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hqi® illumination module service manual and troubleshooting guide

1. 36 8 2 1 How to Remove the Illumination Module from the Lamp Box 37 8 2 2 How to Install the Illumination Module into the Lamp Box 37 8 2 3 How to Replace HQI Lamp 38 8 2 4 How to Replace a Fan of the Illumination Module 42 8 2 5 Howto Replace a Fan the Lamp Box 44 8 3 coe ERU PE EMG ees 45 8 3 1 How to Replace the Power Supply Unit 45 8 3 2 How to Replace the ICU 47 8 3 3 Howto Replace the Rotary Solenoid 49 8 3 4 How to Replace a Fuse of the Illumination Module 51 8 3 5 How to Replace a Fuse the Lamp 52 8 3 6 How to Replace the Master Switch 53 8 3 7 How to Replace the IR Cut Filter of the Illumination Module 54 8 3 8 How to Replace the Temperature 56 8 3 9 How to Replace the Line Connector 58 Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 iii 9 Rom m RR Dn DR ede 59 9 1 How to Detect That an Error Occurred Is
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7. T T T T T 200 180 160 140 120 100 Substrates 17 08 2005 14 57 42 220105 Inspection has been canceled 17 08 2005 14 57 18 220008 Inspection has been started 17 08 2005 14 57 12 220105 Inspection has been canceled 17 08 2005 14 56 43 220008 Inspection has been started 17 08 2005 14 56 42 220105 Inspection has been canceled 17 08 2005 14 56 21 220008 Inspection has been started 17 08 2005 14 56 13 220105 Inspection has been canceled Information 17 08 2005 14 55 52 220008 Inspection has been started G Information 17 08 2005 14 55 43 220105 Inspection has been canceled Fig 2 Line Scan Controller Fig 2 For service purposes select the Illumination button in Line Scan Controller An Illumination Control window will appear which among other things displays the intensity operating time temperature and the output control voltage of the illumination modules You can also switch lamps and shutters in the Illumination Control window For details on the Illumination Control window refer to Section 7 on page 33 Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 2 Functional Description 9 2 3 1 Filters The illumination module can be equipped with up to three optical filters in order to adapt the wave length characteristics of the light In the bright field illumination application a Calflex B1 K1 IR cut filter is inserted at position 1 and a diffusor
8. 4315 8 50027705 XX6811000 Ja1seg Josuas jisuajul ajqej 0670200001 30 LL 1 60 8 Jaquinu Je d JaJn432e jnueyw 9 Saluas dy 1043auuo3 aBuejJ 4 22590 7170700001 Jaquinujuap AW00018501000 Revision History Revision History 73 Document Number Date Changes 00018501000 13 Feb 2007 Initial release version of this manual Continued from DB00015106 For Basler SENSIC software version 9 0 0 0 General corrections or additions New Basler Inc address back of front page Telephone and fax numbers will remain the same Revised instructions in Section 8 2 3 on page 38 Table 9 Revision History Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 74 Revision History AW00018501000 Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 Index CAN bus 66 circuit diagrams 71 13 D coerente eee 16 E electric service documentation 71 event log viewer 59 F AS RR ME RT NS 13 18 replacing nt 42 MINE 16 54
9. 33 SAUTER nettes 17 spare 5 specifications 7 T temperature 17 replacing uere nes 56 troubleshooting 59 Basler SENSIC HQI Illumination Module AW00018501000 Copyright 2007 by Basler AG
10. 19 18 17 16 15 14 13 12 11 Fig 3 Internal Components Top View 1 24 V DC power supply for fan no 1 2 230 V power out to the power supply unit 3 230 V power in Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 12 3 Hardware Components AW00018501000 4 Shorting plug 5 24 V DC additional power connection not used 6 CAN bus connector not terminated 7 Rotary solenoid with blade bright field only 8 Fiber connection 9 Filter holder 10 IR cut filter in position 1 bright field only Not shown in Fig 3 Diffusor in position 2 bright field only HQI lamp Analog input port no 1 intensity sensor Operating hours reset button Connector for HQI lamp s power supply Analog input port no 4 temperature sensor Power supply unit 11 12 13 14 15 16 17 18 Digital output port shutter 19 Digital input port reset status reset operating hours status power supply unit 20 RS 232 connector only used for changing firmware 21 Potentiometer for adjusting the intensity sensor 22 Dip switch for setting the CAN mode ID 23 Illumination control unit ICU This board controls all functions of the illumination module ae a ae a ae Analog output port HQI lamp power Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 3 Hardware Components 13 3 1 2 Fans Fuses
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12. TT 18 10 Intensity 19 11 Lamp Box 20 12 Cabling 4 20 13 Illumination Module 27 14 HQI Lamp Lever 29 15 HQI Lamp Adjustment Screw 30 16 Illumination Control Menu 33 17 Removal of Illumination 37 18 Replacing the 38 19 Replacing a Ventilation 42 20 Mounting Screws for the Fans at Rear Side 43 21 Power Supply 46 22 Replacing the IGU oos ua n x Eu eae ee Ada 48 23 Rotary Solenoid 5 hoyo E Re See es PPA Gas te Fee eee ae 50 24 FUSES 2 2 oda 3 Eb Pw oe Eee Pea awe Deeds pa eee eed KE YF 51 25 IR Cut Fier ananas eek e eL ele RO 54 26 Temperature Sensor Analog Input 56 27 Temperature
13. 56 28 Status 60 29 Temperature Sensor 61 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module vi List of Figures Basler SENSIC HQI Illumination Module AW00018501000 Copyright 2007 by Basler AG AW00018501000 List of Tables vii List of Tables Table 1 Technical Specifications of HQI 7 Table 2 Illumination Control Parameter 08 21 Table 3 CAN Node 105 x ete db geeks eased dow iP PEE GO GE Rp bx ta 26 Table 4 Maintenance 36 Table 5 Event 59 Table 6 Indications of Operating Hours LED 2 61 Table 7 Indications of Temperature 61 Table 8 Indications of Intensity LED 62 Table 9 Revision HISLOTY EX x ____________ 73 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module viii List of Tables AW00018501000 Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 1 Safety Instructions 1 1 Safety Instructions 1 1 Conventions Used in This Manual The following symbols are used for safety
14. HEALTH RISK Never inhale swallow or get in skin contact with mercury or mercury compounds Inhaling mercury or mercury compounds in vapour or powder form can lead to health problems Mercury can also be absorbed through the skin Only operate the lamp if the bulb is intact If broken intensive UV radiation will be released and damage your eye or skin PROTECTION AGAINST LAMP BREAKAGE To avoid health risks the manufacturer recommends the following procedure in the event of a lamp exploding or lamp breakage Everyone in the immediate vicinity should leave the room as quickly as possible to avoid inhaling mercury vapour The room should be carefully ventilated for 20 to 30 minutes at least Once the luminaire has cooled down and certainly before it is used again all residual mercury must be thoroughly removed from the inside of the luminaire To avoid contact with the skin use disposable gloves Clear up liquid mercury using a cloth dampened with a commercial adsorption agent that contains a tenside See Section 1 5 on page 4 for disposal information FIRST AID If you inhale swallow or get in skin contact with mercury or mercury compounds observe the following first aid measures First aid personnel Avoid contact with mercury or mercury compounds After inhalation Fresh air If required artificial respiration Immediately consult a doctor After skin contact Wash the mercury off with much water Remove conta
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16. HQI amp ILLUMINATION MODULE SERVICE MANUAL AND TROUBLESHOOTING GUIDE Document Number AW000185 Version 01 Language 000 English Release Date 13 February 2007 SENSIC Software Release 9 0 0 0 Serial Number 2 This Manual This manual is designed to give service instructions and troubleshooting information for the Basler SENSIC illumination module It contains important information on how to service the illumination module safely properly and most efficiently Observing the manual helps to avoid danger to reduce repair costs and downtime and to increase the reliability and life time of the light source The manual must be read and applied by any person who sets up services or troubleshoots the illumination module The manual must always be available wherever the lillumination module is in use For a full description of the Basler SENSIC inspection system and its capabilities this document must be used together with the Basler SENSIC hardware operating manual software operating manual service manual and troubleshooting guide Warranty Basler AG is not liable for damage caused as a consequence of disregarding this manual In addition the warranty may become void Copyright All material in this publication is copyright Basler Vision Technologies All trademarks and registered trademarks are the property of their respective owners Basler Technical Support Europe Headquarters Basler Vision Technologie
17. PM x 709S1L00P 7007 9011 apis 73 ade 2105 NOILdO LVE LA6 21004428 8 5 Lez ses q 709S1L00P euB o jusuae doy payepdn aJnjonJJs 9 saiboj ouu3a 4461 DH 315 8 gt CIEL LIEZ J8JunD g 18 2 wut L 7000174 EEN 310044238 8 JN NJJS JO 9 payepdn saiBojouyja 4451 10H ke LOEX 31579 c0 X 70 94 00 0021 6 LEE 15 L 4460 0 1 pajepdn saibo ouu2a UOISIA J94UDD d wur Cunsvea 50027705 Xx68110002 181584 58 Josuas jisuajul 0670200001 XX Ja seg JOJIBUUOI jejuoziJou OLA 4 159 9568100001 XX06LL00P3 Ja1seg 91985 0014 06100001 XXG611000 Ja seg 6 000 Ja seg XX9611000 Ja1seg 00 8 66 obeM Sf 8192 ul JaMod uul UIJIMS 4 S Y S 06100001 LE06L00001 8706100001 XX9 611000 Ja seg 006 UJIMS 8594 1706100001 Ja seg JISN3S 52100 4
18. Event Messages Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 60 9 Troubleshooting AW00018501000 ID Description Severity Explanation Action 220065 Illumination module Error No communication See Section 9 2 3 on page 64 NodelD OXxx S N between illumination yyyy Rev zzz is module and Line Scan not responding Controller via CAN bus is possible xx CAN node ID of the illumination module yyyy serial number of the illumination module serial number of the ICU within the illumination module zzz revision of the ICU firmware Table 5 Event Messages 9 1 2 Status LEDs Fig 28 Status LEDs 1 Status reset button To be pressed before restarting the illumination module after an error has occurred and its cause is removed 2 For future use 3 Operating hours of HQI lamp 4 Temperature close to the fiber connector 5 Intensity of HQI lamp A green LED signals that the status is OK A red LED signals a critical condition see Sections 9 1 2 1 on page 61 to 9 1 2 3 on page 62 Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 9 1 2 1 Operating Hours 9 Troubleshooting 61 LED Status Action Red HQI lamp operating hours have reached error threshold of 6 000 hours Replace HQI lamp immediately See Section 8 2 3 on page 38 Red flashing HQI lamp operating hours have reached warning threshold of
19. Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 55 4 Fig 25 Remove the old IR cut filter 1 from the filter holder 2 Install the new IR cut filter in the same position in the filter holder as the old one Make sure that the coated side of the IR cut filter faces the HQI lamp 6 Install the lid of the illumination module 7 Close and lock the lid with the quarter turn fastener 8 Lock in and turn on system power Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 56 8 Maintenance and Repair AW00018501000 8 3 8 How to Replace the Temperature Sensor Fig 26 Temperature Sensor Analog Input Cable Fig 27 Temperature Sensor Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 57 Danger HAZARDOUS VOLTAGE Danger of electric shock Turn off and lock out system power before servicing Danger BRIGHT LIGHT The HQI lamp emits very bright light which can be harmful to your eyes Never look into the light Never open the illumination module while the light is still switched on To replace the temperature sensor Turn off and lock out system power Open the servicing lid of the lamp box Disconnect the mains supply cable and the CAN bus cable of the illumination module Bee Carefully unscrew the four mounting screws that connect the illumination module to
20. and illumination module is disrupted nection 2 Restart Line Scan Controller With the aid of the not mandatory PeakCanView software check whether CAN messages can be sent to the illumination module and whether the module is responding correctly Which event messages Illumination module s logged off due to high 1 If applicable remove occurred before illumination bus load 5 5 1 ose Line Scan Controller 90989 of 3 Start the PeakCanStat soft With the aid of the ware and if applicable PeakCanView software check close all CANLib objects whether CAN messages can 4 pou Line Scan Control be sent to the illumination module and whether the module is responding correctly HQI illumination module is defective 1 Disconnect CAN bus con nection of the potentially defective illumination mod ule 2 To avoid this problem from arising again the defective illumination module must be replaced Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 9 2 4 HQI Lamp Cannot Be Switched On If the HQI lamp cannot be switched on check the following 9 Troubleshooting Check Result Action Whether lamp status is not cooling down LED blinks slowly Lamp status is cooling down Wait until HQI lamp has cooled down status LED is off and switch the HQI lamp on again Whether operating time of the HQI lamp has expired Operating time
21. 10 1000 Ja seg dz nig 6706100001 XxX961L000 Ja1seg WWOEL YIJIMS jasay 8706100001 XxX961L000 Ja seg XX 0210003 Ja seg XX2021000J Ja seg 006 JMS jasay uuo due ajqe uug z NV 9192 1706100001 670610000 7706100001 XXLOZLOOQJ Ja seg wwozz 4 2 1706100001 XX0021000J Ja seg 81482 0706100001 XX661 0002 Ja seg 81482 6 06100001 XX861 0002 Ja1seg uuez 91922 8 06100001 XXL61L000 Ja seg ul JaMod ajqe 106100001 XXG61L0003 Ja seg 00 8 obeM Sf 8142 SE06100001 XXZ6LL00P2 Ja1seg XXL 6LLOOP2 Ja seg XX0611 00P3 Ja1seg XXE6LL00P2 Ja seg Snid Sf ue 319282 0014 095 EEL 5 9102 6206100001 8206100001 706100001 0206100001 XX Ja seg J0428uU02 jejuoziJOu OLA 4 1569 pJeog 9568100001 80L L 7 WY j dg oniy 0 2 02 5568100001 Ja seg JISN3S 5210 4 j Alquesseqns 1568100001 90 1 0926N3 43N34VH2S Jaquinu Je d JaJn42e jnuey pajes jodiq 13411 4 4 22590 1768100001 Jaquinujuap LEE 096LL00P3 4511 JapJQ lt jeuJajul euB o No 1 pajepdn saibo ouu2a UOISIA
22. 13 51 H HOU aM pit E 7 POSION sericis 29 teer eet 38 ICU replacing 47 illumination 51 installing eee 37 remoVvirig 37 intensity sensor 19 IR cut filter replacing 54 Copyright 2007 by Basler AG Index 75 L 20 LEDS Rd ns 14 intensity 62 operating time 61 temperature 61 troubleshooting 60 line connector replacing 58 M maintenance 35 master switch replacing ad ini 53 mounting Unit 20 N node IDS 26 5 56 ed 31 parameter settings in Parameter Set Manager 21 using 66 niet tisse 66 PDOs HQI lamp and shutter control 70 power distribution 20 power distribution and mounting unit 20 power supply 15 replacing ertt rens 45 R eS 35 45 45 rotary solenoid replacing et 49 Basler SENSIC HQI Illumination Module 76 Index S i em
23. 4 1 6 Hot Surface dum epe TRE Aere EE eer RE 4 1 7 Bright danse RR EE 4 1 8 Maintenance Service and Repairs 5 1 9 Spare 2 5 2 Functional 7 2 1 Generale uta IC 7 2 2 Technical Specifications 7 2 3 Basic Operation 8 2 9 1 ah ae nes ie hide 9 2 3 2 Temperature 9 2 3 3 Intensity 4 9 2 3 4 Closed Loop Control 9 2 35 Status 5 9 3 Hardware Components 11 3 1 Where to Find Which 11 3 1 1 Internal Components 11 3 1 2 Fans Fuses and Connectors 13 3 153 Status LEDS ee 200 5044 eme xe S TED 14 3 1 4 Power Supply 15 3 2 Power Supply Unit
24. About to Occur 59 9 1 1 Event Log 59 97 22 Status 25590 ee 60 9 1 2 1 Operating Hours 61 9 1 2 2 Temperature 61 9 1 2 3 Intensity 62 9 2 Lamp Switched Off 1 63 9 2 1 Overheating Temperature 63 9 2 2 Operating Hours Operating Time 63 9 2 3 HQI Module Not Responding 64 9 2 4 HQI Lamp Cannot Be Switched 65 9 3 Shutter 65 9 4 How to Set Parameters from a Notebook 66 9 4 1 How to Send CAN Bus Messages from a Notebook 66 9 4 2 Parameter Settings via CAN 67 9 4 2 1 Operating Time 0 67 9 4 2 2 Operating Time 67 9 4 2 3 Temperature 68 9 4 24 MENSI 4 2212 E desert same EX 68 9 4 2 5 How to Store Parameter 69 9 4 2 6 How to Restore Def
25. Make sure the power switch of the lamp box is switched off Open the revision opening in the lamp box Insert the illumination module into the lamp box Fasten the illumination module with 4 screws M6x12 Plug the CAN bus connectors of the lamp box to the respective bushes of the illumination module refer to the electric circuit diagram Connect the cold appliance connectors of the lamp housing to the respective bushes of the illumination module refer to the electric circuit diagram Close the revision opening of the lamp box Close the lid of the illumination module Connect two CAN bus cables to the respective sockets of the lamp box Alternatively you can connect one CAN bus cable and a terminating resistor Switch the main switch of the lamp housing on The result is the following The illumination modules go into pre operational mode Fan no 1 4 of each illumination module is running The lamps are still out Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 5 Initial Start Up 29 5 2 How to Position the HQI Lamp Fig 14 HQI Lamp Lever Each time you replace an HQI lamp make sure that it is positioned correctly Fig 14 The HQI lamp is mounted on a spring lever 1 which allows adjusting the bulb s height to maximize the intensity of the light You adjust the lamp with the adjustment screw under the fiber connector Fig 15 3 To adjust the height pr
26. an HQI lamp is 9 000 hours Frequent switching on and off can reduce the lifetime of the lamp considerably as frequent cooling down and heating up cause stress to the material A warning Operating Time message is displayed after 5 000 operating hours of the HQI lamp This time is set by parameter To guarantee an efficient operation of the entire system the respective HQI lamp should be replaced shortly after the Operating Time warning message Components that have to be replaced regularly due to wear and tear are HQI lamp e fans of the illumination module fans of the power distribution and mounting unit that holds the illumination modules Observe the maintenance intervals listed in table 4 Typical Rate What to do See every 5000 to 6000 operating Replace the HQI lamp Section 8 2 3 on page 38 hours every 35 000 operating hours In each HQI illumination module and the power Section 8 2 4 on page 42 when operated at max distribution and mounting unit replace the Section 8 2 5 on page 44 temperature to 70 000 fans operating hours room temperature Table 4 Maintenance Intervals Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 37 8 2 1 How to Remove the Illumination Module from the Lamp Box Fig 17 Removal of Illumination Module When changing an lamp it is necessary to remove the respective illumination
27. at position 2 by default for details refer to Section 3 3 on page 16 2 3 2 Temperature Control To avoid damage to the fiber connector of the illumination module due to excessive heat a temperature sensor is located close to the fiber connector This sensor switches the HQI lamp off as soon as the temperature at the sensor reaches 100 C 2 3 3 Intensity Control You can vary the intensity of the HQI lamp between 85 and 125 A photo diode located close to the fiber connector measures the actual output intensity 2 3 4 Closed Loop Control When closed loop control is switched on the signal of the intensity sensor is compared with the target value by a PI control unit which calculates the control signal for the HQI lamp s power supply unit When closed loop control is switched off you can set the control signal for the HQI lamp s power supply unit directly 2 3 5 Status LEDs The illumination module permanently monitors its own operational status For details refer to Section 3 1 3 on page 14 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 10 2 Functional Description AW00018501000 Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 3 Hardware Components 11 3 Hardware Components The HQI illumination module consists of the following components 3 1 Where to Find Which Component 3 1 1 Internal Components 23 22 21 20
28. disconnect all wires from the master switch 5 Remove the rotary handle of the master switch by unscrewing its fastening screw and tearing off the handle 6 Unscrew and remove the four mounting screws of the master switch and remove it 7 Install the new master switch and fasten the four mounting screws 8 Fasten the rotary handle to the new switch 9 Connect the wires to the new master switch as described in the electric circuit diagram 10 Check whether the wiring is correct 11 Cover the contacts with the blind 12 Insert the DO1 fuses again 13 Close the service lid 14 Lock in and turn on system power Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 54 8 Maintenance and Repair AW00018501000 8 3 7 How to Replace the IR Cut Filter of the Illumination Module IR cut filters are used in bright field illumination only Fig 25 IR Cut Filter 1 2 Danger HAZARDOUS VOLTAGE Danger of electric shock Turn off and lock out system power before servicing Danger BRIGHT LIGHT The HQI lamp emits very bright light which can be harmful to your eyes Never look into the light Never open the illumination module while the light is still switched on To replace the IR cut filter 1 Turn off and lock out system power 2 Open the lid of the illumination module by turning the quarter turn fastener 3 Remove the lid of the illumination module Basler SENSIC
