PA 1309/10. Topaz. Service Manual TRAD. Philips Electronic Manufacturing Technology

Transcription

1 PA 1309/10 Topaz Service Manual Philips Electronic Manufacturing Technology TRAD

2 DOCUMENT DATA MANUAL TITLE MANUAL NUMBER PA NUMBER Service Manual Topaz (01.05) PA 1309/10 ISSUE DATE ORDER NUMBER HISTORY REVISION CODE STATUS First Draft Replaced - First Issue Update Second Issue Update Oct-97 Mar-98 Mar-99 Jan Replaced Replaced Replaced Replaced RELEASE DOCUMENT DI-CSM-025 DI-CSM-050 DI-CSM-076 DI-CSM-105 Third Issue April Current DI-CSM-138 Preventive and corrective maintenance is reserved for personnel certified by Assembléon. The Philips EMT Customer Support organization has created a series of web pages on 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. It has the advantages that it can be updated regularly. The Customer Support website address is: 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).

3 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 manuals 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. NOTE Explains the mounter operation and procedures in a simple and clear manner. 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. EMERGENC BUTTON Press the emergency button. REMARK Gives a comment. Training level personnel: Operation, adjustment, maintenance and repair of the CSM system may only be carried out by qualified and trained personnel 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/EEC. Low Voltage directive 73/23/EEC. EMC 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 Service 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.

4 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, the customer, receive the highest possible quality of information and service. Manual Title: Service Manual Topaz Manual Number: PA Number: PA 1309/10 Update Code Manual: Please, don t forget to fill-in this!. FROM: Name Company Address Date DOCUMENT IRREGULARITIES: Page/Paragraph Number Erroneous Entry Consequence Suggestion TO: Philips Electronic Manufacturing Technology Supply Centre Customer Support P.O. Box 218 Building BAF MD Eindhoven The Netherlands

5 Service Manual Topaz Table of Contents 1. Introduction General Introduction Chapter Overview Safety General Basic Rules Safety Standards Cautionary Remarks Warning Stickers ESD Precaution Noise Level Liability Oil and Greases Abbreviations General and Electrical Block Diagram System Principles Introduction Mains Specifications and Connection Schedule Air Specifications and Connection Interfaces Bus Definitions Serial Interface Line Interconnections MCX-Control Unit MCX-Controller Lay-Out (Second Generation) System Board Servo Board Service Manual Topaz PA 1309/10 1

6 Table of Contents Vision Board Mother Board Hard- and Floppy-Drives and Flash Disk Driver Board Assy D(river) - Power Assy V / 12V Power Supply Assy s LED Driver Board I/O - Boards Connection-Board General nd Generation Connection-Board rd Generation Connection-Board Keyboards PC-Keyboards Hand Held Keyboard (HHK) Monitors VIOS Monitor Vision Monitor I/O - Signals VIOS Manual Mode I/O-Monitor List of OUTPUT Signals (DO s) List of INPUT Signals (DI s) Power and Safety Circuits Introduction Safety Circuit Description Safety Circuit Power Circuits Description V / 12V Power Supply MCX Box V I/O and Emergency Power Supply (GS21) D - Power Assembly (282V Power) Measuring and Adjusting Data Performance Check and Trouble Shooting Maintenance Instructions Vacuum and Pneumatic Systems Vacuum Systems Introduction Functional Description Air Supply Unit Air Pressure Regulator Pressure-Drop Detection Level Measurement and Adjusting Vacuum Levels Performance Check and Trouble Shooting Maintenance Instructions Pneumatic Systems Introduction Functional Description Topaz 5-5 Service Manual Topaz PA 1309/

7 Table of Contents Tray Changer (TC) Tape Feeders Automatic Tray Stacker FES/SVS Measuring and Adjusting Performance Checks and Trouble Shooting Maintenance Actions Exchanging Head Ejectors, Valves and Base Exchanging the Head Ejector and/or Valves Exchanging the Head Up/Down, Slow Valves and Valve Base PCB Transport Systems Introduction Conveyor Belt Adjusting the Conveyor Belt Tension Adjusting the Carry-In Conveyor Speed Main Stopper Adjusting the Ascent/Descent Speeds of the Main Stopper PCB Contact Point Push-In Locate Pin Edge Clamp Push-Up PCB Detection Sensors Conveyor Errors Component Transport Systems Introduction Head Assembly Mechanical Check Head Assembly Machine Coordinates Pickup and Mount Vacuum Levels R-axis Absolute Accuracy Offset Nozzle Correction Head Offset Nozzle Station Nozzle Station Adjusting the Nozzle Sensor Sensitivity Adjusting the Nozzle Clamp Plate Position Adjusting the Nozzle Station Coordinates Nozzle Station Maintenance Feeder Plates Feeder Plate Parallel Adjustment Feeder Block Positions Component Pickup Test Feeder Plate Maintenance Component Feeders Tape Feeders Minimum Timer / Load Timer / Down Timer Tape Feeder Maintenance Service Manual Topaz PA 1309/10 3

8 Table of Contents 8. Axes Systems Introduction Machine Reference (Origin) W-axis Machine Reference Z-axis Machine Reference X-axis Machine Reference Adjusting the Y-axis Machine Reference R-axis Machine Reference Secondary Limits X-axis Secondary Limits Y-axis Secondary Limits Software Limits W-axis Software Limits Z-axis Software Limits X-axis Software Limits Y-axis Software Limits R-axis Software Limits Initial Position and Initial Movement W-axis Initial Position Adjusting the R-axis Initial Position Z-axis Initial Movement Axes Assembly, Disassembly Adjustments and Maintenance Adjustment of the X- and Y-motor Encoder Position Head Replacement X-axis Assembly X-axis: Replacement X-motor Only X-axis: Ball Screw Replacement X-axis: Linear Guide Replacement Y-axis Assembly Y-axis: Replacement Y-motor Only Y-axis: Removing Y-axis Ball Screw Generation Y-axis: Removing Y-axis Ball Screw Generation Y-axis: Installing and Aligning Y-axis Ball Screw Generation Y-axis: Pre-tension Adjustment (Generation 3 Y-axis) Y-axis: Linear Guide Replacement Z-axis Assembly R-axis Assembly Vision Systems Introduction Vision Systems Pre-Start Operations Moving Camera Adjusting the Focus and Field Of View Adjusting the Lighting Level of the Moving Camera Adjusting the Moving Camera Scale Single Camera Adjustment Maximum Component Size and Field Of View Focus Adjustment Lighting Level Adjustment Camera Scale Adjustment 9-16 Service Manual Topaz PA 1309/

