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PA 1309/10

Topaz

Service Manual

TRAD
Philips
Electronic Manufacturing
Technology
DOCUMENT DATA

MANUAL TITLE MANUAL NUMBER PA NUMBER


Service Manual Topaz 5322 871 63606 (01.05) PA 1309/10

HISTORY
ORDER REVISION RELEASE
ISSUE DATE STATUS
NUMBER CODE DOCUMENT
First Draft - 5322 871 63606 97.00 Replaced -
First Issue Oct-97 5322 871 63606 97.01 Replaced DI-CSM-025
Update Mar-98 5322 871 63606 98.02 Replaced DI-CSM-050
Second Issue Mar-99 5322 871 63606 99.03 Replaced DI-CSM-076
Update Jan. 2000 4022 591 93464 00.04 Replaced DI-CSM-105
Third Issue April 2001 5322 871 63606 01.05 Current DI-CSM-138

Preventive and corrective maintenance is reserved for personnel certified by Assembléon.

The Philips EMT Customer Support organization has part number for the latest documentation currently
created a series of web pages on the World Wide Web available. Access to this area is not restricted by a
for the use of its internal and external customers. These password. It is an on-line reproduction of the manual
pages provide a library of information regarding technical survey. It has the advantages that it can be updated
aspects of the products sold and supported by Philips regularly. The Customer Support website address is:
EMT organizations around the world. The manuals
section is a tool for EMT customers trying to find the 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 man-
uals where applicable. Warnings and cautionary statements and/or symbols are present on the system where applicable.

Cautions and marks:


REFERENCE
Gives useful information related to the mounter operation.

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 Serv-
ice manuals of this system.

Location of the Operator manual:


The Operator manual MUST BE LOCATED CLOSE to the CSM machine. This enables operators to have easy access to
the relevant cards.
HOW TO REPORT DOCUMENT IRREGULARITIES

We have endeavoured to ensure that the information in this document was correct when published. If, when using this
document, errors, omissions or anomalies are discovered, please inform us using the reply-form attached. We thank
you for this service, in advance, as it will help us to ensure that you, the customer, receive the highest possible quality of
information and service.
Manual Title: Service Manual Topaz
Please, don’t forget to fill-in this!
Manual Number: 5322 871 63606
PA Number: PA 1309/10 Update Code Manual: . ✍
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Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DOCUMENT IRREGULARITIES:
Page/Paragraph Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Erroneous Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Consequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Suggestion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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

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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. 2nd Generation Connection-Board 3-33
rd
3.8.3. 3 Generation Connection-Board 3-35
3.9. Keyboards 3-38
3.9.1. PC-Keyboards 3-38
3.9.2. Hand Held Keyboard (HHK) 3-38
3.10. Monitors 3-40
3.10.1. VIOS Monitor 3-40
3.10.2. Vision Monitor 3-40
3.11. 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
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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

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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
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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

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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

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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
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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

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8 PA 1309/10 01.05
Introduction

 CHAPTER 1 Introduction

1.1. General Introduction

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the Topaz equipment is allowed to carry out service actions.

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01.05 PA 1309/10 1-1
Introduction

1.2. Chapter Overview

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Service Manual Topaz 5322 871 63606


1-2 PA 1309/10 01.05
Introduction

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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 1-3
Introduction

1.3. Safety

1.3.1. General
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LVHVVHQWLDOLQVHUYLFLQJWKHPDFKLQHVDIHO\

1.3.2. Basic Rules


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1.3.3. Safety Standards


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Service Manual Topaz 5322 871 63606


1-4 PA 1309/10 01.05
Introduction

1.3.4. Cautionary Remarks


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REFERENCE:
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NOTE:
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WARNING:
*LYHVLQIRUPDWLRQRIXWPRVWLPSRUWDQFHLQHQVXULQJWKHVDIHW\RIWKHRSHUDWRURU
VHUYLFHSHUVRQQHO
EMERGENCY BUTTON:
,QGLFDWHVWRSUHVVILUVWWKHHPHUJHQF\EXWWRQEHIRUHFRQWLQXH

1.3.5. Warning Stickers


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Do not enter

Figure 1-1 Do not enter

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,WLVORFDWHGDWWKHHQWUDQFHDQGH[LWFRQYH\RUUDLO

5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 1-5
Introduction

Electrical shock

Figure 1-2 Electrical shock

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Low Radiation

Figure 1-3 Radiation

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Service Manual Topaz 5322 871 63606


1-6 PA 1309/10 01.05
Introduction

High temperature

Figure 1-4 High temperature

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WHPSHUDWXUHSUHVHQFH7KLVVWLFNHULVORFDWHGXSRQWKH<PRWRURIWKH7RSD]

1.3.6. ESD Precaution


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1.3.7. Noise Level


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1.3.8. Liability
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&60*(0V\VWHPLVQRWXVHGDFFRUGLQJWRWKHVDIHW\UXOHVJLYHQLQWKLVPDQXDO

5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 1-7
Introduction

1.3.9. Oil and Greases


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7RSD]
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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 DU008134
O-rings and seals

Table 1-1

Note:
Philips will not be responsible for any damage to the machine if other greases and/or
oils are used than mentioned above.

1.3.10. Abbreviations
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VHTXHQFH

Abbreviation Explanation
A Ampere
AC Alternating current
ASAP As Soon As Possible
ATS Auto Tray Stacker, tray handling device

B/W Black and white


BGA Ball Grid Array

CE Comité europièn
CN Connector
COB Chip on board
COG Centre Of Gravity
CPU Central processing unit
CS Customer Support
CSM Compact Surface Mounter
CSP Chip scale package, •BGA

Service Manual Topaz 5322 871 63606


1-8 PA 1309/10 01.05
Introduction

Abbreviation Explanation
DC Direct current
DI Document Information
DI Data Input
DO Data Output
DIL Dual In Line, chip package

EMG Emergency
ESD Electro Static Discharge

FD Floppy Disk
FES Feeder exchange system
FV Full Vision

GD1 Good
GEM Product line : Topaz, Emerald and Sapphire

H.H.K. Hand Held Keyboard


HDD Hard Disk Drive
HDLC High Level Data Link Control; More extensive
communication protocol than SDLC

IM Installation Manual
ISO International Standard Organization

LCS Large Component Sequencer, Also called trayfeeder.

MTF Manual Tray Feeder

OM Operator Manual

P1 Priority 1 indicator,
PA Philips Article
PCP Product Creation Process
PCS Philips Consumer Services, worldwide stock for EMT

QFP Quad Flat Package

SI Service Information
SDLC Serial Data Link Control; communication protocol
with one clock and data line.
SM Service Manual
SOP Single Outline Package,
SVS Setup Verification System

TBD To be defined
TBW To Be Written
TC Tray Changer, Tray handling device
TI Technical Information
TPD Technical Product Documentation
TSOP Top Single Outline Package,

UFOS User Friendly operating System


UM User Manual
UP Under Progress
URS User Requirement Specification

VIOS Vision Integrated Operating System

5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 1-9
Introduction

Intentionally left blank.

