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

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

DOCUMENT DATA MANUAL TITLE MANUAL NUMBER PA NUMBER Service Manual Topaz 5322 871 63606 (01.05) PA 1309/10 ISSUE DATE ORDER NUMBER HISTORY REVISION CODE STATUS First Draft - 5322 871 63606 97.00 Replaced - First Issue Update Second Issue Update Oct-97 Mar-98 Mar-99 Jan. 2000 5322 871 63606 5322 871 63606 5322 871 63606 4022 591 93464 97.01 98.02 99.03 00.04 Replaced Replaced Replaced Replaced RELEASE DOCUMENT DI-CSM-025 DI-CSM-050 DI-CSM-076 DI-CSM-105 Third Issue April 2001 5322 871 63606 01.05 Current DI-CSM-138 Preventive and corrective maintenance is reserved for personnel certified by 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: http://www.emt.philips.com/support. Philips Electronic Manufacturing Technology B.V. All rights reserved. No part of this book may be reproduced in any form, by print, photoprint, microfilm or any other means without the written permission from Philips (Electronic Manufacturing Technology).

SAFETY General: For the correct and safe use of the CSM system, it is essential that both OPERATING and SERVICE personnel follow generally accepted safety procedures in addition to the safety precautions specified in these safety and quick reference cards. The operating, service and installation manuals have warning and cautionary statements throughout the whole 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.

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: 5322 871 63606 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 2 5600 MD Eindhoven The Netherlands

Service Manual Topaz Table of Contents 1. Introduction 1-1 1.1. General Introduction 1-1 1.2. Chapter Overview 1-2 1.3. Safety 1-4 1.3.1. General 1-4 1.3.2. Basic Rules 1-4 1.3.3. Safety Standards 1-4 1.3.4. Cautionary Remarks 1-5 1.3.5. Warning Stickers 1-5 1.3.6. ESD Precaution 1-7 1.3.7. Noise Level 1-7 1.3.8. Liability 1-7 1.3.9. Oil and Greases 1-8 1.3.10. Abbreviations 1-8 2. General and Electrical Block Diagram 2-1 3. System Principles 3-1 3.1. Introduction 3-1 3.2. Mains Specifications and Connection Schedule 3-2 3.3. Air Specifications and Connection 3-5 3.4. Interfaces 3-6 3.4.1. Bus Definitions 3-6 3.4.2. Serial Interface 3-6 3.4.3. Line Interconnections 3-8 3.5. MCX-Control Unit 3-11 3.5.1. MCX-Controller Lay-Out (Second Generation) 3-11 3.5.2. System Board 3-12 3.5.3. Servo Board 3-16 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 1

Table of Contents 3.5.4. Vision Board 3-18 3.5.5. Mother Board 3-19 3.5.6. Hard- and Floppy-Drives and Flash Disk 3-20 3.5.7. Driver Board Assy 3-21 3.5.8. D(river) - Power Assy 3-23 3.5.9. 5V / 12V Power Supply Assy s 3-23 3.6. LED Driver Board 3-24 3.7. I/O - Boards 3-27 3.8. Connection-Board 3-32 3.8.1. General 3-32 3.8.2. 2 nd Generation Connection-Board 3-33 3.8.3. 3 rd Generation Connection-Board 3-35 3.9. Keyboards 3-38 3.9.1. PC-Keyboards 3-38 3.9.2. Hand Held Keyboard (HHK) 3-38 3.10. Monitors 3-40 3.10.1. VIOS Monitor 3-40 3.10.2. Vision Monitor 3-40 3.11. I/O - Signals 3-41 3.11.1. VIOS Manual Mode I/O-Monitor 3-42 3.11.2. List of OUTPUT Signals (DO s) 3-43 3.11.3. List of INPUT Signals (DI s) 3-44 4. Power and Safety Circuits 4-1 4.1. Introduction 4-1 4.2. Safety Circuit 4-1 4.2.1. Description 4-1 4.2.2. Safety Circuit 4-2 4.3. Power Circuits 4-5 4.3.1. Description 4-5 4.3.2. 5V / 12V Power Supply MCX Box 4-7 4.3.3. 24V I/O and Emergency Power Supply (GS21) 4-9 4.3.4. D - Power Assembly (282V Power) 4-10 4.3.5. Measuring and Adjusting Data 4-12 4.3.6. Performance Check and Trouble Shooting 4-13 4.3.7. Maintenance Instructions 4-13 5. Vacuum and Pneumatic Systems 5-1 5.1. Vacuum Systems 5-1 5.1.1. Introduction 5-1 5.1.2. Functional Description 5-1 5.1.3. Air Supply Unit 5-2 5.1.4. Air Pressure Regulator 5-2 5.1.5. Pressure-Drop Detection Level 5-3 5.1.6. Measurement and Adjusting Vacuum Levels 5-4 5.1.7. Performance Check and Trouble Shooting 5-4 5.1.8. Maintenance Instructions 5-4 5.2. Pneumatic Systems 5-5 5.2.1. Introduction 5-5 5.2.2. Functional Description 5-5 5.2.3. Topaz 5-5 Service Manual Topaz 5322 871 63606 2 PA 1309/10 01.05

Table of Contents 5.2.4. Tray Changer (TC) 5-5 5.2.5. Tape Feeders 5-5 5.2.6. Automatic Tray Stacker 5-5 5.2.7. FES/SVS 5-5 5.2.8. Measuring and Adjusting 5-6 5.2.9. Performance Checks and Trouble Shooting 5-6 5.2.10. Maintenance Actions 5-6 5.3. Exchanging Head Ejectors, Valves and Base 5-7 5.3.1. Exchanging the Head Ejector and/or Valves 5-7 5.3.2. Exchanging the Head Up/Down, Slow Valves and Valve Base 5-8 6. PCB Transport Systems 6-1 6.1. Introduction 6-1 6.2. Conveyor Belt 6-2 6.2.1. Adjusting the Conveyor Belt Tension 6-2 6.2.2. Adjusting the Carry-In Conveyor Speed 6-3 6.3. Main Stopper 6-5 6.3.1. Adjusting the Ascent/Descent Speeds of the Main Stopper 6-5 6.3.2. PCB Contact Point 6-7 6.4. Push-In 6-8 6.5. Locate Pin 6-10 6.6. Edge Clamp 6-13 6.7. Push-Up 6-14 6.8. PCB Detection Sensors 6-16 6.9. Conveyor Errors 6-19 7. Component Transport Systems 7-1 7.1. Introduction 7-1 7.2. Head Assembly 7-1 7.2.1. Mechanical Check Head Assembly 7-2 7.2.2. Machine Coordinates 7-5 7.2.3. Pickup and Mount Vacuum Levels 7-9 7.2.4. R-axis Absolute Accuracy Offset 7-12 7.2.5. Nozzle Correction 7-13 7.2.6. Head Offset 7-14 7.3. Nozzle Station 7-15 7.3.1. Nozzle Station 7-15 7.3.2. Adjusting the Nozzle Sensor Sensitivity 7-16 7.3.3. Adjusting the Nozzle Clamp Plate Position 7-18 7.3.4. Adjusting the Nozzle Station Coordinates 7-18 7.3.5. Nozzle Station Maintenance 7-20 7.4. Feeder Plates 7-21 7.4.1. Feeder Plate Parallel Adjustment 7-21 7.4.2. Feeder Block Positions 7-22 7.4.3. Component Pickup Test 7-24 7.4.4. Feeder Plate Maintenance 7-26 7.5. Component Feeders 7-27 7.5.1. Tape Feeders 7-27 7.5.2. Minimum Timer / Load Timer / Down Timer 7-31 7.5.3. Tape Feeder Maintenance 7-32 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 3

Table of Contents 8. Axes Systems 8-1 8.1. Introduction 8-1 8.2. Machine Reference (Origin) 8-2 8.2.1. W-axis Machine Reference 8-3 8.2.2. Z-axis Machine Reference 8-4 8.2.3. X-axis Machine Reference 8-5 8.2.4. Adjusting the Y-axis Machine Reference 8-6 8.2.5. R-axis Machine Reference 8-7 8.3. Secondary Limits 8-8 8.3.1. X-axis Secondary Limits 8-8 8.3.2. Y-axis Secondary Limits 8-10 8.4. Software Limits 8-11 8.4.1. W-axis Software Limits 8-11 8.4.2. Z-axis Software Limits 8-14 8.4.3. X-axis Software Limits 8-16 8.4.4. Y-axis Software Limits 8-17 8.4.5. R-axis Software Limits 8-19 8.5. Initial Position and Initial Movement 8-20 8.5.1. W-axis Initial Position 8-20 8.5.2. Adjusting the R-axis Initial Position 8-21 8.5.3. Z-axis Initial Movement 8-22 8.6. Axes Assembly, Disassembly Adjustments and Maintenance 8-24 8.6.1. Adjustment of the X- and Y-motor Encoder Position 8-24 8.6.2. Head Replacement 8-25 8.6.3. X-axis Assembly 8-25 8.6.3.1. X-axis: Replacement X-motor Only 8-25 8.6.3.2. X-axis: Ball Screw Replacement 8-26 8.6.3.3. X-axis: Linear Guide Replacement 8-27 8.6.4. Y-axis Assembly 8-27 8.6.4.1. Y-axis: Replacement Y-motor Only 8-27 8.6.4.2. Y-axis: Removing Y-axis Ball Screw Generation 2 8-28 8.6.4.3. Y-axis: Removing Y-axis Ball Screw Generation 3 8-29 8.6.4.4. Y-axis: Installing and Aligning Y-axis Ball Screw Generation 3 8-30 8.6.4.5. Y-axis: Pre-tension Adjustment (Generation 3 Y-axis) 8-32 8.6.4.6. Y-axis: Linear Guide Replacement 8-33 8.6.5. Z-axis Assembly 8-34 8.6.6. R-axis Assembly 8-34 9. Vision Systems 9-1 9.1. Introduction 9-1 9.2. Vision Systems 9-1 9.2.1. Pre-Start Operations 9-2 9.3. Moving Camera 9-2 9.3.1. Adjusting the Focus and Field Of View 9-2 9.3.2. Adjusting the Lighting Level of the Moving Camera 9-3 9.3.3. Adjusting the Moving Camera Scale 9-7 9.4. Single Camera Adjustment 9-12 9.4.1. Maximum Component Size and Field Of View 9-12 9.4.2. Focus Adjustment 9-13 9.4.3. Lighting Level Adjustment 9-14 9.4.4. Camera Scale Adjustment 9-16 Service Manual Topaz 5322 871 63606 4 PA 1309/10 01.05

Table of Contents 9.4.5. Camera Optical Axis Angle Adjustment 9-20 9.5. Line Array Camera Adjustment 9-25 9.5.1. Maximum Component Size and Field Of View 9-25 9.5.2. Adjusting the Focus and Aperture 9-25 9.5.3. Adjusting the Lighting Level of the Line Array Camera(s) 9-27 9.5.4. Adjusting the Line Array Camera Scale 9-28 9.5.5. Adjusting the Dual Recognition Offset 9-33 9.5.6. Replacement of the Line Array Camera 9-34 9.6. Cleaning the Optical Systems 9-35 9.7. Recognition Errors 9-36 9.7.1. Chip Components 9-36 9.7.2. QFP Components 9-37 10. Software Section 10-1 10.1. Introduction 10-1 10.2. System Software 10-2 10.2.1. Operating System 10-2 10.2.2. Disk Organization 10-2 10.2.3. Installation Disk Contents 10-4 10.2.4. VIOS Software Utility 10-6 10.2.5. Installation of a New Version VIOS System Software 10-13 10.2.6. Backup Creation 10-14 10.2.7. VIOS Configuration 10-15 10.2.8. Floppy Disk Problems 10-16 10.2.9. Flash Disk Problems (Only for Systems with KM5 System Boards) 10-16 10.2.10. Hard Disk Problems 10-17 10.3. PCB File Handling 10-20 10.4. Machine Configuration 10-22 10.4.1. Machine Configuration Detailed 10-24 10.5. ROM and File Configuration (Version Level) 10-28 10.6. System Messages 10-29 10.7. Online Commands 10-32 11. Machine Installation and Calibration 11-1 11.1. Introduction 11-1 11.2. Installation 11-1 11.2.1. Installation Position (Work-Area Condition) 11-3 11.2.2. Environment 11-3 11.2.3. Leveling the System 11-3 11.2.4. Removing the Transportation Locks 11-4 11.2.5. Monitor and Keyboard Installation 11-5 11.2.6. Installation of the Warning Light Tower 11-5 11.2.7. Transformer Power Tabs 11-5 11.2.8. Air Connection 11-6 11.2.9. Power Connection 11-7 11.2.10. Switching On the Machine, Verify the Software Version 11-8 11.2.11. Vacuum Levels 11-9 11.2.12. Warm-up 11-9 11.2.13. Camera Check 11-10 11.2.14. Acceptance Test 11-13 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 5

Table of Contents 11.3. Machine Calibration 11-14 11.3.1. Back-up 11-17 11.3.2. Machine References (Origins) 11-20 11.3.3. Machine Limits 11-23 11.3.4. Initial Movement Z-axis 11-25 11.3.5. Initial Position R-axis 11-25 11.3.6. Teach Nozzle Station Positions 11-26 11.3.7. W-axis Parallelism 11-28 11.3.8. Initial Position W-axis 11-29 11.3.9. Vacuum Levels 11-30 11.3.10. Moving Camera Adjustment: Focus, Lighting Level, Scale 11-31 11.3.11. Single Camera Adjustment: Field Of View, Lighting Level, Focus, Scale 11-32 11.3.12. Line Array Camera Adjustment:Lighting Level, Field Of View, Scale, Focus, Optical Axis Alignment 11-34 11.3.13. Recognition Speed and Dual Recognition Offset 11-35 11.3.14. R-axis Accuracy 11-36 11.3.15. Mount Accuracy Calibration (Glass Plate) 11-37 11.3.15.1. Introduction 11-37 11.3.15.2. Conditions Required 11-38 11.3.15.3. Tools Required 11-38 11.3.15.4. AUTO MOUNT FEEDBACK (AMF) 11-39 11.3.15.5. Program Verification and Setup 11-40 11.3.15.6. Adjustment Procedure 11-40 11.3.15.7. Mount Calibration 11-47 11.3.15.8. Adjustment Steps for Topaz with Only Line Array Camera(s) 11-48 11.3.15.9. Adjustment Steps for Topaz with Line Array and Single Camera 11-55 11.3.15.10. Viewing the Data Offline 11-64 11.3.16. Calibration Feeder Plate 11-66 11.3.17. Final Board Accuracy Checks 11-69 11.3.18. Back-up 11-70 11.4. Procedure How to Run the AMF Program 11-70 11.4.1. Making PCB Data for the AMF Program 11-74 11.4.2. Mount Information 11-75 11.4.3. Component Information 11-76 11.4.4. Mark Information 11-78 11.4.5. Block Information 11-78 11.4.6. Fiducial Information 11-78 11.5. Explanation of Various Parameters AMF Program 11-79 11.5.1. Camera Scale 11-79 11.5.2. Camera Position 11-80 11.5.3. Nozzle Correction 11-82 11.5.4. Head Down Offset 11-83 11.5.5. Head Offset 11-83 11.5.6. R-axis Accuracy 11-84 11.5.7. Inconsistent Parameter 11-84 11.5.8. AMF Program 11-85 12. Maintenance 12-1 12.1. Introduction 12-1 12.2. Oils and Greases 12-2 Service Manual Topaz 5322 871 63606 6 PA 1309/10 01.05

Table of Contents 12.3. Maintenance Checkpoints 12-4 12.3.1. FD Drive, Filters and Air Valves 12-4 12.3.2. Head Area Checkpoints 12-9 12.3.3. X-axis Checkpoints 12-26 12.3.4. Y-axis Checkpoints 12-29 12.3.5. Conveyor Checkpoints 12-32 12.3.6. Feeder Plate Checkpoints 12-37 12.3.7. Vision Systems, Camera Lighting Unit 12-41 12.3.8. Performance Check and Trouble Shooting 12-44 12.4. Overview of Error Messages in VIOS 1.2 12-46 12.4.1. L-error Messages 12-46 12.4.2. E-error Messages 12-52 12.5 Overview of Error Messages in the Vision Monitor 12-150 13. Spare Parts List 13.0-1 13.0.1. General Information 13.0-1 13.0.2. Ordering Spare Parts 13.0-2 13.0.3. Regional Stock Keeping 13.0-2 13.0.4. Overview of the Various System Modules 13.0-3 13.0.5. First Aid Spare Parts Kit 13.0-5 13.1. Module 1, System Principles 13.1-1 13.1.1. MCX2 Control Unit 13.1-2 13.1.2. Cover Assemblies 13.1-8 13.1.3. Monitor Assembly 13.1-10 13.2. Module 2, Power and Safety Circuits 13.2-1 13.3. Module 3, Vacuum and Pneumatic Systems 13.3-1 13.4. Module 4, PCB Transport Systems 13.4-1 13.4.1. Conveyor Assembly 13.4-2 13.4.2. Conveyor Auto Width Assembly 13.4-4 13.4.3. Sub-stopper, Main-stopper and Locate Pin Assembly 13.4-6 13.4.4. Edge-clamp and Push-in Assembly 13.4-8 13.4.5. Push-up Pin and Push-up Assembly 13.4-10 13.5. Module 5, Component Transport Systems 13.5-1 13.5.1. Nozzle Station (Option for Standard Topaz) 13.5-2 13.5.2. Nozzle Selection 13.5-4 13.5.3. Head Assembly Part 1: General Parts 13.5-6 13.5.4. Head Assembly Part 2: Head Splines & SIMM-Topaz Head Assembly Spares 13.5-8 13.5.5. Head Assembly Part 3: Z-axis Assembly 13.5-10 13.5.6. Head Assembly Part 4: Valve and Ejector Assy s 13.5-12 13.5.7. Head Assembly Part 5: R-axis Assembly 13.5-14 13.5.8. Feeder Holder 13.5-16 13.6. Module 6, Axes Systems 13.6-1 13.6.1. X-axis Assembly 13.6-2 13.6.2. Y-axis Assembly 13.6-4 13.6.3. Z-axis Assembly 13.6-6 13.6.4. R-axis Assembly 13.6-6 13.7. Module 7, Vision Systems 13.7-1 13.7.1. Camera Systems 13.7-2 13.7.2. Lighting Systems 13.7-2 13.8. Module 8, Options 13.8-1 13.8.1. Tray Changer 13.8-1 13.8.2. Tape Feeders 13.8-1 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7

Table of Contents 13.8.3. Feeder Exchange System (FES) 13.8-1 13.8.4. Set-up Verification System (SVS) 13.8-1 13.8.5. Automatic Tray Stacker (ATS) 13.8-1 13.9. Module 9, Maintenance Tools 13.9-1 13.10. Module 10, Fixation Parts 13.10-1 14. Drawings and Circuit Diagrams 14-1 15. Main Index 15-1 16. Options 16-1 16.1. Tray Changer (TC) 16-2 16.1.1. Introduction 16-2 16.1.2. Specifications 16-3 16.2. Auto Tray Stacker (ATS 27) 16-4 16.2.1. Introduction 16-4 16.2.2. Specifications 16-5 16.3. Set-up Verification system (SVS) 16-6 16.3.1. Introduction 16-6 16.4. Feeder Exchange System (FES) 16-7 16.4.1. Introduction 16-7 16.4.2. Specifications 16-8 16.5. Component Feeders 16-8 16.6. Project SIMM Topaz (9466 920 06011) 16-9 17. Appendix 1: Material Safety Data Sheets 17-1 Service Manual Topaz 5322 871 63606 8 PA 1309/10 01.05

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. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 1-1

Introduction 1.2. Chapter Overview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ervice Manual Topaz 5322 871 63606 1-2 PA 1309/10 01.05

Introduction &KDSWHU &KDSWHU &KDSWHU &KDSWHU &KDSWHU &KDSWHU 0DLQWHQDQFH 7KLVFKDSWHUGHVFULEHVLQVSHFWLRQSHULRGVDQGSURFHGXUHVIRU GDLO\DQGSHULRGLFLQVSHFWLRQVWKDWVKRXOGEHSHUIRUPHG7KH LQVSHFWLRQOLVWVDUHH[SODLQHGDFFRUGLQJWRHDFKLQVSHFWLRQ ORFDWLRQDQGSHULRG%HVLGHWKHPDLQWHQDQFHSURFHGXUHVDOVR DQRYHUYLHZRIHUURUPHVVDJHVLQWKH9,26VRIWZDUHLVJLYHQ 6SDUHSDUWVOLVWV 7KLVFKDSWHUJLYHVDQRYHUYLHZRIVSDUHSDUWVGHILQHGIRUWKLV PDFKLQH 'UDZLQJVDQGFLUFXLWGLDJUDPV 7KLVFKDSWHUVKRZVWKHPRVWLPSRUWDQWHOHFWULFDODQGDLU FLUFXLWGLDJUDPV 0DLQLQGH[ 7KLVFKDSWHUVKRZVWKHPDLQLQGH[RIWKLVVHUYLFHPDQXDO 2SWLRQV 7KLVFKDSWHUGHVFULEHVDOOPDMRURSWLRQVDYDLODEOHIRUWKH7RSD] $SSHQGL[ 7KLVFKDSWHUHQFORVHVWKH0DWHULDO6DIHW\'DWD6KHHWVRIWKHRLOV DQGJUHDVHVXVHGLQWKH7RSD] 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 1-3

Introduction 1.3. Safety 1.3.1. General 3OHDVHREVHUYHDOOVDIHW\UXOHVDQGFDXWLRQDU\UHPDUNVWRHQVXUHWKDWWKHPDFKLQH LVXVHGLQDVDIHDQGFRUUHFWPDWWHU$OVRSOHDVHEHDULQPLQGWKDWQRWDOOVDIHW\ LWHPVFDQEHOLVWHGLQGHWDLOVRWKDWDQDFFXUDWHMXGJPHQWE\WKHVHUYLFHHQJLQHHU LVHVVHQWLDOLQVHUYLFLQJWKHPDFKLQHVDIHO\ 1.3.2. 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\ 1.3.3. Safety Standards 7KHVDIHW\RIWKH&60*(0V\VWHPVLVLQDFFRUGDQFHZLWKIROORZLQJ&( GLUHFWLYHV 0DFKLQHGLUHFWLYH((&DQG((&LQFOXGLQJDPHQGPHQWV /RZ9ROWDJHGLUHFWLYH((&LQFOXGLQJDPHQGPHQWV (0&GLUHFWLYH((&LQFOXGLQJDPHQGPHQWV Service Manual Topaz 5322 871 63606 1-4 PA 1309/10 01.05

Introduction 1.3.4. Cautionary Remarks 7KLV0DQXDOXVHVWKHIROORZLQJFDXWLRQDU\UHPDUNV REFERENCE: *LYHVXVHIXOLQIRUPDWLRQUHODWHGWRWKHPDFKLQHRSHUDWLRQ NOTE: ([SODLQVWKHPDFKLQHRSHUDWLRQVDQGSURFHGXUHVLQDVLPSOHDQGFOHDUPDQQHU CAUTION: *LYHVLPSRUWDQWLQIRUPDWLRQWRSUHYHQWDQ\GDPDJHWRWKHPDFKLQHRUGDWD WARNING: *LYHVLQIRUPDWLRQRIXWPRVWLPSRUWDQFHLQHQVXULQJWKHVDIHW\RIWKHRSHUDWRURU VHUYLFHSHUVRQQHO EMERGENCY BUTTON:,QGLFDWHVWRSUHVVILUVWWKHHPHUJHQF\EXWWRQEHIRUHFRQWLQXH 1.3.5. Warning Stickers 7KLVSDUDJUDSKJLYHVDQRYHUYLHZRIZDUQLQJVWLFNHUVWKDWDUHXVHGWRZDUQWKH RSHUDWRUVDQGVHUYLFHSHRSOHIRUGDQJHURXVVLWXDWLRQV:LWKHYHU\SLFWXUHDVKRUW GHVFULSWLRQLVJLYHQRIWKDWGDQJHURXVVLWXDWLRQ Do not enter Figure 1-1 Do not enter 7KLVVWLFNHUZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUQRWWRHQWHUE\KDQG,WLVORFDWHGDWWKHHQWUDQFHDQGH[LWFRQYH\RUUDLO 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 1-5

Introduction Electrical shock Figure 1-2 Electrical shock 7KLVVWLFNHUVHHILJXUHZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUIRUHOHFWULFDO VKRFN %HKLQGWKHFRYHUVDUHKLJKHOHFWULFDOYROWDJHVSUHVHQW Low Radiation Figure 1-3 Radiation 7KLVVWLFNHUVHHILJXUHZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUIRUORZUDGLDWLRQ 7KLVVWLFNHULVORFDWHGQHDUE\WKHODVHUWUDQVPLWWHUIRUIHHGHUIORDWLQJGHWHFWLRQ Service Manual Topaz 5322 871 63606 1-6 PA 1309/10 01.05

Introduction High temperature Figure 1-4 High temperature 7KLVVWLFNHUVHHILJXUHZDUQVWKHRSHUDWRUVHUYLFHHQJLQHHUIRUKLJK WHPSHUDWXUHSUHVHQFH7KLVVWLFNHULVORFDWHGXSRQWKH<PRWRURIWKH7RSD] 1.3.6. ESD Precaution $OO SULQWHG FLUFXLW ERDUGV WKDW DUH SDUW RI WKH &60*(0 PDFKLQHV PXVW EH WUDQVSRUWHGDQGVWRUHGLQ(6'SURWHFWHGEDJV $Q\SHUVRQKDQGOLQJDQ&60*(0SULQWHGFLUFXLWERDUG PXVW DGHTXDWHO\ EH HDUWKHG HJ E\ PHDQV RI D EUDFHOHW ZLWK HDUWK FDEOH WR SUHYHQW GHVWUXFWLYH HOHFWURVWDWLFGLVFKDUJHWKURXJKWKHSULQWHGFLUFXLWERDUG,Q DUHDV WKDW DUH QRW (6' SURWHFWHG WKH UHPRYDEOH SURWHFWLYH FRYHUV PXVW EH PRXQWHGRQDOOSODFHPHQWPRGXOHV +DQGOLQJRISULQWHGFLUFXLWERDUGVVKRXOGEHUHVWULFWHGDVPXFKDVSRVVLEOH 1.3.7. Noise Level 7KHDYHUDJHQRLVHOHYHORIWKH7RSD]V\VWHPGXULQJSURGXFWLRQLVG%$ 1.3.8. Liability 3KLOLSV VKDOO QRW EH OLDEOH IRU DQ\ FRVWV GDPDJHV RU SHUVRQDO LQMXULHV LI WKH &60*(0V\VWHPLVQRWXVHGDFFRUGLQJWRWKHVDIHW\UXOHVJLYHQLQWKLVPDQXDO 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 1-7

Introduction 1.3.9. Oil and Greases 7KLVVHFWLRQJLYHVPRUHGHWDLOHGLQIRUPDWLRQDERXWRLOVDQGJUHDVHVXVHGLQWKH 7RSD],QFKDSWHUDFRPSDWLELOLW\OLVWZLWKDQXPEHURIJUHDVHVWKDWFDQEHXVHGLV JLYHQ )ROORZLQJJUHDVHVDQGRLOVDUHFRYHUHG 12NC no. Supplier Trade name General description MSDS no. 5322 390 20159 NSK NSK 1 grease Multitemp CRL No3 Grease 07-230 5322 390 20161 NSK NSK 2 grease Multitemp PS No2 Grease 07-300 5322 390 20155 Molub alloy Grease - AccTech HP-Alco pad Cleaning tissues 806H-806 5322 390 10144 Ausimont Fomblin Y-VAC3 Vacuum grease 12298 O-rings and seals - Shell Alvania grease 2 Grease 56110-08 - Du Pont Krytox GPL-22X GPL-52X Vacuum grease O-rings and seals DU008134 Table 1-1 Note: Philips will not be responsible for any damage to the machine if other greases and/or oils are used than mentioned above. 1.3.10. Abbreviations 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 5322 871 63606 1-8 PA 1309/10 01.05

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 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 1-9

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General and Electrical Block Diagram CHAPTER 2 General and Electrical Block Diagram 7KLVFKDSWHUVKRZVERWKJHQHUDODQGHOHFWULFDOEORFNGLDJUDPVRIWKH7RSD] 7KHJHQHUDOEORFNGLDJUDPILJXUHVKRZVWKHPDLQVHFWLRQVRIWKH7RSD] 5HIHUHQFHVDUHPDGHWRWKHFKDSWHUVLQWKLVPDQXDO 7KHHOHFWULFDOEORFNGLDJUDPILJXUHVKRZVDQRYHUYLHZRIWKHPDLQHOHFWULFDO SDUWVRIWKHV\VWHP 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 2-1

General and Electrical Block Diagram VISION SYSTEM Chapt 9 COMPONENT TRANSPORT SYSTEM 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 5322 871 63606 2-2 PA 1309/10 01.05

General and Electrical Block Diagram * : Flash disk only on new CPU : Located within MCX Controller RS - 232 port VGA - Monitor AT - keyboard Handheld keyb. Power supply 5V, 12V, -12V CPU BOARD HD disk (C) - 80486 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 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 2-3

General and Electrical Block Diagram Intentionally Left Blank. Service Manual Topaz 5322 871 63606 2-4 PA 1309/10 01.05

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 5322 871 63606 Service Manual Topaz 3-1 01.05 PA 1309/10

System Principles 3.2. Mains Specifications and Connection Schedule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hen connecting the MAINS power, make sure to configure the Mains transformers before. When changing the Mains input voltage, always check first with the Philips service centre. Make sure to take all necessary precautions to avoid dangerous situations. NOTE: For the power connection to the system please refer to Machine installation: Power connection in section 11.2.9. For the transformer power tabs see section 11.2.7 as well. 3-2 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles 9 Figure 3.2-1 Tap settings of the mains transformers 5322 871 63606 Service Manual Topaz 3-3 01.05 PA 1309/10

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 3.2-2 Circuit breaker box (with removed cover) 3-4 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

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 5322 871 63606 Service Manual Topaz 3-5 01.05 PA 1309/10

System Principles 3.4. 3.4.1. 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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erial Interface 7ZR56LQWHUIDFHSRUWVDUHSUHVHQWRQWKH7RSD]&01LVXVHGIRUWKHKDQGKHOG NH\ERDUGZKLOH&01LVXVHGIRUWKHFRQQHFWLRQEHWZHHQWKHV\VWHPERDUGDQGDQ H[WHUQDO3&V\VWHP7KHPHDQLQJRIWKH56FRQQHFWRUSLQVLVVKRZQLQWDEOH )LJXUHVKRZVVRPHH[DPSOHVRIFRQQHFWLRQVUHODWHGWRWKH'7('DWDWHUPLQDO (TXLSPHQWFRPSXWHUDQGWKH'&('DWD&RPPXQLFDWLRQ(TXLSPHQWPRGHP 3-6 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

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 3.4-1 RS-232 Connections [RS 232] Figure 3.4-1 RS-232 Connections 5322 871 63606 Service Manual Topaz 3-7 01.05 PA 1309/10

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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 3.4-3 Gate-in connection>*$7(b,1:3*@ * Figure 3.4-4 Gate-out connection >*$7(B287:3*@ 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 5322 871 63606 Service Manual Topaz 3-9 01.05 PA 1309/10

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System Principles 3.5. MCX-Control Unit 3.5.1. MCX-Controller Lay-Out (Second Generation),QWKHILJXUHWKHVHFRQGJHQHUDWLRQ0&;FRQWUROOHUER[LVVKRZQ Figure 3.5-1 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 3.5-1 Controller parts 5322 871 63606 Service Manual Topaz 3-11 01.05 PA 1309/10

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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 - M4200-11x - 12x (5322 214 91532) KJ0 - M4200-01x - 02x (5322 216 04049) KJ0 - M4220-32x (5322 216 04308) KM5 - M4200-00x (5322 216 04468) Base System Board KJ0 - M4210-11x - 12x KJ0 - M4210-01x - 02x KJ0 - M4210-32x KM5 - M4210-00x KM5 - M4210-01x (2) Application Board KJ0 - M4220-10x KJ0 - M4220-10x KJ0 - M4220-10x KM5 - M4220-00x Front Panel KJ0 - M4135-10x (3) KJ0 - M4135-00x (3) KJ0 - M4135-00x (3) KM5 - M4135-00x 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 JP7 2-3 1-2 1-2 Not applicable Table 3.5-2 Overview system boards 1RWHV 9,269RUODWHUQHHGV0E\WHV )URP'HFHPEHURQZDUGV 6L]HLVGLIIHUHQWEHWZHHQ.-«[DQG²[ :LWKV\VWHPERDUG.00; 5322 871 63606 Service Manual Topaz 3-15 01.05 PA 1309/10

System Principles 3.5.3. 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 3.5-5 Servo board 7KHVHUYRERDUGUHFHLYHVFRPPDQGVIURPWKHV\VWHPERDUGYLDWKH,6$EXVFRQQHFWRU &1RQWKHPRWKHUERDUG 3-16 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles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achine type Topaz Emerald Sapphire A-table Sapphire B-table LCS100 LCS 31 ATS 27 Switch Bit S1 1 ON ON ON OFF 2 OFF ON OFF ON S3 1-6 ALL 6 OFF Table 3.5-3 Jumpers settings S1 and S3 :LWKWKHVHUYRERDUGDFRXSOHRIVWLFNHUVDUHGHOLYHUHGWKHVHVWLFNHUVVKRXOGEH PRXQWHGDWWKHSRVLWLRQVLQGLFDWHGLQILJXUHDQGDFFRUGLQJWRIROORZLQJWDEOH Machine type Topaz Emerald Sapphire A-table Sapphire B-table LCS100 LCS 31 ATS 27 Sticker Sticker 1 Servo.. 1 1A 1B 2 Sticker 2 PI.. 1 1A 1B 3 Sticker 3 PI.. 2 2A 2B 4 Table 3.5-4 Stickers versus machine types 7KHWDEOHEHORZVKRZVLIWKHFRQQHFWRUVLQGLFDWHGLQILJXUHKDYHDFDEOHDWWDFKHG WRDQRWKHUERDUG &µdvkruwfrqqhfwru 6µRUDUHOHIWXQFRQQHFWHG 1&µ Machine type Topaz Emerald Sapphire A-table Sapphire B-table LCS100 LCS 31 ATS 27 Connector CN3 C C C C CN5 C C C C CN7 C C C NC CN8 C C C NC CN9 C C S S CN10 C C C NC Table 3.5-5 Connectors versus machine types 5322 871 63606 Service Manual Topaz 3-17 01.05 PA 1309/10

System Principles 3.5.4. Vision Board 7KHYLVLRQERDUGLVWKH9,&6DQGKDQGOHVDOOYLVLRQUHODWHGRSHUDWLRQVH[FHSW ODVHU7KHERDUGOD\RXWLVVKRZQLQILJXUHEHORZ Camera 1 Camera 2 Camera 3 Camera 4 Jumpers F igure 3.5-6 Vision board VICS 2000 7KH9,&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 3.5-6 Camera and jumper settings Position 2 Position 3 Position 1 Jumper on position 2-3 Figure 3.5-7 Jumper setting 3-18 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles 3.5.5. Mother Board 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 3.5-8 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 3.5-7 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). 5322 871 63606 Service Manual Topaz 3-19 01.05 PA 1309/10

System Principles 3.5.6. Hard- and Floppy-Drives and Flash Disk +DUGGLVN,QV\VWHPVHTXLSSHGZLWKDQROGW\SHV\VWHPERDUGSOHDVHUHIHUWRVHFWLRQWKH KDUGGLVNVHHILJXUHLVORFDWHGDWWKHOHIWVLGHRIWKH0&;FRPSDUWPHQW 7KLVSK\VLFDOO\ODUJHGULYHLVIRUPDWWHGDVD0E\WHGULYHIRUVSHHGUHDVRQV 7KH99SRZHUVXSSO\IRUWKHKDUGGLVNLVFRPLQJIURPWKHPRWKHUERDUGYLD FRQQHFWRU&17KHVLJQDOFDEOHLVFRQQHFWHGWRWKHWRSVLGHRIWKHV\VWHPERDUG LQVLGHWKH0&;FRQWUROOHU Signal connector to system board Power connector +5V, +12V Figure 3.5-9 Hard disk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ote: When inserting or removing a flashdisk the Topaz should be switched off because the disk is not protected against such handling and might get damaged. Be sure to always mount the protective cover over the flash disk after mounting. 3-20 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles 3.5.7.Driver Board Assy 7KLVERDUGVHHILJXUHEHORZFDQGULYH$&PRWRUVIRUXSWRD[HV7KH DPRXQWRIPRWRUVXVHGGHSHQGVRQWKHW\SHRIPDFKLQH,QWKH0&;FRQWUROOHUWKH GULYHUERDUGLVDOZD\VXVHGIRUWKHPDLQPDFKLQHZKLOHWKHGULYHUERDUGLV GHGLFDWHGIRURSWLRQVVXFKDVWUD\FKDQJHUDQGDXWRWUD\VWDFNHU$76 CN6 CN1 282V power connection CN4 Power from servo-board CN2 From servo-board PWM/FDB signals CN3 Figure 3.5-10 Driver board 7KHPRWRUGULYHU'&SRZHULV9'&DQGLVVXSSOLHGE\WKH'ULYHUSRZHU VXSSO\YLD&12QWKHGULYHUERDUGWKH9'&LVFRQYHUWHGLQWRDQ$&VLJQDO IRUGULYLQJWKHSKDVH$&PRWRUV7KLVLVGRQHDVVKRZQLQILJXUH U Oscillator 50 khz V W 3 phase AC motor 12V 282V DC Power module Figure 3.5-11 Driver board principle 1RWHWKDWRQO\WKH;DQG<PRWRUVDUHDFWXDOWKUHHSKDVHPRWRUV 5322 871 63606 Service Manual Topaz 3-21 01.05 PA 1309/10

System Principles $.+]RVFLOODWRUSRZHUHGDW9DFWLYDWHVHYHU\SRZHUWUDQVLVWRUZKLFK VZLWFKHV9VHTXHQWLDOO\WKXVFUHDWLQJDSKDVH89:$&VLJQDOIRUGULYLQJ WKHPRWRUV 7KH*75*LDQW7UDQVLVWRUPRGXOHZKLFKFRQWUROVWKHFXUUHQWLVORFDWHGDWWKH UHDUVLGHRIWKHGULYHERDUGDQGLVPRXQWHGRQDODUJHKHDWVLQN 7KHPRWRUFXUUHQWRIDPD[LPXPRID[HVLVIHGYLD&1DQGDPD[RID[HVYLD &1WRWKH$&PRWRUV 7KH9 ±9SRZHUIRUWKHRVFLOODWRUDQGORJLFFLUFXLWU\LVUHFHLYHGIURPVHUYR ERDUGYLD&17KHFXUUHQWRIWKHORJLFSRZHULVFRQWUROOHGE\DQ,30,QWHOOLJHQW 3RZHU0RGXOHZKLFKLVIL[HGRQWKHKHDWVLQN 7KH SXOVH ZLGWK PRGXODWLRQ DQG IHHGEDFN SRZHU IDLOXUH RYHU FXUUHQW HWF VLJQDOV IURPWKHVHUYRERDUGDUHUHFHLYHGYLDFRQQHFWRU&1 Note: It is possible that not fully populated driver-boards are installed. The board only contains the drivers for the axes needed in the system. The not fully populated boards can always be replaced by a fully populated board which are stocked 7KHUH DUH RQO\ WZR YHUVLRQV RI GULYHUERDUGV RQH IRU WKH PDLQ V\VWHPV.- 0([DQGRQHIRUWKHRSWLRQV.-0[VXFKDVWUD\FKDQJHUV/&6 DQGDXWRWUD\VWDFNHUV$76 7KHWDEOHEHORZVKRZVRIWKHYDULRXVGULYHUERDUGVXVHGLQWKH&60)XOO9LVLRQ DQG&60*(0V\VWHPV Factory number KJ0-M5810- xxx Philips service no. Machine type Remarks -31x, -32x 5322 216 04018 CSM 66, 84, 84V III partly populated board -41x, -42x 5322 216 04262 LCS31, LCS100, ATS27 partly populated pcb -51x, -52x, 5322 216 04021 CSM 66, 84, 84V III partly populated, is replaced by 5322-216-04018-71x, 72x 5322 216 04017 CSM 66, 84, 84V III partly populated, is replaced by 5322-216-04018 - A1x, A2x 5322 216 04054 Orion, Eclipse-II, full populated Comet-II - E2x, 5322 216 04309 Topaz, Emerald, Sapphire full populated Table 3.5-8 Driver board types 3-22 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles 3.5.8. D(river) Power Assy 7KH'SRZHUDVV\UHFWLILHVWKHSKDVH9$&SRZHUDQGVXSSOLHV9'&WRWKH GULYHU ERDUGV 7KH DVVHPEO\ FRQVLVWV RXW RI WKH 'SRZHUERDUG LWVHOI DQG WKH FDSDFLWRU&$3ZKLFKLVORFDWHGDWWKHULJKWVLGHEDFNFRUQHURIWKH0&;FRQWUROOHU ER[VHHDOVRILJXUHEHORZ )RUPRUHGHWDLOVSOHDVHUHIHUWR FKDSWHUSRZHUVXSSO\V\VWHPV Figure 3.5-12 Driver power board 3.5.9. 5V / 12V Power Supply Assy s 7KH0&;FRQWUROXQLWKDVRQHSRZHUVXSSO\IRUWKH9'&DQGWKH9'& 7KHSRZHUVXSSO\LVPRXQWHGDWWKHOHIWVLGHLQWKH0&;FRQWUROER[VHHILJ Figure 3.5-13 5V,+12V,-12V Power supply )RUPRUHGHWDLOVSOHDVHUHIHUWRFKDSWHU SRZHUVXSSO\V\VWHPVµ 5322 871 63606 Service Manual Topaz 3-23 01.05 PA 1309/10

System Principles 3.6. LED Driver Board 7KH/('GULYHUERDUGLVWKHERDUGVHHILJXUHZKLFKFRQWUROVWKHOLJKW LQWHQVLW\RIWKHFRPSRQHQWFDPHUDV7KHUHDUHYDULRXVW\SHVRI/('GULYHUVIRU WKH6DSSKLUHDQG7RSD]V\VWHPVWKHVDPHYHUVLRQLVXVHG7KLV ERDUGFDQKDQGOHWZROLQHVHQVRUPXOWLFDPHUDOLJKWLQJRXWSXWVDQGDUHD&&' FDPHUDVLQJOHFDPHUDOLJKWLQJRXWSXW Light driver signals CN15 CN13 CN11 CN14 CN12 CN10 CN3 Motor encoder Power and control signals CN2 CN1 CN9 CN8 CN7 CN6 CN5 CN4 Lighting sensor signals VR1 VR2 VR3 VR4 VR5 VR6 Multi-cam 2 Coax.light Single camera Not used Multi-cam 1 Non-coax.light Multi-cam 1 Coax.light Multi-cam 2 Non-coax.light Figure 3.6-1 LED driver board (DFKRXWSXWKDVFKDQQHOVHDFKFKDQQHOKDVDEULJKWQHVVDGMXVWPHQW9595 7KHOLQHVHQVRUFKDQQHOVDUHHTXLSSHGZLWKDEULJKWQHVVIHHGEDFNV\VWHP 7KLVPHDQVWKHOLJKWLQJXQLWKDVDVHQVRUZKLFKPHDVXUHVWKHEULJKWQHVVWKHODWWHULV FRPSDUHGZLWKWKHUHIHUHQFHEULJKWQHVVDQGDVDUHVXOWRIWKLVWKHEULJKWQHVV GLIIHUHQFHFRQWUROVWKH/('FXUUHQW,QRUGHUWRSURWHFWWKH/(' VIRUPD[LPXP FXUUHQWWKHERDUGFRQWDLQVDFXUUHQWOLPLWWHUFLUFXLW7KHERDUGDOVRFRQWDLQVD VSHHGIHHGEDFNFLUFXLWU\ZKLFKLVFXUUHQWO\QRWLQXVH 3-24 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles HARDWARE VIOS 5HPDUNV 7KHMXPSHUVHWWLQJLVIL[HGDQGLVWKHVDPHIRUERWKWKH6DSSKLUHDQG7RSD] 7KH/('GULYHUERDUGIRUWKH(PHUDOGLV127FRPSDWLEOHZLWKWKHRQHXVHGLQ WKH6DSSKLUH7RSD]EHFDXVHRIWKHGLIIHUHQFHLQWKHFXUUHQWOLPLWHUV 7KHIROORZLQJWDEOHVKRZVWKHUHODWLRQEHWZHHQWKHVHYHUDOFDPHUDVFRQQHFWRUV SRWHQWLRPHWHUVPD[FXUUHQWVDQGMXPSHUVLQWKHKDUGDQGVRIWZDUH3OHDVHUHIHUWR ILJXUHIRUWKHORFDWLRQRIWKHYDULRXVLWHPV Vision Board Camera 1 Fiducial cam. LED driver board LED driver output Light type (note 2) Potentiometer Output connector Sensor connector Sensor jumper Speed jumper SL-bit jumper (note 3) Max current [ma] 3/1/option config/ - - - - - - - - - - - - - - - - - Camera 2 Camera 3 Camera 4 2 A VR3 CN10 CN4 JP9 JP4 JP1 120 B VR2 CN11 CN5 JP10 JP4 JP1 120 3 A VR1 CN12 CN6 JP11 JP6 JP2 90 B VR4 CN13 CN7 JP12 JP6 JP2 400 4 A VR5 CN14 CN8 JP13 JP7 JP3 90 camera combination - 1 2 3 3/2/MCH_DATA/ - Single camera 1 Multi camera 2 camera coordinate (note 1) Table 3.6-1 Vision board settings and controls B VR6 CN15 CN9 JP14 JP7 JP3 400 Multi camera 1 (note 1) NOTE 1: When the Topaz is only equipped with one multi camera, the camera is defined as multi-camera 1 regardless of the physical position of the camera. If the Topaz is equipped with two multi-cameras the front camera is defined as multi-camera 1 and the rear one as multi-camera 2. NOTE 2: When the table indicates a light type A the coaxial light is meant. When referring to the light type B the non-coaxial light is meant. Please be aware that the Emerald uses another definition for light type A and B; the B type in the Emerald is the CSP lighting! NOTE 3: The SL-bit is the Special Light bit setting which is used for switching between the coaxial and non-coaxial light, please refer to the text below. 2Q WKH /(' GULYHUERDUG WKUHH MXPSHUV SURYLGH D VSHFLDO OLJKW ELW VHWWLQJ WKLVVSHFLDOOLJKWELWLVXVHGWRVZLWFKEHWZHHQWKHFRD[LDOOLJKWDQGWKHQRQ FRD[LDOOLJKW$VZHGRQRUPDOO\XVHERWKWRJHWKHUZHGRQRWQHHGWRFKDQJH WKH VHWWLQJV 7DEOH EHORZ VKRZV WKH VHWWLQJV IRU WKHVH MXPSHUV IRU YHULI\LQJSXUSRVHVRQO\ 5322 871 63606 Service Manual Topaz 3-25 01.05 PA 1309/10