9 Table of Contents Camera Optical Axis Angle Adjustment Line Array Camera Adjustment Maximum Component Size and Field Of View Adjusting the Focus and Aperture Adjusting the Lighting Level of the Line Array Camera(s) Adjusting the Line Array Camera Scale Adjusting the Dual Recognition Offset Replacement of the Line Array Camera Cleaning the Optical Systems Recognition Errors Chip Components QFP Components Software Section Introduction System Software Operating System Disk Organization Installation Disk Contents VIOS Software Utility Installation of a New Version VIOS System Software Backup Creation VIOS Configuration Floppy Disk Problems Flash Disk Problems (Only for Systems with KM5 System Boards) Hard Disk Problems PCB File Handling Machine Configuration Machine Configuration Detailed ROM and File Configuration (Version Level) System Messages Online Commands Machine Installation and Calibration Introduction Installation Installation Position (Work-Area Condition) Environment Leveling the System Removing the Transportation Locks Monitor and Keyboard Installation Installation of the Warning Light Tower Transformer Power Tabs Air Connection Power Connection Switching On the Machine, Verify the Software Version Vacuum Levels Warm-up Camera Check Acceptance Test Service Manual Topaz PA 1309/10 5

10 Table of Contents Machine Calibration Back-up Machine References (Origins) Machine Limits Initial Movement Z-axis Initial Position R-axis Teach Nozzle Station Positions W-axis Parallelism Initial Position W-axis Vacuum Levels Moving Camera Adjustment: Focus, Lighting Level, Scale Single Camera Adjustment: Field Of View, Lighting Level, Focus, Scale Line Array Camera Adjustment:Lighting Level, Field Of View, Scale, Focus, Optical Axis Alignment Recognition Speed and Dual Recognition Offset R-axis Accuracy Mount Accuracy Calibration (Glass Plate) Introduction Conditions Required Tools Required AUTO MOUNT FEEDBACK (AMF) Program Verification and Setup Adjustment Procedure Mount Calibration Adjustment Steps for Topaz with Only Line Array Camera(s) Adjustment Steps for Topaz with Line Array and Single Camera Viewing the Data Offline Calibration Feeder Plate Final Board Accuracy Checks Back-up Procedure How to Run the AMF Program Making PCB Data for the AMF Program Mount Information Component Information Mark Information Block Information Fiducial Information Explanation of Various Parameters AMF Program Camera Scale Camera Position Nozzle Correction Head Down Offset Head Offset R-axis Accuracy Inconsistent Parameter AMF Program Maintenance Introduction Oils and Greases 12-2 Service Manual Topaz PA 1309/

11 Table of Contents Maintenance Checkpoints FD Drive, Filters and Air Valves Head Area Checkpoints X-axis Checkpoints Y-axis Checkpoints Conveyor Checkpoints Feeder Plate Checkpoints Vision Systems, Camera Lighting Unit Performance Check and Trouble Shooting Overview of Error Messages in VIOS L-error Messages E-error Messages Overview of Error Messages in the Vision Monitor Spare Parts List General Information Ordering Spare Parts Regional Stock Keeping Overview of the Various System Modules First Aid Spare Parts Kit Module 1, System Principles MCX2 Control Unit Cover Assemblies Monitor Assembly Module 2, Power and Safety Circuits Module 3, Vacuum and Pneumatic Systems Module 4, PCB Transport Systems Conveyor Assembly Conveyor Auto Width Assembly Sub-stopper, Main-stopper and Locate Pin Assembly Edge-clamp and Push-in Assembly Push-up Pin and Push-up Assembly Module 5, Component Transport Systems Nozzle Station (Option for Standard Topaz) Nozzle Selection Head Assembly Part 1: General Parts Head Assembly Part 2: Head Splines & SIMM-Topaz Head Assembly Spares Head Assembly Part 3: Z-axis Assembly Head Assembly Part 4: Valve and Ejector Assy s Head Assembly Part 5: R-axis Assembly Feeder Holder Module 6, Axes Systems X-axis Assembly Y-axis Assembly Z-axis Assembly R-axis Assembly Module 7, Vision Systems Camera Systems Lighting Systems Module 8, Options Tray Changer Tape Feeders Service Manual Topaz PA 1309/10 7

12 Table of Contents Feeder Exchange System (FES) Set-up Verification System (SVS) Automatic Tray Stacker (ATS) Module 9, Maintenance Tools Module 10, Fixation Parts Drawings and Circuit Diagrams Main Index Options Tray Changer (TC) Introduction Specifications Auto Tray Stacker (ATS 27) Introduction Specifications Set-up Verification system (SVS) Introduction Feeder Exchange System (FES) Introduction Specifications Component Feeders Project SIMM Topaz ( ) Appendix 1: Material Safety Data Sheets 17-1 Service Manual Topaz PA 1309/

13 Introduction CHAPTER 1 Introduction 1.1. General Introduction 7KHVHUYLFHPDQXDOGHVFULEHVHOHFWULFDOPHFKDQLFDOVRIWZDUHDQGSQHXPDWLF DVSHFWVRIWKH*(07RSD]V\VWHP7KHUHSDLUSKLORVRSK\RIWKHHOHFWULFSDUWRI WKHPDFKLQHLVEDVHGRQ3&%VZDSSLQJDQGQRWRQFRPSRQHQWOHYHO UHSODFHPHQW7KHUHIRUHRQO\DIXQFWLRQDOGHVFULSWLRQRIHDFK3&%ZLOOEHJLYHQ LQWKLVPDQXDO WARNING Only technical personnel which is trained on the Topaz equipment is allowed to carry out service actions Service Manual Topaz PA 1309/10 1-1