29. fans are on different locations in the illumination module Fan 1 CD001191 SAP No 1000019028 the connector 1 is located on the ICU Fan no 2 CD001192 SAP No 1000019029 the connector is located on the power supply unit 2 So before disconnecting the power supply you have to remove the ICU mounting plate 4 by unscrewing its six mounting screws 3 Fig 20 Mounting Screws for the Fans at Rear Side Fig 20 Unscrew and remove the four mounting screws 1 together with the ventilation grilles of the respective fan Take out the fan and insert the new one Insert and fasten the four mounting screws 1 together with the ventilation grille Reconnect the 24 V DC power supply of the fan If you have changed fan no 2 reinstall the ICU mounting plate and fasten its six mounting screws Fig 19 3 Insert the lid and fasten the quarter turn fastener Insert the illumination module into the power distribution and mounting unit and fasten the mounting screws Connect the CAN bus cable 15 Connect the mains supply Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 44 8 Maintenance and Repair AW00018501000 16 Close the service lid of the power distribution and mounting unit 17 Turn the power on 8 2 5 How to Replace a Fan in the Lamp Box Fans are located inside the power distribution and mounting unit lamp box Their number depends on the number of HQI illumination modul
30. field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings 0 to 1200 Default setting 120 Recommended setting 300 LIGHT GROUP ILLUMINATION COOLDOWN PERIOD 0 19 i e 20 groups of illumination modules can be parameterized Time in seconds the lamps of the specified light group need to cool down Index ID of the light group 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings 0 to 1 200 Default setting 300 Recommended setting depends on the type of lamp HQI lamp 480 fluorescent lamp 10 LIGHT GROUP HEARTBEAT INTERVAL 0 19 i e 20 groups of illumination modules can be parameterized Time interval in seconds the ICUs of the specified light group send a heartbeat message Index ID of the light group 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings 0 to 1200 Default setting 0 Heartbeat disabled Recommended setting 10 Note It is strongly recommended to enable heartbeat messages When disabled 0 the status of the light group will not be monitored That is no lamp failure will be reported LIGHT GROUP INTENSITY CONTROLLER KP 0 19 i e 20 groups of illumination modules can be parameterized P
31. instructions and other important notes Danger Refers to orders and prohibitions designed to prevent injury or extensive damage Danger TOXIC MATERIAL Refers to orders and prohibitions designed to prevent injury caused by toxic material Danger Refers to orders and prohibitions designed to prevent injury caused by touching hot surfaces Danger Refers to orders and prohibitions designed to prevent injury or extensive damage caused by high electric voltage Danger Refers to orders and prohibitions designed to prevent injury caused by bright light Caution Refers to special information and or orders and prohibitions directed towards preventing damage Note Provides special information on how to use the system most efficiently Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 2 1 Safety Instructions AW00018501000 1 2 Designated Use The illumination module is exclusively designed to be used in a Basler SENSIC inspection system Using the illumination modules for purposes other than those mentioned above is considered contrary to its designated use The manufacturer supplier cannot be held liable for any damage resulting from such use The risk of any misuse lies entirely with the user Operating the illumination module within the limits of its designated use also involves observing the instructions set out in this manual and complying with t
32. is higher than the error operating time Replace respective HQI lamp Whether a short flash of light can be seen when the lamp is switched on A short flash of light can be seen The cabling to the HQI lamp s power supply unit may be defective Check the cables from the power supply unit to the HQI bulb Replace the power supply unit if required 9 3 Shutter Doesn t Work If the shutter does not work check the following Check Result Action Whether shutter can move freely Shutter does not move freely Adjust shutter Whether voltage is applied proceed as follows Switch shutter on via Service dialog box Measure voltage on corresponding digital output port Voltage on corresponding digital output port is gt 20 V No voltage on corresponding digital output port Replace rotary solenoid Replace ICU Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 65 66 9 Troubleshooting AW00018501000 9 4 How to Set Parameters from a Notebook Normally you carry out all parameter settings in the machine parameter set in Parameter Set Manager If one of the following problems occurs and you cannot find the reason you should try to modify parameter settings by sending CAN messages from your notebook Problems with intensity control Problems with CAN bus communication See Section 9 4 1 on page 66 for general instructions
33. module out of the lamp box Unfasten the quarter turn fastener and remove the service lid Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 48 10 11 12 13 14 8 Maintenance and Repair AW00018501000 2 Fig 22 Replacing the ICU Fig 22 Disconnect all cables from the ICU mounting 2 Unscrew and remove the six mounting screws 1 Remove the ICU 2 Insert the new ICU Make sure that the DIP switch settings of the new ICU are the same as for the old ICU identical CAN Node ID Insert and fasten the six mounting screws 1 Connect all cables to the new ICU Refer to the circuit diagram for correct assignment Insert the lid and fasten the quarter turn fastener 15 16 17 18 19 Insert the illumination module into the lamp box and fasten the mounting screws Connect the CAN bus cable Connect the mains supply Close the service lid of the lamp box Lock in and turn on system power Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 49 8 3 3 How to Replace the Rotary Solenoid The rotary solenoid is shown in Fig 23 5 on 50 Danger HAZARDOUS VOLTAGE Danger of electric shock Turn off and lock out system power before servicing Danger BRIGHT LIGHT The HQI lamp emits very bright light which can be harmful to your eyes Never look into the light Never open the illumination module whi
34. on 26 4 1 Parameter Settings Basler SENSIC inspection systems come with a factory set of illumination control parameters that has been tested at Basler factory and normally requires no further modifications at the customer s premises You find the parameters in the machine parameter set in the illumination category If modifications to the illumination control parameters are required go through table 2 in the given order The table is ordered by parameter UID Parameter Index Description ILLUMINATION MODULE _ 0 100 i e 101 illumination CAN Node ID of illumination module CAN NODE ID modules can be See Section 4 2 on page 26 parameterized ILLUMINATION MODULE _ 0 100 i e 101 illumination Assignment of illumination module to light group LIGHT GROUP modules can be Index ID of illumination module parameterized Range of possible settings 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission LIGHT GROUP INTENSITY _ 0 19 i e 20 groups of Intensity target value of all illumination modules TARGET VALUE illumination modules can of the specified light group in decimal numbers be parameterized Index ID of the light group 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings O to 2000 Default setting 1000 Setting depends on type of line scan station and t
35. on how to send CAN bus messages In Section 9 4 2 on page 67 you can find a list of the parameters that can be changed To calibrate the illumination module use a notebook PC 9 4 1 How to Send CAN Bus Messages from a Notebook To send CAN bus messages from your notebook PC to the illumination module you may use the USB CAN Bus Adaptor in combination with the PCAN View software To establish communication between your notebook PC and the illumination module proceed as follows To establish communication 1 Disconnect the CAN bus cable from the illumination module 2 Connect a USB CAN bus adaptor with another CAN bus cable to the illumination unit Alternatively remove one of the terminators from the CAN bus and connect the USB CAN bus adaptor instead 3 Send and receive CAN messages using the PCAN View software Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 9 Troubleshooting 67 9 4 2 Parameter Settings via CAN Bus The following parameters can be set via CAN messages Operating Time Warning 67 Operating Time Error 67 Temperature Error 68 Intensity 68 To store or restore parameter changes see Sections 9 4 2 5 on page 69 and 9 4 2 6 on page 69 9 4 2 1 Operating Time Warning The operating time warning message informs the operator that the estimated operating time of the HQI lamp is about to expire To grant a certain time window where the HQI lamp can be c
36. value of the parameter for the maximum temperature is 100 C Check for obstructions in the cooling air flow of fan no 2 Remove obstructions if required Check whether fan no 2 works properly Replace fan no 2 if required 3 You have to press the reset button 3 in Fig 28 on page 60 on the rear side of the illumination module before you can restart it 9 2 2 Operating Hours Operating Time Error If the Operating Time warning after 5 000 operating hours of the HQI lamp is ignored and the lamp is not replaced the error message Operating Time appears after 6 000 operating hours This indicates that the HQI lamp now definitely has to be replaced Otherwise there will be an error due to lamp failure To remedy operating time error 1 Change the HQI lamp as described in Section 8 2 3 on page 38 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 64 9 Troubleshooting 9 2 3 Module Not Responding AW00018501000 If communication between illumination module and Line Scan Controller via CAN bus is not possible check the following Check Result Action Whether status LEDs of the Power supply of the illumination module is Reestablish power supply illumination module are off disconnected 2 Restart Line Scan Controller not mandatory Whether the CAN bus cable is CAN bus connection between line scan PC 1 Reestablish CAN bus con connected properly IPC