System Principles JP1-3 SET JP1-3 REMOVED Special light bit Light A Light B Light A Light B OFF OFF ON ON ON ON ON OFF ON OFF Table 3.6-2 Vision board special light bit settings 2QWKH/('GULYHUERDUGDQXPEHURIMXPSHUVDUHDYDLODEOHZKLFKDUHVHWIURP IDFWRU\7KHWDEOHEHORZVKRZVWKHVHWWLQJRIWKHVHMXPSHUVIRUYHULI\LQJSXUSRVHV RQO\ Jumper No. JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8 Setting: X - - X - X X - ;µ -XPSHUVHW -XPSHUQRWVHW Jumper No. JP9 JP10 JP11 JP12 JP13 JP14 Setting: 2-3 2-3 1-2 1-2 1-2 1-2 µru µlvwkhmxpshuvhwwlqjuhihuwriljxuhirudqh[dpsoh Table 3.6-3 Vision board jumper settings $VPHQWLRQHGEHIRUHWKHERDUGLVHTXLSSHGZLWKDVSHHGIHHGEDFNFLUFXLWU\ZKLFKLV FXUUHQWO\QRWLQXVH)RULQIRUPDWLRQDOSXUSRVHVRQO\WKHWDEOHEHORZLQGLFDWHV ZKLFKOLJKWW\SHDQGZKLFKFDPHUDLVHTXLSSHGZLWKWKLVIXQFWLRQDOLW\ Camera No. Cam. 2 Cam. 3 Cam. 4 Light No. Light A Light B Light A Light B Light A light B Light and feedback control No No No Yes Yes Yes Table 3.6-4 Vision board feedback control overview 3-26 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles 3.7. I/O - Boards Head I/O-board Left conveyor I/O-board Right conveyor I/O-board Figure 3.7-1 Location of the I/O boards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ervice Manual Topaz 3-27 01.05 PA 1309/10

System Principles 7KH,2ERDUGV DUH FRPPXQLFDWLQJ ZLWK WKH V\VWHP &38 ERDUG YLD D 6'/& SURWRFRO 7KH,QWHO PLFURSURFHVVRU RQ WKH GDXJKWHUERDUG LV FRQWUROOLQJ WKLV FRPPXQLFDWLRQ 7KHGDXJKWHUERDUGDOVRFRQWDLQVD520DQGD5$0PHPRU\7KH520PHPRU\ KROGVWKHVRIWZDUHIRUWKHSURFHVVRUWKLVVRIWZDUHLVORDGHGLQWRWKHPHPRU\RI WKLVSURFHVVRUDWVWDUWXS7KHSURFHVVRUXVHVWKH5$0PHPRU\DVDWHPSRUDU\ GDWDVWRUDJH 7KHPRWKHUERDUGRIWKH,2ERDUGFRQWDLQVDFRXSOHRIGLSVZLWFKHVZKLFKIXQFWLRQ,VGHVFULEHGLQWKHWDEOH Dipswitch: 1 2 3 4 5 6 7 8 Board: I/O-conveyor right 0 1 0 0 0 0 0 0 I/O-conveyor left 0 1 0 1 0 0 1 1 Switch functionality Type of board Type of board Type of board Left/right setting No function No function Terminator use Terminator use 1 = ON 0 = OFF Table 3.7-1 I/O-board DIP-switch settings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ervice Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles 7KHERDUGVRIWKHWKLUGJHQHUDWLRQDUHVKRZQLQWKHILJXUHVDQGEHORZ,Q WKHVHILJXUHVWKHORFDWLRQRIWKHLQGLFDWRUVDQGVHWWLQJVDUHKLJKOLJKWHG Flash memory 2 stage DIP switch 7 segment LED display LED-2 6 stage DIP-switch D1 D3 Figure 3.7-2 Conveyor I/O-board Flash memory 2 stage DIP switch 7 segment LED display LED-2 Figure 3.7-3 Head I/O-board D3 D5 D4 5322 871 63606 Service Manual Topaz 3-29 01.05 PA 1309/10

System Principles 7KHJUHHQ/('RQWKHFRUHERDUGDQGWKHJUHHQ/(''RQWKHKHDG,2ERDUG LQGLFDWHDJRRG9VXSSO\ZKHQOLW 7KHVHJPHQWGLVSOD\KDVEHHQDGGHGIRUVHOIGLDJQRVLVSXUSRVHVWKHHUURUFRGHVDUH VKRZQLQWKHWDEOHEHORZ Error code Meaning 1 Host communication time is over; interruption in communication. 2 Analogue-digital conversion error; I/O-board broken. 3 HDLC controller time is over; I/O-board is broken. Table 3.7-2 Core-board error codes 7KH\HOORZ/(''RQWKHFRQYH\RU,2ERDUGDQG'RQWKHKHDG,2ERDUG LQGLFDWHZKHWKHUWKHUHLVDVHULDOFRPPXQLFDWLRQRUQRWIROORZLQJFRGHVDUHXVHGIRU WKLVFRPPXQLFDWLRQ/('LQGLFDWRU Code Meaning Fast flashing Normal operation On-on-off on-on-off Host communication time over error, display shows code 1. On-off on-off +24V line shorted or broken. Table 3.7-3 I/O-board communication indicator 7KHJUHHQ/(''RQWKHFRQYH\RU,2ERDUGDQGWKHJUHHQ/(''RQWKHKHDG,2ERDUGLQGLFDWHDJRRG9ZKHQOLW 7KHVWDJH',3VZLWFKRQWKHFRQYH\RU,2ERDUGLVQHFHVVDU\WRPDNHWKHERDUG VXLWDEOHIRUHLWKHUWKHOHIWRUULJKWVLGHRUDWUD\IHHGHU7KHWDEOHEHORZVKRZVWKH VHWWLQJV Dipswitch: 1 2 3 4 5 6 Meaning: I/O-conveyor right 0 1 0 0 0 0 I/O-conveyor left 0 1 0 1 0 0 Trayfeeder 100 1 0 1 0 0 0 Trayfeeder 31 1 0 1 1 1 0 Table 3.7-4 I/O-board DIP-switch settings 1 = ON 0 = OFF 7KHWKLUGJHQHUDWLRQERDUGVKDYHWKHVDPHDPRXQWRI',3VZLWFKHVDVWKHVHFRQG JHQHUDWLRQERDUGVKRZHYHUWKHVZLWFKHVIRUWHUPLQDWRUXVHKDYHEHHQPRYHGWRWKH GDXJKWHUERDUGFRUHERDUGUHIHUWR VWDJH',3VZLWFKµLQILJXUHVDQG 7KHVHWWLQJVDUHVKRZQLQWKHWDEOHEHORZ Dipswitch: Sapphire Emerald/Topaz 1 2 1 2 1 = ON, enable 0 = OFF, disable Meaning: I/O-conveyor right, Trayfeeder/ATS 0 0 0 0 I/O-conveyor left 0 0 1 1 Head I/O 1 1 1 1 Table 3.7-5 I/O-board DIP-switch terminator settings 3-30 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles 7KHVHFRQGJHQHUDWLRQ,2ERDUGVPD\EHUHSODFHGE\WKLUGJHQHUDWLRQ,2ERDUGV ZLWKVRPHUHVWULFWLRQV7DEOHEHORZVKRZVDQRYHUYLHZRIWKH,2ERDUGVDQG WKHPDFKLQHVWKH\FDQEHXVHGLQ Conveyor I/O Head I/O Board types : KG2-M4520-21x (npn) (5322 214 91259) KG2-M4580-00x (pnp) (5322 216 04002) KM5-M4580-00x (pnp) (5322 216 04471) KG2-M4520-11X (npn) (5322 214 91258) KG2-M4570-00X (pnp) (5322 216 04004) KG7-M4520-01X (npn) (5322 214 91374) KG7-M4570-01X (pnp) (5322 216 04001) KM5-M4570-00X (pnp) (1) (5322 216 04313) KM5-M4570-01X (pnp) (5322 216 04469) KM1-M4570-00X (pnp) (5322 216 04083) KV1-M4570-00X (pnp) (5322 216 04628) Suitable for machines (for abreviations see table below) : EI, CI EI*, EII, EM, O, T, CI*, CII, S EII, O, EM (2), T (2), S (2) CI CI*, CII EI EI*, EII, EM S S O, T O, T ROM versions (latest version, basic flash ROM indicated with F) : KG2-M45R9-002 KG2-M45R9-023 KM5-M45R9-10X (F) KG2-M45R9-002 KG2-M45R9-023 KG7-M45R9-00X KG2-M45R9-023 KG2-M45R9-030 KM5-M45R9-10X (F) KG2-M45R9-023 KM5-M45R9-10X (F) Core board + Mother-board : n.a. n.a. KM5-M4560-11X + KM5-M4582-00X n.a. n.a. n.a. n.a. n.a. KM5-M4560-11X + KM5-M4572-00X n.a. KM5-M4560-110 + KV1-M4572-00X Abreviation EI EI* EII EM CI CI* CII S O T Meaning Eclipse I Eclipse I-CE Eclipse II Emerald Comet I Comet I-CE Comet II Sapphire Orion Topaz Remarks: 1. Board will be stopped in March 1998 and replaced by KM5-M4570-01X. 2. This board is standard implemented in these machines from December 1998 onwards, for Sapphire from august 1998 onwards. Table 3.7-6 I/O-board versions 5322 871 63606 Service Manual Topaz 3-31 01.05 PA 1309/10

System Principles 3.8. Connection-Board 3.8.1. General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onnection-board version Generation Service number KU1-M4550-00X 2 (old type) 5322 216 04312 KV7-M4550-11X 3 (new type) 5322 216 04675 Table 3.8-1 Connection-board versions 7KHGLIIHUHQFHVEHWZHHQWKH.90;ERDUG UG JHQHUDWLRQDQGWKHROGHU.80;ERDUG QG JHQHUDWLRQDUH 7KH UG JHQHUDWLRQERDUGFRQWDLQVPRUH/('LQGLFDWRUV Œ /('6UHGIRU(0*LQGLFDWLRQV Œ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µRIWKLV PDQXDO2QWKHERDUGVVRPHMXPSHUVHWWLQJVFDQEHVHWWRFRQILJXUHWKHV\VWHP GHSHQGLQJRQWKHDGGHGRSWLRQVDQGRUIHDWXUHV 3-32 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles 3.8.2. 2 nd Generation Connection-Board 2QWKHERDUGVHOHFWLRQVZLWFKHVDUHDYDLODEOH66DQG6 6DQG6DUHXVHGIRUWKH3&%GLUHFWLRQ6LVXVHGIRUWUD\FKDQJHUSRVLWLRQV 7KHWDEOHVEHORZVKRZWKHVHWWLQJRI6DQG6IRUWKHWUDQVSRUWVHOHFWLRQDQG6IRU WKHWUD\FKDQJHUSRVLWLRQ PCB direction S1 S2 L R (default) B C R L A C Table 3.8-1 S1 and S2 settings Configuration S3 : bit 1 S3 : bit 2 S3 : bit 3 S3 : bit 4 Standard ON ON ON ON Trayfeeder ON OFF OFF ON ATS-27A ON OFF ON OFF Table 3.8-2 S3 settings )LJXUHVKRZVWKHORFDWLRQRI6 Figure 3.8-1 Location of S1, S2 and S3 Note 1: Note 2: Note 3: The EMG harness of the trayfeeder should be connected to CNF26 and CNF28. The speedcontroller connects on SP1, the jumper harness does not connect on CNF2 and CNF3. When a special emergency input is added, set bit 3 of S3 to OFF and connect the emergency signal harness to CNF25 (dry contact). 5322 871 63606 Service Manual Topaz 3-33 01.05 PA 1309/10

System Principles )LJXUHVKRZVWKHFRPSOHWHOD\RXWRIWKH QG JHQHUDWLRQFRQQHFWLRQERDUG Figure 3.8-2 2 nd generation connection-board layout 3-34 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles 3.8.3. 3 rd Generation Connection-Board 'LSVZLWFKVHWWLQJV :KHQXVLQJWKH UG JHQHUDWLRQFRQQHFWLRQERDUGZLWKIDFWRU\QR.90; LQFRPELQDWLRQZLWKDQH[WHUQDOGHYLFHWKHGLSVZLWFKMXPSHUVHWWLQJVRI6DQG6 KDYHWREHVHWDVIROORZV 7KHVHWWLQJVIRU6DUHDVIROORZ Configuration S3 : bit 1 S3 : bit 2 S3 : bit 3 S3 : bit 4 Standard ON ON ON ON Table 3.8-3 S3 settings,qvrphvfkhpdwlfv6kdvmxpshuvzlwfkhv7khdgglwlrqdomxpshuvlqwkdwfdvh ELWDQGDUHPHDQWIRUDUHDVHQVRUVHOHFWLRQV7KLVRSWLRQLVQRWXVHGLQWKHFXUUHQW V\VWHPVVRWKHVHELWVDUHDOZD\VVHWWR 21 ZKLFKPHDQVWKDWWKH(0*FLUFXLW FRQQHFWHGWRWKLVMXPSHUKDVEHHQEULGJHG 7KHVHWWLQJVIRU6DUHDVIROORZ Configuration S4 : bit 1 S4 : bit 2 S4 : bit 3 S4 : bit 4 S4 : bit 5 S4 : bit 6 No trayfeeder ON ON ON ON ON ON LCS 1 OFF ON ON ON OFF ON ATS27 2 OFF ON ON ON ON ON ATS27 3 ON OFF ON ON ON ON Table 3.8-4 S4 settings Note 1: Connect EMG harness of the tray-feeder to CNF26 (S4-bit1) and CNF28 (S4- bit5) (see position A, figure 3.8-3). Note 2: Connect EMG harness of the tray-feeder to CNF26 (S4-bit1) (see position B, figure 3.8-3). Note 3: Connect EMG harness of the tray-feeder to CNF49 (S4-bit2) (see position C, figure 3.8-3). 5322 871 63606 Service Manual Topaz 3-35 01.05 PA 1309/10

System Principles B C $ Front Side Figure 3.8-3 Position of LCS and ATS on main machine 5HPDUN 3UHGHILQHGVHWWLQJVDUHVKRZQLQWDEOH2WKHUVHWWLQJVDUHSRVVLEOHEXWWKHQ GLIIHUHQWFRQQHFWRUVDUHXVHG3OHDVHUHIHUWRWKHLQWHUFRQQHFWDQGVDIHW\GLDJUDPVDQG WKHRYHUYLHZRIWDEOHWR 7KHUHODWLRQEHWZHHQWKH6DQG6GLSVZLWFKHVFRQQHFWRUVDQG/(' VDUHDVIROORZ 6ZLWKGLSVZLWFKHV Bit Connector Signal LED 1 CNF25 (EMG optional) EMG1 5 2 CNF45 (EMG spare) EMG4 19 3 CNF45 (EMG spare) EMG5 20 4 CNF45 (EMG spare) EMG6 (=8) 21 Table 3.8-5 S3 with 4 dip switches 6ZLWKGLSVZLWFKHV Bit Connector Signal LED 1 CNF25 (EMG optional) EMG1 5 2 n.a. only used for area sensor in main machine EMG3A 19 3 n.a. only used for area sensor in main machine EMG3B 20 4 CNF45 (EMG spare) EMG4 21 5 CNF45 (EMG spare) EMG5 22 6 CNF45 (EMG spare) EMG6 (=8) 23 Table 3.8-6 S3 with 6 dip switches 6GLSVZLWFKHV Bit Connector Signal LED 1 CNF26 (TF1 EMG switch) EMG1F 11 2 CNF49 (TF4 EMG switch) EMG2 12 3 CNF27 (Cover front 1 TF2) EMG2B 14 4 CNF43 (Cover front 2 TF5) EMG2C 15 5 CNF28 (Cover rear 1 TF3) EMG2E 17 6 CNF44 (Cover rear 2 TF6) EMG3 18 Table 3.8-7 S4 dip switches 3-36 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles $IWHUVZDSSLQJWKHFRQQHFWLRQERDUG Π&KHFNDQGRUFKDQJHWKHGLSVZLWFKVHWWLQJVRUKDUQHVVFRQQHFWLRQV Π&KHFNLIWKH(0*FLUFXLWLVDFWLYDWHGDIWHUSUHVVLQJWKHYDULRXVHPHUJHQF\SXVK EXWWRQVRUZKHQRSHQLQJWKHFRYHUVRIWKHPDLQPDFKLQHDQGLIFRQQHFWHGRQWKH H[WHUQDOGHYLFHV,QFKDSWHUDUHYLVHGGLDJUDPLVVKRZQRIWKHVLPSOLILHGVDIHW\FLUFXLW,WVKRZVDOOWKH (0*VLJQDOVWRJHWKHUZLWKWKHFRUUHVSRQGLQJ/(' VDQGWKHSRVLWLRQRIWKHMXPSHUV RIWKHGLSVZLWFKHV6DQG6 Figure 3.8-4 Connection-board KV7-M4550-11X (3 rd generation) 5322 871 63606 Service Manual Topaz 3-37 01.05 PA 1309/10

System Principles 3.9. Keyboards 7KHV\VWHPKDVWZRGHYLFHVWRHQWHULQIRUPDWLRQPDQXDOO\DKDQGKHOGNH\ERDUGDQGD 3&NH\ERDUGVHHILJXUH Dead man switch Emergency button Joy stick Full keyboard enable keyswitch R ead y Runni ng Hand held keyboard Ready Manu al Joy Speed stick Scree n Stop Res et Sel axi s Run Error cl ear Axis group Esc H elp F9 F10 Tab Ins See full keyboard Ctrl Sh ift Del Enter PC keyboard F9, F10 Insert, Delete F1 (Help) Esc 1, 2, 3...4 1 2 3 4 5 6 7 8 9 0 Tab Q W E R T Y U I O P A, B, C...Z Shift A S D F G H J K L Z X C V B N M Enter Shift Ctrl Ctrl SD 6245 Figure 3.9-1 Topaz key-boards 3.9.1. PC-Keyboard 7KLV NH\ERDUG LV D VWDQGDUG VPDOO YHUVLRQ ZLWKRXW NH\SDG 3&$7 NH\ERDUG DQG LV FRQQHFWHGWRWKHFRQWUROOHUYLDDFRQQHFWRUSOXJRQWKHIURQWVLGHRIWKHV\VWHPERDUGLQ WKH0&;FRQWUROOHU7KLVNH\ERDUGFDQEHXVHGIRUDOOGDWDHQWHULQJDFWLYLWLHVLWFDQEH UHPRYHGIURPWKHPDFKLQHLIRSHUDWRUVDUHQRWDOORZHGWRXVHLW 3.9.2. Hand Held Keyboard (HHK) 7KLVNH\ERDUGLVSHUPDQHQWO\FRQQHFWHGWRWKHV\VWHPYLDDFDEOHHQWHULQJWKH7RSD]DW WKH ULJKW VLGH RI WKH V\VWHP 9LD WKLV NH\ERDUG VLPSOH RSHUDWRU IXQFWLRQV FDQ EH SHUIRUPHGVXFKDV5816723DQG5(6(7 7KH FRQQHFWLRQ EHWZHHQ WKLV NH\ERDUG DQG WKH 0&;FRQWUROOHU FRQVLVW RI IROORZLQJ VLJQDOV n $VHULDOFRPPXQLFDWLRQOLQH56JRLQJWRWKH&01SRUWRQWKHIURQWVLGHRI WKHV\VWHPERDUGLQWKH0&;FRQWUROOHU n 7KH9VXSSOLHGIURPWKHLQWHUFRQQHFWLRQERDUG n (PHUJHQF\VZLWFKDQG5HDG\VZLWFKVLJQDOV n 'HDGPDQSXVKEXWWRQVLJQDO 3-38 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles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f one of the SERVICE KEY-switches (front and/or rear) of the system are activated, there is only a limited function possible with the hand-held key-board. The only actions possible are the joystick and emergency-button actions, all other buttons are disabled because of safety reasons. 5322 871 63606 Service Manual Topaz 3-39 01.05 PA 1309/10

System Principles 3.10. Monitors 7KHV\VWHPKDVWZRPRQLWRUVVHHILJXUHORFDWHGDWWKHWRSRIWKHPDFKLQHRQH 9,26PRQLWRUVHHSDUDJUDSKDQGRQHYLVLRQPRQLWRUVHHSDUDJUDSK %RWKPRQLWRUVFDQEHVKLIWHGWRWKHUHDUVLGHE\URWDWLQJGHJUHHVIRUHDV\XVH Vision monitor VIOS monitor Figure 3.10-1 Topaz monitors 3.10.1. VIOS Monitor 7KH9,26PRQLWRULVDVWDQGDUG3KLOLSV9*$PRQLWRUW\SH,QWKHPRQLWRUJXLGHOLQH ERRNOHW DQ H[SODQDWLRQ LV JLYHQ RI WKH YDULRXV DGMXVWPHQWV DV FRQWUDVW EULJKWQHVV + VKLIW+VL]H9VKLIW9VL]HWUDSH]RLGSLQFKXVLRQURWDWLRQDQGGHJDXVV 3.10.2. Vision Monitor 7KLVPRQLWRULVD%:%ODFNDQG:KLWH3KLOLSVYLGHRPRQLWRUIRUGLVSOD\LQJWKH YLVLRQLQIRUPDWLRQIURPWKHYLVLRQERDUG7KHPRQLWRUFDQEHRUGHUHGYLDWKHUHJXODU FKDQQHOV7KHLPSHGDQFHVZLWFKDWWKHEDFNPXVWEHVHWWRRKP 3-40 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles 3.11. I/O - Signals 7KLV SDUDJUDSK ZLOO FRYHU WKH EDVLF LQSXW DQG RXWSXW VLJQDOV,Q WKH 9,26 PHQX D VFUHHQ,2PRQLWRUVHHILJXUHLVDYDLODEOHWKDWJLYHVLQIRUPDWLRQRIDOOLQSXW DQGRXWSXWVLJQDOV$OOWKH,2VLJQDOVVKRZQDUHWKHDFWXDOUHDOWLPHFRQGLWLRQV7KH,2PRQLWRU VFUHHQ FRQVLVWV RI VFUHHQV WKH SLFWXUH RQO\ VKRZV ZKLFK FDQ EH DFFHVVHGE\VFUROOLQJXSRUGRZQ7KHOHIWVLGHRIWKHVFUHHQVKRZVWKHRXWSXWPRQLWRU DQGWKHULJKWVLGHRIWKHVFUHHQWKHLQSXWPRQLWRU DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/MCH_CONFIG 2/MCH_DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT Dialogue box Out Monitor :Select [Enter]:Exec Selected Arm:MAIN XY [ESC]:Command Lists Moving Speed: 100 TR09 TRAY CHANGER SPARE N A M E OUT N A M E IN Screen 1 Front Fdr data TJ01-08 00000000 Origin/Limit * NJ01-08 00000000 Front Fdr index TJ09-16 00000000 Origin/Limit * NJ09-16 00000000 Signal Tower TK01-08 00000000 Spare * NK01-08 00000000 FORE(M123/LEV) TK09-16 00000000 Spare * NK09-16 00000000 Spare * TL01-08 00000000 Conveyor NL01-08 00000000 Spare * TL09-16 00000000 Conveyor NL09-16 00000000 Rear Fdr data TM01-08 00000000 Origin/Limit * NM01-08 00000000 Rear Fdr index TM09-16 00000000 Origin/Limit * NM09-16 00000000 N A M E OUT N A M E IN Screen 2 Head Down TE01-08 00000000 Spare * NE01-08 00000000 LED(FID/BACK) TE09-16 00000000 Spare * NE09-16 00000000 Head Sequence * TF01-08 00000000 Spare * NF01-08 00000000 Head Sequence * TF09-16 00000000 Spare * NF09-16 00000000 Blow Timer * TG01-08 00000000 Head Lowend * NG01-08 00000000 Blow Timer * TG09-16 00000000 Origin/Limit * NG09-16 00000000 Head Vacuum TH01-08 00000000 Head Pic.Vacuum NH01-08 00000000 Head Blow * TH09-16 00000000 Head Mnt.Vacuum NH09-16 00000000 N A M E OUT N A M E IN Screen 3 Conveyors TN01-08 00000000 Nozzle Sensor NN01-08 00000000 Conveyors TN09-16 00000000 Nozzle Sensor NN09-16 00000000 Nzl Clamp/Spare TP01-08 00000000 Spare * NP01-08 00000000 Spare * TP09-16 00000000 Nzl Clamp/Spare NP09-16 00000000 Tray Changer TQ01-08 00000000 Tray Changer NQ01-08 00000000 Tray Changer TQ09-16 00000000 Tray Changer NQ09-16 00000000 Tray Changer TR01-08 00000000 Tray Changer NR01-08 00000000 Tray Changer TR09-16 00000000 Tray Changer NR09-16 00000000 Current selection Figure 3.11-1 VIOS DI/DO-monitor window $ FRPSOHWH OLVW RI DOO LQSXW DQG RXWSXW VLJQDOV LV JLYHQ RQ WKH QH[W SDJHV 7KH\ DUH VKRZQZLWKWKHGHVFULSWLRQFRQQHFWLRQORFDWLRQDQGUHODWLRQVKLSWRRWKHUVLJQDOV Remarks: T(01) stands for: OUTPUT signal N(N01) stands for: INPUT signal The signal names TN01, TP01, TM09, NQ16, etc. are related to the corresponding labels on the harnesses. The DI/DO lists on the next pages shows this relation. 5322 871 63606 Service Manual Topaz 3-41 01.05 PA 1309/10

System Principles 3.11.1. VIOS Manual Mode I/O-Monitor 2XWSXW0RQLWRU,QPDQXDOPRGHWKHRXWSXWPRQLWRUFDQEHVHOHFWHGE\DFFHVVLQJWKHIROORZLQJPHQX 23(5$7,2100$18$/'6$9( (;,7'287387021,725 %\SODFLQJWKHFXUVRURQWKHGHVLUHGILHOGWKHGHVFULSWLRQRIWKHSDUWLFXODUELWLVVKRZQLQ WKHGLDORJXHER[7KH(17(5!NH\FDQEHXVHGWRWRJJOHDVSHFLILFELWEHWZHHQWKH DFWLYHVWDWH µdqgwkhqrwdfwlyhvwdwh µ WARNING ONLY TRAINED CSM SERVICE ENGINEERS ARE ALLOWED TO USE THE INPUT/OUTPUT MONITOR FEATURE!. ACTIVATING MACHINE FUNCTIONS BY MEANS OF THE OUTPUT MONITOR MAY CAUSE DAMAGE TO THE MACHINE IF NOT USED CORRECTLY. The system will not check if an activation of an output signal will cause a dangerous situation.,qsxw0rqlwru,qpdqxdoprghwkhlqsxwprqlwrufdqehvhohfwhge\dffhvvlqjwkhiroorzlqjphqx 23(5$7,2100$18$/'6$9( (;,7',1387021,725 %\SODFLQJWKHFXUVRURQWKHGHVLUHGILHOGWKHGHVFULSWLRQRIWKHSDUWLFXODUELWLVVKRZQ LQWKHGLDORJXHER[7KHVHELWVFDQQRWEHPDQLSXODWHGEHFDXVHWKH\DUHLQSXWELWV 3-42 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

System Principles 3.11.2. List of OUTPUT Signals (DO s) )ROORZLQJWDEOHVKRZVDQRYHUYLHZLQDOSKDEHWLFDORUGHURIDOO'DWD 2XWSXWVXVHGLQWKH7RSD]V\VWHP 7KHWDEOHFRPELQHVVLPLODURXWSXWVDVIROORZV 7+ +HDGWRKHDGYDFXXP 7KLVPHDQVRXWSXW7+LVKHDGYDFXXP7+LVKHDGYDFXXPHWF 7( 6SDUH 7KLVPHDQVRXWSXW7(DQG7(DUHVSDUH TA01-16 Spare TL08 Front non-stop fdr.carriage backward TB01-16 Spare TL09-16 Spare TC01-16 Spare TM01-8 R.feeder data1 to data8 TD01-16 Spare TM09-12 R.feeder select1 to select4 TE01-8 Head1 to head8 down TM13-16 Spare TE09 Head light1(for moving) on TN01 Main stopper TE10+11 Spare TN02 Plate push up TE12 Head 1-2 slow down TN03 Locate pin1 TE13 Head 3-4 slow down TN04 Edge clamp TE14 Head 5-6 slow down TN05 Push in TE15 Head 1-8 slow down TN06 Stopper of entrance TE16 Head serial cmn ok TN07-11 Spare TF01-8 Head1 to 8 active head-sequence TN12 Conveyor reverse TF09-13 Extended do TN13 Conveyor on TF14 Head-sequence vac/mnt TN14 Conveyor speed low TF15 Head-sequence vac.check TN15+16 Spare TF16 Head-sequence start TP01 Nozzle station up TG01-8 Timer set bit0 to bit7 TP02 Nozzle station clamp TG09-11 Timer head-no select bit0 to bit2 TP03+4 Spare TG12-14 Timer port-no select bit0 to bit2 TP05 Rear non-stop fdr.carriage up TG15 Spare TP06 Rear non-stop fdr.carriage down TG16 Timer start TP07 Rear non-stop fdr.carriage forward TH01-8 Head1 to head8 vacuum TP08 Rear non-stop fdr.carriage backward TH09-16 Head1 to head8 blow TP09 Sp. Light (single camera1) up TJ01-8 F.feeder data1 to data8 TP10 Sp. Light (single camera2) up TJ09-12 F.feeder select1 to select4 TP11 Sp. Light (single camera3) up TJ13-16 Spare TP12-16 Spare TK01 Buzzer TQ01 Tray changer pallete home TK02 Blue/yellow lamp TQ02 Tray changer hook forward TK03 White/red lamp TQ03 Tray changer hook close TK04 Green/green lamp TQ04 Tray changer pallete set TK05 Gate out TQ05 Tray changer hook backward TK06 Spare TQ06+7 Tray changer spare TK07 Cover lock TQ08 Ext.tc conveyor on TK08 Ba out(smema) TQ09 Ext.tc conveyor reverse TK09 Spare TQ10 Tray changer door1 lock TK10 Lamp11(single camera 1) on TQ11 Tray changer door2 lock TK11 Lamp12(single camera 2) on TQ12 Tray changer door1 light TK12 Lamp13(multi camera) on TQ13 Tray changer door2 light TK13-15 Brightness1 to brightness3 TQ14+15 Tray changer spare TK16 Spare TQ16 Tray changer servo on TL01 B.c conveyor on TR01-3 Ext.tc station1 to station3 vacuum TL02 B.c conveyor reverse TR04-12 Tray changer spare TL03 B.c speed low TR13 Ext.tc head vacuum TL04 B.c speed high TR14 Tray changer spare TL05 Front non-stop fdr.carriage up TR15 Ext.tc head down TL06 Front non-stop fdr.carriage down TR16 Tray changer spare TL07 Front non-stop fdr.carriage forward Table 3.11-1 List of D(ata) O(utputs) used in the Topaz 5322 871 63606 Service Manual Topaz 3-43 01.05 PA 1309/10

System Principles 3.11.3. List of INPUT Signals (DI s) )ROORZLQJWDEOHVKRZVDQRYHUYLHZLQDOSKDEHWLFDORUGHURIDOO'DWD,QSXWVXVHGLQWKH7RSD]V\VWHP 7KHWDEOHKDQGOHVVLPLODULQSXWVLQWKHVDPHPDQQHUDVGHVFULEHGIRUWKHRXWSXWV UHIHUWRFKDSWHU NA01-16 Spare NM02 W-axis origin NB01-16 Spare NM03+4 Spare NC01-16 Spare NM05 2nd limit spare ND01-16 Spare NM06 Spare NE01-8 Head1 to 8 memory active head-sequence NM07 Rear feeder lock 2 NE09-14 Extended di NM08 Rear feeder-carriage lock NE15 Head sequence finish NM09 Air pressure NE16 Timer busy NM10 Rear feeder lock 1 NF01-16 Spare NM11 Rear area NG01-8 No 1 to no8 head up/down NM12+13 Spare NG09 X-axis origin NM14 Smema discrimination NG10 Spare NM15 Smema ba in NG11 R-axis origin NM16 Spare NG12 Nozzle down NN01-16 Nozzle 1 to nozzle 16 NG13+14 Spare NP01 Rear non-stop fdr.carriage detect switch NG15 X-axis over travel NP02 Rear non-stop fdr.carriage detect upper NG16 Spare NP03 Rear non-stop fdr.carriage detect forward NH01-8 Head1 to head8 pick up judgment NP04 Sp. Light (single camera1) up NH09-16 Head1 to head8 mount judgment NP05 Spare NJ01 Y-axis origin NP06 Sp. Light (single camera1) down NJ02+3 Spare NP07+8 Can t use NJ04 Relay spare NP09 Sp. Light (single camera2) up NJ05 Y-axis over travel NP10 Sp. Light (single camera2) down NJ06 Spare NP11 Sp. Light (single camera3) up NJ07 Front feeder lock 2 NP12 Sp. Light (single camera3) down NJ08 Front feeder-carriage lock NP13+14 Front nozzle station clamp NJ09 Invalid fullkey board service key NP15 Nozzle station up NJ10 Front feeder lock 1 NP16 Nozzle station down NJ11 Front area NQ01 Tray changer pallet origin NJ12 Gate in NQ02+3 Tray changer hook open + close NJ13 Release cover emergency NQ04 Tray changer pallet set NJ14 Contactor ok NQ05 Tray changer relay spare NJ15 Count reset NQ06+7 Tray changer spare NJ16 Can t use NQ08 Tray changer door1 interlock NK01-8 Nozzle 17 to 24 NQ09 Tray changer door2 interlock NK09 Front non-stop fdr.carriage detect switch NQ10 Rack1 in(ext.tc),latch open NK10 Front non-stop fdr.carriage detect upper NQ11 Rack2 in(ext.tc),latch close NK11 Front non-stop fdr.carriage detect forward NQ12 Ext.tc head beam NK12-16 Spare NQ13 Ext.tc head vacuum NL01 Sub position1 of ent. NQ14 Tray changer spare NL02 Conveyor entrance NQ15 Ext.tc head lower NL03 Conveyor exit NQ16 Tray changer spare NL04 Sub position2 of ent. NR01-3 Ext.tc station1 to station3 vacuum NL05 Dump station NR04 Tray changer hook safety(zpos) NL06 Spare NR05+6 Autotc-s hook forward + backward NL07+8 Can t use NR07 Tc board discrimination NL09 Set position NR08 Tray changer +24v ok NL10 Locate pin1 NR09+10 Tray changer door1 + door2 sw NL12 Locate pin2 NR11 Ext.tc conveyor entrance NL13 Spare NR12 Ext.tc pcb check position NL14 Rear nozzle station clamp NR13 Ext.tc conveyor exit NL15 Push up plate fixed NR14 Ext.tc select switch NL16 Spare NR15 Ext.tc pcb check ok NM01 Spare NR16 Ext.tc w axis origin Table 3.11-1 List of D(ata) O(utputs) used in the Topaz 3-44 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

Power and Safety Circuits CHAPTER 4 Power and Safety Circuits 4.1. Introduction 7KH7RSD]KDVDQXPEHURIVDIHW\FLUFXLWVDQGSRZHUVXSSOLHV,QWKHILUVWSDUWRI WKLVFKDSWHUWKHVDIHW\FLUFXLWU\ZLOOEHGLVFXVVHGWKHVHFRQGSDUWZLOOKDQGOHWKH YDULRXVSRZHUVXSSOLHVZKLFKDUHXVHGLQWKHV\VWHP'HWDLOHGVFKHPDWLFVFDQEH IRXQGLQFKDSWHURIWKLVPDQXDO 4.2. Safety Circuit 4.2.1. Description 7KHVDIHW\LQWHUORFNFLUFXLWRIWKH7RSD]FRQVLVWVRXWRIDQXPEHURIVZLWFKHVDQG UHOD\VFRQWDFWV7KHVHVZLWFKHVRUFRQWDFWVDUHDFWLYDWHGGXULQJDQXQVDIHVLWXDWLRQ RI WKH PDFKLQH ([DPSOHV DUH RSHQ FRYHUV RYHUWUDYHO ORZ YROWDJHV ORZ DLU RYHUFXUUHQWDFWLYDWLRQRIWKH(0*VZLWFKHV)LJXUHVKRZVWKHVDIHW\FLUFXLW GLDJUDPZLWKWKHYDULRXVVDIHW\VZLWFKHVDQGUHOD\VFRQWDFWV2QWKHQH[WSDJHD VLPSOLILHGGUDZLQJLVPDGHRIWKLVFLUFXLW 7KH IROORZLQJ VLWXDWLRQV FDQ DFWLYDWH DQ HPHUJHQF\ VLWXDWLRQ ZKLFK FDXVHV DQ LPPHGLDWHVWRSRIDOOPRYHPHQWVLQVLGHWKHPDFKLQH 2SHQLQJRIRQHRIWKHFRYHUVGXULQJUXQQLQJRIWKHPDFKLQH 7KHRYHUWUDYHO27VLJQDOLQGLFDWHVDPRYHPHQWRIRQHRIWKHD[HVEH\RQG WKHVRIWOLPLWUDQJH /RZDLUSUHVVXUH $FWLYDWLRQ RI RQH RI WKH (0(5*(1&< VZLWFKHV ZKLFK DUH ORFDWHG DW WKH IURQWDQGWKHUHDUVLGHRIWKHPDFKLQHDQGDWWKHKDQGKHOGNH\ERDUG )HHGHUIORDWLQJVLJQDOLILQVWDOOHGLQGLFDWLQJDZURQJO\LQVWDOOHGIHHGHU /RZYROWDJHV 2YHUFXUUHQWLQRQHRIWKHPRWRUGULYHUERDUGV,QPRVWFDVHVWKHFRQWUROOHUZLOOGLVSOD\DQ(5525FRGHZLWKDVKRUWGHVFULSWLRQ RIWKHHPHUJHQF\FDXVHRQWKH9,26PRQLWRU,QSDUDJUDSKDOLVWRISRVVLEOH FDXVHVLVJLYHQ,IWKH7UD\&KDQJHULVLQVWDOOHGDOVRHPHUJHQF\FRQGLWLRQVIURP WKLVGHYLFHFDQVWRSWKHPDFKLQH 5HDFWLYDWLRQ RI WKH V\VWHP LV RQO\ SRVVLEOH DIWHU UHVROYLQJ WKH HPHUJHQF\ FDXVH DQGSUHVVLQJWKH5($'<VZLWFKDWWKHKDQGKHOGNH\ERDUG WARNING When working at the systems safety circuit make sure to take all the necessary safety precautions to avoid possible danger. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 4-1

Power and Safety Circuits 4.2.2. Safety Circuit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igure 4-1 Safety circuit Topaz Service Manual Topaz 5322 871 63606 4-2 PA 1309/10 01.05

Power and Safety Circuits Colour Mark Condition for LED ON 1 Yellow LED1 EMG circuit of HEAD I/O-1 board Over Travel is OK 2 Yellow LED2 EMG circuit of HEAD I/O-2 board Over Travel is OK 3 Yellow LED3 EMG circuit of CONVEYOR I/O-1 board Over Travel is OK 4 Yellow LED4 EMG circuit of CONVEYOR I/O-2 board Over Travel is OK 5 Yellow LED5 EMG circuit of optional EMG and HHK EMG STOP is OK 6 Yellow LED6 EMG circuit of CONVEYOR I/O-1 board EMG STOP is OK 7 Yellow LED7 EMG circuit of CONVEYOR I/O-2 board EMG STOP & MCX OK 8 Yellow LED8 EMG circuit of Tray Changer is OK (NOT for Sapphire) 9 Yellow LED9 EMG circuit of FRONT cover stop is OK 10 Yellow LED10 EMG circuit of Tray Changer front cover OK (NOT for Sapphire) 11 Yellow LED11 EMG circuit of REAR cover stop is OK 12 Yellow LED12 EMG circuit of Tray Changer rear cover OK (NOT for Sapphire) 13 Green +24VA DC24V input at CNF22 is OK 14 Green +24VB DC24V input at CNF21 is OK 15 Green +24S Non 16 Green +EMG DC24V input at CNF23 is OK 17 Green +24E DC24V of EMG safety is OK (only when Servo is switched on) Table 4-1 Meaning of LED s on the 2 nd generation connection-board Note 1: When LED1 to LED4 are ON, and the LED5 to LED12 are OFF, then the HHK EMG STOP (LED5) is NOT GOOD (NG). This means that there is something wrong with the HHK circuitry. Note 2: As can be seen from the diagram figure 4-1, it is only possible to have a cover open at one side at the time. It is also needed to press continuously the dead man push-button in order to keep the servo system active. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 4-3

Power and Safety Circuits QG JHQHUDWLRQFRQQHFWLRQERDUG.90; Figure 4-2 Revised safety circuit Topaz Led no. L Colour Mark Condition for LED ON 1 Yellow LED1 X-1 over travel is OK 2 Yellow LED2 Not used 3 Yellow LED3 Y-1 over travel is OK 4 Yellow LED4 Not used 5 Yellow LED5 Not used (on) 6 Yellow LED6 HHK emergency stop is OK 7 Yellow LED7 Not used 8 Yellow LED8 Not used (offf) 9 Yellow LED9 Not used (off) 10 Yellow LED10 Controller & EMG front/rear is OK 11 Yellow LED11 Tray feeder emergency stop 1 is OK 12 Yellow LED12 Tray feeder emergency stop 2 is OK 13 Yellow LED13 Cover stop of front side is OK 14 Yellow LED14 Tray feeder cover stop of front side 1 is OK 15 Yellow LED15 Tray feeder cover stop of front side 2 is OK 16 Yellow LED16 Cover stop of rear side is OK 17 Yellow LED17 Tray feeder cover stop of rear side 1 is OK 18 Yellow LED18 Tray feeder cover stop of rear side 2 is OK 19 Yellow LED19 Spare 1 emergency circuit is OK 20 Yellow LED20 Spare 2 emergency circuit is OK 21 Yellow LED21 Spare 3 emergency circuit is OK Table 4-2 Meaning of LED s on the 3 rd generation connection-board Service Manual Topaz 5322 871 63606 4-4 PA 1309/10 01.05

Power and Safety Circuits Note 1: When LED1 to LED5 are ON, and the LED6 to LED21 are OFF, then the HHK EMG STOP (LED6) is NOT GOOD (NG). This means that there is something wrong with the HHK circuitry. Note 2: As can be seen from the diagram figure 4-2, it is only possible to have a cover open at one side at the time. It is also needed to press continuously the dead man push-button in order to keep the servo system active. 4.3. Power Circuits 4.3.1. Description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ote: Make sure to set the correct input voltage taps when installing the machine. see chapter 3, for the correct settings. WARNING Only trained technical personnel is allowed to work in the power section of the machine. Take care to take the necessary actions to avoid dangerous situations. Switch off the mains power when working in the mains power box. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 4-5

Power and Safety Circuits Figure 4-3 Power rating diagram Topaz system PA1309/10 Figures given are the maximum ratings of the individual items Service Manual Topaz 5322 871 63606 4-6 PA 1309/10 01.05

Power and Safety Circuits 4.3.2. 5V /12V Power Supply MCX Box,QWKH0&;FRQWUROOHUD7'.050SRZHUVXSSO\LVXVHGWRVXSSO\9 9 DQG ²9 7KLV SRZHU VXSSO\ LV ORFDWHG DW WKH OHIW VLGH RI WKH 0&; FRQWUROOHU ER[ SOHDVH UHIHU WR ILJXUH 7KH OD\RXW RI WKLV SRZHU VXSSO\ LV VKRZQLQWKHILJXUH MCX-2 controller box TDK MRM270 Figure 4-4 +5/+12/-12V power supply location Jumper input voltage CP50 Output terminal Input terminal CP1 CP2 (230V ) W1 CP3 (115V ) R76 R57 CP51 CP52 Output terminal Output terminal R83 R86 Output voltage adjust trimmer PFS signal adjust trimmer Output voltage adjust trimmer Figure 4-5 Power supply PCB layout 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 4-7

Power and Safety Circuits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igure 4-6 Jumper setting 7KHIROORZLQJDGMXVWPHQWVFDQEHGRQH 7KH99DGMXVWPHQWLVGRQHE\5DGMXVWWR²99 7KH99DGMXVWPHQWLVGRQHE\5DGMXVWWR99 7KH99DGMXVWPHQWLVGRQHE\5DGMXVWWR99 7KHSRZHUIDLOXUHVLJQDODGMXVWPHQWLVIDFWRU\DGMXVWHG Service Manual Topaz 5322 871 63606 4-8 PA 1309/10 01.05

Power and Safety Circuits 4.3.3. 24V I/O and Emergency Power Supply (GS21) 7KH9SRZHUVXSSO\*6LVRIWKHW\SH+<5*1ZKLFKFDQGHOLYHUDQ RXWSXW FXUUHQW RI PD[ $ 7KH $& LQSXW YROWDJH RI WKLV SRZHU VXSSO\ LV IDFWRU\VHWWR9$& $WWKHUHDUVLGHRIWKLVSRZHUVXSSO\WKHRXWSXWYROWDJHFDQEHDGMXVWHGE\PHDQV RI D SRWHQWLRPHWHU 9DGM SOHDVH UHIHU WR ILJXUH $GMXVW WKH YROWDJH WR 9± Figure 4-7 Back GS21 7KH SRZHU VXSSO\ LV ORFDWHG LQ WKH SRZHU ER[ DW WKH UHDU VLGH RI WKH V\VWHP QH[W WR WKH WZR PDLQV WUDQVIRUPHUV 70DQG7& 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 4-9

Power and Safety Circuits D - Power Assembly (282V Power) 7KH'SRZHUDVV\UHFWLILHVWKHSKDVH9$&SRZHUDQGVXSSOLHV9'&WR WKHGULYHUERDUGV7KHDVVHPEO\FRQVLVWVRXWRIWKH'SRZHUERDUGLWVHOIDQGWKH FDSDFLWRU &$3 ZKLFK LV ORFDWHG DW WKH ULJKWVLGH EDFN FRUQHU RI WKH 0&; FRQWUROOHUER[VHHILJXUHEHORZ 200V AC (U) IN 200V AC (V) IN 200V AC (W) IN Fuse 1 Fuse FU2 LED 5 LED 4 LED 3 LED 2 LED 1 282V to Driverboards Jumper 1 Cap 1 18V in from trafo CN1 Interlock CN3 EMG CN2 Figure 4-8 D(river) power assy 7KHIROORZLQJFLUFXLWVFDQEHGLVWLQJXLVKHG 9UHIHUHQFHFLUFXLW 7KH UHIHUHQFH FLUFXLW UHFHLYHV D 9$& YROWDJH &1 IURP D VHSDUDWH WUDQV RUPHU LQVLGH WKH 0&; ER[ 7KH 9$& LV SURWHFWHG E\ D IXVH )8 RI $PS $IWHU UHFWLI\LQJ D 9'& YROWDJH LV JHQHUDWHG ZKLFK LV XVHG IRU WKH FRQWUROOLQJFLUFXLWU\7KH/('JUHHQZLOOEHOLWDVORQJDVWKHWHPSHUDWXUHLV 2. Service Manual Topaz 5322 871 63606 4-10 PA 1309/10 01.05

Power and Safety Circuits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nterlock CN3 Effect LED Conditions for close INT1 pos.1-2 Voltage low 3 Output over 186V DC INT2 pos.3-4 Phase loss 2 3-phase AC input is active (JP1:1-2) OR only 1-phase AC input is active (JP1:2-3) INT3 pos.5-6 EMG CN2 pos.1-2 Temp./voltage Over flow 4 1 Temp. is under 65 degrees Celcius AND the ouput is under 414V DC. 3OHDVHUHIHUWR&KDSWHUIRUWKHFLUFXLWGLDJUDPRIWKH'SRZHUDVV\ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 4-11