Service Manual Topaz 5322 871 63606


1 - 10 PA 1309/10 01.05
General and Electrical Block Diagram

CHAPTER 2 General and Electrical Block Diagram

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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 USER Chapt 3


Chapt 3 INTERFACE

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

VGA - Monitor
RS - 232 port AT - keyboard

Handheld keyb.
Power supply
5V, 12V, -12V

Power Monitor
CPU BOARD
HD disk (C) - 80486 uP (8 Mb memory) Motherboard
- VGA controller
- HDD controller ISA - bus
- FDD controller Flash disk*
- I/O control
1.44 Mb (A)
3.5” Floppy I/O -1 I/O -2

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 Cam 1, Fid.


EMERG. I/O -2 conveyor Cam 2, Single
CONVEYOR Tray changer or ATS Cam 3, Multi 1 VICS 2000
Cam 4, Multi 2

282 VOLT
MAINS POWER POWER SUPPLY
+
SAFETY CIRCUIT
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

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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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WARNING
When connecting the MAINS power, make sure to configure the
Mains transformers before. When changing the Mains input
voltage, always check first with the Philips service centre.
Make sure to take all necessary precautions to avoid dangerous
situations.

NOTE:
For the power connection to the system please refer to
“Machine installation: Power connection” in section 11.2.9.
For the transformer power tabs see section 11.2.7 as well.

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

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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


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5322 871 63606 Service Manual Topaz 3-5


01.05 PA 1309/10
System Principles

3.4. Interfaces
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3.4.1. Bus Definitions

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3.4.2. Serial Interface


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NH\ERDUGZKLOH&01LVXVHGIRUWKHFRQQHFWLRQEHWZHHQWKHV\VWHPERDUGDQGDQ
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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
System Principles

3.4.3. Line Interconnections


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 7KH%86<RXWVLJQDOIURPWKHPDLQWRWKHSUHYLRXV XSVWUHDP ²PDFKLQH
 7KH%$LQ ERDUGDYDLODEOH VLJQDOIURPWKHSUHYLRXVWRWKHPDLQPDFKLQH
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D :KHQWKHPDLQPDFKLQHLVEXV\ FRQWDFWVDUH¶RSHQ· QRERDUGLVVHQW
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PDFKLQHPXVWJREXV\DQGWKHVLJQDO%$PXVWJRIDOVHZLWKLQDSUHVHWWLPHSHULRG
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¶ERDUGDYDLODEOH·VLJQDOVPXVWDWOHDVWP6LQGXUDWLRQIRUHLWKHUVWDWH

Figure 3.4-2 SMEMA interface

*DWHLQ*DWHRXWLQWHUIDFH
7KH*DWHLQ*DWHRXWLVDPRUHVLPSOHLQWHUIDFHWRFRQQHFWWKHPDFKLQHVLQOLQH

*DWHLQFRQQHFWRU SLQIHPDOH
7KLVLVWKHFRQQHFWRUIRULQFRPLQJ3&%UHTXHVWVLJQDOVIURPWKHPDFKLQHLQWKHQH[W
SURFHVVWKHSLQQLQJRIWKLVFRQQHFWRULVDVIROORZV
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SLQVLJQDO& 9*URXQG VKDUHGE\1-DQG1-

3-8 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
System Principles

*DWHLQVLJQDO LQSXW 
7KLV VLJQDO LV UHFHLYHG IURP WKH PDFKLQH LQ WKH VXEVHTXHQW SURFHVV :KHQ WKHUH LV
FRQGXFWLYLW\EHWZHHQ  !   FORVHG WKHV\VWHPMXGJHVWKDWDUHTXHVWIRUD3&%
ORDGLQJKDVEHHQPDGH:KHQPRXQWLQJKDVILQLVKHGWKH3&%LVHMHFWHG

&RXQWUHVHWVLJQDO
7KLV VLJQDO UHVHWV WKH FRXQWHU IRU WKH PD[ QXPEHU RI 3&%
V ,I   !   EHFRPH
FRQGXFWLYH FORVHG WKH3&%FRXQWHULVUHVHW

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FRQWDFWSRLQWQRYROWDJHRXWSXW ,QILJXUHWKHJDWHLQFRQQHFWLRQLVVKRZQ

Figure 3.4-3 Gate-in connection >*$7(B,1:3*@

* Figure 3.4-4 Gate-out connection


D >*$7(B287:3*@

W
HRXWFRQQHFWRU RXWSXW 
7KLV LV WKH FRQQHFWRU IRU 3&% UHTXHVWVLJQDOV VHQW WR WKH PDFKLQH LQ WKH SUHYLRXV
SURFHVVWKHSLQQLQJRIWKLVFRQQHFWRULVDVIROORZV
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7KLVVLJQDOLVVHQWWRWKHPDFKLQHLQWKHSUHYLRXVSURFHVV,IWKHPDFKLQHLQWKH
SUHYLRXVSURFHVVKDVFRPSOHWHGLWVSUHSDUDWRU\RSHUDWLRQVLWUHQGHUV  ! 
FRQGXFWLYH FORVHG DVD3&%UHTXHVWVLJQDO,QILJXUHWKHJDWHRXWFRQQHFWLRQ
LVVKRZQ

5322 871 63606 Service Manual Topaz 3-9


01.05 PA 1309/10
System Principles

+RZPDFKLQHVDUHFRQQHFWHGWRHDFKRWKHUXVLQJWKHJDWHLQDQGJDWHRXWLVVKRZQLQ
ILJXUH

Figure 3.4-5 SMEMA connections


>)/2::3*@

5HODWLRQEHWZHHQ*DWHLQ*DWHRXWDQG60(0$
7KH UHODWLRQ EHWZHHQ 60(0$ DQG *DWHLQRXW LV VKRZQ LQ ILJXUH  )RU PRUH
GHWDLOVSOHDVHUHIHUWRWKHRYHUDOOLQWHUFRQQHFWGLDJUDPRIWKH7RSD] FKDSWHU 

Figure 3.4-6 Principle SMEMA - Gate-in/out

3 - 10 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
System Principles

3.5. MCX-Control Unit

3.5.1. MCX-Controller Lay-Out (Second Generation)

,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
System Principles

3.5.2. System Board

6HFRQGJHQHUDWLRQV\VWHPERDUG
7KHV\VWHPERDUGRIWKH0&;FRQWUROOHULVD';&38EDVHGV\VWHPUXQQLQJ
DW0]7KHRQERDUGPHPRU\LV0E\WH$SLJJ\EDFN,2FRQWUROERDUGLVXVHGWR
FRQWUROWKH,2FLUFXLWU\7KHERDUGVHHILJXUHKDVWKHIROORZLQJIXQFWLRQV
l ,QWHUIDFLQJWRDOORWKHU3&%VFRQQHFWHGWRWKHPRWKHUERDUG
l +DUGGLVNLQWHUIDFLQJ
l )ORSS\GLVNLQWHUIDFLQJ
l 9LGHRLQWHUIDFH 9*$
l .HHSVWUDFNRI'DWHDQG7LPH
l .H\ERDUGLQWHUIDFH
l 6'/& ,2 LQWHUIDFHFRQWURO
To HDD (CN4)

