execution 10 12 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section 10 2 5 Installation of a New Version VIOS System Software This paragraph describes how to upgrade your system software and how to make a back up CAUTION Before any upgrade is executed make sure you have a system software backup Please refer to paragraph 10 2 4 After VIOS version V1 23 an automatic backup during the installation of new software will be made
103. P6 JP6 JP7 JP7 SL bit jumper note 3 JP JP JP2 JP2 JP3 JP3 Max current mA 120 120 90 400 90 400 3 l option config camera combination 2 3 PESE 3 2 DATA Single camera Multi camera 2 Multi camera camera coordinate note 1 note 1 Table 3 6 1 Vision board settings and controls NOTE 1 When the Topaz is only equipped with one multi camera the camera is defined as multi camera regardless of the physical position of the camera If the Topaz is equipped with two multi cameras the front camera is defined as multi camera and the rear one as multi camera 2 NOTE 2 When the table indicates a light the coaxial light is meant When referring to the light type B the non coaxial light is meant Please be aware that the Emerald uses another definition for light type A and B the B type in the Emerald is the CSP lighting NOTE3 The SL bit is the Special Light bit setting which is used for switching between the coaxial and non coaxial light please refer to the text below On the LED driver board three jumpers provide a special light bit setting this special light bit is used to switch between the coaxial light and the non coaxial light As we do normally use both together we do not need to change the settings Table 3 6 2 below shows the settings for these jumpers for verifying purposes only 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 System
104. PERATION M 2 DATA M 3 MAINTE M 4 SHELL M 0 lt lt MODE gt gt 1 MCH CONFIG 2 DATA 3 ADJUST 4 MANUAL 0 CONFIG Serial KM1 632312 M type SM100 1 2 BASIC CONF Message English Simple Edition imu snis RS232C Normal Sub Machine Type SM100 2 SOFTWARE Online Optimization None Badmark Function Normal Badmark Distinction Normal Air Consumption No Limit Alternate Component WithConfirm Retry Sequence GroupRetry Production Log Use RECOGNITION Laser Alignment Exist Camera Combination 1 amp 2 Single View Cameral Spec Fore amp Back Light Camera2 Spec Fore amp Back Light Camera3 Spec Fore amp Back Light Multi Detection Standard MarkLightingControl Exist CONVEYOR Edge Clamp Exist Conveyor Width Axis Normal Conveyor Direction BESS ily Conveyor Spec Line Conveyor Width Exist Precede Pick None BUFFER CONV Buffer Conveyor A TYPE Buffer Conv Axis Reverse TRAY CHANGE Tray Changer Ext TC A EXC TCO Normal Ext TC Access Table A table OPTIONS Nozzle Changer Exist Slide Feeder Bar None Co Planarity Sensor None Dump Station None Dispense Head None Disp Head R Sensor Single Dot Station None RS232C extension None 5 Figure 10 8 Configuration
105. SHELL M 0 lt lt MODE gt gt 1 DATA FILE MNG 2 DISK_MAINTENANCE 3 VIOS DIC 0 DIRECTORY C orn NO1 Name Ext Size Date Time Name Ext Size Date Time SS UESIDJISSS Ye O2 26 ilies LG 2 EX UIESSSIDHSSSSMEO GE 1000 92 09 20 0 p D BASE gt SUB_DIR lt 96 02 26 L050 92 12 06 1150 1 SBUB DIR 96 02 26 19450 94 10 18 239 INS gt SUB_DIR lt 96 02 26 152 95 1 42 54 NOO gt SUB_DIR lt 96 02 26 MEOS 09524 223 NO1 SUBSDIR 96 02 20 800101 5 BL BO 28 0 93 12 06 11 04 SSUBLDIR lt 96 02 26 Bj 800201 800901 USER 800101 800201 800901 USER 800101 800901 800201 800901 800101 800201 800901 7 5 0 1 317035 25 09 11 3 48 P SSUB DIRS 96 02 26 11200 95 12 4098 35800 RAMD ZOUBADTR 02 6 93 09 24 TI STATUS SUB DIBS 96 02 26 a q i 0 T 3 AZ QAO 1 106 ONES KG2 42M0 SUB DIR 96 02 26 52 915 1 2 05 04 KG2 42T0 gt SUB_DIR lt 96 02 26 152 QeO9 24 20 KG2 4289 476 93 03 06 E99 02 274 52243 KG2 4288 8191 95 05 24 OMS SAE IG 204 KG2 58D9 21097009 ISS 1S 097 09 2 41 KG7 44D0 Zo MEO SSMUS e 010101010101 01 01 O1 Lu5 ow em Mus uo 2 PR NONI 26 Me RO M o5 MN e 2 24561 Figure 10 6 5322 871 63606 01 05 Service Manual Topaz 10 21 PA 1309 10 Software Section In the same C NO1 directory combination of files can
106. Sensor 00000000 Nzl Clamp Spare 00000000 Spare 00000000 Screen 3 Spare TP09 16 00000000 zl Clamp Spare 00000000 Tray Changer 001 08 00000000 Tray Changer 00000000 Tray Changer 009 16 00000000 Tray Changer 00000000 Tray Changer TR01 08 00000000 Tray Changer 00000000 Tray Changer 6 00000000 Tray Changer 00000000 Current selection Figure 3 11 VIOS DI DO monitor window complete list of all input and output signals is given on the next pages They are shown with the description connection location and relationship to other signals Remarks T 01 stands for OUTPUT signal N NOI stands for INPUT signal The signal names TNOI TPOI TM09 16 etc are related to the corresponding labels on the harnesses The DI DO lists on the next pages shows this relation 5322 871 63606 Service Manual Topaz 3 4l 01 05 PA 1309 10 3 11 1 System Principles VIOS Manual Mode I O Monitor Output Monitor In manual mode the output monitor can be selected by accessing the following menu 1 OPERATION M 4 MANUAL D SAVE amp EXIT D2 OUTPUT MONITOR By placing the cursor on the desired field the description of the particular bit is shown in the dialogue box ENTER key can be used to toggle a specific bit between the active state 1 and the not active state 0 WARNING ONLY TRAINED CSM SERVICE ENGINEERS ARE ALLOWED TO USE THE INPUT OUTPUT MONITOR FEATURE ACTIVATING MACHINE FUNCTIONS BY
107. Systems Editing Object Software Limit Axis direct direct Init Pos Init Mov W MAIN i 701 350 00 408 00 Figure 8 13 W axis software setting screen 6 Enter the software limit Subtract 3 00mm from the mechanical limit on the plus side or add 3 00mm to the mechanical limit on the minus side This value you have just entered is the software limit 7 Return the conveyor width to within the software limit Turn the pulley by hand to return the conveyor width 8 Cancel emergency stop Ensure safety then release the emergency stop button and press the READY button of the HHK 9 Save the settings Press the ESC key then select B2 SAVE DATA or BO SAVE amp QUIT and press the ENTER key quit without saving select B3 RECOVER ADJUST or B7 QUIT and press the ENTER key 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 8 13 Axes Systems 8 4 2 Z axis Software Limits The Z axis software limit should be set to 1 00mm inside the mechanical stopper for both the plus side lower direction and the minus side upper direction The plus side must be set at a position where nozzle change is not disturbed and the minus side at a position where the nozzles do not interfere with the back light unit A Structural movable range B Allowable movement range C plus side software limit D Orig
108. TE M 3 MCH ADJUST B SAVE amp QUIT gt B1 ADJUST TARGET Software Limit and press the ENTER key 2 Use the arrow keys to line up the cursor with direct or direct in the X MAIN row Editing Object Software Limit Axis direct direct Init Pos Init Mov X MAIN Figure 8 17 X axis software limit setting screen Service Manual Topaz 5322 871 63606 8 16 PA 1309 10 01 05 Axes Systems 2 3 Enter the software limit On the plus side enter a value you have subtracted 1 00mm from the secondary limit or on the minus side a value you have added 1 00mm to the secondary limit Save the settings Press the ESC key then select B2 SAVE DATA or BO SAVE amp QUIT and press the ENTER key To quit without saving select B3 RECOVER ADJUST or B7 QUIT and press the ENTER key 8 4 4 Y axis Software Limits As with the X axis the Y axis software limit should be set to 1 00mm inside the secondary limit for both the plus side right direction and the minus side left direction y Note Fig 6360711 003 A Structural movable range B Allowable movement range C Software limit D Secondary limit E Origin position F Mechanical limit Retum to origin direction Front Figure 8 18 Y axis movement range To set the Y axis software limit use the Y axis secondary
109. TION box appears so enter 295 and press the ENTER key 3 Check that the data is entered in No 295 Change the moving camera lighting setting Set the moving camera rotary switch to 1 so that the lighting is optimized for recognizing the glass PCB Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Vision Systems Check that the mark is clearly recognized in the Adjust Assistant The Adjust Assistant screen appears by pressing the F6 key Secure the on the conveyor with the FIX command For CONVEYOR WIDTH enter 130 Then press the emergency stop button and make necessary adjustments to the locate pins and push up pins Execute the VISION TEST command When no errors occur the current parameter settings are appropriate Advance to the moving camera scale adjustment in the next section If an error occurs adjust the mark information parameters as necessary For more details on the parameter settings refer to the mounter operation manual 3 Adjusting the moving camera scale When you have prepared the PCB use the following steps to calibrate the moving camera scale Execute the Scale command Select lt 3 3 B1 ADJUST TARGET gt Mov Cam Scale and press the ENTER key 70043308 00 lt lt lt APPLICATION gt gt gt 3 MAINTE M lt lt MODE gt gt 3 MCH ADJUST COMMAND LIST B SAVE amp QUIT B1 ADJUST TARGET Object
110. UN STOP and RESET The connection between this keyboard and the MCX controller consist of following signals A serial communication line RS232 going to the CMNI port on the front side of the system board in the MCX controller The 24V supplied from the interconnection board Emergency switch and Ready switch signals Dead man push button signal Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 74 M NOTE System Principles The keyboard has its own voltage converter 24V to 5V DC and micro processor to control the key functions and the serial communication with the MCX controller dead man push button is added for safety reasons this button must be pressed continuously if a servo action while the front rear safety covers are open The HHK is equipped with a so called full keyboard enable this key is connected to the hand held keyboard by means of a chain When the key is inserted in the key switch on the right front cover this will enable the full keyboard When the key is out of the key switch no actions and commands can be given from the full keyboard This provision is to comply to the European safety rules CE If one of the SERVICE KEY switches front and or rear of the system are activated there is only a limited function possible with the hand held key board The only actions possible are the joystick and emergency button actions all other buttons are disabled because of safety reaso
111. Update the system data from the backup floppy disk Copy the PCB data from the backup floppy disk Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles Reference table As a reference table 3 5 2 shows the system boards used in the various MCX controllers of the CSM Full Vision and CSM GEM systems It is recommended to interchange systems because of the differences in memory front panel and BIOS ROM Applicable Controller Board etc System Board complete assy KG2 KG7 Comet l Eclipse l Full Vision Comet ll KJO Orion Eclipse ll KM5 Sapphire Topaz Emerald KM5 Sapphire Topaz Emerald KJO M4200 Ix 12x 5322 214 91532 KJO 4200 01 02x 5322 216 04049 KJO M4220 32x 5322 216 04308 KM5 M4200 00x 5322 216 04468 KJO M4210 IIx 12x KJO M4210 01 02x KJO M4210 32x KM5 M4210 00x KM5 M4210 0Ix Application Board KJO M4220 10 KJO M4220 10x KJO M4220 10x 5 M4220 00x Base System Board Front Panel KJO M4135 10x KJO M4135 00x KJO M4135 00x KM5 M4135 00x Memory 1 Ix 4Mbytes 01 4Mbytes 8Mbytes 8Mbytes 12x 8Mbytes 02x 8Mbytes 16 5 KJO M42R9 LOx KJO M42R9 00x KJO M42R9 00x Not applicable
112. X 3 Edit of Option Conf iz 4 Copy of Machine Data 5 Read version 1 0 board B Update 1 0 hex 1 0 board Return to MAIN MENU A Installation of VIOS V1 0X Use this command to install V1 0 onto a machine with V1 2x by following the next procedure 1 following messages appears the display If you use this command VIOS V1 2X will be deleted If you want to execute this command hit Space key If you want to stop this command hit other key 2 Press SPACE key to execute the installation Then the next message appears on the display OFF Turn off power switch 3 Turn off the power switch and turn it on again then VIOS Software Utility starts and type in the password of level 8 according to the message 4 Execute 2 Version up of VIOS and install V1 0 following the procedure 5 Although the machine works with V1 0X by next starting up some machine data should be modified by manual operation as is shown in the Note below Xy NOTE Just after these operations 1 Baud rate lt RS 232C gt in 3 2 MCH_DATA gt may NOT BE CORRECT Change the value into original condition if the communication functions are used 2 Z value of PCB Fix T F in Coordinate in 3 2 DATA may NOT BE CORRECT Type in 0 00 into this data Wait point IORMAL 80 00 4 50 Discard point NORMAL 21 80 00 2 Marker height 0 00 Simul pickarea 0 50 3 See Confirmation after th
113. YPE 3F 2 Nzl Station 14 31 21 23 41 72 08 18 39 31 2 Nzl Station 15 31 16 11 07 71 99 18 51 31 Head Nzl Station 16 43 50 6 00 69 00 18 36 TYPE 32 Head Figure 7 15 Nozzle station coordinates screen 11 Save the settings Press the ESC key then select AO0 SAVE amp QUIT or A2 SAVE and press the ENTER key To quit without saving select A7 ABORT amp QUIT and press the ENTER key 12 Cancel emergency stop Ensure safety then release the emergency stop button and press the READY button of the HHK 13 Check that the nozzle can be exchanged smoothly check use the A5 CHANGE NOZZLE command in the Machine Adjust mode Note When you need to adjust other nozzle stations use the same procedure described above Be careful to use the correct head specified for each nozzle station The list of nozzle location and type can be found in figure 7 15 7 3 5 Nozzle Station Maintenance Check at a regular interval quarterly the following functions of the nozzle station Check if the nozzles are going smoothly in and out of the nozzle holder For a readjustment see the previous paragraphs of this chapter Check if the sensing of the nozzle is done in a proper way Use the adjustment described in the previous paragraphs to correct this Check for wear and debris in and around the nozzle station Clean the station and apply a little grease on the moving s
114. Z axis is equal to 25 of the machine reference Do not allow the Z axis to move more than 2mm If you move too far a 0 pulse in a different cycle may be received causing the origin to shift Do not allow the shaft to turn during adjustment Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Axes Systems 8 2 3 X axis Machine Reference The X axis performs the right to left and left to right movement of the head assembly It is driven by ball screw at a lead of 20 00mm per turn of the motor The origin signal is output when the grey origin sensor which is attached to the bottom of the X axis slide plate has detected the origin dog located on the left side of the X axis T o adjust the X axis machine reference proceed as follows see figure 8 5 1 Press the emergency stop button Adjust the machine reference as follows loosen the screw securing the X axis origin dog and slide it slightly To increase the machine reference slide the dog to the right To decrease the machine reference slide the dog to the left 3 Re tighten the screw to secure the origin dog Make sure that the machine reference is set within tolerance Figure 8 5 Adjusting the X axis machine reference Note The machine reference will be adjusted to about 10 for every 2mm of movement of the origin dog Be sure to slide the dog slightly a maximum of 10mm If you slide it too far 0 pulse in a different cycle may be received
115. ad Select 3 4 C1 OUTPUT MONITORs and press the ENTER key Use the arrow key to line up the cursor with THO1 HEADI VACUUM or any other head 02 to 08 3 Press the ENTER key to generate the vacuum in the selected head The output monitor digit changes to 1 when the vacuum ejector is on 4 Select lt 3 4 MANUAL gt lt 3A VACUUM SENSORs and press the ENTER key The current vacuum levels of all heads are displayed on the operation monitor COMMAND LIST A CHANGE CONDITION VACUUM SENSOR LEVEL CURRENT MAXIMUM MINIMUM HEAD 20 mM 135 186 2 A2 70443104 00 Figure 7 2 Vacuum level display 5 Check the vacuum sensor function Make sure that the vacuum level bar graph and numerical value on the of the selected head changes when you place your finger over the nozzle tip opening and then remove it The vacuum level increases when the nozzle tip opening is closed 6 Return to output monitor screen and turn off the vacuum Check that the cursor is on the target head in the Head Vacuum column on the output monitor and press the ENTER key to turn off the vacuum Service Manual Topaz 5322 871 63606 7 4 PA 1309 10 01 05 Component Transport Systems 7 2 2 Machine Coordinates When you select lt lt lt 3 MAINTE M gt gt gt 3 ADJUST gt gt B SAVE amp QUIT gt B1 ADJUST TARGET Position and press the ENTER key the
116. ad I O and two conveyor I O boards refer to figure 3 7 1 The function of the I O boards is to translate and buffer signals from to the system unit to from the actuators sensors The head I O board performs above function for all actuators and sensors in the head assy while the conveyor I O boards perform this function for all other actuators and sensors in the system Second generation I O boards The I O boards of the second generation consist of a mother board and a daughter core board The mother board is a large PCB containing the DI DO drivers power circuitry and some settings The daughter PCB also called the core board contains the logic and communication circuitry of the I O board 5322 871 63606 01 05 Service Manual Topaz 3 27 PA 1309 10 System Principles The I O boards are communicating with the system CPU board via a SDLC protocol The Intel 8344 microprocessor on the daughter board is controlling this communication The daughter board also contains ROM and a RAM memory The ROM memory holds the software for the 8344 processor this software is loaded into the memory of this processor at start up The 8344 processor uses the RAM memory as a temporary data storage The mother board of the I O board contains a couple of dip switches which function Is described in the table 3 7 1 5 6 7 8 4 ON 0 OFF Board 0 0 l O conveyor right 0 0 0 0 0 l O conveyor left 0 0
117. ally a moving distance of 5mm is recommended 4 Enter the component database No and press the Enter key 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 29 Vision Systems Enter the database no of the component you have prepared A540 To return to the command menu Distance mm 5 A461 Enter the component database number Database No 6 A466 The specified component uses A303 CAUTION The axes will move A373 Please pick up the specified component with tl specified head or Figure 9 34 5 Ensure safety and press the lt Enter gt key twice ne The head assembly moves to a point where head 1 is ready to pickup a component 6 Press the emergency stop button then attach the component to head 1 Attach the component to the nozzle of head 1 slightly shifted with the component center Figure 9 35 CAUTION When using a SOP component attach it to the nozzle with the component center slightly shifted Align the long side parallel to the X axis Service Manual Topaz 9 30 1309 10 5322 871 63606 01 05 Vision Systems NOTE 7 When the component has been attached press the Enter key 8 Cancel the emergency stop Release the emergency stop button and press the Ready button of the HHK 9 Ensure safety and p
118. amendments Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Introduction 1 3 4 Cautionary Remarks This Manual uses the following cautionary remarks REFERENCE Gives useful information related to the machine operation NOTE Explains the machine operations and procedures in a simple and clear manner CAUTION Gives important information to prevent any damage to the machine or data WARNING Gives information of utmost importance in ensuring the safety of the operator or service personnel EMERGENCY BUTTON Indicates to press first the emergency button before continue 1 3 5 Warning Stickers This paragraph gives an overview of warning stickers that are used to warn the operators and service people for dangerous situations With every picture a short description is given of that dangerous situation Do not enter 63607104 jpg Figure 1 1 Do not enter This sticker warns the operator service engineer not to enter by hand It is located at the entrance and exit conveyor rail 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 1 5 Introduction Electrical shock 63607102 ipg Figure 1 2 Electrical shock This sticker see figure 1 2 warns the operator service engineer for electrical shock Behind the covers are high electrical voltages present Low Radiation 63607101 jpg Figure 3 Radiation This sticker see figure 1 3 warns the operator service eng
119. arterly the 24 volts which is used to control the various valves of the pneumatic system The two power supply s GS21 and GS22 are located at the left lower rear side of the system 5 2 9 Performance Checks and Trouble Shooting No specific actions are done for the performance check If some valves are not working please first check the 24 volt power supply then check if the I O signal is ok check this by activating manually the I O signal via the manual I O setting screen 5 2 10 Maintenance Actions No specific maintenance actions besides the 24V checking are necessary Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Vacuum and Pneumatic Systems Exchanging Head Ejectors Valves and Base This chapter describes how to replace the head ejectors and valves Exchanging the Head Ejector and or Valves Blow off valve replacement To replace the blow off valves on top of the ejector in the head assy refer to figure 5 and proceed as follows 5 3 5 3 1 1 2 3 4 END BLOCK L Loosen the two screws on top of the valve Remove the valve in the direction of the arrow Install the new valve and take care about the direction of the gasket Tighten the two screws with a torque of 17 6 Ncm 5322 360 10209 T SCREW VALVE Rcommended torque Blow off SF 17 6 Nem SA lt gt 5322 693 11367 Q ASK q d i EJECTOR GASKET 9 8 24 j B SCREW 9 lt gt Rcommended torque
120. axis ball screw Assemble the Y axis ball screw to the Y axis nut holder 7 Position the robot arm at the front of the machine Assemble the two left bolts of the nut holder finger tight Position the robot arm at the middle position of the Y axis Assemble the two right bolts finger tight Tighten all 4 bolts at a torque of 7 4 Nm using a torque wrench Tighten the 2 green bolts at the coupling 22 Switch on the machine to perform the second part of the adjustment procedure of the Y motor encoder position after replacing the Y axis ball screw See section 8 6 1 Switch the machine off again after executing this procedure Tighten the two green bolts at the coupling 22 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 8 31 Axes Systems 8 6 4 5 Y axis Pre tension Adjustment Generation 3 Y axis Y axis ball screw has three spring coned disks which control the tension of the Y axis movement See for reference figure 8 28 Make sure the surface of the guides and ball screw is free of dirt and overdue grease Make sure the spring coned disks are tightened so they just touch each other only Apply one short turn 45 degrees to the lock nut Fig 8 27 27 by hand only see figure 8 30 Figure 8 30 Adjusting the pre tension Move the Y axis by use of any utility program Only tighten the lock nut slightly more if the axis makes noise press EMG switch first Max pre tension adj
121. az In the figure 3 4 2 below the SMEMA connection is shown The following signals can distinguished 1 The BUSY out signal from the main to the previous up stream machine 2 The BA in board available signal from the previous to the main machine 3 The BUSY in signal from the next down stream machine to the main machine 4 The BA out signal from the main machine to the next down stream machine The logic is as follows a When the main machine is busy contacts are open no board is sent b When the up stream previous machine has a board available the contacts are closed c When the main machine is not busy and a board is sent the state of the main machine must go busy and the signal BA must go false within a preset time period Machine actions in case of an error are optional d The next board may not be sent until the next not busy cycle The busy and board available signals must at least 50 mS in duration for either state DIRECTION OF THE BOARDS S a T 2 inea E ras 1 27 47 sw BOARD l BOARD 1 i AVAILABLE 3 e AVAILABLE el az LM qe 4 oo MP S 22 2 a SD 2282 Figure 3 4 2 SMEMA interface Gate in Gate out interface The Gate in Gate out is a more simple interface to connect the machines in line Gate in connector
122. az 5322 871 63606 PA 1309 10 01 05 Vision Systems Press the ENTER key to start calibration The moving camera moves in both X and Y directions The amount of movement on the vision monitor is calibrated and the results are then displayed on the screen 70043311 00 lt lt gt gt 3 MCH ADJUST A431 lt lt lt RESULT gt gt gt Scale_x xxxx The following data is the result of the adsjustment of Scale the moving camera scales Angle To save the result in memory press the ENTER key contents are not saved on disk To abandon press the ESC key Figure 9 13 Start calibration The correct values for the moving camera are as shown in table 9 1 Average FOV Scale range of scale ratio Angle R X and Y value 4 8mm 10 5 0 2 um pixel 1 00 0 01 0 0 5 Table 9 1 Moving camera If the scale value is not within limits move the camera up or down and adjust the camera scale again If the rotation is off rotate the camera and adjust the camera scale again Press the ENTER key to save the calibrated results Press the ESC key if you want to cancel the results Save the calibration settings Select B2 SAVE DATA or B0 SAVE amp QUIT gt and press the ENTER key To quit without saving select B3 RECOVER ADJUST gt or B7 QUIT gt and press the ENTER key Press the emergency stop button then remove the PCB Before removing the PCB the clamping m
123. b Air regulator gauge Air switch ON OFF anagem Sod Push 2 lt Locate Pin Sub Stopper Nozzle Station AU re Figure 5 1 Valves Topaz has two separate air pressure regulators One for the ejectors and one for the air solenoids of the system The air pressure regulator for the vacuum line is located behind the lower left panel at the left side of the machine 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 5 1 Vacuum and Pneumatic Systems 5 1 3 5 1 4 Air Supply Unit The air supply unit is located inside the lower right panel on the rear side of the machine along with a pressure regulator The air pressure regulator must be set correctly in order to provide optimum air pressure for the vacuum ejectors and pneumatic devices Before making the setting be sure that the pressure from the primary air supply is between 0 6 and 0 7 MPa Air Pressure Regulator The air pressure regulator can be adjusted with the valve control knob as follows Open the lower right panel on the rear side of the machine The pressure regulator valve control knob and pressure meter are located inside the panel Adjust the air pressure T urn the valve control knob so that the air pressure is set between 0 45 to 0 5 MPa 4 6 to 5 1 kgf cm2 Pressure meter Valve contro knob Pressure regulator Figure 5 2 Pressure meter If this pressure setting is not correct the vacuum
124. below First prepare a PCB and check that a 31 nozzle is attached to Head 1 1 Press the emergency stop button and secure the on the conveyor Use the push up pins so that the PCB surface is kept level It is not necessary to use the locate pins in this case 2 Move the head assembly by hand so that Head 1 is positioned above a location on the PCB 3 Lower Head 1 first pneumatically and then by hand to the PCB surface 4 Lower Head 1 until the nozzle tip just makes contact with the PCB surface 5 Ensure safety and release the emergency stop 6 Enter the ADJUST mode and set teaching conditions 1 Select lt 3 3 B4 CONDITION OF and press the ENTER key 2 Select Head 1 or Head 2 as the teaching unit and press ENTER 3 Select any speed from Speed 1 to Speed 5 and press the ENTER key 7 Select 3 3 B2 ADJUST TARGETS Position and press the ENTER key 8 Press the F10 key twice to perform teaching for the Z coordinate 9 Press the ESC key then select B2 SAVE DATA or BO SAVE amp QUIT gt and press the ENTER key It is also possible to teach the height on the fixed conveyor rail surface which is basically the same height as the PCB surface 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 7 7 Component Transport Systems H Dual recognition offset This parameter is used to be able to go from left to right and the opposite way over the multi camera