Power and Safety Circuits 4.3.5. Measuring and Adjusting Data 0&;FRQWUROOHUER[ 7KH YROWDJHV LQVLGH WKH 0&; FRQWUROOHU ER[ FDQ EH PHDVXUHG DW WKH PRWKHU ERDUG FRQQHFWRUV &1 DQG QHDU WKH /(' LQGLFDWRUV IROORZ WKH QH[W SURFHGXUHWRGRVR /RRVHQWKH0&;ER[VRLWFDQVOLGHRXWRIWKHPDFKLQH /RRVHQWKHWZRWRSFRYHUVFUHZV 5HPRYHWKHOHIWIURQWFRYHUDWWKHPRWKHUERDUG/(' V 6RPHFRQQHFWRUVFDQQRZEHVHHQVHHPRWKHUERDUG&KDSWHU 0HDVXUHDWFRQQHFWRUV&1RU&1EHKLQGWKH/(' VWKHIROORZLQJ YROWDJHV &1 9±9 SLQV &1 9±9 SLQV &1 *1' SLQV &1 9±9 SLQ &1 9±9 SLQV &1 9±9 SLQV &1 *1' SLQV,IWKHPHDVXUHGYROWDJHLVQRWZLWKLQWKHDERYHJLYHQVSHF VWKH\FDQEH DGMXVWHGZLWKWKHSRWHQWLRPHWHUVDVLVLQGLFDWHGLQILJXUH 5HLQVWDOOWKHIURQWDQGWRSFRYHUDIWHUWKHDGMXVWPHQWLVGRQH 3XVK0&;FRQWUROOHUER[EDFNLQWRWKHPDFKLQHDQGVHFXUHLW WARNING Make sure to check the +5, +12, and -12 Volt power supplies inside the MCX controller at regular intervals (each 3 months). Especially the +12 and -12 Volts are important for the servo systems because they are used for the IC s in the servo control circuitry *6²9SRZHUVXSSO\ 7KH YROWDJH RI WKH *6 SRZHU VXSSO\ FDQ EH PHDVXUHG DW WKH SRZHU VXSSO\ WHUPLQDOV&DUU\RXWIROORZLQJDFWLRQV 2SHQWKHSRZHUER[GRRUVDWWKHUHDUVLGHRIWKHV\VWHP /RFDWHWKH*6SRZHUVXSSO\DQGPHDVXUHDWWKHWHUPLQDOVWKHIROORZLQJ YROWDJH9±9,IWKHYROWDJHLVQRW2.DGMXVWWKHOHYHOZLWKSRWHQWLRPHWHU59ILJ &ORVHWKHSRZHUER[GRRUV Service Manual Topaz 5322 871 63606 4-12 PA 1309/10 01.05

Power and Safety Circuits 4.3.6. Performance Check and Trouble Shooting 1R SHUIRUPDQFH FKHFN LV QHHGHG IRU WKH SRZHU VXSSOLHV RI WKH V\VWHP $OO SRZHUVXSSOLHVKDYHD/('LQGLFDWLRQJUHHQOLJKWZKHQWKHYROWDJHLVRN7KLV FDQEHKDQG\LQFDVHRIWURXEOHVKRRWLQJVRPHSUREOHPV0DNHVXUHWKDWWKH *22'VLJQDO 32:(5 1* LV QRW DFWLYDWHG $OO VHUYR ERDUGV DUH LQWHUFRQQHFWHG ZLWK DQ (0* VLJQDO WKLV VLJQDO JLYHV DQG (0(5*(1&< HUURUZKHQDFWLYH 4.3.7. Maintenance Instructions &KHFNWKHYROWDJHVRIDOOSRZHUVXSSO\VHDFKPRQWKVDQGDGMXVWWKHPLI QHFHVVDU\ &KHFNDQGFOHDQWKHWZRIDQVLQVLGHWKH0&;FRQWUROOHUER[ &KHFNDOOFDEOLQJDQGKDUQHVVHVIURPDQGWRWKHSRZHUVXSSO\VFKHFNIRU EDGFRQQHFWLRQVDQGGLVFRORXUHGZLUHV &KHFNDOOHPHUJHQF\VZLWFKHVDQGKDUQHVVHVHJ(0*FDEOLQJRQWKHLU IXQFWLRQDOLW\ &KHFNDOOIXVHVLQWKHPDLQVFLUFXLW 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 4-13

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Vacuum and Pneumatic Systems CHAPTER 5 Vacuum and Pneumatic Systems Vacuum Systems Introduction 7KLVFKDSWHUGHVFULEHV WKH YDFXXP V\VWHPV ZKLFK DUH XVHG LQ WKH 7RSD] DQG WKH WUD\FKDQJHU7&+RZWRVHWYDFXXPOHYHOVRIWKHPDFKLQHOLNHSLFNXSYDFXXP PRXQWYDFXXPHWFLVGHVFULEHGLQFKDSWHU PDFKLQHFDOLEUDWLRQµ Functional Description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µ DQGRQHHMHFWRUYDOYH <9IRUWKHSLFNXSKHDGORFDWHGRQWKHKHDG7KHYDFXXPRQWKHVKXWWOHSDGV FDQEHVZLWFKHGRQYLDWKHYDOYHV75DQG75LWHPLQFKDSWHU7KH YDFXXPRQWKHKHDGFDQEHVZLWFKHGE\VLJQDO75<9 Air switch ON/OFF Figure 5-1 Valves 7KH7RSD]KDVWZRVHSDUDWHDLUSUHVVXUHUHJXODWRUV2QHIRUWKHHMHFWRUVDQGRQHIRU WKHDLUVROHQRLGVRIWKHV\VWHP7KHDLUSUHVVXUHUHJXODWRUIRUWKHYDFXXPOLQHLV ORFDWHGEHKLQGWKHORZHUOHIWSDQHODWWKHOHIWVLGHRIWKHPDFKLQH 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 5-1

Vacuum and Pneumatic Systems Air Supply Unit 7KHDLUVXSSO\XQLWLVORFDWHGLQVLGHWKHORZHUULJKWSDQHORQWKHUHDUVLGHRI WKHPDFKLQHDORQJZLWKDSUHVVXUHUHJXODWRU7KHDLUSUHVVXUHUHJXODWRUPXVW EHVHWFRUUHFWO\LQRUGHUWRSURYLGHRSWLPXPDLUSUHVVXUHIRUWKHYDFXXP HMHFWRUVDQGSQHXPDWLFGHYLFHV%HIRUHPDNLQJWKHVHWWLQJEHVXUHWKDWWKH SUHVVXUHIURPWKHSULPDU\DLUVXSSO\LVEHWZHHQDQG03D Air Pressure Regulator 7KHDLUSUHVVXUHUHJXODWRUFDQEHDGMXVWHGZLWKWKHYDOYHFRQWURONQREDV IROORZV 2SHQWKHORZHUULJKWSDQHORQWKHUHDUVLGHRIWKHPDFKLQH 7KHSUHVVXUHUHJXODWRUYDOYHFRQWURONQREDQGSUHVVXUHPHWHUDUH ORFDWHGLQVLGHWKHSDQHO $GMXVWWKHDLUSUHVVXUH7XUQWKHYDOYHFRQWURONQREVRWKDWWKHDLU SUHVVXUHLVVHWEHWZHHQWR03DWRNJIFP Figure 5-2 Pressure meter WARNING If this pressure setting is not correct, the vacuum ejector cannot function adequately and air cylinders become unstable. Be sure that the pressure is set within the specified range. Service Manual Topaz 5322 871 63606 5-2 PA 1309/10 01.05

Vacuum and Pneumatic Systems Pressure-Drop Detection Level,IWKHDLUVXSSO\SUHVVXUHGURSVEHORZWKLVDGMXVWDEOHOHYHOWKHSUHVVXUHGURS GHWHFWLRQVZLWFKWULJJHUVDQHPHUJHQF\VWRSDQGLQKLELWVWKHPRYHPHQWRIDOO D[HV$WWKHVDPHWLPHWKHPHVVDJHEHORZDSSHDUVRQWKHRSHUDWLRQPRQLWRU E 0806 QUICK STOP ACTIVE NM09 AIR PRESSURE SW. QUICK STOP FUNCTION for safety is now active. To continue, please check the supplied air 7RDGMXVWWKHVHWWLQJIRUSUHVVXUHGURSGHWHFWLRQSURFHHGDVIROORZV 2SHQWKHORZHUULJKWSDQHORQWKHUHDUVLGHRIWKHPDFKLQH 7KHSUHVVXUHPHWHULVORFDWHGRYHUWKHYDOYHFRQWURONQRE $GMXVWWKHOHYHOIRUSUHVVXUHGURSGHWHFWLRQ - 7XUQWKHDGMXVWPHQWVFUHZLQWKHPHWHUZLWKDVPDOOVORWWHGVFUHZGULYHUVR WKDWWKHQHHGOHUHGLVVHWDWWR03DWRNJIFP Figure 5-3 Air pressure-drop level setting WARNING If this pressure setting is not correct, the vacuum ejector cannot function adequately and air cylinders become unstable. Be sure that the pressure is set within the specified range. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 5-3

Vacuum and Pneumatic Systems Measurement and Adjusting Vacuum Levels 7KHPHDVXUHPHQWRIWKHYDFXXPOHYHOLVGRQHYLDYDFXXPVHQVRUVWUDQVGXFHUV ZKLFKDUHORFDWHGRQWKH,2KHDGDVV\ERDUG(DFKKHDGKDVLWVRZQVHQVRU DQG FDQ EH DGMXVWHG DQG FDOLEUDWHG LQGHSHQGHQW IURP HDFK RWKHU )RU WKH $GMXVWPHQWRIWKHVHQVLQJFLUFXLWSOHDVHUHIHUWRWKHFDOLEUDWLRQFKDSWHU Performance Check and Trouble Shooting,QRUGHUWRJHWDFRUUHFWYDFXXPOHYHOIURPHDFKHMHFWRUPDNHVXUHWKDWWKHDLU SUHVVXUH LV DW D FRUUHFW OHYHO! EDU 0DNH DOVR VXUH WKDW WKH KRVHV WR DQG IURPWKHHMHFWRUDUHQRWFRQWDPLQDWHG Maintenance Instructions (DFKHMHFWRUKDVLWVRZQDLUILOWHUZKLFKQHHGVWREHFKHFNHGDWUHJXODULQWHUYDOV +RXUV,IWKHILOWHULVFRQWDPLQDWHGLWLVDGYLVDEOHWRUHSODFHLWE\DQHZ RQH Service Manual Topaz 5322 871 63606 5-4 PA 1309/10 01.05

Vacuum and Pneumatic Systems Pneumatic Systems Introduction 7KLVFKDSWHUGHVFULEHVWKHHOHFWULFDOLQWHUIDFHRIWKHSQHXPDWLFV\VWHPLQWKH 7RSD]DQG7UD\&KDQJHU Functional Description 7KH7RSD]FRQWDLQVDQXPEHURISQHXPDWLFVROHQRLGYDOYHVDQGF\OLQGHUV7KH DLU VROHQRLG YDOYHV FRQWURO WKH DLU IORZ WR FHUWDLQ DLU SUHVVXUH OLQHV 7KH SQHXPDWLFGULYHQF\OLQGHUVDUHXVHGIRUWKHORFDWHSLQVSXVKXSSLQVSXVKLQ HGJHFODPSVDQGKHDGGRZQPRYHPHQW 7KHDLUVROHQRLGYDOYHVDUHFRQWUROOHGHOHFWULFDOO\E\D9VLJQDOFRPLQJIURP WKH,2ERDUGV 7KH DLU F\OLQGHUV DUH DFWLYDWHG E\ DLU SUHVVXUH ZKLFK DUH FRQWUROOHGE\HOHFWULFDOVROHQRLGV7KHSQHXPDWLFF\OLQGHUVDUHFRQWUROOHGE\DLU VROHQRLGYDOYHV Topaz 7KHDLUVROHQRLGYDOYHVDUHFRQWUROOHGE\WKH,2ERDUGVLQVLGHWKHPDFKLQH,QFKDSWHUWKHLQWHUFRQQHFWLRQVDUHVKRZQEHWZHHQWKHFRQYH\RU,2VDQG WKHYDULRXVYDOYHV Tray Changer (TC) 7KHDLUVROHQRLGYDOYHVRIWKH7UD\&KDQJHUDUHFRQWUROOHGE\WKH,2FRQYH\RU ERDUGLQVLGHWKH7UD\FKDQJHU)RUWKHFRQQHFWLRQVEHWZHHQWKH,2ERDUGDQG WKH YDULRXV VROHQRLGV SOHDVH UHIHU WR WKH RYHUDOO 7& LQWHUFRQQHFW GLDJUDP LQ FKDSWHU 7KH DLU SUHVVXUH IRU WKH 7UD\ &KDQJHU DLU YDOYHV LV VXSSOLHG YLD WKH PDLQ PDFKLQH Tape Feeders 7KHWDSHIHHGHUVGRQRWKDYHDLUVROHQRLGVYDOYHVVRWKH\GRQRWFRQWDLQ HOHFWULFDOFRQQHFWLRQV Automatic Tray Stacker 7KHDXWRPDWLFWUD\VWDFNHUVGRKDYHDLUYDOYHVZKLFKDUHVXSSOLHGYLDWKHPDLQ PDFKLQHDVZHOODVWKHHOHFWULFDOVLJQDOVUHTXLUHG FES/SVS 7KHFRPSUHVVHGDLUXVHGLQWKH)(6DQG696V\VWHPVDUHVXSSOLHGYLDWKH PDFKLQHFRQQHFWHGYLDWKHLQWHUIDFHER[ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 5-5

Vacuum and Pneumatic Systems Measuring and Adjusting &KHFNDQGLIQHFHVVDU\DGMXVWDWUHJXODULQWHUYDOVTXDUWHUO\WKHYROWVZKLFK LVXVHGWRFRQWUROWKHYDULRXVYDOYHVRIWKHSQHXPDWLFV\VWHP 7KHWZRSRZHUVXSSO\V*6DQG*6DUHORFDWHGDWWKHOHIWORZHUUHDUVLGH RIWKHV\VWHP Performance Checks and Trouble Shooting 1RVSHFLILFDFWLRQVDUHGRQHIRUWKHSHUIRUPDQFHFKHFN,IVRPHYDOYHVDUHQRW ZRUNLQJSOHDVHILUVWFKHFNWKHYROWSRZHUVXSSO\WKHQFKHFNLIWKH,2VLJQDO LV RN FKHFN WKLV E\ DFWLYDWLQJ PDQXDOO\ WKH,2 VLJQDO YLD WKH PDQXDO,2 VHWWLQJVFUHHQ Maintenance Actions 1RVSHFLILFPDLQWHQDQFHDFWLRQVEHVLGHVWKH9FKHFNLQJDUHQHFHVVDU\ Service Manual Topaz 5322 871 63606 5-6 PA 1309/10 01.05

Vacuum and Pneumatic Systems Exchanging Head Ejectors, Valves and Base 7KLVFKDSWHUGHVFULEHVKRZWRUHSODFHWKHKHDGHMHFWRUVDQGYDOYHV Exchanging the Head Ejector and/or Valves %ORZRIIYDOYHUHSODFHPHQW 7RUHSODFHWKHEORZRIIYDOYHVRQWRSRIWKHHMHFWRULQWKHKHDGDVV\UHIHUWR ILJXUHDQGSURFHHGDVIROORZV /RRVHQWKHWZRVFUHZVRQWRSRIWKHYDOYH 5HPRYHWKHYDOYHLQWKHGLUHFWLRQRIWKHDUURZ,QVWDOOWKHQHZYDOYHDQGWDNHFDUHDERXWWKHGLUHFWLRQRIWKHJDVNHW 7LJKWHQWKHWZRVFUHZVZLWKDWRUTXHRI1FP %ORZRIIµ Figure 5-4 Ejector and Valves (MHFWRUUHSODFHPHQW 7RUHSODFHWKHHMHFWRULWVHOIUHIHUWRILJXUHDQGSURFHHGDVIROORZV 5HPRYHWKHYDOYHRQWRSRIWKHHMHFWRUE\IROORZLQJVWHSVDQGRIWKH SUHYLRXVSURFHGXUH 9DOYHUHSODFHPHQWµ 5HPRYHWKHWZRVFUHZVKROGLQJWKHHMHFWRUWRWKHHMHFWRUEDVHHQGEORFN 5HPRYHWKHHMHFWRUE\PRYLQJLWLQWKHGLUHFWLRQRIWKHDUURZ,QVWDOOWKHQHZHMHFWRUDQGWDNHFDUHDERXWWKHGLUHFWLRQRIWKHJDVNHW 7LJKWHQWKHWZRVFUHZVZLWKDWRUTXHRI1FP 0RXQWWKHYDOYHRQWRSRIWKHHMHFWRUE\IROORZLQJVWHSVDQGRIWKH SUHYLRXVSURFHGXUH 9DOYHUHSODFHPHQWµ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 5-7

Vacuum and Pneumatic Systems %DVHUHSODFHPHQW 7RUHSODFHWKHEDVHRIWKHHMHFWRULWVHOIUHIHUWRILJXUHDQGSURFHHGDVIROORZV /RRVHQWKHWZRVFUHZVLQWKHOHIWRUULJKWHQGEORFN 5HPRYHWKHDSSOLFDEOHHQGEORFNDQGHMHFWRUEDVH 5HPRYHWKHYDOYHDQGHMHFWRURQWRSRIWKHHMHFWRUEDVHRUHQGEORFNE\ IROORZLQJVWHSVWRRIWKHSURFHGXUH (MHFWRUUHSODFHPHQWµ,QVWDOOWKHUHPRYHGHMHFWRUDQGYDOYHRQWRWKHQHZHMHFWRUEDVHE\IROORZLQJ VWHSVWRRIWKHSURFHGXUH (MHFWRUUHSODFHPHQWµ,QVWDOOWKHHMHFWRUEDVHDQGHQGEORFNZKLOHWDNLQJFDUHRIWKH2ULQJ 7LJKWHQWKHEROWVZLWKDWRUTXHRI1FP REMARK: If there is a need to replace the end-blocks separate code numbers are available in the spare parts list. CAUTION 1. Disconnect the power and air supply prior to replacing the valves. 2. Confirm the torque of each removed bolt prior to reconnecting air and power. 3. Too much torque may damage the plastic ejector base! Exchanging the Head Up/Down, Slow Valves and Valve Base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µDQG 6ORZYDOYHUHSODFHPHQWµ Service Manual Topaz 5322 871 63606 5-8 PA 1309/10 01.05

Vacuum and Pneumatic Systems,QVWDOOWKHUHPRYHGYDOYHVRQWRWKHQHZYDOYHEDVHE\IROORZLQJVWHSVDQG WKHSURFHGXUHV 8S'RZQYDOYHUHSODFHPHQWµDQG 6ORZYDOYH UHSODFHPHQWµ,QVWDOOWKHYDOYHEDVHDQGHQGEORFNVZKLOHWDNLQJFDUHRIWKH2ULQJV 7LJKWHQWKHEROWVZLWKDWRUTXHRI1FP 8S'RZQµ 6ORZµ Figure 5-5 Head valves REMARK: If there is a need to replace the end-blocks separate code numbers are available in the spare parts list. CAUTION 1. Disconnect the power and air supply prior to replacing the valves. 2. Confirm the torque of each removed bolt prior to reconnecting air and power. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 5-9

Vacuum and Pneumatic Systems Intentionally Left Blank. Service Manual Topaz 5322 871 63606 5-10 PA 1309/10 01.05

PCB Transport Systems CHAPTER 6 6.1. PCB Transport Systems Introduction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igure 6-1 PCB transport system (top view) 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 6-1

PCB Transport Systems 6.2. Conveyor Belt 7KHFRQYH\RUEHOWWUDQVSRUWVWKH3&% VE\EHOWLQIRUPRXQWLQJDQGRXW ZKHQUHPRXQWHGWKH7RSD]2QDVWDQGDUGPDFKLQH3&%VDUH FRQYH\HGLQWKHOHIWWRULJKWGLUHFWLRQZKLOHWKHFRQYH\RUZLGWKLV DGMXVWHGE\VOLGLQJWKHUHDUUDLOWKHIURQWUDLOLVIL[HG7KHVHVSHFLILFDWLRQV FDQQRWEHFKDQJHGDIWHUWKHPDFKLQHKDVEHHQVKLSSHG Adjusting the Conveyor Belt Tension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igure 6-2 Adjusting the conveyor belt tension Service Manual Topaz 5322 871 63606 6-2 PA 1309/10 01.05

PCB Transport Systems Adjusting the Carry-In Conveyor Speed 7KHFRQYH\RUVSHHGYDULHVDFFRUGLQJWRWKHIUHTXHQF\RIWKHSRZHUVXSSO\ DQGWKHZHLJKWRIWKH3&%VRQWKHFRQYH\RU<RXFDQDGMXVWWKHFDUU\LQ FRQYH\RUVSHHGVE\XVLQJWKHWZRDGMXVWLQJVFUHZVORFDWHGLQVLGHWKHORZHU ULJKWSDQHORQWKHIURQWVLGH 7KHFDUU\LQFRQYH\RUPRYHVDWWZRVSHHGVDKLJKVSHHG+IRUUHGXFLQJ WKHWUDQVIHUWLPHRI3&%VDQGDORZVSHHG/IRUPLQLPL]LQJLPSDFW ZKHQWKH3&%KLWVWKHHQWUDQFHRUPDLQVWRSSHU7RDGMXVWWKHVHVSHHGV SUHSDUHW\SLFDO3&%VDQGXVHWKHSURFHGXUHEHORZ Figure 6-3 Carry-in conveyor speed adjusting screws $GMXVWWKHFRQYH\RUZLGWKDFFRUGLQJWRWKHVL]HRIWKH3&%7RDGMXVW WKHFRQYH\RUZLGWKWKH&RQYH\RU8QLWXWLOLW\LQWKH'DWD0DQDJHU ZLOOEHFRQYHQLHQW,I\RXUPDFKLQHLVQRWHTXLSSHGZLWKDQDXWR FRQYH\RUZLGWKDGMXVWLQJIXQFWLRQDGMXVWPDQXDOO\ 2SHQWKHRXWSXWPRQLWRUVFUHHQDQGWXUQRQWKHFRQYH\RUVHHILJXUH 6HOHFW0$,17(0!!!0$18$/!!&',63/$< (;,7!^&287387021,725`DQGSUHVVWKH>(17(5@NH\ - 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71 &219(<2521-3UHVVWKH>(17(5@NH\WRWXUQRQWKHFRQYH\RU7KHRXWSXW PRQLWRUGLJLWUHDGVLIWKHFRQYH\RULVRQDQGLILWLVRII Out Monitor [ ] : Select [Enter] : Exec [ESC] : Command Lists Selected Arm : MAIN Moving Speed : 100 XY TN13 CONVEYOR ON OFF 0 / ON 1 NAME OUT NAME IN Conveyors TN09-16 00001000 Figure 6-4 Output monitor screen, activate conveyor 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 6-3

PCB Transport Systems :KLOHUXQQLQJWKHFRQYH\RUVZLWFKWKHVSHHGDVIROORZVILJXUH 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71&219(<25 63(('/2: - 3UHVVWKH>(17(5@NH\WRVZLWFKWKHFRQYH\RUVSHHG7KHRXWSXW PRQLWRUGLJLWUHDGVZKHQWKHFRQYH\RULVDWORZVSHHGDQGUHDGV ZKHQLWLVDWKLJKVSHHG Out Monitor [ ] : Select [Enter] : Exec [ESC] : Command Lists Selected Arm : MAIN Moving Speed : 100 TN14 CONVEYOR SPEED LOW HIGH 0 / LOW 1 ( = 0 / = 1) XY NAME OUT NAME IN Conveyors TN09-16 00001100 Figure 6-5 monitor screen, conveyor speed Output 4) $GMXVWWKHKLJKVSHHGZKLOHUXQQLQJWKHFRQYH\RUDWKLJKVSHHGDGMXVW 7KHVSHHGE\WXUQLQJWKH+VFUHZ'RQRWVHWWKHVSHHGWRRKLJKDV WKLVPD\KDPSHUVZLWFKLQJUHVSRQVH3RVLWLRQWKH+VFUHZDWDSRLQW VOLJKWO\VORZHUWKDQWKHPD[LPXPVSHHG 5) 5DLVHWKHHQWUDQFHVWRSSHUE\VHOHFWLQJ0$,17(0!!! 0$18$/!!&',63/$< (;,7!^&287387 021,725`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ervice Manual Topaz 5322 871 63606 6-4 PA 1309/10 01.05

PCB Transport Systems 6.3. Main Stopper :KHQWKHFRQYH\RUEHOWWUDQVSRUWVD3&%LQWRWKH7RSD]WKHPDLQ VWRSSHUZLOOVWRSWKH3&%DWWKHPRXQWLQJSRVLWLRQ7KHDVFHQWGHVFHQW VSHHGVRIWKHPDLQVWRSSHUDQGWKH3&%FRQWDFWSRLQWFDQEHDGMXVWHG SOHDVHUHIHUWRILJXUHEHORZ Figure 6-6 Main stopper and air solenoid valve Rear right side of the Topaz Adjusting the Ascent/Descent Speeds of the Main Stopper 2SHQWKHRXWSXWPRQLWRUVFUHHQDQGRSHUDWHWKHPDLQVWRSSHUILJ 6HOHFW0$,17(0!!!0$18$/!!&',63/$< (;,7!^&287387021,725`DQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWRVHWWKHFXUVRUDW710$,167233(5 3UHVVWKH>(17(5@NH\WRDOWHUQDWHO\UDLVHDQGORZHUWKHPDLQVWRSSHU 7KHRXWSXWPRQLWRUGLJLWUHDGVZKHQWKHPDLQVWRSSHULVWKHUDLVHG SRVLWLRQDQGUHDGVZKHQLWLVDWWKHORZHUHGSRVLWLRQ Figure 6-7 Output monitor screen, activate main stopper 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 6-5

PCB Transport Systems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igure 6-8 Main stopper exploded view Service Manual Topaz 5322 871 63606 6-6 PA 1309/10 01.05

PCB Transport Systems PCB Contact Point 7KHVWRSSHURIWKHPDLQVWRSSHULVDVWHHO ZDVKHUµ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`XWLOLW\RUWKH RXWSXWPRQLWRULQWKH0DQXDOPRGH 3UHVVWKHHPHUJHQF\VWRSEXWWRQVHWWKH3&%LQWKHPRXQWLQJ SRVLWLRQ3ODFHWKH3&%DJDLQVWWKHPDLQVWRSSHUDQGGHWHUPLQHWKH RIIVHWEHWZHHQWKH3&%SRVLWLRQLQJKROHDQGWKHIL[HGORFDWHSLQ /RRVHQWKHEROWVHFXULQJWKHVWRSSHUE\XVLQJWKHKH[ZUHQFKORRVHQ WKHEROWEXWGRQRWUHPRYHLWWRDOORZWXUQLQJRIWKHVWRSSHU $GMXVWWKHRULHQWDWLRQRIWKHVWRSSHUE\VOLJKWO\URWDWLQJWKHVWRSSHUVR WKDWWKHORFDWHSLQFDQH[DFWO\EHDOLJQHGZLWKWKH3&%SRVLWLRQLQJ KROH 5HWLJKWHQWKHEROWWRVHFXUHWKHVWRSSHU Figure 6-9 Adjusting the PCB contact point CAUTION When you use PCBs having typical positioning holes, you must return the above adjustment to the original setting. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 6-7

PCB Transport Systems 6.4. Push-In 7KHSXVKLQPHFKDQLVPSUHVVHVWKH3&%DJDLQVWWKHPDLQVWRSSHU VHFXULQJLWLQWKHSRVLWLRQIRUPRXQWLQJ7RDGMXVWWKHVSHHGVRIWKHSXVK LQPHFKDQLVPSURFHHGDVIROORZVUHIHUWRILJXUH Figure 6-10 Push in and air solenoid valve Rear right side of the Topaz 2SHQWKHRXWSXWPRQLWRUVFUHHQVHHILJXUHDQGRSHUDWHWKH SXVKLQPHFKDQLVP 6HOHFW0$,17(0!!!0$18$/!!&',63/$< (;,7!^&287387021,725`DQGSUHVVWKH>(17(5@ NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71386+,1 3UHVVWKH>(17(5@NH\WRDOWHUQDWHO\FORVHDQGUHOHDVHWKHSXVKLQ PHFKDQLVP7KHRXWSXWPRQLWRUGLJLWUHDGVZKHQWKHSXVKLQ PHFKDQLVPLVDFWLYHDQGUHDGVZKHQLWLVUHOHDVHG Figure 6-11 Ouput monitor screen, activate push in &KHFNWKHSUHVVLQDQGUHOHDVHVSHHGV%RWKVSHHGVVKRXOGEHDURXQG RQHVHFRQGWKHVSHHGDWZKLFKSUHPRXQWHGFRPSRQHQWVRQWKH3&% ZLOOQRWVKLIW Service Manual Topaz 5322 871 63606 6-8 PA 1309/10 01.05

PCB Transport Systems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igure 6-12 Exploded view Push-in 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 6-9

PCB Transport Systems 6.5. Locate Pin 7ZRORFDWHSLQVDUHDYDLODEOHDORQJWKHFRQYH\RUUDLORQHIL[HGDQGRQH PRYDEOH7KHVHSLQVHQJDJHZLWKWKHSRVLWLRQLQJKROHVRIWKH3&%WR VHFXUHLWLQSODFHUHDG\IRUPRXQWLQJ7RDGMXVWWKHDVFHQWGHVFHQWVSHHGV RIWKHORFDWHSLQVSURFHHGDVIROORZVSOHDVHUHIHUWRILJXUHDQG Figure 6-13 Locate pin arrangement Figure 6-14 Locate pin and air solenoid valve Rear right side of the Topaz Service Manual Topaz 5322 871 63606 6-10 PA 1309/10 01.05

PCB Transport Systems 2SHQWKHRXWSXWPRQLWRUVFUHHQILJXUHDQGRSHUDWHWKHORFDWH SLQV6HOHFW 0$,17(0!!!0$18$/!!&',63/$< (;,7! ^&287387021,725`DQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71/2&$7( 3,1 3UHVVWKH>(17(5@NH\WRDOWHUQDWHO\UDLVHDQGORZHUWKHORFDWHSLQV 7KHRXWSXWPRQLWRUGLJLWUHDGVZKHQWKHORFDWHSLQVDUHDWWKH UDLVHGSRVLWLRQDQGUHDGVZKHQWKH\DUHDWWKHORZHUHGSRVLWLRQ Figure 6-15 Output monitor, activate locate pins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ervice Manual Topaz 01.05 PA 1309/10 6-11

PCB Transport Systems,IWKLVPHWKRGZRUNVWKHUHZLOOSUREDEO\EHDSUREOHPZLWKWKHHOHFWULF FLUFXLWIRUWKHDLUVROHQRLGYDOYH&KHFNWKHIROORZLQJSRLQWV (OHFWURPDJQHWLFFRLOEUHDNDJH /RRVHKDUQHVVFRQQHFWRUV 7URXEOHZLWKWKH'&9VXSSO\,2ERDUGRXWSXWHUURUVHWF,ISUHVVLQJWKHPDQXDOEXWWRQGRHVQRWDOORZQRUPDORSHUDWLRQWKHUHLVD SUREOHPZLWKWKHDLUVXSSO\DLUSLSLQJRUSLSHWWHYDOYHVGDPDJHFORJJLQJ DQGDGKHVLRQRIIRUHLJQPDWWHU&KHFNWKHDLUVXSSO\OLQHRIWKHORFDWH SLQV)RUDQ\UHSODFHPHQWRIWKHORFDWHSLQSOHDVHUHIHUWRILJXUH Figure 6-16 Exploded view Locate pin assembly Service Manual Topaz 5322 871 63606 6-12 PA 1309/10 01.05

PCB Transport Systems 6.6. Edge Clamp $QRWKHU3&%FODPSLQJPHWKRGLVWKHXVHRIWKHHGJHFODPSF\OLQGHUV ZKHQHYHUWKHORFDWHSLQVFDQQRWEHXVHGWKHHGJHFODPSF\OLQGHUVFDQEH XVHGWRSUHVVWKH3&%DJDLQVWWKHIURQWFRQYH\RUUDLODQGVRIL[LWWRWKH PRXQWLQJSRVLWLRQ 7KHHGJHFODPSF\OLQGHUVGRQRWKDYHDQ\DGMXVWPHQWSRVVLELOLWLHV2I FRXUVHWKHHGJHFODPSVFDQEHDFWLYDWHGE\PHDQVRIWKHRXWSXWPRQLWRU 71SOHDVHUHIHUWRILJXUH )RUWKHDQ\UHSODFHPHQWVRIWKHHGJHFODPSDVVHPEO\SOHDVHUHIHUWRWKH ILJXUH Rear right side of the Topaz 71 Figure 6-17 Air solenoid rear right side of Topaz Figure 6-18 Exploded view edge clamp assembly 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 6-13

PCB Transport Systems 6.7. Push-Up 7KHSXVKXSSODWHLVORFDWHGGLUHFWO\XQGHUQHDWKWKHFRPSRQHQWPRXQ WLQJSRVLWLRQ7KHVXSSRUWSLQVDWWDFKHGE\PDJQHWVRQWKHVXUIDFHRIWKH SXVKXSSODWHVXSSRUWWKH3&%GXULQJWKHPRXQWLQJSURFHVV7KH3&% ZLOOEHSXVKHGDJDLQVWWKHWRSVLGHRIWKHFRQYH\RUUDLOSOHDVHUHIHUWR ILJXUH7RDGMXVWWKHDVFHQWGHVFHQWVSHHGVRIWKHSXVKXSSODWH SURFHHGDVIROORZV Figure 6-19 Push-up and air solenoid valve Rear right side of the Topaz 2SHQWKHRXWSXWPRQLWRUVFUHHQDQGRSHUDWHWKHSXVKXSSODWH 6HOHFW0$,17(0!!!0$18$/!!&',63/$< (;,7!^&287387021,725`DQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71386+83 3UHVVWKH>(17(5@NH\WRDOWHUQDWHO\UDLVHDQGORZHUWKHSXVKXS SODWH7KHRXWSXWPRQLWRUGLJLWUHDGVZKHQWKHSXVKXSSODWHLV DWWKHUDLVHGSRVLWLRQDQGUHDGVZKHQLWLVDWWKHORZHUHG SRVLWLRQ Figure 6-19a PCB supporter pins Service Manual Topaz 5322 871 63606 6-14 PA 1309/10 01.05

PCB Transport Systems Figure 6-20 Output monitor, activate push-up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hen you set the push-up pins on the push-up plate, make sure that the push-up pins do not interfere with the conveyor rails and edge clamp cylinder.,isuhvvlqjwkhpdqxdoexwwrqgrhvqrwdoorziruqrupdorshudwlrqwkhuh LVDQRWKHUSUREOHPZLWKWKHDLUVXSSO\DLUSLSLQJDQGSLSHWWHYDOYHV GDPDJHFORJJLQJDQGDGKHVLRQRIIRUHLJQPDWWHU&KHFNWKHDLUVXSSO\ OLQHRIWKHSXVKXSSODWH)RUDQ\UHSODFHPHQWVRQWKHSXVKXSDVV\UHIHU FKDSWHU 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 6-15

PCB Transport Systems 6.8. PCB Detection Sensors,QWKHFRQYH\RUDVV\WKHUHDUHILYH3&%GHWHFWLRQVHQVRUVDUUDQJHGDORQJ WKHIURQWUDLORIWKHFRQYH\RU7KHVHQVRUVHDFKKDYH/('VPRXQWHGRQ WKHVLGHZKLFKDUHQRUPDOO\OLW:KHQWKHVHQVRUGHWHFWVWKHSUHVHQFHRID 3&%WKH/('WXUQVRIISOHDVHUHIHUWRILJXUH SQ53 SQ57 SQ54 SQ51 SQ52 PCB SQ52 SQ51 SQ54 SQ57 SQ53 PCB Figure 6-21 PCB detection sensors 7KHWDEOHEHORZVKRZVWKH3&%GHWHFWLRQVHQVRUVWKHLUIXQFWLRQ DQGWKHLUORFDWLRQ7KHVHQVRUFRGHFDQEHXVHGWRWUDFNWKHVHQVRUVLQWKH GLDJUDPVRIFKDSWHU7KHVLJQLVWKHVRIWZDUHFRGHZKLFKLVXVHGIRU LQVWDQFHLQWKH','2VFUHHQRIWKHVRIWZDUH Sensor Location Sign Remarks SQ51 Entrance stopper 1 NL01 Stopper for decelerating transport. SQ52 Conveyor entrance NL02 - SQ53 Conveyor exit NL04 - SQ54 Entrance stopper 2 NL03 PCB detection. SQ57 PCB securing position NL09 - Table 6.8-1 Service Manual Topaz 5322 871 63606 6-16 PA 1309/10 01.05

PCB Transport Systems 7KHVHQVRUVPD\QRWGHWHFWD3&%VHHILJXUHGXHWRVXFKIDFWRUVDV WKHRULHQWDWLRQGLVWDQFHDQGDQJOHDWZKLFKLWLVDWWDFKHG7KHVHQVRUV PD\DOVREHDIIHFWHGE\VWURQJH[WUDQHRXVOLJKWH[FHVVLYHGXVWDQGWKH VKDSHKROHRUQRWFKDQGFRORURIWKH3&%8VLQJ3&%VRQZKLFK\RX DFWXDOO\PRXQWFRPSRQHQWVFKHFNWKDWWKHVHQVRUVFDQGHWHFWWKHP UHOLDEO\ Figure 6-22 PCB sensors detection errors 3UHSDUHWKH3&%\RXZLOODFWXDOO\XVHIRUFRPSRQHQWPRXQWLQJ $GMXVWWKHFRQYH\RUZLGWKDFFRUGLQJWRWKHVL]HRIWKH3&% 7RDGMXVWWKHFRQYH\RUZLGWK\RXFDQXVHWKH&RQYH\RU8QLWXWLOLW\LQ WKH'DWD0DQDJHU,I\RXUPDFKLQHLVQRWHTXLSSHGZLWKDQDXWR FRQYH\RUZLGWKDGMIXQFWLRQDGMXVWPDQXDOO\ 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGSDFHWKH3&%RQWKHFRQYH\RU 2SHQWKHLQSXWPRQLWRUDQGFKHFNWKHGHWHFWLRQVWDWXVILJXUH 6HOHFW0$,17(0!!!0$18$/!!&',63/$< (;,7!^&,1387021,725`DQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK71WR71 7KHLQSXWPRQLWRUGLJLWUHDGVZKHQWKH3&%LVGHWHFWHGDQGUHDGV ZKHQQRWGHWHFWHG&KHFNWKDWWKHGLJLWRIHDFKVHQVRUUHDGV $OVRFKHFNWKDWWKHGHWHFWLRQVWDWXVRIWKHVHQVRU641/GRHV QRWYDU\HYHQLIWKHORFDWHSLQVDQGSXVKXSSODWHDUHUDLVHG In Monitor [ ] : Select [Enter] : Exec [ESC] : Command Lists Selected Arm : MAIN Moving Speed : 100 XY NL09 SET POSITION DETECT 1 NAME OUT NAME IN Conveyor NL09-16 10000000 Figure 6-23 Input monitor 3ODFHD3&%RYHUHDFKVHQVRUDORQJWKHFRQYH\RUDQGFKHFNLIWKHDUH 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 6-17

PCB Transport Systems 2.7RVHFXUHWKH3&%LQWKHPRXQWLQJSRVLWLRQRYHUWKHVHQVRU 64WKH&RQYH\RU8QLWXWLOLW\ZLOOEHFRQYHQLHQW,IQHFHVVDU\DGMXVWWKHSRVLWLRQRIWKH3&%GHWHFWLRQVHQVRU/RRVHQ WKHVFUHZVVHFXULQJWKHVHQVRUDQGDGMXVWWKHSRVLWLRQRULHQWDWLRQRU DQJOHDWZKLFKLWLVDWWDFKHG 5HPRYHWKH3&%IURPWKHFRQYH\RU Figure 6-24 Adjusting the position of the PCB detection sensor Service Manual Topaz 5322 871 63606 6-18 PA 1309/10 01.05

PCB Transport Systems 6.9. Conveyor Errors 7KHWDEOHVKRZVVRPHSRVVLEOHFRQYH\RUSUREOHPV\PSWRPVWKDW PD\RFFXU 6\PWRP 3RVVLEOHFDXVHV &RUUHFWLYHDFWLRQ The PCB hits hard against the main stopper. The PCB does not reach the main stopper at all. A PCB transfer error (PCB installation error) occurs when a thick PCB is conveyed. After the PCB has been conveyed in the mounting position the pins will not rise to secure the PCB (the conveyor keeps turning). Table 6.9-1 The soft stop function is defect or adjusted incorrectly. The soft stop function takes too much effect. The locate pin will not rise adequately for a thick PCB or a PCB having a small reference hole, so the sensor remians off. The sensor at the PCB installation position is faulty, or the PCB has a cutpout area just above the sensor so the sensor cannot detect the PCB. Possible conveyor problem symptoms Open the front lower right panel of the machine, you will see the two adjustment scres for the conveyor speed, adjust the L-screw to the left slightly to reduce the conveyor speed. Open the front lower right panel of the machine, you will see the two adjustment scres for the conveyor speed, adjust the L-screw to the right slightly to increase the conveyor speed. Loosen the screw for the locate pin sensor and slightly lower its position. Then check that the sensor turns on when the PCB is secured in place. Check the sensor operation in the manual mode (input monitor). If the sensor is defect, replace it. If the sensitivity is too low adjust the height of the sensor. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 6-19

PCB Transport Systems Intentionally left blank. Service Manual Topaz 5322 871 63606 6-20 PA 1309/10 01.05

Component Transport Systems CHAPTER 7 Component Transport Systems 7.1. 7.2. Introduction 7KLVFKDSWHUGHVFULEHVWKHFRPSRQHQWWUDQVSRUWV\VWHPWKDWLVUHVSRQVLEOHIRUIHHGLQJ DQGRUWUDQVSRUWLQJFRPSRQHQWV. Head Assembly 7KHKHDGDVVHPEO\ILJXUHRIWKH723$=FRQVLVWVRIHLJKWLQOLQHKHDGV7KLV FKDSWHUGHVFULEHVKRZWRFKHFNDGMXVWDQGRSWLPL]HDLUGULYHQPHFKDQLFDO PRYHPHQWVYDFXXPJHQHUDWLRQDQGPDFKLQHGDWDUHODWHGWRWKHKHDGDVVHPEO\VHH WKHWDEOHEHORZ Head descent movement Head lower end detection Vacuum generation Vacuum sensor function Machine coordinates (position) Pick and mount vacuum levels R-axis absolute accuracy offset* Nozzle correction* Head offset* Check that each head descends smoothly Check that the lower end is correctly detected when each head descends. Check that the vacuum ejector provides adequate vacuum levels. Check that the vacuum sensor display levels are correct. These coordinates include the stand-by point for the head and discard point for components The reference vacuum pressure (suction) is used to determine whether each head has picked up or mounted a component. Angular offset for the R-axis that rotates each nozzle shaft. This is used to correct an off-center nozzle shaft when it rotates by 180 degrees. The position of the heads related to fiducial camera 7KHVHSDUDPHWHUVDUHDXWRPDWLFDOO\FRUUHFWHGZKHQ\RXSHUIRUPPRXQWIHHGEDFN GHVFULEHGODWHULQFKDSWHU 0DFKLQH,QVWDOODWLRQDQG&DOLEUDWLRQµ Figure 7-1 Topaz head assembly 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-1

Component Transport Systems 7.2.1. Mechanical Check Head Assembly 7KLVFKDSWHUGHVFULEHVKRZWRFKHFNWKHDLUGULYHQPHFKDQLFDOPRYHPHQWV DQGYDFXXPJHQHUDWLRQLQWKHKHDGDVVHPEO\ Note1: &KHFNLQJWKHDVFHQWGHVFHQWPRYHPHQW )LUVWPDNHVXUHWRWKHKHDGLVLQVXFKDSRVLWLRQWKDWLWFDQQRWKLWDQ\WKLQJ ZKHQORZHUHG/RZHUWKHKHDGDVIROORZV - 2SHQWKHRXWSXWPRQLWRUZLWK&RXWSXWPRQLWRU!DQGVHOHFWWKH WDUJHWKHDG7(WR7(ZLWKWKHFXUVRU - 3UHVVWKHHQWHUNH\WRORZHUWKHWDUJHWKHDGWKHRXWSXWPRQLWRUSRVLWLRQ UHDGV µzkhqorzhuhgdqg µzkhqwkhkhdglvudlvhg &KHFNLQJWKHORZHUHQGGHWHFWLRQVHQVRU - :KLOHWKHKHDGLVORZHUHGPRYHWKHFXUVRUZLWKWKH7$%NH\WRWKHLQSXW VFUHHQDQGPRYHWKHFXUVRUWRWKHKHDGXSGRZQVHQVRULQSXW1*WR 1* - &KHFNWKHVWDWXVRIWKHLQSXW - :KHQWKHKHDGLVORZHUHGRXWSXW µµwkhlqsxwprqlwruvkrxoguhdg µ7khrssrvlwhvlwxdwlrqlvydolgzkhqwkhkhdglvudlvhg The head end-lower sensor that are used are of the type normally closed For safety reasons. When a sensor wire breaks the machine will detect a head in the lower position and will stop immediately. Note2: If the head does not move normally during the above testing, check the operation of the head manually as follows; - Press the emergency button. - Press the manual button (red button on top of the air valve) of the air valve that is the most close to the nozzles by means of a narrow screw driver. When the head lowers in this situation the circuitry that should operate the valve is defect. Points to check are following; - Damaged valve - Loose harness connectors, - DC24V power supply - I/O-board etc. When performing manual operation does not move the head down there is a problem with the pneumatic installation. Check following; - Air supply - Air filters - Air piping - Air valves Service Manual Topaz 5322 871 63606 7-2 PA 1309/10 01.05

Component Transport Systems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ervice Manual Topaz 01.05 PA 1309/10 7-3

Component Transport Systems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igure 7-2 Vacuum level display &KHFNWKHYDFXXPVHQVRUIXQFWLRQ 0DNHVXUHWKDWWKHYDFXXPOHYHOEDUJUDSKDQGQXPHULFDOYDOXHRQWKH RIWKHVHOHFWHGKHDGFKDQJHVZKHQ\RXSODFH\RXUILQJHURYHUWKHQR]]OH WLSRSHQLQJDQGWKHQUHPRYHLW7KHYDFXXPOHYHOLQFUHDVHVZKHQWKH QR]]OHWLSRSHQLQJLVFORVHG 5HWXUQWRRXWSXWPRQLWRUVFUHHQDQGWXUQRIIWKHYDFXXP &KHFNWKDWWKHFXUVRULVRQWKHWDUJHWKHDGLQWKH+HDG9DFXXPFROXPQ RQWKHRXWSXWPRQLWRUDQGSUHVVWKH>(17(5@NH\WRWXUQRIIWKH YDFXXP Service Manual Topaz 5322 871 63606 7-4 PA 1309/10 01.05