14 Introduction 1.2. Chapter Overview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ervice Manual Topaz PA 1309/

15 Introduction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ervice Manual Topaz PA 1309/10 1-3

16 Introduction 1.3. Safety General 3OHDVHREVHUYHDOOVDIHW\UXOHVDQGFDXWLRQDU\UHPDUNVWRHQVXUHWKDWWKHPDFKLQH LVXVHGLQDVDIHDQGFRUUHFWPDWWHU$OVRSOHDVHEHDULQPLQGWKDWQRWDOOVDIHW\ LWHPVFDQEHOLVWHGLQGHWDLOVRWKDWDQDFFXUDWHMXGJPHQWE\WKHVHUYLFHHQJLQHHU LVHVVHQWLDOLQVHUYLFLQJWKHPDFKLQHVDIHO\ Basic Rules 7KHIROORZLQJDUHEDVLFVDIHW\UXOHVZKLFKPXVWEHREVHUYHG 7KHSHUVRQZKR VVHUYLFLQJWKHPDFKLQHPXVWKDYHUHFHLYHGSURSHUWUDLQLQJ WRRSHUDWHVHUYLFHWKHPDFKLQHLQDVDIHDQGFRUUHFWPDQQHU 7KHSRZHUVXSSO\PXVWEHWXUQHG2))ZKHQHYHUWKHPDFKLQHLVLQVSHFWHG SDUWVDUHUHSODFHGRULQWHUQDODGMXVWPHQWVDUHPDGH 'XULQJRSHUDWLRQRIWKHPDFKLQHEHVXUHWRNHHSDOOSDUWVRIWKHERG\VXFK DVWKHKDQGVRUKHDGDZD\IURPWKHPDFKLQH VPRYLQJSDUWV %HVXUHWRNHHSWKH++.+DQG+HOG.H\ERDUGLQ\RXUKDQGZKHQHYHU WHDFKLQJµRUPDNLQJDGMXVWPHQWVWRWKHPDFKLQHVRWKDWLWFDQEHVWRSSHG DWDQ\WLPH %HVXUHWKH LQWHUORFNµVDIHW\GHYLFHVDUHPDLQWDLQHGLQDQRSHUDEOH FRQGLWLRQVRWKDWLWFDQEHXVHGWRVWRSWKHPDFKLQHDWDQ\WLPH 'RQRWXVHWKHPDFKLQHLQDQHQYLURQPHQWZKHUHIODPPDEOHJDVVHVDUH SUHVHQWRUZKHUHLWLVH[WUHPHO\GLUW\ Safety Standards 7KHVDIHW\RIWKH&60*(0V\VWHPVLVLQDFFRUGDQFHZLWKIROORZLQJ&( GLUHFWLYHV 0DFKLQHGLUHFWLYH((&DQG((&LQFOXGLQJDPHQGPHQWV /RZ9ROWDJHGLUHFWLYH((&LQFOXGLQJDPHQGPHQWV (0&GLUHFWLYH((&LQFOXGLQJDPHQGPHQWV Service Manual Topaz PA 1309/

17 Introduction Cautionary Remarks 7KLV0DQXDOXVHVWKHIROORZLQJFDXWLRQDU\UHPDUNV REFERENCE: *LYHVXVHIXOLQIRUPDWLRQUHODWHGWRWKHPDFKLQHRSHUDWLRQ NOTE: ([SODLQVWKHPDFKLQHRSHUDWLRQVDQGSURFHGXUHVLQDVLPSOHDQGFOHDUPDQQHU CAUTION: *LYHVLPSRUWDQWLQIRUPDWLRQWRSUHYHQWDQ\GDPDJHWRWKHPDFKLQHRUGDWD WARNING: *LYHVLQIRUPDWLRQRIXWPRVWLPSRUWDQFHLQHQVXULQJWKHVDIHW\RIWKHRSHUDWRURU VHUYLFHSHUVRQQHO EMERGENCY BUTTON:,QGLFDWHVWRSUHVVILUVWWKHHPHUJHQF\EXWWRQEHIRUHFRQWLQXH Warning Stickers 7KLVSDUDJUDSKJLYHVDQRYHUYLHZRIZDUQLQJVWLFNHUVWKDWDUHXVHGWRZDUQWKH RSHUDWRUVDQGVHUYLFHSHRSOHIRUGDQJHURXVVLWXDWLRQV:LWKHYHU\SLFWXUHDVKRUW GHVFULSWLRQLVJLYHQRIWKDWGDQJHURXVVLWXDWLRQ Do not enter Figure 1-1 Do not enter 7KLVVWLFNHUZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUQRWWRHQWHUE\KDQG,WLVORFDWHGDWWKHHQWUDQFHDQGH[LWFRQYH\RUUDLO Service Manual Topaz PA 1309/10 1-5

18 Introduction Electrical shock Figure 1-2 Electrical shock 7KLVVWLFNHUVHHILJXUHZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUIRUHOHFWULFDO VKRFN %HKLQGWKHFRYHUVDUHKLJKHOHFWULFDOYROWDJHVSUHVHQW Low Radiation Figure 1-3 Radiation 7KLVVWLFNHUVHHILJXUHZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUIRUORZUDGLDWLRQ 7KLVVWLFNHULVORFDWHGQHDUE\WKHODVHUWUDQVPLWWHUIRUIHHGHUIORDWLQJGHWHFWLRQ Service Manual Topaz PA 1309/