37. while the light is still switched on To replace the power supply unit Bog m oc Turn off and lock out system power Open the servicing lid of the lamp box Disconnect the mains supply cable and the CAN bus cable of the illumination module Carefully unscrew the four mounting screws that connect the illumination module to the lamp box Make sure the illumination module does not fall off Take the illumination module out of the lamp box Unfasten the quarter turn fastener and remove the service lid Fig 19 Remove the ICU mounting plate 4 by unscrewing its four mounting screws 3 Now you can access the power supply unit 3 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 46 8 Maintenance and Repair AW00018501000 Fig 21 Power Supply Unit 8 Fig 21 Disconnect all plugs connected to the power supply unit 1 9 Unscrew and remove the four standoff screws 2 which fasten the power supply s mounting plate to the illumination module housing 3 10 Remove the power supply unit 1 from the illumination module housing 3 In case you install a power supply unit of an older making that comes without a mounting plate proceed as follows Remove the old power supply unit from its mounting plate Attach the new power supply unit to the mounting plate Make sure that there is a sil pad between the power supply unit and the mounting plate 11 Insert the new power s
38. 5 000 hours Replace HQI lamp in the near future See Section 8 2 3 on page 38 Green HQI lamp operating hours below warning threshold of 5 000 hours No action required Table 6 Indications of Operating Hours LED 9 1 2 2 Temperature To protect the illumination module from overheating the illumination module is equipped with a temperature sensor 1 close to the fiber connector If an overheating condition is present this sensor triggers a switch off of the HQI lamp and sends error messages to the operator and the SENSIC application Additionally the temperature status LED 2 on the rear side of the illumination module turns red This status LED indicates the following temperature conditions table 7 Fig 29 Temperature Sensor 1 LED Status Action Red Temperature level has become critical Refer to Section 9 2 1 on page 63 Illumination module has switched off Red flashing Temperature has been critical but has cooled down by now Find out the cause for the temperature increase and rectify Acknowledge that the illumination module is OK by pressing the status reset button Fig 28 1 Green Temperature level OK No action required Table 7 Indications of Temperature LED Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 62 9 Troubleshooting 9 1 2 3 Intensity AW00018501000 LED Status Action Red Intensi
39. 915 0 uug z NV 9192 6981000001 0611000001 7706100001 XX 16 000 Ja seg JOA7Z 408 720 Jaubew Asejoy 56810000 0 2 7 144 LINGNVd OL AZ A 2 13 51990 6708100001 69d 1573 UUE uus JIH 69d 9514 95 ZIW NN 1052000001 70 11 167 lt 60 30 18 J0438uuo3 eDue J 211020000 XXE6LL00P2 Ja seg 7 EL obeM sf 3192 0206100001 SOL 9217 18483 dde HM 500 Ar 3M 616100000 200 9217 jaqey dde 00 92 7 18483 dde 100 9217 aqey dde 5 20 Ng 520 AIT 9JIM uugz AT 9JIM LAG 40 jJed 55000001 6661000001 5661000001 XXL0cLOOQJ Ja seg 077 4 2 J3MOd 17106100001 80 0 5 797 0671 1Sdvd 819500000 XXL 6LLOOP2 Ja seg bnjd uey 8206100001 Jaquinu Je d JaJn42e jnueyw 20 ggs Jo 4ed 1141125 Jaquinujuap LEE No 4 pajepdn L saibo ouu2a UOISIA J94UDD d uu 4451 10H 50027705 0 2 7 1344 LINGNVd OL AZA 2 13 51990 6708100001 01 A A 771 13 LINGNVd OL AZA 2 13d 51992 JINPUEd 670EL00001 OL ACA 4 13 LINGNVd OL AZA 2 Tdd 51992
40. C HQI Illumination Module 20 3 Hardware Components AWO00018501000 3 9 Power Distribution and Mounting Unit Lamp Box Fig 11 HQI illumination modules are mounted to a power distribution and mounting unit lamp box for short Fig 11 shows an example Several illumination modules 1 are grouped to generate light Number of modules and design of the unit vary depending on the inspection system The light is transported via optical fibres not shown in Fig 11 to the illumination bar in the sensor unit that illuminates the scan line on the substrate Each power distribution and mounting unit has a separate main switch 3 to connect or disconnect power to the unit 3 9 1 Mounting Sub Unit The illumination modules are fastened on the unit 2 3 9 2 Power Distribution Sub Unit Fig 11 Lamp Box Example The illumination modules are connected to the power distribution unit 2 of the lamp box Fig 12 In the power distribution unit of the illumination unit you find the cabling for power distribution to the illumination modules Fig 12 Cabling Example Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 4 Parameter Settings 21 4 Parameter Settings The following parameter settings in the machine parameter set are used to control the illumination modules An illumination module can be an illumination module or a fluorescent lamp Also see the note box
41. ERATING 0 19 i e 20 groups of TIME ERROR THRESHOLD illumination modules If the operating time of an illumination module of the specified light group is higher than this threshold in hours an error occurs Index ID of the light group 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings O to 20000 Default setting 6000 Recommended setting depends on the type of lamp HQI lamp 6000 fluorescent lamp 6000 CONTROL INTERVAL LIGHT GROUP INTENSITY 0 19 i e 20 groups of illumination modules can be parameterized Interval of the ICU control cycle in milliseconds Index ID of the light group 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings O to 60000 Default setting 768 Recommended setting depends on the type of lamp HQI lamp 768 fluorescent lamp 0 Table 2 Illumination Control Parameter Settings Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 24 4 Parameter Settings AW00018501000 Parameter Index Description LIGHT GROUP _ ILLUMINATION WARMUP _ PERIOD 0 19 i e 20 groups of illumination modules can be parameterized Time in seconds the lamps of the specified light group need to warm up Index ID of the light group 1 bright
42. T operating hours L earmarked for future use U 14 Display whether shutter is open yellow or closed gray 15 Display whether HQI lamp is switched on yellow or off gray Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 35 8 Maintenance and Repair 8 1 Safety Danger HAZARDOUS VOLTAGE Danger of electric shock Turn off and lock out system power before servicing Danger TOXIC MATERIAL Refers to orders and prohibitions designed to prevent injury caused by toxic material Danger BURN HAZARD Due to the powerful HQI lamp components of the illumination module can get very hot You can suffer serious burns if you do not let the illumination module cool down for 30 minutes before touching its components Danger BRIGHT LIGHT The HQI lamp emits very bright light which can be harmful to your eyes Never look into the light Never open the illumination module while the light is still switched on Danger QUALIFICATION REQUIRED To avoid injury all maintenance must be performed by qualified technicians only mpi Note FINGER PRINTS To avoid finger prints on the HQI lamp make sure that you wear gloves when changing the lamp Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 36 8 Maintenance and Repair AW00018501000 8 2 Maintenance The estimated life time of
43. TENSITY TARGET VALUE LIGHT GROUP TEMPERATURE THRESHOLD MAX 0 19 i e 20 groups of illumination modules can be parameterized If the temperature of an illumination module of the specified light group is higher than this threshold in degrees Celsius an error occurs Index ID of the light group 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings 0 to 150 Default setting 100 Recommended setting depends on the type of lamp HQI lamp 100 fluorescent lamp 100 Currently no temperature sensor fluorescent lamp Table 2 Illumination Control Parameter Settings Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 4 Parameter Settings 23 Parameter Index Description _TIME_WARNING_ THRESHOLD be parameterized LIGHT GROUP OPERATING 0 19 i e 20 groups of illumination modules can If the operating time of an illumination module of the specified light group is higher than this threshold in hours a warning occurs Index ID of the light group 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings O to 20000 Default setting 5000 Recommended setting depends on the type of lamp HQI lamp 5000 fluorescent lamp 5000 be parameterized LIGHT GROUP OP
44. To replace a fuse 1 Turn off and lock out system power 2 Remove the service lid Danger HAZARDOUS VOLTAGE Fuse holders remain under power even if the entire system is powered down Contact may cause death electric shock or burn Turn off and lock out system power before servicing 3 Replace the blown fuse D Note Two types of fuses are applied in the power distribution and mounting unit lamp box 001 melting fuses to protect the internal wiring They are located in front of the main switch 5x 20 mm melting fuses to protect sets of modules They are located behind the main switch 4 Close the service lid 5 Lockin and turn on system power Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 53 8 3 6 How to Replace the Master Switch The master switch is located in the power distribution and mounting unit lamp box To replace the master switch 1 Turn off and lock out system power 2 Open the service lid of the lamp box Danger HAZARDOUS VOLTAGE Fuse holders remain under power even if the entire system is powered down Contact may cause death electric shock or burn Turn off and lock out system power before servicing 3 Remove both 001 fuses Refer to the circuit diagram in the appendix of this manual 4 Make sure that no voltage is applied to a wire connected to the master switch and
45. and Connectors Fig 4 Fans Fuses and Connectors Side View of Module 1 2 3 4 5 6 Ventilation grille for fan 2 The fan runs only while lamp is switched CAN bus socket not terminated Melting fuses 2 5 2 x slow blowing Mains supply connection Ventilation grille for fan no 1 The fan runs while power is connected to the illumination module Threaded nuts for fastening the illumination module to a lamp box Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 14 3 Hardware Components AW00018501000 3 1 3 Status LEDs Fig 5 Status LEDs Side View of Module 1 Status reset button To be pressed before restarting the illumination module after an error has occurred and its cause is removed 2 For future use 3 Operating hours of HQI lamp 4 Temperature close to the fiber connector 5 Intensity of HQI lamp For information on status indications see Section 9 2 1 on page 63 Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 3 Hardware Components 15 3 1 4 Power Supply Unit Fig 6 Power Supply Unit Bottom View of Module ICU Mounting Plate Removed 1 Fan no 1 blowing in outside direction 2 Fan no 2 blowing in outside direction 3 Filter holder 4 IR cut filter bright field only in slot no 1 Not shown Diffusor bright field only in slot no 2 5 HQI lamp 6 CAN bu