Component Transport Systems 7.2.2. Machine Coordinates :KHQ\RXVHOHFW0$,17(0!!!0&+B$'-867!!% 6$9( 48,7!^%$'-8677$5*(7`3RVLWLRQDQGSUHVVWKH >(17(5@NH\WKHIROORZLQJGLVSOD\DSSHDUVVKRZLQJWKHSRVLWLRQRIHDFK SDUWYHUVXVWKHRULJLQDQGRWKHUEDVLFSDUDPHWHUVHWWLQJV7KLVVHFWLRQ GHVFULEHVKRZWRVHWWKHPRVWLPSRUWDQWSDUDPHWHUV Figure 7-3 Machine coordinates editing screen A) Fine angle :KHQ),1(PRGHLVVHOHFWHGWRUHFRJQL]HD4)3ZLWKWKHVLQJOHYLVLRQ FDPHUDWKH),1(DQJOHSDUDPHWHUGHWHUPLQHVKRZDFFXUDWHO\WKHUHFRJQLWLRQ DQJOHVKRXOGEHFRQYHUJHGDGMXVWHGWRWKHVSHFLILHGDQJOH7KLVSDUDPHWHU FDQEHRUGHJUHHV:HUHFRPPHQGVHWWLQJWRWKH PLQLPXPYDOXHRIIRUDGMXVWPHQWDQGWRRUIRUDFWXDO PRXQWLQJRSHUDWLRQWDNHVPRUHWLPH8VHWKH>,16@^'(/@RU >63$&(@NH\WRPDNHDVHOHFWLRQ NOTE: The smaller the setting of this parameter, the higher the recognition angle accuracy. However, the recognition time will be longer affecting the cycle time, or there may be occasions when the component is dumped without being converged to the specified angle. B) Multi camera )RUWKHPXOWLFDPHUDIROORZLQJSDUDPHWHUVDUHIRUHVHHQ - 0XOWLFDPHUD <µ 7KLVSDUDPHWHUUHIOHFWVWKHVSHHGLQPLOOLPHWHUVSHUVHFRQGDWZKLFKWKH KHDGDVVHPEO\WUDYHOVRYHUWKHPXOWLFDPHUDGXULQJFRPSRQHQW UHFRJQLWLRQ6HWWKLVSDUDPHWHUWR µwklvydoxhlvdqrswlpxpvrgr QRWFKDQJHWKLVYDOXH - 0XOWLFDPHUD =µdqg 5µ 7KHVHVHWWLQJVDUHIRUFRUUHFWLQJWKHDQJXODUVKLIWRIWKHPXOWLYLVLRQ FDPHUDYHUVXVWKHPRXQWHUD[LV7KH =µfroxpqlviruwkhrswlrqdo PXOWLFDPHUDZKLOHWKH 5µFROXPQLVXVHGIRUWKHVWDQGDUGPXOWL FDPHUD3OHDVHVHWWKLVYDOXHWR µ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-5

Component Transport Systems C) Locate pin 7KLVVHWWLQJLVWKHUHIHUHQFHSRVLWLRQZKHQWKH3&%LVVHFXUHGLQWKH PRXQWLQJSRVLWLRQRQWKHFRQYH\RU7KLVSRVLWLRQLVDOVRUHIHUUHGWRDVWKH 3&%RULJLQ:KHQVHWWLQJWKLVORFDWHSLQSRVLWLRQXVHIROORZLQJSURFHGXUH - 2SHQWKHSRVLWLRQVVFUHHQE\$VHOHFWWDUJHW! SRVLWLRQµDQGSUHVV (QWHU - /LQHXSWKHFXUVRUZLWKWKH ;µru <µydoxhlqwkh ORFDWHSLQURZµ - 3UHVV)DQGVHWWKHWHDFKLQJFRQGLWLRQVVHOHFWWKHFDPHUDDVWKH WHDFKLQJXQLWDWDVORZVSHHGHJDQGSUHVVHQWHUDJDLQ - 0RYHWKHKHDGDERYHWKHIL[HGORFDWHSLQE\PHDQVRIWKHMR\VWLFN$OLJQ WKHFURVVFXUVRULQFHQWHURIWKHORFDWHSLQ - 3HUIRUPWHDFKLQJRIWKHORFDWHSLQE\SUHVVLQJWKH)NH\WZLFHWRHQWHU WKH;FRRUGLQDWHSHUIRUPWKHVDPHIRUWKH<FRRUGLQDWH - 6DYHWKHVHWWLQJVE\SUHVVLQJ(6&DQGVHOHFW%VDYHGDWD!RU% VDYH TXLW! D) Edge clamp :KHQWKHHGJHFODPSVDUHXVHGWRVHFXUHD3&%RQWKHFRQYH\RULQVWHDGRI XVLQJWKHORFDWHSLQVWKH3&%SRVLWLRQPD\VKLIWVOLJKWO\UHODWLYHWRWKHSRVLWLRQ GHWHUPLQHGE\WKHSLQV,IDVKLIWLQPLOOLPHWHUVLVIRXQGVXEWUDFWLWIURPWKH ORFDWHSLQFRRUGLQDWHVDQGHQWHUWKLVFRRUGLQDWHLQWKHHGJHFODPSSDUDPHWHUV 1RUPDOO\WKHVDPHSDUDPHWHUVDVWKHORFDWHSLQVDUHHQWHUHGLQKHUH E) Wait point 3UH&RQGLWLRQ2ULJLQWKHPDFKLQH :KHQWKHPDFKLQHLVLGOHZDLWLQJIRUQHZ3&%VWKHKHDGVZLOOPRYHWRD :DLW3RVLWLRQ7KLVSRVLWLRQFDQDWDQ\OG ;<SRVLWLRQEXWWDNHFDUHRIWKH IROORZLQJQRWHV n 6HQVRUSRVLWLRQVWKH\PLJKWDFFLGHQWDOO\EHDFWLYDWHG n,iwkh)(6rswlrqlvlqvwdoohglqwkhv\vwhplwlvdgylvhgwrwhdfkwkhzdlw SRVLWLRQDWVXFKDORFDWLRQWKDWWKH)(6KHDGSURWHFWLRQVHQVRULV DFWLYDWHG ZKHQWKHZDLWSRVLWLRQLVUHDFKHG7KLV)(6KHDGSURWHFWLRQVHQVRULVXVHGWR UHOHDVHWKH)(6HQDEOLQJD)(6FDUULDJHH[FKDQJH 7RVHOHFWWKHSRVLWLRQE\PHDQVRIWKHMR\VWLFNGRIROORZLQJ - 6HOHFW$VHOHFWD[LV!DQGSUHVV(QWHU - 6HOHFW0DLQ;<DQGSUHVV(QWHU - 0RYHDQ\GHVLUHGKHDGWRWKHGHVLUHGZDLWSRLQW - 6HOHFW%FRQGLWLRQVRI7&+!DQGSUHVV(QWHU - 6HOHFWWKHGHVLUHGKHDGIRUWHDFKLQJDQGSUHVV(QWHU - 6HOHFWDQ\VSHHGDQGSUHVV(QWHU - 6HOHFW%DGMXVWWDUJHW! SRVLWLRQµ - 3RVLWLRQWKHFXUVRURQWKH;FROXPQRIWKH,ZDLWSRVLWLRQDQGSUHVV )WZLFH'RWKHVDPHIRUWKH<YDOXH - 6DYHWKHVHWWLQJVE\SUHVVLQJ(6&DQGVHOHFWLQJVDYHGDWD Service Manual Topaz 5322 871 63606 7-6 PA 1309/10 01.05

Component Transport Systems F) Discard point 7KLVLVWKHSRVLWLRQDWZKLFKWKHKHDGGLVFDUGVDFRPSRQHQW7\SLFDOGLVFDUG SRLQWFRRUGLQDWHVDUHHQWHUHGSULRUWRVKLSPHQW 6LQFHLWLVQRWQHFHVVDU\WRORZHUWKHQR]]OHZKHQGLVFDUGLQJDFRPSRQHQW WKH=FRRUGLQDWHLVXVXDOO\VHWWR7RFKDQJHWKHGLVFDUGSRLQW;< FRRUGLQDWHVXVHWKHVDPHSURFHGXUHDVIRUVHWWLQJWKHZDLWSRLQW0DNHVXUH WKDWWKHKHDGDVVHPEO\ZLOOQRWEHGHWHFWHGE\D3&%VHQVRU9HULI\WKDWZKHQ DFRPSRQHQWLVGLVFDUGHGWKHGLVFDUGHGFRPSRQHQWZLOOQRWLQWHUIHUHZLWKWKH 3&%WUDQVSRUWDVV\FDPHUDRUVHQVRUV 7KH )HHGHUFROXPQLQGLFDWHVWKHGXUDWLRQIRUZKLFKWKHDLUEORZWXUQVRQWR GLVFDUGDFRPSRQHQWLQPLOOLVHFRQGV7KLVYDOXHLVVHWW\SLFDOO\WRWR PVHF G) PCB/Fix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t is also possible to teach the height on the fixed conveyor rail surface, which is basically the same height as the PCB surface. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-7

Component Transport Systems H) Dual recognition offset 7KLVSDUDPHWHULVXVHGWREHDEOHWRJRIURPOHIWWRULJKWDQGWKHRSSRVLWHZD\ RYHUWKHPXOWLFDPHUDVWKLVLVVHWGXULQJDGMXVWLQJRIWKHFDPHUDV I) Simultaneous pickup area 7KLVSDUDPHWHULVXVHGWRGHWHUPLQHZKHWKHUPXOWLSOHKHDGVFDQSLFNXS FRPSRQHQWVVLPXOWDQHRXVO\(DFKFROXPQUHVSHFWLYHO\VKRZVWKHDOORZDEOH UDQJHVRISLFNXSSRVLWLRQV;<5=WKDWSHUPLWVLPXOWDQHRXVSLFNXSIURP GLIIHUHQWFRPSRQHQWIHHGHUV7\SLFDOO\;<DQG=VKRXOGEHVHWWRPPDQG WKH5WRGHJUHH J) QFP clearance,idodujhlpsdfwlvdssolhgwrd4)3dwwkhlqvwdqwzkhqdkhdgorzhuvwrslfn RUPRXQWLWWKHOHDGVRIWKH4)3LQTXHVWLRQVDUHOLNHO\WREHQW7RDYRLGWKLV WKHVRIWODQGLQJSLFNXSRUPRXQWLQJLVXVHIXO7KLVSDUDPHWHUVSHFLILHVWKH= VWURNHWRSHUIRUPWKHVRIWODQGLQJDQGLVW\SLFDOO\VHWWRPP:KHQ µ LVHQWHUHGWKHVRIWODQGLQJLVQRWSHUIRUPHG K) CngTimer/Speed 7KHYDOXHLQWKH ;µfroxpqlvwkhwlphgxudwlrqiruzklfkdkhdgvwd\vdw WKHORZHUHQGSRVLWLRQZKHQFKDQJLQJDQR]]OH8QLWVDUHPLOOLVHFRQGV$ W\SLFDOVHWWLQJLVDURXQGPVHF,IDQR]]OHFKDQJHLVXQVXFFHVVIXOWU\ HQWHULQJDVOLJKWO\ODUJHUYDOXH$YDOXHRIDVORQJDVRQHVHFRQGPVHF FDQEHVHW 7KHYDOXHLQWKH <µfroxpqlvwkhuhodwlyhdvfhqwdqgghvfhqwvshhgiruwkh KHDGGXULQJQR]]OHFKDQJH7KLVLVQRUPDOO\VHWWR,IDQR]]OHFKDQJHLV XQVXFFHVVIXOWU\GHFUHDVLQJWKLVYDOXHVOLJKWO\ L) Retry limit 7KLVLVWKHPD[LPXPQXPEHURIUHWULHVWKDWWKHPRXQWHULVDOORZHGWRUHWU\ SLFNLQJRUUHFRJQL]LQJDIWHUZKHQDQHUURURFFXUV7KLVSDUDPHWHUFDQEHDQ\ YDOXHIURPWR8VHWKHVSDFHLQVHUWDQGGHOHWHNH\ VWRFKDQJHWKH VHWWLQJ:KHQ\RXGRQRWZDQWWRDOORZUHWULHVVHWWKLVSDUDPHWHUWR12 5(75<7KHQXPEHURIUHWULHVFDQDOVREHVSHFLILHGIRUHDFKFRPSRQHQWWR EHPRXQWHG,QWKHVHFDVHVWKHUHWU\LVSHUIRUPHGDQXPEHURIWLPHVXSWRD PLQLPXPVHWWLQJ M) Dump point 7KLVSDUDPHWHUGHVFULEHVZKHUHDFRPSRQHQWWKDWIDLOHGWKHUHFRJQLWLRQ VKRXOGEHGXPSHG N) Moving height 7KLVSDUDPHWHULVLQYDOLGLQWKH7RSD]VXUIDFHPRXQWHUDQGVKRXOGEHVHWWR µ Service Manual Topaz 5322 871 63606 7-8 PA 1309/10 01.05

Component Transport Systems 7.2.3. Pickup and Mount Vacuum Levels 3UH&RQGLWLRQV 1RQH 7KHYDFXXPSUHVVXUHWRSLFNXSDFRPSRQHQWLVDQDORJXHGHWHFWHGDQGGLJLWDOO\ UHSUHVHQWHGE\DVFDOHRIWR7KHFXUUHQWOHYHOVDUHVKRZQLQWKHIROORZLQJ VFUHHQ 0&+B'$7$!$ 6(/(&7 7$5*(7! 9DFXXP OHYHOµ DQG SUHVV(QWHU6HHILJXUH Editing Object Vacuum Level Head No. Head 1 Head 2 Head 3 Head 4 Head 5 Head 6 Head 7 Head 8 Low level 141 137 10 10 10 10 10 10 High level 160 162 150 150 150 150 150 150 Current vacuum levels Figure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ick level adjustment: :KHQDQR]]OHGHVFHQGVDQGSLFNVDFRPSRQHQWQRDLULVDOORZHGWRHQWHUWKH QR]]OH VR WKH YDFXXP VHQVRU GHWHFWV DQ LQFUHDVHG YDFXXP :KHQ WKLV OHYHO EHFRPHVKLJKHUWKDQWKHSUHVHWSLFNXSYDFXXPOHYHOWKHPDFKLQHDVVXPHVWKH QR]]OHKDVSLFNHGXSDFRPSRQHQW 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-9

Component Transport Systems 7KH SLFNXS YDFXXP OHYHO VKRXOG EH SUHVHW IRU HDFK KHDG IRU D OHYHO WKDW LV VOLJKWO\KLJKHURIIVHWLVWKDQWKHPLQLPXPYDFXXPOHYHOPDLQWDLQHGZKHQ WKHQR]]OHLVRSHQQRFRPSRQHQWDWWKHQR]]OH 3UHVVWKHHPHUJHQF\EXWWRQDQGDWWDFKQR]]OHWRDOOKHDGV &DQFHOWKHHPHUJHQF\VWRSDQGSUHVVWKHUHDG\EXWWRQ ([HFXWH WKH YDFXXP OHYHO XWLOLW\ E\ VHOHFWLQJ PHQX 0$,17(0 0&+B$'-867%$'-8677$5*(7DQGVHOHFW9DFXXP/HYHO6HH ILJXUH 7RDGMXVWWKHPDFKLQHORZOHYHOVHOHFWWKH $//µdqg 3LFNµIURPWKH PHQX7KH$OOFKRLFHZLOODOORZWKHDGMXVWPHQWRIDOOKHDGVDWWKHVDPH WLPH7KH.H\,QRSWLRQZLOOSURPSWWKHXVHUWRVHOHFWDQ\RIWKHHLJKW KHDGV 5) $IWHUWKHDERYHFKRLFHVKDYHEHHQPDGH9,26SURPSWVWKHXVHUWRLQSXWD YDFXXPRIIVHW7KLVLVWRFUHDWHDVDIHZRUNLQJUDQJH*HQHUDOO\DQ RIIVHW RI LV D FRUUHFW YDOXH +RZHYHU ZKHQ XVLQJ QR]]OH VPDOO FRPSRQHQWV FKDQJLQJ WKH RIIVHW IURP WR ZLOO LQFUHDVH WKH YDFXXXP UDQJH 7KLV ZLOO DOORZ D EHWWHU GLVWLQFWLRQ EHWZHHQ DQ RSHQ DQG D FORVHG QR]]OH(QWHUWKLVYDOXHDQGSUHVV <ENTER>. See figure 7-5 3UHVVHQWHUWRVWDUWWKHPHDVXUHPHQWWKHSLFNXSYDFXXPOHYHOLVPHDVXUHG IRUWRVHFRQGVWKHQWKHUHVXOWVDUHGLVSOD\HG 7KHSLFNXSOHYHOZLOOEHPHDVXUHGIRUWRVHFRQGV$IWHUWKDWWKH UHVXOWVZLOOEHGLVSOD\HG6HHDOVRILJXUH7-5. 6HOHFW%6DYH'$7$!RU%VDYH TXLW!DQGSUHVVHQWHU <<<APPLICATION>>>1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH-ADJUST 4/MANUAL 0/EXIT <COMMAND_LIST> A/CHANGE-CONDTION B/SAVE & QUIT C/DISPLAY & EXIT B1 ADJUST TARTET Object Vacuum Level Head ALL Key in Target Pick Mount <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT A441 Please input the offset value of the vacuum level. Picking level used is higher than open level by offset. Mounting vacuum level is Offset 5 A443 It will measure the vacuum level when picking. This adjustment requires a nozzle or no nozzle on the head with no component attached. Press the EMG A444 <<Measuring!!>> New it is measuring vacuum level. It takes 20 sec. A445 <<Result>> The following data is the result of the adjustment of the vacuum level when picking and mounting. Level Max. Current Result 1 XXX XXX XXX XXX 2 XXX XXX XXX XXX 3 0 0 0 0 4 0 0 0 0 5 0 0 0 0 6 0 0 0 0 7 0 0 0 0 8 0 0 0 0 Figure 7-5 Vacuum results Service Manual Topaz 5322 871 63606 7-10 PA 1309/10 01.05

Component Transport Systems B) Mount level adjustment :KHQDQR]]OHGHVFHQGVWRPRXQWDFRPSRQHQWRQWRWKH3&%WKHYDFXXP SUHVVXUHDWWKHQR]]OHLVLQVWDQWDQHRXVO\LQYHUWHGWRDSRVLWLYHSUHVVXUHVRWKH GHWHFWHGYDOXHRIWKHYDFXXPVHQVRUGHFUHDVHV:KHQWKLVOHYHOEHFRPHVORZHU WKDQWKHSUHVHWPRXQWYDFXXPOHYHOWKHPDFKLQHDVVXPHVWKHFRPSRQHQWKDV EHHQVHSDUDWHGIURPWKHQR]]OHDQGPRXQWHGRQWRWKH3&% 7KH PRXQW YDFXXP OHYHO VKRXOG EH SUHVHW IRU HDFK RI WKH HLJKW KHDGV DW D VOLJKWO\ORZHURIIVHWLVYDOXHWKDQWKHPD[LPXPYDFXXPOHYHOZKHQWKH QR]]OHRSHQLQJLVVHDOHG *R WR PHQX 0$,17(0 0&+B$'-867 % $'-867 7$5*(7 DQGVHOHFW9DFXXP/HYHO6HHILJXUH 2) 7RDGMXVWWKHPDFKLQHORZOHYHOVHOHFW $//µdqg PRXQWµ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bject Vacuum Level Head ALL Key in Target Pick Mount <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH-ADJUST 4/MANUAL 0/EXIT A441 Please input the offset value of the vacuum level. Picking vacuum level is higher than open level by offset. Mounting vacuum level is A442 It will measure the vacuum level when mounting. This adjustment requires a nozzle and a component A444 <<Measuring!!>> New it is measuring vacuum level. It takes 20 sec. A445 <<Result>> The following data is the result of the adjustment of the vacuum level when picking and mounting. Level Min. Current Result 1 XXX XXX XXX XXX 2 XXX XXX XXX XXX 3 0 0 0 0 4 0 0 0 0 5 0 0 0 0 6 0 0 0 0 7 0 0 0 0 8 0 0 0 0 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-11

Component Transport Systems Figure 7-6 Vacuum results 7.2.4. R-axis Absolute Accuracy Offset 7KLVLVWKHDQJXODURIIVHWIRUWKH5D[LVWKDWURWDWHVHDFKQR]]OHVKDIWWRPRXQW WKHFRPSRQHQW:KHQ\RXVHOHFW$VHOHFWWDUJHW! 5D[LVDFFXUDF\µ (QWHUWKHFXUUHQWRIIVHWVHWWLQJVIRUWKHPRXQWLQJDQJOHVDQG² DUHGLVSOD\HGDVVKRZQEHORZ <<<APPLICAITON>>> <<MODE>> 2/MCH_DATA 3/MAINTE/M Editing Object R Axis Accuracy Head No. Head 1 Head 2 Head 3 Head 4 Head 5 Head 6 Head 7 Head 8 0deg. 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 180deg. 0.07 0.20 0.00 0.00 0.00 0.00 0.00 0.00 90deg. 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00-90deg. 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Figure 7-7 Note These off-sets are automatically corrected when you execute the mount feedback (Vision). Since the position at 0-degree is used as a reference, it is always set to 0.00 7RGHWHUPLQHWKHVHRIIVHWVXVHWKH5D[LVDFFXUDF\URXWLQHLQWKHPDLQWHQDQFH PDQDJHU7KHPDFKLQHDXWRPDWLFDOO\HYDOXDWHVWKHVHRIIVHWVHWWLQJVE\ UHFRJQL]LQJWKHFRPSRQHQWWKDWDKHDGSLFNVXSZKLOHURWDWLQJWKHQR]]OH VKDIWDWWKHIRXUDQJOHV 7ZRVLWXDWLRQVFDQEHGLVWLQJXLVKHG - 7RSD]ZLWKRQO\WKHPXOWLFDPHUDLQVWDOOHG :KHQWKHPXOWLFDPHUDZLWKWKHUHIHUHQFHPRXQWLQJDQJOHVSHFLILHGDW GHJUHHVLVXVHGPRXQWLQJVDWDQG²PLJKWGHYLDWHVOLJKWO\ 7KLVGHYLDWLRQRURIIVHWFDQEHFRUUHFWHGZLWKWKH5D[LVDFFXUDF\ FRPPDQGLQZKLFKWKHPXOWLFDPHUDUHFRJQL]HVD4)3FRPSRQHQWDW WKHIRXUPRXQWLQJDQJOHVWRGHWHUPLQHWKHRIIVHWZLWKUHVSHFWWRWKH UHFRJQLWLRQUHVXOWDWGHJUHHV6LQFHWKHGHJUHHSDUDPHWHULVXVHGDVD UHIHUHQFHLWLVVHWWRGHJUHHV - 7RSD]ZLWKDQRSWLRQDOVLQJOHFDPHUDLQVWDOOHG :KHQDVLQJOHFDPHUDZLWKWKHUHIHUHQFHPRXQWLQJDQJOHVSHFLILHGDW GHJUHHVLVXVHGPRXQWLQJVDWDQG²PLJKWGHYLDWHVOLJKWO\7KLV GHYLDWLRQRURIIVHWFDQEHFRUUHFWHGZLWKWKH5D[LVDFFXUDF\FRPPDQG LQZKLFKWKHPXOWLFDPHUDUHFRJQL]HVD4)3FRPSRQHQWDWWKHIRXU PRXQWLQJDQJOHVWRGHWHUPLQHWKHRIIVHWZLWKUHVSHFWWRWKHUHFRJQLWLRQ UHVXOWDWGHJUHHV6LQFHWKHGHJUHHSDUDPHWHULVXVHGDVDUHIHUHQFH LWLVVHWWRGHJUHHV Service Manual Topaz 5322 871 63606 7-12 PA 1309/10 01.05

Component Transport Systems Note The R-table will always show the 90 degree as a reference, so the value in this table is always 0.00. In case the multi-camera is used as a reference internally a calculation is carried out to get the correction for the other angles 90, -90 and 180 degrees. Preparing the component and nozzle 3UHSDUHD4)3FRPSRQHQWWREHXVHGDVDUHIHUHQFH3UHIHUDEO\DODUJHSRSXODU 4)3RINQRZQVL]HZKLFKLVUHJLVWHUHGLQWKHFRPSRQHQWGDWDEDVH ([DPSOHLV4)33/3UHVVWKHHPHUJHQF\EXWWRQDQGDWWDFKD4)3 QR]]OHW\SHWRHDFKKHDG Calibrating the R-axis accuracy )ROORZWKHSURFHGXUHEHORZ - &DQFHOWKHHPHUJHQF\VWRSDQGVHOHFW%DGMXVWWDUJHW! 5D[LVDFFXUDF\µ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ozzle Correction 7KLVSDUDPHWHULVXVHGWRFRUUHFWDQRIIFHQWHUQR]]OHVKDIWZKHQLWURWDWHVE\ GHJUHHV:KHQ\RXVHOHFW0&+B'$7$!!$0&+B'$7$! ^$6(/(&77$5*(7`µ1R]]OH&RUUHFWLRQµDQGSUHVVWKH>(17(5@ NH\WKHFXUUHQWVHWWLQJIRUWKLVRIIVHWLVGLVSOD\HG <<<APPLICATION>>> <<MODE>> 2/MCH_DATA 3/MAINTE/M Editing Object NozzleCorrection Head No. Atbl Head 1 Atbl Head 2 Atbl Head 3 Atbl Head 4 X -0.03 0.00 0.00 0.00 Y 0.03 0.00 0.00 0.00 Figure 7-8 Note This offset is automatically corrected when you execute mount feedback (Vision). 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-13

Component Transport Systems 7.2.6. Head Offset 7KLVLVWKHSRVLWLRQRI+HDGVUHODWHGWR+HDG:KHQ\RXVHOHFW 0&+B'$7$!!!$0&+B'$7$!!^$6(/(&77$5*(7`!µ+HDG2IIVHWµDQGSUHVVWKH>(17(5@NH\WKHFXUUHQWVHWWLQJIRUWKLV RIIVHWLVGLVSOD\HG <<<APPLICATION>>> <<MODE>> 2/MCH_DATA 3/MAINTE/M Editing Object Head Offset Head No. Head 1 Head 2 HeadType AutoNzlChg. AutoNzlChg. X Y Z nozzle 0.00 25.00 0.00 12.00 0.00 0.95 TYPE-31 TYPE-32 Head 7 Head 8 None None 0.00 0.00 0.00 0.00 0.00 0.00 TYPE-31 TYPE-31 Figure 7-9 Note This offset is automatically corrected when you execute mount feedback. Since the position of Head 1 is used as a reference, this is always set to 0.00. Service Manual Topaz 5322 871 63606 7-14 PA 1309/10 01.05

Component Transport Systems 7.3. Nozzle Station 7.3.1. Nozzle Station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igure 7-10 Nozzle station, positions and sensors 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-15

Component Transport Systems 7.3.2. Adjusting the Nozzle Sensor Sensitivity (DFKQR]]OHKROGHULQWKHQR]]OHVWDWLRQKDVDVHQVRUWKDWGHWHFWVWKHSUHVHQFH RIWKHQR]]OHDOORZLQJWKHPDFKLQHWRLGHQWLI\ZKLFKW\SHRIQR]]OHLV FXUUHQWO\DWWDFKHGWRHDFKKHDG7KHQR]]OHVHQVRULVVHSDUDWHGIURPLWV DPSOLILHUXQLWZKLFKLVLQVWDOOHGLQVLGHWKHPDFKLQHMXVWEHKLQGWKHOHIWVLGH RIWKHIURQWIHHGHUSODWH6LQFHDJDLQFRQWUROLVSURYLGHGRQWKHDPSOLILHUWKH QR]]OHVHQVRUVHQVLWLYLW\FDQEHFKHFNHGDQGDGMXVWHGLIQHFHVVDU\DVGHVFULEHG EHORZ Figure 7-11 Nozzle sensor amplifier 2SHQWKHRXWSXWPRQLWRUDQGUHOHDVHWKHQR]]OHFODPSSODWH 6HOHFW0$,17(0!!!0$18$/!!&',63/$< (;,7! ^&287387021,725`DQGSUHVVWKH>(17(5@NH\ /LQHXSWKHFXUVRUZLWK 73µ)521712==/(67$7,21 &/$03 3UHVVWKH>(17(5@NH\WRRSHQWKHFODPSSODWH 7KHRXWSXWPRQLWRUGLJLWUHDGV µzkhqwkhfodpssodwhlvfxuuhqwo\ FORVHGDQGUHDGV µzkhqlwlvrshqhg Out Monitor [ ] : Select [Enter] : Exec [ESC] : Command Lists Selected Arm : MAIN Moving Speed : 100 TP02 FRONT NOZZLE STATION CLAMP CLAMP 0 / OPEN 1 (NP14= 1 / NP14= 0) XY NAME OUT NAME IN Nzl Clamp/Spare TP01-08 01000000 Nzl Clamp/Spare NP09-16 00000100 Figure 7-12 Nozzle clamp in output monitor Service Manual Topaz 5322 871 63606 7-16 PA 1309/10 01.05

Component Transport Systems 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGLQVHUWDQR]]OHLQWRWKHQR]]OHKROGHU \RXZDQWWRFKHFN 2SHQWKHLQSXWPRQLWRUDQGVHOHFWWKHFRUUHFWQR]]OHVHQVRU 3UHVVWKH>7$%@NH\WRPRYHWKHFXUVRULQWRWKHLQSXWPRQLWRUZLQGRZ /LQHXSWKHFXUVRUZLWKWKHGLJLWIRUWKHFRUUHVSRQGLQJVHQVRUIURP DPRQJ 11µWR 11µVHHILJXUH In Monitor [ ] : Select [Enter] : Exec [ESC] : Command Lists Selected Arm : MAIN Moving Speed : 100 XY NN06 NOZZLE 6 SENSOR NAME OUT NAME IN Nozzle Sensor NN01-08 00000100 Nozzle Sensor NN09-16 00000000 Figure 7-13 Nozzle sensors in input monitor 7RPDWFKWKHQR]]OHKROGHU1RRUQR]]OHVWDWLRQ1RDQGWKHVHQVRU LQSXWGLVSOD\FRGHVHHILJXUH &KHFNWKHLQSXWVWDWXVRIWKHVHOHFWHGVHQVRU 7KHGLJLWUHDGV µzkhqwkhqr]]ohlvvwruhglqwkhkroghuexwuhdgv µ ZKHQLWLVQRW,IWKHGLJLWUHDGV µwkhdpsolilhujdlqiruwkhqr]]oh VHQVRULVWRRORZ*UDGXDOO\WXUQWKHJDLQFRQWURORIWKHDPSOLILHU FORFNZLVHXQWLOWKHGLJLWUHDGV µ 7DNHWKHQR]]OHRXWRIWKHKROGHUDQGFKHFNWKHLQSXWVWDWXV &KHFNLIWKHGLJLWKDVFKDQJHGWR µ,iqrwwkhdpsolilhujdlqlvvhwwrr KLJK7XUQEDFNWKHJDLQFRQWURORIWKHDPSOLILHUVOLJKWO\WRWKHOHIWVRWKDW WKHGLJLWUHDGV µ Caution Do not change the amplifier s MODE selector setting. With this setting, the red and green LED s of the amplifier are both lit when the nozzle is in the holder, and only the green LED is lit when not in the holder. If this detection still occurs even after you have adjusted the amplifier gain, the position of the nozzle sensor is probably incorrect. Loosen the set screw located on the bottom of the nozzle station and make adjustment to the sensor position. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-17

Component Transport Systems 7.3.3. Adjusting the Nozzle Clamp Plate Position 7KHQR]]OHFODPSSODWHLVORFDWHGRQWKHWRSVXUIDFHRIWKHQR]]OHVWDWLRQ,W RSHQVWRDOORZDKHDGWRH[WUDFWDQR]]OHIURPWKHQR]]OHVWDWLRQRUFORVHVWR ORFNDQR]]OHLQSODFHDQGH[WUDFWLWIURPWKHKHDG 7KHQR]]OHFODPSSODWHRSHQVDQGFORVHVE\PHDQVRIDQDLUF\OLQGHUZKLOHWKH SRVLWLRQRIWKHSODWHDLUF\OLQGHULVGHWHFWHGE\DVHQVRU,IWKHSRVLWLRQLV QRWFRUUHFWWURXEOHPD\RFFXUGXULQJWKHQR]]OHFKDQJH,IQHVVHFDU\DGMXVW WKHFODPSSODWHDVIROORZV - 2SHQWKHFODPSSODWHE\DFWLYDWLQJ73)URQWQR]]OHVWDWLRQFODPSLQ WKHRXWSXWPRQLWRU$ µphdqvwkhfodpslvrshq - 3UHVVWKHHPHUJHQF\EXWWRQDQGORRVHQWKHFODPSSODWHEROWVVHHILJXUH - $GMXVWWKHSRVLWLRQRIWKHFODPSE\XVLQJWKHSOD\RIWKHPRXQWLQJKROHV 7KHSRVLWLRQLVFRUUHFWZKHQWKHDSHUWXUHRIHDFKQR]]OHVWDWLRQLVH[DFWO\ DOLJQHGZLWKWKHKROHVLQWKHFODPSSODWH - 7LJKWHQWKHEROWVLQWKHFODPSSODWH - &KHFNWKHVWDWXVRIWKHFODPSSODWHVHQVRUVDVLQIROORZLQJWDEOH Output Input TP02 = 0 (clamp) NP13 = 0 NP14 = 1 TP02 = 1 (open) NP13 = 1 NP14 = 0 7.3.4. Adjusting the Nozzle Station Coordinates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µ)521712==/(67$7,21&/$03 3UHVVWKH>(17(5@NH\WRRSHQWKHFODPSSODWH 7KHRXWSXWPRQLWRUGLJLWUHDGV µzkhqwkhsodwhlvrshqhgdqguhdgv µzkhqlwlvforvhg Service Manual Topaz 5322 871 63606 7-18 PA 1309/10 01.05

Component Transport Systems Out Monitor [ ] : Select [Enter] : Exec [ESC] : Command Lists Selected Arm : MAIN Moving Speed : 100 TP02 FRONT NOZZLE STATION CLAMP CLAMP 0 / OPEN 1 (NP14= 1 / NP14= 0) XY NAME OUT NAME IN Nzl Clamp/Spare TP01-08 01000000 Nzl Clamp/Spare NP09-16 00000100 Figure 7-14 6HOHFWWKHD[LVWRGLVSOD\WKHFRRUGLQDWHVRQWKHPRQLWRU 3UHVVWKH>6(/$;,6@NH\RIWKH++.WRVHOHFWWKHD[LV 0$,1;<µ 5DLVHWKHQR]]OHVWDWLRQLQWKHPDQXDOVFUHHQ 3UHVVWKHHPHUJHQF\VWRSEXWWRQ $WWDFKD7\SHQR]]OHWR+HDGE\KDQG 7\SHQR]]OHLVXVHGRQO\IRU+HDG 0RYHWKHKHDGDVVHPEO\E\KDQGWRRYHUWKHQR]]OHVWDWLRQ 0RYHWKHKHDGDVVHPEO\VRWKDWWKHQR]]OHWLSLVSRVLWLRQHGGLUHFWO\DERYH 1R]]OH6WDWLRQ Caution When moving the head assembly, do not push on the camera or head shaft. The settings for the coordinates may become unreliable. $OLJQWKHRULHQWDWLRQRIWKHQR]]OH7XUQWKHQR]]OHVKDIWE\KDQGVRWKDW WKHQRWFKRQWKHQR]]OHLVDOLJQHGZLWKWKHVWRSSLQIRUSUHYHQWLQJ URWDWLRQDORIIVHWLQWKHQR]]OHKROGHU$WWKLVSRLQWFKHFNWKDWWKH5 FRRUGLQDWHGLVSOD\HGRQWKHERWWRPRIWKHRXWSXWPRQLWRUVFUHHQVKRZVD YDOXHZLWKLQ GHJUHHV,IQRWGHWDFKWKHQR]]OHWXUQLWGHJUHHVDQG WKHQUHDWWDFKLWWR+HDG /RZHU+HDGWRLQVHUWWKHQR]]OHLQWRWKHQR]]OHVWDWLRQ $FWLYDWHKHDGSQHXPDWLFDOO\DQGPRYHWKHKHDGDVVHPEO\GRZQZDUGV XQWLOWKHQR]]OHFOLFNVVPRRWKO\LQWRSODFHLQWKHQR]]OHKROGHU7KHQ IXUWKHUORZHUWKHKHDGXQWLOLWVWRSVLQWKHQR]]OHKROGHU. Reference Turning the coupling assembly located between the motor and the ball screw allows for easy minute movement of the X-axis and Y-axis. For the vertical movement of the Z-axis, it is advisable to gently press the metallic plate (lower limit detection dog) downwards or pull upwards attached to the nozzle shaft. &KHFNWKH;<=DQG5FRRUGLQDWHV0DNHDQRWHRIWKHUHDGLQJV GLVSOD\HGRQWKHERWWRPRIWKHRXWSXWPRQLWRUVFUHHQ 2SHQWKHQR]]OHVWDWLRQFRRUGLQDWHVVFUHHQ 6HOHFW$^$6(/(&77$5*(7`µ1R]]OH6WDWLRQµDQGSUHVV WKH>(17(5@NH\ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-19

Component Transport Systems (QWHUWKH;<=DQG5FRRUGLQDWHV (QWHUWKH;<=DQG5 FRRUGLQDWHV\RXPDGHDQRWHRILQ6WHSDORQJWKH 1]O6WDWLRQµURZ Editing Object Nozzle Station Nzl.Station No. Nzl. Station 1 Nzl. Station 2 Nzl. Station 3 Nzl. Station 4 Nzl. Station 5 Nzl. Station 6 Nzl. Station 7 X 13.78 20.13-29.50 19.44-29.50 6.75-43.50 Y 57.33 32.33 19.00 5.72-6.00 39.40 34.00 Z 74.62 74.54 69.0 74.63 69.00 76.64 69.00 R -59.44-57.95-57.21-59.71-57.21-57.97-18.36 Nzl.Type TYPE-34 TYPE-3F TYPE-33 TYPE-3F TYPE-3F TYPE-3F TYPE-3F HeadNo. Head1 Head1 Head1 Head1 Head1 Head2 Head2 Nzl. Station 14 Nzl. Station 15 Nzl. Station 16 31.21 31.16-43.50 23.41 11.07-6.00 72.08 71.99 69.00-18.39-18.51-18.36 TYPE-31 TYPE-31 TYPE-32 Head2 Head1 Head1 Figure 7-15 Nozzle station coordinates screen 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^$6$9( 48,7`RU^$6$9(`DQG SUHVVWKH>(17(5@NH\ 7RTXLWZLWKRXWVDYLQJVHOHFW^$$%257 48,7`DQGSUHVVWKH >(17(5@NH\ &DQFHOHPHUJHQF\VWRS(QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRS EXWWRQDQGSUHVVWKH>5($'<@EXWWRQRIWKH++. &KHFNWKDWWKHQR]]OHFDQEHH[FKDQJHGVPRRWKO\ 7RFKHFNXVHWKH^$&+$1*(12==/(`FRPPDQGLQWKH0DFKLQH $GMXVWPRGH Note When you need to adjust other nozzle stations, use the same procedure described above. Be careful to use the correct head specified for each nozzle station The list of nozzle location and type can be found in figure 7-15. 7.3.5. Nozzle Station Maintenance &KHFNDWDUHJXODULQWHUYDOTXDUWHUO\WKHIROORZLQJIXQFWLRQVRIWKHQR]]OH VWDWLRQ í í í &KHFNLIWKHQR]]OHVDUHJRLQJVPRRWKO\LQDQGRXWRIWKHQR]]OHKROGHU )RUDUHDGMXVWPHQWVHHWKHSUHYLRXVSDUDJUDSKVRIWKLVFKDSWHU &KHFNLIWKHVHQVLQJRIWKHQR]]OHLVGRQHLQDSURSHUZD\8VHWKH DGMXVWPHQWGHVFULEHGLQWKHSUHYLRXVSDUDJUDSKVWRFRUUHFWWKLV &KHFNIRUZHDUDQGGHEULVLQDQGDURXQGWKHQR]]OHVWDWLRQ&OHDQWKH VWDWLRQDQGDSSO\DOLWWOHJUHDVHRQWKHPRYLQJVXUIDFHVRIWKHFODPS SODWH Service Manual Topaz 5322 871 63606 7-20 PA 1309/10 01.05

Component Transport Systems 7.4. 7.4.1. Feeder Plates 7KLVVHFWLRQGHVFULEHVKRZWRDGMXVWWKHSRVLWLRQRIWKHIHHGHUSODWHVDQGWKHLU PDFKLQHGDWDLQRUGHUWKDWHDFKKHDGSURSHUO\SLFNVXSDFRPSRQHQW$OVR H[SODLQHGDUHDGMXVWPHQWVWRIHHGSLWFKRIWDSHIHHGHUV&RUUHFWDGMXVWPHQWRI WKHIHHGHUSODWHVLVHVVHQWLDOWRWKHSURSHUZRUNLQJRIWKHV\VWHP,PSURSHU DGMXVWPHQWZLOOUHGXFHWKHFRPSRQHQWSLFNXSUDWHRIHDFKKHDG7KHVHFRQG SDUWRIWKLVFKDSWHUH[SODLQVKRZWRDGMXVWWKHIHHGSLWFKDQGVSHHGRIWKHWDSH IHHGHUV Feeder Plate Parallel Adjustment 7KHIHHGHUSODWHLVVHFXUHGWRWKHIHHGHUEDVHRIWKHPDLQXQLWE\EROWV8QGHU QRUPDOZRUNLQJFRQGLWLRQVWKHIHHGHUSODWHZLOOQRWUHTXLUHSDUDOOHO DGMXVWPHQW+RZHYHULI\RXQHHGWRUHPRXQWWKHIHHGHUSODWHIRUVRPH UHDVRQVILUVWPDNHWKHSDUDOOHODGMXVWPHQWDVIROORZV)LQHDGMXVWPHQWVWR IHHGHUSRVLWLRQVZLOOEHSHUIRUPHGLQWKHQH[WVHFWLRQ7HDFKLQJWKH IHHGHUEORFNSRVLWLRQV0RXQWWZRIHHGHUEDUDGMXVWPHQWEORFNVRQWKH IHHGHUEDUDWWKHHQGDQGEHJLQQLQJ Figure 7-16 Feeder plates (top view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ervice Manual Topaz 01.05 PA 1309/10 7-21

Component Transport Systems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eeder Block Positions 2QHDFKRIWKHWZRIHHGHUSODWHVIHHGHUVHWSRVLWLRQVSLFNXSSRVLWLRQV DUHSURYLGHG7KHVHSLFNXSSRVLWLRQVDUHGLYLGHGLQWRVHYHQIHHGHUEORFNVSHU SODWHDVVKRZQEHORZ(DFKIHHGHUEORFNLVFRPSULVHGRIHLJKWIHHGHU SRVLWLRQVH[FHSWWKHULJKWPRVWIHHGHUEORFN3)3)RQHDFKSODWHZKLFK FRQVLVWVRIWZRIHHGHUSRVLWLRQV7KHILUVWIHHGHUVHWSRVLWLRQRIHDFKIHHGHU EORFNLVVSHFLILHGDVDUHIHUHQFHSRVLWLRQ7KHUHIRUHIHHGHUVHWSRVLWLRQVRI 1RDQGRQWKHIURQWSODWHDQG1R DQGRQWKHUHDUSODWHDUHXVHGDVUHIHUHQFHSRVLWLRQV Figure 7-17 Feeder block arrangement Service Manual Topaz 5322 871 63606 7-22 PA 1309/10 01.05

Component Transport Systems CAUTION Due to the configuration design of the Topaz head assembly, the feeder set positions that can be actually accessed by each head are limited to No. 1 to 47 on the front side and No. 104 to 150 on the rear side (94 positions in total). Accordingly, to teach the reference position No. 101, use No. 104 instead and add 48.00mm to the X coordinate determined. (One pitch of the feeder set positions equals to 16.00mm.) The Y coordinate will be the same as feeder position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`)HHGHU3ODWH2IIVHWDQGSUHVV WKH>(17(5@NH\ <<<APPLICATION>>>1/OPERATION/M 2/DATA/M 3/MAINTE/M <<MODE>> 1/MCH-CONFIG 2/MCH_DATA <COMMAND_LIST> A/MCH_DATA A1 SELECT TARGET Object FeederPlateOffset <<<APPLICATION>>>1/OPERATION/M 2/DATA/M 3/MAINTE/M <<MODE>> 1/MCH-CONFIG 2/MCH_DATA Editing Object FeederPlateOffset Plate No. X FeederPlate 1 51.50 FeederPlate 2 179.50 FeederPlate 3 307.50 FeederPlate 4 435.50 FeederPlate 5 563.50 Y 3.53 3.51 3.35 3.51 3.53 Figure 7-18 Feeder plate offset editing screen /LQHXSWKHFXUVRUZLWKWKH;FROXPQRIWKHIHHGHUEORFN\RXDUH WHDFKLQJ 3UHVVWKH>)@NH\7KHPHQXZLQGRZIRUVHOHFWLQJWHDFKLQJFRQGLWLRQV WKHQDSSHDUV 6HWWHDFKLQJFRQGLWLRQV 6HOHFWWKHWHDFKLQJXQLWDQGSUHVVWKH>(17(5@NH\ 7KHKHDG1R\RXDUHXVLQJIRUWHDFKLQJPXVWEHVHOHFWHG 6HOHFWDQ\VSHHGIURP6SHHGWR6SHHGDQGSUHVV>(17(5@ 3UHVVWKH>)@NH\WZLFHWRSHUIRUPWHDFKLQJ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-23

Component Transport Systems 7KH;FRRUGLQDWHYDOXHRIWKHUHIHUHQFHIHHGHUSRVLWLRQLVHQWHUHG 7KHQOLQHXSWKHFXUVRUZLWKWKH<FROXPQ 3UHVVWKH>)@NH\WZLFHWRSHUIRUPWHDFKLQJ 7KH<FRRUGLQDWHYDOXHRIWKHUHIHUHQFHIHHGHUSRVLWLRQLVHQWHUHG 5HSHDWWKHSURFHVVIRURWKHUUHIHUHQFHIHHGHUSRVLWLRQV8VHWKHDERYH VWHSVLQVWDOOLQJWKHVDPHWDSHIHHGHULQHDFKUHIHUHQFHIHHGHUSRVLWLRQ 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^$6$9( 48,7`RU^$6$9(`DQG SUHVVWKH>(17(5@NH\7RTXLWZLWKRXWVDYLQJVHOHFW ^$$%257 (;,7`DQGSUHVVWKH>(17(5@NH\ 3HUIRUPWKHFRPSRQHQWSLFNXSWHVWWRFKHFNWKHVHWWLQJV7KLVWHVW VKRXOGEHSHUIRUPHGIRUDOOUHIHUHQFHIHHGHUSRVLWLRQV5HIHUWRWKHQH[W VHFWLRQ&RPSRQHQWSLFNXSWHVW,IDQ\RIIVHWLVIRXQGFRUUHFWLW RQWKHIHHGHUSODWHRIIVHWVFUHHQ 7.4.3. Component Pickup Test 7RFKHFNFRPSRQHQWSLFNXSSRVLWLRQRUSLFNXSIXQFWLRQ\RXFDQXVHWKH FRPSRQHQWSLFNXSWHVWFRPPDQG,QVWDOOLQDGYDQFHDWDSHIHHGHULQWKH IHHGHUVHWSRVLWLRQZKHUH\RXZDQWWRSHUIRUPWKHFRPSRQHQWSLFNXSWHVW,W V UHFRPPHQGHGWRSHUIRUPWKHWHVWZLWKWKHVPDOOHVWDYDLODEOHFRPSRQHQW 5HIHUDOVRWRILJXUHVDQG ([HFXWHWKHFRPSRQHQWSLFNXSWHVW 6HOHFW$^$3,&.&20321(17`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`DQGSUHVVWKH>(17(5@NH\ (QVXUHVDIHW\WKHQSUHVVWKH>(17(5@NH\ 7KHKHDGPRYHVWRWKHGLVFDUGSRLQWDQGGXPSVWKHFRPSRQHQW DXWRPDWLFDOO\ Service Manual Topaz 5322 871 63606 7-24 PA 1309/10 01.05