19 Introduction High temperature Figure 1-4 High temperature 7KLVVWLFNHUVHHILJXUHZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUIRUKLJK WHPSHUDWXUHSUHVHQFH7KLVVWLFNHULVORFDWHGXSRQWKH<PRWRURIWKH7RSD] ESD Precaution $OO SULQWHG FLUFXLW ERDUGV WKDW DUH SDUW RI WKH &60*(0 PDFKLQHV PXVW EH WUDQVSRUWHGDQGVWRUHGLQ(6'SURWHFWHGEDJV $Q\SHUVRQKDQGOLQJDQ&60*(0SULQWHGFLUFXLWERDUG PXVW DGHTXDWHO\ EH HDUWKHG HJ E\ PHDQV RI D EUDFHOHW ZLWK HDUWK FDEOH WR SUHYHQW GHVWUXFWLYH HOHFWURVWDWLFGLVFKDUJHWKURXJKWKHSULQWHGFLUFXLWERDUG,Q DUHDV WKDW DUH QRW (6' SURWHFWHG WKH UHPRYDEOH SURWHFWLYH FRYHUV PXVW EH PRXQWHGRQDOOSODFHPHQWPRGXOHV +DQGOLQJRISULQWHGFLUFXLWERDUGVVKRXOGEHUHVWULFWHGDVPXFKDVSRVVLEOH Noise Level 7KHDYHUDJHQRLVHOHYHORIWKH7RSD]V\VWHPGXULQJSURGXFWLRQLVG%$ Liability 3KLOLSV VKDOO QRW EH OLDEOH IRU DQ\ FRVWV GDPDJHV RU SHUVRQDO LQMXULHV LI WKH &60*(0V\VWHPLVQRWXVHGDFFRUGLQJWRWKHVDIHW\UXOHVJLYHQLQWKLVPDQXDO Service Manual Topaz PA 1309/10 1-7

20 Introduction Oil and Greases 7KLVVHFWLRQJLYHVPRUHGHWDLOHGLQIRUPDWLRQDERXWRLOVDQGJUHDVHVXVHGLQWKH 7RSD],QFKDSWHUDFRPSDWLELOLW\OLVWZLWKDQXPEHURIJUHDVHVWKDWFDQEHXVHGLV JLYHQ )ROORZLQJJUHDVHVDQGRLOVDUHFRYHUHG 12NC no. Supplier Trade name General description MSDS no NSK NSK 1 grease Multitemp CRL No3 Grease NSK NSK 2 grease Multitemp PS No2 Grease Molub alloy Grease - AccTech HP-Alco pad Cleaning tissues 806H Ausimont Fomblin Y-VAC3 Vacuum grease O-rings and seals - Shell Alvania grease 2 Grease Du Pont Krytox GPL-22X GPL-52X Vacuum grease O-rings and seals DU 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 Abbreviations 7KLVFKDSWHUGHVFULEHVFRPPRQXVHGDEEUHYLDWLRQVLQWKLVPDQXDOLQDOSKDEHWLF VHTXHQFH Abbreviation A AC ASAP ATS B/W BGA CE CN COB COG CPU CS CSM CSP Explanation Ampere Alternating current As Soon As Possible Auto Tray Stacker, tray handling device Black and white Ball Grid Array Comité europièn Connector Chip on board Centre Of Gravity Central processing unit Customer Support Compact Surface Mounter Chip scale package, BGA Service Manual Topaz PA 1309/

21 Introduction Abbreviation DC DI DI DO DIL EMG ESD FD FES FV GD1 GEM H.H.K. HDD HDLC IM ISO LCS MTF OM P1 PA PCP PCS QFP 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 1 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 Service Manual Topaz PA 1309/10 1-9

22 Introduction Intentionally left blank. Service Manual Topaz PA 1309/

23 General and Electrical Block Diagram CHAPTER 2 General and Electrical Block Diagram 7KLVFKDSWHUVKRZVERWKJHQHUDODQGHOHFWULFDOEORFNGLDJUDPVRIWKH7RSD] 7KHJHQHUDOEORFNGLDJUDPILJXUHVKRZVWKHPDLQVHFWLRQVRIWKH7RSD] 5HIHUHQFHVDUHPDGHWRWKHFKDSWHUVLQWKLVPDQXDO 7KHHOHFWULFDOEORFNGLDJUDPILJXUHVKRZVDQRYHUYLHZRIWKHPDLQHOHFWULFDO SDUWVRIWKHV\VWHP Service Manual Topaz PA 1309/10 2-1

24 General and Electrical Block Diagram VISION SYSTEM Chapt 9 COMPONENT TRANSPORT SYSTEM Chapt 7 AXES SYSTEM Chapt 8 PCB TRANSPORT SYSTEM Chapt 6 MCX CONTROLLER Chapt 3 USER INTERFACE Chapt 3 SOFTWARE Chapt 10 AIR SUPPLY Chapt 11 POWER SUPPLY Chapt 11 Figure 2-1 General block diagram Topaz Service Manual Topaz PA 1309/

25 General and Electrical Block Diagram * : Flash disk only on new CPU : Located within MCX Controller RS port VGA - Monitor AT - keyboard Handheld keyb. Power supply 5V, 12V, -12V CPU BOARD HD disk (C) up (8 Mb memory) Motherboard - VGA controller - HDD controller ISA - bus - FDD controller - I/O control 1.44 Mb (A) 3.5 Floppy I/O -1 I/O -2 Flash disk* Power Monitor SDLC Encoder signals SMEMA LY LX (FES) LW DRIVER - 2 FEEDER LZ BOARD SERVO -2 CONVEYOR I/O - 2 left - side LH ASSY board assy EMG. LT Traychanger Tray changer or ATS or ATS VACUUM UP/DOWN I/O - 1 HEAD I/O SENSING Encoder signals W Z DRIVER - 1 (FES) R BOARD SERVO -1 FEEDER X ASSY board assy CONVEYOR I/O -2 right side Y EMG. VACUUM EMERG. I/O -2 conveyor Cam 1, Fid. Cam 2, Single CONVEYOR Tray changer or ATS Cam 3, Multi 1 VICS 2000 Cam 4, Multi 2 MAINS POWER + SAFETY CIRCUIT 282 VOLT POWER SUPPLY EMG & I/O VISION POWER SUPPLY monitor Figure 2-2 Electrical block diagram Topaz Service Manual Topaz PA 1309/10 2-3