125. ble the new nozzle holder and leaf springs in the reverse way Check the leaf springs if they can hold the nozzle well if not replace the springs Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Axes Systems R axis Replacing the Spline Shaft Replacement of the spline shaft is done as follows 1 Remove the head assembly from the machine as described in the previous section 2 Loosen belt item 38 and remove the bolts 206 Remove items 62 31 12 and loosen circlip 234 The spline shaft can now be removed 3 in the reverse order R axis Replacing and Maintaining the Piston and Plugs Assy s This part describes how to replace parts of the piston and plugs assy s as well as what has to be done to maintain them The piston assy of head 1 is different from heads 2 to 8 but the maintenance actions are similar for both Disassembling is done as follows 1 Disassembling the piston assy is done by removing the plug assy item 3 2 Allassy s item 2 26 or 6 and 10 are now accessible 3 Item 2 can be disassembled into the parts 3 4 and 5 When this assy is reassembled proceed as follows Apply molykote 6189 grease to packing item 4 Insert the special stopper tool 5322 395 10712 from the top into item 3 Insert packing 4 into item 3 from the bottom while taking care of the correct direction Set packing item 4 into position by using the special pusher pin 5322 395 10712 4 The piston ass
126. boot up from floppy disk mow enter 5322 871 63606 01 05 Service Manual Topaz 10 17 PA 1309 10 Software Section 3 3 1 32 3 3 3 4 Installation of MS DOS V 6 2 operating system and the Application software VIOS To install a new MS DOS V 6 2 operating system and other utilities proceed with the next steps The MS DOS V6 2 system will be covered by the sections 3 1 3 5 while the Application software installation is covered by step 3 6 REMARK Only in case of the complete installation i e with a new hard disk or reformatted disk it is needed to follow the sequence as is given below Select DELETE HARDDISK CONFIGURATION press ENTER the partition on the hard disk will be deleted a press any key to continue b type 3 and press enter type 1 and press enter d type and press enter enter volume label the same name as seen on the screen f press enter are you sure Y enter h Esc Esc press any key when ready i the system will restart j press any key to continue Select DEFINE HARDDISK CONFIGURATION Press ENTER make a new partition on the hard disk a press any key to continue b type and press enter type 1 and press enter d type Y and press enter e the system will restart after pressing any key f press any key to continue Select FORMAT HARDDISK press ENTER the C driv
127. bration Feeder Plate 11 3 17 Final Board Accuracy Checks 11 3 18 Back up Procedure How to Run the AMF Program 11 4 1 Making Data for the AMF Program 11 4 2 Mount Information 11 4 3 Component Information 11 4 4 Mark Information 11 4 5 Block Information 11 4 6 Fiducial Information Explanation of Various Parameters AMF Program 11 5 1 Camera Scale 11 5 2 Camera Position 11 5 3 Nozzle Correction 11 5 4 Head Down Offset 11 5 5 Head Offset 11 5 6 R axis Accuracy 11 5 7 Inconsistent Parameter 11 5 8 AMF Program 12 Maintenance 12 1 12 2 Introduction Oils and Greases 11 14 11 17 11 20 11 23 11 25 11 25 11 26 11 28 11 29 11 30 11 31 11 32 11 34 11 35 11 36 11 37 11 37 11 38 11 38 11 39 11 40 11 40 11 47 11 48 11 55 11 64 11 66 11 69 11 70 11 70 11 74 11 75 11 76 11 78 11 78 11 78 11 79 11 79 11 80 11 82 11 83 11 83 11 84 11 84 11 85 12 1 12 1 12 2 Service Manual Topaz PA 1309 10 5322 871 63606 01 05 Table of Contents 12 3 Maintenance Checkpoints 12 4 12 3 1 FD Drive Filters and Air Valves 12 4 12 3 2 Head Area Checkpoints 12 9 12 3 3 X axis Checkpoints 12 26 12 3 4 Y axis Checkpoints 12 29 12 3 5 Conveyor Checkpoints 12 32 12 3 6 Feeder Plate Checkpoints 12 37 12 3 7 Vision Systems Camera Lighting Unit 12 41 12 3 8 Performance Check and Trouble Shooting 12 44 12 4 Overview of Error Messages in VIOS 1 2 12 46 12 4 1 L error Messages 1
128. c 1 phase 200 23 TC11 V 250V I 14 I 5A 1 phase Fuse CRT Vision Output v 200 QF21 3 44 P 750VA v 250V I 2 CRT Robot Figure 4 3 Power rating diagram Topaz system 1309 10 Figures given are the maximum ratings of the individual items P 1000W Service Manual Topaz PA 1309 10 5322 871 63606 01 05 Power and Safety Circuits 4 3 2 5V 12V Power Supply MCX Box In the MCX controller a MRM270 power supply is used to supply 5V 12V and 12V This power supply is located at the left side of the MCX controller box please refer to figure 4 4 The lay out of this power supply is shown in the figure 4 5 2 controller box TDK MRM270 Output Jumper input terminal voltage Output terminal Input Output terminal terminal Output voltage PFS signal Output voltage adjusttrimmer adjust trimmer adjust trimmer Figure 4 5 Power supply layout 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 4 7 Power and Safety Circuits The following connectors are available CPI CP50 52 This is the input AC L N FG terminal make sure to connect this to the 200 230V single phase line while the ground wire is connected to the case This is the output of V1 45V V2 12V and V3 12V All three voltages are connected to the load as much as the DC common output 0V Furthermore the power failure signal PFS is output at this terminal however this DC ou
129. camera following parameters are foreseen Multi camera Y This parameter reflects the speed in millimeters per second at which the head assembly travels over the multi camera during component recognition Set this parameter to 900 this value is an optimum so do not change this value Multi camera 7 and These settings are for correcting the angular shift of the multi vision camera versus the mounter axis The Z column is for the optional multi camera 2 while the R column is used for the standard multi camera 1 Please set this value to 0 00 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 7 5 Component Transport Systems C Locate pin This setting is the reference position when the PCB is secured in the mounting position on the conveyor This position is also referred to as the PCB origin When setting this locate pin position use following procedure Open the positions screen by lt 3 2 1 select target position and press Enter Line up the cursor with the X or Y value in the locate pin row Press F10 and set the teaching conditions select the camera as the teaching unit at a slow speed e g 20 and press enter again Move the head above the fixed locate pin by means of the joystick Align the cross cursor in center of the locate pin Perform teaching of the locate pin by pressing the F10 key twice to enter the X coordinate perform the same for the Y c
130. causing the origin position to shift 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 8 5 Axes Systems 8 2 4 Adjusting the Y axis Machine Reference The Y axis performs the forward and backward movement of the head assembly It is driven by ball screw at a lead of 20 00mm per turn of the motor The origin signal is output when the grey origin sensor which is attached to the bottom of the right hand Y axis slide plate has detected the origin dog located on the forward end of the Y axis adjust the Y axis machine reference proceed as follows see figure 8 6 1 Press the emergency stop button 2 Adjust the machine reference as follows loosen the screw securing the Y axis origin dog and slide it slightly To increase the machine reference slide the dog backwards to the rear feeder plate To decrease the machine reference slide the dog forwards to the front feeder plate 3 Re tighten the screw to secure the origin dog Make sure that the machine reference is set within tolerance Y axis ball screw Secondary limit dog Y axis motor Figure 8 6 Adjusting the Y axis machine reference Note The machine reference will be adjusted about 10 for every 2mm movement of the origin dog Be sure to slide the dog slightly a maximum of 10mm If you slide it too far a 0 pulse in a different cycle may be received causing the origin position to shift Service Manual Topaz 5322 871 63606 PA 1309
131. ce QFP s are generally superior in dimensional precision to other components PHILIPS recommends using components registered in the database e a No 766 QFP100 P0 65 25 7L or 767 QFPI00 P0 65 24 7L You can also use the inner QFP 68 of the glass calibration set PA 1912 00 but this can give problems with the outer glass QFP208 4 Check the registration data in the component database e To open the component database select lt lt lt 2 DATA M gt gt gt lt lt 3 DATABASE gt lt A DISPLAY gt A1 COMPONENT MARK D B COMPONENT DATABASE and press the ENTER key Check the registration data of the selected QFP In particular check that the component size exactly matches the registration data If not the adjustment will be aborted 5 Edit Search Area mm in the component data Data registered in the database as a number larger than No 500 cannot be edited due to write protection Make a copy of the data as a number smaller Service Manual Topaz 5322 871 63606 9 16 PA 1309 10 01 05 Vision Systems than No 500 then edit this data For instance the following steps are explained in cases where a copy is made onto registration No 6 e Open the sub screen Vision for the component of registration No Edit the data on Search Area mm e Use the numeric keys to set the normal value 4 00 to 9 99 maximum setting This is for off center pickup of the QFP to be performed later
132. cklight type camera Camera 3 is a reflective type camera light Camera 3 can handle both In FINE mode placements spindle expenditure is included in the correction algorithm Remark decreases system output Standard vision Only for factory and calibration use Only for factory and calibration use Fiducial lighting control This option is always available Do not select Automatic width exists Do not select 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 10 25 Software Section Parameter Selection 3 Conveyor Direction L gt R R gt L 4 Conveyor Spec Line Line Return Manual Manual Return 5 Conveyor Width Exist None 6 Precede Pick Exist None Machine config BUFFER CONV 1 Buffer Conveyor None A Type B Type 2 Buffer W axis Normal Reverse Machine config TRAY CHANGE 1 Tray Changer None Ext TC A Ext TC B Auto TC A Auto TC B Auto TC C 2 Ext TC Trv Axis Normal Reverse 3 TC Access Table A Table B Table Machine config OPTIONS 1 Nozzle Changer Exist None 2 Slide Feeder Bar Exist None 3 CoPlanarity Sensor Exist None 4 Dump Station None Exist Description Left to Right conveyor movement Right to Left conveyor movement If a production Line exists In line but board is returned to entrance Board stops at output sensor Board stops at input sensor Auto width exists Precede pick sensors are ava
133. creen Perform the same procedure for all other heads Save the calibrated data by pressing ESC and the appropriate save command Nozzle Correction This parameter is used to correct an off center nozzle shaft when it rotates by 180 degrees When you select lt lt 2 DATA gt gt lt A DATA gt 1 SELECT TARGET Nozzle Correction and press the ENTER key the current setting for this offset is displayed lt lt lt APPLICATION gt gt gt 3 MAINTE M lt lt MODE gt gt 2 MCH_DATA Editing Object NozzleCorrection Head No X Y Atbl Head 1 0 03 0 03 Atbl Head2 0 00 0 00 Atbl Head3 0 00 0 00 Head4 0 00 0 00 Figure 7 8 Note This offset is automatically corrected when you execute mount feedback Vision 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 7 13 Component Transport Systems 7 2 6 Head Offset This is the position of Heads 2 8 related to Head 1 When you select 2 DATA lt MCH DATA gt gt Al SELECT TARGET gt HeadOffset and press the ENTER key the current setting for this offset is displayed lt lt lt APPLICATION gt gt gt 3 MAINTE M lt lt MODE gt gt 2 MCH_DATA Editing Object Head Offset Head No HeadType X 2 nozzle Head 1 AutoNzlIChg 0 00 0 00 0 00
134. crews item 218 holding it to bracket 29 Assemble in reverse order Z axis Z bearing replacement replace the Z bearings proceed as follows Remove the head assembly as described in the beginning of this section Remove the moving part of the head assy from plate item 2 by means of removing the bolts item 216 Remove the ball slides item 36 in figure 13 5 2 by removing the bolts item 217 in figure 13 5 2 Replace the ball slides by assembling in the reverse order The position of the ballslides in vertical direction is secured by the shape of frame item 1 in figure 13 5 2 The horizontal direction on this frame is determined by means of fitting pins The horizontal position of the whole unit on plate item 2 in figure 13 5 3 is also determined by means of fitting pins The vertical position on plate item 2 may shift a little as much as the holes allow R axis Assembly The mechanical assembly of the R Axes of the Topaz is shown in figure 13 5 2 The Topaz uses a belt drive while the encoder a part is of the R motor assembly R Axis Replacing the Nozzle Holder Remove the leaf springs item 103 by means of screw 104 take care not to loose the washer item 105 Remove the pin item 2 in figure 13 5 2a The pin has to be driven out of the hole before replacing the nozzle holder is possible The best way to do this to make sure the spline is supported at the rear side and by using a small pin to drive the pin out of the shaft Reassem
135. ction adequately 5322 871 63606 Service 01 05 PA 1309 10 Manual Topaz Vacuum and Pneumatic Systems 5 1 6 Measurement Adjusting Vacuum Levels The measurement of the vacuum level is done via vacuum sensors transducers which are located on the I O 1 head assy board Each head has its own sensor and can be adjusted and calibrated independent from each other For the Adjustment of the sensing circuit please refer to the calibration chapter 11 5 1 7 Performance Check and Trouble Shooting In order to get a correct vacuum level from each ejector make sure that the air pressure is at a correct level 25 5 bar Make also sure that the hoses to and from the ejector are not contaminated 5 1 8 Maintenance Instructions Each ejector has its own air filter which needs to be checked at regular intervals 500 Hours If the filter is contaminated it is advisable to replace it by a new one Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Vacuum and Pneumatic Systems 5 2 5 2 1 5 2 2 5 2 3 5 2 4 5 2 5 5 2 6 5 2 T Pneumatic Systems Introduction This chapter describes the electrical interface of the pneumatic system in the Topaz and Tray Changer Functional Description The Topaz contains a number of pneumatic solenoid valves and cylinders The air solenoid valves control the air flow to certain air pressure lines The pneumatic driven cylinders are us
136. ctor is as follows pin 1 empty pin 2 24C relay contact point output gt Dry contact point pin 3 TK05 gate out signal Gate out signal output This signal is sent to the machine in the previous process If the machine in the previous process has completed its preparatory operations it renders 2 lt gt 3 conductive closed as a PCB request signal In figure 3 4 4 the gate out connection is shown 5322 871 63606 01 05 Service Manual Topaz 3 9 PA 1309 10 3 10 System Principles How machines are connected to each other using the gate in and gate out is shown in figure 3 4 5 UPSTREAM MACHINE DOWNSTREAM MACHINE GATE Signal GATE GATE Si IN OUT IN Count Reset Count Reset Main Unit IM Ate tases sec BER EE AF 22 9 Figure 3 4 5 5 connections FLOW WPG Relation between Gate in Gate out and SMEMA The relation between SMEMA and Gate in out is shown in figure 3 4 6 For more details please refer to the overall interconnect diagram of the Topaz chapter 14 GATE IN GATE OUT l 0 BOARD Busy out Figure 3 4 6 Principle SMEMA Gate in out Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles 3 5 MCX Control Unit 3 5 1 MCX Controller Lay Out Second Generation In the figure 3 5 1 the second generation MCX controller box is shown Figure 3 5
137. cuit diagram of the D power assy 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 4 11 Power and Safety Circuits 4 3 5 Measuring and Adjusting Data MCX controller box The voltages inside the MCX controller box can be measured at the mother board connectors 5 6 and 9 near the LED indicators follow the next procedure to do so Loosen the MCX 2 box so it can slide out of the machine Loosen the two top cover screws Remove the left front cover at the motherboard LED s Some connectors can now be seen see mother board Chapter 3 Measure at connectors CN9 or CN11 behind the LED s the following voltages CN9 5V 0 1V pins 1 2 12V 0 25V pins 3 4 CN9 GND pins 5 6 7 CN5 12V 0 5V 3 CN5 12 0 25 pins 4 5 CN6 45V t0 1V pins 1 2 3 4 CN6 GND pins 5 6 7 8 If the measured voltage is not within the above given spec s they can be adjusted with the potentiometers as is indicated in figure 4 5 Reinstall the front and top cover after the adjustment is done Push MCX controller box back into the machine and secure it WARNING Make sure to check the 5 12 and 12 Volt power supplies inside the controller at regular intervals each 3 months Especially the 12 and 12 Volts are important for the servo systems because they are used for the IC s in the servo control circuitry GS21 24V power supply The voltage of the GS21 power supply can be measured at the power
138. d The flash disk can be removed very easy from front of the MCX controller Never do this while power is on Also take care of the correct position when inserting the disk There are two positions to support 2 flash disks Drive C is the one in the left slot slot 1 while drive D is the one in the right slot slot 2 seen from the front Remark Drive D cannot be accessed by VIOS PCB handling only the SHELL manager can handle this drive useful to make back ups As already said use the procedures mentioned in paragraph 10 2 10 to solve problems or to version up VIOS releases 10 16 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section 10 2 10 Hard Disk Problems In case there are problems with the hard disk the following actions can be done to locate the problem cause Check the 5V and 12V power supply s inside the MCX box Check if the disk is addressed by the system during booting of the VIOS LED at the front of the system PCB If it is still possible to address the disk check the disk by means of the software utility command selection 7 in paragraph 10 2 2 The Scan disk command will check and if possible repair the corrupted disk files If the disk cannot be addressed any more check the harnesses from disk to system board and the power cables If it is needed to replace the disk or to re format the existing disk then it is needed to reinstall the complete MS DOS and VIOS syste
139. d cover door at the right bottom front side of the machine The drive is connected via a harness to the front side of the system board FDD connector Flash disk In systems equipped with a new type system board please refer to section 3 5 2 the hard disk has been replaced by an on board flash disk The flash disk is located on the system board and has two slots which are accessible from the front side of the system board Each slot can contain a removable flash disk Standard one 40 MB flash disk 5322 693 11447 is available on the system board optional this disk can be replaced by a 85 MB drive If a flashdisk is mounted in the second slot this disk is only accessible via the shell manager Note When inserting or removing a flashdisk the Topaz should be switched off because the disk is not protected against such handling and might get damaged Be sure to always mount the protective cover over the flash disk after mounting Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles 3 5 7 Driver Board Assy This board see figure 3 5 10 below can drive AC motors for up to 7 axes The amount of motors used depends on the type of machine In the MCX controller the driver 1 board is always used for the main machine while the driver 2 board is dedicated for options such as traychanger and auto tray stacker AT S 282V power connection CN4 Power from servo board A 9 3 From servo board PWM FDB signals
140. d to a three phase Mains power system The Topaz has the following specifications AC Voltage selection 200 208 220 240 380 400 416 V AC 10 Frequency 50 60Hz Power rating 4KVA max Voltage interruptions Not longer then 6 mS Voltage drops Not higher than 15 and not longer then 0 5 Sec The mains has to be connected with 3 cables with 2 5 mm to the terminal block XB11 Always connect a ground wire of 2 5 mm to the ground terminal M PE The Mains transformers must be configured according to the supplied Mains voltage level The tap settings on the two transformers TC11 and TM11 must be configured according to the schedule given in figure 3 2 1 In every system the transformer tap setting schedule can be found at the in side of the power box door WARNING When connecting the MAINS power make sure to configure the Mains transformers before When changing the Mains input voltage always check first with the Philips service centre Make sure to take all necessary precautions to avoid dangerous situations NOTE For the power connection to the system please refer to Machine installation Power connection in section 11 2 9 For the transformer power tabs see section 11 2 7 as well Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles CONNECTION for primary side of TRANSFORMERS 66767666 Ye el 9 0 6 6 6 9 6 4 e 11 or ine bide i
141. e In the GEM line systems we use always the 3 phase input voltage so the jumper is always set to 1 2 part of the phase check circuit the jumper image is shown in figure 3 6 3 Under voltage detection This circuit checks if the Input voltage is active AND if the output voltage is lower then 186VDC If this is the case then LED 3 orange will be OFF and the servo board will be informed via the INTLCK connector CN3 Over voltage detection This circuit checks if the output is over 414VDC If this is the case LED 4 red will lit as long as the 12V of the ref circuit is on The servo board will be informed AND an EMG signal will be generated Not used Temperature sensing The temperature inside the controller is continuously sensed If the temperature is more than 65 C LED 1 green will be OFF while a signal is sent to the servo board Drive power charging An indication LED 5 is made to see when the capacitor is charging up As mentioned before the INTERLOCK connector which is going to the servo board to switch off the D power and stops the motors has the following 4 signals INTI 1 2 Voltage low 3 Output over 186V DC INT2 pos 3 4 Phase loss 2 3 phase AC input is active 1 2 OR only phase AC input is active JP1 2 3 INT3 pos 5 6 Temp voltage 4 Temp is under 65 degrees Celcius AND the EMG CN2 1 2 Over flow ouput is under 414V DC Please refer to Chapter 14 for the cir
142. e Multi camera utility e Select lt 3 3 B1 adjust target multi camera and press the Enter key e Select Dual rec Offset and press the Enter key e Select Multi cam 1 and press Enter If your machine is equipped with an optional multi vision camera and you are making adjustments to it select the correct camera number Enter the component database no and press Enter Here enter the database number of the QFP you have prepared Ensure safety and press Enter twice The head assembly moves to a point where head 1 is ready to pick up the component Press emergency an attach an SOP to head 1 by hand When using a rectangular SOP align the long side in parallel with the X axis When the SOP has been attached press Enter Figure 9 37 7 9 Cancel emergency Release the emergency button and press the Ready button on the hand held keyboard Ensure safety and press Enter again The head assembly passes repeatedly over the multi camera and the dual recognition offset is measured The results are displayed in the upper right corner of the operation monitor Press Enter key to save the results 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 33 Vision Systems 9 5 6 Press Esc if you want to cancel the results 10 When the measurement is complete dump the component 11 Save the results Select B2 Save data or Save and Quit and p
143. e X and Y positions by performing the first part of the adjustment procedure of the Y motor encoder position before removing the Y axis ball screw See section 8 6 1 Switch off the machine Quit the VIOS software operation and turn off the main switch of the machine Remove the support unit bearing 4C in the back of the machine Remove the lock nut 27 watch for the copper chip which is under the set screw Remove the three spring coned disks 26 Remove the thrust bearing 25 Remove the four hexagon bolts 30 and the bearing holder 20 Remove the and the support unit bearing 4C Do NOT remove the Y axis bearing holder 6 T he ball screw 3 is now free on one side 30 2 6 ex 4 P S ENS 27 4 20 Figure 8 27 ball screw generation 3 Remove the ball screw Move the robot arm backwards near the Y axis bearing holder 6 Remove the two hexagon bolts of the green coupling 22 Remove the four hexagon bolts 4B that secure the support unit 4A Do NOT remove the Y axis motor holder 5 Remove the four hexagon bolts 29 from the ball screw which are mounted in the Y axis nut holder 7 Now gently take out the complete ball screw Remove the lock nut and support unit 4A Continue with installing and aligning the new Y axis ball screw generation 3 see section 8 6 4 4 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 8 29 Axes Syste
144. e air supply of the Topaz must fulfill the following requirements Pressure 6 0 7 0 bar 88 102 psi Flow 350 Nl min 12 4 CFM Oil content 0 1 mg m Dew point 2 C at 7 bar 35 F at 101 psi lt 4 Cat7 2bar 40 F at 105 psi An air supply of 6 0 7 0 bar must be connected to the system via a 1 2 ID hose 3 8 inch minimum suitable for high pressure The air must remain within the above specifications Otherwise increased frequency of some maintenance actions or damage to the machine will occur For the air supply connection to the system please refer to the air circuit diagram in chapter 14 and to Machine installation Air connection in section 11 2 8 5322 871 63606 01 05 Service Manual Topaz 3 5 PA 1309 10 3 4 3 4 1 3 4 2 System Principles Interfaces There are 4 general interfaces between the various parts of the machine and between the machine and the out side world The inside interfaces SDLC Synchronous Data Link Control and ISA bus The outside interfaces are RS232 serial interface Centronics parallel interface SMEMA and Gate in Gate out interface Bus Definitions ISA bus The used bus structure which connects the various PCB s inside the controller is the standard ISA International Standard Architecture bus SDLC link The communication between the System board and the I O boards front rear tray changer is done via the SDLC link With this bi di
145. e conveyor width W distance between the fixed and the movable rail 2 Subtract 1 mm from this width as a clearance margin and then prefix a minus sign to this value This is the W axis initial position Fixed conveyor 4 Origin 19 i Initial position W 0 5 T Figure 8 21 Conveyor width measurement and initial position Movable conveyor rail 4 Enter the initial position 1 Select lt lt lt 3 MAINTE M gt gt gt lt lt 3 MCH_ADJUST gt gt lt B SAVE amp QUIT gt B1 ADJUST TARGET Soft Limit and press the ENTER 2 Use the arrow keys to line up the cursor with Init Pos in the W MAIN row 3 Use the numeric keys to enter the initial position value determined in the previous step 3 5 Cancel the emergency stop Ensure safety then release the emergency stop button and press the READY button of the HHK 6 Save the settings Press the ESC key then select B2 SAVE DATA or BO SAVE amp QUIT and press the ENTER key To quit without saving select B3 RECOVER ADJUST or B7 QUIT and press the ENTER key Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Axes Systems Editing Object Software Limit Axis direct direct Init Pos Init Mov W MAIN 3 70 350 00 1 Figure 8 22 W axis initial position setting screen 8 5 2 Adjusting the R axis Initial Position Nozzle