46. ault Parameters 69 9 4 3 Boot Up 70 9 4 4 HQI Lamp and Shutter Control Using Process Data Objects PDO 70 Appendix A Electric Service Documentation CD00115604 71 Revision HIStory uerb PRIOR PEE PTS 73 75 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module iv AW00018501000 Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 List of Figures V List of Figures Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 1 Hot Area Around Fibre Cable 4 2 JLine Scan Controller re RR yeas 8 3 Internal Components Top 11 4 Fans Fuses and Connectors Side View of Module 13 5 Status LEDs Side View 14 6 Power Supply Unit Bottom View of Module ICU Mounting Plate Removed 15 7 Cut Filter and Shutter Blade 16 8 Temperature 1 17 FANS
47. b containing the gas A rod running through both ends of the smaller bulb connects the two voltage rails with each other The power for the HQI lamp is delivered by a large capacitor and a transformer to enable a constant very high voltage to create the arc in the smaller bulb 2 2 Technical Specifications of Lamp wattage 150W bulb R30 operating time approx 9 000 h base type AMP Universal Mate N Lock color temperature 4 200 K initial lumens 11 000 lumen output with 25 5 200 mm aperture operating voltage rated 95 V operating current rated 1 8 A Table 1 Technical Specifications of HQI Lamp Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module CONFIDENTIAL 8 2 Functional Description AW00018501000 2 3 Basic Operation The HQI illumination module serves as light source for various types of visual quality control It offers the possibility of closed loop control and can be parameterized via CAN bus messages Additionally in bright field illumination application the illumination module comprises a switchable shutter blade which can be set with CAN bus messages too The Basler SENSIC software release 8 0 and later supports the HQI illumination module When starting the Line Scan Controller software it sets the parameters given in the machine parameter set and switches on all lamps stated in the machine parameter set Defects 30 15
48. d of each illumination module and fasten the quarter turn fastener Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 42 8 Maintenance and Repair AW00018501000 8 2 4 How to Replace a Fan of the Illumination Module 3 1 Fan No 1 Fan No 2 4 2 Fig 19 Replacing a Ventilation Fan Danger HAZARDOUS VOLTAGE Danger of electric shock Turn off and lock out system power before servicing Danger BRIGHT LIGHT The HQI lamp emits very bright light which can be harmful to your eyes Never look into the light Never open the illumination module while the light is still switched on Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 43 To replace a fan 10 11 12 13 14 Turn off and lock out system power Open the servicing lid of the power distribution and mounting unit Disconnect the mains supply cable and the CAN bus cable of the illumination module whose fan you want to change Carefully unscrew the four mounting screws that connect the illumination module to the power distribution and mounting unit Make sure the illumination module does not fall off Take the illumination module out of the power distribution and mounting unit Unfasten the quarter turn fastener and remove the service lid Fig 19 Disconnect the 24 V DC power supply of the fan to be changed The power supply connectors for both
49. ed e the respective HQI lamp is switched off an error message is sent via the CAN bus an error message is sent to the SENSIC application and displayed in Event Log Viewer To set the parameter for the temperature error message enter the following message ID Length Message 600 node ID 8 2F 00 60 02 LB HB 00 00 The temperature is given in increments of 0 1 C i e 100 C is obtained by entering O3E8h For details on how to proceed when this error has occurred refer to Section 9 2 1 on page 63 9 4 2 4 Intensity To set the parameters for the light intensity of the HQI lamp send the following CAN messages ID Length Message 600 node ID 8 2B 00 51 index LB HB 00 00 The following parameter values are defined by index Index Parameter values sets the intensity target value in integers sets the minimum threshold 2 3 4 sets the maximum threshold 5 sets the sampling time in milliseconds Setting this parameter to 0 switches the closed loop control off The parameter of index 2 is sent to the control output port 6 Starting time in seconds When this period of time has elapsed the closed loop control is started 7 linear term of the closed loop control 8 integral term of the closed loop control 9 cool down time of the illumination module in seconds The illumination module cannot be restarted before the cool down time ha
50. ed set the first digital output port to HIGH shutter open set the first digital output port to LOW You can access the shutter via Line Scan Controller For details refer to Section 7 on page 33 It is not possible to scan with shutters closed When the scan is started Start button in Line Scan Controller is selected Line Scan Controller automatically opens all closed shutters 3 6 Temperature Sensor Fig 8 To protect the illumination module from damage by overheating it is equipped with a PT100 resistor serving as a temperature sensor 1 The temperature sensor is located close to the fiber connector Once the temperature of the sensor exceeds 100 C the sensor triggers the following actions the HQI lamp in the respective illumination module is switched off the respective temperature status LED in the illumination module housing turns red an error message is sent via CAN bus an error message is displayed in Event Log Fig 8 Temperature Sensor Viewer The sensor s trigger threshold of 100 C is defined in the firmware of the ICU and can be changed with SDO messages Or by changing the associated parameter for the temperature threshold in the machine parameter set Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 18 3 Hardware Components AW00018501000 3 7 Fans Fig 9 Fans Fig 9 Each illumination module is equipped with two fans They direct the air flow from the illum
51. es installed into the system To replace a fan Turn off and lock out system power Remove the service lid Remove the covers from the cable ducts Disconnect the corresponding wires from their clamps refer to the circuit diagram Dismount the fan you want to change DOTE o Ny c Mount the new fan In some cases it may become necessary to lengthen the wires to the fan refer to the circuit diagram for the correct extension wire 7 Connect the wires to the corresponding clamps 8 Install the covers of the cable ducts 9 Close the service lid 10 Switch on power to the power distribution and mounting unit Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 45 8 3 Repair Vital components may break down after extensive operation The following sections describe how to replace these components D Note REPAIRS AT BASLER FACTORY ONLY The following instructions are for Basler Technical Service only All repair work must be done at Basler factory only Do not start repair at your factory Your warranty may become void 8 3 1 How to Replace the Power Supply Unit Danger HAZARDOUS VOLTAGE Danger of electric shock Turn off and lock out system power before servicing Danger BRIGHT LIGHT The HQI lamp emits very bright light which can be harmful to your eyes Never look into the light Never open the illumination module
52. etting 30 Recommended setting 30 Table 2 Illumination Control Parameter Settings Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 26 4 Parameter Settings AW00018501000 4 2 Node IDs for Various Illumination Units The table below lists the node IDs you should allocate to the HQI illumination modules when used for the various illumination units Illumination Unit Illumination Bright Field Bright Field Dark Field Dark Field Unit 3 Unit 4 Module No Reflection Transmission Reflection Transmission Future Use Future Use Illumination Illumination Illumination Illumination 0 40 50 60 70 20 30 1 41 51 61 71 21 31 2 42 52 62 72 22 32 3 43 53 63 73 23 33 4 44 54 64 74 24 34 5 45 55 65 75 25 35 6 46 56 66 76 26 36 7 47 57 67 77 27 37 8 48 58 68 78 28 38 9 49 59 69 79 29 39 10 4A 5A 6A 7A 2A 3A 11 4B 5B 6B 7B 2B 3B 12 4C 5C 6c 7C 2C 3C 13 4D 5D 6D 7D 2D 3D 14 4E 5E 6E 2 15 4F 5F 6F 7F 2F 3F Table 3 CAN Node IDs D Note The counting of the illumination modules numbers runs from bottom to top see electric circuit diagram of the inspection system With Gen5 systems the illumination units normally comprise illumination modules 0 to 5 With Gen6 systems the illumination units normally comprise illumination modules 0 to 7 With Gen7 systems the il
53. ff ID Length Message Action 200 node ID 1 00 switch off HQI lamp 200 node ID 1 01 switch on HQI lamp with open shutter 200 node ID 1 03 switch on HQI lamp with closed shutter To view status of the illumination module ID Length Message Checkbox 180 node ID 1 00 RTR To switch between operational mode and pre operational mode ID Length Message Action 000 node ID 2 01 switch to operational mode 000 node ID 2 80 switch to pre operational mode Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 71 Appendix A Electric Service Documentation CD00115604 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 72 AW00018501000 Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG Dy vayseg Aq 4ubiJKdo aBed 1840 4460 0 4096LL00P2 XX9G L00 0 Jaqunujueun oq 4461 DH polos uoije juaulnao e2314128 3 juaua3e day pajepdn J94unp g 84294 saiboj ouu3a uoisiA 31s v8 vor aSM4 JO JUBJIN e juaJJn 1044009 ZHO9 0S DuijeJadg QV213 juauiaje day d payepdn sjuajuo Z
54. hanged before it actually breaks down the parameter value for warning operating time is shorter than the actual estimated operating time Thus idle time due to unexpected breakdown of the HQI lamp can be kept to an absolute minimum Recommended warning parameter value 1388 h i e 5 000 h To define this parameter enter the following message ID Length Message 600 node ID 8 29 00 52 02 LB HB 00 00 9 4 2 2 Operating Time Error If the lamp is not changed within a certain period of time after the operating time warning message was displayed an operating time error message will occur This message informs the operator that there will be an error due to brake down of the lamp if it is not immediately replaced Recommended error parameter value 1770 h i e 6 000 h To define this parameter enter the following message ID Length Message 600 node ID 8 29 00 52 03 LB HB 00 00 For details on how to proceed when this error has occurred refer to Section 9 2 2 on page 63 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 68 9 Troubleshooting AW00018501000 9 4 2 3 Temperature Error To protect the illumination module from overheating a parameter for a trigger temperature of 100 C for the temperature sensor must be defined When this critical temperature is reached the temperature sensor triggers the following actions The status LED turns r