Component Transport Systems <<<APPLICATION>>>1/OPERATION/M 2/DATA/M 3/MAINTE/M <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH_ADJUST <COMMAND_LIST> A/UTILITY A3 PICK COMPONENT <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH_ADJUST A461 Please input the data base number which has already prepared. After input, please press the [ENTER] key. Database No. 1 A463 It will pick one component. An nozzle type used by this is Type 11 Please input the head number. Head No. 1 A462 As a Tape feeder is specified by this component, the machine can pick component automatically. Please type feeder position number. Feeder Set No. 1 A303 CAUTION!! The axes will move. After confirming safety, please press the [ENTER] key. A394 <<<Picking!!>>> Now it is picking up the specified component automatically. To pause, press [ESC] key. Figure 7-19 Component pickup Figure 7-20 Offset of the nozzle and center position of the component Note In both the X and Y directions, if the nozzle tip is shifted to the machine origin side with respect to the center of the component, then this is a plus offset. If shifted in the opposite side, this is a minus offset. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-25

Component Transport Systems 7.4.4. Feeder Plate Maintenance &KHFNRQDZHHNO\EDVLVWKHZHDURIWKHIHHGHUSODWH5HSODFHWKHDLUMRLQWLI ZHDULVQRWLFHGRULIDLUOHDNDJHLVQRWLFHG$OVRDPDOIXQFWLRQIHHGHUFDQEH FDXVHGE\DEDGDLUVXSSO\RUEDGFRXSOLQJ&OHDQWKHLQQHUSDUWRIWKHDLU FRXSOLQJDQGDSSO\OLWWOHJUHDVHRQWKHLQQHUSDFNLQJRIWKHDLUMRLQW &KHFNWKHIHHGHUDOLJQPHQWHYHU\WKUHHPRQWKV3URFHHGZLWKWKHGHVFULSWLRQ JLYHQLQWKHSUHYLRXVSDUDJUDSKLIQHHGHG Service Manual Topaz 5322 871 63606 7-26 PA 1309/10 01.05

Component Transport Systems 7.5. 7.5.1. Component Feeders 7KLVVHFWLRQH[SODLQVKRZWRDGMXVWWKHIHHGSLWFKDQGVSHHGRIWDSHIHHGHUV DQGPXOWLVWLFNIHHGHUVWKDWFRQWLQXRXVO\VXSSO\FRPSRQHQWVIRUPRXQWLQJ 5HIHUWRWKH&60*(0)HHGHU0DQXDOIRUPRUH LQIRUPDWLRQDERXWWDSHIHHGHUV&EXONIHHGHUVDQGLQWHOOLJHQWWDSH IHHGHUV Tape Feeders )RUVWDEOHDQGDFFXUDWHFRPSRQHQWIHHGLQJWKHIROORZLQJLWHPVPXVWEH DGMXVWHGFRUUHFWO\. Adjustment item Feed pitch Feeder speed Tape peeling load Lock lever position Figure 7-21 Tape feeder type All feeder except 8mm and 32 mm tape feeder 16 mm, 24 mm, 32 mm and 44 mm tape feeders 8 mm and 12 mm tape feeders 32 and 44 emboss tape feeders Tape feeder pitch 7KHVSDFLQJEHWZHHQFRPSRQHQWVRQWKHWDSHDOVRNQRZQDVWKHSLWFKGLIIHUV GHSHQGLQJRQW\SHRIFRPSRQHQWV7KHWDSHIHHGSLWFKRQWKHWDSHIHHGHUPXVW WKHUHIRUHEHVHWWRPDWFKWKHFRPSRQHQWSLWFK7KHWDEOHEHORZVKRZVIHHGSLWFKHV DYDLODEOHIRUHDFKW\SHRIIHHGHU Tape Feeder ( Model No. ) Pitch ( m/m ) 8mm tape feeder ( PL-084 ) 4 8mm tape feeder for 1005 chip ( PL-082 ) 2, 4 12mm tape feeder ( PL-12 ) 4, 8 16mm tape feeder ( PL-16 ) 4, 8, 12, 16 24mm tape feeder ( PL-24 ) 4, 8, 12, 16 32mm tape feeder ( PL-32) 12, 16, 20, 24, 28, 32, 36 44mm tape feeder ( PL-44 ) 12, 16, 20, 24, 28, 32, 36 32mm adhensive tape feeder ( PL-N32 ) 12 Figure 7-22 Tape feeder pitch 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-27

Component Transport Systems 8mm (for 0402 chip) and 12mm tape feeders 7RFKDQJHWKHWDSHIHHGSLWFKVHWWLQJPRGLI\WKHSRVLWLRQRIWKHDLUF\OLQGHU RQWKHWDSHIHHGHUDVGHVFULEHGEHORZ /RRVHQWKHWZRVFUHZVIRUWKHDLUF\OLQGHU,QVHUWWKHWZRVFUHZVLQWRWKHRWKHUSDLURIKROHV 8VHQXPEHUKROHVIRUPPSLWFKDQGQXPEHUKROHVIRUPPSLWFK FKLS 7LJKWHQWKHVFUHZVWRVHFXUHWKHDLUF\OLQGHU Figure 7-23 8mm (0402 chip) tape feeder Figure 7-24 12mm tape feeder Service Manual Topaz 5322 871 63606 7-28 PA 1309/10 01.05

Component Transport Systems 16mm, 24mm, 32mm, 44mm tape feeders /RRVHQWKHWZRVFUHZVRQWKHDLUF\OLQGHUKROGHUSODWH )LWWKHVPDOOSLQLQWRWKHGHVLUHGQRWFKLQWKHKROGHUSODWH 7KHQXPEHUVPDUNHGRQWKHKROGHUSODWHLQGLFDWHVWKHDFWXDOIHHGSLWFKHV LQPLOOLPHWHUV 7LJKWHQWKHVFUHZVWRVHFXUHWKHDLUF\OLQGHU Figure 7-25 16mm, 24mm, 32mm, 44mm tape feeders Feeder speed (for 12 LP, 16, 24, 32 and 44mm tape feeders) 7KHVSHHGDGMXVWHUOLQNHGWRWKHDLUF\OLQGHURIWKHWDSHIHHGHUDOORZV\RXWR YDU\WKHVSHHGDWZKLFKWKHFRPSRQHQWVDUHGHOLYHUHG7XUQWKHDGMXVWHUNQRE WRWKHOHIWWRLQFUHDVHWKHVSHHGDQGWXUQLWWRWKHULJKWWRUHGXFHWKHVSHHG 7KHRSWLPXPVSHHGGLIIHUVGHSHQGLQJRQWKHFRPSRQHQWDQGWDSH,IWKH VSHHGLVVHWWRRIDVWFRPSRQHQWVPD\EHVNLSSHGRUEHFRPHMDPPHGRUWKH WDSHPD\FRPHRIIWKHWDSHJXLGHVSURFNHWSUHYHQWLQJWKHFRPSRQHQWVIURP EHLQJIHGFRUUHFWO\,QVXFKFDVHVWKHVSHHGVKRXOGEHUHGXFHG Figure 7-26 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-29

Component Transport Systems Changing the tape peeling load D7DSHSHHOLQJORDGIRUPPDQGPPWDSHIHHGHUV 7KHWRSWDSDQGFDUULHUWDSRIDWDSHUHHODUHJOXHGZLWKDGKHVLYH,IWKLV DGKHVLYHLVWRRVWURQJWKHWRSWDSHPD\QRWSHHODZD\IURPWKHFDUULHUWDSHDW SURSHUWLPLQJLQSDUWLFXODUSDSHUWDSH 7RLQFUHDVHWKHWDSHSHHOLQJORDGVHWWKHVSULQJVKRZQLQWKHGUDZLQJRQWKH XSSHUVXSSRUWSLQ Figure 7-27 $GMXVWLQJ/RFNOHYHUIRUPPDQGPPHPERVVWDSHIHHGHUV,IWKHUHLVDJDSEHWZHHQWKHWDSHJXLGHDQGWKHORFNOHYHUWKHWDSHJXLGHPD\ ZRUNORRVHDQGLQKLELWSURSHUIHHGLQJRIWKHFRPSRQHQWV7RSUHYHQWWKLV DGMXVWWKHORFNOHYHUDVIROORZV 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGDWWDFKWKHWDSHIHHGHUWRWKHIHHGHU SODWH /RRVHQWKHWZRVFUHZVVHFXULQJWKHORFNOHYHU%HFDUHIXOQRWWRUHPRYH WKHVFUHZDWWKLVSRLQW $GMXVWSODWHV$DQG%VRWKDWWKHWDSHJXLGHDQGWKHORFNOHYHUWRXFK 5HWLJKWHQWKHVFUHZV Figure 7-28 Adjusting the lock lever position Service Manual Topaz 5322 871 63606 7-30 PA 1309/10 01.05

Component Transport Systems 7.5.2. Minimum Timer / Load Timer / Down Timer :KHQDKHDGPRYHVGRZQWRWKHFRPSRQHQWSLFNXSSRVLWLRQWKHIHHGHU VDLU F\OLQGHUVKDIWLVSXVKHGRXWWRRSHQWKHVKXWWHUWKHF\OLQGHULVRQ :KHQWKHKHDGPRYHVXSWKHVKDIWUHWXUQVWKHF\OLQGHULVRIIDQGWKHQH[W FRPSRQHQWLVGHOLYHUHGWRWKHSLFNXSSRVLWLRQ,IWKLVRQRIIWLPLQJLVQRW FRUUHFWFRPSRQHQWGHOLYHU\HUURUVPD\RFFXU7RDYRLGWKLVSUREOHPWKH PLQLPXPWLPHUDQGORDGWLPHUPXVWEHDGMXVWHGFRUUHFWO\ 7RFKHFNWKHPLQLPXPWLPHUDQGORDGWLPHUVHWWLQJVVHOHFW 0$,17(0!!!0&+B&21),*!!$0&+B&21),*!^$ )(('(563(&,1)`DQGSUHVVWKH>(17(5@NH\7KHVFUHHQDSSHDUVDV VKRZQEHORZ DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/MCH_CONFIG 2/MCH_DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT PNEUMATIC Type FeederType LeftWidt RightWid PickPos Min.Time LoadTime DownTime Sequence 8mmTape 7.80 8.00 0.00 0 0 0 TapeType 8mm1005cmp 7.80 8.00 0.00 0 20 40 TapeType 12mmEmboss 14.50 11.20 0.00 10 30 0 TapeType 16mmEmboss 16.50 13.20 0.00 10 50 0 TapeType 24mmEmboss 20.50 17.20 0.00 10 50 0 TapeType 32mmTape 25.00 21.90 0.00 15 50 0 TapeType 32mmEmboss 24.70 22.50 0.00 50 100 0 TapeType 44mmEmboss 30.70 28.50 0.00 50 100 0 TapeType 56mmEmboss 42.50 34.50 0.00 50 100 0 TapeType MultiStick 39.80 87.00 0.00 0 140 0 StickTyp Fix.TF 0.00 0.00 0.00 0 0 0 TrayType Figure 7-29 Feeder plate spec information screen Minimum timer 7KHPLQLPXPWLPHULVWKHWLPHGXULQJZKLFKWKHDLUF\OLQGHULVNHSWRQVR WKDWWKHQR]]OHLQWKHORZHUHGSRVLWLRQFDQSLFNXSDFRPSRQHQWZLWKRXWIDLO 7KHWLPHLVH[SUHVVHGLQKXQGUHGWKVRIDVHFRQG Load timer 7KHORDGWLPHULVWKHWLPHIURPZKLFKWKHDLUF\OLQGHULVWXUQHGRIIXQWLOWKH QH[WFRPSRQHQWLVVHFXUHO\GHOLYHUHGWRWKHSLFNXSSRVLWLRQ7KLVLVH[SUHVVHG LQKXQGUHGWKVRIDVHFRQG. Down timer 7LPHWKDWPXVWEHDOORZHGEHWZHHQWKHIHHGHUVKXWWHURSHQLQJDQGWKHKHDG EHLQJORZHUHGRQWRWKHFRPSRQHQWLQWKRXVDQGWKRIDVHFRQG Caution: This information is set at the factory prior to shipment. It is unlikely that you will need to change it. If, however, this information needs to be adjusted, enter the optimum settings on this screen while checking for feeder operation. To save the new settings, select {A0/EXIT} and press the [ENTER] key. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-31

Component Transport Systems 7.5.3. Tape Feeder Maintenance Introduction 7KHWDSHIHHGHUVFRPSO\WRWKH(,$VWDQGDUG7KHIROORZLQJWDSHIHHGHUV DUHDYDLODEOH 3$ 3$ 3$ 3$ 3$ 3$ 3$ 3$ 3$ PP7DSH)HHGHUPPSLWFK5HHO PP7DSH)HHGHUPPSLWFK5HHO PP7DSH)HHGHUPPSLWFK5HHO PP7DSH)HHGHU5HHO PP7DSH)HHGHU5HHO PP7DSH)HHGHU PP7DSH)HHGHU PP7DSH)HHGHU PP7DSH)HHGHU Adjustment 7DSH IHHGHU DGMXVWPHQW PP WR PP RQO\ FDQ EH GRQH ZLWK WKH 2SWLFDO 7DSH)HHGHU$GMXVWPHQW7RRO$XVHUPDQXDOLVLQFOXGHGZLWKWKLVWRRO7KH WRROFDQEHRUGHUHGZLWK3$ Service Manual Topaz 5322 871 63606 7-32 PA 1309/10 01.05

Component Transport Systems Preventive Maintenance for tape feeders a) Preventive Maintenance Schedule Item every feeder change Daily Weekly Monthly > 1/2 million indexes > 2 million indexes Tape waste Cleanliness Tape path Transport assy Top cover assy Moving parts Top foil wheel Bottom surface check clean clean clean check clean lubricate replace Figure 7-30 Preventive Maintenance Schedule b) Recommended Materials: 5HFRPPHQGHG(TXLSPHQWDQG0DWHULDOVIRU&OHDQLQJDQG/XEULFDWLQJ 9DFXXPFOHDQHUIRUPDLQWHQDQFHFORVHWRWKH7RSD] &RPSUHVVHGDLUJXQIRUPDLQWHQDQFHLQZRUNVKRS 3DLURIWZHH]HUV 6PDOOEUXVKHV 4WLSV /LQWIUHHWLVVXHSDSHU,VRSURSDQRO /LJKWPDFKLQHRLOHJ6KHOO7HOOXV 6FUHZGULYHU3KLOLSVQR IHHOHUJDXJHVRIPPWKLFN 6HDOORFNDJHQW/RFNWLWH 3XQFKPD[LPDOGLDPPP $OOHQNH\PP 6FUHZGULYHU7RUFQR7 +DPPHUVPDOO 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-33

Component Transport Systems c) Checking the Cleanliness )UHTXHQF\ :HHNO\ 5HTXLUHGWLPH KUSHUIHHGHU 3URFHGXUH &KHFN WKH ZKROH WDSH SDWK IRU FRQWDPLQDWLRQ DQG FOHDQ LW LI QHFHVVDU\ ZLWK D OLQWIUHH WLVVXH SDSHU EUXVKHVRU4WLSVPRLVWHQHGLQLVRSURSDQRO &OHDQWKHIHHGHUZLWKFRPSUHVVHGDLURUZLWKD YDFXXPFOHDQHUWRUHPRYHDOOGXVW d) Tape Path Cleaning )UHTXHQF\ GDLO\ 5HTXLUHGWLPH KUSHUIHHGHU 3URFHGXUH &KHFN LI WKHUH LV DQ\ WDSH VHGLPHQW DGKHVLYH RU FRPSRQHQW GHEULV DGKHULQJ WR WKH WDSH WUDYHOOLQJ VXUIDFH6SHFLDODWWHQWLRQPXVWEHJLYHQWRWKHWDSH SDWKDUHDXQGHUQHDWKWKHWRSFRYHUSODWH&OHDQLI QHFHVVDU\ ZLWK WKH UHFRPPHQGHG HTXLSPHQW DQG PDWHULDOV e) Tape Transport Cleaning )UHTXHQF\ GDLO\ 5HTXLUHGWLPH KUSHUIHHGHU 3URFHGXUH &KHFNLIWKHUHLVDQ\GLUWRQWKHVSURFNHWVRIWKH VSURFNHW ZKHHO RQ WKH WZR SDZOV WKH SDZO ZKHHO DQGLQEHWZHHQWKHZKHHOV &OHDQLIQHFHVVDU\ZLWKWKHUHFRPPHQGHGHTXLSPHQWDQGPDWHULDOV1HYHUXVHD VROYHQWRWKHUZLVHWKHJUHDVHLQVLGHWKHWUDQVSRUWDVV\ZLOOEHGLVVROYHG f) Top Cover Plate cleaning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ervice Manual Topaz 5322 871 63606 7-34 PA 1309/10 01.05

Component Transport Systems Figure 7-31 CSM top cover plate 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-35

Component Transport Systems g) Top Cover Plate replacement (see fig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emark: If the spring (12) is deformed, the complete top-cover plate must be replaced (assembly). The spring is good if the spring ends face each other 180 degrees ± 10 degrees (visual inspection). h) Replace Gear Wheel (Small) )UHTXHQF\ (YHU\PLOOLRQLQGH[HV 5HTXLUHGWLPH PLQXWHV 5HTXLUHG0DWHULDO ['ULYHWRSIRLOZKHHO 3URFHGXUH Œ /RRVHQ WKH FRXQWHUVXQN VFUHZ DQG UHPRYH WKH IODQJH DQG JHDU ZKHHO E\ XVLQJD3KLOLSVVFUHZGULYHUQR Œ 0RXQWDQHZJHDUZKHHOLQWKHUHYHUVHGLUHFWLRQ0DNHVXUHWKDWWKHJHDU ZKHHOPRYHVIUHHO\LIWXUQLQJLWFORFNZLVHVHHDUURZ Figure 7-32 Replacing of the gear wheel (small) [SD-2355.WPG] Service Manual Topaz 5322 871 63606 7-36 PA 1309/10 01.05

Component Transport Systems i) Bottom Surface )UHTXHQF\ 5HTXLUHGWLPH (YHU\IHHGHUFKDQJH KUSHUIHHGHU Procedure: Check if the bottom surface of the feeder is clean and free of mechanical damage. &OHDQLIQHFHVVDU\ZLWKWKHUHFRPPHQGHGHTXLSPHQWDQGPDWHULDOV j) Lubrication )UHTXHQF\ 5HTXLUHGWLPH (YHU\LQGH[HV KUSHUIHHGHU 3URFHGXUH Π&OHDQWKHSRLQWVWKDWKDYHWREHOXEULFDWHGILJDQGUHPRYHDOOGXVW E\XVLQJDYDFXXPFOHDQHU Π&OHDQDQGUHPRYHLIQHFHVVDU\ROGRLODQGGXVWZLWKDOLQWIUHHWLVVXHSDSHU EUXVKHV RU 4WLSV PRLVWHQHG LQ GHQDWXUHG LVRSURS\O PHWK\O DOFRKRO KDVWREHSXUFKDVHGORFDOO\ Remark: The fig. 7-33 shows the mechanical feeder and not the FV feeder. This is of no importance because most of the lubrication points are the same. WARNING WHEN USING DENATURED ISOPROPYL OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS: a) KEEP CONTAINER CLOSED TIGHT WHEN NOT USED. b) KEEP AWAY FROM INFLAMMABLE SOURCES - NO SMOKING. c) HARMFUL IF INHALED OR SWALLOWED. d) HIGHLY INFLAMMABLE. e) AVOID CONTACT WITH THE SKIN. f) DO NOT EMPTY INTO DRAINS. $GGRLOEHWZHHQWKHSDUWVDVVKRZQE\DUURZVLQILJXUH /XEULFDQW7HOOXVIURP6KHOOKDVWREHSXUFKDVHGORFDOO\ 5RWDWHRUPRYHWKHSDUWVVHYHUDOWLPHVVRWKDWWKHOXEULFDQWFDQVSUHDG Note: The amount of lubrication oil should be a single drop supplied with a small screw driver or needle pin (has to be purchased locally). After lubrication, wipe off excessive oil to avoid contamination. Use only the type of lubricant that is mentioned above. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-37

Component Transport Systems [SD-2354A.WPG] [SD-2354B.WPG] Figure 7-33 Lubrication of the rotating and moving parts (figures show mech. feeders) Service Manual Topaz 5322 871 63606 7-38 PA 1309/10 01.05

Component Transport Systems Trouble shooting Symptom description Possible cause Solution Automatic refire level to high (number of re-pick actions) Feeder does not index correctly Tape out of specification (diam. sprocket holes 1.6 mm max, play component in pocket 0.5 mm max) Feeder not placed correctly Feeder interface damaged Tape or cover tape path not correct or obstructed Speed air-cylinder too low Index mechanism polluted Clamping lever of feeder to the left presses against index mechanism Index mechanism damaged Cover plate not completely closed Cover plate damaged Index force extremely high Spring (left-pulley) broken/absent Spring (top-foil) broken/absent Replace tape Clean feeder-bar Clean feeder bottom Send feeder back for repair Correct path and/or remove obstructions Check adjustment Clean index mechanism Tighten clamping lever to the feeder body Send feeder back for repair Remove obstructing components Replace cover plate Lubricate rotating parts Replace Replace 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 7-39

Component Transport Systems Symptom description Possible cause Solution (continue) Feeder does not index correctly Pick position wrong Cover tape does not peel back from carrier tape Cover tape does not peel back from the carrier tape at the appropriate timing (specially paper tape) Spring (set-up) broken/absent See index problems Tape not inserted correctly Tape stuck between wheels Spring (left pulley) broken/absent Spring (top-foil) broken/absent Spring (set-up) broken/absent Reel/tape stuck Top foil wheel (small) rotates during upward stroke Set up spring incorrect mounted Replace Check pick position with Tape Feeder Adjustment Tool PA 2849/10 Insert tape according instructions Insert tape again, make sure the scrapers are close to the wheels and the double guiding is straight Replace spring Replace spring Replace spring Check for obstructions Replace small wheel Check if the spring is set onto the correct fixing pin Service Manual Topaz 5322 871 63606 7-40 PA 1309/10 01.05

Axes Systems CHAPTER 8 Axes Systems 8.1. Introduction 7KLVFKDSWHUGHVFULEHVWKHD[HVV\VWHPVRIWKH7RSD] 7KHPHFKDQLFDOPRYHPHQWRIWKH723$=V\VWHPVLVFRQWUROOHGE\WKHILYH D[HVGHVFULEHGLQWDEOHEHORZ Axis Function Power drive method W axis Adjust the width of the conveyor that carries AC motor/ ball screw in or out a PCB Z axis Moves the nozzle shafts of heads 1 to 8 AC motor/ ball screw simultaneously in vertical direction. X axis Moves the head assembly in parallel with the AC motor/ ball screw PCB transfer direction(right to left and left to right as viewed from the front of the machine) Y axis Moves the head assy forwards and backwards AC motor/ ball screw as viewed from the front of the machine R axis Rotates the nozzle shaft of the head 1-8. AC motor/ belt drive Table 8-1 Axes overview 7RSUHVHUYHWKHUHSHDWDELOLW\RID[LVPRYHPHQWDQGPRXQWLQJDFFXUDF\WKH IROORZLQJSDUDPHWHUVPXVWEHVHWFRUUHFWO\ Parameter Machine reference Secondary limit Software limit Initial position Initial movement Table 8-2 Adjustment parameters of moving axes Axis W, Z, X, Y, R X, Y W, Z, X, Y, R W, R Z WARNING MAKE SURE TO TAKE ALL NECESSARY SAFETY PRECAUTIONS WHEN DOING MECHANICAL ACTIONS AT THE SYSTEM. ALWAYS SWITCH OFF THE MACHINE IF MECHANICAL ASSEMBLY OR DISASSEMBLY ACTIONS ARE CARRIED OUT. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-1

Axes Systems 8.2. Machine Reference (Origin) 7KHEXLOWLQPRWRUHQFRGHURIHDFKD[LVLVVXHVD µsxovhhdfkwlphrqhwxuq LVFRPSOHWH :KHQUHWXUQWRRULJLQLVSHUIRUPHGWKHUHZLOOEHDGLIIHUHQFHLQGLVWDQFH EHWZHHQWKHSRVLWLRQZKHUHWKHRULJLQVLJQDOLVGHWHFWHGDQGWKHSRLQWDW ZKLFKWKHQH[WHQFRGHU µsxovhlvuhfhlyhgwkhruljlqsrvlwlrqdfwxdoo\vhw 7KLVLVFDOOHGWKHPDFKLQHUHIHUHQFHDQGLVXVXDOO\H[SUHVVHGLQSHUFHQWDJHV ZLWKEHLQJHTXDOWRRQHIXOOWXUQRIWKHPRWRU Figure 8-1 Machine reference &KHFNWKHPDFKLQHUHIHUHQFHVHWWLQJV 0RYHWKHFXUVRUWR0$,17(0!!! 0$18$/!! %$8720$7,&B029(! ^%,1,76(59225,*,1`DQGSUHVVWKH >6+,)7@>(17(5@NH\ 7KHPDFKLQHUHIHUHQFHRIHDFKD[LVDSSHDUVRQWKHRSHUDWLRQPRQLWRUDIWHUWKH UHWXUQWRRULJLQKDVEHHQSHUIRUPHG Figure 8-2 Machine reference display Service Manual Topaz 5322 871 63606 8-2 PA 1309/10 01.05

Axes Systems 8.2.1. W-axis Machine Reference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igure 8-3 Adjusting the W-axis machine reference Note: The machine reference will be adjusted to about 20% for every 1mm movement of the origin dog. Be sure to slide the dog slightly (a maximum of 2.5mm). If you slide it too far, a 0 pulse in a different cycle may be received, causing the origin position to shift 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-3

Axes Systems 8.2.2. Z-axis Machine Reference 7KH=D[LVYHUWLFDOO\PRYHVWKHKHDGDVVHPEO\E\EDOOVFUHZ:KHQUHWXUQWR RULJLQLVSHUIRUPHGWKH=D[LVWUDYHOVDWORZVSHHGXSDJDLQVWWKHXSSHUHQG DQGWKHUHVXOWLQJH[FHVVLYHPRWRUFXUUHQWLVGHWHFWHGDVDQRULJLQVLJQDOWKHQ WKHRULJLQLVVHWDWWKHSRVLWLRQRIWKHSUHFHGLQJHQFRGHU µsxovhdvwkh PRWRUUHYHUVHVVOLJKWO\7KHUHLVQRRULJLQVHQVRUDQGRULJLQGRJ7RDGMXVW WKH=D[LVPDFKLQHUHIHUHQFHIROORZWKHVHVWHSV 3UHVVWKHHPHUJHQF\VWRSEXWWRQ /RRVHQWKHEROWVHFXULQJWKHFRXSOLQJRQWKH=D[LVEDOOVFUHZVLGHUHIHU WRILJXUHEHORZ $GMXVWWKHPDFKLQHUHIHUHQFHURWDWHWKHEDOOVFUHZWRDGMXVWWKHPDFKLQH UHIHUHQFHDVIROORZV - 7RLQFUHDVHWKHPDFKLQHUHIHUHQFHURWDWHLQGLUHFWLRQ$GRZQ - 7RGHFUHDVHWKHPDFKLQHUHIHUHQFHURWDWHLQGLUHFWLRQ%XS 5HWLJKWHQWKHEROWWRVHFXUHWKHFRXSOLQJDIWHUWKHPDFKLQHUHIHUHQFHLV VHWZLWKLQWKHWROHUDQFHUDQJH Figure 8-4 Adjusting the Z-axis machine reference Note: A 1mm movement of the Z-axis is equal to 25% of the machine reference. Do not allow the Z-axis to move more than 2mm. If you move too far, a 0 pulse in a different cycle may be received, causing the origin to shift. Do not allow the shaft to turn during adjustment. Service Manual Topaz 5322 871 63606 8-4 PA 1309/10 01.05

Axes Systems 8.2.3. X-axis Machine Reference 7KH;D[LVSHUIRUPVWKHULJKWWROHIWDQGOHIWWRULJKWPRYHPHQWRIWKHKHDG DVVHPEO\,WLVGULYHQE\EDOOVFUHZDWDOHDGRIPPSHUWXUQRIWKH PRWRU7KHRULJLQVLJQDOLVRXWSXWZKHQWKHJUH\RULJLQVHQVRUZKLFKLV DWWDFKHGWRWKHERWWRPRIWKH;D[LVVOLGHSODWHKDVGHWHFWHGWKHRULJLQGRJ ORFDWHGRQWKHOHIWVLGHRIWKH;D[LV7RDGMXVWWKH;D[LVPDFKLQHUHIHUHQFH SURFHHGDVIROORZVVHHILJXUH 3UHVVWKHHPHUJHQF\VWRSEXWWRQ 2. $GMXVWWKHPDFKLQHUHIHUHQFHDVIROORZVORRVHQWKHVFUHZVHFXULQJWKH; D[LVRULJLQGRJDQGVOLGHLWVOLJKWO\ 7RLQFUHDVHWKHPDFKLQHUHIHUHQFHVOLGHWKHGRJWRWKHULJKW 7RGHFUHDVHWKHPDFKLQHUHIHUHQFHVOLGHWKHGRJWRWKHOHIW 3. 5HWLJKWHQWKHVFUHZWRVHFXUHWKHRULJLQGRJ0DNHVXUHWKDWWKHPDFKLQH UHIHUHQFHLVVHWZLWKLQWROHUDQFH Figure 8-5 Adjusting the X-axis machine reference Note: The machine reference will be adjusted to about 10% for every 2mm of movement of the origin dog. Be sure to slide the dog slightly (a maximum of 10mm). If you slide it too far, a 0 pulse in a different cycle may be received, causing the origin position to shift. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-5

Axes Systems 8.2.4. Adjusting the Y-axis Machine Reference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igure 8-6 Adjusting the Y-axis machine reference Note: The machine reference will be adjusted about 10% for every 2mm movement of the origin dog. Be sure to slide the dog slightly (a maximum of 10mm). If you slide it too far, a 0 pulse in a different cycle may be received, causing the origin position to shift Service Manual Topaz 5322 871 63606 8-6 PA 1309/10 01.05

Axes Systems 8.2.5. R-axis Machine Reference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igure 8-7 Adjusting the R-axis machine reference Note: Be sure to turn the dog ring slightly, if you turn it too far a 0 pulse in a different cycle may be received, causing the origin to shift. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-7

Axes Systems 8.3. Secondary Limits :KHQWKHKHDGDVVHPEO\UXQVLQWRWKHVHFRQGDU\OLPLWDUHDRYHUWKHVRIWZDUH OLPLWWKHVHUYRFRQWUROLPPHGLDWHO\VWRSVWRDYRLGFROOLGLQJZLWKWKH PHFKDQLFDOKDUGVWRSSHU$OLJKWLPSDFWPD\RFFXUKRZHYHUGHSHQGLQJ RQWKHUXQQLQJVSHHG 7KHVHFRQGDU\OLPLWDUHDLVSURYLGHGIRUWKH;DQG<D[HVDQGFDQEH DGMXVWHGE\VOLGLQJWKHSRVLWLRQRIWKHVHFRQGDU\OLPLWGRJORFDWHGDWWKHERWK HQGVRIWKHPRYHPHQWUDQJH 8.3.1. X-axis Secondary Limits 8VXDOO\WKH;D[LVVHFRQGDU\OLPLWVDUHVHWWRDSRLQWPPLQVLGHWKH PHFKDQLFDOVWRSSHUKDUGOLPLWVHHILJXUH 6HOHFWWKHD[LV6SHFLI\LQDGYDQFHWKHD[LVZKRVHFRRUGLQDWHVQHHGWREH GLVSOD\HGLQ6WHS7RVSHFLI\WKHD[LVVHOHFW0$,17(0!!! 0$18$/!!$&+$1*(B&21',7,21!^$6(/(&7 $;(6`µ0$,1;<µDQGSUHVVWKH>(17(5@NH\ 3UHVVWKHHPHUJHQF\VWRSEXWWRQWKHQORRVHQWKHVFUHZVIRUWKHVHFRQGDU\ OLPLWGRJ7KHVHFRQGDU\OLPLWGRJVDUHORFDWHGDWERWKHQGVRIWKH; D[LV6OLJKWO\ORRVHQWKHVFUHZVVRWKDW\RXFDQMXVWVOLGHWKHGRJ'RQRW UHPRYH Figure 8-8 X-axis secondary limit dog 0RYHWKHKHDGDVVHPEO\WRWKHHQGRIWKHD[LV 0RYHWKHKHDGDVVHPEO\E\KDQGXQWLOLWPDNHVFRQWDFWZLWKWKH PHFKDQLFDOVWRSSHUIRUWKHVHFRQGDU\OLPLWGRJZLWKWKHEROWORRVHQHG 7KHEOLQNLQJPHVVDJH (0(5*(1&<672321µLQGLFDWHGRQWKH ORZHUOHIWRIWKHRSHUDWLRQPRQLWRUZLOOFKDQJHWR QG/,0,729(5µ Service Manual Topaz 5322 871 63606 8-8 PA 1309/10 01.05

Axes Systems 4. 0RYHEDFNWKHKHDGDVVHPEO\WRPPLQVLGHWKHPHFKDQLFDOVWRSSHU 7RGRWKLVRSHQWKHRXWSXWPRQLWRUVFUHHQRULQSXWPRQLWRUVFUHHQ DQGZKLOHREVHUYLQJWKH;FRRUGLQDWHYDOXHLQGLFDWHGRQWKHERWWRPRI WKHRSHUDWLRQPRQLWRUVWRSWKHKHDGDWDSRVLWLRQDSSUR[LPDWHO\ PPIURPWKHPHFKDQLFDOVWRSSHULHIURPWKHKDUGOLPLW7KLV SRVLWLRQLVWKHVHFRQGDU\OLPLWRIWKH;D[LV Note: Make a Note of the X-axis co-ordinates displayed on the monitor. This is used as a reference for the X-axis software limit settings. $GMXVWWKHSRVLWLRQRIWKHVHFRQGDU\OLPLWGRJ:LWKWKHKHDGDVVHPEO\ OHIWDWWKHSRVLWLRQRI6WHSVOLGHWKHSRVLWLRQRIWKHVHFRQGDU\OLPLWGRJ VRWKDWWKHVHFRQGDU\OLPLWVHQVRUMXVWGHWHFWVLW)LQGWKHRSWLPXPSRVL WLRQZKLOHFKHFNLQJWKHVHQVRUGHWHFWLRQ/('RUUHDGLQJWKHEOLQNLQJ PHVVDJHRQWKHORZHUOHIWRIWKHRSHUDWLRQPRQLWRUVHHILJXUH L013: 2nd LIMIT OVER! Figure 8-9 Secondary limit over display screen 5HWLJKWHQWKHVFUHZVRIWKHVHFRQGDU\OLPLWGRJ 8VHWKHVDPHSURFHGXUHIURP6WHSVWRIRUWKHRWKHUVHFRQGDU\OLPLW $IWHUWKHDGMXVWPHQWLVFRPSOHWHPRYHWKHKHDGDVVHPEO\E\KDQGWR ZLWKLQWKHDOORZDEOHPRYHPHQWUDQJH 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-9

Axes Systems 8.3.2. Y-axis Secondary Limits 7KH<D[LVVHFRQGDU\OLPLWVDUHVHWWRDSSUR[LPDWHO\PPLQVLGHWKH PHFKDQLFDOVWRSSHUKDUGOLPLW6LQFHWKLVDGMXVWPHQWSURFHGXUHLVH[DFWO\ WKHVDPHDVIRUWKH;D[LVUHIHUWRWKHSUHYLRXVVHFWLRQ7KHORFDWLRQVRI WKH<D[LVVHFRQGDU\OLPLWGRJVDUHVKRZQEHORZ Figure 8-10 Y-axis secondary limit dogs Note: To make settings for the Y-axis secondary limits, use the same procedure as for the X-axis except that you move the head assembly to a point 2.00mm inside the mechanical stopper in Step 5. Service Manual Topaz 5322 871 63606 8-10 PA 1309/10 01.05

Axes Systems 8.4. 8.4.1. Software Limits :KHQDQD[LVPRYHVWRDWDUJHWSRVLWLRQWKHVRIWZDUHOLPLWLVXVHGWRUHVWULFW PRYHPHQWWRDYRLGLQWHUIHULQJZLWKWKHPHFKDQLFDOVWRSSHUVORFDWHGDWWKH ERWKHQGVRIWKHD[LV,IWKHWDUJHWSRVLWLRQH[FHHGVWKHVRIWZDUHOLPLWWKH HUURUPHVVDJH $;,662)7/,0,729(5µDSSHDUVDQGD[LVPRYHPHQWLV SURKLELWHG,QWKH0DQXDOPRGH\RXFDQXVHWKHMR\VWLFNRQWKH++. ZLWKLQWKHVRIWZDUHOLPLWUDQJH W-axis Software Limits 7KH:D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRPPLQVLGHWKHPHFKDQLFDO VWRSSHUIRUERWKWKH SOXVµVLGHZLGWKHQODUJLQJGLUHFWLRQDQGWKH PLQXVµ VLGHZLGWKUHGXFLQJGLUHFWLRQ :KHQWKHVRIWZDUHOLPLWVHWWLQJVDUHFRUUHFWWKLVPHHWVWKHVSHFLILFDWLRQVIRU WKHPLQLPXPPPDQGPD[LPXPPPZLGWKVRI3&%VWKDW FDQEHWUDQVIHUUHG F C D 3.00mm A: Structural movable range B: Allowable movement range C: plus side software limit (rear) D: Origin position E: minus side software limit (front) F: Mechanical limit B A E F 3.00mm Figure 8-11 W-axis movement range 7RVHWWKH:D[LVVRIWZDUHOLPLWIROORZWKHVHVWHSV 6HOHFWWKH:D[LVWRVHWWKHVRIWZDUHOLPLW 6HOHFW0$,17(0!!!0$18$/!!$&+$1*(&21',7,21!^$6(/(&7$;(6`µ:0$,1µDQGSUHVVWKH>(17(5@NH\ 0DQLSXODWHWKHMR\VWLFNRQWKH++.WRPRYHWKH:D[LVFRQYH\RU ZLGWK7RVHWWKH SOXVµVLGHVRIWZDUHOLPLWPRYHWKHD[LVLQWKHZLGWK HQODUJLQJGLUHFWLRQ7RVHWWKH PLQXVµVLGHPRYHWKHD[LVLQWKHZLGWK UHGXFLQJGLUHFWLRQ Note: Tilting the joystick on the HHK to the right you reduces the width, and tilting it to the left you enlarges the width. Set the conveyor width to a maximum or minimum as long as the movable rail does not make contact with the mechanical stopper. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-11

Axes Systems Figure 8-12 W-axis pulley 6HWWHDFKLQJFRQGLWLRQVDVIROORZV 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%&21',7,212)7&+`DQGSUHVV>(17(5@ 6HOHFW 7($&+81,76(/µDQGSUHVVWKH>(17(5@NH\ 6HOHFWDQ\RI &DPHUDµ +HDGµRU +HDGµ 6HOHFW 63(('6(/(&7µ6HOHFWDQ\VSHHGIURPWR <<<APPLICATION>>> <<MODE>> <COMMAND_LIST> 3/MAINTE/M 3/MCH_ADJUST B/SAVE & QUIT B4 CONDITION OF TCH TEACH-UNIT SEL. Camera Head 1 Head 2 SPEED SELECT. Speed1= 100 Speed2= 80 Speed3= 60 Speed4= 40 Speed5= 20 3UHVVWKHHPHUJHQF\VWRSEXWWRQWKHQPRYHWKHFRQYH\RUUDLO7XUQWKH :D[LVSXOOH\E\KDQGXQWLOWKHPRYDEOHUDLOPDNHVFRQWDFWZLWKWKH PHFKDQLFDOVWRSSHU:KHQWKHPRYDEOHUDLOLVSRVLWLRQHGLQFRQWDFWZLWK WKHPHFKDQLFDOVWRSSHUWKHPD[LPXPFRQYH\RUZLGWKLVDSSUR[ PPDQGWKHPLQLPXPZLGWKLVDSSUR[PP&KHFNWKHZLGWKE\ PHDVXULQJZLWKDVTXDUHRUWDSHPHDVXUH 3HUIRUPWHDFKLQJDWWKHSRVLWLRQLQFRQWDFWZLWKWKHPHFKDQLFDOVWRSSHU 6HOHFW0&+B$'-867!!%6$9( 48,7!^%$'-867 7$5*(7`µ6RIW/LPLWµDQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK GLUHFWµRU GLUHFWµ RIWKHFRQYH\RUZLGWKEHLQJDGMXVWHG7KHFXUVRUVKRXOGEH SRVLWLRQHGRQWKH GLUHFWµ\RXPRYHGWKH D[LVLQ6WHS 3. 3UHVVWKH>)@NH\WZLFHWRSHUIRUPWHDFKLQJ 7KHQXPHULFDOYDOXHRIWKHSDUDPHWHUWKDWWKHFXUVRULVRQFKDQJHV Service Manual Topaz 5322 871 63606 8-12 PA 1309/10 01.05

Axes Systems Editing Object Software Limit Axis +direct. -direct. Init.Pos Init.Mov W/MAIN 3.70-350.00-408.00 Figure 8-13 W-axis software setting screen (QWHUWKHVRIWZDUHOLPLW 6XEWUDFWPPIURPWKHPHFKDQLFDOOLPLWRQWKH SOXVµVLGHRUDGG PPWRWKHPHFKDQLFDOOLPLWRQWKH PLQXVµVLGH7KLVYDOXH\RX KDYHMXVWHQWHUHGLVWKHVRIWZDUHOLPLW 5HWXUQWKHFRQYH\RUZLGWKWRZLWKLQWKHVRIWZDUHOLPLW 7XUQWKHSXOOH\E\KDQGWRUHWXUQWKHFRQYH\RUZLGWK &DQFHOHPHUJHQF\VWRS (QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH >5($'<@EXWWRQRIWKH++. 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVVWKH>(17(5@NH\ 7RTXLWZLWKRXWVDYLQJVHOHFW^%5(&29(5$'-867`RU ^%48,7`DQGSUHVVWKH>(17(5@NH\ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-13

Axes Systems 8.4.2. Z-axis Software Limits 7KH=D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRPPLQVLGHWKHPHFKDQLFDO VWRSSHUIRUERWKWKH SOXVµVLGHORZHUGLUHFWLRQDQGWKH PLQXVµVLGH XSSHUGLUHFWLRQ 7KH SOXVµVLGHPXVWEHVHWDWDSRVLWLRQZKHUHQR]]OHFKDQJHLVQRW GLVWXUEHGDQGWKH PLQXVµVLGHDWDSRVLWLRQZKHUHWKHQR]]OHVGRQRW LQWHUIHUHZLWKWKHEDFNOLJKWXQLW E C 1.00 A: Structural movable range B: Allowable movement range C: plus side software limit D: Origin position E: minus side software limit F: Mechanical limit B A D F Figure 8-14 1.00 Z-axis movement 7RVHWWKH=D[LVVRIWZDUHOLPLWIROORZWKHVHVWHSV 1) 6HWWHDFKLQJFRQGLWLRQV 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%&21',7,212)7&+`DQGSUHVVWKH>(17(5@NH\ 6HOHFW 7($&+81,76(/µDQGSUHVVWKH>(17(5@NH\ 6HOHFWDQ\RI &DPHUDµ +HDGµRU +HDGµ 3. 6HOHFW 63(('6(/(&7µ6HOHFWDQ\VSHHGIURPWR5. 2) 3UHVVWKHHPHUJHQF\VWRSEXWWRQWKHQPRYHWKH=D[LV 5DLVHRUORZHUWKH=D[LVE\KDQGXQWLOWKHPDNHVFRQWDFWZLWKWKH PHFKDQLFDOVWRSSHU5DLVHWKH=D[LVWRDGMXVWWKH PLQXVµVLGHZKLOH ORZHULWWRDGMXVWWKH SOXVµVLGH 3) 3HUIRUPWHDFKLQJDWWKHSRVLWLRQLQFRQWDFWZLWKWKHPHFKDQLFDOVWRSSHU 6HOHFW0&+B$'-867!!%6$9( 48,7!^%$'-867 7$5*(7`µ6RIW/LPLWµDQGSUHVVWKH>(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK =0$,1µIRUWKH =D[LVRU =0$,1µIRUWKH=D[LV7KHFXUVRUVKRXOGEH SRVLWLRQHGRQ GLUHFWµ\RXKDYHPRYHGLQ6WHS Service Manual Topaz 5322 871 63606 8-14 PA 1309/10 01.05

Axes Systems 3. 3UHVVWKH>)@NH\WZLFHWRSHUIRUPWHDFKLQJ7KHQXPHULFDOYDOXH RIWKHSDUDPHWHUWKDWWKHFXUVRULVRQFKDQJHV 7KLVYDOXHLVWKHPHFKDQLFDOOLPLWKDUGOLPLW Editing Object Software Limit Axis +direct. -direct. Init.Pos Init.Mov Z1/MAIN Z2/MAIN 22.90 23.00 0.16 0.05 0.00 0.00 18.72 18.00 Figure 8-15 Z-axis software setting screen 4) (QWHUWKHVRIWZDUHOLPLW 6XEWUDFWPPIURPWKHPHFKDQLFDOOLPLWRQWKH SOXVµVLGHRUDGG PPWRWKHPHFKDQLFDOOLPLWRQWKH PLQXVµVLGH7KLVYDOXH\RX KDYH MXVWHQWHUHGLVWKHVRIWZDUHOLPLW 5) 5HWXUQWKH=D[LVE\KDQGWRZLWKLQWKHVRIWZDUHOLPLW 6) &DQFHOHPHUJHQF\VWRS(QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRS EXWWRQDQGSUHVVWKH>5($'<@EXWWRQRIWKH++. 7) 6DYHWKHVHWWLQJV3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU ^%6$9( 48,7`DQGSUHVVWKH>(17(5@NH\7RTXLWZLWKRXW VDYLQJVHOHFW^%5(&29(5$'-867`RU^%48,7`DQGSUHVVWKH >(17(5@ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-15

Axes Systems 8.4.3. X-axis Software Limits 7KH;D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRPPLQVLGHWKHVHFRQGDU\OLPLW IRUERWKWKH SOXVµVLGHULJKWGLUHFWLRQDQGWKH PLQXVµVLGHOHIWGLUHFWLRQ A 1 1 B 1 1 Mechanical stopper Mechanical stopper A: Structural movable range B: Allowable movement range C: Software limit D: Secondary limit E: Origin position F: Mechanical limit F D C E C D F Figure 8-16 X-axis movement range Note: To set the X-axis software limit, use the X-axis secondary limit values you have made a note when adjusting the secondary limits. 2SHQWKHVRIWZDUHOLPLWVFUHHQ 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%$'-8677$5*(7`µ6RIWZDUH/LPLWµDQGSUHVVWKH >(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK GLUHFWµRU GLUHFWµ LQWKH ;0$,1µURZ Editing Object Software Limit Axis +direct. -direct. Init.Pos Init.Mov X/MAIN 666.42-16.38 Figure 8-17 X-axis software limit setting screen Service Manual Topaz 5322 871 63606 8-16 PA 1309/10 01.05