146. e in reverse order 8 Switch on the machine to perform the second part of the adjustment procedure of the X motor encoder position after replacing the X motor See section 8 6 1 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 8 25 Axes Systems 8 6 3 2 Cox 12 Po 11 24 10 11 X axis Ball Screw Replacement Replacing the X axis ball screw is done as described below See for reference figure 8 25 Do NOT remove the X motor Determine the X and Y positions by performing the first part of the adjustment procedure of the X motor encoder position before removing the X axis ball screw See section 8 6 1 Switch off the machine Quit the VIOS software operation and turn off the main switch of the machine Remove the head assembly as described in section 8 6 2 Remove the two green bolts of the green coupling 4 da 0 24 GP zi F q dis 10 15 Remove the four bolts firmly tightened of the support unit 24 at the right hand side Do NOT remove the holders 10 11 and 12 Remove the four bolts that secure the ball screw nut holder 14 to the head holder unit 13 Move the head holder unit to the left and the ball screw nut holder 14 to the right Gently move the ball screw to the left to free the support unit 24 from the X motor holder 10 Remove the circlip and the bearing of the support unit 24 on the left side Figure 8 25 X axis ball screw Now gently take out the comple
147. e light adjuster plate is displayed over the entire field of view OK NG Figure 9 4 Position the light adjuster tool 10 Adjust the camera lighting level according to the messages The moving camera lighting pattern is divided into a triple ringed area outer inner and coaxial 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 5 Vision Systems Adjust the lighting level for each pattern by using the LED trimmers and selecting the lighting pattern with the rotary switch Three LED trimmers are located on the side of the moving camera light unit for adjustment of the outer inner and coaxial areas The light level increases by turning the trimmer to the right clockwise and decreases by turning it to the left Adjust each trimmer so that the AveGrayLevel value displayed at the upper right of the operation monitor matches the optimum level indicated in the table below 70043307 00 A657 In this type of LED light turning the dial next to 3 screws enables outer inner and A658 Please adjust the light intensity of outer LED by turning A659 Please adjust the light intensity of inner LED by urning the screw in the middle of 3 screws until A660 Please adjust the light intensity of coaxial LED by turning Figure 9 5 Calibration procedure Figure 9 7 Optimum level settings Service Manua
148. e optical systems use a cleaning stick supplied with the machine or cotton swab slightly moistened with ethyl alcohol and wipe the surface of the lens Do not use organic solvents for cleaning Figure 9 39 Line array camera Moving camera Head assembly CE 6 CAUTION Do not apply excessive force to the cameras while cleaning this may cause the calibration parameters to be unreliable Be sure to press emergency prior to cleaning 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 35 Vision Systems 9 7 9 7 1 Recognition Errors This chapter describes some recognition errors that might occur Chip Components Symptom Possible cause Corrective action Recognition error frequently occurs with almost all components Dust or dirt on the camera lens Whip the lens surface with its special cleaner Recognition error frequently occurs with specific components The shape data in the component information width is not correct or the nozzle is picking up the component by the edge Check the shape data and make adjustments by using the adjust assistant If the pickup position is off center of the component check the tape feeder for operation Recognition error frequently occurs with a specific head specific components cannot be recognized The buffing part of the nozzle does not move smoothly or dirt is on the nozzle
149. e vacuum levels that are defined are machine reference values and must cover the whole range of nozzle types and the whole range of components For all eight heads in the machine two levels are defined 1 Vacuum low Level This is the lowest possible level that can be reached for vacuum for any of the heads A type 31 nozzle should be attached to all heads while measuring this vacuum level 2 Vacuum high Level This is the highest possible level that can be reached for vacuum for any of the heads This should be determined with any nozzle attached to the head and closing completely the nozzle tip no vacuum leakage Closing the nozzles can be done for instance with a piece of rubber A Pick level adjustment When a nozzle descends and picks a component no air is allowed to enter the nozzle so the vacuum sensor detects an increased vacuum When this level becomes higher than the preset pickup vacuum level the machine assumes the nozzle has picked up a component 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 7 9 Component Transport Systems The pickup vacuum level should be preset for each head for a level that is slightly higher offset is 5 than the minimum vacuum level maintained when the nozzle is open no component at the nozzle 1 Press the emergency button and attach nozzle 31 to all heads 2 Cancel the emergency stop and press the ready button 3 Execute the vacuum level utility by selecting menu M
150. e version up in 2 5 2 Version up of YVOS2 gt and following to the description confirm the values in 3 1 A3 FEEDER PLATE BASE INF and FEEDER PLATE OFFSET in 3 2 A1 and so on 10 10 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section B Installation of VIOS V1 1x Use this command to install 1 1 onto a machine with V1 2x by following the next procedure 1 M NOTE Wait following messages appears on the display If you use this command VIOS V1 2X will be deleted If you want to execute this command hit Space key If you want to stop this command hit other key Press SPACE key to execute the installation Then the next message appears on the display OFF Turn off power switch Turn off the power switch and turn on it again then VIOS Software Utility starts and type in the password of level 8 according to the message Execute 2 Version up of VIOS and install V1 1 following the procedure Although the machine works with V1 1X by next starting up some machine data should be modified with manual operation as shown in the note below Just after these operations check the following l Baud rate lt RS 232C gt in 3 2 DATA may NOT BE CORRECT Change the value into the original values if the communication functions are used C Edit of Option Config This command calls up the editor of 3 1 A1 OPTION C
151. e will be formatted a press any key b ALL DATA DRIVE C WILL BE LOST input Y and press enter d enter volume label MS DOS 6 Select INVESTIGATE PROBLEMS ON HARDDISK Press ENTER This starts up the scan disk program which checks the complete hard disk Only in case there are problems this command is needed 10 18 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section 3 5 Select COPY MS DOS 6 2 INTO HARDDISK Press Enter MS DOS V 6 2 will be copied into the hard disk a insert HARDDISK MAINTENANCE disk no 2 press any key to continue b insert HARDDISK MAINTENANCE disk no 3 press any key to continue c insert HARDDISK MAINTENANCE disk no 4 press any key to continue d insert HARDDISK MAINTENANCE disk no 5 press any key to continue e insert HARDDISK MAINTENANCE disk no 6 press any key to continue f insert HARDDISK MAINTENANCE disk no 1 press any key to continue Now the files will be extracted g Press any key to continue and to terminate the utility 3 6 Proceed with the next steps to install the Application software VIOS on the hard disk a Turn off power and remove the floppy disk b Turn power and during boot up press and hold the del key if the system ask for the password type in kj0m42 c Select advanced CMOS setup and press enter d Press any key e Change system boot up sequence from A C
152. ed for the locate pins push up pins push in edge clamps and head down movement The air solenoid valves are controlled electrically by a 24V signal coming from the I O boards The air cylinders are activated by air pressure which are controlled by electrical solenoids The pneumatic cylinders are controlled by air solenoid valves Topaz air solenoid valves are controlled by the I O boards inside the machine In chapter 14 the interconnections are shown between the conveyor I O s and the various valves Tray Changer TC The air solenoid valves of the Tray Changer are controlled by the I O conveyor board inside the Tray changer For the connections between the I O board and the various solenoids please refer to the overall T C interconnect diagram in chapter 14 The air pressure for the Tray Changer air valves is supplied via the main machine Tape Feeders The tape feeders do not have air solenoids valves so they do not contain electrical connections Automatic Tray Stacker The automatic tray stackers do have air valves which are supplied via the main machine as well as the electrical signals required FES SVS The compressed air used in the FES and SVS systems are supplied via the machine connected via the interface box 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 5 5 Vacuum and Pneumatic Systems 5 2 8 Measuring and Adjusting Check and if necessary adjust at regular intervals qu
153. ee figure 7 6 2 To adjust the machine low level select ALL and mount from the menu The choice will allow the adjustment of both heads at the same time The Key In option will prompt the user to select one of the heads 1 to 8 3 After the above choices have been made VIOS prompts the user to input a vacuum offset This is to create a safe 100 working range Generally an offset of 5 is a correct value However when using nozzle 31 small components changing the offset from 5 to 0 will increase the vacuuum range This will allow a better distinction between an open and a closed nozzle Enter this value and press lt ENTER gt See figure 7 6 5 Press the emergency stop button and seal the nozzle holes of the applicable heads with adhesive tape make sure no air leak can occur 6 Release the emergency stop and press ready followed by ENTER Now the mount level will be measured for 8 to 20 seconds After that the results will be displayed See also figure 7 6 7 Select lt B2 Save DATA gt or lt BO save amp quit gt and press enter lt lt lt APPLICATION gt gt gt S MAINTE M lt lt MODE gt gt 3 MCH ADJUST lt COMMAND_LIST gt B SAVE amp QUIT B1 ADJUST TARTET Object Head Target Vacuum Level as lisaa lt lt MODE gt gt 3 MCH ADJUST A441 Please input the offset value of the vacuum level Picking vacuum level is hig
154. eeds Turning the speed adjuster knob for the orange tube adjusts the ascent speed while turning the speed adjuster knob for the black tube adjusts the descent speed If the main stopper does not work normally in Step 1 manually check the operation without using the output monitor as follows Press the emergency stop button Press the manual button of the air solenoid valve marked TNO1 with a narrow screwdriver or similar tool having a pointed tip to raise the main stopper If this method works there will probably be a problem with the electric circuit for the air solenoid valve Check the following points Electromagnetic coil breakage Loose harness connectors Trouble with the DC24V supply I O board output errors etc If pressing the manual button does not allow normal operation there is a problem with the air supply air piping or valves damage clogging and adhesion of foreign matter Check the air supply line of the main stopper For any replacements on the main stopper please refer to figure 6 8 7 Figure 6 8 Main stopper exploded view Service Manual Topaz 5322 871 63606 6 6 PA 1309 10 01 05 PCB Transport Systems 6 3 2 PCB Contact Point The stopper of the main stopper is a steel washer with an out centred fixation hole enabling the PCB contact point to be adjusted If the positioning hole of the PCBs used has an offset to the typical position you can adjust the orientation of the stopper i
155. ent database and Component Mark database An example of the contents of the 5 floppies is shown in the next screens SYSTEM 1 SM100 001 1 07 23 97 07 33 INFDSK V12 381 11 29 95 12 06 INS1 LZH 1 114 237 21 12 98 08 55 SYSTEM 2 SM100 002 1 07 23 97 07 33 INFDSK V12 56 11 29 95 12 05 INS2 LZH 995 318 21 12 98 04 54 SYSTEM 3 SM100 003 1 07 23 97 07 33 INFDSK V12 56 11 29 95 12 05 INS3 LZH 781 441 21 12 98 04 55 VERSION STS 6 12 14 96 11 47 SYSTEM DATA NOO gt SUB_DIR lt 98 06 17 15 58 NO1 gt SUB_DIR lt 98 06 17 15 58 FTABLE BIN 740 06 09 98 08 33 INFDSK V12 56 11 29 95 12 06 DATABASE LZH 29730 06 11 98 04 59 MCXCONF SYS 2110 05 29 98 01 10 SM100 1 07 23 98 VIOS SOFTWARE UTILITY DISK Name Ext Size Date Time 1 574866 LZH 333812 12 21 98 8 15 UPDATE 478 11 04 98 8 19 COMMAND COM 58886 12 06 93 6 20 LHA DOC 27059 17 20 91 2 13a LHA EXE 34445 7 20 91 2 13a HDDCHK EXE 113005 12 22 97 11 17 Figure 10 1 Contents of installation disks 10 4 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section The SYSTEM DATA disk is very important because it contains the MACHINE PARAMETER files USER ED and USER HD in the Nol Directory The USER ED contains the machine configuration Equipment Data and the USER HD all the machine parameters Hardware Data Another important is the DATABASE LZH This file contains the compressed component
156. er tape To increase the tape peeling load set the spring shown in the drawing on the upper support pin Figure 7 27 Adjusting Lock lever for 32mm and 44mm emboss tape feeders If there is a gap between the tape guide and the lock lever the tape guide may work loose and inhibit proper feeding of the components To prevent this adjust the lock lever as follows l Press the emergency stop button and attach the tape feeder to the feeder plate 2 Loosen the two screws securing the lock lever Be careful not to remove the screw at this point 3 Adjust plates A and B so that the tape guide and the lock lever touch 4 Re tighten the screws Tape guide Lock lever Plate B Plate A Figure 7 28 Adjusting the lock lever position Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Component Transport Systems 7 5 2 Minimum Timer Load Timer Down Timer When a head moves down to the component pickup position the feeder s air cylinder shaft is pushed out to open the shutter the cylinder is on When the head moves up the shaft returns the cylinder is off and the next component is delivered to the pickup position If this on off timing is not correct component delivery errors may occur To avoid this problem the minimum timer and load timer must be adjusted correctly To check the minimum timer and load timer settings select lt lt lt 3 MAINTE M gt gt gt lt lt 1 MCH_CONFIG gt gt lt
157. ervice Manual Topaz 3 33 01 05 PA 1309 10 System Principles Figure 3 8 2 shows the complete layout of the 274 generation connection board te E em IAE 8 Dara stao nap L ooooooo mia 41 Goa so toa odo so CETT t eocooeccooo o6o660cocccvo m E de em PES p o ee rJ vu AD u3A03 31 aano Z _ r and i sion 2000 H3AO03 1 MOABAND 6037 9015 31753099 AVHL gdan EA dois 9W3 feri oo dOlS 93 t NOASANO2 9097 oore 915 IWI NdAPNOILdO Si sdan YIO Z MOASANOD vdd Cei wand 17 OASANO2 d3 oos Yano 27 mvia daa E S TBAVYEL 1 07 1037 o vou eso se cH ote 9449 e DKL HR Iioc 221 foe eo ee gz nd Figure 3 8 2 2 generation connection board layout 5322 871 63606 Service Manual Topaz PA 1309 10 3 34 01 05 System Principles 3 8 3 3 Generation Connection Board Dip switch settings When using the 374 generation connection board with factory no 7 4550 11 in c
158. es the measurement a table of results will be displayed on the VIOS monitor The data in the table is presented in a format that represents a downward movement of the spline beginning at 2 mm above the recognition height to a point 2mm below In this table the total deviation for each axis should not exceed 20 microns 0 020mm Example of the results table REC Height 2 0 Camera Pos 320 467 140 295 REC Height 1 6 Camera Pos X 320 463 140 287 REC Height 0 0 Camera Pos X 320 460 140 281 REC Height 1 6 Camera Pos X 320 457 140 273 REC Height 2 0 Camera Pos 320 452 Y 140 266 Camera Position cogniti on Re Hei ght m m 0 04 0 03 0 02 Figure 9 26 If the deviation exceeds 0 02mm per 4mm it is recommended that you save the data to a floppy and use the Excel Template to determine the camera position As you make adjustments the template will provide history data that is very useful to visually interpret the amount and direction of correction yielded by each adjustment 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 23 Vision Systems 5 Placea floppy in the A drive when prompted to save the data 6 Run the Cam pos xls and import the information into this program by clicking on the a results dat button 7 Observe the value of the numbers to the right of the decimal point The
159. ess adjustment VR6 The line sensor channels are equipped with a brightness feedback system This means the lighting unit has a sensor which measures the brightness the latter is compared with the reference brightness and as a result of this the brightness difference controls the LED current In order to protect the LED s for maximum current the board contains a current limitter circuit The board also contains a speed feedback circuitry which is currently not in use Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles Remarks The jumper setting is fixed and is the same for both the Sapphire and Topaz The LED driver board for the Emerald is NOT compatible with the one used in the Sapphire Topaz because of the difference in the current limiters The following table shows the relation between the several cameras connectors potentiometers max currents and jumpers in the hard and software Please refer to figure 3 6 1 for the location of the various items 3 4 Vision Board Camera 2 Fiducial cam LED driver board LED driver output 2 3 4 Light type note 2 A B A B A B Yq Potentiometer VR3 VR2 VRI VR4 VR5 VR6 DAE Output connector CNIO CNII CNI2 4 5 4 Sensor connector CN4 CN5 CN6 CN7 CN8 CN9 Sensor jumper JP9 0 JPII JP12 JP13 4 Speed jumper JP4 JP4 J
160. for the connection between the system board and an external PC system The meaning of the RS232 connector pins is shown in table 3 4 1 Figure 3 4 1 shows some examples of connections related to the DTE Data terminal Equipment computer and the DCE Data Communication Equipment modem Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles Pin Nr Meaning input output 2 TXD Transmit data Output from mounter 3 RXD Receive data Input to mounter 4 RTS Request to send Output from mounter 5 CTS Clear to send Input to mounter 6 DSR Data set ready Input to mounter 7 GND Signal ground 8 DCD Data carrier detected Input to mounter 20 DTR Data transmission ready Output from mounter Table 3 4 RS 232 Connections SUB D CONNECTOR 25 PINS DCE SUB D CONNECTOR 25 PINS DTE 3 WIRE CONNECTION DTE DTE 3 WIRE CONNECTION DTE DCE 1 TxD 2 RxD 3 m Na FULL CONNECTION DTE DCE 1 TxD 2 RxD 3 RTS RIS 4 CIS CTS 05 DSR 6 TxD 3 Figure 3 4 1 RS 232 Connections 5322 871 63606 Service Manual Topaz 3 7 01 05 PA 1309 10 3 4 3 System Principles Line Interconnections There are two methods which can be used to interconnect two or more systems in a line the GATE IN GATE OUT and the SMEMA method SMEMA interface The SMEMA interface is standard in the Top
161. formation is set at the factory prior to shipment It is unlikely that you will need to change it If however this information needs to be adjusted enter the optimum settings on this screen while checking for feeder operation To save the new settings select A0 EXIT press the ENTER key 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 7 31 Component Transport Systems 7 5 3 Tape Feeder Maintenance Introduction The tape feeders comply to the EIA 481 standard The following tape feeders are available 2903 70 PA2903 71 PA2903 72 PA2903 80 PA2903 81 PA2903 20 PA2903 30 PA2903 40 PA2903 50 Adjustment 8mm Tape Feeder 2mm pitch 7 Reel 8mm Tape Feeder 4mm pitch 7 Reel 8mm Tape Feeder 4mm pitch 15 Reel 12mm Tape Feeder 7 Reel 12mm Tape Feeder 15 Reel 16mm Tape Feeder 24mm Tape Feeder 32mm Tape Feeder 44mm Tape Feeder Tape feeder adjustment 8mm to 16mm only can be done with the Optical Tape Feeder Adjustment Tool A user manual is included with this tool The tool can be ordered with PA2849 10 Service Manual Topaz PA 1309 10 5322 871 63606 01 05 Component Transport Systems Preventive Maintenance for tape feeders a Preventive Maintenance Schedule Item Tape waste every Daily Weekly Monthly gt 1 2 million gt 2 million feeder m change indexes indexes clean Cleanliness Tape path check clean Transport
162. ftware for the SH7021 processor to be uploaded from the system unit at start up For this reason the flash ROM contains a read only part and a readable writable part The read only part contains some dedicated software nessecary for the software download The readable writable part is used for the software download from the system unit The connectors of both the second and third generation board are fully compatible enabling upwards compatibility for the PNP type I O boards Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles The boards of the third generation are shown in the figures 3 7 2 and 3 7 3 below In these figures the location of the indicators and settings are highlighted Flash memory 2 stage DIP switch I 0 CONVEYOR UNIT AS 7 segment LED display 6 stage LED 2 DIP switch p4 D3 maca IW i mi 2 070 KMS M4SB0 G cmos 7 1 TPS Pici pm C35 pet 20 4 ow h gt acts73 7 EU ES puo o nersa UD E Vii v Ei 5 B m wer ry T 7541 ee AF 57 mme 0 lam E 3 esa g i i f w i Mm sh 24 i 25 e H aaa E E D LUE deus
163. gned with the holes in the clamp plate Tighten the bolts in the clamp plate Check the status of the clamp plate sensors as in following table Output Input 02 0 camp NPI3 0 14 I TP02 open NPI4 0 7 3 4 Adjusting the Nozzle Station Coordinates The position of each nozzle holder in the nozzle station is defined as a set of the X Y Z and R coordinates the R coordinate is used since some nozzles have an orientation Each head moves according to these coordinates to extract a nozzle from or deposit a nozzle into the nozzle holder These coordinates are set at the factory prior to shipment There will be no need for adjustment under normal conditions If for some reason adjustment is necessary proceed as follows The following gives an example for adjusting the coordinates of Nozzle Station 1 Use the same procedure for other nozzle stations 1 Open the output monitor and release the nozzle clamp plate Select lt lt 3 4 lt C DISPLAY amp EXIT gt lt C1 OUTPUT MONITORs and press the ENTER key Use the arrow keys to line up the cursor with TP02 FRONT NOZZLE STATION CLAMP Press the ENTER key to open the clamp plate The output monitor digit reads 1 when the plate is opened and reads 0 when it is closed Service Manual Topaz 5322 871 63606 7 18 PA 1309 10 01 05 Component Transport Systems Out Monitor T Select Enter Exec Selected Ar
164. h head are limited to No to 47 the front side and No 104 to 150 on the rear side 94 positions in total Accordingly to teach the reference position No 101 use No 104 instead and add 48 00mm to the X coordinate determined One pitch of the feeder set positions equals to 16 00mm The Y coordinate will be the same as feeder position 104 To perform teaching for the reference position of each feeder block proceed as follows You can use either head for teaching 1 Check if a nozzle is attached to the head A nozzle for small chip components example type 31 is recommended 2 Press the emergency stop button 3 Set a tape feeder at a reference feeder position Use a tape feeder you have used for the parallel adjustment in the preceding section 4 Open the shutter of the tape feeder Refer to Step 5 of chapter 7 4 1 5 Move the head assembly by hand to over the tape feeder While lowering the nozzle position the head assembly so that the nozzle tip is at the center of the component pickup position 6 Open the feeder plate offset screen Select lt lt lt 3 2 A Al SELECT TARGET FeederPlateOffset and press the ENTER key lt lt lt APPLICATION gt gt gt gt 2 DATA COMMAND LIST DATA A1 SELECT TARGET Object FeederPlateOffset lt lt lt APPLICATION gt gt gt 3 MAINTE M gt 2 MCH_DATA Editing Object
165. her than open level by offset Mounting vacuum level is A442 It will measure the vacuum level when mounting This adjustment requires a nozzle and a component A444 lt lt Measuring gt gt New it is measuring vacuum level It takes 20 A445 lt lt Result gt gt The following data is the result of the adjustment of the vacuum level when picking and mounting 1 2 345 67 8 Level XXX XXX 0 0 0 00 0 Min XXX XXX 0 00000 Current XXX 0 0 0 0 0 0 Result XXX XXX 0 0 0 00 0 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 7 11 Component Transport Systems Figure 7 6 Vacuum results 7 2 4 R axis Absolute Accuracy Offset This is the angular offset for the R axis that rotates each nozzle shaft to mount the component When you select 3 2 A1 select target gt R axis accuracy Enter the current offset settings for the mounting angles 0 180 90 and 90 are displayed as shown below lt lt lt APPLICAITON gt gt gt 3 MAINTE M lt lt MODE gt gt 2 MCH_DATA Editing Object R Axis Accuracy Head No Odeg 180deg 90deg 90deg Head 1 0 00 0 07 0 00 0 00 Head 2 0 00 0 20 0 00 0 00 Head 3 0 00 0 00 0 00 0 00 Head 4 0 00 0 00 0 00 0 00 Head 5 0 00 0 00 0 00 0 00 Head 6 0 00 0 00 0 00 0 00 Head 7 0 00 0 00 0 00 0 0
166. ibed below the scale is calibrated automatically and at the same time the XY positions and installation angle R of the line array camera 1 and 2 in the Camera Coordinate machine data are adjusted also Setting up for the line array camera Before you begin the calibration check the current camera scale settings and y g g prepare the component and nozzle as described below 1 Check the current settings of the camera scale e Select lt 3 2 1 Select target Vision parameter and press Enter Check the settings of the Multi cam 1 or 2 scale When you execute the Multi camera camera scale command explained later the X Y values will be calibrated Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Vision Systems lt lt lt APPLICATION gt gt gt lt lt gt gt 2 MCH DATA Editing Objec Vision Parameter Object X Y 2 R 1 Delta pos 60 03 70 05 Figure 9 33 2 Prepare a component to be used as a reference Use a relatively large popular QFP of known size which is registered in the component database If you have no SOP available you can use chip capacitors such as a C2125 if you use a component that is not registered in the database it must be registered 3 Edit search area mm in the component data Data registered in the database as a number larger than 500 cannot be edited due to w
167. ifies the 3 phase 200VAC power and supplies 282VDC to the driver boards The assembly consists out of the D power board itself and the capacitor CAP1 which is located at the right side back corner of the 2 controller box see figure 4 8 below Fuse 1 200V AC U IN 200V AC V IN 200V AC W IN Jumper 1 282 to Driver boards Cap 1 od Ze 18V in from we trafo CN1 Interlock CN3 EMG CN2 Figure 4 8 D river power assy The following circuits can be distinguished 12V reference circuit The reference circuit receives a 18VAC voltage CN2 from a separate trans ormer inside the MCX 2 box The 18VAC is protected by a fuse FU2 of 0 3 Amp After rectifying 12VDC voltage is generated which is used for the controlling circuitry LED 1 green will be lit as long as the temperature is OK Service Manual Topaz 5322 871 63606 4 10 PA 1309 10 01 05 Power and Safety Circuits Inrush protection circuit This circuit inhibits a high inrush current when the 200VAC is switched on After some time measured via the input voltage period the serial resistors R1 R3 are shorted Phase check circuit This circuit checks the 3 phases of the input voltage If not OK a signal will be send to the Servo card via the INTLCK connector CN3 and the LED 2 green will be OFF There is a jumper selection on the board to select 1 phase jumper on position 2 3 or 3 phase jumper on position 1 2 input voltag