To Servo 2 (option)
JP1 to JP3 BIOS ROM To Servo 1
JP4 to JP6
Keyboard

Floppy disk
EMG
JP7 underneath the
application board RS232 con.1

CN4 (Appl. Board) RS232 con.2


LED Good
LED I/O VGA monitor
LED Nogate
LED Timeout
Good signal
Figure 3.5-2 System board I/O-1
I/O-2
7KHMXPSHUVHWWLQJVHHILJRQWKLVVHFRQGJHQHUDWLRQV\VWHPERDUGLVIROORZLQJ
l -3WR-3 6HWWRSRVLWLRQ
l -3 6HWWRSRVLWLRQ
2QWKHDSSOLFDWLRQERDUGDOOVL[6:MXPSHUVDUHVHWWR
2))


Position 2 Position 3

Position 1 Jumper on position 2-3

Figure 3.5-3 Jumper setting

$WWKHIURQWWKLVV\VWHPERDUGKDV/('LQGLFDWRUVWKH*22'VLJQDOLQGLFDWLQJWKH
32:(5 2. WKH ,2 VLJQDO ZKLFK LV IODVKLQJ DV ORQJ DV WKHUH LV D FRUUHFW

3 - 12 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
System Principles

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FLUFXLWU\ 1RJDWH QR FRPPXQLFDWLRQ DW DOO DQG WLPHRXW QR UHVSRQVH IRU D FHUWDLQ
WLPH 

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DPRWRUPRYHPHQWLQFDVHVRPHWKLQJ·VZURQJLQVLGHWKH0&;FRQWUROOHU 6HUYR12.
9SRZHU12.HWF 7KHERDUGLVHTXLSSHGZLWKWZR6,00PRGXOHVRI0E\WH
2URQH6,00PRGXOHRI0E\WH 

7KH DSSOLFDWLRQ ERDUG HVWDEOLVKHV WKH ,2FRPPXQLFDWLRQ EHWZHHQ WKH V\VWHP ERDUG
DQGWKHYDULRXV,2ERDUGVLQWKH7RSD]7KHPDLQSURFHVVRURQWKLVERDUGLVD
0K]PLFURFRQWUROOHURIWKHEUDQG,QWHO7KHVFDQQLQJVSHHGRIWKH,2SRUWVLVDERXW
PVHF VFDQQLQJRIDOOSRUWV 

7KLUGJHQHUDWLRQV\VWHPERDUG
,Q QHZHU *(0 V\VWHPV D QHZ V\VWHP ERDUG LV EHLQJ XVHG ZKLFK PDNHV WKH XVH RI D
VHSDUDWHKDUGGLVNQRORQJHUQHFHVVDU\SOHDVHUHIHUWRILJXUH

Base system board


To servo 2 (option)
Card PC

Flash disk

To servo 1

CN6

Application board

Figure 3.5-4 Third generation system board

5322 871 63606 Service Manual Topaz 3 - 13


01.05 PA 1309/10
System Principles

7KHQHZV\VWHPERDUGLVDPRGXODUEXLOWXQLWZKLFKHQFORVHVIROORZLQJPRGXOHV

n $EDVHV\VWHPERDUG
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n $3&FDUGPRGXOH
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3 - 14 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
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, Topaz, Topaz,
Eclipse-II Emerald Emerald
Board, etc.
System Board KJ0 - M4200 - 11x KJ0 - M4200 - 01x KJ0 - M4220 - 32x KM5 - M4200 - 00x
(complete assy) - 12x - 02x
(5322 214 91532) (5322 216 04049) (5322 216 04308) (5322 216 04468)
Base System Board KJ0 - M4210 - 11x KJ0 - M4210 - 01x KJ0 - M4210 - 32x KM5 - M4210 - 00x
(2)
- 12x - 02x KM5 - M4210 - 01x
Application Board KJ0 - M4220 - 10x KJ0 - M4220 - 10x KJ0 - M4220 -10x KM5 - M4220 - 00x
(3) (3) (3)
Front Panel KJ0 - M4135 - 10x KJ0 - M4135 - 00x KJ0 - M4135 - 00x KM5 - M4135 - 00x
(1)
Memory -11x : 4Mbytes -01x : 4Mbytes 8Mbytes 8Mbytes
-12x : 8Mbytes -02x : 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


7KLVERDUGVHHILJXUHFRQWUROVWKH$&PRWRUGULYHUFLUFXLWU\
7KHVHUYRERDUGDOZD\VFRQWUROVWKHGULYHUERDUGERWKERDUGVDUHGHGLFDWHGIRUWKH
PDLQ PDFKLQH 7KH VHUYR ERDUG LV RSWLRQDO DQG FRQWUROV WKH GULYHU ERDUG ERWK
ERDUGVDUHGHGLFDWHGIRURSWLRQVVXFKDVWUD\FKDQJHUVDQGDXWRWUD\VWDFNHUV

7KHVHUYRERDUGUHFHLYHVLWVSRZHU 999 YLDWKH,6$EXV &1 RIWKH


PRWKHUERDUG7KLVSRZHULVIRUZDUGHGWRWKHGULYHUERDUGYLDFRQQHFWRU&1WRIHHG
WKHORJLFFLUFXLWU\RQWKHGULYHUERDUG

7KHSRZHUIDLOVLJQDOLVFRQQHFWHGWRWKH' ULYHU SRZHUERDUGYLDFRQQHFWRU&17KH


*RRGVLJQDOLVFRQQHFWHGWRWKHVHUYRERDUGYLDFRQQHFWRU&1

To Driver 1(2)
To Vision To Driver Power
To Driver 1(2)

Good signal
To Vision

CN7

CN9
CN10

Sticker 1

CN3 CN5 LED GOOD

Sticker 2
Encoder signals
CN8 CN1

Sticker 3
S1 Encoder signals
S3 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

7KH SXOVH ZLGWK PRGXODWLRQ DQG IHHGEDFN SRZHU IDLOXUH RYHU FXUUHQW HWF  VLJQDOV
ZKLFK FRQWURO WKH GULYHUV RQ WKH GULYHUERDUG DUH VHQG WR WKH GULYHUERDUG YLD
FRQQHFWRU&13RVLWLRQDOIHHGEDFNLVREWDLQHGIURPWKHPRWRUHQFRGHUVZKLFK DUH
FRQQHFWHGWRWKHIURQWVLGHRIWKHVHUYRERDUGYLDFRQQHFWRUV&1DQG&1

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LQIRUPDWLRQ DQG&1 HQFRGHULQIRUPDWLRQ 