26 General and Electrical Block Diagram Intentionally Left Blank. Service Manual Topaz PA 1309/

27 System Principles CHAPTER 3 System Principles 3.1. Introduction 7KLVFKDSWHUGHVFULEHVDOOWKHLQVWDOODWLRQDQGWKH EDVLF V\VWHP SULQFLSOHV RI WKH 723$= 7KH ILUVW SDUW RI WKLV FKDSWHU GHVFULEHV WKH 0DLQV $LU DQG V\VWHP LQVWDOODWLRQ VSHFLILFDWLRQV7KHVHFRQGSDUWGLVFXVVHVWKH&RQWUROXQLW0&;ZLWKWKHUHODWHG 3&% VWKHWKLUGSDUWJLYHVDRYHUYLHZRIWKHYDULRXV,23&% V.H\ERDUGVDQG PRQLWRUV7KHODVWSDUWFRYHUVWKH,2VLJQDOVDQGDEULHILQWURGXFWLRQKRZWRXVH WKHYDULRXVDGMXVWPHQWFRPPDQGVDGMXVWPHQWPHWKRGVZKHQGRLQJDPDFKLQH DGMXVWPHQW Service Manual Topaz PA 1309/10

28 System Principles 3.2. Mains Specifications and Connection Schedule 7KH7RSD]PXVWEHFRQQHFWHGWRDWKUHHSKDVH0DLQVSRZHUV\VWHP7KH7RSD]KDV WKHIROORZLQJVSHFLILFDWLRQV $&9ROWDJHVHOHFWLRQ 9$& )UHTXHQF\ +] 3RZHUUDWLQJ.9$PD[ 9ROWDJHLQWHUUXSWLRQV 1RWORQJHUWKHQP6 9ROWDJHGURSV 1RWKLJKHUWKDQDQGQRWORQJHUWKHQ6HF 7KH PDLQV KDV WR EH FRQQHFWHG ZLWK FDEOHV ZLWK PP WR WKH WHUPLQDO EORFN ;%$OZD\VFRQQHFWDJURXQGZLUHRIPP WRWKHJURXQGWHUPLQDO03( 7KH0DLQVWUDQVIRUPHUVPXVWEHFRQILJXUHGDFFRUGLQJWRWKHVXSSOLHG0DLQVYROWDJH OHYHO7KHWDSVHWWLQJVRQWKHWZRWUDQVIRUPHUV7&DQG70PXVWEHFRQILJXUHG DFFRUGLQJWRWKHVFKHGXOHJLYHQLQILJXUH,QHYHU\V\VWHPWKHWUDQVIRUPHUWDS VHWWLQJVFKHGXOHFDQEHIRXQGDWWKHLQVLGHRIWKHSRZHUER[GRRU 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 For the transformer power tabs see section as well. 3-2 Service Manual Topaz PA 1309/

29 System Principles 9 Figure Tap settings of the mains transformers Service Manual Topaz PA 1309/10

30 System Principles,QILJXUHWKHFLUFXLWEUHDNHUER[LVVKRZQZLWKUHPRYHGIURQWFRYHU7KLVER[ ORFDWHVDOOWKHFLUFXLWEUHDNHUVRIWKH7RSD]V\VWHP%HORZDOLVWLVJLYHQRIDOOWKH FLUFXLWEUHDNHUVIXQFWLRQV 4) $ 0DLQVFLUFXLWEUHDNHU 4) $ 0RQLWRUV9*$9LVLRQPRQLWRUV 4) $ &RQWUROOHUER[DQGSRZHUVXSSO\*6 4) $ 0RWRUGULYHUV 4) $ &RQYH\RUPRWRUV ;% 0DLQVLQSXWWHUPLQDO Figure Circuit breaker box (with removed cover) 3-4 Service Manual Topaz PA 1309/

31 System Principles 3.3. Air Specifications and Connection 7KHDLUVXSSO\RIWKH7RSD]PXVWIXOILOOWKHIROORZLQJUHTXLUHPHQWV 3UHVVXUH ²EDU SVL )ORZ 1OPLQ &)0 2LOFRQWHQW PJP 'HZSRLQW ƒ&dwedu ƒ)dwsvl ƒ&dwedu ƒ)dwsvl $QDLUVXSSO\RI²EDUPXVWEHFRQQHFWHGWRWKHV\VWHPYLDDµ,'KRVH LQFKPLQLPXPVXLWDEOHIRUKLJKSUHVVXUH 7KHDLUPXVWUHPDLQZLWKLQWKHDERYHVSHFLILFDWLRQV2WKHUZLVHLQFUHDVHGIUHTXHQF\ RIVRPHPDLQWHQDQFHDFWLRQVRUGDPDJHWRWKHPDFKLQHZLOORFFXU )RUWKHDLUVXSSO\FRQQHFWLRQWRWKHV\VWHPSOHDVHUHIHUWRWKHDLUFLUFXLWGLDJUDPLQ FKDSWHUDQGWR 0DFKLQHLQVWDOODWLRQ$LUFRQQHFWLRQµLQVHFWLRQ Service Manual Topaz PA 1309/10