168. igure 7 12 Nozzle clamp in output monitor Service Manual Topaz 5322 871 63606 7 16 PA 1309 10 01 05 Component Transport Systems 4 Press the emergency stop button and insert a nozzle into the nozzle holder you want to check 5 Open the input monitor and select the correct nozzle sensor Press the TAB key to move the cursor into the input monitor window Line up the cursor with the digit for the corresponding sensor from among NNOI to 10 see figure 7 10 In Monitor lt Select Enter Exec Selected Arm MAIN XY ESC Command Lists Moving Speed 100 06 NOZZLE 6 SENSOR NAME OUT NAME IN Nozzle Sensor 01 08 00000100 Nozzle Sensor 09 16 00000000 Figure 7 13 Nozzle sensors in input monitor To match the nozzle holder No or nozzle station No and the sensor input display code see figure 7 10 4 Check the input status of the selected sensor The digit reads 0 when the nozzle is stored in the holder but reads 1 when it is not If the digit reads 1 the amplifier gain for the nozzle sensor is too low Gradually turn the gain control of the amplifier clockwise until the digit reads 0 5 Take the nozzle out of the holder and check the input status Check if the digit has changed to 1 If not the amplifier gain is set too high Turn back the gain control of the amplifier slightly to the left so that the digit reads
169. ilable only VIOS gt V1 xx No buffer conveyor Buffer with external tray changer stand alone buffer conveyor No buffer conveyor with W axis Front side fixed fixed side is door side Rear side fixed fixed side is door side No tray defined External TC for 50 pallets External TC for 32 pallets Automatic TC for 27 pallets Automatic TC for 10 pallets Automatic for 30 pallets Nozzle change station is available Set to exist if this slide system is installed Do not select No such option available yet No dump station Dump station attached on the feeder plate 10 26 Service Manual Topaz PA 1309 10 5322 871 63606 01 05 Software Section Parameter Selection 5 Dispense Head None Exist 6 dispense head R sensor Single Double 7 Dot station Exists Not exists 8 RS232C extension None Exist Description Not possible for GEM systems Do not select Not used in GEM machines Not applicable for GEM systems Is set to exist if an ext RS232 board is installed 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 10 27 Software Section 10 5 ROM and File Configuration Version Level The screen in fig 10 9 is showing the version of the various used in the system DATA non lt lt lt APPLICATION gt gt gt 1 OPERATION M 2 DATA M 3 MAINTE M 4 SHELL M 0 lt lt MODE gt gt 1 MCH CONFIG 2 MCH_DATA 3 MCH_ADJUST 4 MANUAL 0 EXIT
170. ility of axis movement and mounting accuracy the following parameters must be set correctly Axis W ZXY R Parameter Machine reference Secondary limit Software limit Initial position Initial movement Table 8 2 Adjustment parameters of moving axes MAKE SURE TO TAKE ALL NECESSARY SAFETY PRECAUTIONS WHEN WARNING DOING MECHANICAL ACTIONS AT THE SYSTEM ALWAYS SWITCH OFF THE MACHINE IF MECHANICAL ASSEMBLY OR DISASSEMBLY ACTIONS ARE CARRIED OUT 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 8 1 Axes Systems 8 2 Machine Reference Origin The built in motor encoder of each axis issues a 0 pulse each time one turn is complete When return to origin is performed there will be a difference in distance between the position where the origin signal is detected and the point at which the next encoder 0 pulse is received the origin position actually set This is called the machine reference and is usually expressed in percentages with 10096 being equal to one full turn of the motor W Machine reference Origin signal p Origin sensor signal m achine reference X Y R ax s Machine reference Z axis A e A B phase 0 phase Moter 1 rotation 10043601 00 Figure 8 Machine reference Check the machine reference settings Move the cursor to 3 MAINTE M E 4 MANUAL E B AUTOMATIC
171. in position E minus side software limit F Mechanical limit Figure 8 14 Z axis movement To set the Z axis software limit follow these steps 1 Set teaching conditions 1 Select lt lt lt 3 MAINTE M gt gt gt lt lt 3 MCH_ADJUST gt gt lt B SAVE amp QUIT gt B4 CONDITION OF TCH and press the ENTER key 2 Select TEACH UNIT SEL and press the ENTER key Select any of Camera Head 1 or Head 2 3 Select SPEED SELECT Select any speed from 1 to 5 2 Press the emergency stop button then move the Z axis Raise or lower the Z axis by hand until the makes contact with the mechanical stopper Raise the Z axis to adjust the minus side while lower it to adjust the plus side 3 Perform teaching at the position in contact with the mechanical stopper 1 Select lt lt 3 MCH_ADJUST gt gt lt B SAVE amp QUIT gt B1 ADJUST TARGET SoftLimit and press the ENTER key 2 Use the arrow keys to line up the cursor with Z1 MAIN for the Z1 axis or Z2 MAIN for the Z2 axis The cursor should be positioned on direct you have moved in Step 2 Service Manual Topaz 5322 871 63606 8 14 PA 1309 10 01 05 Axes Systems 3 Press the F10 key twice to perform teaching The numerical value of the parameter that the cursor is on changes This value is the mechanical limit hard limit Editing Software Limit Axis direct direct Init P
172. in tenths of a millimeter is recommended Ensure safety then press the ENTER key again The W axis moves to set the specified conveyor width When you have already adjusted the conveyor width for performing the Adjust Assistant in the previous section the W axis does not move Press the emergency stop button then set the PCB in position When the PCB has already been set on the conveyor skip this step Cancel emergency stop If you have set emergency stop in Step 6 release the emergency stop button and press the READY button on the HHK Ensure safety then press the ENTER key The locate pins and push up pins rise to secure the PCB and the head assembly moves to over the PCB The teaching screen for the fiducial mark position then appears 70043309 00 lt lt MODE gt gt 3 MCH ADJUST A427 lt lt lt Moving gt gt gt Now it is fixing the PCB and moving the axes To quit please press the ESC key A428 lt lt lt Teaching gt gt gt Please set the fiducial mark on the center cross cursor of the monitor by using the joy stick After teaching please press the ENTER key To quit please press the ESC key Figure 9 11 Teaching fiducials Position the fiducial mark in the center of the screen Manipulate the HHK joystick to align the mark with the cross cursor in the center of the screen 70043305 00 Figure 9 12 Mark info screen 9 10 Service Manual Top
173. ind the assemble direction of the disks see figure 8 28 Note check at the ball screw nut holder bearing nipple if it properly has been greased Generation 2 Generation 3 Direction of spring coned disks Figure 8 28 Replacement of generation 2 ball screw for generation 3 ball screw Service Manual Topaz 5322 871 63606 8 30 PA 1309 10 01 05 Axes Systems Difference generation 2 and generation 3 The difference between the 2 and 3 generation ball screw assembly is found in the Bearing holder 34 Sleeve bearing 32 and thrust bearing 36 In the 3rd generation these have been changed for a new Bearing holder 20 and new Thrust bearing 25 only See figure 8 28 Alignment of the Y axis ball screw Use the alignment tool 4022 591 74241 see fig 8 29 and put it carfully on the linear guide first at the front of the machine 30mm from the motor Secondly at the back 30mm from the Y axis bearing holder 6 Make sure both the tips of the dial gauges are not in a valley of the ball screw For horizontal alignment check the distance between the linear guide and the ball screw at the front and at the back max 0 02mm difference between front and back For vertical alignment of the ball screw the difference is also max 0 02mm between front and back Adjust both alignments by shifting the bearing holder 20 Then tighten its four bolts with a torque of 6 7 Nm Figure 8 29 alignment tool of the Y
174. ineer for low radiation This sticker is located nearby the laser transmitter for feeder floating detection Service Manual Topaz 5322 871 63606 1 6 PA 1309 10 01 05 Introduction High temperature 63607103 JPG HIGH TEMPERATURE Figure 1 4 High temperature This sticker see figure 1 4 warns the operator service engineer for high temperature presence This sticker is located upon the Y motor of the Topaz 1 3 6 ESD Precaution All printed circuit boards that are part of the CSM GEM machines must be transported and stored in ESD protected bags Any person handling an CSM GEM printed circuit board must adequately be earthed e g by means of a bracelet with earth cable to prevent destructive electrostatic discharge through the printed circuit board In areas that are not ESD protected the removable protective covers must be mounted on all placement modules Handling of printed circuit boards should be restricted as much as possible 1 3 7 Noise Level The average noise level of the Topaz system during production is 72 dB A 1 3 8 Liability Philips shall not be liable for any costs damages or personal injuries if the CSM GEM system is not used according to the safety rules given in this manual 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 1 7 D gt Introduction 1 3 9 Oil and Greases This section gives more detailed information about oils and greases used in the T
175. ing the highlighted bar to a file and pressing F8 it is possible to view the contents of this file The most important files are displayed in bolt and are ERRMES E TXT see fig 10 12 HLPMES E TXT see fig 10 13 ITMMES E TXT see fig 10 14 MODMES E TXT see fig 10 15 see fig 10 16 VISMES E TXT fig 10 17 PPERR E TXT DATA non lt lt lt APPLICATION gt gt gt 1 OPERATION M 2 DATA M 3 MAINTE M lt lt MODE gt gt 1 DATA FILE _2 DISK_ MAINTENANCE DIRECTORY C KG7 42M0 009 Name Ext ERRMES_E TXT ERRMES_J TXT ERRMES S TXT HLPMES E HLPMES 7 HLPMES 5 ITMMES E ITMMES J ITMMES S LASERPOS MODMES E MODMES J MODMES S Figure Size 110282 98592 93584 432420 379910 337020 33961 35227 34076 213 ENTERS 16734 16639 10 11 S S09 109 022249 Su 95 09 09 02 29 5 S5 09 09 965025219 102222 oo 09 109 112 219 Time gt OI On uS gt iS BOO S5 9 95 2 amp 5 8595 US5 POT RSS 27315 857 go s39 SQ 507 4 SHELL M 3 VIOS_DIC 0 0 DIRECTORY C NECL92NKG7 42M0 009 Date IG ULSA Name QWORDS_S SBMMES_E SBMMES_J SBMMES_S SPEED5 TITLE_X TKNSCD TKNSYM UFOSBRD UFOSFD2 UFOSFDR UFOSMCH UFOSVIS CAKG7 42M0 009 Ext TAL TAE TXT TXT TXT PEL TXT TXT TAE TXT TXT TXT TXT Size 2839 23530 22763 22314 252 47897
176. ion data Check in particular that the mark size of the PCB exactly matches the registration data MarkOutSize Check also that the Search Area parameter in the Vision Info sub window is 4 00 or larger not too large but also not smaller than 4 00 70043302 01 i discs lt lt lt APPLICATION gt gt gt 2 DATA M lt lt MODE gt gt 3 DATABASE OBJ MARK DATABASE Mark size Info No NAME COMMENT Edit Term Mark OutSize mm 1 0 151 CIRCLE 1 0 Cu Vision Info Edit Term Search Area 2 4 00 Figure 9 8 Mark data base Open the Adjust Assist to check that the mark is clearly recognized The Adjust Assistant screen appears by pressing the F6 key Secure the PCB on the conveyor by means of the FIX PCB command 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 7 Vision Systems Adjust the conveyor unit according to the size of the PCB you are going to use After pressing the emergency stop button make necessary adjustments to the locate pins and push up pins The test board CT 346 is 136mm wide Execute the VISION TEST command When no errors occur the current parameter settings are appropriate Advance to the moving camera scale adjustment in the next section If an error occurs adjust the moving camera lighting pattern and or mark information parameters as necessary For more details on the parameter settings refer to
177. ion of the feeder plate Loosen the bolts that temporarily fasten the feeder plate then carefully slide the plate so that it is set parallel to the X axis 12 Re tighten the bolts securely Then advance to the next step in 7 3 2 Teaching the feeder block positions Feeder Block Positions On each of the two feeder plates 50 feeder set positions pickup positions are provided These pickup positions are divided into seven feeder blocks per plate as shown below Each feeder block is comprised of eight feeder positions except the rightmost feeder block PF7 PF15 on each plate which consists of two feeder positions The first feeder set position of each feeder block is specified as a reference position Therefore feeder set positions of No 1 9 17 25 33 41 and 49 on the front plate and No 101 109 117 125 133 141 and 149 on the rear plate are used as reference positions PF15 Rear 1 14 PFI3 PF12 PF11 PF10 i H i i O00100000000 00000000i00000000 00000000 00000000000000 149 141 133 125 117 109 101 0000000000000000 00000000 00000009 00000000 000000090 996 i SEG Fri E PF1 PF2 PF5 PF6 Front Figure 7 17 Feeder block arrangement Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Component Transport Systems CAUTION Due to the configuration design of the Topaz head assembly the feeder set positions that can be actually accessed by eac
178. ips Production Control Software and can be ordered via regular channels The set of online commands will not be printed in this manual but are available on special request at Philips Eindhoven 10 32 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05
179. istance between the two guides is fixed to 70mm The bottom and top linear guide are parallel to each other with no tolerance Y axis Assembly The mechanical assembly of the Y axis is shown in figure 13 6 2 Y axis Replacement Y motor Only The Y axis motor is a 400W AC Servo motor Removing the motor is done as described below See for reference figure 13 6 2 Determine the X and Y positions by performing the first part of the adjustment procedure of the Y motor encoder position before removing the Y motor See section 8 6 1 Disconnect the PI and MO cable in the cable duct right side of system Loosen the coupling on the motor shaft Remove the four bolts which holding the Y motor Remove the AC Motor Assemble in reverse order Switch on the machine to perform the second part of the adjustment procedure of the Y motor encoder position after replacing the Y motor See section 8 6 1 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 8 27 Axes Systems 8 6 4 2 Y axis Removing Y axis Ball Screw Generation 2 Removing a 274 generation Y axis ball screw is done as described below See for reference figure 8 26 Do NOT remove the Y motor Determine the X and Y positions by performing the first part of the adjustment procedure of the Y motor encoder position before removing the Y axis ball screw See section 8 6 1 Switch off the machine Quit the VIOS software operation and turn off the main switch of the machine
180. ition Position the cursor on the X column of the Iwait position and press F10 twice Do the same for the Y value Save the settings by pressing ESC and selecting save data Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Component Transport Systems 41 2 TY NOTE F Discard point This is the position at which the head discards a component Typical discard point coordinates are entered prior to shipment Since it is not necessary to lower the nozzle when discarding a component the Z coordinate is usually set to 0 00 To change the discard point XY coordinates use the same procedure as for setting the wait point Make sure that the head assembly will not be detected by a PCB sensor Verify that when a component is discarded the discarded component will not interfere with the PCB transport assy camera or sensors Feeder column indicates the duration for which the air blow turns on to discard a component in milliseconds This value is set typically to 20 to 100msec G PCB Fix TF The Z coordinate represents the height of the head assembly positioned to mount components on a PCB Set this parameter by teaching the height at which the nozzle of Head 1 just makes contact with the surface of a PCB which is secured in the mounting position The R coordinate is the height of a pallet when a manual tray feeder is used To perform teaching for the PCB height Z coordinate follow the steps
181. k 09 Air pressure NMIO Rear feeder lock I NMII Rear area NM12 13 Spare NMI4 Smema discrimination NMI5 Smema ba in NMI6 Spare NNOI I6 Nozzle to nozzle l6 NPOI Rear non stop fdr carriage detect switch NP02 Rear non stop fdr carriage detect upper NP03 Rear non stop fdr carriage detect forward NP04 Sp Light single cameral up NP05 Spare 06 Sp Light single cameral down 07 8 Can t use 09 Sp Light single camera2 up NPIO Sp Light single camera2 down NPII Sp Light single camera3 up NPI2 Sp Light single camera3 down NPI3 14 Front nozzle station clamp NPI5 Nozzle station up NPI6 Nozzle station down NQOI Tray changer pallet origin NQ02 3 Tray changer hook open close NQ04 Tray changer pallet set NQ05 Tray changer relay spare NQ06 7 Tray changer spare 008 Tray changer door interlock 009 Tray changer door2 interlock NQIO Rackl in ext tc latch open Rack2 in ext tc latch close NOQI2 Ext tc head beam NOQI3 Ext tc head vacuum 14 Tray changer spare NQI5 Ext tc head lower NQI6 Tray changer spare NROI 3 Ext tc station to station3 vacuum NRO4 Tray changer hook safety zpos NR05 6 Autotc s hook forward backward NR07 Tc board discrimination NR08 Tray changer 24v ok NRO9 10 Tray changer door door2 sw NRII Ext tc conveyor entrance NRI2 Ext tc pcb check position NRI3 Ext tc conveyor exit NRI4 Ext tc select switch NRI5 Ext tc pcb check ok NRI6 Ext tc w axis origin
182. k EMG RS232 con 1 JP7 underneath the application board CN4 Appl Board RS232 con 2 lt q VGA monitor Good signal Figure 3 5 2 System boai 1 2 The jumper setting see fig 3 5 2 this second generation system board is following e to JP6 Set to position 1 2 e JP7 Set to position 1 2 On the application board all six SW1 jumpers are set to OFF Position 2 Position 3 Position 1 Jumper on position 2 3 Figure 3 5 3 Jumper setting At the front this system board has 4 LED indicators the GOOD signal indicating the POWER OK the I O signal which is flashing as long as there is a correct Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles communication with the I O and two signal indications regarding the I O circuitry No gate no communication at all and time out no response for a certain time The signal connector EMG at the front is connected to the EMG circuitry and inhibits a motor movement in case something s wrong inside the MCX controller Servo NOK 282V power NOK etc The board is equipped with two SIMM modules of 4 Mbyte Or one SIMM module of 8 Mbyte The application board establishes the I O communication between the system board and the various I O boards in the Topaz The main processor on this board is a 8344 12Mhz microcontroller of the brand Intel The scanning speed of the I O ports is about 3 msec scanning of all ports Third genera
183. l Topaz 5322 871 63606 PA 1309 10 01 05 Vision Systems Return the rotary switch to 0 When adjustment of each lighting pattern is complete set the rotary switch to 0 all LED s turned on I2 Press the ESC key to quit the adjustment The locate pins and push up pins are automatically released After pressing the emergency stop button remove the PCB There is no machine data to be saved in this adjustment 9 3 3 Adjusting the Moving Camera Scale The moving camera scale is a vision parameter representing a measurement equivalent to one pixel This scale must be adjusted correctly for accurate recognition of PCB fiducial marks T o make the adjustment you will need a PCB having a fiducial mark of known size 1 Preparing the PCB normal Prepare a PCB having a precise fiducial mark that is registered in the database When you use a PCB having a mark not registered in the database it must be registered M al NOTE Use of a circular mark is recommended since circular marks are generally superior in dimensional precision to other marks Use of a Imm diameter circular mark that faithfully reflects light is especially preferred A doughnut shape is not suited for use in this adjustment Check the registration in the mark database 1 To open the mark database select lt 2 3 DATABASE gt AI COMPONENT MARK D B gt MARK DATABASE and press the ENTER key 2 Check for the registrat
184. l axis might also be very useful to check in this case see the end of this chapter lt lt MODE gt gt 3 MCH_ADJUST A711 Cam cor X 4 MultiCam2 Position Error MaltCam1 18 61 Position angle of MItCam2 is not correct MaltCam2 0 00 Please adjust position of MitCam2 as difference between MltCam1 Cam cor and Cam cor is less than 10 0 Adjusting method is shown in next display Please press Enter key A712 Cam cor X ME MaltCam1 18 61 Adjusting Method of MitCam2 When you see the machine from front 2 0 00 1 if you tilt MitCam to right direction value of Cam cor X is decreasing 2 if you tilt MitCam to front direction value of Cam cor Y is decreasing Caution Please move only Mltcam2 Please don t move 1 Please press Enter key to stop this adjustment Figure 9 37 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 9 31 Vision Systems e To adjust the Cam coord X loosen the bolt securing the camera stay to the camera stand then make the fine adjustments to the camera installation angle Retighten the bolt to secure the camera e To adjust the Cam coord Y loosen the bolts securing the camera stay and insert a shim of 0 05mm between the stay and camera Then retighten the bolts to secure the camera In either case adjust the camera installation in the A direction when increasing the Cam X Y values and in B direction when reducing them
185. l reference feeder positions Refer to the next section 7 4 3 Component pickup test If any offset is found correct it on the feeder plate offset screen 7 4 3 Component Pickup Test To check component pickup position or pickup function you can use the component pickup test command Install in advance a tape feeder in the feeder set position where you want to perform the component pickup test It s recommended to perform the test with the smallest available component 0402 1005 Refer also to figures 7 23 and 7 24 1 2 3 Execute the component pickup test Select 3 3 A A3 PICK COMPONENT and press the ENTER key Enter the database No of the component and press ENTER Enter the head No and press the ENTER key Specify the head No for which you want to perform the component pickup test Enter the feeder set No and press the ENTER key Specify the feeder set No at which you have installed the tape feeder in Step 2 Ensure safety then press the ENTER key again The head assembly starts to move and the specified head picks up a component from the feeder Check the component pickup position Look at the position of the nozzle tip relative to the component If any offset is found in the X and Y directions enter the offset on the feeder plate offset editing screen as explained in the previous section teaching the reference feeder block positions Dump the component Select A4 DUMP COMPONENT and pre
186. lect any of Camera Head 1 or Head 2 3 Select SPEED SELECT Select any speed from 1 to 5 lt lt lt APPLICATION gt gt gt lt lt MODE gt gt lt COMMAND_LIST gt Front view gt Pulley Nl S MAINTE M 3 MCH ADJUST B SAVE amp QUIT B4 CONDITION OF TCH TEACH UNIT SEL Camera Head 1 Head 2 SPEED SELECT Speed1 100 Speed2 80 Speed3 60 Speed4 40 Speed5 20 4 Press the emergency stop button then move the conveyor rail Turn the W axis pulley by hand until the movable rail makes contact with the mechanical stopper When the movable rail is positioned in contact with the mechanical stopper the maximum conveyor width is approx 410 00 mm and the minimum width is approx 50 00mm Check the width by measuring with a square or tape measure 5 Perform teaching at the position in contact with the mechanical stopper 1 Select lt lt 3 MCH_ADJUST gt gt lt B SAVE amp QUIT gt B1 ADJUST TARGET Soft Limit and press the ENTER key 2 Use the arrow keys to line up the cursor with direct or direct of the conveyor width being adjusted The cursor should be positioned on the direct you moved the axis in Step 2 3 Press the F10 key twice to perform teaching The numerical value of the parameter that the cursor is on changes Service Manual Topaz 8 12 PA 1309 10 5322 871 63606 01 05 Axes
187. ll not effect the machine s calibration data This program COM pgm has been written to help to determine if a deviation exists and give us the ability to measure the deviation The results of the measurement are displayed on the VIOS monitor It is also possible to save the result on a floppy for importing into the Microsoft Excel template CAM POS xls The Excel template creates a graph that provides a visual interpretation of the results as well as a measurement history that is very useful for comparing prior adjustments measurement should be done directly after the scale adjustment is done If the results show that a mechanical readjustment is needed and consequently is carried out a new scale calibration adjustment is needed at the end To Correctly measure the relationship between the Single camera and Z axis the program COM pgm is used This program measures a component at 4 angles and at different Z positions in the optical plane The results are displayed on the monitor and can be saved to disk The utility program COM pgm can be obtained from the system 3 disk of VIOS 1 20 3 or later as well as the Glass Adjustment Kit The Microsoft Excel template CAMPOS xls can be obtained electronically from Philips Technical Support This adjustment should be performed immediately following the camera scale adjustment of the machine calibration procedure 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9
188. ller 80486 uP 8 Mb memory AT keyboard Power supply 5V 12V 12V SA 2 2 2 2 Encoder signals 2 LY 4 4 y 2 LX 4 2 LW DRIVER 2 2 LZ lt BOARD SERVO 2 LH ASSY board assy 2 LT lt 4 Traychanger Tray changer or ATS or ATS lt Encoder signals SS DRIVER 1 or AUS Cam 1 Fid 2 Cam A hui VICS 2000 Cam 4 Multi 2 VISION monitor Figure 2 2 Electrical block diagram Topaz 5322 01 05 871 63606 Service Manual Topaz PA 1309 10 General and Electrical Block Diagram Intentionally Left Blank Service Manual Topaz PA 1309 10 5322 871 63606 01 05 System Principles CHAPTER3 System Principles 3 1 Introduction This chapter describes all the installation and the basic system principles of the TOPAZ The first part of this chapter describes the Mains Air and system installation specifications The second part discusses the Control unit MCX with the related the third part gives a overview of the various I O PCB s Key boards and monitors The last part covers the I O signals and a brief introduction how to use the various adjustment commands adjustment methods when doing a machine adjustment 5322 871 63606 Service Manual Topaz 3 1 01 05 PA 1309 10 wiley 2 DT System Principles 3 2 Mains Specifications and Connection Schedule The Topaz must be connecte
189. m MAIN XY ESC Command Lists Moving Speed 100 02 FRONT NOZZLE STATION CLAMP CLAMP 0 OPEN 1 NPi4 1 NP14 0 NAME OUT NAME IN Nzi Clamp Spare 01 08 01000000 Nzl Clamp Spare 09 16 00000100 Figure 7 14 2 Select the axis to display the coordinates on the monitor Press the SEL AXIS key of the HHK to select the axis MAIN X Y Raise the nozzle station in the manual screen Press the emergency stop button Attach a Type 34 nozzle to Head 1 by hand Type 34 nozzle is used only for Head 1 5 Move the head assembly by hand to over the nozzle station Move the head assembly so that the nozzle tip is positioned directly above Nozzle Station 1 HX OUS Caution When moving the head assembly do not push on the camera or head shaft The settings for the coordinates may become unreliable 6 Align the orientation of the nozzle Turn the nozzle shaft by hand so that the notch on the nozzle is aligned with the stop pin for preventing rotational offset in the nozzle holder At this point check that the R coordinate displayed on the bottom of the output monitor screen shows a value within 90 degrees If not detach the nozzle turn it 180 degrees and then re attach it to Head 1 7 Lower Head 1 to insert the nozzle into the nozzle station Activate head 1 pneumatically and move the head assembly downwards until the nozzle clicks smoothly into place in the noz
190. m 8 and set the parallelity of the linear guide to the ball screw The NON linearity should not exceed 0 05mm per 595mm Re assemble in reverse order Left linear guide driven side The left linear guide can only be replaced if the X axis is disconnected from both bearings especially the rear 1 Remove the left linear guide by removing the bolt and replace the guide Fix the X axis beam to the bearings of the guide Move by hand at the motor side the X axis beam to the rear of the system Fix the rear screw of the guide BN cabe Slowly move the X axis beam by hand to the front move only at the motor side Every time a bolt can be fixed then slowly fix the guide bolt by bolt 6 For the front bolts If the X axis is moved all the way to the front then slowly move it to the back while attaching one by one the bolts of the linear guide 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 8 33 Axes Systems 8 6 5 1 2 3 1 2 3 4 8 6 6 Z axis Assembly mechanical assembly of the Z axis is detailed in figure 13 5 3 Z axis Z Motor replacement Replace the Z motor by proceding as follows Remove the head assembly as described in the beginning of this section this is not absolutely necessary but easy If the head is not removed make sure to disconnect the motor and encoder cable from connector plate item 33 in figure 13 6 1 Remove the motor by loosening the four s