Axes Systems (QWHUWKHVRIWZDUHOLPLW 2QWKH SOXVµVLGHHQWHUDYDOXH\RXKDYHVXEWUDFWHGPPIURPWKH VHFRQGDU\OLPLWRURQWKH PLQXVµVLGHDYDOXH\RXKDYHDGGHGPP WRWKHVHFRQGDU\OLPLW 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVVWKH>(17(5@NH\7RTXLWZLWKRXWVDYLQJVHOHFW ^%5(&29(5$'-867`RU^%48,7`DQGSUHVVWKH>(17(5@NH\ 8.4.4. Y-axis Software Limits $VZLWKWKH;D[LVWKH<D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRPPLQVLGH WKHVHFRQGDU\OLPLWIRUERWKWKH SOXVµVLGHULJKWGLUHFWLRQDQGWKH PLQXVµ VLGHOHIWGLUHFWLRQ Figure 8-18 Y-axis movement range Note: To set the Y-axis software limit, use the Y-axis secondary limit values you have made a note when adjusting the secondary limits. 1) 2SHQWKHVRIWZDUHOLPLWVFUHHQ 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%DGMXVWWDUJHW`µ6RIWZDUH/LPLWµDQGSUHVV>(17(5@ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK GLUHFWµRU GLUHFWµ LQWKH <0$,1µURZ 2) (QWHUWKHVRIWZDUHOLPLW 2QWKH SOXVµVLGHHQWHUDYDOXH\RXKDYHVXEWUDFWHGPPIURPWKH VHFRQGDU\OLPLWRURQWKH PLQXVµVLGHDYDOXH\RXKDYHDGGHGPP WRWKHVHFRQGDU\OLPLW 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-17

Axes Systems Editing Object Software Limit Axis Y/MAIN +direct. 699.00 -direct. Init.Pos Init.Mov -11.86 Figure 8-19 Y-axis software limit setting screen 3) 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVVWKH>(17(5@NH\ 7RTXLWZLWKRXWVDYLQJVHOHFW^%5(&29(5$'-867`RU ^%48,7`DQGSUHVVWKH>(17(5@NH\ Service Manual Topaz 5322 871 63606 8-18 PA 1309/10 01.05

Axes Systems 8.4.5. R-axis Software Limits 7KH5D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRDIL[HGYDOXHRIRQWKH PLQXVµVLGHFORFNZLVHDQGWRDIL[HGYDOXHRIRQWKH SOXVµVLGH FRXQWHUFORFNZLVH 2SHQWKHVRIWZDUHOLPLWVFUHHQ 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%$'-8677$5*(7`µ6RIWZDUH/LPLWµDQGSUHVVWKH >(17(5@NH\ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK GLUHFWµRU GLUHFWµ LQWKH 50$,1µRU 50$,1URZ\RXZDQWWRDGMXVW 2) (QWHUWKHVRIWZDUHOLPLW (QWHUIRUWKHVRIWZDUHOLPLWRQWKH SOXVµVLGHZKLOHRQ WKH PLQXVµVLGH Editing Object Software Limit Axis +direct. -direct. Init.Pos Init.Mov 12 R-NO1 13 R-NO2 360.00 360.00-360.00-360.00 80.00-80.50 Figure 8-20 R-axis software setting screen 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVV>(17(5@NH\ 7RTXLWZLWKRXWVDYLQJVHOHFW^%5(&29(5$'-867`RU ^%48,7`DQGSUHVVWKH>(17(5@NH\ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-19

Axes Systems 8.5. 8.5.1. Initial Position and Initial Movement 7KLVVHFWLRQH[SODLQVKRZWRDGMXVWWKH:D[LVDQG5D[LVLQLWLDOSRVLWLRQDQG =D[LVLQLWLDOPRYHPHQW W-axis Initial Position 7KH:D[LVLQLWLDOSRVLWLRQLVWKHGLVWDQFHEHWZHHQWKHFRQYH\RUUDLOVZKHQ WKH:D[LVLVLQWKHUHWXUQWRRULJLQSRVLWLRQH[SUHVVHGDVDPLQXVYDOXH 7RVHWWKH:D[LVLQLWLDOSRVLWLRQIROORZWKHVHVWHSV 3HUIRUPUHWXUQWRRULJLQ 3UHVVWKHHPHUJHQF\VWRSEXWWRQ 'HWHUPLQHWKHLQLWLDOSRVLWLRQ 0HDVXUHWKHFRQYH\RUZLGWK:GLVWDQFHEHWZHHQWKHIL[HGDQGWKH PRYDEOHUDLO 6XEWUDFWPPIURPWKLVZLGWKDVDFOHDUDQFHPDUJLQDQGWKHQSUHIL[ D PLQXVµVLJQWRWKLVYDOXH7KLVLVWKH:D[LVLQLWLDOSRVLWLRQ Figure 8-21 Conveyor width measurement and initial position (QWHUWKHLQLWLDOSRVLWLRQ 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%$'-8677$5*(7`µ6RIW/LPLWµDQGSUHVVWKH >(17(5@ 8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK,QLW3RVµLQWKH :0$,1µURZ 8VHWKHQXPHULFNH\VWRHQWHUWKHLQLWLDOSRVLWLRQYDOXHGHWHUPLQHG LQWKHSUHYLRXVVWHS &DQFHOWKHHPHUJHQF\VWRS (QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH >5($'<@EXWWRQRIWKH++. 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\WKHQVHOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVVWKH>(17(5@NH\7RTXLWZLWKRXWVDYLQJVHOHFW ^%5(&29(5$'-867`RU^%48,7`DQGSUHVVWKH>(17(5@NH\ Service Manual Topaz 5322 871 63606 8-20 PA 1309/10 01.05

Axes Systems Editing Object Software Limit Axis +direct. -direct. Init.Pos Init.Mov W/MAIN 3.70-350.00-408.00 Figure 8-22 W-axis initial position setting screen 8.5.2. Adjusting the R-axis Initial Position 1R]]OHVVXFKDV7\SHKDYHDQRULHQWDWLRQ6LQFHFRPSRQHQWVDUHXVXDOO\ SLFNHGDWGHJUHHWKH5D[LVLQLWLDOSRVLWLRQPXVWEHDGMXVWHGVRWKDWWKHVH QR]]OHVDUHDOLJQHGZLWKWKHGLUHFWLRQRIFRPSRQHQWVWKHQR]]OHKROGHUVOHDI VSULQJVDUHVHWSDUDOOHOZLWKWKH;D[LV ([HFXWHWKH &+$1*(12==/(µ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µDQGSUHVV(17(58VHWKHDUURZNH\VWROLQHXSWKH FXUVRUZLWKWKH LQLWSRVµRIWKH 5PDLQµURZDQGSUHVV)WZLFH WRSHUIRUPWHDFKLQJ 6DYHWKHVHWWLQJV 3UHVVWKH>(6&@NH\VHOHFW^%6$9('$7$`RU^%6$9( 48,7` DQGSUHVVWKH>(17(5@NH\7RTXLWZLWKRXWVDYLQJVHOHFW ^%5(&29(5$'-867`RU^%48,7`DQGSUHVVWKH>(17(5@ NH\ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-21

Axes Systems Editing Object Software Limit Axis +direct. -direct. Init.Pos Init.Mov R1/MAIN R2/MAIN 360.00 360.00-360.00-360.00 138.00 138.00 Figure 8-23 R-axis initial position setting screen 8.5.3. Z-axis Initial Movement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ervice Manual Topaz 5322 871 63606 8-22 PA 1309/10 01.05

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Axes Systems 8.6. Axes Assembly, Disassembly, Adjustments and Maintenance 7KLVVHFWLRQGHVFULEHVWKHDVVHPEO\GLVDVVHPEO\DQGDGMXVWPHQWVRIWKHYDULRXV D[HVV\VWHPVLQWKH7RSD] WARNING MAKE SURE TO TAKE ALL THE NECESSARY SAFETY PRECAUTIONS WHEN DOING MECHANICAL ACTIONS AT THE SYSTEM. ALWAYS SWITCH OFF THE MACHINE IF MECHANICAL ASSEMBLY OR DISASSEMBLY ACTIONS ARE CARRIED OUT. 8.6.1. Adjustment of the X- and Y-motor Encoder Position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µNH\RQWKH++.ZKLOHVWLOODWWKHDERYH;DQG<SRVLWLRQV 7KLVZLOOEORFNWKHSRVLWLRQVRIWKH;<PRWRUHQFRGHU 0RYHWKHKHDGDVVHPEO\WRWKHH[DFWFRUUHFWSRVLWLRQVE\KDQGORRNDWWKH YLVLRQPRQLWRU 5HWLJKWHQWKHVFUHZVRQWKHPRWRUFRXSOLQJ 3RLQWPRYHWRWKHQRWHGSRVLWLRQVDJDLQMXVWWREHVXUH 3HUIRUPLQLWVHUYRRULJLQ &KHFNIRUYDOXHVDQGUHDGMXVWLIQHFHVVDU\ Service Manual Topaz 5322 871 63606 8-24 PA 1309/10 01.05

Axes Systems 8.6.2. Head Replacement 'LVDVVHPEOHWKHKHDGDVGHVFULEHGEHORZVHHILJXUH 0DNHVXUHWRNQRZWKHVWDWXVRIWKHV\VWHPLQDGYDQFHRIWKLVUHSODFHPHQW 6ZLWFKRIIWKHV\VWHP &XWORVVDOWKHWLHZUDSVELQGLQJWKHFDEOHVDQGKRVHVWRWKHKHDGXQLW 5HPRYHWKHWZRRUDQJHDLUKRVHV 5HPRYHDOOFDEOLQJFRQQHFWLQJWKHKHDGDVVHPEO\WRWKH;EHDP)ROORZLQJ FDEOHVDUHWREHUHPRYHGIURPFRQQHFWRUSODWHLWHPLQILJXUH Π9DFXXPVHQVRUKDUQHVV Π5PRWRUDQGHQFRGHUFDEOH Π$OOFDEOHVDVKHDGEORZRIIYDFXXPGRZQVORZGRZQGRZQVHQVRU Π(DUWKFDEOHDQGILGXFLDOFDPHUDFDEOHVDVZHOODVWKHRYHUDOOKHDGGRZQ VHQVRUFDEOLQJ 5HPRYHWKHFRPSOHWHKHDGDVV\E\UHPRYLQJWKHEROWVLWHPLQILJXUH 7KHKHDGLVDWWDFKHGWRSODWHLWHPLQILJXUHE\PHDQVRI ILWWLQJSLQV $VVHPEOLQJLVGRQHLQUHYHUVHRUGHU 8.6.3. X-axis Assembly 7KHPHFKDQLFDODVVHPEO\RIWKH;D[LVLVVKRZQLQILJXUH 8.6.3.1. X-axis: Replacement X-motor Only 7KH;D[LVPRWRULVD:$&6HUYRPRWRU5HPRYLQJWKHPRWRULVGRQH DVGHVFULEHGEHORZ6HHIRUUHIHUHQFHILJXUH 'HWHUPLQH WKH ; DQG < SRVLWLRQV E\ SHUIRUPLQJ WKH ILUVW SDUW RI WKH DGMXVWPHQWSURFHGXUHRIWKH;PRWRUHQFRGHUSRVLWLRQ EHIRUH UHPRYLQJ WKH ;PRWRU6HHVHFWLRQ 6ZLWFKRIIWKHV\VWHP 'LVFRQQHFWWKH3,DQG02FDEOHLQWKHFDEOHGXFWULJKWVLGHRIV\VWHP /RRVHQWKHFRXSOLQJIURPWKHPRWRUVKDIW 5HPRYHWKHIRXUEROWVZKLFKKROGWKH;PRWRUWRWKHEUDFNHW 5HPRYHWKH$&0RWRU 5HDVVHPEOHLQUHYHUVHRUGHU 6ZLWFK RQ WKH PDFKLQH WR SHUIRUP WKH VHFRQG SDUW RI WKH DGMXVWPHQW SURFHGXUHRIWKH;PRWRUHQFRGHUSRVLWLRQDIWHUUHSODFLQJWKH;PRWRU6HH VHFWLRQ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-25

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Axes Systems 8.6.4.2. Y-axis: Removing Y-axis Ball Screw Generation 2 5HPRYLQJD QG JHQHUDWLRQ<D[LVEDOOVFUHZLVGRQHDVGHVFULEHGEHORZ6HHIRU UHIHUHQFHILJXUH 'RNOTUHPRYHWKH<PRWRU 'HWHUPLQHWKH;DQG<SRVLWLRQVE\SHUIRUPLQJWKHILUVWSDUWRIWKH DGMXVWPHQWSURFHGXUHRIWKH<PRWRUHQFRGHUSRVLWLRQEHIRUHUHPRYLQJWKH <D[LVEDOOVFUHZ6HHVHFWLRQ 6ZLWFKRIIWKHPDFKLQH4XLWWKH9,26VRIWZDUHRSHUDWLRQDQGWXUQRIIWKH PDLQVZLWFKRIWKHPDFKLQH 5HPRYHWKHVXSSRUWXQLWEHDULQJ&LQWKHEDFNRIWKHPDFKLQH Œ 5HPRYHWKHFRYHUDQGWKHORFNQXWZDWFKIRUWKH FRSSHUFKLSµ ZKLFKLVXQGHUWKHVHWVFUHZ Œ 5HPRYHWKHWKUHHVSULQJFRQHGGLVNV Œ 5HPRYHWKHVOHHYHEHDULQJDQGWKHWKUXVWEHDULQJ Œ 5HPRYHWKHIRXUKH[DJRQEROWVDQGWKHEHDULQJKROGHU Œ 5HPRYHWKHFLUFOLSDQGWKHVXSSRUWXQLWEHDULQJ& Œ Do NOT remove the Y-axis bearing holder (6). 7KHEDOOVFUHZLVQRZIUHHRQRQHVLGH Figure 8-26 Y-axis ball screw generation 2 5HPRYHWKHEDOOVFUHZ Œ 0RYHWKHURERWDUPEDFNZDUGVQHDUWKH<D[LVEHDULQJKROGHU Œ 5HPRYHWKHWZRKH[DJRQEROWVRIWKHJUHHQFRXSOLQJ Œ 5HPRYHWKHIRXUKH[DJRQEROWV%WKDWVHFXUHWKHVXSSRUWXQLW$ Œ Do NOT remove the Y-axis motor holder (5). Œ 5HPRYHWKHIRXUKH[DJRQEROWVIURPWKHEDOOVFUHZZKLFKDUHPRXQWHG LQWKH<D[LVQXWKROGHU Œ 1RZJHQWO\WDNHRXWWKHFRPSOHWHEDOOVFUHZ Œ 5HPRYHWKHORFNQXWDQGVXSSRUWXQLW$ &RQWLQXHZLWKLQVWDOOLQJDQGDOLJQLQJWKHQHZ<D[LVEDOOVFUHZJHQHUDWLRQ VHHVHFWLRQ Service Manual Topaz 5322 871 63606 8-28 PA 1309/10 01.05

Axes Systems 8.6.4.3. Y-axis: Removing Y-axis Ball Screw Generation 3 5HPRYLQJD JHQHUDWLRQ<D[LVEDOOVFUHZLVGRQHDVLVGHVFULEHGEHORZ6HH UG IRUUHIHUHQFHILJXUH 'RNOTUHPRYHWKH<PRWRU 'HWHUPLQHWKH;DQG<SRVLWLRQVE\SHUIRUPLQJWKHILUVWSDUWRIWKH DGMXVWPHQWSURFHGXUHRIWKH<PRWRUHQFRGHUSRVLWLRQEHIRUHUHPRYLQJWKH <D[LVEDOOVFUHZ6HHVHFWLRQ 6ZLWFKRIIWKHPDFKLQH4XLWWKH9,26VRIWZDUHRSHUDWLRQDQGWXUQRIIWKH PDLQVZLWFKRIWKHPDFKLQH 5HPRYHWKHVXSSRUWXQLWEHDULQJ&LQWKHEDFNRIWKHPDFKLQH Œ 5HPRYHWKHORFNQXWZDWFKIRUWKH FRSSHUFKLSµZKLFKLVXQGHUWKH VHWVFUHZ Œ 5HPRYHWKHWKUHHVSULQJFRQHGGLVNV Œ 5HPRYHWKHWKUXVWEHDULQJ Œ 5HPRYHWKHIRXUKH[DJRQEROWVDQGWKHEHDULQJKROGHU Œ 5HPRYHWKHFLUFOLSDQGWKHVXSSRUWXQLWEHDULQJ& Œ Do NOT remove the Y-axis bearing holder (6). 7KHEDOOVFUHZLVQRZIUHHRQRQHVLGH Figure 8-27 Y-axis ball screw generation 3 5HPRYHWKHEDOOVFUHZ Œ 0RYHWKHURERWDUPEDFNZDUGVQHDUWKH<D[LVEHDULQJKROGHU Œ 5HPRYHWKHWZRKH[DJRQEROWVRIWKHJUHHQFRXSOLQJ Œ 5HPRYHWKHIRXUKH[DJRQEROWV%WKDWVHFXUHWKHVXSSRUWXQLW$ Œ Do NOT remove the Y-axis motor holder (5). Œ 5HPRYHWKHIRXUKH[DJRQEROWVIURPWKHEDOOVFUHZZKLFKDUHPRXQWHG LQWKH<D[LVQXWKROGHU Œ 1RZJHQWO\WDNHRXWWKHFRPSOHWHEDOOVFUHZ Œ 5HPRYHWKHORFNQXWDQGVXSSRUWXQLW$ &RQWLQXHZLWKLQVWDOOLQJDQGDOLJQLQJWKHQHZ<D[LVEDOOVFUHZJHQHUDWLRQ VHHVHFWLRQ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-29

Axes Systems 8.6.4.4. Y-axis: Installing and Aligning Y-axis Ball Screw Generation 3 )RUUHSODFLQJD UG JHQHUDWLRQ<D[LVEDOOVFUHZDUHSODFHPHQWNLWLVDYDLODEOH :KHQD QG JHQHUDWLRQ<D[LVEDOOVFUHZLVUHSODFHGIRUD UG JHQHUDWLRQ<D[LV EDOOVFUHZRUGHULQJDJUHDVHQLSSOHLQDGGLWLRQWRWKHUHSODFHPHQWNLWLV UHFRPPHQGHG 6HHIRUUHIHUHQFHILJXUHVDQG &KHFNWKHSDUWVRIWKHUHSODFHPHQWNLWOLVWHGLQWDEOH Item Figure Service number Description Qty (12NC) Complete replacement kit: 3 8-27 5322 816 11327 Ball screw 1 4A/B/C 8-27 5322 520 40305 Support unit 1 20 8-27/28 5322 816 11298 Bearing holder 1 25 8-27/28 5322 816 11296 Thrust bearing 1 26 8-27/28 5322 816 11297 Spring coned disk 3 27 8-27/28 5322 816 11292 Lock nut 1 31 8-28 5322 526 10729 Grease nipple 2 Table 8-3 Y-axis ball screw replacement kit 3ODFHWKHQHZJHQHUDWLRQEDOOVFUHZ Π$VVHPEOHWKHVXSSRUWXQLW$DQGWKHVXSSRUWXQLWEHDULQJDQGFLUFOLS &RQWKHEDOOVFUHZ Π1RZFDUHIXOO\SODFHWKHEDOOVFUHZ Π$VVHPEOHWKHQHZEHDULQJKROGHUEXWGRQRWIXOO\WLJKWHQWKHEROWV Π7LJKWHQWKHIRXUEROWV%DWWKHIURQWVXSSRUWXQLW$ZLWKDWRUTXH RI1P Π$VVHPEOHWKHQHZWKUXVWEHDULQJEXWJUHDVHILUVW16. Π$VVHPEOHWKHVSULQJFRQHGGLVNVDQGORFNQXWVRWKDWWKHVSULQJ FRQHGGLVNVMXVWWRXFKHDFKRWKHURQO\0LQGWKHDVVHPEOHGLUHFWLRQRIWKH GLVNVVHHILJXUH Π1RWHFKHFNDWWKHEDOOVFUHZQXWKROGHUEHDULQJQLSSOHLILWSURSHUO\KDV EHHQJUHDVHG Figure 8-28 Replacement of generation 2 ball screw for generation 3 ball screw Service Manual Topaz 5322 871 63606 8-30 PA 1309/10 01.05

Axes Systems Difference generation 2 and generation 3. The difference between the 2 nd and 3 rd generation ball screw assembly is found in the Bearing holder (34), Sleeve bearing (32) and thrust bearing(36). In the 3rd generation these have been changed for a new Bearing holder (20) and new Thrust bearing (25) only. See figure 8-28. $OLJQPHQWRIWKH<D[LVEDOOVFUHZ Π8VHWKHDOLJQPHQWWRROVHHILJDQGSXWLWFDUIXOO\ RQWKHOLQHDUJXLGHILUVWDWWKHIURQWRIWKHPDFKLQHPPIURPWKHPRWRU 6HFRQGO\DWWKHEDFNPPIURPWKH<D[LVEHDULQJKROGHU0DNHVXUH ERWKWKHWLSVRIWKHGLDOJDXJHVDUHQRWLQDYDOOH\RIWKHEDOOVFUHZ Π)RUKRUL]RQWDODOLJQPHQWFKHFNWKHGLVWDQFHEHWZHHQWKHOLQHDUJXLGHDQG WKHEDOOVFUHZDWWKHIURQWDQGDWWKHEDFNPD[PPGLIIHUHQFH EHWZHHQIURQWDQGEDFN Π)RUYHUWLFDODOLJQPHQWRIWKHEDOOVFUHZWKHGLIIHUHQFHLVDOVRPD[ PPEHWZHHQIURQWDQGEDFN Π$GMXVWERWKDOLJQPHQWVE\VKLIWLQJWKHEHDULQJKROGHU7KHQWLJKWHQ LWVIRXUEROWVZLWKDWRUTXHRI1P Figure 8-29 alignment tool of the Y-axis ball screw $VVHPEOHWKH<D[LVEDOOVFUHZWRWKH<D[LVQXWKROGHU Π3RVLWLRQWKHURERWDUPDWWKHIURQWRIWKHPDFKLQH Π$VVHPEOHWKHWZROHIWEROWVRIWKHQXWKROGHUILQJHUWLJKW Π3RVLWLRQWKHURERWDUPDWWKHPLGGOHSRVLWLRQRIWKH<D[LV Π$VVHPEOHWKHWZRULJKWEROWVILQJHUWLJKW Π7LJKWHQDOOEROWVDWDWRUTXHRI1PXVLQJDWRUTXHZUHQFK Π7LJKWHQWKHJUHHQEROWVDWWKHFRXSOLQJ 6ZLWFKRQWKHPDFKLQHWRSHUIRUPWKHVHFRQGSDUWRIWKHDGMXVWPHQW SURFHGXUHRIWKH<PRWRUHQFRGHUSRVLWLRQDIWHUUHSODFLQJWKH<D[LVEDOO VFUHZ6HHVHFWLRQ6ZLWFKWKHPDFKLQHRIIDJDLQDIWHUH[HFXWLQJWKLV SURFHGXUH 7LJKWHQWKHWZRJUHHQEROWVDWWKHFRXSOLQJ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 8-31

Axes Systems 8.6.4.5. Y-axis: Pre-tension Adjustment (Generation 3 Y-axis) 7KH<D[LVEDOOVFUHZKDVWKUHHVSULQJFRQHGGLVNVZKLFKFRQWUROWKHWHQVLRQRI WKH<D[LVPRYHPHQW6HHIRUUHIHUHQFHILJXUH 0DNHVXUHWKHVXUIDFHRIWKHJXLGHVDQGEDOOVFUHZLVIUHHRIGLUWDQGRYHUGXH JUHDVH 0DNHVXUHWKHVSULQJFRQHGGLVNVDUHWLJKWHQHGVRWKH\MXVWWRXFKHDFKRWKHU RQO\ $SSO\RQHVKRUWWXUQGHJUHHVWRWKHORFNQXW)LJE\KDQG RQO\VHHILJXUH Figure 8-30 Adjusting the pre-tension 0RYHWKH<D[LVE\XVHRIDQ\XWLOLW\SURJUDP 2QO\WLJKWHQWKHORFNQXWVOLJKWO\PRUHLIWKHD[LVPDNHVQRLVHSUHVV(0* VZLWFKILUVW 0D[SUHWHQVLRQDGMXVWPHQWLVOHVVWKDQGHJUHHVWXUQ 7LJKWHQWKHVHWVFUHZZDWFKIRUWKHFRSSHUFKLSRIWKHORFNQXWVHHILJXUH Set screw Copper chip Lock nut Figure 8-31 Lock nut set &KHFNLIDOOEROWVRIWKH<D[LVDUHWLJKWHQHGZHOO Service Manual Topaz 5322 871 63606 8-32 PA 1309/10 01.05

Axes Systems 8.6.4.6. Y-axis: Linear Guide Replacement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ervice Manual Topaz 01.05 PA 1309/10 8-33

Axes Systems 8.6.5. Z-axis Assembly 7KHPHFKDQLFDODVVHPEO\RIWKH=D[LVLVGHWDLOHGLQILJXUH Z-axis: Z-Motor replacement 5HSODFHWKH=PRWRUE\SURFHGLQJDVIROORZV 5HPRYHWKHKHDGDVVHPEO\DVGHVFULEHGLQWKHEHJLQQLQJRIWKLVVHFWLRQWKLVLV QRWDEVROXWHO\QHFHVVDU\EXWHDV\,IWKHKHDGLVQRWUHPRYHGPDNHVXUHWR GLVFRQQHFWWKHPRWRUDQGHQFRGHUFDEOHIURPFRQQHFWRUSODWHLWHPLQILJXUH 5HPRYHWKHPRWRUE\ORRVHQLQJWKHIRXUVFUHZVLWHPKROGLQJLWWREUDFNHW $VVHPEOHLQUHYHUVHRUGHU Z-axis: Z-bearing replacement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axis Assembly 7KHPHFKDQLFDODVVHPEO\RIWKH5$[HVRIWKH7RSD]LVVKRZQLQILJXUH 7KH7RSD]XVHVDEHOWGULYHZKLOHWKHHQFRGHUDSDUWLVRIWKH5PRWRUDVVHPEO\ R-Axis: Replacing the Nozzle Holder 1) 5HPRYHWKHOHDIVSULQJVLWHPE\PHDQVRIVFUHZWDNHFDUHQRWWRORRVH WKHZDVKHULWHP 2) 5HPRYHWKHSLQLWHP LQILJXUHD7KHSLQKDVWREHGULYHQRXWRIWKH KROHEHIRUHUHSODFLQJWKHQR]]OHKROGHULVSRVVLEOH7KHEHVWZD\WRGRWKLVWR PDNHVXUHWKHVSOLQHLVVXSSRUWHGDWWKHUHDUVLGHDQGE\XVLQJDVPDOOSLQWR GULYHWKHSLQRXWRIWKHVKDIW 3) 5HDVVHPEOHWKHQHZQR]]OHKROGHUDQGOHDIVSULQJVLQWKHUHYHUVHZD\ &KHFNWKHOHDIVSULQJVLIWKH\FDQKROGWKHQR]]OHZHOOLIQRWUHSODFHWKHVSULQJV Service Manual Topaz 5322 871 63606 8-34 PA 1309/10 01.05

Axes Systems R-axis: Replacing the Spline Shaft 5HSODFHPHQWRIWKHVSOLQHVKDIWLVGRQHDVIROORZV 1) 5HPRYH WKH KHDG DVVHPEO\ IURP WKH PDFKLQH DV GHVFULEHG LQ WKH SUHYLRXV VHFWLRQ 2) /RRVHQEHOWLWHPDQGUHPRYHWKHEROWV5HPRYHLWHPVDQG ORRVHQFLUFOLS7KHVSOLQHVKDIWFDQQRZEHUHPRYHG 3) 5HDVVVHPEOHLQWKHUHYHUVHRUGHU R-axis: Replacing and Maintaining the Piston and Plugs Assy s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ervice Manual Topaz 01.05 PA 1309/10 8-35

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Vision Systems CHAPTER 9 Vision Systems 9.1. 9.2. Introduction 7KLVFKDSWHUGHVFULEHVWKHYLVLRQV\VWHPVWKDWDUHXVHGLQWKH7RSD] Vision Systems 7KHVWDQGDUGPRGHORI7RSD]XVHVIROORZLQJFDPHUDUHFRJQLWLRQHTXLSPHQW l l $PRYLQJFDPHUDWRUHFRJQLVHWKH3&%ILGXFLDOPDUNVWREHDEOHWRFRUUHFW IRUDQ\VKLIWVLQWKH3&%OD\RXW 2QHLQWKHIURQWRUWZRVHFRQGDWWKHEDFNOLQHDUVHQVRUFDPHUDV\VWHPV DOVRUHIHUUHGWRDVPXOWLFDPHUD7KLVFDPHUDLVXVHGWRUHFRJQLVH FRPSRQHQWVDVFKLSVHWF7KHFDPHUDXVHVDRQHOLQH&&'WRUHDGRQHOLQH RIWKHSLFWXUHDWDWLPHWKHSLFWXUHRIWKHFRPSRQHQWLVEXLOGE\IO\LQJ RYHUWKHFDPHUDZLWKDVSHFLILHGVSHHGDQGVWRULQJOLQHE\OLQHLQPHPRU\ l 2QH&&'FDPHUDDOVRUHIHUUHGWRDVWKHVLQJOHYLVLRQFDPHUDWRUHFRJQLVH FRPSRQHQWDV4)3HWF 7KLVVHFWLRQGHVFULEHVKRZWRDGMXVWWKHYLVLRQV\VWHP$OODGMXVWPHQWLWHPVFDQ EHDGMXVWHGZLWKWKHXWLOLWLHVLQWKH0DFKLQH$GMXVWPRGHRIWKHPDLQWHQDQFH 0DQDJHU %HDZDUHWKDWWKHVHFRQGPXOWLFDPHUDZKLFKLVDQRSWLRQUHGXFHVWKH PD[LPXP3&%ZLGWKIURPPPWRPP Figure 9-1 Vision Systems of the Topaz 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-1

Vision Systems 9.2.1. Pre-Start Operations 3ULRUWRWKHFDPHUDDGMXVWPHQWVHVSHFLDOO\WKHVLQJOHDQGPXOWLFDPHUD DGMXVWPHQWVLWLVZLVHWRSHUIRUPRQHRUPRUHRIWKHIROORZLQJSUHVWDUW RSHUDWLRQV l l,id)(6lvlqvwdoohgwriurqwriwkhv\vwhpuhpryhwkh)(6fduuldjhwr HQDEOHHDV\DFFHVVWRWKHPXOWLDQGLILQVWDOOHGDOVRWKHVLQJOHYLVLRQ FDPHUD,ID)(6LVLQVWDOOHGDWWKHEDFNVLGHRIWKHV\VWHPUHPRYHWKH)(6FDUULDJH LIDQRSWLRQDOVHFRQGPXOWLFDPHUDLVLQVWDOOHG,I12)(6LVLQVWDOOHGDWWKHIURQWRIWKHV\VWHPUHPRYHWKHWDSHZDVWH JXLGHRIWKHIURQWIHHGHUEDUWRHQDEOHHDVLHUDFFHVVWRWKHFDPHUD VDWWKH IURQW,IWKHRSWLRQDOVHFRQGPXOWLFDPHUDLVLQVWDOOHGDWWKHEDFNRIWKHV\VWHP WKDQUHPRYHWKHWDSHZDVWHJXLGHDOVRIURPWKHUHDUIHHGHUEDU 9.3. Moving Camera 7KHPRYLQJFDPHUDLVORFDWHGLQWKHKHDGDVVHPEO\DQGXVHGWRUHFRJQLVH3&% ILGXFLDOPDUNVDQGSHUIRUPWHDFKLQJ7KHOLJKWLQJOHYHODQGWKHVFDOHRIWKH PRYLQJFDPHUDFDQEHDGMXVWHG 9.3.1. Adjusting the Focus and Field Of View )RFXVLQJWKHPRYLQJFDPHUDLVDIDLUO\VLPSOHSURFHVV:KLOHORRNLQJDW VRPHWKLQJRQWKH3&%WKDWSURYLGHVJRRGFRQWUDVWVLPSO\PRYHWKHFDPHUDXS RUGRZQDVQHFHVVDU\WRREWDLQWKHVKDUSHVWSLFWXUH2QHWKLQJWRNHHSLQPLQG ZKLOHPRYLQJWKHFDPHUDLVWRNHHSLWVWUDLJKWKDVDGLUHFWLPSDFWRQWKHVFDOH SURFHGXUH NOTE: You may use a fiducial for focus, however, any thing on the board that provides good contrast and detail will work (i.e. any writing or etchings on the board). 6\QRSVLV )L[DERDUGLQSODFHWKDWKDVDJRRGFOHDUILGXFLDO*RWRWKHGDWDEDVHDQG SHUIRUPDQ)IXQFWLRQ8VHWKH 7HDFK0DUNµVHFWLRQWRPRYHWKHFDPHUD RYHUWKHILGXFLDODQGWKHQPRYHWKHFDPHUDXSRUGRZQDVQHFHVVDU\WRREWDLQ WKHVKDUSHVWSLFWXUH'RQ WIRUJHWWRNHHSWKHFDPHUDVWUDLJKW $GMXVWLQJWKHIRFXV 6HWXSWKHWUDQVSRUWVHFWLRQWRUHFHLYHWKH3&%WREHXVHGIRUWKLVVHFWLRQXVHD 3&%WKDWKDVDUHIOHFWLYHILGXFLDOGRQWXVHWKHJODVVSODWH7KLVLVWKHVDPHDVD SURGXFWFKDQJHRYHUZLWKRXWWKHIHHGHUV *RWRWKH'DWDEDVH'$7$0 '$7$%$6( 0$5.'% 0RYHWKHFXUVRUWRDQ\OLQHFRQWDLQLQJDILGXFLDODQGSUHVV)\RXZRQ W DFWXDOO\XVHWKHZKROH)IXQFWLRQ Service Manual Topaz 5322 871 63606 9-2 PA 1309/10 01.05

Vision Systems 7KHFXUVRUZLOOEHRQWKH ),;3&%µOLQH3UHVV(QWHU,IWKHERDUGLVDOUHDG\ IL[HGLQSRVLWLRQPRYHWKHFXUVRUWR 5(7851µDQGSUHVV(QWHU,IWKHERDUG LVQRWLQSODFHIL[LWLQSODFHDWWKLVWLPHWKHQJRWR 5(7851µDQGSUHVV (QWHU 0RYHWKHFXUVRUWR 7($&+0$5.µ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djusting the Lighting Level of the Moving Camera )RUDFFXUDWHUHFRJQLWLRQRI3&%ILGXFLDOPDUNVWKHOLJKWLQJOHYHORIWKH PRYLQJFDPHUDPXVWEHRSWLPLVHG7RPDNHWKHDGMXVWPHQWDQRSWLRQDO FXVWRPWRROOLJKWDGMXVWHUSODWHVKRXOGEHXVHG NOTE: If fiducial lighting unit has 1 dial and three potentiometers, and you have a light adjuster tool (part number 5322 395 10274) you should use the special tool option in Moving Camera Light. This will take you through adjusting the individual light of the moving camera. Inner Light, Outer Light, and Coaxial, with each dial position being set for each position. Ensure to reset the Dial position to 0 so all light types will be available to the machine. When using the light adjuster tool, ensure that the lighter side of the tool is in full view of the camera when setting the lighting level. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-3

Vision Systems 7KLVDXWRPDWHGSURFHGXUHFKHFNVWKHEULJKWQHVVRIWKH/('OLJKWVIRUWKH PRYLQJFDPHUD7RGRWKLV\RXZLOOQHHGWRIL[DERDUGLQSRVLWLRQWKDWKDVD FOHDQILGXFLDO,WLVSUHIHUUHGWRXVHDFLUFOHRIDWOHDVWPP 7KHUHLVDGLUHFWUHODWLRQVKLSEHWZHHQWKH7KUHVKROGYDOXHRIWKHPDUNDQGWKH OHYHORIOLJKWWKHPDFKLQHZLOODFFHSWDV 2.µ%HIRUHSHUIRUPLQJWKLV SURFHGXUHLWLVUHFRPPHQGHGWRJRWRWKHGDWDEDVHZKHUHWKLVPDUNUHVLGHVDQG ILQGRXWZKDWWKH7KUHVKROGYDOXHLVVHHVHFWLRQ$ IRU GLUHFWLRQVKRZWRJHWWKHUH2QFHLQWKHGDWDEDVHSUHVVWKH)NH\XQWLOWKH 9LVLRQ,QIRµVXEZLQGRZLVGLVSOD\HG,QWKLVVXEZLQGRZLVWKH7KUHVKROG YDOXH7KHOLJKWLQJOHYHOQHHGHGWRSURGXFHDQ $YHUDJH*UD\/HYHOWKDWLV 2.µLVYHU\FORVHWRWKLVOHYHO 1. Prepare the light adjuster plate. 3UHSDUHWKHOLJKWDGMXVWHUSODWHDQGDSURSHU3&%RQZKLFKWKHOLJKW DGMXVWHUFDQEHSODFHG3&%ILGXFLDOPDUNVDUHQRWQHFHVVDU\ 2. Execute the Mov.Cam. Light command. 6HOHFW%$'-8677$5*(7!µ0RY&DP/LJKWµDQGSUHVVWKH >(17(5@NH\ 6HOHFW'LDOVFUHZV 6HOHFW8VHIRUWKHVSHFLDOWRRO <<<APPLICATION>>> <<MODE>> <COMMAND_LIST> B/SAVE 3/MAINTE/M 3/MCH_ADJUST B1 ADJUST TARGET Object Mov.Cam.Light A650 This procedure adjusts the light intensity of the moving camera. The way of... LED Type 0 Dial + 2 screws 1 Dial + 3 screws A651 Please select whether you will use a Light Adjuster (special adjustment... Special Tool Use Not Use A653 This adjustment requires placing... PCBwidth(mm) 128 A303 CAUTION! The axes will move. A426 Please put the specified PCB at the mounting... Figure 9-2 Moving camera light adjustment procedure Service Manual Topaz 5322 871 63606 9-4 PA 1309/10 01.05

Vision Systems 3. Enter the width of the PCB and press the [ENTER] key. (QWHUWKHZLGWKPLOOLPHWUHVRIWKH3&%XVHGLQWKLVDGMXVWPHQW 4. Ensure safety, then press the [ENTER] key again. 7KH:D[LVPRYHVWRVHWWKHVSHFLILHGFRQYH\RUZLGWK 5. Press emergency button, set the PCB & light adjuster plate. $OLJQWKHORFDWHSLQVZLWKWKHFHQWUHRIWKHSRVLWLRQLQJKROHVRIWKH3&% 7KHQSODFHWKHOLJKWDGMXVWHUSODWHLQWKHFHQWUHRIWKH3&%ZLWKWKHWZR WRQHVXUIDFHIDFLQJXS 6. Adjust the conveyor unit. $GMXVWWKHSRVLWLRQVRIWKHORFDWHSLQDQGSXVKXSSLQVWRPDWFKWKH3&% 7. Cancel emergency stop. (QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH >5($'<@EXWWRQRIWKH++. 8. Press the [ENTER] key. 7KHORFDWHSLQVDQGSXVKXSSLQVULVHWRVHFXUHWKH3&%DQGWKHKHDG DVVHPEO\PRYHVWRRYHUWKH3&%7KHWHDFKLQJVFUHHQIRUWKHOLJKWDGMXVWHU SODWHWKHQDSSHDUV HSV A655 <<<Teaching>>> Please position the cross hair cursor over the Light Adjuster Figure 9-3 Adjusting light intensity 9. Adjust the camera position. :KLOHPDQLSXODWLQJWKH++.MR\VWLFNDGMXVWWKHSRVLWLRQRIWKHPRYLQJ FDPHUDVRWKDWWKHOLJKWJUH\DUHDRQWKHOLJKWDGMXVWHUSODWHLVGLVSOD\HGRYHU WKHHQWLUHILHOGRIYLHZ OK NG Figure 9-4 Position the light adjuster tool 10. Adjust the camera lighting level according to the messages. 7KHPRYLQJFDPHUDOLJKWLQJSDWWHUQLVGLYLGHGLQWRDWULSOHULQJHGDUHD RXWHULQQHUDQGFRD[LDO 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-5

Vision Systems $GMXVWWKHOLJKWLQJOHYHOIRUHDFKSDWWHUQE\XVLQJWKH/('WULPPHUVDQG VHOHFWLQJWKHOLJKWLQJSDWWHUQZLWKWKHURWDU\VZLWFK7KUHH/('WULPPHUV DUHORFDWHGRQWKHVLGHRIWKHPRYLQJFDPHUDOLJKWXQLWIRUDGMXVWPHQWRI WKHRXWHULQQHUDQGFRD[LDODUHDV7KHOLJKWOHYHOLQFUHDVHVE\WXUQLQJWKH WULPPHUWRWKHULJKWFORFNZLVHDQGGHFUHDVHVE\WXUQLQJLWWRWKHOHIW $GMXVWHDFKWULPPHUVRWKDWWKH $YH*UD\/HYHOYDOXHGLVSOD\HGDWWKH XSSHUULJKWRIWKHRSHUDWLRQPRQLWRUPDWFKHVWKHRSWLPXPOHYHOLQGLFDWHG LQWKHWDEOHEHORZ A657 In this type of LED light, turning the dial next to 3 screws enables outer, inner and A658 Please adjust the light intensity of outer LED by turning A659 Please adjust the light intensity of inner LED by turning the screw in the middle of 3 screws. until A660 Please adjust the light intensity of coaxial LED by turning Figure 9-5 Calibration procedure Figure 9-6 Rotary SW 0 1 2 3 4 5 6 7 Figure 9-7 Fiducial light adjustment Outer Middle Inner (coaxial) Optimum level settings Optimum level Normal lighting pattern 50±5 50±5 20±5 Service Manual Topaz 5322 871 63606 9-6 PA 1309/10 01.05

Vision Systems 11. Return the rotary switch to "0". :KHQDGMXVWPHQWRIHDFKOLJKWLQJSDWWHUQLVFRPSOHWHVHWWKHURWDU\ VZLWFKWRDOO/(' VWXUQHGRQ 12. Press the [ESC] key to quit the adjustment. 7KHORFDWHSLQVDQGSXVKXSSLQVDUHDXWRPDWLFDOO\UHOHDVHG$IWHUSUHVVLQJ WKHHPHUJHQF\VWRSEXWWRQUHPRYHWKH3&%7KHUHLVQRPDFKLQHGDWDWR EHVDYHGLQWKLVDGMXVWPHQW 9.3.3. Adjusting the Moving Camera Scale 7KHPRYLQJFDPHUDVFDOHLVDYLVLRQSDUDPHWHUUHSUHVHQWLQJDPHDVXUHPHQW HTXLYDOHQWWRRQHSL[HO7KLVVFDOHPXVWEHDGMXVWHGFRUUHFWO\IRUDFFXUDWH UHFRJQLWLRQRI3&%ILGXFLDOPDUNV7RPDNHWKHDGMXVWPHQW\RXZLOOQHHGD 3&%KDYLQJDILGXFLDOPDUNRINQRZQVL]H 1) Preparing the PCB (normal PCB) 3UHSDUHD3&%KDYLQJDSUHFLVHILGXFLDOPDUNWKDWLVUHJLVWHUHGLQWKH GDWDEDVH:KHQ\RXXVHD3&%KDYLQJDPDUNQRWUHJLVWHUHGLQWKH GDWDEDVHLWPXVWEHUHJLVWHUHG NOTE: Use of a circular mark is recommended since circular marks are generally superior in dimensional precision to other marks. Use of a 1mm diameter circular mark that faithfully reflects light is especially preferred. (A doughnut shape is not suited for use in this adjustment.) Check the registration in the mark database. 7RRSHQWKHPDUNGDWDEDVHVHOHFW'$7$%$6(!$ &20321(170$5.'%!0$5.'$7$%$6(DQGSUHVVWKH >(17(5@NH\ &KHFNIRUWKHUHJLVWUDWLRQGDWD&KHFNLQSDUWLFXODUWKDWWKHPDUNVL]H RIWKH3&%H[DFWO\PDWFKHVWKHUHJLVWUDWLRQGDWD0DUN2XW6L]H&KHFN DOVRWKDWWKH6HDUFK$UHDSDUDPHWHULQWKH9LVLRQ,QIRVXEZLQGRZLV RUODUJHUQRWWRRODUJHEXWDOVRQRWVPDOOHUWKDQ Sub-window <<<APPLICATION>>> <<MODE>> 2/DATA/M 3/DATABASE OBJ : MARK DATABASE No. MARK NAME COMMENT Mark size Info. Edit Term Mark OutSize : : mm 1.0 151 CIRCLE_1.0_Cu Vision Info. Edit Term Search Area : : 4:00 Figure 9-8 Mark data base Open the Adjust Assist. to check that the mark is clearly recognized. 7KH$GMXVW$VVLVWDQWVFUHHQDSSHDUVE\SUHVVLQJWKH>)@NH\ Secure the PCB on the conveyor by means of the FIX PCB command. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-7

Vision Systems $GMXVWWKHFRQYH\RUXQLWDFFRUGLQJWRWKHVL]HRIWKH3&%\RXDUHJRLQJWR XVH$IWHUSUHVVLQJWKHHPHUJHQF\VWRSEXWWRQPDNHQHFHVVDU\DGMXVWPHQWV WRWKHORFDWHSLQVDQGSXVKXSSLQV7KHWHVWERDUG&7LVPP ZLGH Execute the VISION TEST command. :KHQQRHUURUVRFFXUWKHFXUUHQWSDUDPHWHUVHWWLQJVDUHDSSURSULDWH $GYDQFHWRWKHPRYLQJFDPHUDVFDOHDGMXVWPHQWLQWKHQH[WVHFWLRQ,IDQ HUURURFFXUVDGMXVWWKHPRYLQJFDPHUDOLJKWLQJSDWWHUQDQGRUPDUN LQIRUPDWLRQSDUDPHWHUVDVQHFHVVDU\)RUPRUHGHWDLOVRQWKHSDUDPHWHU VHWWLQJVUHIHUWRWKHPRXQWHURSHUDWLRQPDQXDO 2) Preparing the PCB (glass PCB) :KHQXVLQJDJODVV3&%VSHFLDOO\WDLORUHGIRUFDPHUDVFDOHDGMXVWPHQW IROORZWKHVHVWHSV Prepare a glass PCB which is set in the jig. $JODVV3&%ZLWKLQ3$VHWZLWKWKHMLJGHVLJQHGIRUWKLV DGMXVWPHQWLVDYDLODEOHIURP3+,/,36'RQRWUHPRYHWKH3&%IURPWKHMLJ GXULQJDGMXVWPHQW Register the mark on the PCB in the mark database. 2SHQWKHPDUNLQIRUPDWLRQVFUHHQ 6HOHFW'6:,7&+3&%'$7$!$0)B4)30DUN,QIR DQGSUHVVWKH>(17(5@NH\ &KHFNWKDWWKHGDWDEDVH1XPEHURIWKH1RPDUNGDWDLV 3UHVVWKH>(6&@NH\VHOHFWWKH%6(7)520'$7$%$6(! FRPPDQGZLWKWKHDUURZNH\VDQGSUHVVWKH>6+,)7@>(17(5@NH\V $QDOHUWPHVVDJHDSSHDUVEXWSURFHHGDVLQGLFDWHGWRH[HFXWHWKLV FRPPDQG Sub-window <<<APPLICATION>>> <<MODE>> 2/DATA/M 3/DATABASE OBJ : MARK DATABASE No. MARK NAME COMMENT Mark size Info. Edit Term Mark OutSize : : mm 1.0 151 CIRCLE_1.0_Cu Vision Info. Edit Term Search Area : : 4:00 Figure 9-9 Mark info screen Check for the registration data in the mark database. 2SHQWKHPDUNGDWDEDVH6HOHFW'$7$%$6(!$ &20321(170$5.'%!0$5.'$7$%$6(DQGSUHVVWKH >(17(5@NH\WRRSHQWKHPDUNGDWDEDVH 3UHVVWKH>)@NH\DQGWKHQ>(6&@NH\7KH&+$1*(326,7,21ER[ DSSHDUVVRHQWHUDQGSUHVVWKH>(17(5@NH\ &KHFNWKDWWKHGDWDLVHQWHUHGLQ1R Change the moving camera lighting setting. 6HWWKHPRYLQJFDPHUDURWDU\VZLWFKWRVRWKDWWKHOLJKWLQJLVRSWLPL]HG IRUUHFRJQL]LQJWKHJODVV3&% Service Manual Topaz 5322 871 63606 9-8 PA 1309/10 01.05