55. he light Never open the illumination module while the light is still switched on Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 1 Safety Instructions 5 1 8 Maintenance Service and Repairs Danger QUALIFICATION REQUIRED To avoid injury make sure that maintenance and service are performed by qualified technicians only Repair must be performed by Basler Technical Service at the Basler factory only 1 9 Spare Parts Spare parts must comply with the technical requirements specified by the manufacturer Spare parts from original equipment manufacturers can be relied on to do so For spare part information please contact Basler Technical Support The support addresses appear on the back of the title page of this manual Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 6 1 Safety Instructions AW00018501000 Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 2 Functional Description 7 2 Functional Description 2 1 General illumination modules are based on HQI lamps whose light is conducted to the substrate via an interfacing fiber cable stands for the chemical elements Mercury Hg Quartz and lodide 1 An HQI lamp uses a high voltage arc in a gas filled environment to produce light It consists of an outer glass shield surrounding two voltage rails connecting to each end of a smaller bul
56. he maintenance directives 1 3 Electric Shock Danger ELECTRIC SHOCK To avoid the danger of electric shock the following safety measures must be observed Turn off and lock out system power immediately if a fault occurs in the electric system Turn off and lock out system power before you start maintenance service or repair Never work on the electric system with power switched on Contact with open cables will cause electric shock Melting fuses before the main switches remain under power when the main switch is switched off Contact may cause death electric shock or burn Turn off and lock out system power before servicing Work on the electric system or equipment must only be carried out by a skilled electrician or by specially instructed personnel under the control and supervision of an electrician and in accordance with the applicable electric engineering rules Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 1 Safety Instructions 3 1 4 Health Risk in Case of HQI Lamp Breakage Danger TOXIC MATERIAL The inspection system is equipped with metal halide lamps HQI lamps in which the discharge arc burns at high pressure in an atmosphere of halogen and mercury vapour and rare earths The wattage of an HQI lamp is 150W 150 HQI lamp contains a maximum of 15 mg mercury To avoid health risk in case of lamp breakage observe the following safety instructions
57. ination module into the lamp box and fasten the mounting screws 20 Connect the CAN bus cable 21 Connect the mains supply 22 Close the service lid of the lamp box 23 Turn the power on Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 51 8 3 4 How to Replace a Fuse of the Module Danger HAZARDOUS VOLTAGE Danger of electric shock Turn off and lock out system power before servicing The illumination module s 2 5 A slow blowing melting fuses are located in a fuse holder 1 at the rear side of the illumination module close to the mains supply connector Fig 24 Fuses To replace a blown fuse 1 Turn off and lock out system power 2 Open the servicing lid of the lamp box 3 Disconnect the mains supply cable of the illumination module 4 Open the fuse holder with the help of a screwdriver 5 Replace the blown fuse 6 Insert the fuse holder again 7 Reconnect the mains supply cable 8 Fasten the service lid 9 Lock in and turn on system power 10 Check whether the illumination module with the new fuse works correctly Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 52 8 Maintenance and Repair AW00018501000 8 3 5 How to Replace a Fuse in the Lamp Box The fuses of the power distribution and mounting unit lamp box are located inside the unit in the bottom area above the outlet fans
58. ination module into the power distribution and mounting unit lamp box One fan 1 cools the following components the ICU the power supply unit This fan runs as long as the illumination module is connected to the line s mains supply The other fan 2 cools the following components the fiber end the filters diffusors the rotary solenoid and the HQI lamp This fan only runs while the HQI lamp is switched on i e the power supply unit is connected to the line s mains supply Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 3 Hardware Components 19 3 8 Intensity Sensor For intensity measurement the illumination module is equipped with a silicon photo diode BPW34 as an intensity sensor 1 The intensity status LED see Section 3 1 3 on page 1 14 displays the following intensity states measured Fig 10 Intensity Sensor by the intensity sensor LED Status green Intensity OK i e intensity is within the threshold parameters defined in Parameter Set Manager green flashing HQI lamp is warming up Hence it has not yet reached the intensity defined by the threshold parameters red Intensity not OK i e intensity is either beyond the maximum or the minimum threshold parameter The potentiometer on the ICU responsible for the correct intensity control has already been adjusted during fabrication Copyright 2007 by Basler AG Basler SENSI
59. itionally this filter comprises a dielectric mirror 4 2 3 4 5 which reflects wavelengths longer than approximately 700 nm thus strongly reducing the thermal load of the fiber end and the intensity sensor The thermal load of the filter itself is lower than that of absorption filters like e g KG2 or KG3 Fig 7 IR Cut Filter and Shutter Blade In the dark field illumination set up the Cal Flex B1 K1 filter is removed to achieve a maximum intensity 3 4 Diffusor In the bright field application a diffusor is used to improve the uniformity of illumination The diffusor is normally installed in the second slot after the IR cut filter Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 3 Hardware Components 17 3 5 Shutter The HQI lamp can only be switched on in cold condition This means that it requires 10 minute cool down period after switch off before it can be switched back on So procedures like Media Adaptation or Intensity Correction which demand several cycles with the illumination switched on and off would take a very long time Fig 7 To overcome this drawback a mechanical shutter is integrated inside the illumination module directly in front of the fiber connector 3 The mechanical shutter consists of a rotary solenoid 5 and a shutter blade 4 You can directly control the mechanical shutter with CAN bus messages Shutter position Action shutter clos
60. le the light is still switched on To replace the rotary solenoid Be OO IN 10 11 Turn off and lock out system power Open the servicing lid of the lamp box Disconnect the mains supply cable and the CAN bus cable of the illumination module Carefully unscrew the four mounting screws that connect the illumination module to the lamp box Make sure the illumination module does not fall off Take the illumination module out of the lamp box Unfasten the quarter turn fastener and remove the service lid Fig 23 Disconnect the WAGO 8 port connector from the ICU Remove the cable ties 1 at the cooling duct 2 Remove the rotary solenoid 5 by unscrewing the two screws 3 which fasten it to the illumination module housing 6 Remove the blind from the axis of the rotary solenoid Remove the bolts from the rotary solenoid 12 Attach the bolts to the new rotary solenoid 13 Attach the blind to the axis of the new rotary solenoid 14 15 Install the new rotary solenoid Make sure that when in active position the blind totally covers the opening of the fiber connector 4 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 50 8 Maintenance and Repair AW00018501000 Fig 23 Rotary Solenoid 16 Connect the WAGO 8 port connector 17 Fasten the cables using new cable ties 18 Insert the lid and fasten the quarter turn fastener 19 Insert the illum
61. lumination units normally comprise illumination modules 0 to 9 Using a fluorescent lamp for bright field transmission illumination node ID 50 is used for the fluorescent lamp Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 5 Initial Start Up 27 5 Initial Start Up 5 1 Startup At this stage the illumination module is not yet installed in the power distribution and mounting unit of the sensor unit lamp box Proceed as follows when installing the illumination module into the lamp box for the first time Fig 13 Illumination Module To start up the illumination module 1 Open the illumination module by unlocking the quick fastening screw at the front side of the illumination module Pull out the lid 2 Fig 13 Select CAN basic address with the DIP switch 3 The node ID is set with the corresponding DIP switches The values for the individual switches 01 h 02 h 04 h 08 h 10 h 20 h 40 h 80 h from the front side to the rear side Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 28 wo 5 Initial Start Up AW00018501000 Check resistance value of the potentiometer for the intensity control Check whether the HQI lamp 2 is positioned correctly Make sure that the lamp is installed in such a way that its mains supply cable 1 faces upwards so it is not cramped under the lamp Check whether all connections fit correctly
62. measures First aid personnel Avoid contact with mercury or mercury compounds After inhalation Fresh air If required artificial respiration Immediately consult a doctor After skin contact Wash the mercury off with much water Remove contaminated clothes After eye contact Wash the mercury off while you keep your eyelid open 15 minutes Immediately consult an eye specialist After swallowing If conscious drink a lot of water trigger a vomit Immediately consult a doctor Copyright 2007 by Basler AG Basler SENSIC Illumination Module 40 8 Maintenance and Repair AW00018501000 Danger DISPOSAL Since metal halide lamps contain noxious substances particularly mercury they have to be disposed of in Europe as special waste under EWC Code 20 01 21 Fluorescent tubes and other mercury containing waste Metal halide lamps therefore have to be transported to special waste disposal facilities In other countries the relevant national regulations must be followed Do not allow mercury to pour into water exhaust water or earth Danger BURN HAZARD Due to the powerful HQI lamp components of the illumination module can get very hot You can suffer serious burns if you do not let the illumination module cool down for 30 minutes before touching its components Danger BRIGHT LIGHT The HQI lamp emits very bright light which can be harmful to your eyes Never look into