191. m again Perform the following procedure to do this Make sure to have the following materials at hand before continuing 1 Hard disk maintenance disks for 80486 system board disks 1 6 order 5322 901 10003 VIOS SOFTWARE UTILITY disk Installation disk SYSTEM 1 latest SW version Installation disk SYSTEM 2 latest SW version 5322 901 10018 Installation disk SYSTEM 3 latest SW version Installation disk SYSTEM DATA delivered with the machine with the latest machine data back up Back up disks to copy the PCB data Hard disk if needed ESD protection kit NO 00 ON VA uA UE CAUTION The following steps have to be followed in the same order as described below Do not follow a different order Replace the hard disk if necessary use ESD protection Change boot sequence In order to access the floppy drive at boot up a change of the boot sequence normally always from C must be done For this the BIOS setting has to be changed Carry out the following action a Turn on power and during boot up press and hold del key Enter password kj m42 b Select advanced CMOS set up and press enter c any key d Change system boot up sequence from C A to A C by using FUNC Pgup Pgdwn e Insert hard disk maintenance disk no 1 in the floppy drive f Esc and press F10 to save and exit g The system asks Write to Cmos and exit y n Answer Now the system will
192. ments of the two vision systems used in the Topaz Chapter 10 Software section This chapter explains the machine operating software VIOS the PCB file structure and machine configuration screens Chapter 11 Machine Installation and Calibration This chapter explains the machine installation procedure and explains adjustment and calibration of the Topaz in order to obtain placement results within the given specifications Service Manual Topaz 5322 871 63606 1 2 PA 1309 10 01 05 Introduction Chapter 12 Chapter 13 Chapter 14 Chapter 15 Chapter 16 Chapter 17 Maintenance This chapter describes inspection periods and procedures for daily and periodic inspections that should be performed The inspection lists are explained according to each inspection location and period Beside the maintenance procedures also an overview of error messages in the VIOS software is given Spare parts lists This chapter gives an over view of spare parts defined for this machine Drawings and circuit diagrams This chapter shows the most important electrical and air circuit diagrams Main index This chapter shows the main index of this service manual Options This chapter describes all major options available for the Topaz Appendix 1 This chapter encloses the Material Safety Data Sheets of the oils and greases used in the Topaz 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 Introduction Safety
193. ms 8 6 4 4 Y axis Installing and Aligning Y axis Ball Screw Generation 3 For replacing a 34 generation Y axis ball screw replacement kit is available When a 274 generation Y axis ball screw is replaced for a 3 generation Y axis ball screw ordering a grease nipple in addition to the replacement kit is recommended See for reference figures 8 27 and 8 28 1 Check the parts of the replacement kit 5322 310 11287 listed in table 8 3 Figure Service number Description Complete replacement kit 3 827 532281611327 Ball screw 1 4A B C 827 5322 520 40305 Support unit 1 20 827 28 532281611298 Bearing holder li 25 8 27 28 532281611296 Thrust bearing li 26 8 27 28 532281611297 Spring disk 27 8 27 28 5322816 11292 Lock nut li 31 8 28 532252610729 Grease nipple 2 Table 8 3 Y axis ball screw replacement kit 2 Place the new generation 3 ball screw Assemble the support unit 4A and the support unit bearing and circlip 4C on the ball screw Now carefully place the ball screw Assemble the new bearing holder 20 but do not fully tighten the bolts 30 Tighten the four bolts 4B at the front support unit 4A with a torque of 3 8 Nm Assemble the new thrust bearing 25 but grease first NSK1 Assemble the spring coned disks 26 and lock nut 27 so that the spring coned disks just touch each other only M
194. multi camera is installed e If NO FES is installed at the front of the system remove the tape waste guide of the front feederbar to enable easier access to the camera s at the front If the optional second multi camera is installed at the back of the system than remove the tape waste guide also from the rear feederbar Moving Camera The moving camera is located in the head assembly and used to recognise PCB fiducial marks and perform teaching The lighting level and the scale of the moving camera can be adjusted Adjusting the Focus and Field Of View Focusing the moving camera is a fairly simple process While looking at something on the PCB that provides good contrast simply move the camera up or down as necessary to obtain the sharpest picture One thing to keep in mind while moving the camera is to keep it straight has a direct impact on the scale procedure NOTE You may use a fiducial for focus however any thing on the board that provides good contrast and detail will work i e any writing or etchings on the board Synopsis Fix a board in place that has a good clear fiducial Go to the database and perform an F6 function Use the Teach Mark section to move the camera over the fiducial and then move the camera up or down as necessary to obtain the sharpest picture Don t forget to keep the camera straight Adjusting the focus Set up the transport section to receive the PCB to be used for this section use a PC
195. n always be replaced by a fully populated board which are stocked There are only two versions of driver boards one for the main systems 0 M5810 E2x and one for the options KJ0 M5810 42x such as traychangers LCS and auto tray stackers ATS The table below shows of the various driver boards used in the CSM F ull V ision and CSM GEM systems Factory Philips service Machine ty a KJO M5810 xxx 31x 32x 532221604018 CSM 66 84 84V III partly populated board 41x 42x 532221604262 LCS31 LCS100 527 partly populated pcb 5Ix 52 5322 216 04021 CSM 66 84 84V III partly populated is replaced by 5322 216 04018 7 x 72x 5322 216 04017 CSM 66 84 84V III partly populated is replaced by 5322 216 04018 Alx A2x 5322 216 04054 Orion Eclipse ll full populated Comet ll E2x 5322 216 04309 Topaz Emerald full populated Sapphire Table 3 5 8 Driver board types Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 3 5 8 3 5 9 System Principles D river Power Assy The D power assy rectifies the 3 phase 200VAC power and supplies 282VDC to the driver boards The assembly consists out of the D power board itself and the capacitor CAP1 which is located at the right side back corner of the MCX controller box see also figure 3 5 12 below For more details please refer to chapter 4 power supply systems Figure 3 5 12 D
196. n such a way that the locate pin can be exactly aligned with the PCB positioning hole following steps indicate how please refer to figure 6 9 below 1 Adjust the conveyor width according to the size of the PCB To adjust the conveyor width the conveyor unit utility in the data manager will be very convenient If your machine is not equipped with an auto conveyor width adjusting function adjust manually 2 Raise the main stopper by using the B7 Conveyor Unit utility or the output monitor in the Manual mode 3 Press the emergency stop button set the PCB in the mounting position Place the PCB against the main stopper and determine the offset between the PCB positioning hole and the fixed locate pin 4 Loosen the bolt securing the stopper by using the hex wrench loosen the bolt but do not remove it to allow turning of the stopper 5 Adjust the orientation of the stopper by slightly rotating the stopper so that the locate pin can exactly be aligned with the PCB positioning hole 6 Re tighten the bolt to secure the stopper PCB receiver Securing bolt Figure 6 9 Adjusting the PCB contact point CAUTION When you use PCBs having typical positioning holes you must return the above adjustment to the original setting 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 6 7 PCB Transport Systems 6 4 Push In The push in mechanism presses the PCB against the main stopper securing it in
197. ndary Limits When the head assembly runs into the secondary limit area over the software limit the servo control immediately stops to avoid colliding with the mechanical hard stopper A light impact may occur however depending on the running speed The secondary limit area is provided for the X and Y axes and can be adjusted by sliding the position of the secondary limit dog located at the both ends of the movement range 8 3 1 X axis Secondary Limits Usually the X axis secondary limits are set to a point 1 00mm inside the mechanical stopper hard limit see figure 8 8 1 Select the axis Specify in advance the axis whose co ordinates need to be displayed in Step 5 To specify the axis select lt lt lt 3 MAINTE M gt gt gt lt lt 4 MANUAL gt gt lt A CHANGE_ CONDITIONS gt A1 SELECT AXES MAIN XY and press the ENTER key 2 Press the emergency stop button then loosen the screws for the secondary limit dog The secondary limit dogs are located at both ends of the X axis Slightly loosen the screws so that you can just slide the dog Do not remove Secondary limit dog ayes 3 Origin detect c dog E SS P X axis ball screw Figure 8 8 X axis secondary limit dog 3 Move the head assembly to the end of the axis Move the head assembly by hand until it makes contact with the mechanical stopper for the secondary limit dog with the bolt loosened The blinking message EMERGENCY STOP
198. ns 5322 871 63606 01 05 Service Manual Topaz 3 39 PA 1309 10 System Principles 3 10 Monitors The system has two monitors see figure 3 10 1 located at the top of the machine one VIOS monitor see paragraph 3 10 1 and one vision monitor see paragraph 3 10 2 Both monitors can be shifted to the rear side by rotating 180 degrees for easy use Vision monitor 3 10 1 VIOS Monitor VIOS monitor ZU F 7 4 J Topaz monitors The VIOS monitor is a standard Philips VGA monitor type In the monitor guide line booklet an explanation is given of the various adjustments as contrast brightness H shift H size V shift V size trapezoid pinchusion rotation and degauss 3 10 2 Vision Monitor This monitor is a 9 B W Black and White Philips video monitor for displaying the vision information from the vision board The monitor can be ordered via the regular channels The impedance switch at the back must be set to 75 ohm Service Manual Topaz PA 1309 10 5322 871 63606 01 05 System Principles 3 11 Signals This paragraph will cover the basic input and output signals In the VIOS menu a screen I O monitor see figure 3 11 1 is available that gives information of all input and output signals All the I O signals shown are the actual real time conditions The I O monitor screen consists of 4 screens the picture only shows 3 which can be accessed
199. ns l6 Table 9 2 Scale adjustments 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 17 Vision Systems 637064 O tif lt lt lt APPLICATION gt gt gt 3 MAINTE M lt lt MODE gt gt 3 MCH_ADJUST lt COMMAND_LIST gt B SAVE amp QUIT B1 ADJUST TARGET Object Target SingleCam 1 SingleCam 2 SingleCam Scale SingleCam 3 lt lt MODE gt gt 3 MCH_ADJUST A475 This procedure adjusts the values for the scale position and angle of This procedure requires a component Distance mm 5 L or lt for CSP A461 Enter the component database number and press the ENTER key to continue To return to Databese No 6 A466 The specified component uses a feeder type which does not support automatic pickup during adjustment To continue press A303 CAUTION The axes will move Check that everything is safe then press the ENTER key A373 Please pick up the specified component with the specified head or attach it to the nozzle by hand If you are attaching A476 lt lt lt Adjusting gt gt gt The single vision camera scale is now being adjusted During the adjustment the component Figure 9 23 Procedure of scale adjustment 2 Confirm that distance mm 5 is displayed and press the ENTER ke
200. ntil the FOV is within acceptable range Note that the FOV is not very critical 5mm as well as 4 6 is also acceptable 5 Ifthe FOV is changed the focus should be checked again find the optimum of the two 9 3 2 Adjusting the Lighting Level of the Moving Camera For accurate recognition of PCB fiducial marks the lighting level of the moving camera must be optimised To make the adjustment an optional custom tool light adjuster plate 5322 395 10274 should be used sl ay NOTE If fiducial lighting unit has dial and three potentiometers and you have a light adjuster tool part number 5322 395 10274 you should use the special tool option in Moving Camera Light This will take you through adjusting the individual light of the moving camera Inner Light Outer Light and Coaxial with each dial position being set for each position Ensure to reset the Dial position to 0 so all light types will be available to the machine When using the light adjuster tool ensure that the lighter side of the tool is in full view of the camera when setting the lighting level 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 3 Vision Systems This automated procedure checks the brightness of the LED lights for the moving camera To do this you will need to fix a board in position that has a clean fiducial It is preferred to use a circle of at least 1 0mm There is a direct relationship between the Threshold value of
201. numbers should increase or decrease uniformly If the numbers indicate a sudden rise or fall of 0 01 or more run the program again to verify results If the deviation returns or if measurements seem random check the spline shaft nozzle holder camera lens and the vision file A small rise and fall in the values is perfectly acceptable and will be a normal indication It is only important that the overall deviation remain within the 0 02 per 4mm tolerance If not carry out the following steps If the Y axis deviates negative to positive L R then the top of the camera must move towards the rear of the machine A shim must be placed between the camera body and adapter plate see figure 9 27 If the X axis deviates positive to negative then rotate the top of the camera in the direction of machine origin it may be necessary to remove the camera and realign the adapter plate to the camera 8 After a correction is made a new scale measurement must be performed before the REC COM command can be repeated REMARK Sometimes it can be the case that the bolts M3x10 holding the lighting unit too long and as such protruding through the camera stand pressing against the camera bracket This can cause a tilted camera body Adding some washers between the bolt and camera stand can prevent it d Placing a shim above the screw will tilt camera
202. odulation and feedback power failure over current etc signals which control the drivers on the driver board are send to the driver board via connector CN3 Positional feedback is obtained from the motor encoders which are connected to the front side of the servo board via connectors CN1 and CN2 The servo board is linked to the vision board by means of connectors CN7 positional information and CN 8 encoder information If an error occurs in this unit the display LED GOOD green will go out and the system will enter the emergency stop state servo off jumpers 51 and 53 this board have the have the following settings Machine type gt Topaz Sapphire Sapphire LCS1I00 Emerald A table B table LCS 31 Switch Bit ATS 27 SI 2 OFF ON S3 1 6 ALL 6 OFF Table 3 5 3 Jumpers settings SI and S3 With the servo board a couple of stickers are delivered these stickers should be mounted at the positions indicated in figure 3 5 5 and according to following table Machine type gt Topaz Sapphire Sapphire LCSI00 Emerald A table B table LCS 31 Sticker ATS 27 Sticker Servo 1 Sticker 2 l IA Sticker 3 2 2A Table 3 5 4 Stickers versus machine types The table below shows if the connectors indicated in figure 3 5 5 have a cable attached to another board a short connector S or are left unconnec
203. of each counter bored hole so that the feeder plate can be swiveled when making the parallel adjustment 4 Set the two feederbar adjustment blocks on the feeder plate The blocks must be the same type and hold the same type of components Set the two blocks far apart as possible as long as you can access the bolts securing the feeder plate for example 2 or 3 points inside the both ends of the feeder plate 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 7 21 Component Transport Systems 7 4 2 7 Go with the head to one block and lower the nozzle by hand to the middle of the cross and check the position Note the position of the nozzle tip relative to the chip component especially in the Y direction 8 Then move the head assembly by hand to the other block Making sure that the nozzle does not interfere with the blocks move the head assembly only in the X direction so that it is positioned above the feeder 9 Lower the nozzle by hand and check the position Look at the position of the nozzle tip relative to the middle of the block especially in the Y direction 10 Compare the above two positions If the two positions are nearly the same in the Y direction no further adjustment is needed at this point If shifted too far the plate is not parallel with the X axis Proceed with Step 11 Fine adjustments will be performed in the next section 7 3 2 Teaching the feeder block positions 11 Adjust the orientat
204. oftware Limit Axis 4direct Init Pos Init Mov R1 MAIN R2 MAIN 360 00 360 00 360 00 360 00 138 00 Figure 8 23 R axis initial position setting screen 8 5 3 Z axis Initial Movement The Z axis initial movement setting is the height at which the nozzle tip makes contact with the surface of a PCB placed on the conveyor You will need a PCB to make this setting 1 2 3 4 5 Check that a nozzle is attached to Head 1 Any type of nozzle can be used for this setting Adjust the conveyor width according to the PCB To adjust the conveyor width you can use the Conveyor Unit utility in the Data Manager If your machine is not equipped with an auto conveyor width adjusting function adjust manually Press the emergency stop button then set the PCB Also adjust the locate pins and push up pins according to the PCB secure the in position it is convenient to use the Conveyor Unit utility in Step 2 Move the head assembly to around the centre of the PCB Lower the nozzle by hand Lower the nozzle until the nozzle tip just makes contact with the surface of the PCB Set teaching conditions 1 Select 3 3 B4 CONDITION OF and press the ENTER 2 Select the teaching unit Head 1 and press the ENTER key 3 Select any speed from 1 to 5 and press the ENTER Service Manual Topaz 5322 871 63606 8 22 PA 1309 10
205. ombination with an external device the dip switch jumper settings of 53 and S4 have to be set as follows The settings for S3 are as follow prc 53 HT 53 Hy 3 HUE 53 E Standard Table 3 8 3 53 settings In some schematics S3 has 6 jumper switches The 2 additional jumpers in that case bit 2 and 3 are meant for area sensor selections This option is not used in the current systems so these bits are always set to ON which means that the EMG circuit connected to this jumper has been bridged The settings for S4 are as follow Configuration 54 biel s bits s4 bit 4 54 pics 54 bit 6 No trayfeeder ON 165 OF on on Su oF T ATS27 OF ON ON ON ON 5277 ON ON ON ON Table 3 8 4 54 settings ae M 41 TD Note I Connect EMG harness of the tray feeder to CNF26 S4 bitl and CNF28 54 bit5 see position A figure 3 8 3 Note 2 Connect EMG harness of the tray feeder to CNF26 S4 bitl see position B figure 3 8 3 Note 3 Connect EMG harness of the tray feeder to CNF49 S4 bit2 see position C figure 3 8 3 5322 871 63606 Service Manual Topaz 3 35 01 05 PA 1309 10 System Principles Front Side Figure 3 8 3 Position of LCS and ATS on main machine Remark Pre defined settings are shown in table 3 8 4 Other settings are possible but then different connect
206. on board in the flash memory of the I O boards The board connectors are fully compatible with the previous system board any difference of application board is detected automatically by the VIOS software which must be of version 1 2 or higher On the application board two LED s are available the green LED will light whenever all basic functions work normal The yellow LED flashes when the I O serial communication is OK A flash memory board module This board replaces the harddisk in the system by a flash disk The board includes two slots slot 1 is standard occupied by a 40Mb flashdisk which can be replaced by a 85 Mb flashdisk Slot 2 which is only accessible by the shell manager of the VIOS software is an optional 40 Mb or 85 Mb disk The interface for the flash disk is the IDE interface Replacing the Old system board with a new system board When replacing the KJO system unit with the KM5 system unit the following procedure should be followed Update the application software to VIOS 1 2x or a later version with the KJO system unit and harddisk Backup the system data and the PCB data from the harddisk to the floppy disk Remove the KJO system unit the harddisk the harddisk harness and the harddisk power harness from the controller Install the KM5 system unit to the controller and install the application software VIOS 1 2x or a later version Make sure to use a keyboard adapter to convert from DIN to mini DIN 5322 263 21196
207. ons or when opening the covers of the main machine and if connected on the external devices In chapter 4 a revised diagram is shown of the simplified safety circuit It shows all the signals together with the corresponding LED s and the position of the jumpers of the dip switches S3 and S4 Preece eee sr ws OEC i35 D Figure 3 8 4 Connection board KV IM455U 11X 3 generation 5322 871 63606 Service Manual Topaz 3 37 01 05 PA 1309 10 3 9 3 9 1 3 9 2 System Principles Keyboards The system has two devices to enter information manually a handheld keyboard and a PC keyboard see figure 3 9 1 Ful keyboard enable key switch h Hand held keyboard ww OOOO s i aas siaaa oaoa aloji aJa 998555 SOS Figure 3 9 1 Topaz key boards PC Keyboard This keyboard is a standard small version without keypad PC AT keyboard and is connected to the controller via a connector plug on the front side of the system board in the MCX controller This keyboard can be used for all data entering activities it can be removed from the machine if operators are not allowed to use it Hand Held Keyboard HHK This keyboard is permanently connected to the system via a cable entering the Topaz at the right side of the system Via this keyboard simple operator functions can be performed such as R
208. oordinate Save the settings by pressing ESC and select B2 save data or BO save amp quit D Edge clamp When the edge clamps are used to secure a PCB on the conveyor instead of using the locate pins the PCB position may shift slightly relative to the position determined by the pins If a shift in millimeters is found subtract it from the locate pin coordinates and enter this coordinate in the edge clamp parameters Normally the same parameters as the locate pins are entered in here E Wait point Pre Condition Origin the machine When the machine is idle waiting for new PCBs the heads will move to a Wait Position This position can at any d X Y position but take care of the following notes Sensor positions they might accidentally be activated If the FES option is installed in the system it is advised to teach the wait position at such a location that the FES head protection sensor is activated when the wait position is reached This FES head protection sensor is used to release the FES enabling a FES carriage exchange To select the position by means of the joystick do following Select lt 3 4 1 select axis and press Enter Select Main XY and press Enter Move any desired head to the desired wait point Select lt 3 3 B4 conditions of TCH gt and press Enter Select the desired head for teaching and press Enter Select any speed and press Enter Select 3 3 B1 adjust target pos
209. opaz In chapter 12 a compatibility list with a number of greases that can be used is given Following greases and oils are covered 5322 390 20159 NSK NSK grease Multitemp CRL No3 Grease 07 230 5322 390 20161 NSK NSK 2 grease Multitemp PS No2 Grease 07 300 5322 390 20155 Molub alloy Grease AccTech HP Alco pad Cleaning tissues 806H 806 5322 390 10144 Ausimont Fomblin Y VAC3 Vacuum grease 12298 O rings and seals Shell Alvania grease 2 Grease 56110 08 Du Pont Krytox GPL 22X GPL 52X Vacuum grease DU008 134 O rings and seals Table 1 1 Note Philips will not be responsible for any damage to the machine if other greases and or oils are used than mentioned above 1 3 10 Abbreviations This chapter describes common used abbreviations in this manual in alphabetic sequence Abbreviation Explanation A Ampere AC Alternating current ASAP As Soon As Possible ATS Auto Tray Stacker tray handling device B w Black and white BGA Ball Grid Array CE Comit europi n CN Connector Chip on board COG Centre Of Gravity CPU Central processing unit CS Customer Support CSM Compact Surface Mounter CSP Chip scale package BGA Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Introduction Abbreviation DC DI DI DO DIL EMG ESD FD FES FV GDI GEM H H K HDD HDLC IM ISO LCS MTF OM
210. orrect settings WARNING Only trained technical personnel is allowed to work in the power section of the machine Take care to take the necessary actions to avoid dangerous situations Switch off the mains power when working in the mains power box 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 4 5 Power and Safety Circuits Power source 3 Phase 50 60 Hz Connection board X motor C Y motor He v 200V I 6A P 750W 200 6 7 R motor Z motor 124 W motor v 200v I 0 74 P 60W 200 0 7 P 60W v 200v I 0 7 P 60W P40 Conveyor motor 200 208 220 240 380 400 416V AC Fuse v 200V I 0 3A WESS Input Output 200 v 200v Motor transformer V 250V I 14 I 14 I 2 3 phase by Capacitor TM11 Fuse Motor relay Motor controller Mains connect QF91 KM11 12 Input i v 200v motor Mains fuse Mains switch Output 250v v 690V Pret 11 V 200V 104 I 104 3 phase T ON QF11 511 I 4 94 P 2250VA 24 3 phase 6 KHz 6521 V i000V 6mm zq 690 690 Driver 2 I 41 6mm sq I 32A Control transformer Fuse v 282V 5 Phase l I 3A Qree Input control logi
211. ors are used Please refer to the interconnect and safety diagrams and the overview of table 3 8 5 to 3 8 7 The relation between the S3 and 54 dip switches connectors and LED s are as follow 53 with 4 dip switches LENT E NN TN N CNF25 EMG optional EMGI 5 2 45 EMG spare EMG4 19 3 45 EMG spare 5 20 4 45 EMG spare 6 8 2 Table 3 8 5 S3 with 4 dip switches 53 with 6 dip switches Lac Unn gm CNF25 EMG optional EMGI 5 n a only used for area sensor in main machine 1 2 3 n a only used for area sensor in main machine 2 4 45 EMG spare 4 21 5 2 le 2 CNF45 EMG spare CNF45 EMG spare Table 3 8 6 53 with 6 dip switches S dip switches LAC NN NN 7M CNF26 TFI EMG switch EMGIF N 2 CNF49 TF4 EMG switch 7 3 CNF27 Cover front TF2 14 4 CNF43 Cover front 2 TF5 EMG2C 5 5 6 CNF28 Cover rear TF3 7 CNF44 Cover rear 2 TF6 8 Table 3 8 7 54 dip switches Service Manual Topaz PA 1309 10 5322 871 63606 01 05 System Principles After swapping the connection board Check and or change the dip switch settings or harness connections Check if the EMG circuit is activated after pressing the various emergency push butt
212. os Init Mov Z1 MAIN 0 16 0 00 Z2 MAIN 23 00 0 05 0 00 Figure 8 15 Z axis software setting screen 4 Enter the software limit Subtract 1 00mm from the mechanical limit on the plus side or add 1 00mm to the mechanical limit on the minus side This value you have just entered is the software limit 5 Return the Z axis by hand to within the software limit 6 Cancel emergency stop Ensure safety then release the emergency stop button and press the READY button of the HHK 7 Save the settings Press the ESC key then select B2 SAVE DATA or BO SAVE amp QUIT and press the ENTER key To quit without saving select B3 RECOVER ADJUST or B7 QUIT and press the ENTER 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 8 15 Axes Systems 8 4 3 X axis Software Limits The X axis software limit should be set to 1 00mm inside the secondary limit for both the plus side right direction and the minus side left direction A Mechanical stopper Mechanical stopper A Structural movable range B Allowable movement range C Software limit D Secondary limit E Origin position F Mechanical limit Figure 8 16 X axis movement range Note To set the X axis software limit use the X axis secondary limit values you have made a note when adjusting the secondary limits 1 Open the software limit screen 1 Select 3 MAIN