,IDQHUURURFFXUVLQWKLVXQLWWKHGLVSOD\/('*22' JUHHQ ZLOOJRRXWDQGWKH


V\VWHPZLOOHQWHUWKHHPHUJHQF\VWRSVWDWH VHUYRRII 

7KHMXPSHUV6DQG6RQWKLVERDUGKDYHWKHKDYHWKHIROORZLQJVHWWLQJV

Machine type → Topaz Sapphire Sapphire LCS100


Emerald A-table B-table LCS 31
Switch ↓ Bit ↓ ATS 27
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 Sapphire Sapphire LCS100


Emerald A-table B-table LCS 31
Sticker ↓ ATS 27
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 ´&µ DVKRUWFRQQHFWRU ´6µ RUDUHOHIWXQFRQQHFWHG ´1&µ 

Machine type → Topaz Sapphire Sapphire LCS100


Emerald A-table B-table LCS 31
Connector ↓ ATS 27
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


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ODVHU 7KHERDUGOD\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 &RQQHFWRUIRUWKHILGXFLDOFDPHUD
&DPHUD´µ &RQQHFWRUIRUWKHRSWLRQDOVLQJOHYLHZFDPHUD
&DPHUD´µ ´µ 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


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VHUYRERDUGDQGYLVLRQERDUGYLDDQ,6$EXV7KHPRWKHUERDUGFRQWDLQVDOVRDQ$&
DQG'&SRZHUIDLOXUHGHWHFWLRQIXQFWLRQ7KH$&LQSXWWKH'&9DQGWKH9
9DUHPRQLWRUHG$/('LQGLFDWLRQZLOOVKRZDSRZHUYROWDJHGURSLQVWDQWDQHRXV
SRZHUIDLOXUHVDQGHUURUVLQWKH'&SRZHUVXSSO\IRUWKHFRQWUROV\VWHP7DEOH
EHORZVKRZVWKHYDULRXVSRVVLELOLWLHV
SERVO SYSTEM VISION
BOARDS BOARD BOARDS

LED 1, 2, 3, 4

CN9: I/O power

CN6: 5V IN

CN5: 12V IN

CN11: AC 12V IN CN7: FAN POWER SPARE


/HJHQGD5→/LWUHG NOT USED
 *→/LW
Figure 3.5-8 Mother board
JUHHQ ;→1RWOLW
→QRWGHILQHG
Display LED PWR NG +5V +12V -12V
(Normally (Normally (Normally (Normally NOTE
Specification off) on) on) on)
LED 1 LED 2 LED 3 LED 4
200VAC: VAC ≥ 180V X    Normal AC
(VAC) VAC ≤ 160V R    voltage drop
+5VDC: V1: ≥ 4.75V  G   Normal DC
(V1) V1: < 4,75V  X   5V
V1: < 4.5V R X   Error
+12VDC: 10.8V ≤ V2 ≤ 13.2V Normal DC
(V2) 10.8V > V2 > 13.2V   G  +12V error
  X 
-12VDC: V3 < -10.8V    G Normal DC
(V3) V3 > -10.8V    X -12V drop
Table 3.5-7 Meaning of the LED indicators

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

)ORSS\GLVN
7KH0E\WHIORSS\GULYHLVORFDWHGLQWKHVHUYLFHSDQHOEHKLQGFRYHUGRRUDWWKH
ULJKWERWWRPIURQWVLGHRIWKHPDFKLQH

7KHGULYHLVFRQQHFWHGYLDDKDUQHVVWRWKHIURQWVLGHRIWKHV\VWHPERDUG)''
FRQQHFWRU

)ODVKGLVN
,QV\VWHPVHTXLSSHGZLWKDQHZW\SHV\VWHPERDUGSOHDVHUHIHUWRVHFWLRQWKH
KDUGGLVNKDVEHHQUHSODFHGE\DQRQERDUGIODVKGLVN

7KHIODVKGLVNLVORFDWHGRQWKHV\VWHPERDUGDQGKDVWZRVORWVZKLFKDUHDFFHVVLEOH
IURPWKHIURQWVLGHRIWKHV\VWHPERDUG(DFKVORWFDQFRQWDLQDUHPRYDEOHIODVKGLVN

6WDQGDUGRQH0%IODVKGLVN  LVDYDLODEOHRQWKHV\VWHPERDUG


RSWLRQDOWKLVGLVNFDQEHUHSODFHGE\D0%GULYH,IDIODVKGLVNLVPRXQWHGLQWKH
VHFRQGVORWWKLVGLVNLVRQO\DFFHVVLEOHYLDWKHVKHOOPDQDJHU

Note:
When inserting or removing a flashdisk the Topaz should be switched off because the disk
is not protected against such handling and might get damaged. Be sure to always mount
the protective cover over the flash disk after mounting.

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 
282V power
connection CN4
CN6
CN1

Power from CN2


servo-board

From servo-board
PWM/FDB signals
CN3

Figure 3.5-10 Driver board

7KHPRWRUGULYHU'&SRZHULV9'&DQGLVVXSSOLHGE\WKH' ULYHU SRZHU


VXSSO\YLD&12QWKHGULYHUERDUGWKH9'&LVFRQYHUWHGLQWRDQ$&VLJQDO
IRUGULYLQJWKHSKDVH$&PRWRUV7KLVLVGRQHDVVKRZQLQILJXUH

U
Oscillator V
50 kHz 3 phase
AC motor
W

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\SRZHUWUDQVLVWRU ZKLFK
VZLWFKHV9 VHTXHQWLDOO\WKXVFUHDWLQJDSKDVH 89: $&VLJQDOIRUGULYLQJ
WKHPRWRUV

7KH*75 *LDQW7UDQVLVWRU PRGXOHZKLFKFRQWUROVWKHFXUUHQWLVORFDWHGDWWKH


UHDUVLGHRIWKHGULYHERDUGDQGLVPRXQWHGRQDODUJHKHDWVLQN

7KHPRWRUFXUUHQWRIDPD[LPXPRID[HVLVIHGYLD&1DQGDPD[RID[HVYLD
&1WRWKH$&PRWRUV

7KH9 ±9SRZHUIRUWKHRVFLOODWRUDQGORJLFFLUFXLWU\LVUHFHLYHGIURPVHUYR
ERDUGYLD&17KHFXUUHQWRIWKHORJLFSRZHULVFRQWUROOHGE\DQ,30 ,QWHOOLJHQW
3RZHU0RGXOH ZKLFKLVIL[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) XOO 9 LVLRQ


DQG&60*(0V\VWHPV

Factory Philips service Machine type Remarks


number no.
KJ0-M5810- xxx
-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, full populated
Sapphire

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\RIWKHFRPSRQHQWFDPHUD V 7KHUHDUHYDULRXVW\SHVRI/('GULYHUVIRU
WKH6DSSKLUHDQG7RSD]V\VWHPVWKHVDPHYHUVLRQ  LVXVHG7KLV
ERDUGFDQKDQGOHWZROLQHVHQVRU PXOWLFDPHUD OLJKWLQJRXWSXWVDQGDUHD&&'
FDPHUD VLQJOHFDPHUD OLJKWLQJRXWSXW