63. minated clothes After eye contact Wash the mercury off while you keep your eyelid open 15 minutes Immediately consult an eye specialist After swallowing If conscious drink a lot of water trigger a vomit Immediately consult a doctor Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 4 1 Safety Instructions AW00018501000 1 5 Disposal of HQI Lamps Danger DISPOSAL Since metal halide lamps contain noxious substances particularly mercury they have to be disposed of in Europe as special waste under EWC Code 20 01 21 Fluorescent tubes and other mercury containing waste Metal halide lamps therefore have to be transported to special waste disposal facilities In other countries the relevant national regulations must be followed Do not allow mercury to pour into water exhaust water or earth 1 6 Hot Surface Danger HOT SURFACE Do not touch the illumination modules in the area around the fibre cable connector Fig 1 The area can reach a temperature of more than 70 C Parts of the lamp can reach temperature of several 100 C Make sure that at least 30 minutes have passed from system shutdown before you open the housing and Fig 1 Hot Area Around Fibre Cable Connectors touch the lamps 1 7 Bright Light Danger BRIGHT LIGHT The HQI lamp emits very bright light which can be harmful to your eyes Never look into t
64. module from the power distribution and mounting unit lamp box To remove the module 1 Fig 17 Pull down the safety catch and remove the mains supply cable from the mains socket 1 Unscrew the fastening screws of the CAN bus cable and remove it from the CAN bus socket 2 Unscrew and remove the four mounting screws 3 Carefully take the illumination module out of the power distribution and mounting unit lamp box 8 2 2 How to Install the Illumination Module into the Lamp Box To install the module Carefully insert the illumination module into the power distribution and mounting unit lamp box Fig 17 Insert and fasten the four fastening screws 3 Insert the CAN bus cable into the CAN bus socket 2 and fasten the fastening screws Insert the mains supply cable into the mains socket 1 and fasten the safety catch Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 38 8 Maintenance and Repair AW00018501000 8 2 3 How to Replace the HQI Lamp Fig 18 Replacing the HQI Lamp Danger HAZARDOUS VOLTAGE Danger of electric shock Turn off and lock out system power before servicing Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 39 Danger TOXIC MATERIAL The inspection system is equipped with metal halide lamps HQI lamps in which the discharge arc burns at high pressure in an atmosphere of haloge
65. n and mercury vapour and rare earths The wattage of an HQI lamp is 150W 150 HQI lamp contains a maximum of 15 mg mercury To avoid health risk in case of lamp breakage observe the following safety instructions HEALTH RISK Never inhale swallow or get in skin contact with mercury or mercury compounds Inhaling mercury or mercury compounds in vapour or powder form can lead to health problems Mercury can also be absorbed through the skin Only operate the lamp if the bulb is intact If broken intensive UV radiation will be released and damage your eye or skin PROTECTION AGAINST LAMP BREAKAGE To avoid health risks the manufacturer recommends the following procedure in the event of a lamp exploding or lamp breakage Everyone in the immediate vicinity should leave the room as quickly as possible to avoid inhaling mercury vapour The room should be carefully ventilated for 20 to 30 minutes at least Once the luminaire has cooled down and certainly before it is used again all residual mercury must be thoroughly removed from the inside of the luminaire To avoid contact with the skin use disposable gloves Clear up liquid mercury using a cloth dampened with a commercial adsorption agent that contains a tenside See the safety advice regarding disposal on the following page for disposal information FIRST AID If you inhale swallow or get in skin contact with mercury or mercury compounds observe the following first aid
66. oceed as follows Note 1 The optimal height of the HQI lamp is measured between the upper surface of the spring lever and the bottom of the illumination module housing A deviation in the adjustment of 1 0 mm leads to an intensity loss of less than 196 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 30 5 Initial Start Up AW00018501000 How to position the bulb 1 Fig 15 Loosen the lock nut 1 2 Adjust the height of the HQI bulb by turning the adjustment screw 2 in such a way that the top surface of the spring lever Fig 14 1 is 7 5mm above the base plate of the illumination module 3 Tighten the lock nut to secure your settings 1 2 3 Fig 15 HQI Lamp Adjustment Screw Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 6 Operation 31 6 Operation Note 1 After switch off HQI lamps cannot switched back on immediately Allow a 10 minutes cool down period before switching a HQI lamp on again Hence the illumination module is equipped with mechanical shutters in case the illumination has to be interrupted only for a short while bright field systems only The illumination module has two operation modes pre operational mode after being switched on i e only fan no 1 is running see Fig 13 4 operational mode When Line Scan Controller is started it automatically switches all connected ill
67. ow offers the following functions 1 Select illumination module bright field dark field or all 2 CAN node IDs in hexadecimal numbers of the individual illumination modules Once one or more illumination modules are selected buttons 4 7 become active Select individual illumination modules with mouse click Select groups of illumination modules by holding the lt CTRL gt button on the keyboard while selecting the desired illumination modules with mouse click 3 Press to select all illumination modules Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 34 7 Service AW00018501000 iN Press to switch selected illumination module s on Press to switch selected illumination module s off Press to open shutter of selected illumination module s Press to close shutter of selected illumination module s It is not possible to scan with shutters closed When the scan is started Start button in Line Scan Controller is selected Line Scan Controller automatically opens all closed shutters Error display of the illumination modules N TZ 8 9 Display of control voltage Display of lamp s operating time in per cent Display of HQI lamp s temperature in degrees Celsius 8 9 10 11 12 Display of HQI lamp s intensity in per cent 13 2 Status display corresponding with the LEDs in the illumination module housing for intensity I temperature
68. roportional parameter of control loop Index ID of the light group 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings 0 to 1000 Default setting 100 Recommended setting 100 Table 2 Illumination Control Parameter Settings Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 4 Parameter Settings 25 Parameter Index Description CONTROLLER_KI be parameterized LIGHT_GROUP_INTENSITY_ 0 19 i e 20 groups of illumination modules can Integral parameter of control loop Index ID of the light group 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings O to 10000 Default setting 500 Recommended setting 500 ILLUMINATION MODULE TENSITY TARGET VALUE CORRECTION FACTOR For each illumination module correction factor for the global intensity target value of the whole light group LIGHT GROUP INTENSITY TARGET VALUE Used to compensate slight intensity variations from lamp to lamp Index ID of illumination module Range of possible settings 0 01 to 10 0 Default setting 1 STATUS INFORMATION _ INTERVAL Interval in seconds the illumination unit sends status information like current intensity value etc Range of possible settings O to 3600 Default s
69. s Event message in Event Log Viewer see Section 9 1 1 on page 59 Red status LED on module see Section 9 1 2 on page 60 9 1 1 Event Log Viewer table 5 lists the events caused by the illumination modules For critical error and warning events you can find actions The table also applies to the fluorescent lamp ID Description Severity Explanation Action 220060 Light intensity too Error Intensity is lower than Check parameter settings low on illumination LIGHT GROUP Check lamp s position module x Current INTENSITY ERROR _ Replace the HQI lamp 220061 Light intensity too Error Intensity is higher than Check parameter settings high on illumination LIGHT GROUP _ Check HQI lamp s position module x Current INTENSITY ERROR _ Check intensity sensor 220062 Temperature Critical Illumination module is See Section 9 2 1 on page 63 threshold x overheating exceeded on Temperature is higher illumination module than LIGHT GROUP y TEMPERATURE _ THRESHOLD MAX 220063 Operating time Warning Lamp s operating hours See Section 9 2 2 on page 63 exceeded on reached the LIGHT illumination module GROUP OPERATING x Current operation TIME WARNING _ time y THRESHOLD 220064 Operating time Error Lamp s operating hours See Section 9 2 2 on page 63 exceeded on reached the LIGHT illumination module GROUP OPERATING x Current operation TIME ERROR time y THRESHOLD Table 5
70. s An der Strusbek 60 62 22926 Ahrensburg Germany Phone 49 4102 463 0 Fax 49 4102 463 109 support di baslerweb com Asia Basler Vision Technologies Taiwan Inc 3F No 87 6 Guangming 6th Rd Jhubei Hsinchu County 302 Taiwan R O C Phone 886 3 558 3955 Fax 886 3 558 3956 di service basler com tw Americas Basler Inc 855 Springdale Drive Suite 160 Exton PA 19341 USA Phone 1 610 524 8506 Fax 1 610 280 7608 support usa baslerweb com Basler Representative Office Korea 889 2 Ssang Yong dong 7th Floor at Daewoo Tower ChungNam Choon ChungNam do Korea Phone 82 41 578 2717 Fax 82 41 578 2717 support di baslerweb com Spare Parts Phone 49 1803 22 75 37 regular phone rate Fax 49 4102 463 279 partsandrepair baslerweb com AW00018501000 i Table of Contents List 4 V List of Tables vii 1 Safety Instructions 20 206 deme ce keene ee eEeS 1 1 1 Conventions Used in This 1 1 2 Designated Use 2 1 3 Electric Shock 4 2 1 4 Health Risk in Case of HQI Lamp Breakage 3 1 5 Disposal of HQI
71. s cable 7 Power supply cable and connection always mount HQI lamp with the power supply cable facing upwards 8 Control output port 9 Power supply unit 10 Power supply for fan no 2 11 Control input port for tuning the HQI lamp s power 12 Power connection Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 16 3 Hardware Components AW00018501000 3 2 Power Supply Unit Fig 6 The power for the HQI lamp is supplied via the power supply unit 7 It supplies 330 kHz AC voltage The power supply unit comprises a line input port and an output port to the HQI lamp Additionally it features the following ports a control input port 0 10 V a 24 V output port e g for a fan digital output port for the lamp status This port is connected through when the HQI lamp is and blocked when the HQI lamp is off 3 3 IR Cut Filter Fig 7 The bright field illumination set up requires homogeneous light with a reasonable intensity and a limited spectral distribution Therefore a filter 2 is inserted into slots in a filter holder 1 between the lamp and the fiber connector 3 The filter holder 1 has got three slots with slot no 1 being closest to the HQI lamp and slot no closest to the fiber connector 3 The filter used for the bright field illumination set up is a CalFlex B1 K1 filter It is made of heat absorbing glass absorbing long wavelength IR light Add