213. ower right cover door of the machine and you will see the LED driver board Turn trimmer VR6 for line array camera 1 and VR4 for camera 2 in such a way that the brightness difference between the two tones is set to one scale 64 levels If your machine has two line array cameras perform the same adjustment for both cameras 6 Press the emergency button and invert the light adjuster plate Turn the light adjuster plate up side down and re attach it to head 1 the white surface facing down 7 Cancel the emergency stop and press the Enter key Only the coaxial light turns on and the average brightness level is displayed on the upper right corner of the operation monitor 8 Adjust the coaxial light level Turn the trimmer VR5 for line array camera 1 and VRI for camera 2 in such a way that the average brightness level becomes 30 If the average light level cannot be set to 30 the lens aperture may be incorrect Readjust the lens aperture as explained in previous sections 9 Press the Enter or Esc key when the adjustment is complete Follow the messages displayed on the monitor there is no machine data to be saved Adjusting the Line Array Camera Scale The line array camera scale represents an actual measurement in microns equivalent to one pixel This scale must be calibrated correctly for accurate recognition of components To calibrate the camera scale you will need a SOP of known size When you execute the adjustment utility descr
214. pgm in the same manner as a standard program b Highlight Machine Config and select lt CNTRL ENTER gt c Select Change Program and file name d Select F5 to initiate The program will need about 25 seconds to load 2 Select Machine type 1 Topaz 2 Emerald Eclipse 3 Select 1 Pick up component Select 3 Camera Position Component DB nol Data Base number Component DBno2 0 Component Height Component Z Add 1mm if you are using a type 33 34 nozzle Lighting Level Level from component vision file How many Times Number of times to recognize the component at all 4 angles at every Z reference position 2 is sufficient 10 if you have all day Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Vision Systems Adjust Component Select NO yes will cause a Fine mode type of adjustment The component s angle will be verified and corrected prior to each X Y measurement Height Range from Select 2 Do not forget the decimal point Height Range to Select 2 Do not forget the decimal point How many Steps 5 10 is recommended As the program runs the head starts in the top most position and moves down throughout the camera s field of view If the vision system fails to recognize the component too many times the program will display the Soft Limit Over Error message If this occurs Verify the Search area is 9 99 and component focus is good Evaluating the Results After the program complet
215. ponent Transport Systems 24mm 32mm 44mm tape feeders 1 Loosen the two screws on the air cylinder holder plate 2 Fit the small pin into the desired notch in the holder plate The numbers marked on the holder plate indicates the actual feed pitches in millimeters 3 Tighten the screws to secure the air cylinder Adjustment screws Air cylinder Air cylinder holder plate Figure 7 25 16mm 24mm 32mm 44mm tape feeders Feeder speed for 12 LP 16 24 32 and 44mm feeders The speed adjuster linked to the air cylinder of the tape feeder allows you to vary the speed at which the components are delivered Turn the adjuster knob to the left to increase the speed and turn it to the right to reduce the speed The optimum speed differs depending on the component and tape If the speed is set too fast components may be skipped or become jammed or the tape may come off the tape guide sprocket preventing the components from being fed correctly In such cases the speed should be reduced Air cylinder Speed adjuster Figure 7 26 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 7 29 Component Transport Systems Changing the tape peeling load a Tape peeling load for 8mm and 12mm tape feeders The top tap and carrier tap of a tape reel are glued with adhesive If this adhesive is too strong the top tape may not peel away from the carrier tape at proper timing in particular pap
216. ponent level replacement Therefore only a functional description of each PCB will be given in this manual A WARNING Only technical personnel which is trained on the Topaz equipment is allowed to carry out service actions 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 1 1 Introduction 1 2 Chapter Overview This chapter provides a brief description of the contents of each chapter of this manual Chapter 1 Introduction Chapter 2 General block diagram This chapter shows the electrical block diagram of the machine Chapter 3 Systems principles This chapter explains the electrical principles of the various circuits and the general adjustment methods Chapter 4 Power and safety circuits This chapter describes the power and safety circuits Chapter 5 Vacuum and pneumatic systems This chapter describes the air and vacuum pneumatic systems Chapter 6 PCB transport systems This chapter explains the PCB transport and fixation systems like conveyor push up push in edge clamp main stopper locate pin etc Chapter 7 Component transport systems This chapter explains the items of the Topaz that takes care of the transportation of the component Like head assy nozzle station feeder plates feeders etc Chapter 8 Axes systems This chapter explains the function and adjustment of the X Y R Z and W axis systems of the Topaz Chapter 9 Vision systems This chapter explains the function and adjust
217. pply data is created for the database with the lateral supply as standard Therefore when the component is to be supplied in a lengthwise direction enter 90 degrees 90 degrees for the Pick Angle parameter in the Component Information 5322 871 63606 Service Manual Topaz PA 1309 10 Vision Systems Intentionally left blank 38 Service Manual Topaz PA 1309 10 5322 871 63606 01 05 Software Section CHAPTER 10 Software Section 10 1 Introduction This chapter of the service manual describes issues related to the machine software VIOS version 1 23 and PCB software files The installation and back up procedures will be described and a list of all system messages will be given Also a description how to deal with floppy hard disk problems will be given The final part is an overview of system messages basis knowledge of the DOS operating system is recommended MS DOS is a trademark of Microsoft Corporation The above mentioned software packages may only be used in accordance with terms of the software License agreement 5322 871 63606 Service Manual Topaz 10 1 01 05 PA 1309 10 Software Section 10 2 System Software 10 2 1 Operating System The DISK operating system which is used by the system is the MS DOS version 6 2 The operating system is installed at the factory on the hard disk drive C together with the VIOS software package The contents of the root directory of d
218. r can be any value from 1 to 14 Use the space insert and delete key s to change the setting When you do not want to allow retries set this parameter to NO RETRY The number of retries can also be specified for each component to be mounted In these cases the retry is performed a number of times up to a minimum setting M Dump point This parameter describes where a component that failed the recognition should be dumped N Moving height This parameter is invalid in the Topaz surface mounter and should be set to 0 00 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Component Transport Systems 7 2 3 Pickup and Mount Vacuum Levels Pre Conditions None The vacuum pressure to pickup a component is analogue detected and digitally represented by a scale of 0 to 255 The current levels are shown in the following screen 3 2 gt 1 SELECT TARGET Vacuum level and press Enter See figure 7 4 Editing Vacuum Level Head No Low level High level Head 1 Head 2 Head 3 Head 4 Head 5 Head 6 Head 7 Head 8 Figure 7 4 Current vacuum levels Machine vacuum levels must be set for the following purposes 1 If components are vacuum checked 2 The vacuum build up time before the head can move up during a component pickup action 3 The vacuum release time before the head can move up during a component mount action 4 Th
219. re shown Since the PCB is very important for the safety circuit a number of LED s are mounted on the PCB to indicate the EMG status For more information on these LED s please refer to chapter 4 Power and Safety of this manual On the boards some jumper settings can be set to configure the system depending on the added options and or features Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles 3 8 2 2 Generation Connection Board On the board 3 selection switches are available S1 S2 and S3 51 and 52 are used for the direction S3 is used for tray changer positions The tables below show the setting of S1 and S2 for the transport selection and S3 for the traychanger position L R default B A Table 3 8 1 and S2 settings CHUTENENCITIUY Standard Trayfeeder 5 27 Table 3 8 2 S3 settings Figure 3 8 1 shows the location of 51 3 CONNECTION BOARD ASSY 83 NF2 CNF3 1890 4 5 CNF26 CNF28 CNF25 CNF27 B Figure 3 8 1 Location of SI S2 and S3 Note The EMG harness of the trayfeeder should be connected to CNF26 and CNF28 Note 2 The speedcontroller connects on SPI the jumper harness does not connect on CNF2 and CNF3 Note 3 When a special emergency input is added set bit 3 of S3 to OFF and connect the emergency signal harness to CNF25 dry contact 5322 871 63606 S
220. reads 1 Also check that the detection status of the sensor SQ57 NL09 does not vary even if the locate pins and push up plate are raised In Monitor lt Select Enter Exec Selected Arm MAIN XY ESC Command Lists Moving Speed 100 NLO9 SET POSITION DETECT 1 NAME OUT NAME IN Conveyor NL09 16 10000000 Figure 6 23 Input monitor 5 Place a PCB over each sensor along the conveyor and check if the are 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 6 17 PCB Transport Systems OK To secure the PCB in the mounting position over the sensor 5057 the Conveyor Unit utility will be convenient 6 If necessary adjust the position of the PCB detection sensor Loosen the screws securing the sensor and adjust the position orientation or angle at which it is attached 7 Remove the PCB from the conveyor Figure 6 24 Adjusting the position of the detection sensor Service Manual Topaz 5322 871 63606 6 18 PA 1309 10 01 05 PCB Transport Systems 6 9 Conveyor Errors The table 6 9 1 shows some possible conveyor problem symptoms that may occur The PCB hits hard against the main stopper Possible causes The soft stop function is defect or adjusted incorrectly Corrective action Open the front lower right panel of the machine you will see the two adjustment scres for the conveyor speed adjust the L screw to the left slightl
221. rectional synchronous link the data clock is serially transported to the I O boards The information sent via this link contains address information followed by data information Each I O board has its own unique address After sending an address it will be decoded by the I O PCB circuitry an if there is a match the I O PCB in question will take over or send the data information There are 2 wires for the data signals and 2 wires for the clock signal The two wires are needed for each signal because the signals are sent via bus transmitters receivers low voltages to reduce the influence of noise signals As can be seen from the block diagram the signals are fed to the first I O board and via a receive transmit circuitry past on to the next I O board This means that a defect in the receive transmit circuitry on the first I O board can cause troubles on the next I O boards in the chain This can be important for the chain where the LCS is connected 1 2 this because the traychanger is connected between the front head I O board and the front conveyor I O board To over come possible problems it is possible to interconnect the I O 2 signal line between the front head I O and front conveyor I O in the machine HDIC link The HDLC link protocol is similar to the SDLC but only used in the third generation boards Serial Interface Two RS232 interface ports are present on the Topaz CMNI is used for the hand held keyboard while CMN2 is used
222. related to the PCB files of VIOS In the 4 SHELL M DATA_FILE_MNG the PCB files on the disk are shown See figure 3 3 1a The file name descriptions are stored in a hidden file named FTABLE BIN The names that can be given to each PCB may consist of 20 consecutive characters no spacing DATA non lt lt lt APPLICATION gt gt gt 1 OPERATION M 2 DATA M 3 MAINTE M 4 SHELL M 0 EXIT lt lt MODE gt gt 1 DATA FILE 2 DISK_MAINTENANCE 3 VIOS_DIC 0 SUIT OSEE DVIG RWIS IWC Vios Pcb Name Date ri Vios Pcb Name Date e XO OO C0 to 5 COMPONENTS 94 07 16 0 5 COMPONENTS 94 07 16 091 102 0 CONVEYOR 22 12 09 ANC TEST ANC TEST JAS 2 Ae PALLET_80 9a 2E PALLET 80 94 02 12 ADJUST CHIP ADJUST CHIP 95 005 OFFSET 5 05 OFFSET 575 09 11 Clun 20 01 1L e 2001 11 94 01 10 CUK 93001 0 022 CU SSO O 02 02 ECLIPSE 5008 ECLIPSE JS OG MFB CHIP 013209 Ie e e gt e XO OO Q0 CO tio CO ES Figure 10 3 file names DATA non lt lt lt APPLICATION gt gt gt 1 OPERATION M 2 DATA M 3 MAINTE M 4 SHELL M 0 lt lt MODE gt gt 1 DATA_FILE_MNG 2 DISK MAINTENANCE 3 VIOS_DIC 0 EXIT DIRECTORY 2 92 DIRECTORY Name Ext Size Date Time Name Ext Size Date Time 2 SUB DIR 96 02 26 D BASE gt 50 lt 96 02 26
223. ress Enter Quit without saving by means of B3 or B7 Replacement of the Line Array Camera When replacing a new line array camera into the system one should take care the camera is mounted correctly Figure 9 38 shows the way the cameras should be mounted into the system seen from the front side of the system E ARRAY CAM 2 EAR SIDE LINE ARRAY CAM 1 FRONT SIDE 23 Figure 9 38 Multi camera and 2 positions For both the front and rear line array camera the line array camera is the same The difference is the way of mounting the bracket item 20 onto the camera For the front line array camera 1 this is the position indicated with the F while item 20 should be mounted at position R for line array camera 2 The right side of figure 8 25 shows the exact mounting positions note that both cameras are mounted with the camera cable pointing to the left In this way the rear side line array camera is rotated 180 degrees with respect to the front side line array camera When installing a second camera into the system be sure to set the knurled ring of the complete lens in its middle position as this enables better adjustment Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Vision Systems 9 6 Cleaning the Optical Systems The optical systems of the Topaz must be cleaned periodically When making adjustments to the camera s make sure to remove any dust and debris in advance To clean th
224. ress Enter again The head assembly passes repeatedly over the line array camera and the camera scale is calibrated The results are then displayed on the upper right of the operation monitor lt lt lt APPLICATION gt gt gt 3 MAINTE M lt MODE gt gt 3 MCH_ADJUST A542 Camera 1 lt lt lt Result gt gt gt Distance 5 00 The results of calculating the scales of the Scale_x 58 59 multi vision camera are as follows Scale_y 73 28 nts Cam posx 328 96 Cam posy 111 88 Cam posr 0 03 Div_x 0 00 Divy 043 Cam corx 1 80 Cam cory 1 48 Rat 0 5969 Figure 9 36 10 Press the lt Enter gt key to save the calibrated results Press the lt Esc gt key if you want to cancel the results Then proceed to the next step to calibrate the scale of the line array camera 2 When your machine is not equipped with a line array camera 2 advance to step 12 11 Next calibrate the scale of the second optional line array camera With the component still picked up by hand execute the Multi Camera command again as in step 2 and select Multi Cam 2 In case of two line array cameras the difference in Cam Co ordinate X and Y parameters between the two cameras should be within 10 If this difference exceeds 10 an error message window appears as shown below The advise is to make fine adjustments to the installation of camera 2 as described below the procedure to adjust the camera optica
225. rials e Tape Transport Cleaning Frequency daily Required time 0 1 hr per feeder Procedure Check if there is any dirt on the sprockets of the sprocket wheel on the two pawls the pawl wheel and in between the wheels Clean if necessary with the recommended equipment and materials Never use a solvent otherwise the grease inside the transport assy will be dissolved f Top Cover Plate cleaning Frequency monthly Required time 0 1 hr per feeder see figure Procedure Unlock the lock lever 4 so that the top cover plate 1 is lifted Check if the sliding lip 2 in the top cover plate is sliding smoothly Clean if necessary with the recommended equipment and materials If after cleaning the bracket is still not shifting smoothly then the top cover plate must be replaced Check if the top cover plate is not bent else replace the top cover Refer to spare part section for order numbers Check if the top cover plate is not bent else replace the top cover For order numbers refer to the spare parts section of this manual Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Component Transport Systems Figure 7 31 CSM top cover plate 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 7 35 Component Transport Systems g Top Cover Plate replacement see fig 7 31 Procedure Remove the top cover plate 1 by loosening the M3 socket set screw 16 on the top of the
226. rite protection Make a copy of the data as a number smaller than 500 and edit this data Following is an example of this e Open the Vision sub window of the component registration No 6 e Edit the Search area parameter Use the number key s to change the normal value to 9 99 max setting This is to enable off center pickup of the SOP to be performed later on Set the trayfeeder parameter in the User Item window to Tray The sub window switches by pressing the F4 key 4 Save the edited data Press the Esc key twice then select CO Save amp Exit and press the Enter key 5 Press the emergency stop button and attach a nozzle to head 1 Attach a nozzle for SOP type 32 to head 1 6 Execute the adjust assistant to check that the component is recognized For details on the adjust assistant refer to the user manual if necessary increase the search area value Adjusting the line array camera scale When the preparation is complete adjust the scale of the line array camera with the procedure below 1 Cancel the emergency stop Ensure safety and release the emergency stop button and press lt Ready gt on the HHK 2 Execute the Multi camera command e Select lt 3 3 B1 adjust target Multi cam gt and press Enter e Select camera scale and press Enter e Select the camera to be adjusted and press Enter 3 Confirm that Distance mm 5 is displayed and press Enter Norm
227. rive C is listed in paragraph 10 2 2 10 2 2 Disk Organization The hard disk is basically organised as is shown below ROOT SUB EXPLAINATION C DIRECTORY s DOS Contains the standard DOS commands INS Contains some utilities like MONITOR to adjust VIOS monitor KG7 42T0 012 Contains all machine parameter tables KG7 42M0 012 Contains all text messages used the VIOS screens P_BASE The P BASE is the European USA database it contains 4 HIDDEN files with the basic PCB component marker and ID information s D_BASE The D_BASE is the Asian Japanese database and is not supported by Philips NOO Is used for the optimiser NOI This directory is the Machine no 1 directory which contains data of the various action specs mount programs and the machine data USER HD and USER ED files RAMD In this directory all temporary files are stored hidden STATUS In this directory a number of status files are stored SRVUTL This directory contains a number of factory adjust and check programs RESULT Some result files are stored here PGM This directory is used to store the auto mount feedback files TEMPLET PRT 10 2 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section PROGRAMS Command com INSTALL WINA20 386 YDEV EXE UPDATE BAT DOS4GW exe CONFIG us CONFIG sys AUTOEXEC us AUTOEXEC bat MCXCONF sys FIX2000 exe NCJ ini LHA EXE LHA DOC SERIAL STS Ftable bin 2 4250 005 2 4257 005
228. river power board 5V 12V Power Supply Assy s The MCX 2 control unit has one power supply for the 5 VDC and the 12V DC The power supply is mounted at the left side in the MCX 2 control box see fig 3 5 3 Figure 3 5 13 5V I2V 12V Power supply For more details please refer to chapter 4 power supply systems 5322 871 63606 01 05 Service Manual Topaz 3 23 1309 10 3 6 System Principles LED Driver Board The LED driver board is the board see figure 3 6 1 which controls the light intensity of the component camera s There are various types of LED drivers for the Sapphire and Topaz systems the same version 5322 216 04315 is used This board can handle two line sensor multi camera lighting outputs and 1 area CCD camera single camera lighting output Light CN1 N1 N11 dg c AR ee i IEEE signals Mc ee CN10 Motor encoder Power and control signals eps x ala 2 a cC Dy d 4A d EU LED DRIVER JP3 CN9 1 JP14 H JP13 1 12 H H 3 CN6 H i 1 1 10 p 1 E Lighting ie el sensor signals ec eb p VR1 VR2 VR3 VR4 VR5 VR6 Multi cam 2 Multi cam 1 Coax light Non coax light Multi cam 1 Single camera Coax light Not used Multi cam 2 Non coax light Figure 3 6 1 LED driver board Each output has 2 channels each channel has a brightn
229. rmer Power Tabs 11 5 11 2 8 Air Connection 11 6 11 2 9 Power Connection 11 7 1 2 10 Switching On the Machine Verify the Software Version 11 8 11 2 11 Levels 11 9 11 2 12 11 9 11 2 13 11 10 11 2 14 Acceptance Test 11 13 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 Table of Contents 11 3 11 4 11 5 Machine Calibration 11 3 1 Back up 11 3 2 Machine References Origins 11 3 3 Machine Limits 11 3 4 Initial Movement Z axis 11 3 5 Initial Position R axis 11 3 6 Teach Nozzle Station Positions 11 3 7 W axis Parallelism 11 3 8 Initial Position W axis 11 3 9 Vacuum Levels 11 3 10 Moving Camera Adjustment Focus Lighting Level Scale 11 3 1 I Single Camera Adjustment Field Of View Lighting Level Focus Scale 11 3 12 Line Array Camera Adjustment Lighting Level Field Of View Scale Focus Optical Axis Alignment 11 3 13 Recognition Speed and Dual Recognition Offset 1 3 1 4 R axis Accuracy 11 3 15 Mount Accuracy Calibration Glass Plate 11 3 15 1 Introduction 11 3 15 2 Conditions Required 11 3 15 3 Tools Required 11 3 15 4 AUTO MOUNT FEEDBACK AMF 11 3 15 5 Program Verification and Setup 11 3 15 6 Adjustment Procedure 11 3 15 7 Mount Calibration 11 3 15 8 Adjustment Steps for Topaz with Only Line Array Camera s 11 3 15 9 Adjustment Steps for Topaz with Line Array and Single Camera 11 3 15 10 Viewing the Data Offline 11 3 16 Cali
230. rray Camera s To adjust the lighting level of the line array camera s you will need the special light adjuster plate 5322 395 10274 The lighting level is adjusted on the LED driver board located on the left side of the MCX controller while an image is displayed on the monitor proceed as follows 1 Execute the Multi camera Brightness level e Execute the multi camera lt 3 3 B1 Adjust target Multi camera Brightness and press the Enter key e Select going on and off from the LED type box e Select Use from the special tool box e Select the camera to be adjusted 2 Press the emergency stop button and attach the light adjuster plate to head1 Attach the light adjuster plate to head 1 with the two tone surface facing down Orientation of the light adjuster plate must be such that the boundary line between the two tones is set horizontal on the screen Light adjuster Plate Figure 9 31 3 Cancel the emergency stop Ensure safety then release the emergency stop button and press the Ready button on the HHK 4 Ensure safety then press the Enter key again The head assembly moves repeatedly over the multi view camera while the image of the light adjuster plate is displayed on the vision monitor 64 levels Figure 9 32 5 Adjust the non coaxial light level 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 9 27 Vision Systems xd M ETN NOTE 9 5 4 Open the l
231. rrection 7 13 7 2 6 Head Offset 7 14 7 3 Nozzle Station 7 15 7 3 1 Nozzle Station 7 15 7 3 2 Adjusting the Nozzle Sensor Sensitivity 7 16 7 3 3 Adjusting the Nozzle Clamp Plate Position 7 18 7 3 4 Adjusting the Nozzle Station Coordinates 7 18 7 3 5 Nozzle Station Maintenance 7 20 7 4 Feeder Plates 7 21 7 4 1 Feeder Plate Parallel Adjustment 7 21 7 4 2 Feeder Block Positions 7 22 7 4 3 Component Pickup Test 7 24 7 4 4 Feeder Plate Maintenance 7 26 7 5 Component Feeders 7 27 7 5 1 Tape Feeders 7 27 7 52 Minimum Timer Load Timer Down Timer 7 31 7 5 3 Feeder Maintenance 7 32 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 Table of Contents 8 Axes Systems 8 1 8 1 Introduction 8 1 8 2 Machine Reference Origin 8 2 8 2 1 W axis Machine Reference 8 3 8 2 2 Z axis Machine Reference 8 4 8 2 3 X axis Machine Reference 8 5 8 2 4 Adjusting the Y axis Machine Reference 8 6 8 2 5 R axis Machine Reference 8 7 8 3 Secondary Limits 8 8 8 3 1 X axis Secondary Limits 8 8 8 3 2 Y axis Secondary Limits 8 10 8 4 Software Limits 8 11 8 4 1 Software Limits 8 11 8 42 Z axis Software Limits 8 14 8 4 3 X axis Software Limits 8 16 8 4 4 Y axis Software Limits 8 17 8 4 5 R axis Software Limits 8 19 8 5 Initial Position and Initial Movement 8 20 8 5 1 Initial Position 8 20 8 5 2 Adjusting the R axis Initial Position 8 21 8 5 3 Z axis Initial Movement 8 22 8 6 Axes A
232. s 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 7 15 Component Transport Systems 7 3 2 Adjusting the Nozzle Sensor Sensitivity Each nozzle holder in the nozzle station has a sensor that detects the presence of the nozzle allowing the machine to identify which type of nozzle is currently attached to each head The nozzle sensor is separated from its amplifier unit which is installed inside the machine just behind the left side of the front feeder plate Since a gain control is provided on the amplifier the nozzle sensor sensitivity can be checked and adjusted if necessary as described below Sensitivity control Figure 7 11 Nozzle sensor amplifier Open the output monitor and release the nozzle clamp plate 1 Select lt lt 3 MAINTE M gt gt gt lt lt 4 MANUAL gt gt lt C DISPLAY amp EXIT gt C1 OUTPUT MONITOR and press the ENTER key 2 Line up the cursor with TP02 FRONT NOZZLE STATION CLAMP 3 Press the ENTER key to open the clamp plate The output monitor digit reads 0 when the clamp plate is currently closed and reads 1 when it is opened Out Monitor T Select Enter Exec Selected Arm MAIN XY ESC Command Lists Moving Speed 100 2 FRONT NOZZLE STATION CLAMP CLAMP 0 OPEN 1 NP14 1 NP14 0 NAME OUT NAME IN Nzl Clamp Spare TP01 08 01000000 Nzl Clamp Spare 09 16 00000100 F
233. s etc If pressing the manual button does not allow normal operation there is a problem with the air supply air piping or pipette valves damage clogging and adhesion of foreign matter Check the air supply line of the locate pins For any replacement of the locate pin please refer to figure 6 16 DU 4 0 T 12 9 10 13 2 m 10 lt I 13 5 10 e 5 14 Figure 6 16 Exploded view Locate pin assembly Service Manual Topaz 5322 871 63606 6 12 PA 1309 10 01 05 PCB Transport Systems 6 6 Edge Clamp Another PCB clamping method is the use of the edge clamp cylinders whenever the locate pins cannot be used the edge clamp cylinders can be used to press the PCB against the front conveyor rail and so fix it to the mounting position The edge clamp cylinders do not have any adjustment possibilities Of course the edge clamps can be activated by means of the output monitor 04 please refer to figure 6 17 For the any replacements of the edge clamp assembly please refer to the figure 6 18 Rear right side of the Topaz 4 13 Ye 5 Figure 6 18 Exploded view edge clamp assembly 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 6 13 PCB Transport Systems 6 7 Push Up The push up plate is located directly underneath the component moun ting position The support pins attached by magnets on the surface of the push up plate support the PCB during the mounting