Light CN15 CN13 CN11 Motor


driver encoder
CN14 CN12 CN10 CN3
signals
Power and
control signals

CN2

CN1

CN9

CN8

CN7

CN6

CN5

CN4

Lighting
sensor
signals

VR1 VR2 VR3 VR4 VR5 VR6

Multi-cam 2 Multi-cam 1
Coax.light Non-coax.light
Multi-cam 1
Single camera
Coax.light
Not used Multi-cam 2
Non-coax.light
Figure 3.6-1 LED driver board

(DFKRXWSXWKDVFKDQQHOVHDFKFKDQQHOKDVDEULJKWQHVVDGMXVWPHQW 9595 
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

5HPDUNV
• 7KHMXPSHUVHWWLQJLVIL[HGDQGLVWKHVDPHIRUERWKWKH6DSSKLUHDQG7RSD]
• 7KH/('GULYHUERDUGIRUWKH(PHUDOGLV127FRPSDWLEOHZLWKWKHRQHXVHGLQ
WKH6DSSKLUH7RSD]EHFDXVHRIWKHGLIIHUHQFHLQWKHFXUUHQWOLPLWHUV

7KHIROORZLQJWDEOHVKRZVWKHUHODWLRQEHWZHHQWKHVHYHUDOFDPHUDVFRQQHFWRUV
SRWHQWLRPHWHUVPD[FXUUHQWVDQGMXPSHUVLQWKHKDUGDQGVRIWZDUH3OHDVHUHIHUWR
ILJXUHIRUWKHORFDWLRQRIWKHYDULRXVLWHPV

Vision Board Camera 1 Camera 2 Camera 3 Camera 4


“Fiducial
cam.”
LED driver board -
HARDWARE

LED driver output - 2 3 4


Light type (note 2) - A B A B A B
Potentiometer - - VR3 VR2 VR1 VR4 VR5 VR6
Output connector - - CN10 CN11 CN12 CN13 CN14 CN15
Sensor connector - - CN4 CN5 CN6 CN7 CN8 CN9
Sensor jumper - - JP9 JP10 JP11 JP12 JP13 JP14
Speed jumper - - JP4 JP4 JP6 JP6 JP7 JP7
SL-bit jumper (note 3) - - JP1 JP1 JP2 JP2 JP3 JP3
Max current [mA] - - 120 120 90 400 90 400
3/1/option config/
VIOS

camera combination - 1 2 3
3/2/MCH_DATA/ - Single camera 1 Multi camera 2 Multi camera 1
camera coordinate (note 1) (note 1)
Table 3.6-1 Vision board settings and controls

NOTE 1:
When the Topaz is only equipped with one multi camera, the camera is
defined as multi-camera 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 Right conveyor


I/O-board I/O-board

Figure 3.7-1 Location of the I/O boards

7KH7RSD]LVHTXLSSHGZLWKWKUHH,2ERDUGVRQHKHDG,2 DQG WZR FRQYH\RU,2


ERDUGVUHIHUWRILJXUH

7KHIXQFWLRQRIWKH,2ERDUGVLVWR WUDQVODWH DQG EXIIHU VLJQDOV IURPWR WKH V\VWHP


XQLWWRIURPWKHDFWXDWRUVVHQVRUV

7KHKHDG,2ERDUGSHUIRUPVDERYHIXQFWLRQIRUDOODFWXDWRUVDQGVHQVRUVLQWKHKHDG
DVV\ZKLOHWKHFRQYH\RU,2ERDUGVSHUIRUPWKLVIXQFWLRQIRUDOORWKHUDFWXDWRUVDQG
VHQVRUVLQWKHV\VWHP

6HFRQGJHQHUDWLRQ,2ERDUGV
7KH,2ERDUGVRIWKHVHFRQGJHQHUDWLRQFRQVLVWRIDPRWKHUERDUGDQGDGDXJKWHU
FRUH ERDUG

7KHPRWKHUERDUGLVDODUJH3&%FRQWDLQLQJWKH','2GULYHUVSRZHUFLUFXLWU\DQG
VRPHVHWWLQJV7KHGDXJKWHU3&%DOVRFDOOHGWKHFRUHERDUGFRQWDLQVWKHORJLFDQG
FRPPXQLFDWLRQFLUFXLWU\RIWKH,2ERDUG

5322 871 63606 Service 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 “1” = ON
“0” = OFF
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

Left/right setting
functionality

Terminator use

Terminator use
Type of board

Type of board

Type of board

No function

No function
Table 3.7-1 I/O-board DIP-switch settings

7KLUGJHQHUDWLRQ,2ERDUGV
7KH ,2ERDUGV RI WKH WKLUG JHQHUDWLRQ WKH VXFFHVVRUV RI WKH VHFRQG JHQHUDWLRQ
FRQVLVWDOVRRIDPRWKHUERDUGDQGGDXJKWHU FRUH ERDUGZLWKWKHVDPHIXQFWLRQDOLW\
DVWKHVHFRQGJHQHUDWLRQERDUGV

7KH ,QWHO  PLFURSURFHVVRU RQ WKH GDXJKWHUERDUG KDV EHHQ UHSODFHG ZLWK WKH
+LWDFKL 6+0+] SURFHVVRU WR FRQWURO WKH FRPPXQLFDWLRQ EHWZHHQ V\VWHP
ERDUGDQG,2ERDUGV7KHFRPPXQLFDWLQJSURWRFROKDVEHHQFKDQJHGIURP6'/&WR
+'/& +LJK /HYHO 'DWD /LQN &RQWURO  )RU HVWDEOLVKLQJ WKH +'/& SURWRFRO WKH
6+SURFHVVRU PDNHV XVH RI WKH GHGLFDWHG FRPSRQHQW 6$%1 DOVR ORFDWHG
RQWKHGDXJKWHUERDUG

7KHQHZSURFHVVRUUHGXFHVWKH,2VFDQQLQJWLPHWROHVVWKDQPVHFLQVWHDGRIWKH
WRPVHFLQWKHVHFRQGJHQHUDWLRQERDUGV

6LPLODU WR WKH VHFRQG JHQHUDWLRQ ,2ERDUGV WKH WKLUG JHQHUDWLRQ GDXJKWHUERDUG
SURFHVVRUPDNHVXVHRID520DQG5$0PHPRU\7KH5$0PHPRU\EDVLFDOO\KDV
QRW FKDQJHG DQG LV XVHG E\ WKH SURFHVVRU IRU WHPSRUDU\ GDWD VWRUDJH +RZHYHU WKH
520PHPRU\KDVEHHQFKDQJHGWRDIODVK520

7KLV IODVK520 LQ FRPELQDWLRQ ZLWK WKH WKLUGJHQHUDWLRQ V\VWHPERDUG DQG 9,26
VRIWZDUHRUKLJKHUHQDEOHVWKHVRIWZDUHIRUWKH6+SURFHVVRUWREHXSORDGHG
IURPWKHV\VWHPXQLWDWVWDUWXS)RUWKLVUHDVRQWKHIODVK520FRQWDLQVDUHDGRQO\
SDUWDQGDUHDGDEOHZULWDEOHSDUW7KHUHDGRQO\SDUWFRQWDLQVVRPHGHGLFDWHGVRIWZDUH
QHVVHFDU\ IRU WKH VRIWZDUH GRZQORDG 7KH UHDGDEOHZULWDEOH SDUW LV XVHG IRU WKH
VRIWZDUHGRZQORDGIURPWKHV\VWHPXQLW