32 System Principles Interfaces 7KHUHDUHJHQHUDOLQWHUIDFHVEHWZHHQWKHYDULRXVSDUWVRIWKHPDFKLQHDQGEHWZHHQ WKH PDFKLQH DQG WKH RXWVLGH ZRUOG 7KH LQVLGH LQWHUIDFHV DUH 6'/& 6\QFKURQRXV 'DWD /LQN &RQWURO DQG,6$EXV 7KH RXWVLGH LQWHUIDFHV DUH 56 VHULDO LQWHUIDFH &HQWURQLFVSDUDOOHOLQWHUIDFH60(0$DQG*DWHLQ*DWHRXWLQWHUIDFH Bus Definitions,6$EXV 7KHXVHGEXVVWUXFWXUHZKLFKFRQQHFWVWKHYDULRXV3&%VLQVLGHWKHFRQWUROOHULVWKH VWDQGDUG,6$,QWHUQDWLRQDO6WDQGDUG$UFKLWHFWXUHEXV 6'/&OLQN 7KH FRPPXQLFDWLRQ EHWZHHQ WKH 6\VWHP ERDUG DQG WKH,2 ERDUGV IURQWUHDUWUD\ FKDQJHU LV GRQH YLD WKH 6'/& OLQN :LWK WKLV ELGLUHFWLRQDO V\QFKURQRXV OLQN WKH GDWDFORFNLVVHULDOO\WUDQVSRUWHGWRWKH,2ERDUGV7KHLQIRUPDWLRQVHQWYLDWKLVOLQN FRQWDLQV DGGUHVV LQIRUPDWLRQ IROORZHG E\ GDWD LQIRUPDWLRQ (DFK,2 ERDUG KDV LWV RZQ XQLTXH DGGUHVV $IWHU VHQGLQJ DQ DGGUHVV LW ZLOO EH GHFRGHG E\ WKH,2 3&% FLUFXLWU\DQLIWKHUHLVDPDWFKWKH,23&%LQTXHVWLRQZLOOWDNHRYHURUVHQGWKH GDWDLQIRUPDWLRQ 7KHUHDUHZLUHVIRUWKHGDWDVLJQDOVDQGZLUHVIRUWKHFORFNVLJQDO7KHWZRZLUHV DUH QHHGHG IRU HDFK VLJQDO EHFDXVH WKH VLJQDOV DUH VHQW YLD EXVWUDQVPLWWHUVUHFHLYHUV ORZYROWDJHVWRUHGXFHWKHLQIOXHQFHRIQRLVHVLJQDOV $VFDQEHVHHQIURPWKHEORFNGLDJUDPWKHVLJQDOVDUHIHGWRWKHILUVW,2ERDUGDQG YLDDUHFHLYHWUDQVPLWFLUFXLWU\SDVWRQWRWKHQH[W,2ERDUG7KLVPHDQVWKDWDGHIHFW LQWKHUHFHLYHWUDQVPLWFLUFXLWU\RQWKHILUVW,2ERDUGFDQFDXVHWURXEOHVRQWKHQH[W,2 ERDUGV LQ WKH FKDLQ 7KLV FDQ EH LPSRUWDQW IRU WKH FKDLQ ZKHUH WKH /&6 LV FRQQHFWHG,2WKLVEHFDXVHWKHWUD\FKDQJHULVFRQQHFWHGEHWZHHQWKHIURQWKHDG,2 ERDUG DQG WKH IURQW FRQYH\RU,2 ERDUG 7R RYHUFRPH SRVVLEOH SUREOHPV LW LV SRVVLEOH WR LQWHUFRQQHFW WKH,2 VLJQDO OLQH EHWZHHQ WKH IURQW KHDG,2 DQG IURQW FRQYH\RU,2LQWKHPDFKLQH +'/&OLQN 7KH+'/&OLQNSURWRFROLVVLPLODUWRWKH6'/&EXWRQO\XVHGLQWKHWKLUGJHQHUDWLRQ ERDUGV Serial Interface 7ZR56LQWHUIDFHSRUWVDUHSUHVHQWRQWKH7RSD]&01LVXVHGIRUWKHKDQGKHOG NH\ERDUGZKLOH&01LVXVHGIRUWKHFRQQHFWLRQEHWZHHQWKHV\VWHPERDUGDQGDQ H[WHUQDO3&V\VWHP7KHPHDQLQJRIWKH56FRQQHFWRUSLQVLVVKRZQLQWDEOH )LJXUHVKRZVVRPHH[DPSOHVRIFRQQHFWLRQVUHODWHGWRWKH'7('DWDWHUPLQDO (TXLSPHQWFRPSXWHUDQGWKH'&('DWD&RPPXQLFDWLRQ(TXLSPHQWPRGHP 3-6 Service Manual Topaz PA 1309/

33 System Principles Pin. Nr. Name 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 RS-232 Connections [RS 232] Figure RS-232 Connections Service Manual Topaz PA 1309/10

34 System Principles Line Interconnections 7KHUHDUHWZRPHWKRGVZKLFKFDQEHXVHGWRLQWHUFRQQHFWWZRRUPRUHV\VWHPVLQD OLQHWKH*$7(,1*$7(287DQGWKH60(0$PHWKRG 60(0$LQWHUIDFH 7KH 60(0$ LQWHUIDFH LV VWDQGDUG LQ WKH 7RSD],Q WKH ILJXUH EHORZ WKH 60(0$FRQQHFWLRQLVVKRZQ7KHIROORZLQJVLJQDOVFDQGLVWLQJXLVKHG 7KH%86<RXWVLJQDOIURPWKHPDLQWRWKHSUHYLRXVXSVWUHDP²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igure SMEMA interface *DWHLQ*DWHRXWLQWHUIDFH 7KH*DWHLQ*DWHRXWLVDPRUHVLPSOHLQWHUIDFHWRFRQQHFWWKHPDFKLQHVLQOLQH *DWHLQFRQQHFWRUSLQIHPDOH 7KLVLVWKHFRQQHFWRUIRULQFRPLQJ3&%UHTXHVWVLJQDOVIURPWKHPDFKLQHLQWKHQH[W SURFHVVWKHSLQQLQJRIWKLVFRQQHFWRULVDVIROORZV SLQVLJQDO1- &RXQWUHVHWVLJQDO SLQVLJQDO1- *DWHLQVLJQDOLQSXW SLQVLJQDO& 9*URXQGVKDUHGE\1-DQG Service Manual Topaz PA 1309/