Vision Systems Check that the mark is clearly recognized in the Adjust Assistant. 7KH$GMXVW$VVLVWDQWVFUHHQDSSHDUVE\SUHVVLQJWKH>)@NH\ Secure the PCB on the conveyor with the FIX PCB command. )RU&219(<25:,'7+HQWHU7KHQSUHVVWKHHPHUJHQF\VWRS EXWWRQDQGPDNHQHFHVVDU\DGMXVWPHQWVWRWKHORFDWHSLQVDQGSXVKXSSLQV Execute the VISION TEST command. :KHQQRHUURUVRFFXUWKHFXUUHQWSDUDPHWHUVHWWLQJVDUHDSSURSULDWH $GYDQFHWRWKHPRYLQJFDPHUDVFDOHDGMXVWPHQWLQWKHQH[WVHFWLRQ,IDQ HUURURFFXUVDGMXVWWKHPDUNLQIRUPDWLRQSDUDPHWHUVDVQHFHVVDU\)RUPRUH GHWDLOVRQWKHSDUDPHWHUVHWWLQJVUHIHUWRWKHPRXQWHURSHUDWLRQPDQXDO 3) Adjusting the moving camera scale :KHQ\RXKDYHSUHSDUHGWKH3&%XVHWKHIROORZLQJVWHSVWRFDOLEUDWHWKH PRYLQJFDPHUDVFDOH Execute the Mov.Cam. Scale command 6HOHFW%$'-8677$5*(7!µ0RY&DP6FDOHµDQGSUHVVWKH >(17(5@NH\ <<<APPLICATION>>>1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH-ADJUST 4/MANUAL 0/EXIT <COMMAND_LIST> A/CHANGE-CONDTION B/SAVE & QUIT C/DISPLAY & EXIT B1 ADJUST TARGET Object Mov.Cam. Scale <<MODE>> 1/MCH-CONFIG 2/MCH-DATA 3/MCH-ADJUST 4/MANUAL 0/EXIT A420 This procedure adjusts the vertical (Y) and horizontal (X) scales of the moving camera. A fiducial mark is meeded for this adjustment. Recommended is an easy recognizable Mark No. 153 A422 Please input the PCB width (mm) which you want to use and confirm if the PCB uses the fiducial that is described in the used mark database number. PCB width (mm) 128 A423 By moving the axes, the fiducial mark will be recognized in three steps. Please input the allowed moving distance : 1 3 (mm). The unit of Distance (mm/10) 20 A303 CAUTION!! The axes will move. After confirming safety, please press the [ENTER] key. A426 Please set the specified PCB on the mount position. When using your hands, you must first press the EMG STOP button. After the board is inserted on the Figure 9-10 Moving scale adjustment Enter the mark database No. and press the [ENTER] key. +HUHHQWHUWKHGDWDEDVH1RRIWKHPDUNRQWKH3&%\RXDUHXVLQJ Check or enter the width of the PCB and press the [ENTER] key. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-9

Vision Systems 7KHZLGWKRIWKH3KLOOLSVERDUGLVPPDQGRIWKHJODVV3&%PP Confirm that Distance (mm/10) 15 is displayed, and press [ENTER]. 1RUPDOO\DPRYHPHQWGLVWDQFHRI µlqwhqwkvridploolphwhulv UHFRPPHQGHG Ensure safety, then press the [ENTER] key again. 7KH:D[LVPRYHVWRVHWWKHVSHFLILHGFRQYH\RUZLGWK:KHQ\RXKDYH DOUHDG\DGMXVWHGWKHFRQYH\RUZLGWKIRUSHUIRUPLQJWKH$GMXVW$VVLVWDQWLQ WKHSUHYLRXVVHFWLRQWKH:D[LVGRHVQRWPRYH Press the emergency stop button, then set the PCB in position. :KHQWKH3&%KDVDOUHDG\EHHQVHWRQWKHFRQYH\RUVNLSWKLVVWHS Cancel emergency stop.,i\rxkdyhvhwhphujhqf\vwrslq6whsuhohdvhwkhhphujhqf\vwrsexwwrq DQGSUHVVWKH>5($'<@EXWWRQRQWKH++. Ensure safety, then press the [ENTER] key. 7KHORFDWHSLQVDQGSXVKXSSLQVULVHWRVHFXUHWKH3&%DQGWKHKHDG DVVHPEO\PRYHVWRRYHUWKH3&%7KHWHDFKLQJVFUHHQIRUWKHILGXFLDOPDUN SRVLWLRQWKHQDSSHDUV <<MODE>> 3/MCH-ADJUST A427 <<<Moving!!>>> Now it is fixing the PCB and moving the axes. To quit, please press the [ESC] key. A428 <<<Teaching>>> Please set the fiducial mark on the center cross cursor of the monitor by using the joy stick. After teaching, please press the [ENTER] key. To quit, please press the [ESC] key. Figure 9-11 Teaching fiducials Position the fiducial mark in the center of the screen. 0DQLSXODWHWKH++.MR\VWLFNWRDOLJQWKHPDUNZLWKWKHFURVVFXUVRULQWKH FHQWHURIWKHVFUHHQ Figure 9-12 Mark info screen Service Manual Topaz 5322 871 63606 9-10 PA 1309/10 01.05

Vision Systems Press the [ENTER] key to start calibration. 7KHPRYLQJFDPHUDPRYHVLQERWK;DQG<GLUHFWLRQV 7KHDPRXQWRIPRYHPHQWRQWKHYLVLRQPRQLWRULVFDOLEUDWHGDQGWKH UHVXOWVDUHWKHQGLVSOD\HGRQWKHVFUHHQ <<MODE>> 3/MCH_ADJUST A431 <<<RESULT>>> The following data is the result of the adsjustment of the moving camera scales. To save the result in memory, press the [ENTER] key (contents are not saved on disk). To abandon, press the [ESC] key. Scale_x Scale_y Angle = = = xx.xx yy.yy rr.rr Figure 9-13 Start calibration 7KHFRUUHFWYDOXHVIRUWKHPRYLQJFDPHUDDUHDVVKRZQLQWDEOH Average FOV Scale range of X/Y scale ratio Angle R X and Y value 4.8mm 10.5 ±0.2 (µm/pixel) 1.00 ±0.01 0 ±0.5 Table 9-1 Moving camera,iwkhvfdohydoxhlvqrwzlwklqolplwvpryhwkhfdphudxsrugrzqdqg DGMXVWWKHFDPHUDVFDOHDJDLQ,IWKHURWDWLRQLVRIIURWDWHWKHFDPHUDDQGDGMXVWWKHFDPHUDVFDOHDJDLQ Press the [ENTER] key to save the calibrated results. 3UHVVWKH>(6&@NH\LI\RXZDQWWRFDQFHOWKHUHVXOWV Save the calibration settings. 6HOHFW%6$9('$7$!RU%6$9( 48,7!DQGSUHVVWKH>(17(5@ NH\7RTXLWZLWKRXWVDYLQJVHOHFW%5(&29(5$'-867!RU% 48,7!DQGSUHVVWKH>(17(5@NH\ Press the emergency stop button, then remove the PCB. %HIRUHUHPRYLQJWKH3&%WKHFODPSLQJPXVWEHUHPRYHGWKLVFDQEHGRQH E\PHDQVRIWKH'2VFUHHQ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-11

Vision Systems 9.4. 9.4.1. Single Camera Adjustment 7KLVVHFWLRQGHVFULEHVWKHFDOLEUDWLRQRIWKHVLQJOHFDPHUD,IQRWLQVWDOOHGWKDQ VNLSWKLVVHFWLRQ Maximum Component Size and Field Of View 7KLVSURFHGXUHH[SODLQVKRZWRDGMXVWWKHPD[LPXPFRPSRQHQWVL]H7KH PD[LPXPFRPSRQHQWVL]HLVGLUHFWO\UHODWHGWRWKH)LHOG2I9LHZ)RUWKH7RSD] WKHUHFRPPHQGHG)LHOG2I9LHZLVPPRUODUJHUWKHPD[LPXPFRPSRQHQWLV PPVTXDUH 7RDGMXVWXVHDWUDQVSDUHQWUXOHUVKHHWWLSFRS\RQDFRS\PDFKLQHDUXOHURQD WUDQVSDUHQWVKHHW 6HWWKHIRFXVULQJLQWKHPLGGOHSRVLWLRQ 6HOHFWWKHDGMXVWDVVLVWDQW)!NH\SLFNXSWKHUXOHUVKHHWDQGEULQJLWDERYH WKHVLQJOHFDPHUDRQZKLFK\RXZDQWWRDGMXVWWKHDSHUWXUH$GMXVWWKH)LHOG2I 9LHZVL]HE\VKLIWLQJWKHFDPHUDXSRUGRZQ Figure 9-14 Ruler sheet on the vision monitor NOTE: Adjusting the Field Of View too large may give problems with the nozzle back plate. If you can see two stripes on the screen as shown in the figure 9-15 below please readjust again. White stripes next to the nozzle back plate may influent the recognition of components in a negative way. nozzle back plate Figure 9-15 Nozzle back plate sides visible Service Manual Topaz 5322 871 63606 9-12 PA 1309/10 01.05

Vision Systems 9.4.2. NOTE: Focus Adjustment 7R DGMXVW WKH IRFXV WKH VSHFLDO IRFXV DGMXVWHU WRRO FDQ EH XVHG 7KH IRFXV DGMXVWHU LV DOVR XVHG WR DGMXVW WKH FDPHUDV RI WKH 2ULRQ 7RSD]RU6DSSKLUH 3UHSDUHDFRPSRQHQWLQWKHFRPSRQHQWGDWDEDVHVRWKDWWKHIRFXVDGMXVWHU FDQ EH SLFNHG XS ZLWK QR]]OH W\SH RU 0DNH VXUH WKH FRPSRQHQW WKLFNQHVV= DQGWKDWWKHFRPSRQHQWIRFXVDGMXVWHULVUHFRJQLVHGDWWKH FRUUHFWFDPHUD 6HWWKHIRFXVULQJRQWKHOHQVWRWKH µ SRVLWLRQ EHIRUH DGMXVWLQJ WKH IRFXV The Focus adjustment tool can only be used with a Fore lighting system. Set the Alignment Module to Fore. 3UHVV)DGMXVWDVVLVW 0DUNWKHQR]]OHSRVLWLRQZLWKDSHUPDQHQWPDUNHURQWRWKHSLFNXSVXUIDFH RI WKH IRFXV DGMXVWHU WRRO VHH ILJXUH 7KLV HQVXUHV WKDW WKH WRRO LV DWWDFKHGWRKHDGDWDIL[HGSRVLWLRQ 3LFNXSWKHIRFXVDGMXVWHUWRRODVVKRZQLQILJXUH Figure 9-16 Focus adjuster tool direction $GMXVWWKHIRFXVE\VKLIWLQJWKHFDPHUD XSRUGRZQVHHILJXUH $WWKHOHYHOSRVLWLRQRIWKHIRFXV DGMXVWHUWRROWKHIRFXVPXVWEHRSWLPDO 7KHPDFKLQHZLOOWDNHLQWRDFFRXQWWKH =KHLJKW RI WKH FRPSRQHQW DQG ZLOO VXEWUDFWWKDWQXPEHUIURPWKH&DPHUD =FRRUGLQDWH Figure 9-17 Nozzle back plate sides visible 7KH ERWWRP RI WKH FRPSRQHQW ZLOO DOZD\V EH UHFRJQLVHG DW WKH VDPH = SRVLWLRQ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-13

Vision Systems NOTE: 7KH IRFXV DGMXVWPHQW LQIOXHQFHV WKH PD[LPXP FRPSRQHQW VL]H DGMXVWPHQW VRWDNHFDUHRIWKDWDQGILQGWKHRSWLPXPYDOXHIRUERWKIRFXVDQGPD[LPXP FRPSRQHQW The focus must be adjusted by moving the camera up or down, not by turning the focus ring. Only use the focus ring adjustment if no good results can be obtained. This because it is a very precise adjustment. Figure 9-18 Nozzle back plate sides visible 9.4.3. Lighting Level Adjustment 7KLV VHFWLRQ GHVFULEHV KRZ WR DGMXVW WKH OLJKWLQJ OHYHO RI WKH 6LQJOH YLVLRQ FDPHUD 7KLV FDQ EH GRQH LQ WZR GLIIHUHQW ZD\V SURFHHG DV LQGLFDWHG LQ IROORZLQJVWHSV 7KH OHQV DSHUWXUH VHWWLQJ GLDSKUDJP RI WKH VLQJOH FDPHUD LV FRUUHFWHG DXWRPDWLFDOO\ LQ VRIWZDUH ZKLOH GRLQJ WKH IRUH OLJKW DGMXVWPHQW 7KH DSHUWXUH ULQJ RQ WKH OHQV RI WKH VLQJOH FDPHUD PXVW EH VHW LQEHWZHHQ SRVLWLRQ )µdqg )µ ([HFXWHWKH 6LQJOH&DP/LJKWµXWLOLW\DVIROORZV l l l 6HOHFW%$GMXVWWDUJHW6LQJOH&DP/LJKW!DQGSUHVV(QWHU! (QWHU WKH GDWDEDVH QXPEHU RI WKH FRPSRQHQW \RX DUH XVLQJ IRU WKLV DGMXVWPHQW DQG SUHVV (QWHU!,I \RX KDYH DGGHG DQ RSWLRQDO KLJK SUHFLVLRQYLVLRQFDPHUDVHOHFW 6LQJOH&DPµWRDGMXVWLW (QWHU WKH IHHGHU VHW QXPEHU DQG SUHVV WKH (QWHU! NH\ :KHQ WKH VHOHFWHGFRPSRQHQWLVUHJLVWHUHGDVDWUD\FRPSRQHQWWKLVGLDORJER[ GRHVQRWDSSHDU Service Manual Topaz 5322 871 63606 9-14 PA 1309/10 01.05

Vision Systems DRIVER 1 Figure 9-19 Led driver board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ull Scale Figure 9-20 Forelight adjustment NOTE: Finish the adjustment within 30 seconds because the lighting level becomes lower and lower. Check the gap between dark and bright, not the absolute value. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-15

Vision Systems 9.4.4. Camera Scale Adjustment )RUDFFXUDWHUHFRJQLWLRQRIFRPSRQHQWVVXFKDV4)3 VWKHOLJKWLQJOHYHODQG WKHVFDOHRIWKHVLQJOHYLVLRQFDPHUDIL[HGFDPHUDPXVWEHDGMXVWHGFRUUHFWO\ 7KHVLQJOHYLVLRQFDPHUDVFDOHUHSUHVHQWVDQDFWXDOPHDVXUHPHQWLQXQLWVRI PLFURQVHTXLYDOHQWWRRQHSL[HO)RUDFFXUDWHUHFRJQLWLRQRIFRPSRQHQWVWKLV VFDOHPXVWEHDGMXVWHGFRUUHFWO\7RPDNHWKHDGMXVWPHQW\RXZLOOQHHGD4)3 RINQRZQVL]H Preparation for the single vision camera scale )LUVWFKHFNWKHFXUUHQWVHWWLQJVRIWKHVLQJOHYLVLRQFDPHUDVFDOH 6HOHFW$0&+B'$7$!^$6(/(&7TARGET} /"Vision Parameter" and press the [ENTER] key. &KHFNWKHVHWWLQJVRI6LQJOH&$0VFDOH :KHQ\RXH[HFXWHWKHVLQJOHFDPHUDVFDOHXWLOLW\WKH;DQG<YDOXHV PLFURQVZLOOEHDGMXVWHG <<MODE>> 3/MCH_ADJUST A377 <<<Result>>> The results of calculating the scales of the single vision camera are as follows. To save the result in memory, press the [ENTER] key (the results are... Camera Distance = 1 = 5.00 Scale_x Scale_y = = 83.33 83.97 Cam.posx= Cam.posy= 0.00 0.00 Cam.posr = 180.19 Rate = 0.9923 Figure 9-21 Camera scale parameters 3UHSDUHD4)3FRPSRQHQWWREHXVHG 8VHDUHODWLYHO\ODUJHRIWHQXVHGFRPSRQHQWRINQRZQVL]HZKLFKLV UHJLVWHUHGLQWKHFRPSRQHQWGDWDEDVH,I\RXXVHDFRPSRQHQWQRW UHJLVWHUHGLQWKHGDWDEDVHLWPXVWEHUHJLVWHUHGILUVW NOTE: Use of a QFP component is recommended since QFP s are generally superior in dimensional precision to other components, PHILIPS recommends using QFP components registered in the database, e.a."no.766; QFP100-P0.65-25.7L" or "No.767; QFP100-P0.65-24.7L". You can also use the inner QFP 68 of the glass calibration set (PA 1912/00) but this can give problems with the outer glass QFP208. &KHFNWKHUHJLVWUDWLRQGDWDLQWKHFRPSRQHQWGDWDEDVH 7RRSHQWKHFRPSRQHQWGDWDEDVHVHOHFW'$7$0!!! '$7$%$6(!$',63/$<!^$&20321(170$5.'%` &20321(17'$7$%$6(DQGSUHVVWKH>(17(5@NH\ &KHFNWKHUHJLVWUDWLRQGDWDRIWKHVHOHFWHG4)3,QSDUWLFXODUFKHFNWKDWWKHFRPSRQHQWVL]HH[DFWO\PDWFKHVWKH UHJLVWUDWLRQGDWD,IQRWWKHDGMXVWPHQWZLOOEHDERUWHG (GLW6HDUFK$UHDPPLQWKHFRPSRQHQWGDWD 'DWDUHJLVWHUHGLQWKHGDWDEDVHDVDQXPEHUODUJHUWKDQ1RFDQQRWEH HGLWHGGXHWRZULWHSURWHFWLRQ0DNHDFRS\RIWKHGDWDDVDQXPEHUVPDOOHU Service Manual Topaz 5322 871 63606 9-16 PA 1309/10 01.05

Vision Systems WKDQ1RWKHQHGLWWKLVGDWD)RULQVWDQFHWKHIROORZLQJVWHSVDUH H[SODLQHGLQFDVHVZKHUHDFRS\LVPDGHRQWRUHJLVWUDWLRQ1R 2SHQWKHVXEVFUHHQ9LVLRQIRUWKHFRPSRQHQWRIUHJLVWUDWLRQ1R (GLWWKHGDWDRQ6HDUFK$UHDPP 8VHWKHQXPHULFNH\VWRVHWWKHQRUPDOYDOXHWR PD[LPXPVHWWLQJ7KLVLVIRURIIFHQWHUSLFNXSRIWKH4)3WREH SHUIRUPHGODWHU F igure 9-22 Edit search area 6DYHWKHHGLWHGGDWD 3UHVVWKH>(6&@NH\WZLFHWKHQVHOHFW^&6$9( (;,7`DQGSUHVVWKH >(17(5@NH\ $GMXVWPHQWRIWKHFDPHUDVFDOH :KHQWKHSUHSDUDWLRQLVFRPSOHWHXVHWKHIROORZLQJSURFHGXUHWRFDOLEUDWHWKH VFDOHRIWKHVLQJOHYLVLRQFDPHUD ([HFXWHWKH6LQJOH&DP6FDOHXWLOLW\ 6HOHFW0$,17(0!!!0&+B$'-867!!%6$9( 48,7!^%$'-8677$5*(7`6LQJOH&DP6FDOHDQGSUHVVWKH >(17(5@NH\ 6HOHFW6LQJOH&DPDQGSUHVVWKH>(17(5@NH\,I\RX KDYHDGGHGDQRSWLRQDOYLVLRQFDPHUDVHOHFW6LQJOH&DPWRDGMXVWLW NOTE: Camera scale adjustment on a camera using side illumination need to be run with a part that uses the fore lighting system. If a part cannot be recognized, check the Single Cam. Scale levels in [MCH_DATA] Vision Parameter. The following numbers should be close to what the scale adjustment will find if the field of view is set correctly. Max component size X Y Lens 32mm 77.5 77 Lens 16 Table 9-2 Scale adjustments 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-17

Vision Systems Figure 9-23 Procedure of scale adjustment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ervice Manual Topaz 5322 871 63606 9-18 PA 1309/10 01.05

Vision Systems Figure 9-24 CAUTION When you use a rectangular QFP, align the long side in parallel with the X-axis. :KHQWKH4)3KDVEHHQDWWDFKHGSUHVVWKH>(17(5@NH\ &DQFHOHPHUJHQF\VWRS 5HOHDVHWKHHPHUJHQF\EXWWRQDQGSUHVVWKH>5($'<@EXWWRQRIWKH++. (QVXUHVDIHW\WKHQSUHVVWKH>(17(5@NH\DJDLQ +HDGPRYHVWRDERYHWKHVLQJOHYLVLRQFDPHUDDQGWKH4)3LVGLVSOD\HG RQWKHYLVLRQPRQLWRU7KHQR]]OHURWDWHVVRWKDWWKHFDPHUDVFDOHSRVLWLRQ DQGDQJOHDUHFDOLEUDWHGILYHWLPHV7KHUHVXOWVDUHGLVSOD\HGLQWKHXSSHU ULJKWFRUQHURIWKH9,26PRQLWRU <<MODE>> 3/MCH_ADJUST A377 <<<Result>>> The results of calculating the scales of the single vision camera are as follows. To save the result in memory, press the [ENTER] key (the results are... Camera Distance = 1 = 5.00 Scale_x Scale_y = = 83.33 83.97 Cam.posx= Cam.posy= 0.00 0.00 Cam.posr = 180.19 Rate = 0.9923 Figure 9-25 Scale parameters 3UHVVWKH>(17(5@NH\WRVDYHWKHFDOLEUDWHGUHVXOWV 3UHVVWKH>(6&@NH\LI\RXZDQWWRGLVFDUGWKHUHVXOWV 1RWHWKHFDPHUDSRVLWLRQ;<LQWKHUHVXOWV :KHQWKH&DPSRV[DQG&DPSRV\YDOXHVDUHQHDUO\]HUR WKHFDOLEUDWLRQLVVDWLVIDFWRU\3UHVVWKH>(6&@NH\WRDGYDQFHWRWKHQH[W 6WHS,IWKH&DPSRV[DQG&DPSRV\YDOXHVDUHWRRIDUIURP]HURWKHUHLV OLNHO\DQHUURULQWKHFDOLEUDWLRQ3UHVVWKH>(17(5@NH\WRUHWU\FDOLEUDWLQJ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-19

Vision Systems NOTE: Verify the Cam.posx and Cam.posy values to be 0.00 by running the scale utility again. One of the most important items of camera scale is that these values go to zero and are stabile. If the position move by.05 or more with each run of scale then a mechanical problem exists (loose elements in the lens or lens that is loose on the camera). :KHQWKHFDOLEUDWLRQLVFRPSOHWHGXPSWKHFRPSRQHQW 3UHVVWKH>(17(5@NH\WRGXPSWKHFRPSRQHQWDXWRPDWLFDOO\,I\RXZDQWWRTXLWZLWKRXWGXPSLQJSUHVVWKH>(6&@NH\DQGIROORZWKH PHVVDJHRQWKHRSHUDWLRQPRQLWRU 6DYHWKHFDOLEUDWLRQGDWD 6HOHFW^%6$9('$7$`RU^%6$9( 48,7`DQGSUHVVWKH>(17(5@ NH\7RTXLWZLWKRXWVDYLQJVHOHFW^%5(&29(5$'-867`RU ^%48,7`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amera Optical Axis Angle Adjustment Introduction 7KH&DPHUDRSWLFDOD[HVDQJOHDGMXVWPHQWLVDSURFHGXUHWKDWDOORZVIRUWKH PHDVXUHPHQWRIWKHUHODWLRQVKLSEHWZHHQWKHFDPHUDVRSWLFDOD[LVDQGWKH= D[LVPRYHPHQWRIWKHKHDGRU6SLQHDVVHPEO\,WFDQEHXVHGRQWKH7RSD]ZLWK DQDGGLWLRQDOVLQJOHFDPHUD 7KLVUHODWLRQVKLSSOD\VDQLPSRUWDQWUROHLQWKHSODFHPHQWDFFXUDF\EHWZHHQ 4)3DQG)LQH0RGHDQGEHFRPHVPRUHVLJQLILFDQWZKHQRUPRUHVLQJOH FDPHUDVDUHXVHG Service Manual Topaz 5322 871 63606 9-20 PA 1309/10 01.05

Vision Systems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easurement Principles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ingle Camera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ervice Manual Topaz 01.05 PA 1309/10 9-21

Vision Systems Line Array Camera 8QOLNHWKHVLQJOHFDPHUDWKHOLQHDUUD\FDPHUDGRHVQRWUHTXLUHDQH[WHUQDO SURJUDP7KHVWDQGDUGFDPHUDVFDOHXWLOLW\DYDLODEOHLQ>0DFKLQH$GMXVW@LV XVHG7KHKHDGDVVHPEO\LVUDLVHGDQGORZHUHGGXULQJWKHXWLOLW\7KH FRPSRQHQWLVPHDVXUHGDWVHYHUDODQJOHVDQGSRVLWLRQVDERYHWKHFDPHUD7KH UHVXOWVDUHGLVSOD\HGLQDWDEOHDWWKHFRPSOHWLRQRIWKHVFDOHPHDVXUHPHQW7KLV WDEOHFRQWDLQVWKHFDPHUDVFDOHUDWHDQGKHDGGHOWDLQIRUPDWLRQ7KHFDPHUD V SRVLWLRQDQGDQJOHDUHLQGLFDWHGE\WKHFDPHUDGHOWDRUFDPHUDFRUUHFWLRQ LQIRUPDWLRQ&$0&25 Required Tools and Supplies 6TXDUHVKDSHG4)3UHFRPPHQGHGIRUVLQJOHFDPHUDDOLJQPHQW 7KLQVKLPVUDQJLQJIURPPPWRPP $OOHQZUHQFKHV Single Camera Adjustment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µDQGVHOHFW&175/(17(5! F 6HOHFW&KDQJH3URJUDPDQGILOHQDPH G 6HOHFW)WRLQLWLDWH7KHSURJUDPZLOOQHHGDERXWVHFRQGVWRORDG 6HOHFW0DFKLQHW\SH 7RSD] (PHUDOG(FOLSVH 6HOHFW3LFNXSFRPSRQHQW 6HOHFW&DPHUD3RVLWLRQ &RPSRQHQW'%QR 'DWD%DVHQXPEHU &RPSRQHQW'%QR &RPSRQHQW+HLJKW &RPSRQHQW= $GGPPLI\RXDUHXVLQJDW\SHQR]]OH /LJKWLQJ/HYHO /HYHOIURPFRPSRQHQWYLVLRQILOH +RZPDQ\7LPHV 1XPEHURIWLPHVWRUHFRJQL]HWKH FRPSRQHQWDWDOODQJOHVDWHYHU\= UHIHUHQFHSRVLWLRQLVVXIILFLHQWLI\RX KDYHDOOGD\ Service Manual Topaz 5322 871 63606 9-22 PA 1309/10 01.05

Vision Systems $GMXVW&RPSRQHQW5 6HOHFW12\HVZLOOFDXVHD)LQHPRGHW\SH RIDGMXVWPHQW7KHFRPSRQHQWVDQJOHZLOO EHYHULILHGDQGFRUUHFWHGSULRUWRHDFK;< PHDVXUHPHQW +HLJKW5DQJHIURP 6HOHFW² 'RQRWIRUJHWWKHGHFLPDOSRLQW +HLJKW5DQJHWR 6HOHFW 'RQRWIRUJHWWKHGHFLPDOSRLQW +RZPDQ\6WHSV LVUHFRPPHQGHG $VWKHSURJUDPUXQVWKHKHDGVWDUWVLQWKHWRSPRVWSRVLWLRQDQGPRYHVGRZQ WKURXJKRXWWKHFDPHUD VILHOGRIYLHZ,IWKHYLVLRQV\VWHPIDLOVWRUHFRJQL]HWKHFRPSRQHQWWRRPDQ\WLPHVWKH SURJUDPZLOOGLVSOD\WKH6RIW/LPLW2YHU(UURUPHVVDJH,IWKLVRFFXUV9HULI\ WKH6HDUFKDUHDLVDQGFRPSRQHQWIRFXVLVJRRG Evaluating the Results $IWHUWKHSURJUDPFRPSOHWHVWKHPHDVXUHPHQWDWDEOHRIUHVXOWVZLOOEH GLVSOD\HGRQWKH9,26PRQLWRU 7KHGDWDLQWKHWDEOHLVSUHVHQWHGLQDIRUPDWWKDWUHSUHVHQWVDGRZQZDUG PRYHPHQWRIWKHVSOLQHEHJLQQLQJDWPPDERYHWKHUHFRJQLWLRQKHLJKWWRD SRLQWPPEHORZ,QWKLVWDEOHWKHWRWDOGHYLDWLRQIRUHDFKD[LVVKRXOGQRW H[FHHGPLFURQVPP ([DPSOHRIWKHUHVXOWVWDEOH REC.Height = -2.0 Camera Pos X = 320.467 Y = 140.295 REC.Height = -1.6 Camera Pos X = 320.463 Y = 140.287 REC.Height = 0.0 Camera Pos X = 320.460 Y = 140.281 REC.Height = 1.6 Camera Pos X = 320.457 Y = 140.273 REC.Height = 2.0 Camera Pos X = 320.452 Y = 140.266 Figure 9-26,IWKHGHYLDWLRQH[FHHGVPPSHUPPLWLVUHFRPPHQGHGWKDW\RXVDYHWKH GDWDWRDIORSS\DQGXVHWKH([FHO7HPSODWHWRGHWHUPLQHWKHFDPHUDSRVLWLRQ $V\RXPDNHDGMXVWPHQWVWKHWHPSODWHZLOOSURYLGHKLVWRU\GDWDWKDWLVYHU\ XVHIXOWRYLVXDOO\LQWHUSUHWWKHDPRXQWDQGGLUHFWLRQRIFRUUHFWLRQ\LHOGHGE\ HDFKDGMXVWPHQW 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-23

Vision Systems 3ODFHDIORSS\LQWKH$GULYHZKHQSURPSWHGWRVDYHWKHGDWD 5XQWKH&DPBSRV[OVDQGLPSRUWWKHLQIRUPDWLRQLQWRWKLVSURJUDPE\ FOLFNLQJRQWKH>D?UHVXOWVGDW@EXWWRQ 2EVHUYHWKHYDOXHRIWKHQXPEHUVWRWKHULJKWRIWKHGHFLPDOSRLQW7KH QXPEHUVVKRXOGLQFUHDVHRUGHFUHDVHXQLIRUPO\,IWKHQXPEHUVLQGLFDWHD VXGGHQULVHRUIDOORIRUPRUHUXQWKHSURJUDPDJDLQWRYHULI\UHVXOWV,IWKHGHYLDWLRQUHWXUQVRULIPHDVXUHPHQWVVHHPUDQGRPFKHFNWKHVSOLQH VKDIWQR]]OHKROGHUFDPHUDOHQVDQGWKHYLVLRQILOH$VPDOOULVHDQGIDOOLQ WKHYDOXHVLVSHUIHFWO\DFFHSWDEOHDQGZLOOEHDQRUPDOLQGLFDWLRQ,WLVRQO\ LPSRUWDQWWKDWWKHRYHUDOOGHYLDWLRQUHPDLQZLWKLQWKHSHUPP WROHUDQFH,IQRWFDUU\RXWWKHIROORZLQJVWHSV Œ,IWKH<D[LVGHYLDWHVQHJDWLYHWRSRVLWLYH/5WKHQWKHWRSRIWKH FDPHUDPXVWPRYHWRZDUGVWKHUHDURIWKHPDFKLQH$VKLPPXVWEH SODFHGEHWZHHQWKHFDPHUDERG\DQGDGDSWHUSODWHVHHILJXUH Œ,IWKH;D[LVGHYLDWHVSRVLWLYHWRQHJDWLYHWKHQURWDWHWKHWRSRIWKH FDPHUDLQWKHGLUHFWLRQRIPDFKLQHRULJLQLWPD\EHQHFHVVDU\WRUHPRYH WKHFDPHUDDQGUHDOLJQWKHDGDSWHUSODWHWRWKHFDPHUD $IWHUDFRUUHFWLRQLVPDGHDQHZVFDOHPHDVXUHPHQWPXVWEHSHUIRUPHG EHIRUHWKH5(&&20FRPPDQGFDQEHUHSHDWHG REMARK: Sometimes it can be the case that the bolts (M3x10) holding the lighting unit are too long and as such protruding through the camera stand pressing against the camera bracket. This can cause a tilted camera body. Adding some washers between the bolt and camera stand can prevent it. Placing a shim above the screw will tilt camera towards the front rail. =Y positive movement. Placing a shim below the screw will tilt camera Away from the front rail. =Y negative movement. Rotate the adater plate against the camera for large movements. Rotate the adapter plate on the camera stand for small movements. Figure 9-27 Service Manual Topaz 5322 871 63606 9-24 PA 1309/10 01.05

Vision Systems 9.5. 9.5.1. 9.5.2. Line Array Camera Adjustment 7KLVVHFWLRQGHVFULEHVWKHFDOLEUDWLRQRIWKHOLQHDUUD\FDPHUDV Maximum Component Size and Field Of View 7KLVSURFHGXUHH[SODLQVKRZWRDGMXVWWKHPD[LPXPFRPSRQHQWVL]H)LHOG2I 9LHZ7KHILHOGRIYLHZLVHYHU\WKLQJWKHFDPHUDFDQUHFRJQL]H VHHµRQLWVIRFDO SODQH7KHPD[LPXPFRPSRQHQWLVDOZD\VVPDOOHUWKDQWKH)LHOG2I9LHZDQGLV WKH)29PLQXVWKHGHYLDWLRQRIWKHOHQVERUGHUVRWKHVL]HZLWKLQWKH)29LQ ZKLFKDFRPSRQHQWFDQEHUHFRJQL]HGZLWKRXWSUREOHPV 0HDVXUHWKH)LHOG2I9LHZE\PHDQVRIDSODVWLFUXOHU$WWDFKWKHUXOHULQVXFKD ZD\WKDWWKHUXOHULVYLVLEOHLQ;GLUHFWLRQ(DVW:HVWGLUHFWLRQRQWKHVFUHHQDV WKH;GLUHFWLRQLVDIL[HGYDOXHRI7KH)LHOG2IYLHZGHSHQGVRQWKHKHLJKW RIWKHOLQHDUUD\FDPHUDDVZHOODVWKHXVHGOHQVDQGH[WHQVLRQULQJ$GMXVWWKH )29WRPP Adjusting the Focus and Aperture 7RDGMXVWWKHIRFXVDQGDSHUWXUHDVSHFLDOIRFXVDGMXVWHUWRRO LVQHFHVVDU\)ROORZWKHVWHSVEHORZ 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGSUHSDUHIRUDGMXVWPHQW l /RRVHQWKHVHWVFUHZVRIWKHDSHUWXUHULQJDQGOHQVKROGHU l 3UHSDUHWKHOLJKWDGMXVWHUWRRO Focus ring Aperture ring Knurled ring (complete lens) Figure 9-28 ([HFXWHWKHOLQHDUUD\FDPHUD )RFXVDQG,ULVµFRPPDQG l 6HOHFW%$GMXVWWDUJHW0XOWLFDPHUD)RFXV,ULV!DQGSUHVVWKH (QWHU!NH\ l 6HOHFW 8VHµIRUWKHVSHFLDOWRRO l 6HOHFWWKHFDPHUDWREHDGMXVWHG $WWDFKWKHIRFXVDGMXVWHUWRROWRKHDGDVIROORZV l $WWDFKDW\SHQR]]OHWRKHDG LIGRQHE\KDQGSUHVVWKH HPHUJHQF\EXWWRQSULRUWRWKLV DFWLRQ l &KHFNWKDWWKHHPHUJHQF\ EXWWRQLVSUHVVHG Figure 9-29 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-25

Vision Systems 4. &DQFHOWKHHPHUJHQF\VWRS (QVXUHVDIHW\UHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH5HDG\! EXWWRQRQWKH+DQGKHOGNH\ERDUG 5. (QVXUHVDIHW\DQGSUHVVWKH(QWHU!NH\DJDLQ 7KHKHDGDVVHPEO\PRYHVDQGSDVVHVUHSHDWHGO\RYHUWKHOLQHDUUD\FDPHUD ZKLOHWKHLPDJHRIWKHIRFXVDGMXVWHUWRRODQGLWVLQWHQVLW\SURILOHLV GLVSOD\HGRQWKHYLVLRQPRQLWRU 6. $GMXVWWKH)RFXVDQGDSHUWXUH %\URWDWLQJWKHDSHUWXUHDQGIRFXVE\PHDQVRIWKHOHQVKROGHUWKHRSWLPXP LPDJHLQDVFDOHUDQJHRI²WRDVVKRZQLQWKHILJXUHPXVWEHIRXQG LEVEL:80 Figure 9-30 2QHZD\RISHUIRUPLQJWKLVDGMXVWPHQWLVIROORZLQJ l 2SHQWKHDSHUWXUHIRUPD[LPXPOLJKWZLWKDPLQLPXPGHSWKRIILHOG ERWWRPOHQVULQJDQGVHWWKHIRFXVULQJXSSHUOHQVULQJWR²<RX ZLOORQO\VHHRQHSHHNRQWKHVFUHHQURWDWHWROHQVKROGHUFRPSOHWH OHQVXSGRZQWRVKLIWWKLVSHHNWRWKH µydoxhrqwkhdgmxvwhuwrro l $GMXVWWKHDSHUWXUHFORVHLWWRLQFUHDVHWKHGHSWKRIILHOGWRWKHVFDOH YDOXHRI²WRRQWKHDGMXVWHUWRRO l,ilwlvqrwsrvvleohwrdgmxvwlwlqwklvzd\wkhfdxvhpd\ehwkh DPRXQWRIOLJKWPLJKWZKLFKLVWRRPXFKRUWRRORZ7U\FORVLQJWKH DSHUWXUHDOLWWOHRULIWKLVZLOOQRWZRUNLQFUHDVHWKHOLJKWLQJLQWHQVLW\ RQWKH/('GULYHUERDUGVHHQH[WSDUDJUDSK l,qfdvhriwzrolqhduud\fdphudvwu\wrrewdlqwkhvdpholjkwlqjohyho RQERWKIURQWDQGUHDUFDPHUD WARNING The head assembly passes repeatedly over the multi-vision camera during the adjustment. Be extremely careful not to touch the head with your body! 7. 3UHVVWKH(QWHU!RUWKH(VF!NH\ZKHQWKHDGMXVWPHQWLVFRPSOHWH )ROORZWKHPHVVDJHVGLVSOD\HGRQWKHRSHUDWLRQPRQLWRU7KHUHLVQR PDFKLQHGDWDWKDWQHHGVWREHVDYHGDIWHUWKLVDGMXVWPHQW Service Manual Topaz 5322 871 63606 9-26 PA 1309/10 01.05

Vision Systems 8. 7LJKWHQWKHVHWVFUHZV l 3UHVVHPHUJHQF\DQGUHPRYHWKHDGMXVWHUWRROIURPKHDG l 7LJKWHQWKHVFUHZVQRWWRRWLJKWRIWKHDSHUWXUHDQGOHQVKROGHU 5HFKHFNWKHIRFXVDIWHUWLJKWHQLQJ 9.5.3. Adjusting the Lighting Level of the Line Array Camera(s) 7RDGMXVWWKHOLJKWLQJOHYHORIWKHOLQHDUUD\FDPHUDV\RXZLOOQHHGWKHVSHFLDO OLJKWDGMXVWHUSODWH7KHOLJKWLQJOHYHOLVDGMXVWHGRQWKH /('GULYHUERDUGORFDWHGRQWKHOHIWVLGHRIWKH0&;FRQWUROOHUZKLOHDQ LPDJHLVGLVSOD\HGRQWKHPRQLWRUSURFHHGDVIROORZV ([HFXWHWKH 0XOWLFDPHUD%ULJKWQHVVOHYHOµ l ([HFXWHWKHPXOWLFDPHUD%$GMXVWWDUJHW0XOWLFDPHUD %ULJKWQHVV!DQGSUHVVWKH(QWHU!NH\ l 6HOHFW JRLQJRQDQGRIIµIURPWKH/('W\SHER[ l 6HOHFW 8VHµIURPWKHVSHFLDOWRROER[ l 6HOHFWWKHFDPHUDWREHDGMXVWHG 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGDWWDFKWKHOLJKWDGMXVWHUSODWHWRKHDG $WWDFKWKHOLJKWDGMXVWHUSODWHWRKHDGZLWKWKHWZRWRQHVXUIDFHIDFLQJ GRZQ2ULHQWDWLRQRIWKHOLJKWDGMXVWHUSODWHPXVWEHVXFKWKDWWKH ERXQGDU\OLQHEHWZHHQWKHWZRWRQHVLVVHWKRUL]RQWDORQWKHVFUHHQ Figure 9-31 &DQFHOWKHHPHUJHQF\VWRS (QVXUHVDIHW\WKHQUHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH5HDG\! EXWWRQRQWKH++. (QVXUHVDIHW\WKHQSUHVVWKH(QWHU!NH\DJDLQ7KHKHDGDVVHPEO\PRYHV UHSHDWHGO\RYHUWKHPXOWLYLHZFDPHUDZKLOHWKHLPDJHRIWKHOLJKWDGMXVWHU SODWHLVGLVSOD\HGRQWKHYLVLRQPRQLWRU OHYHOV Figure 9-32 Full Scale $GMXVWWKHQRQFRD[LDOOLJKWOHYHO 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-27

Vision Systems 2SHQWKHORZHUULJKWFRYHUGRRURIWKHPDFKLQHDQG\RXZLOOVHHWKH/(' GULYHUERDUG7XUQWULPPHU95IRUOLQHDUUD\FDPHUDDQG95IRU FDPHUDLQVXFKDZD\WKDWWKHEULJKWQHVVGLIIHUHQFHEHWZHHQWKHWZRWRQHV LVVHWWRRQHVFDOHOHYHOV,I\RXUPDFKLQHKDVWZROLQHDUUD\FDPHUDV SHUIRUPWKHVDPHDGMXVWPHQWIRUERWKFDPHUDV 3UHVVWKHHPHUJHQF\EXWWRQDQGLQYHUWWKHOLJKWDGMXVWHUSODWH 7XUQWKHOLJKWDGMXVWHUSODWHXSVLGHGRZQDQGUHDWWDFKLWWRKHDGWKH ZKLWHVXUIDFHIDFLQJGRZQ &DQFHOWKHHPHUJHQF\VWRSDQGSUHVVWKH(QWHUNH\ 2QO\WKHFRD[LDOOLJKWWXUQVRQDQGWKHDYHUDJHEULJKWQHVVOHYHOLVGLVSOD\HG RQWKHXSSHUULJKWFRUQHURIWKHRSHUDWLRQPRQLWRU $GMXVWWKHFRD[LDOOLJKWOHYHO 7XUQWKHWULPPHU95IRUOLQHDUUD\FDPHUDDQG95IRUFDPHUDLQ VXFKDZD\WKDWWKHDYHUDJHEULJKWQHVVOHYHOEHFRPHV NOTE: If the average light level cannot be set to 30 the lens aperture may be incorrect. Readjust the lens aperture as explained in previous sections. 3UHVVWKH(QWHURU(VFNH\ZKHQWKHDGMXVWPHQWLVFRPSOHWH )ROORZWKHPHVVDJHVGLVSOD\HGRQWKHPRQLWRUWKHUHLVQRPDFKLQHGDWDWR EHVDYHG 9.5.4. Adjusting the Line Array Camera Scale 7KHOLQHDUUD\FDPHUDVFDOHUHSUHVHQWVDQDFWXDOPHDVXUHPHQWLQPLFURQV HTXLYDOHQWWRRQHSL[HO7KLVVFDOHPXVWEHFDOLEUDWHGFRUUHFWO\IRUDFFXUDWH UHFRJQLWLRQRIFRPSRQHQWV 7RFDOLEUDWHWKHFDPHUDVFDOH\RXZLOOQHHGD623RINQRZQVL]H:KHQ\RX H[HFXWHWKHDGMXVWPHQWXWLOLW\GHVFULEHGEHORZWKHVFDOHLVFDOLEUDWHG DXWRPDWLFDOO\DQGDWWKHVDPHWLPHWKH;<SRVLWLRQVDQGLQVWDOODWLRQDQJOH5RI WKHOLQHDUUD\FDPHUDDQGLQWKH &DPHUD&RRUGLQDWHµPDFKLQHGDWDDUH DGMXVWHGDOVR Setting up for the line array camera %HIRUH\RXEHJLQWKHFDOLEUDWLRQFKHFNWKHFXUUHQWFDPHUDVFDOHVHWWLQJVDQG SUHSDUHWKHFRPSRQHQWDQGQR]]OHDVGHVFULEHGEHORZ &KHFNWKHFXUUHQWVHWWLQJVRIWKHFDPHUDVFDOH l 6HOHFW$6HOHFWWDUJHW9LVLRQSDUDPHWHU!DQGSUHVV(QWHU! l &KHFNWKHVHWWLQJVRIWKH0XOWLFDPRUVFDOH:KHQ\RXH[HFXWH WKH 0XOWLFDPHUDFDPHUDVFDOHµFRPPDQGH[SODLQHGODWHUWKH;< YDOXHVZLOOEHFDOLEUDWHG Service Manual Topaz 5322 871 63606 9-28 PA 1309/10 01.05