7KH FRQQHFWRUV RI ERWK WKH VHFRQG DQG WKLUG JHQHUDWLRQ ERDUG DUH IXOO\ FRPSDWLEOH
HQDEOLQJXSZDUGVFRPSDWLELOLW\IRUWKH313W\SH,2ERDUGV

3 - 28 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
System Principles

7KHERDUGVRIWKHWKLUGJHQHUDWLRQDUHVKRZQLQWKHILJXUHVDQGEHORZ,Q
WKHVHILJXUHVWKHORFDWLRQRIWKHLQGLFDWRUVDQGVHWWLQJVDUHKLJKOLJKWHG

7 segment LED display 6 stage


Flash
DIP-switch D1 D3
memory 2 stage DIP switch LED-2

Figure 3.7-2 Conveyor I/O-board

Flash 7 segment LED display


memory
LED-2
2 stage DIP switch

D3 D5
Figure 3.7-3 Head I/O-board 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 “1” = ON
“0” = OFF
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

7KHWKLUGJHQHUDWLRQERDUGVKDYHWKHVDPHDPRXQWRI',3VZLWFKHVDVWKHVHFRQG
JHQHUDWLRQERDUGVKRZHYHUWKHVZLWFKHVIRUWHUPLQDWRUXVHKDYHEHHQPRYHGWRWKH
GDXJKWHUERDUG FRUHERDUG UHIHUWR´VWDJH',3VZLWFKµLQILJXUHVDQG
7KHVHWWLQJVDUHVKRZQLQWKHWDEOHEHORZ

Sapphire Emerald/Topaz “1” = ON , enable


“0” = OFF, disable
Dipswitch: 1 2 1 2

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

Board types : Suitable for machines ROM versions Core board +


(for abreviations see table (latest version, basic Mother-board :
below) : flash ROM indicated
with F) :
Conveyor KG2-M4520-21x (npn) EI, CI KG2-M45R9-002 n.a.
I/O (5322 214 91259)
KG2-M4580-00x (pnp) EI*, EII, EM, O, T, CI*, CII, S KG2-M45R9-023 n.a.
(5322 216 04002)
(2) (2) (2)
KM5-M4580-00x (pnp) EII, O, EM , T , S KM5-M45R9-10X (F) KM5-M4560-11X +
(5322 216 04471) KM5-M4582-00X
Head I/O KG2-M4520-11X (npn) CI KG2-M45R9-002 n.a.
(5322 214 91258)
KG2-M4570-00X (pnp) CI*, CII KG2-M45R9-023 n.a.
(5322 216 04004)
KG7-M4520-01X (npn) EI KG7-M45R9-00X n.a.
(5322 214 91374)
KG7-M4570-01X (pnp) EI*, EII, EM KG2-M45R9-023 n.a.
(5322 216 04001)
(1)
KM5-M4570-00X (pnp) S KG2-M45R9-030 n.a.
(5322 216 04313)
KM5-M4570-01X (pnp) S KM5-M45R9-10X (F) KM5-M4560-11X +
(5322 216 04469) KM5-M4572-00X
KM1-M4570-00X (pnp) O, T KG2-M45R9-023 n.a.
(5322 216 04083)
KV1-M4570-00X (pnp) O, T KM5-M45R9-10X (F) KM5-M4560-110 +
(5322 216 04628) KV1-M4572-00X

Abreviation Meaning Remarks:


EI Eclipse I
1. Board will be stopped in March 1998 and replaced by
EI* Eclipse I-CE
KM5-M4570-01X.
EII Eclipse II
2. This board is standard implemented in these machines
EM Emerald
from December 1998 onwards, for Sapphire from august
CI Comet I
CI* Comet I-CE
1998 onwards.
CII Comet II
S Sapphire
O Orion
T Topaz

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

7KHFRQQHFWLRQERDUGLQWHUFRQQHFWVDOOVLJQDOVIURPDQGWRWKHVHQVRUVVZLWFKHV
UHOD\VDQGVRPHYDOYHV$OOVLJQDOVZKLFKDUHQRWGLUHFWO\FRQWUROOHGE\WKH0&;
FRQWUROOHUDQG,2·VVLJQDOVZKLFKDUHFRQWUROOHGGLUHFWO\E\WKH,2ERDUGVDUHQRW
JRLQJYLDWKHFRQQHFWLRQERDUG7KHERDUGLVDOVRGLVWULEXWLQJWKH9'&FRPLQJ
IURPWKH*6SRZHUVXSSO\DQGZKLFKLVXVHGIRUWKH,2DQGWKH(0*FLUFXLWV

)URP$SULORQZDUGVWKH7RSD]V\VWHPLVHTXLSSHGZLWKWKHW\SHRIFRQQHFWLRQ
ERDUGWKDWLVDOVRXVHGLQWKH;VHULHV7RSD]6RWKHQGJHQHUDWLRQFRQQHFWLRQERDUG
.80; ZLWKVHUYLFHQR KDVEHHQUHSODFHGE\DQHZ
YHUVLRQWKHUGJHQHUDWLRQFRQQHFWLRQERDUG.90; ZLWKVHUYLFHQR
 

Connection-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 UGJHQHUDWLRQ DQGWKHROGHU


.80;ERDUG QGJHQHUDWLRQ DUH
 7KHUGJHQHUDWLRQERDUGFRQWDLQVPRUH/('LQGLFDWRUV
Π/('6 UHG IRU(0*LQGLFDWLRQV
Π/('6 JUHHQ IRUWKHYDULRXV9SRZHUVRXUFHV
 $WWKHUGJHQHUDWLRQERDUGRQO\RQH9LQSXWFRQQHFWLRQ &1) LVXVHG
7KLVPHDQVWKDWWKHFRQQHFWRUJRLQJWR&1)RQWKHQGJHQHUDWLRQ
FRQQHFWLRQERDUGLVQRWXVHGDQ\PRUHDQGFDQEHVWRZHGDZD\LQWKHFDEOHGXFW
 7KHUGJHQHUDWLRQERDUGFRQWDLQVDXWRPDWLFIXVHV7KHVHIXVHVSURWHFWWKHYDULRXV
9SRZHUVVRXUFHV7KHIXVHVDUHRIDW\SHZKLFKWULSDERYHDFHUWDLQFXUUHQW
DQGUHVWRUHVLWVHOIDIWHUSRZHULVGLVFRQQHFWHG

,QFKDSWHUDGHWDLOHGORJLFGLDJUDPLVVKRZQRIERWKERDUGVDQGRQWKHQH[WSDJHV
WKHOD\RXWRIERWK3&%·VDUHVKRZQ6LQFHWKH3&%LVYHU\LPSRUWDQWIRUWKHVDIHW\
FLUFXLWDQXPEHURI/('·VDUHPRXQWHGRQWKH3&%WRLQGLFDWHWKH(0*VWDWXV)RU
PRUHLQIRUPDWLRQRQWKHVH/('·VSOHDVHUHIHUWRFKDSWHU´3RZHUDQG6DIHW\µRIWKLV
PDQXDO2QWKHERDUGVVRPHMXPSHUVHWWLQJVFDQEHVHWWRFRQILJXUHWKHV\VWHP
GHSHQGLQJRQWKHDGGHGRSWLRQVDQGRUIHDWXUHV

3 - 32 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
System Principles

nd
3.8.2. 2 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: The EMG harness of the trayfeeder should be connected to CNF26 and CNF28.