234. s this is set during adjusting of the cameras I Simultaneous pickup area This parameter is used to determine whether multiple heads can pickup components simultaneously Each column respectively shows the allowable ranges of pickup positions XYRZ that permit simultaneous pickup from different component feeders Typically XY and Z should be set to 0 2mm and the R to 1 degree J QFP clearance If a large impact is applied to a QFP at the instant when a head lowers to pick or mount it the leads of the QFP in questions are likely to bent To avoid this the soft landing pickup or mounting is useful This parameter specifies the Z stroke to perform the soft landing and is typically set to 4mm When 0 00 is entered the soft landing is not performed K CngTimer Speed The value in the X column is the time duration for which a head stays at the lower end position when changing a nozzle Units are milliseconds A typical setting is around 200msec If a nozzle change is unsuccessful try entering a slightly larger value A value of as long as one second 1000msec can be set The value in the Y column is the relative ascent and descent speed for the head during nozzle change This is normally set to 10096 If a nozzle change is unsuccessful try decreasing this value slightly L Retry limit This is the maximum number of retries that the mounter is allowed to retry picking or recognizing after when an error occurs This paramete
235. s Moving Speed 100 TN13 CONVEYOR ON OFF 0 ON 1 NAME OUT NAME IN Conveyors 09 16 00001000 Figure 6 4 Output monitor screen activate conveyor 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 PCB Transport Systems 3 While running the conveyor switch the speed as follows figure 6 5 Use the arrow keys to line up the cursor with N14 CONVEYOR SPEED LOW Press the ENTER key to switch the conveyor speed The output monitor digit reads 1 when the conveyor is at low speed and reads 0 when it is at high speed Out Monitor Tl Select Enter Exec Selected Arm XY ESC Command Lists Moving Speed 100 TN14 CONVEYOR SPEED LOW HIGH 0 LOW 1 0 7 1 NAME OUT NAME IN Conveyors 09 16 00001100 Figure 6 5 Output monitor screen conveyor speed 4 Adjust the high speed while running the conveyor at high speed adjust The speed by turning the screw Do not set the speed too high as this may hamper switching response Position the H screw at a point slightly slower than the maximum speed 5 Raise the entrance stopper by selecting lt lt lt 3 MAINTE M gt gt gt lt lt 4 MANUALS gt lt C DISPLAY amp EXIT gt C1 OUTPUT MONITOR and press the ENTER key Use the arrow keys to line up the cursor with N06 STOPPER OF ENTRANCE Press the ENTER key to raise the entrance stopper The output monitor
236. s such as Type 32 have an orientation Since components are usually picked at 0 degree the R axis initial position must be adjusted so that these nozzles are aligned with the direction of components the nozzle holder s leaf springs are set parallel with the X axis 1 Execute the CHANGE NOZZLE command to attach a nozzle for example Type 32 to a head 2 Press the emergency stop button 3 Check that the nozzle holder s leaf springs are set parallel with the X axis If not parallel with the X axis adjust by rotating the nozzle shaft Moving the R axis belt by hand allows easy adjustment 4 Set teaching conditions 1 Press the emergency button 2 Attach a 31 type nozzle to headl 3 Check that the nozzle holder s leaf springs are set parallel with the X axis if not rotate the R axis until they do 4 Setteaching conditions by selecting 3 3 B4 and press ENTER 5 Perform teaching for the R axis initial position Select lt 3 3 1 gt Softlimit and press ENTER Use the arrow keys to line up the cursor with the init pos of the R main row and press F10 twice to perform teaching 6 Save the settings Press the ESC key select B2 SAVE DATA or BO SAVE amp QUIT and press the ENTER key To quit without saving select B3 RECOVER ADJUST or B7 QUIT and press the ENTER key 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 8 21 Axes Systems Editing Objec S
237. s the most close to the nozzles by means of a narrow screw driver When the head lowers in this situation the circuitry that should operate the valve is defect Points to check are following Damaged valve Loose harness connectors DC24V power supply O board etc When performing manual operation does not move the head down there is a problem with the pneumatic installation Check following Air supply Air filters Air piping Air valves Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Component Transport Systems Checking the vacuum generation This chapter explains how to check the vacuum generation of Heads 1 to 8 You can also find whether maintenance cleaning or replacement is required by measuring the vacuum intensity of the vacuum ejector Measuring the vacuum generation of the desired head Press the emergency stop button 1 Open the output monitor screen and select the target head Select lt 3 4 C1 OUTPUT and press the ENTER Use the arrow key to line up the cursor with THO1 HEADI VACUUM or any other head 02 to 08 2 Press the ENTER key to generate the vacuum in the selected head The output monitor digit changes to 1 when the vacuum ejector is on 3 Check the vacuum generation Check that the pickup vacuum is generated by placing your finger over the nozzle tip opening of the target head and feeling the suction If the vacuum generation
238. se and lower the main stopper The output monitor digit reads 1 when the main stopper is the raised position and reads 0 when it is at the lowered position Out Monitor Tle Select Enter Exec Selected Am MAIN XY ESC Command Lists Moving Speed 100 TNO1 MAIN STOPPER DOWN 0 UP 1 Conveyors 01 08 10000000 KEWkunuygy azststsw w maste RWAN KARR BAKED Wee AK eRe kxsuettsesSs4Ausus sacks vaanausa X 52 459 AUssuct KXERAWMAPEXEtAXE catars HRM ee mw ASH 9 X34 teas Rana wwxuexs wwsomxus snusare z9z4 KWNAMMEARETEATYAE n 255 522 sresuosaxasess aumavxsusesenw wumaases wvxuamsos sun RAR Kean EHH AS KEE see Rae EH WWE xa NOSE SR AMEE EEN amp vuszwuwe ax muxum auxveeveewvacex xuawvrtu Figure 6 7 Output monitor screen activate main stopper 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 6 5 PCB Transport Systems 2 Check the ascent and descent speeds Both speeds should be around one second at this speed the components which are pre mounted on the PCB will not shift 3 Press the emergency stop button then adjust the ascent descent sp
239. sh up plate make sure that the push up pins do not interfere with the conveyor rails and edge clamp cylinder If pressing the manual button does not allow for normal operation there is another problem with the air supply air piping and pipette valves damage clogging and adhesion of foreign matter Check the air supply line of the push up plate For any replacements on the push up assy refer chapter 13 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 6 15 PCB Transport Systems 6 8 PCB Detection Sensors In the conveyor assy there are five PCB detection sensors arranged along the front rail of the conveyor The sensors each have LEDs mounted on the side which are normally lit When the sensor detects the presence of a PCB the LED turns off please refer to figure 6 21 5053 FCs 5052 5051 Figure 6 21 5054 5051 8 5057 PCB detection sensors e F 5053 The table 6 8 1 below shows the PCB detection sensors their function and their location The sensor code can be used to track the sensors in the diagrams of chapter 14 sign is the software code which is used for instance in the DI DO screen of the software Sensor Location Sign Remarks joe 5 Entrance stopper NLOI Stopper for decelerating transport 52
240. sition 1 2 Set jumper to position 2 3 Table 3 5 6 Camera and jumper settings Position 2 Position 3 Position 1 Jumper on position 2 3 Figure 3 5 7 Jumper setting 3 18 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 System Principles 3 5 5 Mother Board This board see figure 3 5 8 connects the various boards such as the system board servo board and vision board via an ISA bus The mother board contains also an AC and DC power failure detection function The AC input the DC5V and the 12V 12V are monitored A LED indication will show a power voltage drop instantaneous power failures and errors in the DC power supply for the control system Table 3 5 7 below shows the various possibilities SERVO SYSTEM VISION BOARDS BOARD BOARDS ZI LED 1 2 3 4 MOTHER BOARD ASSY 5 4510 MADE JAPAN zz zz CNg I O power CN6 5V IN 12V o TUS Power ICNG6 t5V 12 5 12V IN uz sevo SERVO E gt d telo Wan 52 509 4 Q 82 2 Nass TP 58 8 M o pale YAMAHA MOTOR CO LTO CN11 AC 12V IN CN7 FAN POWER SPARE Legenda R gt Lit red NOT USED G gt Lit Figure 3 5 8 Mother board not defined
241. sk formatted as 1 44Mbyte for this purpose Use this command to save and use the Extract MARK D B into FD command to copy the database onto other machines Extract COMPONENT D B from FD This command extracts the component database from the floppy disk to the hard disk Use the floppy disk with the database data saved by Freeze COMPONENT D B into FD Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Software Section 3 7 3 8 Extract MARK D B from FD This command extracts the mark database from the floppy disk to the hard disk Use the floppy disk with the database data saved by Freeze MARK D B into FD Production History Utility Production History Utility is an optional function This command is available only when this option is equipped for the machine Disk Utility HAIN Starting llp Machine N System SUB MENU 2 Format of FDD 3 DiskCopy of FDD 4 Return to MAIN MENU 3 VIOS Special Command Check of HDD This command calls the SCANDISK of MS DOS Use this command for the hard disk troubles Also refer to the paragraph 10 2 10 in this chapter Format of FDD This command calls FORMAT command of MS DOS to format floppy disks Disk Copy of FDD This command calls DISKCOPY command of MS DOS to copy floppy disks 5322 871 63606 01 05 Service Manual Topaz 10 9 PA 1309 10 Software Section 3 9 VIOS Special Command MAIN 2 Installation of VIOS V1 1
242. sonnel who are aware of the hazards involved The following training levels are defined Operator level Official Philips training course or training received by a qualified maintenance engineer User or Supervisor level Official Philips training at one of the official Philips Training Centres Maintenance or Service level Official Philips training at one of the official Philips Training Centres Safety standards The safety standard of the CSM system is in accordance with CE directives Machine directive 89 392 EEC and 91 368 Low Voltage directive 73 23 EEC directive 89 336 EEC Liability Philips shall not be liable for any costs damages or personal injuries if the CSM system is not used according to the safety rules given in this paragraph Detailed information For more detailed information how to operate and to maintain the CSM machine please refer to the Operating and Serv ice manuals of this system Location of the Operator manual The Operator manual MUST BE LOCATED CLOSE to the CSM machine This enables operators to have easy access to the relevant cards HOW TO REPORT DOCUMENT IRREGULARITIES We have endeavoured to ensure that the information in this document was correct when published If when using this document errors omissions or anomalies are discovered please inform us using the reply form attached We thank you for this service in advance as it will help us to ensure that you
243. sports the PCB s by belt in for mounting and out when remounted the Topaz On a standard machine PCB s are conveyed in the left to right direction while the conveyor width is adjusted by sliding the rear rail the front rail is fixed These specifications cannot be changed after the machine has been shipped 6 2 1 Adjusting the Conveyor Belt Tension If the conveyor belts are too loose they may slip on the pulleys causing unstable transfer If the belts are too tight they may break or wear excessively Both the tension of each belt on the fixed and movable rails should be adjusted evenly If necessary adjust the tension as follows refer to figure 6 2 1 Press the emergency stop button 2 Loosen the tension adjusting bolt The tension adjusting bolt is located on the right side of the conveyor rails and is linked to the idler Use a hex wrench to loosen the bolt but do not remove it 3 Adjust the belt tension by sliding the tension adjusting bolt towards the outer side of the machine to increase the tension or towards the inner side to reduce the tension 4 Re tighten the tension adjusting bolt 5 Check the tension by hand then run the conveyor belt in manual mode as described in the operator manual and check that the motor pulley does not slip Tension adjust bolt C Figure 6 2 Adjusting the conveyor belt tension Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 PCB Transport Systems 6 2 2 Adju
244. ss the ENTER key Ensure safety then press the ENTER key The head moves to the discard point and dumps the component automatically Service Manual Topaz 5322 871 63606 7 24 1309 10 01 05 Component Transport Systems lt lt lt APPLICATION gt gt gt 3 MAINTE M lt lt MODE gt gt 3 MCH_ADJUST COMMAND LIST A UTILITY A3 PICK COMPONENT ls ccc eem Uer lt lt MODE gt gt 3 MCH_ADJUST A461 Please input the data base number which has already prepared After input please press the ENTER key Database No 1 A463 It will pick one component An nozzle type used by this is Type 11 Please input the head number Head No 1 A462 As a Tape feeder is specified by this component the machine can pick component automatically Please type feeder position number Feeder Set No 1 A303 CAUTION The axes will move After confirming safety please press the ENTER key A394 lt lt lt Picking gt gt gt Now it is picking up the specified component automatically To pause press ESC key Figure 7 19 Component pickup Y Pickup offset in X direction Pickup offset in Y direction Center of the nozzle Center of the component X Figure 7 20 Offset of the nozzle and center position of the component Note In both the X and Y directions if the nozzle tip is shifted
245. ssembly Disassembly Adjustments and Maintenance 8 24 8 6 1 Adjustment of the X and Y motor Encoder Position 8 24 8 6 2 Head Replacement 8 25 8 6 3 X axis Assembly 8 25 8 6 3 1 X axis Replacement X motor Only 8 25 8 6 3 2 X axis Ball Screw Replacement 8 26 8 6 3 3 X axis Linear Guide Replacement 8 27 8 6 4 Y axis Assembly 8 27 8 6 4 1 Y axis Replacement Y motor Only 8 27 8 6 4 2 Y axis Removing Y axis Ball Screw Generation 2 8 28 8 6 4 3 Y axis Removing Y axis Ball Screw Generation 3 8 29 8 6 4 4 Y axis Installing and Aligning Y axis Ball Screw Generation 3 8 30 8 6 4 5 Y axis Pre tension Adjustment Generation 3 Y axis 8 32 8 6 4 6 Y axis Linear Guide Replacement 8 33 8 6 5 Z axis Assembly 8 34 8 6 6 R axis Assembly 8 34 9 Vision Systems 9 1 9 1 Introduction 9 1 9 2 Vision Systems 9 1 92 1 Pre Start Operations 9 2 9 3 Moving Camera 9 2 9 3 1 Adjusting the Focus and Field Of View 9 2 9 3 2 Adjusting the Lighting Level of the Moving Camera 9 3 9 3 3 Adjusting the Moving Camera Scale 9 7 9 4 Single Camera Adjustment 9 12 9 4 1 Maximum Component Size and Field Of View 9 12 9 4 2 Focus Adjustment 9 13 9 4 3 Lighting Level Adjustment 9 14 9 4 4 Camera Scale Adjustment 9 16 Service Manual Topaz 5322 871 63606 4 PA 1309 10 01 05 Table of Contents 9 4 5 Camera Optical Axis Angle Adjustment 9 20 9 5 Line Array Camera Adjustment 9 25 9 5 Maximum Component Size and Field Of View 9 25 9 5 2 Adjusting
246. sting the Carry In Conveyor Speed The conveyor speed varies according to the frequency of the power supply and the weight of the PCBs on the conveyor You can adjust the carry in conveyor speeds by using the two adjusting screws located inside the lower right panel on the front side The carry in conveyor moves at two speeds a high speed H for reducing the transfer time of PCBs and a low speed L for minimizing impact when the PCB hits the entrance or main stopper To adjust these speeds prepare typical PCBs and use the procedure below Low speed Figure 6 3 SPEED ADJUSTMENT CONVEYOR Carry in conveyor speed adjusting screws High speed 1 Adjust the conveyor width according to the size of the PCB To adjust the conveyor width the Conveyor Unit utility in the Data Manager will be convenient If your machine is not equipped with an auto conveyor width adjusting function adjust manually 2 Open the output monitor screen and turn on the conveyor see figure 6 4 Select lt lt 3 MAINTE M gt gt gt lt lt 4 MANUAL gt gt lt C DISPLAY amp EXIT gt C1 OUTPUT MONITOR and press the ENTER key Use the arrow keys to line up the cursor with TN13 CONVEYOR ON Press the ENTER key to turn on the conveyor The output monitor digit reads 1 if the conveyor is on and 0 if it is off Out Monitor Ne Select Enter Exec Selected Arm MAIN XY ESC Command List
247. supply terminals Carry out following actions Open the power box doors at the rear side of the system Locate the GS21 power supply and measure at the terminals the following voltage 24V 0 5V If the voltage is not OK adjust the level with potentiometer RV1 fig 4 7 Close the power box doors Service Manual Topaz 5322 871 63606 4 12 PA 1309 10 01 05 Power and Safety Circuits 4 3 6 Performance Check and Trouble Shooting No performance check is needed for the power supplies of the system power supplies have a LED indication green light when the voltage is ok This can be handy in case of trouble shooting some problems Make sure that the GOOD signal POWER NG is not activated All servo boards are interconnected with EMG signal this signal gives and EMERGENCY error when active 4 3 7 Maintenance Instructions Check the voltages of all power supply s each 3 months and adjust them if necessary e Check and clean the two fans inside the MCX 2 controller box Check all cabling and harnesses from and to the power supply s check for bad connections and discoloured wires Check all emergency switches and harnesses e g EMG cabling on their functionality Check all fuses in the mains circuit 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 4 13 Power and Safety Circuits Intentionally left blank Service Manual Topaz 5322 871 63606 4 14 PA 1309 10 01 05 Vac
248. talled feeder Low voltages Over current in one of the motor driver boards In most cases the controller will display an ERROR code with a short description of the emergency cause on the VIOS monitor In paragraph 1 4 3 a list of possible causes is given If the Tray Changer is installed also emergency conditions from this device can stop the machine Re activation of the system is only possible after resolving the emergency cause and pressing the READY switch at the hand held keyboard WARNING When working at the systems safety circuit make sure to take all the necessary safety precautions to avoid possible danger 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 4 1 Power and Safety Circuits 4 2 2 Safety Circuit The detailed safety diagrams of the system can be found in Chapter 14 A more simplified diagram is shown in figure 4 1 and figure 4 2 signals from and to the various switches and sensors are going via the connection board On this connection board various LED s are mounted which indicate the status of the Over Travel OT and emergency EMG signals Also the 24VDC from the GS21 power supply is distributed via this board From April 2000 onwards the Topaz system is equipped with a 3 generation connection board The 24 eneration connection board has been replaced by this new version 2 generation connection board KU1 M4550 00X EMG SW EMG SW EMG HHK REAR
249. tation results in a deviation in mounting accuracy that will exist between the cameras if their mechanical alignment in relation to the machine s moving axis is not equal On Machines that have Fine Mode Capabilities this effect is significantly reduced providing that all cameras are used only in Fine Mode Fine Mode recognition has the ability to mask a significant portion of mechanical deviation and reduces its influence on mounting accuracy For the Topaz system this adjustment can be used if more then one single view camera is installed and the customer uses both the QFP and Fine mode Measurement Principles During the machine calibration the verification of the optical axis should be performed immediately following the camera scale function and is in principle only needed after re installation of the camera The primary focus of the utility is to align the camera in respect to the moving axis of the machine To accomplish this we will measure the head at the different Z positions above the camera A properly aligned camera will have very small deviation between the center of the camera and the path of the spline If adjustments are required the camera must be shimmed or repositioned on the camera stand Single Camera For the single vision camera the program COM pgm is used This program is similar to the Auto Mount feedback routines and is executed in the same manner Unlike the standard AMF programs the camera utility wi
250. te ball screw assembly Do NOT remove the items 10 11 12 and 13 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Axes Systems 12 13 8 6 3 3 8 6 4 8 6 4 1 NAY Dm Re install the new X axis ball screw nstall the ball screw with the right hand mounted support unit Assemble the bearing and the circlip of the left hand support unit nstall the support unit 24 into the X motor holder 10 and tighten the four bolts at 7 4 Nm by using a torque wrench Position the head holder unit 13 to the right of the X axis and install the two left screws of the ball screw nut holder 14 Position the head holder unit 13 to the centre of the X axis and install the two right screws of the ball screw nut holder 14 Tighten all four screws at 7 4 Nm by using a torque wrench Switch on the machine to perform the second part of the adjustment procedure of the X motor encoder position after replacing the X axis ball screw See section 8 6 1 X axis Linear Guide Replacement Replacing the X axis linear guides is done as described below See for reference figure 13 6 1 Remove the head assembly as described in section 8 6 2 From the guide that must be replaced disconnect the guide bearings from the head holder unit 13 by removing the bolts Remove the guide from the X axis beam by removing the bolts holding the guide Replace the guide and assemble in reverse order During assembling the d
251. ted Machine type gt Topaz Sapphire Sapphire 5100 Emerald A table B table LCS 3I Connector ATS 27 CN3 CN5 CN8 C C C NC CN9 10 Table 3 5 5 Connectors versus machine types 5322 871 63606 Service Manual Topaz 3 17 01 05 PA 1309 10 System Principles 3 5 4 Vision Board The vision board is the VICS2000 and handles all vision related operations except laser The board layout is shown in figure 3 5 6 below Camera 1 3X Camera 2 0 Camera 3 3J Camera 4 J 7 mor i igure 3 5 6 Vision board VICS 2000 The VICS 2000 vision board is equipped with 4 camera connectors from top to bottom they are used as follows Camera 1 Connector for the fiducial camera Camera 2 Connector for the optional single view camera Camera 3 amp 4 The connectors 3 and 4 can either be used both for single view camera s or both for multi view camera s depending on the jumper settings It is not possible to use eg camera connection 3 for a single view camera and camera connection 4 for a multi view camera The settings for the jumpers 1 to 4 of the vision board are shown in the table below see also figure 3 5 7 Camera 3 amp 4 Jumpers to 4 Set jumper to po
252. the customer receive the highest possible quality of information and service Manual Title Service Manual Topaz Manual Number 5322 871 63606 PA Number PA 1309 10 FROM eed m ees e dui med hae Address dre e e E EMT ER e UR DOCUMENT IRREGULARITIES Page Paragraph Erroneous Philips Electronic Manufacturing Technology Supply Centre Customer Support P O Box 218 Building BAF 2 5600 MD Eindhoven The Netherlands Please don t forget to fill in this Update Code Manual Service Manual Topaz Table of Contents l Introduction l l General Introduction 1 1 1 1 1 2 Chapter Overview 1 2 1 3 Safety 1 4 1 3 1 General 1 4 1 3 2 Basic Rules 1 4 1 3 3 Safety Standards 1 4 1 3 4 Cautionary Remarks 1 5 1 3 5 Warning Stickers 1 5 1 3 6 ESD Precaution 1 7 1 3 7 Noise Level 1 7 1 3 8 Liability 1 7 1 3 9 and Greases 1 8 1 3 10 Abbreviations 1 8 2 General and Electrical Block Diagram 2 1 3 System Principles 3 1 3 1 Introduction 3 1 3 2 Mains Specifications and Connection Schedule 3 2 3 3 Air Specifications and Connection 3 5 3 4 Interfaces 3 6 3 4 1 Bus Definitions 3 6 3 4 2 Serial Interface 3 6 3 4 3 Line Interconnections 3 8 3 5 MCX Control Unit 3 11 3 5 1 MCX Controller Lay Out Second Generation 3
253. the mark and the level of light the machine will accept as Before performing this procedure it is recommended to go to the database where this mark resides and find out what the Threshold value is see section 11 3 9 A 1 2 3 for directions how to get there Once in the database press the F4 key until the Vision Info sub window is displayed In this sub window is the Threshold value The lighting level needed to produce an Average Gray Level that is is very close to this level l Prepare the light adjuster plate Prepare the light adjuster plate and a proper PCB on which the light adjuster can be placed PCB fiducial marks are not necessary 2 Execute the Mov Cam Light command 1 Select lt 3 3 B1 ADJUST TARGET gt Mov Cam Light and press the ENTER key 2 Select 1 Dial 3 screws 3 Select Use for the special tool lt lt lt APPLICATION gt gt gt 3 MAINTE M lt lt MODE gt gt 3 MCH_ADJUST lt COMMAND_LIST gt B SAVE B1 ADJUST TARGET Object Mov Cam Light A650 This procedure adjusts the light intensity of the moving camera The way of LED Type 0 Dial 2 screws L1 Dial 3 screws A651 Please select whether you will use a Light Adjuster special adjustment A653 This adjustment requires placing PCBwidth mm 128
254. the mounter operation manual 2 Preparing the PCB glass PCB When using a glass PCB specially tailored for camera scale adjustment follow these steps Prepare a glass PCB which is set in the jig glass within PA1912 00 set with the jig designed for this adjustment is available from PHILIPS Do not remove the PCB from the jig during adjustment Register the mark on the PCB in the mark database 1 Open the mark information screen Select lt 2 2 D1 SWITCH PCB DATA QFP Mark Info and press the ENTER key 2 Check that the database Number of the No 1 mark data is 295 3 Press the ESC key select the B2 SET FROM DATABASE command with the arrow keys and press the SHIFT ENTER keys 4 An alert message appears but proceed as indicated to execute this command 70443302 01 Sub window lt lt lt APPLICATION gt gt gt 2 DATA M lt lt MODE gt gt 3 DATABASE OBJ MARK DATABASE Mark size Info No MARK NAME COMMENT Edit Term Mark OutSize mm 1 0 151 1 0 Vision Info Edit Term Search Area B 4 00 Figure 9 9 Mark info screen Check for the registration data in the mark database 1 Open the mark database Select lt 2 3 DATABASE gt lt A1 COMPONENT MARK D B gt MARK DATABASE and press the ENTER key to open the mark database 2 Press the F5 key and then ESC key The CHANGE POSI
255. there is a need to replace the end blocks separate code numbers are available in the spare parts list CAUTION Disconnect the power and air supply prior to replacing the valves 2 Confirm the torque of each removed bolt prior to reconnecting air and power 3 Too much torque may damage the plastic ejector base 5 3 2 Exchanging the Head Up Down Slow Valves and Valve Base Up Down Valve replacement To replace the valves on the head assy refer to figure 5 5 and proceed as follows 1 Loosen the two screws top of the up down valve 2 Remove the valve in the direction of the arrow 3 Install the new valve and take care about the direction of the gasket 4 Tighten the two screws with a torque of 17 6 Ncm Slow Valve replacement To replace the valves on the head assy refer to figure 5 5 and proceed as follows 1 Loosen the two screws on top of the up down valve 2 Remove the valve in the direction of the arrow 3 Install the new valve and take care about the direction of the gasket 4 Tighten the two screws with a torque of 17 6 Ncm Valve base replacement To replace the valve base on the head assy refer to figure 5 5 and proceed as follows 1 Loosen the two screws in the left or right end block 2 Remove the applicable end block and valve base 3 Remove the valves on the valve base by following steps 1 and 2 of the procedures Up Down valve replacement and Slow valve replacement Service Manual Topa