72. s elapsed Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 9 Troubleshooting 69 To return the parameter values given by the index send this message ID Length Message 600 node ID 8 40 ID 00 51 index 00 00 00 00 9 4 2 5 How to Store Parameter Changes Changes to the parameters are lost once the power is shut off To save changes permanently send the following message ID Length Message 600 node ID 8 23 10 10 04 73 61 76 65 9 4 2 6 How to Restore Default Parameters To undo changes to the parameters and to restore the default parameters send the following message ID Length Message 600 node ID 8 23 11 10 04 6C 6F 61 64 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 70 9 Troubleshooting 9 4 3 Boot Up Message AW00018501000 When the power is switched on the ICU boots up in pre operational mode On booting up the illumination module automatically returns the boot up message The message below returns the status on request ID Length Message 600 node ID 8 40 CO 02 10 00 00 00 00 9 4 4 Lamp and Shutter Control Using Process Data Objects PDO In operational mode the illumination module can be accessed via R PD01 and T PD01 for service purposes Using R PD01 you control HQI lamp and shutter with the following messages To switch HQI lamp on o
73. the lamp box Make sure the illumination module does not fall off Take the illumination module out of the lamp box Unfasten the quarter turn fastener and remove the service lid Fig 26 Disconnect the analog input cable 1 for the temperature sensor from the ICU Take the analog input cable out To do so you have to remove some cable ties 9 Fig 27 Remove the temperature sensor 3 by undoing its fastening screw 4 10 Install the new temperature sensor and fasten it with the screw 11 Check whether the shutter blade 5 can freely move into closed position 12 Fig 26 Run the sensor s analog input cable 1 towards the input connector 2 on the ICU and fasten it with cable ties and clamps 13 Connect the analog input cable to the connector on the ICU 14 Insert the lid and fasten the quarter turn fastener 15 Insert the illumination module into the lamp box and fasten the mounting screws 16 Connect the CAN bus cable 17 Connect the mains supply 18 Close the service lid of the lamp box 19 Lock in and turn on system power Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 58 8 Maintenance and Repair AW00018501000 8 3 9 How to Replace the Line Connector Danger HAZARDOUS VOLTAGE Danger of electric shock Turn off and lock out system power before servicing Danger BRIGHT LIGHT The HQI lamp emits very bright light which can be harmful to your eyes Ne
74. the light Never open the illumination module while the light is still switched on To replace the HQI lamp 1 Turn off and lock out system power Repeat the below procedure for every lamp you need to replace 2 Wait until the illumination module has cooled down Then unlock the quarter turn fastener of the mounting unit 3 Remove the lid of the illumination module Fig 18 Disconnect the lamp plug 2 To avoid injuries from sharp edges of the mounting frame use a tool like e g a screwdriver 5 Push the bracket 3 away from the lamp 4 with one hand and take the spent lamp out with the other 6 Push the bracket 3 away from the lamp holding with one hand and insert the new lamp 4 with the other Install the HQI lamp in such a way that its mains supply cable 5 faces upwards 8 Insert the mains supply cable s plug 2 into the respective socket After you exchanged all lamps proceed as follows Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 41 9 Turn the power on but leave the lamps switched off Danger HIGH VOLTAGE Danger of electric shock Do not touch electronic boards Parts of the electronic boards are under high voltage 10 On each illumination module where you exchanged a lamp press the operating hours reset button 1 to set the counter for the new HQI lamp back to zero 11 Close the li
75. ty not OK i e intensity is either beyond the maximum or the minimum threshold parameter Check whether the parameters in the parameter set manager are correct Refer to section Parameter Settings on page 21 Green flash ing lamp is warming up Hence it has not yet reached the intensity defined by the threshold parameters No action required Green Intensity OK i e intensity is within the threshold parameters defined in Parameter Set Manager No action required Table 8 Indications of Intensity LED Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 9 Troubleshooting 63 9 2 HQI Lamp Switched Off An HQI lamp can switch off for the following reasons Overheating Temperature Error page 63 Operating Hours Operating Time Error page 63 HQI Lamp Cannot Be Switched On page 65 Check whether one of the above mentioned reasons applies 9 2 1 Overheating Temperature Error If the temperature sensor switched off the lamp see Section 9 1 2 2 on page 61 proceed as follows To remedy temperature error Danger BURN HAZARD Due to the powerful HQI lamp components of the illumination module can get very hot You can suffer serious burns if you do not let the illumination module cool down for 30 minutes before touching its components Let the HQI lamp cool down for 30 minutes 2 Verify the following Check whether the
76. umination modules into operational mode In the pre operational mode only SDO communication is possible In operational mode SDO as well as PDO process data objects communication are possible PDOs are required for controlling the HQI lamp see Section 9 4 4 on page 70 and the status LEDs see Section 9 1 2 on page 60 During operation you only have to check the status LEDs regularly and in case an LED indicates an error rectify as described in Section 9 on page 59 Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 32 6 Operation AW00018501000 Basler SENSIC HQI Illumination Module Copyright 2007 by Basler AG AW00018501000 7 Service 33 7 Service For service purposes you can open an Illumination Control window on the line scan station In this window you can view the status of all installed illumination modules and control them individually or all together To open the Illumination Control menu select the Illumination button in Line Scan Controller 15 14 13 12 11 10 9 8 Illumination control xi r Module state 1 Filter i Boom o Deme messe Tine CulVoltage Error 5 2 9 4 105v 2 2 G 6 039V 3 SelectAll Switch ON Switch Close Shutter Fig 16 Illumination Control Menu The Illumination Control wind
77. upply unit into the illumination module 12 Insert and fasten the four standoff screws 2 13 Connect all plugs you have loosened before to the new power supply unit 14 Fig 19 Install the ICU mounting plate 4 in its original position 15 Fasten the six mounting screws 3 of the ICU mounting plate 16 Insert the lid and fasten the quarter turn fastener Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 8 Maintenance and Repair 47 17 Insert the illumination module into the lamp box and fasten the mounting screws 18 Connect the CAN bus cable 19 Connect the mains supply 20 Close the service lid of the lamp box 21 Turn the power on 8 3 2 How to Replace the ICU The ICU is shown in Fig 22 2 on 48 Danger HAZARDOUS VOLTAGE Danger of electric shock Turn off and lock out system power before servicing Danger BRIGHT LIGHT The HQI lamp emits very bright light which can be harmful to your eyes Never look into the light Never open the illumination module while the light is still switched on To replace the ICU peo qe c Turn off and lock out system power Open the servicing lid of the lamp box Disconnect the mains supply cable and the CAN bus cable of the illumination module Carefully unscrew the four mounting screws that connect the illumination module to the lamp box Make sure the illumination module does not fall off Take the illumination
78. ver look into the light Never open the illumination module while the light is still switched on To replace the line connector Deo Ne no wg 11 15 17 Turn off and lock out system power Open the servicing lid of the lamp box Disconnect the mains supply cable and the CAN bus cable of the illumination module Carefully unscrew the four mounting screws that connect the illumination module to the lamp box Make sure the illumination module does not fall off Take the illumination module out of the lamp box Unfasten the quarter turn fastener and remove the service lid Remove the cable sockets from the filter plug Loosen the filter plug by removing the strap and the screws Remove the old filter plug Insert the new filter plug Fasten the filter plug and insert the strap 12 13 14 Connect the cable sockets Make sure to connect the ground wire to the correct port Insert the lid and fasten the quarter turn fastener Insert the illumination module into the lamp box and fasten the mounting screws Connect the CAN bus cable 16 Connect the mains supply Close the service lid of the lamp box 18 Lock in and turn on system power Basler SENSIC Illumination Module Copyright 2007 by Basler AG AW00018501000 9 Troubleshooting 59 9 Troubleshooting 9 1 How to Detect That an Error Occurred Is About to Occur The operator recognizes warning and error states in two different way
79. ype of lamp Bright field HQI lamp 640 Fluorescent lamp Must be adjusted to reach the right reflection transmission ratio Dark field HQI lamp 640 Table 2 Illumination Control Parameter Settings Copyright 2007 by Basler AG Basler SENSIC HQI Illumination Module 22 4 Parameter Settings AW00018501000 Parameter Index Description LIGHT_GROUP_INTENSITY_ ERROR_THRESHOLD_ MIN 0 19 i e 20 groups of illumination modules can be parameterized If the intensity of an illumination module of the specified light group is lower than this threshold in decimal numbers an error occurs Index ID of the light group 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings 0 to 2000 Default setting 800 Recommended setting 20 lower than LIGHT GROUP INTENSITY TARGET VALUE LIGHT GROUP INTENSITY _ ERROR THRESHOLD _ MAX 0 19 i e 20 groups of illumination modules can be parameterized If the intensity of an illumination module of the specified light group is higher than this threshold in decimal numbers an error occurs Index ID of the light group 1 bright field reflection 2 bright field transmission 3 dark field reflection 4 dark field transmission Range of possible settings 0 to 2000 Default setting 1200 Recommended setting 20 higher than LIGHT GROUP IN

hqi® illumination module service manual and troubleshooting guide

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hqi® illumination module service manual and troubleshooting guide