Note 2: The speedcontroller connects on SP1, the jumper harness does not connect on
CNF2 and CNF3.

Note 3: When a special emergency input is added, set bit 3 of S3 to OFF and connect
the emergency signal harness to CNF25 (dry contact).

5322 871 63606 Service Manual Topaz 3 - 33


01.05 PA 1309/10
System Principles

)LJXUHVKRZVWKHFRPSOHWHOD\RXWRIWKHQGJHQHUDWLRQFRQQHFWLRQERDUG

nd
Figure 3.8-2 2 generation connection-board layout

3 - 34 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
System Principles

rd
3.8.3. 3 Generation Connection-Board

'LSVZLWFKVHWWLQJV
:KHQXVLQJWKHUGJHQHUDWLRQFRQQHFWLRQERDUGZLWKIDFWRU\QR.90;
LQFRPELQDWLRQZLWKDQH[WHUQDOGHYLFHWKHGLSVZLWFK MXPSHU VHWWLQJVRI6DQG6
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

,QVRPHVFKHPDWLFV6KDVMXPSHUVZLWFKHV7KHDGGLWLRQDOMXPSHUV LQWKDWFDVH
ELWDQG DUHPHDQWIRUDUHDVHQVRUVHOHFWLRQV7KLVRSWLRQLVQRWXVHGLQWKHFXUUHQW
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
1
LCS OFF ON ON ON OFF ON
2
ATS27 OFF ON ON ON ON ON
3
ATS27 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

rd
Figure 3.8-4 Connection-board KV7-M4550-11X (3 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
Emergency
button Joy stick
Full keyboard
enable key-
Dead man switch
swit ch

R ead y Runni ng

Stop R un
Ready
Res et Error
cl ear

Hand held Manu al


Joy Speed
stick
Sel
axi s
Axis
group

keyboard Scree n

Esc H elp F9 F10


See full
Tab Ins keyboard
C trl Del

Sh ift Ent er

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 S D F G H J K L Enter
A, B, C ....Z
Shift Z X C V B N M Shift

Ctrl Ctrl S D 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 $VHULDOFRPPXQLFDWLRQOLQH 56 JRLQJWRWKH&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

7KHNH\ERDUGKDVLWVRZQYROWDJHFRQYHUWHU 9WR9'& DQGPLFURSURFHVVRUWR


FRQWUROWKHNH\IXQFWLRQVDQGWKHVHULDOFRPPXQLFDWLRQZLWKWKH0&;FRQWUROOHU

7KH GHDGPDQ SXVK EXWWRQ LV DGGHG IRU VDIHW\ UHDVRQV WKLV EXWWRQ PXVW EH SUHVVHG
FRQWLQXRXVO\LIDVHUYRDFWLRQZKLOHWKHIURQWUHDUVDIHW\FRYHUVDUHRSHQ

7KH++.LVHTXLSSHGZLWKDVRFDOOHG¶IXOONH\ERDUGHQDEOHNH\·WKLVNH\LVFRQQHFWHG
WRWKHKDQGKHOGNH\ERDUGE\PHDQVRIDFKDLQ:KHQWKHNH\LVLQVHUWHGLQWKHNH\
VZLWFKRQWKHULJKWIURQWFRYHUWKLVZLOOHQDEOHWKHIXOONH\ERDUG:KHQWKHNH\LVRXW
RIWKHNH\VZLWFKQRDFWLRQVDQGFRPPDQGVFDQEHJLYHQIURPWKHIXOONH\ERDUG7KLV
SURYLVLRQLVWRFRPSO\WRWKH(XURSHDQVDIHW\UXOHV &( 

NOTE: If one of the SERVICE KEY-switches (front and/or rear) of the system are activated, there is
only a limited function possible with the hand-held key-board. The only actions possible are
the joystick and emergency-button actions, all other buttons are disabled because of safety
reasons.

5322 871 63606 Service Manual Topaz 3 - 39


01.05 PA 1309/10
System Principles

3.10. Monitors
7KHV\VWHPKDVWZRPRQLWRUV VHHILJXUH ORFDWHGDWWKHWRSRIWKHPDFKLQHRQH
9,26PRQLWRU VHHSDUDJUDSK DQGRQHYLVLRQPRQLWRU VHHSDUDJUDSK 
%RWKPRQLWRUVFDQEHVKLIWHGWRWKHUHDUVLGHE\URWDWLQJGHJUHHVIRUHDV\XVH

Vision VIOS
monitor 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:KLWH 3KLOLSVYLGHRPRQLWRUIRUGLVSOD\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 ,2PRQLWRUVHHILJXUH LVDYDLODEOHWKDWJLYHVLQIRUPDWLRQRIDOOLQSXW
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

Out Monitor :Select [Enter]:Exec Selected Arm:MAIN XY


[ESC]:Command Lists Moving Speed: 100
Dialogue box TR09 TRAY CHANGER SPARE

N A M E OUT N A M E IN

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
Screen 1 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

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
Screen 2 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

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
Screen 3 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 ´µ DQGWKHQRWDFWLYHVWDWH ´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
2 XWSXWV XVHGLQWKH7RSD]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
, QSXWV XVHGLQWKH7RSD]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
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IRXQGLQFKDSWHURIWKLVPDQXDO

4.2. Safety Circuit

4.2.1. Description
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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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WKLVQHZYHUVLRQ

QGJHQHUDWLRQFRQQHFWLRQERDUG.80;

Figure 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)
nd
Table 4-1 Meaning of LED’s on the 2 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

QGJHQHUDWLRQFRQQHFWLRQERDUG.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
rd
Table 4-2 Meaning of LED’s on the 3 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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Note: 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


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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

Output
CP50
Jumper input terminal
voltage

CP51 Output
terminal
CP1 CP2 CP3(115V)
(230V)
R57
Input Output
R76 CP52
terminal W1 terminal
R83 R86

Output voltage PFS signal Output voltage


adjust trimmer adjust trimmer adjust trimmer

Figure 4-5 Power supply PCB layout

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01.05 PA 1309/10 4-7
Power and Safety Circuits

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XVHG

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Figure 4-6 Jumper setting

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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)


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9±

Figure 4-7 Back GS21


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70DQG7&

5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 4-9
Power and Safety Circuits

 D - Power Assembly (282V Power)


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Fuse 1
200V AC (U) IN
200V AC (V) IN
200V AC (W) IN

LED 5
LED 4
LED 3
LED 2
Fuse LED 1
FU2

Jumper 1
282V to Driver-
boards

Cap 1

18V in from
trafo CN1 Interlock CN3
EMG
CN2

Figure 4-8 D(river) power assy

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2.