256. tion of VIOS V1 2 for the machine using SYSTEM DATA DISK CAUTION This command can be dangerous because it initialises all machine data on the hard disk Use this command only in case the machine data is corrupted or out of date or if there are hard disk problems 5322 871 63606 Service Manual Topaz 10 7 01 05 PA 1309 10 Software Section 3 4 3 5 3 6 VIOS SOFTWARE UTILITY Installation This command installs the VIOS Software Utility itself Use this command for the version up of VIOS Software Utility Change of Protect Level The protection level is selectable using this command The protection level limits the operation just after the starting up of the machine Protect Level Can Use Only 1 0PERATION M LEADER Except for 3 MAINTE M LICENSEE appricat ions SPECIALIST Cancel Database Utility MAIN 1 Starting Up Machine SUB MENU 2 Freeze MARK D B into FD 3 Extract COMPONENT D B from FD 4 Extract MARK D B from FD 5 Return to MAIN MENU Freeze COMPONENT D B onto FD This command saves the component database of the machine onto a floppy disk Prepare a new floppy disk formatted as 1 44Mbyte for this purpose Use this command to save and use the Extract COMPONENT D B into FD command to copy the database onto other machines Freeze MARK D B onto FD This command saves the mark database of the machine onto a floppy disk Prepare a new floppy di
257. tion system board In newer GEM systems a new system board is being used which makes the use of a separate harddisk no longer necessary please refer to figure 3 5 4 Base system board To servo 2 option To servo 1 Application board Figure 3 5 4 Third generation system board 5322 871 63606 01 05 Service Manual Topaz 3 13 PA 1309 10 System Principles The new system board is a modular built unit which encloses following modules A base system board This interconnects all modules attached to this board The connectors of this board are almost compatible with the previous board The keyboard connector has been changed from DIN to mini DIN an adapter is available in case the new system board has to be retrofitted in the previous version controller A PC card module The card PC includes the 486DX4 100 chipset a peripheral controller VGA controller and memory The card PC is a module with specifications standardised by OKI EPSON and PFU An application board module This board establishes the serial communication between the system board and the various I O boards in the Topaz The processor on this board is a Hitachi RISC processor of type SH7021 20Mhz The I O port capacity is expanded while the scanning speed of the I O ports has been increased to 1 msec scanning of all ports The board has a on board flash memory for error logging and the software for the various I O boards is loaded via the applicati
258. tip The shape data in the component information is not properly supplied Generate a negative pressure for all heads in the manual mode and move the nozzles If any incorrect value is entered for the shape data the component is supplied in a wrong direction this also results in recognition errors For components to be supplied laterally specify 0 degree in the database While specifying 90 degrees for lengthwise supply Table 9 3 Service Manual Topaz PA 1309 10 5322 871 63606 01 05 Vision Systems 9 7 2 Recognition error frequently occurs QFP Components Possible cause Corrective action Incorrect data is entered for the Component Information Check the data on the Component Information and perform PARAM SEARCH in the Adjust Assistant Recognition error frequently occurs QFP is not displayed on the vision monitor If the component has deviated from the center of pickup position it may shift from the center of the monitor resulting in a recognition error Check the Feeder Pos_X Y and X Y CompPitch values in the Component Information and make the corrections Components cannot be recognized Table 9 4 The direction supplying the component is not correct If the supply direction is wrong the number of leads is switched between the length and width sides causing a recognition error even if the SHAPE data is correct Component su
259. to the machine origin side with respect to the center of the component then this is a plus offset If shifted in the opposite side this is a minus offset 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 7 25 Component Transport Systems 7 4 4 Feeder Plate Maintenance Check on a weekly basis the wear of the feeder plate Replace the air joint if wear is noticed or if air leakage is noticed Also a malfunction feeder can be caused by a bad air supply or bad coupling Clean the inner part of the air coupling and apply little grease on the inner packing of the air joint Check the feeder alignment every three months Proceed with the description given in the previous paragraph if needed Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Component Transport Systems 7 5 Component Feeders This section explains how to adjust the feed pitch and speed of tape feeders and multi stick feeders that continuously supply components for mounting Refer to the CSM GEM Feeder Manual 5322 871 61605 for more information about tape feeders C0603 bulk feeders and intelligent tape feeders 7 5 1 Feeders For stable and accurate component feeding the following items must be adjusted correctly Adjustment item Tape feeder type Feed pitch All feeder except 8mm and 32 mm tape feeder Feeder speed 16 mm 24 mm 32 mm and 44 mm tape feeders Tape peeling load 8 mm and 12 mm tape
260. topper 10 11 TNO2 Plate push up TEI2 Head 1 2 slow down TNO3 Locate pinl TEI3 Head 3 4 slow down 04 Edge clamp TEI4 Head 5 6 slow down TNO5 Push in TEIS Head 1 8 slow down 06 Stopper of entrance TEI6 Head serial cmn ok TNO7 11 Spare 01 8 to 8 active head sequence TNI2 Conveyor reverse TFO9 13 Extended do TNI3 Conveyor on TFI4 Head sequence vac mnt TNI4 Conveyor speed low TFI5 Head sequence vac check TNI5 16 Spare TFI6 Head sequence start 01 Nozzle station up TGOI 8 Timer set bitO to bit7 TP02 Nozzle station clamp 09 11 Timer head no select bitO bit2 03 4 TGI2 14 Timer port no select bitO to bit2 05 Rear non stop fdr carriage up TGI5 Spare TP06 Rear non stop fdr carriage down TGI6 Timer start TPO7 Rear non stop fdr carriage forward 01 8 to head8 vacuum 08 Rear non stop fdr carriage backward TH09 16 Head to head8 blow TPO9 Sp Light single cameral up 01 8 F feeder datal to data8 TPIO Sp Light single camera2 up 709 12 F feeder select to select4 TPII Sp Light single camera3 up TJI3 16 Spare TPI2 16 Spare Buzzer TQOI Tray changer pallete home TKO2 Blue yellow lamp TQ02 Tray changer hook forward TK03 White red lamp TQ03 Tray changer hook close 04 Green green lamp 004 Tray changer pallete set 05 Gate out TQ05 Tray changer hook backward 06 5 TQ06 7 Tray changer spare TKO7 Cover lock 008 Ext tc conveyor on 08 out smema
261. tput monitor signal is not used Following jumpers are available Jumper W1 CP2 CP3 is to set the input voltage to either 115V or 230V for the Topaz the jumper should be set to 230V which means the jumper wire is connected from W1 to CP3 see figure 4 6 Make sure to check the input voltage setting when replacing the power supply CP2 wi 115V 230V The following adjustments can be done The 12V V3 adjustment is done by R57 adjust to 12V 0 5V The 12V V2 adjustment is done by R72 adjust to 12V 0 25V The 5V V1 adjustment is done by R83 adjust to 45V 0 1V The power failure signal adjustment is factory adjusted Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Power and Safety Circuits 4 3 3 24V I O and Emergency Power Supply GS21 The 24V power supply GS21 is of the type HY248R5GN which can deliver an output current of max 8 5A The AC input voltage of this power supply is factory set to 220VAC At the rear side of this power supply the output voltage can be adjusted by means of a potentiometer V adj please refer to figure 4 7 Adjust the voltage to 24V 0 25 Figure 4 7 Back GS21 The power supply is located in the power box at the rear side of the system next to the two mains transformers TMI11 and 11 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 4 9 Power and Safety Circuits 4 3 4 D Power Assembly 282V Power D power assy rect
262. tus of the system in advance of this replacement Switch off the system Cut loss al the tie wraps binding the cables and hoses to the head unit Remove the two orange air hoses Remove all cabling connecting the head assembly to the X beam Following cables are to be removed from connector plate item 33 in figure 13 6 1 Vacuum sensor harness R motor and encoder cable All cables as head blow off vacuum down slow down down sensor Earth cable and fiducial camera cables as well as the overall head down sensor cabling 6 Remove the complete head assy by removing the bolts item 216 in figure 13 5 3 The head is attached to plate item 13 in figure 13 6 1 by means of fitting pins 7 Assembling is done in reverse order 8 6 3 X axis Assembly The mechanical assembly of the X axis is shown in figure 13 6 1 8 6 3 1 X axis Replacement X motor Only The X axis motor is a 750W AC Servo motor Removing the motor is done as described below See for reference figure 13 6 1 1 Determine the X and Y positions by performing the first part of the adjustment procedure of the X motor encoder position before removing the X motor See section 8 6 1 2 Switch off the system 3 Disconnect the PI and MO cable in the cable duct right side of system 4 Loosen the coupling 4 from the motor shaft 5 Remove the four bolts which hold the X motor to the bracket 10 6 Remove the AC Motor 15 7 Re assembl
263. um 407 00mm widths of PCBs that can be transferred A Structural movable range B Allowable movement range C plus side software limit rear D Origin position E minus side software limit front F Mechanical limit Figure 8 11 movement range To set the W axis software limit follow these steps 1 Select the W axis to set the software limit Select lt lt 3 MAINTE M gt gt gt lt lt 4 MANUAL gt gt lt A CHANGECONDIT ION gt A1 SELECT AXES W MAIN and press the ENTER key 2 Manipulate the joystick on the HHK to move the W axis conveyor width To set the plus side software limit move the axis in the width enlarging direction To set the minus side move the axis in the width reducing direction Note Tilting the joystick on the HHK to the right you reduces the width and tilting it to the left you enlarges the width Set the conveyor width to a maximum or minimum as long as the movable rail does not make contact with the mechanical stopper 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 8 11 Axes Systems Side view Man 47 T T Figure 8 12 W axis pulley Pulley 3 Set teaching conditions as follows l Select lt lt lt 3 MAINTE M gt gt gt lt lt 3 MCH_ADJUST gt gt lt B SAVE amp QUIT gt B4 CONDITION OF TCH and press ENTER 2 Select TEACH UNIT SEL and press the ENTER key Se
264. urfaces of the clamp plate Service Manual Topaz 5322 871 63606 7 20 PA 1309 10 01 05 Component Transport Systems 7 4 7 4 1 Feeder Plates This section describes how to adjust the position of the feeder plates and their machine data in order that each head properly picks up a component Also explained are adjustments to feed pitch of tape feeders Correct adjustment of the feeder plates is essential to the proper working of the system Improper adjustment will reduce the component pickup rate of each head The second part of this chapter explains how to adjust the feed pitch and speed of the tape feeders Feeder Plate Parallel Adjustment The feeder plate is secured to the feeder base of the main unit by bolts Under normal working conditions the feeder plate will not require parallel adjustment However if you need to remount the feeder plate for some reasons first make the parallel adjustment as follows Fine adjustments to feeder positions will be performed in the next section 7 4 2 Teaching the feeder block positions Mount two feederbar adjustment blocks on the feederbar at the end and beginning Figure 7 16 Feeder plates top view 1 Check if a nozzle is attached to a head A nozzle for small chip components example type 31 is recommended 2 Press the emergency stop button 3 Temporarily fasten the feeder plate to the feeder base Tighten the bolts but not to fast in the center position
265. ust be removed this can be done by means of the DO screen 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 9 11 Vision Systems 9 4 Single Camera Adjustment This section describes the calibration of the single camera If not installed than skip this section 9 4 1 Maximum Component Size and Field Of View This procedure explains how to adjust the maximum component size The maximum component size is directly related to the Field Of View For the Topaz the recommended Field Of View is 37mm or larger the maximum component is 32mm square To adjust use a transparent ruler sheet tip copy on a copy machine a ruler on a transparent sheet Set the focus ring in the middle position Select the adjust assistant lt F6 gt key pick up the ruler sheet and bring it above the single camera on which you want to adjust the aperture Adjust the Field Of View size by shifting the camera up or down Vision monitor 63706315 pg NY e U gt I Figure 9 14 Ruler sheet on the vision monitor NOTE Adjusting the Field Of View too large may give problems with the nozzle back plate If you can see two stripes on the screen as shown in the figure 9 15 below please readjust again Vision monitor 63706315 White stripes next to the nozzle back plate may influent the recognition of components in a negative way nozzle back plate Figure 9 15 Nozzle back plate sides visible
266. ustment is less than 90 degrees turn Tighten the set screw watch for the copper chip of the lock nut see figure 8 31 Set screw Copper chip Lock nut Figure 8 31 Lock nut set Check if all bolts of the Y axis are tightened well Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Axes Systems 8 6 4 6 Y axis Linear Guide Replacement For replacing the Y axis linear guides please refer to figure 13 6 2 Remark For the Topaz the left driven side linear guide is different from the right drive side linear guide See spare parts list Right linear guide drive side When the right linear guide must be replaced it is recommended to remove the whole X axis beam After the X axis beam is removed adjusting the linear guides is done as follows 1 Remove the plate above item 17 2 Remove the right linear guide 23 by loosen the bolts holding the guide 3 Replace the old guide by new one 4 The distance between the nut holder item 8 and the centre of the bearings is defined by plate 2 in the X axis system see fig 13 6 1 This distance is 50mm 5 Set plate 2 on the nut holder item 8 and fix it to the rear bearing Move the plate to the rear of the system Fix the guide at the rear 6 Fix plate 2 to the front bearing and move plate 2 to the front of the system If the distance is set to 50mm then fix the rear of the linear bearing 7 Remove plate 2 Set a dial gauge to nut holder ite
267. uum and Pneumatic Systems CHAPTER5 Vacuum and Pneumatic Systems 5 1 Vacuum Systems 5 1 1 Introduction This chapter describes the vacuum systems which are used in the Topaz and the tray changer How to set vacuum levels of the machine like pickup vacuum mount vacuum etc is described in chapter 11 machine calibration 5 1 2 Functional Description The vacuum pumps of the Topaz and TC are based on the use of ejectors An ejector uses compressed air to create a vacuum Each head of the Topaz has its own ejector which can be switched on and off via an air valve inside the ejector pump As can be seen in the total air circuit diagram in chapter 14 the compressed air for the vacuum section is fed from the regulator and sent via a hose and a coupling to the ejector assy The vacuum level is sensed at the head I O 1 board please refer to the Head I O board logic diagram in chapter 3 T he ejector can be switched on off via the signals TH01 and 02 on the I O 1 head board The TC vacuum system uses 2 ejector units item 34 on the shuttle please refer to the spare parts drawings in chapter 13 8 Traverser assy and one ejector valve YV11 for the pick up head located on the head The vacuum on the shuttle pads can be switched on via the valves TRO1 and TRO02 item 30 in chapter 13 8 The vacuum on the head be switched by signal TR13 YV11 Interlock indicator needle Interlock adjustment kno
268. vice Manual Topaz 01 05 PA 1309 10 6 9 PCB Transport Systems 6 5 Locate Pin Two locate pins are available along the conveyor rail one fixed and one movable These pins engage with the positioning holes of the PCB to secure it in place ready for mounting To adjust the ascent descent speeds of the locate pins proceed as follows please refer to figure 6 13 and 6 14 lt 1 Direction of PCB flow Fixed located pin Movable locate pin Unclamped Clamped Locate pin slide dial lever Figure 6 13 Locate pin arrangement Locate pin Ascent speed adjuster Orange tube Black tube Rear right side of the Topaz Figure 6 14 Locate pin and air solenoid valve Service Manual Topaz 5322 871 63606 6 10 PA 1309 10 01 05 PCB Transport Systems 1 Open the output monitor screen figure 6 12 and operate the locate pins Select lt lt 3 MAINTE M gt gt gt lt lt 4 MANUAL gt gt lt C DISPLAY amp EXIT gt C1 OUTPUT MONITOR and press the ENTER key Use the arrow keys to line up the cursor with TN03 LOCATE PIN Press the ENTER key to alternately raise and lower the locate pins The output monitor digit reads 1 when the locate pins are at the raised position and reads 0 when they are at the lowered position Out Monitor T1 51 Select Enter Exec Selected Arm XY ESC Command Lists Moving Speed 100 TNO3 LOCATE DOWN 0 UP 1 NL11 0 NL11 1 NAME
269. vice Manual Topaz 5322 871 63606 9 14 PA 1309 10 01 05 Vision Systems Figure 9 19 Led driver board 3 Ensure safety then press the Enter key again The head assembly moves to above the single vision camera and measurement of brightness around the nozzle will start 4 Adjust the single vision camera lighting level with pot meter VR2 on the LED driver board second potentiometer from the bottom at the right side of the MCX controller Adjust the AveGrayLevel on the upper right corner of the screen to 32 3 If this value cannot be reached please adjust the aperture ring a little and try again 5 Press Esc or Enter to quit the adjustment There is no machine data to be saved in this adjustment Optional adjustment method 1 Select 3 3 Bl SingleCameralighting SingleCamera Front light gt 2 Follow the explanation on the VIOS monitor and adjust the LED driver board potentiometer VR2 3 Use the Light adjuster tool 5322 395 10274 4 Adjust the potentiometer so that the border between dark and bright is one full scale 64 levels Full Scale Figure 9 20 Forelight adjustment xm Finish the adjustment within 30 seconds because the lighting level becomes lower and lower Check the gap between dark and bright not the absolute value 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 9 15 Vision Systems 9 4 4 Camera Scale Adjustment For accurate recognition of
270. w and remove the flange and gear wheel by using a Philips screwdriver no 00 Mount a new gear wheel in the reverse direction Make sure that the gear wheel moves freely if turning it clockwise see arrow Gear wheel Figure 7 32 Replacing of the gear wheel small SD 2355 WPG Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Component Transport Systems i Bottom Surface Frequency Every feeder change Required time 0 1 hr per feeder Procedure Check if the bottom surface of the feeder is clean and free of mechanical damage Clean if necessary with the recommended equipment and materials j Lubrication Frequency Every 500 000 indexes Required time 0 1 hr per feeder Procedure Clean the 11 points that have to be lubricated fig 7 33 and remove all dust by using a vacuum cleaner Clean and remove if necessary old oil and dust with a lint free tissue paper brushes or Q tips moistened in denatured isopropyl 596 methyl alcohol has to be purchased locally Remark The fig 7 33 shows the mechanical feeder and not the FV feeder This is of no importance because most of the lubrication points are the same WARNING WHEN USING DENATURED ISOPROPYL OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS a KEEP CONTAINER CLOSED TIGHT WHEN NOT USED b KEEP AWAY FROM INFLAMMABLE SOURCES NO SMOKING c HARMFUL IF INHALED OR SWALLOWED d HIGHLY INFLAMMABLE e AVOID CONTACT
271. y Normally a movement distance of 5 millimetres is recommended 3 Enter the component database No and press the ENTER key Here enter the database No 6 you have edited previously 4 Ensure safety then press the ENTER key twice The head assembly moves to a point where Head 1 is ready to pick up a component 5 Press the emergency stop button then attach a QFP to Head 1 by hand Attach the QFP to the nozzle so that it is slightly off center in relation to the nozzle tip as long as the component does not go out of the field of view during component recognition 9 18 Service Manual Topaz 5322 871 63606 PA 1309 10 01 05 Vision Systems Figure 9 24 CAUTION When you use a rectangular QFP align the long side in parallel with the X axis 6 When the has been attached press the ENTER key 7 Cancel emergency stop Release the emergency button and press the READY button of the HHK 8 Ensure safety then press the ENTER key again Head 1 moves to above the single vision camera and the is displayed on the vision monitor The nozzle rotates so that the camera scale position and angle are calibrated five times The results are displayed in the upper right corner of the VIOS monitor lt lt MODE gt gt 3 MCH_ADJUST A377 Camera 1 lt lt lt Result gt gt gt Distance 5 00 The results of calculating the scales of the single Scale_x 83 33 vision camera are
272. y for head 1 can be disassembled into the parts 27 28 29 9 235 8 and 9 staring by removing the set screw item 27 When this assy is reassembled proceed as follows Apply molykote 6189 grease to packings item 8 and 9 Set packing item 9 into place using a small screw driver while taking care of the direction of the packing Insert packing item 8 into by using the special rocket tool 5322 395 10713 Insert packing item 9 on the same side as packing 8 Mount the whole assembly into place and close the assembly by means of screw item 27 5 The piston assy of the other heads is handled in the same way as for head 1 with the exception that the items 27 28 and 29 are not present 6 The plug 2 assy the bottom part can be disassembled into item 5 11 4 and again 5 When assembling this part take care the packing item 4 is greased with molykote 6189 and the direction of the packing is the same as when it was disassembled 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 8 35 Axes Systems Intentionally left blank 36 Service Manual Topaz PA 1309 10 5322 871 63606 01 05 Vision Systems CHAPTER 9 Vision Systems 9 1 Introduction This chapter describes the vision systems that are used in the Topaz 9 2 Vision Systems The standard model of uses following camera recognition equipment e A moving camera to recognise the PCB fiducial marks to be able to correct for any shifts in
273. y to reduce the conveyor speed The PCB does not reach the main stopper at all The soft stop function takes too much effect Open the front lower right panel of the machine you will see the two adjustment scres for the conveyor speed adjust the L screw to the right slightly to increase the conveyor speed A PCB transfer error PCB installation error occurs when a thick PCB is conveyed The locate pin will not rise adequately for a thick PCB or a PCB having a small reference hole so the sensor remians off Loosen the screw for the locate pin sensor and slightly lower its position Then check that the sensor turns on when the PCB is secured in place After the PCB has been conveyed in the mounting position the pins will not rise to secure the PCB the conveyor keeps The sensor at the PCB installation position is faulty or the PCB has a cutpout area just above the sensor so Check the sensor operation in the manual mode input monitor If the sensor is defect replace it If the sensitivity is too low adjust the height of the sensor turning the sensor cannot detect the PCB Table 6 9 1 Possible conveyor problem symptoms 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 6 19 PCB Transport Systems Intentionally left blank Service Manual Topaz PA 1309 10 5322 871 63606 01 05 Component Transport Systems CHAPTER 7 Component Transport S
274. ystems 7 1 Introduction This chapter describes the component transport system that is responsible for feeding and or transporting components 7 2 Head Assembly The head assembly figure 7 1 of the TOPAZ consists of eight in line heads This chapter describes how to check adjust and optimize air driven mechanical movements vacuum generation and machine data related to the head assembly see the table below Head descent movement Check that each head descends smoothly Head lower end detection Check that the lower end is correctly detected when each head descends Check that the vacuum ejector provides adequate vacuum levels Vacuum sensor function Check that the vacuum sensor display levels are correct Machine coordinates position These coordinates include the stand by point for the head and discard point for components Pick and mount vacuum levels The reference vacuum pressure suction is used to determine whether each head has picked up or mounted a component R axis absolute accuracy offset Angular offset for the R axis that rotates each nozzle shaft Nozzle correction This is used to correct an off center nozzle shaft when it rotates by 180 degrees Head offset The position of the heads related to fiducial camera These parameters are automatically corrected when you perform mount feedback described later in chapter 11 Machine Installation and Calibration Figure 7 Topaz head assembly
275. z 5322 871 63606 PA 1309 10 01 05 Vacuum and Pneumatic Systems 4 Install the removed valves onto the new valve base by following steps 3 and 4 the procedures Up Down valve replacement and Slow valve replacement Install the valve base and end blocks while taking care of the O rings 6 Tighten the bolts with a torque of 147 0 Ncm t SCREW 5322 360 10208 Rcommended torque VALVE 17 6 Nem 12 Up Down 55 360 10207 CL VALVE o ST GASKET Slow Ce 0 E gt i E 6 0 7573 sam 2 P y Rcommended torque SI 17 6 Nem E GASKET END BLOCKL END BLOCK 5322 464 10348 VALVE BASE 5322 530 10442 O RING 5322 530 10441 O RING JOINT BAR BOLT O Rcommended torque 147 0 Nem Figure 5 5 Head valves REMARK If there is a need to replace the end blocks separate code numbers are available in the spare parts list CAUTION Disconnect the power and air supply prior to replacing the valves 2 Confirm the torque of each removed bolt prior to reconnecting air and power 5322 871 63606 Service Manual Topaz 01 05 PA 1309 10 5 9 Vacuum and Pneumatic Systems Intentionally Left Blank Service Manual Topaz 5322 871 63606 5 10 PA 1309 10 01 05 PCB Transport Systems 6 PCB Transport Systems 6 1 Introduction This chapter describes the PCB transport system The PC
276. zle holder Then further lower the head until it stops in the nozzle holder Reference Turning the coupling assembly located between the motor and the ball screw allows for easy minute movement of the X axis and Y axis For the vertical movement of the Z axis it is advisable to gently press the metallic plate lower limit detection dog downwards or pull upwards attached to the nozzle shaft 8 Check the X Y Z1 and coordinates Make a note of the readings displayed on the bottom of the output monitor screen 9 Open the nozzle station coordinates screen Select 3 2 A Al SELECT TARGET Nozzle Station and press the ENTER key 5322 871 63606 01 05 Service Manual Topaz PA 1309 10 7 19 Component Transport Systems 10 Enter the X Y 71 and coordinates Enter the X Y 71 and R1 coordinates you made a note of in Step 8 along the Nzl Station 1 row Editing Object Nozzle Station Nzl Station No x Y Z R Nzl Type HeadNo Nzl Station 1 13 78 57 33 74 62 59 44 TYPE 34 Head Nzl Station 2 20 13 32 33 174 54 57 95 Head Nzl Station 3 29 50 19 00 69 0 57 21 33 Head Nzl Station 4 19 44 5 72 7463 5971 TYPE 3F Nzl Station 5 29 50 6 00 69 00 57 21 Head 1 Station 6 6 75 3940 76 64 57 97 TYPE 3F Head2 1 Station 7 43 50 34 00 69 00 18 36 T

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