35 System Principles *DWHLQVLJQDOLQSXW 7KLV VLJQDO LV UHFHLYHG IURP WKH PDFKLQH LQ WKH VXEVHTXHQW SURFHVV :KHQ WKHUH LV FRQGXFWLYLW\EHWZHHQ!FORVHGWKHV\VWHPMXGJHVWKDWDUHTXHVWIRUD3&% ORDGLQJKDVEHHQPDGH:KHQPRXQWLQJKDVILQLVKHGWKH3&%LVHMHFWHG &RXQWUHVHWVLJQDO 7KLV VLJQDO UHVHWV WKH FRXQWHU IRU WKH PD[ QXPEHU RI 3&%V,I! EHFRPH FRQGXFWLYHFORVHGWKH3&%FRXQWHULVUHVHW 7KHRXWSXWIURPWKHVXEVHTXHQWSURFHVVVKRXOGEHKDQGOHGDVUHOD\FRQWDFWSRLQWVGU\ FRQWDFWSRLQWQRYROWDJHRXWSXW,QILJXUHWKHJDWHLQFRQQHFWLRQLVVKRZQ Figure Gate-in * Figure Gate-out connection D W HRXWFRQQHFWRURXWSXW 7KLV LV WKH FRQQHFWRU IRU 3&% UHTXHVWVLJQDOV VHQW WR WKH PDFKLQH LQ WKH SUHYLRXV SURFHVVWKHSLQQLQJRIWKLVFRQQHFWRULVDVIROORZV SLQHPSW\ SLQ& UHOD\FRQWDFWSRLQWRXWSXW!'U\FRQWDFWSRLQW SLQ7. JDWHRXWVLJQDO *DWHRXWVLJQDORXWSXW 7KLVVLJQDOLVVHQWWRWKHPDFKLQHLQWKHSUHYLRXVSURFHVV,IWKHPDFKLQHLQWKH SUHYLRXVSURFHVVKDVFRPSOHWHGLWVSUHSDUDWRU\RSHUDWLRQVLWUHQGHUV! FRQGXFWLYH FORVHGDVD3&%UHTXHVWVLJQDO,QILJXUHWKHJDWHRXWFRQQHFWLRQ LVVKRZQ Service Manual Topaz PA 1309/10

36 System Principles +RZPDFKLQHVDUHFRQQHFWHGWRHDFKRWKHUXVLQJWKHJDWHLQDQGJDWHRXWLVVKRZQLQ ILJXUH Figure SMEMA connections 5HODWLRQEHWZHHQ*DWHLQ*DWHRXWDQG60(0$ 7KH UHODWLRQ EHWZHHQ 60(0$ DQG *DWHLQRXW LV VKRZQ LQ ILJXUH )RU PRUH GHWDLOVSOHDVHUHIHUWRWKHRYHUDOOLQWHUFRQQHFWGLDJUDPRIWKH7RSD]FKDSWHU Figure Principle SMEMA - Gate-in/out 3-10 Service Manual Topaz PA 1309/

37 System Principles 3.5. MCX-Control Unit MCX-Controller Lay-Out (Second Generation),QWKHILJXUHWKHVHFRQGJHQHUDWLRQ0&;FRQWUROOHUER[LVVKRZQ Figure Second generation MCX-control unit 7DEOHVKRZVWKHFRPSRQHQWVRIWKHFRQWUROOHU,QFKDSWHUDQLQWHUFRQQHFW GLDJUDPFDQEHIRXQGRIDOOWKHLQWHUQDOFRQQHFWLRQVRIWKH0&;FRQWUROXQLW Part no. Description Remarks 1 Driver power board 1x 282V power supply 2 Servo assy 1x servo board 2A Servo assy 1x servo board for the optional trayfeeder 3 Driver board 1x driver board (X,Y,R,Z, W ) 3A Driver board 1x driver board for the optional trayfeeder 4 System board 1x system board equipped with a 40486DX2 CPU, 8 Mb internal memory 5 VICS2000 1x Vision board 6 5V/12V power supply 5V, +12V and -12V power supply 7 HDD Hard disk 8 Mother board Mother board Table Controller parts Service Manual Topaz PA 1309/10

38 System Principles System Board 6HFRQGJHQHUDWLRQV\VWHPERDUG 7KHV\VWHPERDUGRIWKH0&;FRQWUROOHULVD';&38EDVHGV\VWHPUXQQLQJ DW0]7KHRQERDUGPHPRU\LV0E\WH$SLJJ\EDFN,2FRQWUROERDUGLVXVHGWR FRQWUROWKH,2FLUFXLWU\7KHERDUGVHHILJXUHKDVWKHIROORZLQJIXQFWLRQV l,qwhuidflqjwrdoorwkhu3&%vfrqqhfwhgwrwkhprwkhuerdug l +DUGGLVNLQWHUIDFLQJ l )ORSS\GLVNLQWHUIDFLQJ l 9LGHRLQWHUIDFH9*$ l.hhsvwudfnri'dwhdqg7lph l.h\erduglqwhuidfh l 6'/&,2LQWHUIDFHFRQWURO To HDD (CN4) JP1 to JP3 JP4 to JP6 JP7 underneath the application board BIOS ROM To Servo 1 Keyboard Floppy disk EMG RS232 con.1 To Servo 2 (option) Figure CN4 (Appl. Board) LED Good LED I/O LED Nogate LED Timeout System board Good signal I/O-1 I/O-2 RS232 con.2 VGA monitor 7KHMXPSHUVHWWLQJVHHILJRQWKLVVHFRQGJHQHUDWLRQV\VWHPERDUGLVIROORZLQJ l -3WR-3 6HWWRSRVLWLRQ l -3 6HWWRSRVLWLRQ 2QWKHDSSOLFDWLRQERDUGDOOVL[6:MXPSHUVDUHVHWWR2)) Position 2 Position 3 Position 1 Jumper on position 2-3 Figure Jumper setting $WWKHIURQWWKLVV\VWHPERDUGKDV/('LQGLFDWRUVWKH*22'VLJQDOLQGLFDWLQJWKH 32:(5 2. WKH,2 VLJQDO ZKLFK LV IODVKLQJ DV ORQJ DV WKHUH LV D FRUUHFW 3-12 Service Manual Topaz PA 1309/