Vision Systems <<<APPLICATION>>> 3/MAINTE/M <<MODE>> 2/MCH_DATA Editing Object Vision Parameter Object X Y Z R M-CAM 1 Delta pos. A 60.03 70.05 Figure 9-33 3UHSDUHDFRPSRQHQWWREHXVHGDVDUHIHUHQFH 8VHDUHODWLYHO\ODUJHSRSXODU4)3RINQRZQVL]HZKLFKLVUHJLVWHUHGLQWKH FRPSRQHQWGDWDEDVH,I\RXKDYHQR623DYDLODEOH\RXFDQXVHFKLS FDSDFLWRUVVXFKDVD&LI\RXXVHDFRPSRQHQWWKDWLVQRWUHJLVWHUHG LQWKHGDWDEDVHLWPXVWEHUHJLVWHUHG (GLW VHDUFKDUHDPPµLQWKHFRPSRQHQWGDWD 'DWDUHJLVWHUHGLQWKHGDWDEDVHDVDQXPEHUODUJHUWKDQFDQQRWEH HGLWHGGXHWRZULWHSURWHFWLRQ0DNHDFRS\RIWKHGDWDDVDQXPEHU VPDOOHUWKDQDQGHGLWWKLVGDWD)ROORZLQJLVDQH[DPSOHRIWKLV l l l 2SHQWKH9LVLRQVXEZLQGRZRIWKHFRPSRQHQWUHJLVWUDWLRQ1R (GLWWKH6HDUFKDUHDSDUDPHWHU8VHWKHQXPEHUNH\ VWRFKDQJHWKH QRUPDOYDOXHWRPD[VHWWLQJ7KLVLVWRHQDEOHRIIFHQWHUSLFNXS RIWKH623WREHSHUIRUPHGODWHURQ 6HWWKHWUD\IHHGHUSDUDPHWHULQWKH8VHU,WHPZLQGRZWR 7UD\µ7KH VXEZLQGRZVZLWFKHVE\SUHVVLQJWKH)NH\ 6DYHWKHHGLWHGGDWD3UHVVWKH (VFµNH\WZLFHWKHQVHOHFW&6DYH ([LW!DQGSUHVVWKH(QWHU!NH\ 3UHVVWKHHPHUJHQF\VWRSEXWWRQDQGDWWDFKDQR]]OHWRKHDG $WWDFKDQR]]OHIRU623W\SHWRKHDG ([HFXWHWKHDGMXVWDVVLVWDQWWRFKHFNWKDWWKHFRPSRQHQWLVUHFRJQL]HG )RUGHWDLOVRQWKHDGMXVWDVVLVWDQWUHIHUWRWKHXVHUPDQXDOLIQHFHVVDU\ LQFUHDVHWKHVHDUFKDUHDYDOXH Adjusting the line array camera scale :KHQWKHSUHSDUDWLRQLVFRPSOHWHDGMXVWWKHVFDOHRIWKHOLQHDUUD\FDPHUDZLWK WKHSURFHGXUHEHORZ &DQFHOWKHHPHUJHQF\VWRS (QVXUHVDIHW\DQGUHOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVV5HDG\!RQ WKH++. ([HFXWHWKH 0XOWLFDPHUDµFRPPDQG l 6HOHFW%DGMXVWWDUJHW0XOWLFDPµ!DQGSUHVV(QWHU! l 6HOHFW FDPHUDVFDOHµDQGSUHVV(QWHU! l 6HOHFWWKHFDPHUDWREHDGMXVWHGDQGSUHVV(QWHU! &RQILUPWKDW 'LVWDQFHPPµLVGLVSOD\HGDQGSUHVV(QWHU! 1RUPDOO\DPRYLQJGLVWDQFHRIPPLVUHFRPPHQGHG (QWHUWKHFRPSRQHQWGDWDEDVH1RDQGSUHVVWKH(QWHU!NH\ 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-29

Vision Systems (QWHUWKHGDWDEDVHQRRIWKHFRPSRQHQW\RXKDYHSUHSDUHG A540 To return to the command menu... Distance (mm) 5 A461 Enter the component database number... Database No. 6 A466 The specified component uses... A303 CAUTION! The axes will move. A373 Please pick up the specified component with the specified head, or... Figure 9-34 (QVXUHVDIHW\DQGSUHVVWKH(QWHU!NH\WZLFH 7KHKHDGDVVHPEO\PRYHVWRDSRLQWZKHUHKHDGLVUHDG\WRSLFNXSD FRPSRQHQW 3UHVVWKHHPHUJHQF\VWRSEXWWRQWKHQDWWDFKWKHFRPSRQHQWWRKHDG $WWDFKWKHFRPSRQHQWWRWKHQR]]OHRIKHDGZLWKWKHFRPSRQHQWFHQWHU VOLJKWO\VKLIWHG Figure 9-35 CAUTION When using a SOP component, attach it to the nozzle with the component center slightly shifted. Align the long side parallel to the X-axis. Service Manual Topaz 5322 871 63606 9-30 PA 1309/10 01.05

Vision Systems :KHQWKHFRPSRQHQWKDVEHHQDWWDFKHGSUHVVWKH(QWHU!NH\ &DQFHOWKHHPHUJHQF\VWRS 5HOHDVHWKHHPHUJHQF\VWRSEXWWRQDQGSUHVVWKH5HDG\!EXWWRQRIWKH++. (QVXUHVDIHW\DQGSUHVV(QWHU!DJDLQ 7KHKHDGDVVHPEO\SDVVHVUHSHDWHGO\RYHUWKHOLQHDUUD\FDPHUDDQGWKH FDPHUDVFDOHLVFDOLEUDWHG7KHUHVXOWVDUHWKHQGLVSOD\HGRQWKHXSSHU ULJKWRIWKHRSHUDWLRQPRQLWRU <<<APPLICATION>>> <MODE>> A542 <<<Result>>> The results of calculating the scales of the multi-vision camera are as follows. 3/MAINTE/M 3/MCH_ADJUST Camera = 1 Distance = 5.00 Scale_x Scale_y = 58.59 = 73.28 Cam.posx= 328.96 Cam.posy= 111.88 Cam.posr = 0.03 Div_x Div_y = = 0.00 0.43 Cam.corx = Cam.cory = -1.80 1.48 Rat = 0.5969 Figure 9-36 3UHVVWKH(QWHU!NH\WRVDYHWKHFDOLEUDWHGUHVXOWV 3UHVVWKH(VF!NH\LI\RXZDQWWRFDQFHOWKHUHVXOWV7KHQSURFHHGWRWKH QH[WVWHSWRFDOLEUDWHWKHVFDOHRIWKHOLQHDUUD\FDPHUD:KHQ\RXU PDFKLQHLVQRWHTXLSSHGZLWKDOLQHDUUD\FDPHUDDGYDQFHWRVWHS 1H[WFDOLEUDWHWKHVFDOHRIWKHVHFRQGRSWLRQDOOLQHDUUD\FDPHUD :LWKWKHFRPSRQHQWVWLOOSLFNHGXSE\KDQGH[HFXWHWKH 0XOWL&DPHUDµ FRPPDQGDJDLQDVLQVWHSDQGVHOHFW 0XOWL&DPµ NOTE: In case of two line array cameras the difference in Cam Co-ordinate X and Y parameters between the two cameras should be within 10. If this difference exceeds 10 an error message window appears as shown below. The advise is to make fine adjustments to the installation of camera 2 as described below, the procedure to adjust the camera optical axis might also be very useful to check in this case, see the end of this chapter. <<MODE>> 3/MCH_ADJUST A711 MultiCam2 Position Error Position(angle) of MltCam2 is not correct. Please adjust position of MltCam2 as difference between [MltCam1 Cam.cor] and [MltCam Cam.cor] is less than "10.0". Adjusting method is shown in next display. Please press [Enter] key. Cam. cor X MaltCam1 : -18.61 MaltCam2 : 0.00 Figure 9-37 A712 Adjusting Method of MltCam2 When you see the machine from front, 1.if you tilt MltCam to right direction, value of [Cam.cor X] is decreasing. 2.if you tilt MltCam to front direction, value of [Cam.cor Y] is decreasing. (Caution) Please move only Mltcam2. Please don't move MltCam1. Please press [Enter] key to stop this adjustment. Cam. cor X MaltCam1 : -18.61 MaltCam2 : 0.00 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-31

Vision Systems Figure 9-38 l 7RDGMXVWWKH&DPFRRUG;ORRVHQWKHEROWVHFXULQJWKHFDPHUDVWD\WR WKHFDPHUDVWDQGWKHQPDNHWKHILQHDGMXVWPHQWVWRWKHFDPHUD LQVWDOODWLRQDQJOH5HWLJKWHQWKHEROWWRVHFXUHWKHFDPHUD l 7RDGMXVWWKH&DPFRRUG<ORRVHQWKHEROWVVHFXULQJWKHFDPHUDVWD\ DQGLQVHUWDVKLPRIPPEHWZHHQWKHVWD\DQGFDPHUD7KHQ UHWLJKWHQWKHEROWVWRVHFXUHWKHFDPHUD,QHLWKHUFDVHDGMXVWWKH FDPHUDLQVWDOODWLRQLQWKH$GLUHFWLRQZKHQLQFUHDVLQJWKH&DPFRRUG ;<YDOXHVDQGLQ%GLUHFWLRQZKHQUHGXFLQJWKHP Multi-camera 2 Camera stay Adjusting cam coor. X A Camera stand B Adjusting cam coor. Y (insert a shim) :KHQWKHFDOLEUDWLRQLVFRPSOHWHGXPSWKHFRPSRQHQW 3UHVVWKH(QWHU!NH\WRGXPSWKHFRPSRQHQWDXWRPDWLFDOO\,I\RXZDQWWRTXLWZLWKRXWGXPSLQJSUHVVWKH(VF!NH\DQGIROORZWKH PHVVDJHRQWKHRSHUDWLRQPRQLWRU 6DYHWKHFDOLEUDWHGGDWD 6HOHFW%6DYHGDWD!RU%6DYH 4XLW!DQGSUHVVWKH(QWHU!NH\ WRTXLWZLWKRXWVDYLQJVHOHFW%RU% 5HWXUQWKHHGLWHGGDWDWRWKHRULJLQDOVHWWLQJ 5HWXUQWKHHGLWHGGDWDWRWKHRULJLQDOVHWWLQJDVQHVVHFDU\,I\RXZDQWWR NHHSWKLVHGLWHGGDWDLWLVDGYLVDEOHWRHQWHUDSURSHUFRPPHQW Service Manual Topaz 5322 871 63606 9-32 PA 1309/10 01.05

Vision Systems 9.5.5. Adjusting the Dual Recognition Offset 7KHOLQHDUUD\FDPHUDFDQUHFRJQL]HFRPSRQHQWVWUDYHOOLQJIURPOHIWWRULJKW DQGULJKWWROHIW7KLVUHFRJQLWLRQRIIVHWEHWZHHQWKHERWKGLUHFWLRQVLV LQGLFDWHGE\WKHSDUDPHWHU 'XDO5HF2IIVHWµLQWKHSRVLWLRQSDUDPHWHUVDQG PXVWEHDGMXVWHGFRUUHFWO\IRUDFFXUDWHPRXQWLQJ,WLVUHFRPPHQGHGWKDW\RX XVHD623VXFKDVWKRVHXVHGLQFDPHUDVFDOHDGMXVWPHQW $WWDFKDQ623WRKHDG 3UHVVWKHHPHUJHQF\EXWWRQDQGDWWDFKDQ623QR]]OHW\SHWRKHDG &DQFHOHPHUJHQF\ (QVXUHVDIHW\DQGUHOHDVHWKHHPHUJHQF\EXWWRQDQGSUHVV5HDG\! ([HFXWHWKH0XOWLFDPHUDXWLOLW\ l 6HOHFW%DGMXVWWDUJHWPXOWLFDPHUDµDQGSUHVVWKH(QWHU!NH\ l 6HOHFW 'XDOUHF2IIVHWµDQGSUHVVWKH(QWHU!NH\ l 6HOHFW 0XOWLFDPµDQGSUHVV(QWHU!,I\RXUPDFKLQHLVHTXLSSHGZLWKDQRSWLRQDOPXOWLYLVLRQFDPHUDDQG \RXDUHPDNLQJDGMXVWPHQWVWRLWVHOHFWWKHFRUUHFWFDPHUDQXPEHU (QWHUWKHFRPSRQHQWGDWDEDVHQRDQGSUHVV(QWHU! +HUHHQWHUWKHGDWDEDVHQXPEHURIWKH4)3\RXKDYHSUHSDUHG (QVXUHVDIHW\DQGSUHVV(QWHU!WZLFH 7KHKHDGDVVHPEO\PRYHVWRDSRLQWZKHUHKHDGLVUHDG\WRSLFNXSWKH FRPSRQHQW 3UHVVHPHUJHQF\DQDWWDFKDQ623WRKHDGE\KDQG :KHQXVLQJDUHFWDQJXODU623DOLJQWKHORQJVLGHLQSDUDOOHOZLWKWKH ;D[LV:KHQWKH623KDVEHHQDWWDFKHGSUHVV(QWHU! Figure 9-37 &DQFHOHPHUJHQF\ 5HOHDVHWKHHPHUJHQF\EXWWRQDQGSUHVVWKH5HDG\!EXWWRQRQWKHKDQG KHOGNH\ERDUG (QVXUHVDIHW\DQGSUHVV(QWHU!DJDLQ 7KHKHDGDVVHPEO\SDVVHVUHSHDWHGO\RYHUWKHPXOWLFDPHUDDQGWKHGXDO UHFRJQLWLRQRIIVHWLVPHDVXUHG7KHUHVXOWVDUHGLVSOD\HGLQWKHXSSHUULJKW FRUQHURIWKHRSHUDWLRQPRQLWRU 3UHVV(QWHU!NH\WRVDYHWKHUHVXOWV 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-33

Vision Systems 3UHVV(VF!LI\RXZDQWWRFDQFHOWKHUHVXOWV :KHQWKHPHDVXUHPHQWLVFRPSOHWHGXPSWKHFRPSRQHQW 6DYHWKHUHVXOWV 6HOHFW%6DYHGDWD!RU%6DYHDQG4XLW!DQGSUHVV(QWHU! 4XLWZLWKRXWVDYLQJE\PHDQVRI%RU% 9.5.6. Replacement of the Line Array Camera :KHQUHSODFLQJDQHZOLQHDUUD\FDPHUDLQWRWKHV\VWHPRQHVKRXOGWDNHFDUHWKH FDPHUDLVPRXQWHGFRUUHFWO\)LJXUHVKRZVWKHZD\WKHFDPHUDVVKRXOGEH PRXQWHGLQWRWKHV\VWHPVHHQIURPWKHIURQWVLGHRIWKHV\VWHP Figure 9-38 Multi-camera 1 and 2 positions )RUERWKWKHIURQWDQGUHDUOLQHDUUD\FDPHUDWKHOLQHDUUD\FDPHUDLVWKHVDPH 7KHGLIIHUHQFHLVWKHZD\RIPRXQWLQJWKHEUDFNHWLWHPRQWRWKHFDPHUD)RU WKHIURQWOLQHDUUD\FDPHUDWKLVLVWKHSRVLWLRQLQGLFDWHG ZLWK WKH )µ ZKLOH LWHPVKRXOGEHPRXQWHGDWSRVLWLRQ 5µIRUOLQHDUUD\FDPHUD7KHULJKWVLGH RI ILJXUH VKRZV WKH H[DFW PRXQWLQJ SRVLWLRQV QRWH WKDW ERWK FDPHUDV DUH PRXQWHGZLWKWKHFDPHUDFDEOHSRLQWLQJWRWKHOHIW,QWKLVZD\WKHUHDUVLGHOLQHDUUD\FDPHUDLVURWDWHGGHJUHHVZLWKUHVSHFWWR WKHIURQWVLGHOLQHDUUD\FDPHUD :KHQLQVWDOOLQJDVHFRQGFDPHUDLQWRWKHV\VWHPEHVXUHWRVHWWKHNQXUOHGULQJRI WKHFRPSOHWHOHQVLQLWVPLGGOHSRVLWLRQDVWKLVHQDEOHVEHWWHUDGMXVWPHQW Service Manual Topaz 5322 871 63606 9-34 PA 1309/10 01.05

Vision Systems 9.6. Cleaning the Optical Systems 7KHRSWLFDOV\VWHPVRIWKH7RSD]PXVWEHFOHDQHGSHULRGLFDOO\:KHQPDNLQJ DGMXVWPHQWVWRWKHFDPHUD VPDNHVXUHWRUHPRYHDQ\GXVWDQGGHEULVLQ DGYDQFH 7RFOHDQWKHRSWLFDOV\VWHPVXVHDFOHDQLQJVWLFNVXSSOLHGZLWKWKHPDFKLQHRU FRWWRQVZDEVOLJKWO\PRLVWHQHGZLWKHWK\ODOFRKRODQGZLSHWKHVXUIDFHRIWKH OHQV'RQRWXVHRUJDQLFVROYHQWVIRUFOHDQLQJ Figure 9-39 CAUTION Do not apply excessive force to the cameras while cleaning, this may cause the calibration parameters to be unreliable. Be sure to press emergency prior to cleaning! 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-35

Vision Systems 9.7. 9.7.1. Recognition Errors 7KLVFKDSWHUGHVFULEHVVRPHUHFRJQLWLRQHUURUVWKDWPLJKWRFFXU Chip Components Symptom Possible cause Corrective action Recognition error frequently occurs with almost all components Dust or dirt on the camera lens. Whip the lens surface with its special cleaner. Recognition error frequently occurs with specific components Recognition error frequently occurs with a specific head, specific components cannot be recognized Table 9-3 The shape data in the component information width is not correct, or the nozzle is picking up the component by the edge. The buffing part of the nozzle does not move smoothly, or dirt is on the nozzle tip. The shape data in the component information is not properly supplied. Check the shape data and make adjustments by using the adjust assistant. If the pickup position is off center of the component check the tape feeder for operation. Generate a negative pressure for all heads in the manual mode and move the nozzles. If any incorrect value is entered for the shape data the component is supplied in a wrong direction, this also results in recognition errors. For components to be supplied laterally specify 0 degree in the database. While specifying 90 degrees for lengthwise supply. Service Manual Topaz 5322 871 63606 9-36 PA 1309/10 01.05

Vision Systems 9.7.2. QFP Components Symptom Possible cause Corrective action Recognition error frequently occurs. Recognition error frequently occurs. (QFP is not displayed on the vision monitor.) Components cannot be recognized. Table 9-4 Incorrect data is entered for the Component Information. If the component has deviated from the center of pickup position, it may shift from the center of the monitor, resulting in a recognition error. The direction supplying the component is not correct. (If the supply direction is wrong, the number of leads is switched between the length and width sides, causing a recognition error even if the SHAPE data is correct.) Check the data on the Component Information, and perform "PARAM. SEARCH" in the Adjust Assistant. Check the "Feeder Pos_X/Y" and "X/Y- CompPitch" values in the Component Information, and make the corrections. Component supply data is created for the database, with the lateral supply as standard. Therefore, when the component is to be supplied in a lengthwise direction, enter "90 degrees (-90 degrees)" for the "Pick Angle" parameter in the Component Information. 5322 871 63606 Service Manual Topaz 01.05 PA 1309/10 9-37

Vision Systems Intentionally left blank. Service Manual Topaz 5322 871 63606 9-38 PA 1309/10 01.05

Software Section CHAPTER 10 Software Section 10.1. Introduction 7KLVFKDSWHURIWKHVHUYLFHPDQXDOGHVFULEHVLVVXHVUHODWHGWRWKHPDFKLQHVRIWZDUH 9,26YHUVLRQDQG3&%VRIWZDUHILOHV7KHLQVWDOODWLRQDQGEDFNXS SURFHGXUHVZLOOEHGHVFULEHGDQGDOLVWRIDOOV\VWHPPHVVDJHVZLOOEHJLYHQ$OVRD GHVFULSWLRQKRZWRGHDOZLWKIORSS\KDUGGLVNSUREOHPVZLOOEHJLYHQ7KHILQDOSDUW LVDQRYHUYLHZRIV\VWHPPHVVDJHV $EDVLVNQRZOHGJHRIWKH'26RSHUDWLQJV\VWHPLVUHFRPPHQGHG 06'26LVDWUDGHPDUNRI0LFURVRIW&RUSRUDWLRQ 7KHDERYHPHQWLRQHGVRIWZDUHSDFNDJHVPD\RQO\EHXVHGLQDFFRUGDQFHZLWKWHUPV RIWKHVRIWZDUH/LFHQVHDJUHHPHQW 5322 871 63606 Service Manual Topaz 10-1 01.05 PA 1309/10

Software Section 10.2. System Software 10.2.1. Operating System 7KH',6.RSHUDWLQJV\VWHPZKLFKLVXVHGE\WKHV\VWHPLVWKH06'26YHUVLRQ 7KHRSHUDWLQJV\VWHPLVLQVWDOOHGDWWKHIDFWRU\RQWKHKDUGGLVNGULYH&WRJHWKHU ZLWKWKH9,26VRIWZDUHSDFNDJH 7KHFRQWHQWVRIWKHURRWGLUHFWRU\RIGULYH&LVOLVWHGLQSDUDJUDSK 10.2.2. Disk Organization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ervice Manual Topaz 5322 871 63606 PA 1309/10 01.05

Software Section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ervice Manual Topaz 10-3 01.05 PA 1309/10

Software Section 10.2.3. Installation Disk Contents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ame Ext Size Date Time INST486 LZH 333812 12-21-98 8:15p UPDATE BAT 478 11-04-98 8:19p COMMAND.COM 58886 12-06-93 6:20a LHA DOC 27059 7-20-91 2:13a LHA EXE 34445 7-20-91 2:13a HDDCHK EXE 113005 12-22-97 11:17a Figure 10.1 Contents of installation disks 10-4 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

Software Section 7KH 6<67(0 '$7$ GLVN LV YHU\ LPSRUWDQW EHFDXVH LW FRQWDLQV WKH 0$&+,1( 3$5$0(7(5 ILOHV 86(5(' DQG 86(5+' LQ WKH 1R'LUHFWRU\ 7KH 86(5(' FRQWDLQV WKH PDFKLQH FRQILJXUDWLRQ (TXLSPHQW 'DWD DQG WKH 86(5+' DOO WKH PDFKLQH SDUDPHWHUV +DUGZDUH 'DWD $QRWKHU LPSRUWDQW ILOH LV WKH '$7$%$6(/=+7KLVILOHFRQWDLQVWKHFRPSUHVVHGFRPSRQHQWDQGPDUNGDWD CAUTION Before re-writing the software or hard disk always check if there is a system back up on disk. It is strongly recommended to make a back up via the VIOS SOFTWARE UTILITY immediate after the system is unpacked and set-up. Keep this back up on a safe place away from the machine. 7KHEDFNXSFDQEHGRQHYLDWKH9,2662)7:$5(87,/,7<6HHIRUWKLVSURFHGXUH SDUDJUDSKRIWKLVFKDSWHU 7KH 6<67(0 GLVNV DQG FRQWDLQLQJ WKH ILOHV,16/=+,16/=+ DQG,16/=+ZKLFKDUHFRPSUHVVHGE\PHDQVRIWKH/+$FRPPDQG7KHVHILOHVDUHWKH FRPSOHWH 9,26 RSHUDWLQJ V\VWHP DQG GDWDEDVH ZKLFK PXVW EH GHFRPSUHVVHG YLD WKH VDPH/+$FRPPDQG7KH83'$7(EDWDQGUHODWHGILOHVZLOOWDNHFDUHRIWKLVH[WUDFWLRQ 5322 871 63606 Service Manual Topaz 10-5 01.05 PA 1309/10

Software Section 10.2.4. VIOS Software Utility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ervice Manual Topaz 5322 871 63606 PA 1309/10 01.05

Software Section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his command can be dangerous because it initialises all machine data on the hard disk. Use this command only in case the machine data is corrupted or out of date or if there are hard disk problems. 5322 871 63606 Service Manual Topaz 10-7 01.05 PA 1309/10

Software Section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ervice Manual Topaz 5322 871 63606 PA 1309/10 01.05

Software Section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ervice Manual Topaz 10-9 01.05 PA 1309/10

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Software Section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his command is dangerous because the machine data is initialized. Use this command only when the hard disk in the machine has problems. 5322 871 63606 Service Manual Topaz 10-11 01.05 PA 1309/10

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Software Section 10.2.5. Installation of a New Version VIOS System Software 7KLVSDUDJUDSKGHVFULEHVKRZWRXSJUDGH\RXUV\VWHPVRIWZDUHDQGKRZWRPDNHDEDFN XS CAUTION Before any upgrade is executed, make sure you have a system software backup. Please refer to paragraph 10.2.4. After VIOS version V1.23 an automatic backup during the installation of new software will be made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µ>9,26vriwzduhxwlolw\lqvwdoodwlrq@dqgiroorzwkhlqvwuxfwlrqvrqwkh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ervice Manual Topaz 10-13 01.05 PA 1309/10

Software Section 9HUVLRQXS)LQLVKHGVXFFHVVIXOO\KLWDQ\NH\ 6WHS 6WHS 6HOHFW6\VWHP'DWDXWLOLW\DQGVHOHFW>6\VWHPGDWD@EDFNXSWKHQSUHVVWKH >(17(5@NH\,QVHUWWKH6<67(0'$7$',6.LQWKHIORSS\GULYHDQG KLWDQ\NH\)ROORZWKHLQVWUXFWLRQVRQWKHVFUHHQ 6HOHFWWRVWDUWWKH9,26VRIWZDUH 10.2.6. Backup Creation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µ>v\vwhp'dwd@edfnxsdqgiroorzwkhlqvwuxfwlrqvrqwkhvfuhhq :KHQ WKH EDFNXS LV FRPSOHWHG WKH IROORZLQJ PHVVDJH ZLOO DSSHDU RQ WKH VFUHHQ%DFNXSGDWDILQLVKHGVXFFHVVIXOO\+LWDQ\NH\ 5HPRYHWKHIORSS\GLVNIURPWKHGULYHODEHOLWZLWKWKHFRUUHFWLQIRUPDWLRQ QDPHWLPHVWDPSPDFKLQHW\SHHWFDQGVWRUHLWDZD\RQDVDYHSODFH 6HOHFWWRVWDUWWKH9,26VRIWZDUH 10-14 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

Software Section 10.2.7. VIOS Configuration 7KH 9,26 FRQILJXUDWLRQ ILOH LV ORFDWHG LQ WKH 5227 GLUHFWRU\ RQ WKH & GULYH DQG LV FDOOHG0&;&21)6<6 7KLVILOHVHH ILJ LV YHU\ LPSRUWDQW IRU WKH 9,26 V\VWHP,I QRW 2. WKH 9,26 VRIWZDUHZLOOQRWVWDUWXS _ /REM+--------------------------------------+ /REM FILE: MCX-CONFIGRATION /REM TYPE: 120-YV100 /REM+--------------------------------------+ /REM /REM+--------------------------------------+ /REM TITLE: ROM /REM+--------------------------------------+ /ROM:SYS=KG2-M42R9-002/*SYS bd.(bios+drdos)*/ /ROM:HED=KG7-M45R9-000/*IO bd.(head) */ /ROM:CNV=KG2-M45R9-002/*IO bd.(conveyor) */ /ROM:P&P=KG2-M45R9-002/*IO bd.(ytf100) */ /ROM:YPU=KG2-M51R9-003/*YPU */ /REM+--------------------------------------+ /REM TITLE: SOFT /REM+--------------------------------------+ /S:EXE=KM1-42E0-012 /*MAIN ExeFile//KG7R.EXE */ /S:TYP=KG2-42T0.012\\ /*MCH TYPE TxtFile//TYPE\*.* */ /S:MSG=KG2-42M0.012\\ /*MESSAGES TxtFile//TEXT\*.TXT */ /S:VAL=KG7-44D0.237 /*VISION HexFile//TMSLIBIN.OUT*/ /S:IPL=KG2-42S8.00A /*IO-OS BinFile//8344OS.BIN */ /S:IOS=KG2-42S9.005 /*IO-IPL HexFile//8344IPL.HEX */ /S:APL=KM5-42S8.001 /*IO HexFile//OS&IPL.HEX */ /S:MC1=KG2-58D9.044 /*SERVO HexFile//SRV.HEX */ /S:MC2=KJ0-58D9.044 /*SERVO HexFile//SRV.HEX */ /S:MC3=KM5-58D9.007 /*SERVO HexFile//SRV.HEX */ /REM+--------------------------------------+ /REM TITLE: ENVIRONMENT /REM+--------------------------------------+ /H /*User sub directry*/ /WRAMD\ /*Work sub directry*/ /REM+--------------------------------------+ /REM TITLE: OPTION SWITCHES /REM+--------------------------------------+ /Dsleep /*SLEEP(NoServo)/ACTIVE(WithServo)/EMUL(Emulate) */ /Vsleep /*SLEEP(NoVision)/ACTIVE(WithVision) */ /Isleep /*SLEEP(NoIOcard)/ACTIVE(WithIOcard)/PART(OnlyBasicIO) */ /Csleep /*SLEEP(NoCOM1)/ACTIVE(WithCOM1) */ /Ysleep /*SLEEP(Fixed)/ACTIVE(Variable) */ /P0 /*Bit0=SkipBackupCheck: Bit1=WithDRDOS: Bit2=QuickStart */ /L8 /*Protrction 0(RUNNING)/2(OPERATION)/4(MAINTE),L8(ALL) */ /A0 /J0 /XC7000 /XD2 Figure 10.2.6 MCXCONF.sys 5322 871 63606 Service Manual Topaz 10-15 01.05 PA 1309/10

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Software Section 10.3. PCB File Handling 7KLVFKDSWHUGHVFULEHVWKHLVVXHVUHODWHGWRWKH3&%ILOHVRI9,26,Q WKH >6+(//0@>'$7$B),/(B01*@ WKH 3&% ILOHV RQ WKH GLVN DUH VKRZQ 6HH ILJXUHD7KHILOHQDPHGHVFULSWLRQVDUHVWRUHGLQDKLGGHQILOHQDPHG)7$%/(%,1 7KHQDPHVWKDWFDQEHJLYHQWRHDFK3&%PD\FRQVLVWRIFRQVHFXWLYHFKDUDFWHUVQR VSDFLQJ DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/DATA_FILE_MNG 2/DISK_MAINTENANCE 3/VIOS_DIC 0/EXIT <VIOS PCB> /Drv:C <VIOS PCB> /Drv:C Vios Pcb Name Date Time Vios Pcb Name Date Time STATIC_COMPONENTS 94-07-16 07:58 STATIC_COMPONENTS 94-07-16 07:58 CONVEYOR 93-12-06 11:04 CONVEYOR 93-12-06 11:04 ANC_TEST 94-02-12 10:01 ANC_TEST 94-02-12 10:01 PALLET_80 94-02-12 09:25 PALLET_80 94-02-12 09:25 ADJUST_CHIP 95-08-11 13:46 ADJUST_CHIP 95-08-11 13:46 OFFSET 95-08-11 13:47 OFFSET 95-08-11 13:47 CUK_92001_1 94-01-10 18:05 CUK_92001_1 94-01-10 18:05 CUK_93001_0 94-02-12 09:18 CUK_93001_0 94-02-12 09:18 ECLIPSE 95-08-11 13:48 ECLIPSE 95-08-11 13:48 MFB_CHIP 95-08-09 13:38 MFB_CHIP 95-08-09 13:38 Figure 10.3 PCB file names DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/DATA_FILE_MNG 2/DISK_MAINTENANCE 3/VIOS_DIC 0/EXIT DIRECTORY C:\ECL92 DIRECTORY C:\ECL92 Name Ext Size Date Time Name Ext Size Date Time.. >SUB_DIR< 96-02-26 15:15 STATUS >SUB_DIR< 96-02-26 15:16 D_BASE >SUB_DIR< 96-02-26 15:16 KG2-42M0 009 >SUB_DIR< 96-02-26 15:16 FONT >SUB_DIR< 96-02-26 15:16 KG2-42T0 009 >SUB_DIR< 96-02-26 15:16 INS >SUB_DIR< 96-02-26 15:16 KG2-42S9 005 476 93-03-06 08:57 NO0 >SUB_DIR< 96-02-26 15:16 KG2-42S8 007 8191 95-05-24 12:10 NO1 >SUB_DIR< 96-02-26 15:16 KG2-58D9 010 46706 95-05-12 12:11 PGM >SUB_DIR< 96-02-26 15:16 KG7-44D0 146 555410 95-11-08 18:09 P_BASE >SUB_DIR< 96-02-26 15:16 KG7-44D1 146 1082 95-02-17 17:11 RAMD >SUB_DIR< 96-02-26 15:16 AUTOEXEC BAT 97 96-02-26 15:36 STATUS >SUB_DIR< 96-02-26 15:16 FTABLE BIN 308 95-09-06 19:07 KG2-42M0 009 >SUB_DIR< 96-02-26 15:16 ECL92 EXE 1584018 95-11-09 14:58 KG2-42T0 009 >SUB_DIR< 96-02-26 15:16 COM92 ICO 4026 96-02-26 15:23 KG2-42S9 005 476 93-03-06 08:57 ECL92 ICO 4026 96-02-26 15:30 KG2-42S8 007 8191 95-05-24 12:10 MCXCONF NEW 2499 95-11-08 20:37 KG2-58D9 010 46706 95-05-12 12:11 SERIAL STS 785 92-09-19 10:51 KG7-44D0 146 555410 95-11-08 18:09 MCXCONF SYS 2493 95-12-18 16:16 Figure 10.4 Dos files 10-20 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

Software Section 7KH&?12GLUHFWRU\ILUVWRIDOOKDVWKHWZRIROORZLQJILOHV 86(5(' 86(5+' $OO0DFKLQHHTXLSPHQW237,21B&)* $OO0DFKLQHSDUDPHWHUV0&+B'$7$ $EDFNXSRIWKHVHILOHVRQWKH 6<67(0'$7$',6.µVKRXOGDOZD\VEHSUHVHQWLQWKH QHLJKERXUKRRGRIWKHPDFKLQH6HHILJXUH DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/DATA_FILE_MNG 2/DISK_MAINTENANCE 3/VIOS_DIC 0/EXIT DIRECTORY C:\orn\NO1 DIRECTORY C:\orn Name Ext Size Date Time Name Ext Size Date Time.. >SUB_DIR< 96-02-26 15:16.. >SUB_DIR< 96-02-26 15:15 @00101 BD 1000 93-09-24 09:53 D_BASE >SUB_DIR< 96-02-26 15:16 @00201 BD 1050 93-12-06 11:04 FONT >SUB_DIR< 96-02-26 15:16 @00901 *BD 19450 94-10-18 17:35 INS >SUB_DIR< 96-02-26 15:16 USER ED 152 95-12-18 15:54 NO0 >SUB_DIR< 96-02-26 15:16 @00101 FD 0 93-09-24 10:23 NO1 >SUB_DIR< 96-02-26 15:16 @00201 FD 0 93-12-06 11:04 PGM >SUB_DIR< 96-02-26 15:16 @00901 *FD 57036 95-08-11 13:48 P_BASE >SUB_DIR< 96-02-26 15:16 USER HD 11800 95-12-08 15:09 RAMD >SUB_DIR< 96-02-26 15:16 @00101 ID 0 93-09-24 11:29 STATUS >SUB_DIR< 96-02-26 15:16 @00901 *PD 4257 94-07-16 07:58 KG2-42M0 009 >SUB_DIR< 96-02-26 15:16 @00201 ID 152 93-12-06 11:04 KG2-42T0 009 >SUB_DIR< 96-02-26 15:16 @00901 *ID 152 94-09-22 11:20 KG2-42S9 005 476 93-03-06 08:57 @00101 MD 0 93-09-24 10:23 KG2-42S8 007 8191 95-05-24 12:10 @00201 MD 0 93-12-06 11:04 KG2-58D9 010 46706 95-05-12 12:11 @00901 *MD 130 94-09-22 11:41 KG7-44D0 146 555410 95-11-08 18:09 Figure 10.5 DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/DATA_FILE_MNG 2/DISK_MAINTENANCE 3/VIOS_DIC 0/EXIT DIRECTORY C:\orn\NO1 DIRECTORY C:\orn Name Ext Size Date Time Name Ext Size Date Time.. >SUB_DIR< 96-02-26 15:16.. >SUB_DIR< 96-02-26 15:15 @00101 BD 1000 93-09-24 09:53 D_BASE >SUB_DIR< 96-02-26 15:16 @00201 BD 1050 93-12-06 11:04 FONT >SUB_DIR< 96-02-26 15:16 @00901 *BD 19450 94-10-18 17:35 INS >SUB_DIR< 96-02-26 15:16 USER ED 152 95-12-18 15:54 NO0 >SUB_DIR< 96-02-26 15:16 @00101 FD 0 93-09-24 10:23 NO1 >SUB_DIR< 96-02-26 15:16 @00201 FD 0 93-12-06 11:04 PGM >SUB_DIR< 96-02-26 15:16 @00901 *FD 57036 95-08-11 13:48 P_BASE >SUB_DIR< 96-02-26 15:16 USER HD 11800 95-12-08 15:09 RAMD >SUB_DIR< 96-02-26 15:16 @00101 ID 0 93-09-24 11:29 STATUS >SUB_DIR< 96-02-26 15:16 @00901 *PD 4257 94-07-16 07:58 KG2-42M0 009 >SUB_DIR< 96-02-26 15:16 @00201 ID 152 93-12-06 11:04 KG2-42T0 009 >SUB_DIR< 96-02-26 15:16 @00901 *ID 152 94-09-22 11:20 KG2-42S9 005 476 93-03-06 08:57 @00101 MD 0 93-09-24 10:23 KG2-42S8 007 8191 95-05-24 12:10 @00201 MD 0 93-12-06 11:04 KG2-58D9 010 46706 95-05-12 12:11 @00901 *MD 130 94-09-22 11:41 KG7-44D0 146 555410 95-11-08 18:09 Figure 10.6. 5322 871 63606 Service Manual Topaz 10-21 01.05 PA 1309/10

Software Section,QWKHVDPH&?12GLUHFWRU\FRPELQDWLRQRIILOHVFDQEHIRXQGWKDWWKH\WRJHWKHUIRUP GDWDRIRQH3&%7KRVHILOHVDUH #>),/(@,' &RQWDLQVWKH3&%QDPHDQGUXQFRQGLWLRQ #>),/(@%' &RQWDLQVWKH3&%PRXQWGDWD #>),/(@)' &RQWDLQVWKHFRPSRQHQWDQGYLVLRQLQIR #>),/(@0' &RQWDLQVDOO0DUNLQIRUPDWLRQ #>),/(@3' &RQWDLQVWKHSURGXFWLRQKLVWRU\ $QH[DPSOHLVVKRZQLQILJXUH 10.4. Machine Configuration 7KHPDFKLQHFRQILJXUDWLRQOLVWLVORFDWHGLQWKHDSSOLFDWLRQ0$,17(1$1&( 0$1$*(5$237,21&21),*'HSHQGLQJRQWKHFRQILJXUDWLRQRIWKHV\VWHPLWLV SRVVLEOHWRGLVDEOHRUHQDEOHSDUWVDQGRSWLRQVRIWKHPDFKLQHVHHILJ DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/MCH_CONFIG 2/MCH_DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT <COMMAND_LIST> A/MCH_CFG A1 OPTION CONFIG. A2 HEAD SPEC.INF. A3 FEEDER BASE INF. A4 NOZZLE SPEC.INF. A5 FEEDER SPEC.INF. A6 ROM CONFIG. A7 FILE CONFIG. A0 EXIT Figure 10.7 Maintenance manager 10-22 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

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Software Section 10.5. ROM and File Configuration (Version Level) 7KHVFUHHQLQILJLVVKRZLQJWKHYHUVLRQRIWKHYDULRXV520 VXVHGLQWKHV\VWHP DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/MCH_CONFIG 2/MCH_DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT ROM TYPE CURRENT ROM HEAD-I/O-ROM CONVEYOR(A)-I/O-ROM CONVEYOR(B)-I/O-ROM Ext.TC-I/O-ROM SYSTEM-ROM HHK-ROM Figure 10.9 ROM IC version 7KHVFUHHQLQ)LJVKRZVDQH[DPSOHRIWKHILOHFRQILJXUDWLRQILOHYHUVLRQRIWKH V\VWHP,IDILOHKDVQRWWKHFRUUHFWOHYHOLWZLOOEHVKRZQLQUHG,WLVQHFHVVDU\WKDWDOOILOHV KDYHWKHFRUUHFWOHYHOWRDYRLGSUREOHPV7KHVFUHHQLQILJVKRZVDQH[DPSOHRIWKH YDULRXVILOHVZLWKWKHLUOHYHO'HSHQGLQJRQWKH9,26YHUVLRQWKHILOHYHUVLRQVZLOOFKDQJH DFFRUGLQJO\ DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/MCH_CONFIG 2/MCH_DATA 3/MCH_ADJUST 4/MANUAL 0/EXIT FILES & DIRECTORY REQUEST VERSION STATUS MACHINE-TYPE-PATH KG2-42T0.011\\ OK MESSAGE-FILE-PATH KG2-42M0.011\\ OK APL-EXE.FILE KM5-42E0-011 OK VISION-HEX.FILE KG7-44D0.208 OK IO(OS)BIN.FILE KG2-42S8.00A OK IO(IPL)HEX.FILE KG2-42S9.005 OK SEQUENCE-HEX.FILE DC-SERVO-HEX.FILE AC-SERVO-HEX.FILE KM5-58D9.900 OK Figure 10.10 File configuration 10-28 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

Software Section 10.6. System Messages 7KLVFKDSWHUJLYHVDOLVWRIWKHV\VWHPPHVVDJHVRIWKH9,26RSHUDWLQJV\VWHP7KHVFUHHQV EHORZDUHYDOLGIRUWKH[VRIWZDUHDQGKLJKHU,QVFUHHQ6+(//0',6. 0$,17(1$1&(VXEGLU.*B0DOLVWLVVKRZQRIWKHFRQWHQWVRIWKLVVXE GLUHFWRU\VHHILJ:LWKPRYLQJWKHKLJKOLJKWHGEDUWRDILOHDQGSUHVVLQJ>)@LWLV SRVVLEOHWRYLHZWKHFRQWHQWVRIWKLVILOH7KHPRVWLPSRUWDQWILOHVDUHGLVSOD\HGLQEROW DQGDUH (550(6B(7;7VHHILJ +/30(6B(7;7VHHILJ,700(6B(7;7VHHILJ 02'0(6B(7;7VHHILJ 33(55B(7;7VHHILJ 9,60(6B(7;7VHHILJ DATA[non ] <<<APPLICATION>>> 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT <<MODE>> 1/DATA_FILE_MNG 2/DISK_MAINTENANCE 3/VIOS_DIC 0/EXIT DIRECTORY C:\KG7-42M0.009 DIRECTORY C:\ECL92\KG7-42M0.009 Name Ext Size Date Time Name Ext Size Date Time ERRMES_E TXT 110282 95-11-09 15:35 QWORDS_S TXT 2859 96-02-29 14:58 ERRMES_J TXT 98592 95-11-09 15:35 SBMMES_E TXT 23530 95-11-09 15:35 ERRMES_S TXT 93584 96-02-29 14:55 SBMMES_J TXT 22763 95-11-09 15:35 HLPMES_E TXT 432420 95-11-09 15:35 SBMMES_S TXT 22314 96-02-29 14:58 HLPMES_J TXT 379910 95-11-09 15:35 SPEED5 TXT 252 96-02-29 14:59 HLPMES_S TXT 337020 96-02-29 14:57 TITLE_X TXT 47897 95-11-09 15:35 ITMMES_E TXT 33961 95-11-09 15:35 TKNSCD TXT 177 95-11-09 15:35 ITMMES_J TXT 35227 95-11-09 15:35 TKNSYM TXT 2235 95-11-09 15:35 ITMMES_S TXT 34076 96-02-29 14:57 UFOSBRD TXT 297 95-11-09 15:35 LASERPOS TXT 213 96-02-29 14:57 UFOSFD2 TXT 57 95-11-09 15:35 MODMES_E TXT 17373 95-11-09 15:35 UFOSFDR TXT 248 95-11-09 15:35 MODMES_J TXT 16734 95-11-09 15:35 UFOSMCH TXT 1868 95-11-09 15:35 MODMES_S TXT 16639 96-02-29 14:57 UFOSVIS TXT 816 95-11-09 15:35 Figure 10.11 C:\KG7-42M0.009 7KHB(7;7ILOHVFRQWDLQVWKH(QJOLVKWH[WILOHV7KHB-7;7ILOHVFRQWDLQVWKH-DSDQHVH WH[WILOHV$QGWKHB67;7 ILOHV FRQWDLQV WKH WH[W ILOHV IRU D VSHFLDO ODQJXDJH HD)UHQFK *HUPDQLIDYDLODEOH$OOWKHVHWH[WILOHVFDQRQO\EHYLHZHGLQWKH9,26VRIWZDUH 5322 871 63606 Service Manual Topaz 10-29 01.05 PA 1309/10

Software Section (550(6B(W[W,QILJDVPDOOSDUWRIWKH(UURUOLVWLVVKRZQ #0000 Detection succeeded. The corrected data is now effective. S50xX /0000/E #0001 CORRECTION DATA ERROR Only 1 Lead detected. $5022 /0000/E #0002 CORRECTION DATA ERROR Correction data is not loaded. Or it diversifies. $5022 /0000/E #0003 COMPONENT DETECTION ERROR Figure 10.12 ERROR_E.TXT +/30(6B(W[W 7KLVILOHFRQWDLQVWKHKHOSPHVVDJHVZKLFKLVVKRZQZLWKWKH>)@NH\ILJ #0000 YOU CAN PUT 74 CHARACTERS PER 1 LINE, 19 LINES PER 1 PAGE. USE, AND. FOR INTEGRITY. THIS IS A TEXT FILE FOR ONLINE-HELP MESSAGES. IF YOU PUSH THE [F1] KEY, YOU WILL GET AN EXPLANATION AND PUSH ANY KEY TO CLEAR THE EXPLANATION. THIS MESSAGE IS NO.0 $37 /0000/E #0001 1/OPERATION/M <<<OPERATION MANAGER>>> supports daily production. MODE RUNNING :Production, Warming Up [CTRL] + [F1] PRD.DATA :PCB data modification [CTRL] + [F2] PRD.HISTORY :See production history [CTRL] + [F3] Figure 10.13 HLPMES_E.TXT 10-30 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05

Software Section 0260(6B(W[W 7KLVILOHFRQWDLQVWKHWH[WILOHVIRUHDFKPRGHILJ #0010 1/OPERATION/M 2/DATA/M 3/MAINTE/M 4/SHELL/M 0/EXIT ---------------» ----------------- <<<OPERATION MANAGER>>> supports daily production. MODE RUNNING :Production, Warming Up PRD.DATA :PCB data modification PRD.HISTORY:See production history MANUAL :Manual operating Figure 10.14 MODMES_E.TXT 9,60(6B(W[W 7KLVILOHFRQWDLQVDOOWKHYLVLRQWH[WILOHV #0000 Component was detected successfully Position and angle data is available $57XX /0000/E #0001 Component detection Error: (1) - Only 1 Lead detected. $57XX /0000/E #0002 Calculation Error: (2) Calibration data is not ready to read $57XX /0000/E #0003 Component detection Error: (3) Failed to detect component Figure 10.17 VISMES_E.TXT 5322 871 63606 Service Manual Topaz 10-31 01.05 PA 1309/10

Software Section 10.7. Online Commands 2QOLQHFRPPDQGVDUHXVHGWRFRQWUROWKH7RSD]IURPD3& ([SHULHQFHVLQSURJUDPPLQJDUHUHTXLUHG $SURJUDPWKDWPDNHVIXOOXVHRIWKHVHLQVWUXFWLRQVLVWKH3KLOLSV3URGXFWLRQ&RQWURO 6RIWZDUHDQGFDQEHRUGHUHGYLDUHJXODUFKDQQHOV 7KHVHWRIRQOLQHFRPPDQGVZLOOQRWEHSULQWHGLQWKLVPDQXDOEXWDUHDYDLODEOHRQ VSHFLDOUHTXHVWDW3KLOLSV(LQGKRYHQ 10-32 Service Manual Topaz 5322 871 63606 PA 1309/10 01.05