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41 System Principles 5HIHUHQFHWDEOH $VDUHIHUHQFHWDEOHVKRZVWKHV\VWHPERDUGVXVHGLQWKHYDULRXV0&;FRQWUROOHUV RI WKH &60 )XOO9LVLRQ DQG &60*(0 V\VWHPV,W LV 127 UHFRPPHQGHG WR LQWHUFKDQJHV\VWHPVEHFDXVHRIWKHGLIIHUHQFHVLQPHPRU\IURQWSDQHODQG%,26520 Full Vision GEM Applicable KG2: Comet-I KL0: Comet-II KM5: Sapphire, KM5: Sapphire, Controller KG7: Eclipse-I KJ0: Orion, Eclipse-II Topaz, Emerald Topaz, Emerald Board, etc. System Board (complete assy) KJ0 - M x - 12x ( ) KJ0 - M x - 02x ( ) KJ0 - M x ( ) KM5 - M x ( ) Base System Board KJ0 - M x - 12x KJ0 - M x - 02x KJ0 - M x KM5 - M x KM5 - M x (2) Application Board KJ0 - M x KJ0 - M x KJ0 - M x KM5 - M x Front Panel KJ0 - M x (3) KJ0 - M x (3) KJ0 - M x (3) KM5 - M x Memory (1) -11x : 4Mbytes -12x : 8Mbytes -01x : 4Mbytes -02x : 8Mbytes 8Mbytes 8Mbytes 16Mbytes (4) BIOS ROM KJ0 - M42R9 - L0x KJ0 - M42R9-00x KJ0 - M42R9-00x Not applicable JP Not applicable Table Overview system boards 1RWHV 9,269RUODWHUQHHGV0E\WHV )URP'HFHPEHURQZDUGV 6L]HLVGLIIHUHQWEHWZHHQ.-«[DQG²[ :LWKV\VWHPERDUG.00; Service Manual Topaz PA 1309/10

42 System Principles Servo Board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o Vision To Driver Power To Driver 1(2) To Driver 1(2) Good signal To Vision CN7 CN9 CN10 CN3 CN5 CN8 Sticker 1 LED GOOD Sticker 2 Encoder signals CN1 S1 S3 Sticker 3 Encoder signals CN2 CN4 Figure Servo board 7KHVHUYRERDUGUHFHLYHVFRPPDQGVIURPWKHV\VWHPERDUGYLDWKH,6$EXVFRQQHFWRU &1RQWKHPRWKHUERDUG 3-16 Service Manual Topaz PA 1309/

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44 System Principles Vision Board 7KHYLVLRQERDUGLVWKH9,&6DQGKDQGOHVDOOYLVLRQUHODWHGRSHUDWLRQVH[FHSW ODVHU7KHERDUGOD\RXWLVVKRZQLQILJXUHEHORZ Camera 1 Camera 2 Camera 3 Camera 4 Jumpers F igure Vision board VICS KH9,&6YLVLRQERDUGLVHTXLSSHGZLWKFDPHUDFRQQHFWRUVIURPWRSWR ERWWRPWKH\DUHXVHGDVIROORZV &DPHUD µ &DPHUD µ &DPHUD µ µ &RQQHFWRUIRUWKHILGXFLDOFDPHUD &RQQHFWRUIRUWKHRSWLRQDOVLQJOHYLHZFDPHUD 7KHFRQQHFWRUVDQGFDQHLWKHUEHXVHGERWKIRUVLQJOH YLHZFDPHUD VRUERWKIRUPXOWLYLHZFDPHUD VGHSHQGLQJ RQWKHMXPSHUVHWWLQJV,WLVQRWSRVVLEOHWRXVHHJFDPHUD FRQQHFWLRQIRUDVLQJOHYLHZFDPHUDDQGFDPHUD FRQQHFWLRQIRUDPXOWLYLHZFDPHUD 7KHVHWWLQJVIRUWKHMXPSHUVWRRIWKHYLVLRQERDUGDUH VKRZQLQWKHWDEOHEHORZVHHDOVRILJXUH Camera 3 & 4 : Jumpers 1 to 4 : Single-camera Set jumper to position 1-2 Multi-camera Set jumper to position 2-3 Table Camera and jumper settings Position 2 Position 3 Position 1 Jumper on position 2-3 Figure Jumper setting 3-18 Service Manual Topaz PA 1309/

45 System Principles Mother Board 7KLVERDUGVHHILJXUHFRQQHFWVWKHYDULRXVERDUGVVXFKDVWKHV\VWHPERDUG VHUYRERDUGDQGYLVLRQERDUGYLDDQ,6$EXV7KHPRWKHUERDUGFRQWDLQVDOVRDQ$& DQG'&SRZHUIDLOXUHGHWHFWLRQIXQFWLRQ7KH$&LQSXWWKH'&9DQGWKH9 9DUHPRQLWRUHG$/('LQGLFDWLRQZLOOVKRZDSRZHUYROWDJHGURSLQVWDQWDQHRXV SRZHUIDLOXUHVDQGHUURUVLQWKH'&SRZHUVXSSO\IRUWKHFRQWUROV\VWHP7DEOH EHORZVKRZVWKHYDULRXVSRVVLELOLWLHV SERVO BOARDS SYSTEM BOARD VISION BOARDS LED 1, 2, 3, 4 CN9: I/O power CN6: 5V IN CN5: 12V IN /HJHQGD5 /LWUHG * /LW JUHHQ ; 1RWOLW CN11: AC 12V IN Figure Display LED PWR NG (Normally Specification off) LED 1 200VAC: VAC 180V X (VAC) VAC 160V R +5VDC: V1: 4.75V (V1) V1: < 4,75V V1: < 4.5V R +12VDC: 10.8V V2 13.2V (V2) 10.8V > V2 > 13.2V -12VDC: V3 < -10.8V (V3) V3 > -10.8V Table Meaning of the LED indicators CN7: FAN POWER NOT USED Mother board +5V (Normally on) LED 2 G X X +12V (Normally on) LED 3 G X SPARE QRWGHILQHG -12V (Normally NOTE on) LED 4 Normal AC voltage drop Normal DC 5V Error Normal DC +12V error G X Normal DC -12V drop Remark: It is possible that some mother boards have more connectors, this because some GEM machines need more PCB s (more axes, etc) Service Manual Topaz PA 1309/10