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4 - 10 PA 1309/10 01.05
Power and Safety Circuits

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Interlock 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 Temp./voltage 4 Temp. is under 65 degrees Celcius AND the
EMG CN2 pos.1-2 Over flow 1 ouput is under 414V DC.

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01.05 PA 1309/10 4 - 11
Power and Safety Circuits

4.3.5. Measuring and Adjusting Data

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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

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• &ORVHWKHSRZHUER[GRRUV

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4 - 12 PA 1309/10 01.05
Power and Safety Circuits

4.3.6. Performance Check and Trouble Shooting


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4.3.7. Maintenance Instructions


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• &KHFNDOOIXVHVLQWKHPDLQVFLUFXLW

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01.05 PA 1309/10 4 - 13
Power and Safety Circuits

Intentionally left blank.

Service Manual Topaz 5322 871 63606


4 - 14 PA 1309/10 01.05
Vacuum and Pneumatic Systems

CHAPTER 5 Vacuum and Pneumatic Systems

 Vacuum Systems

 Introduction
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 Functional Description


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Air switch ON/OFF

Figure 5-1 Valves

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ORFDWHGEHKLQGWKHORZHUOHIWSDQHODWWKHOHIWVLGHRIWKHPDFKLQH

5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 5-1
Vacuum and Pneumatic Systems

 Air Supply Unit


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WKHPDFKLQHDORQJZLWKDSUHVVXUHUHJXODWRU7KHDLUSUHVVXUHUHJXODWRUPXVW
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 Air Pressure Regulator


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IROORZV
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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


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E 0806

QUICK STOP ACTIVE “NM09 AIR


PRESSURE SW”.
QUICK STOP FUNCTION for safety is
now active.
To continue, please check the supplied air

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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


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 Performance Check and Trouble Shooting


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 Maintenance Instructions


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Service Manual Topaz 5322 871 63606


5-4 PA 1309/10 01.05
Vacuum and Pneumatic Systems

 Pneumatic Systems

 Introduction
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7RSD]DQG7UD\&KDQJHU

 Functional Description


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FRQWUROOHGE\HOHFWULFDOVROHQRLGV7KHSQHXPDWLFF\OLQGHUVDUHFRQWUROOHGE\DLU
VROHQRLGYDOYHV

 Topaz
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VDQG
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 Tray Changer (TC)


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PDFKLQH

 Tape Feeders


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HOHFWULFDOFRQQHFWLRQV

 Automatic Tray Stacker


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PDFKLQHDVZHOODVWKHHOHFWULFDOVLJQDOVUHTXLUHG

 FES/SVS
7KHFRPSUHVVHGDLUXVHGLQWKH)(6DQG696V\VWHPVDUHVXSSOLHGYLDWKH
PDFKLQH FRQQHFWHGYLDWKHLQWHUIDFHER[ 

5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 5-5
Vacuum and Pneumatic Systems

 Measuring and Adjusting


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7KHWZRSRZHUVXSSO\
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RIWKHV\VWHP

 Performance Checks and Trouble Shooting


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VHWWLQJVFUHHQ

 Maintenance Actions


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Service Manual Topaz 5322 871 63606


5-6 PA 1309/10 01.05
Vacuum and Pneumatic Systems

 Exchanging Head Ejectors, Valves and Base


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 Exchanging the Head Ejector and/or Valves

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Figure 5-4 Ejector and Valves

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SUHYLRXVSURFHGXUH´9DOYHUHSODFHPHQWµ

5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 5-7
Vacuum and Pneumatic Systems

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 /RRVHQWKHWZRVFUHZVLQWKHOHIWRUULJKWHQGEORFN
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 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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SURFHGXUHV´8S'RZQYDOYHUHSODFHPHQWµDQG´6ORZYDOYHUHSODFHPHQWµ

Service Manual Topaz 5322 871 63606


5-8 PA 1309/10 01.05
Vacuum and Pneumatic Systems

 ,QVWDOOWKHUHPRYHGYDOYHVRQWRWKHQHZYDOYHEDVHE\IROORZLQJVWHSVDQG
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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 PCB Transport Systems

6.1. Introduction
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EHORZFRQVLVWVRI

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Figure 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


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 Adjusting the Conveyor Belt Tension


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Figure 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


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Figure 6-3
Carry-in conveyor speed adjusting screws
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Out Monitor [↑↓←→] : Select [Enter] : Exec Selected Arm : MAIN XY
[ESC] : Command Lists Moving Speed : 100
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\RUVZLWFKWKHVSHHGDVIROORZV ILJXUH 
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ZKHQLWLVDWKLJKVSHHG

Out Monitor [↑↓←→] : Select [Enter] : Exec Selected Arm : MAIN XY


[ESC] : Command Lists Moving Speed : 100
TN14 CONVEYOR SPEED LOW
HIGH 0 / LOW 1
( = 0 / = 1)

NAME OUT NAME IN

Conveyors TN09-16 00001100


Figure 6-5 Output
monitor screen, conveyor speed

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Service Manual Topaz 5322 871 63606


6-4 PA 1309/10 01.05
PCB Transport Systems

6.3. Main Stopper


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Rear right side


of the Topaz
Figure 6-6 Main stopper and air solenoid valve

 Adjusting the Ascent/Descent Speeds of the Main Stopper


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 6HOHFW0$,17(0!!!0$18$/!!&',63/$<
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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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Figure 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


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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.

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01.05 PA 1309/10 6-7
PCB Transport Systems

6.4. Push-In
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Rear right side


of the Topaz
Figure 6-10 Push in and air solenoid valve

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Figure 6-11 Ouput monitor screen, activate push in

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6-8 PA 1309/10 01.05
PCB Transport Systems

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Figure 6-12 Exploded view Push-in

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01.05 PA 1309/10 6-9
PCB Transport Systems

6.5. Locate Pin


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Figure 6-13 Locate pin arrangement

Rear right side


of the Topaz
Figure 6-14 Locate pin and air solenoid valve

Service Manual Topaz 5322 871 63606


6 - 10 PA 1309/10 01.05
PCB Transport Systems

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Figure 6-15 Output monitor, activate locate pins

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01.05 PA 1309/10 6 - 11
PCB Transport Systems

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Figure 6-16 Exploded view Locate pin assembly

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6 - 12 PA 1309/10 01.05
PCB Transport Systems

6.6. Edge Clamp


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71

Rear right side


of the Topaz

Figure 6-17 Air solenoid rear right side of Topaz

Figure 6-18 Exploded view edge clamp assembly

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01.05 PA 1309/10 6 - 13
PCB Transport Systems

6.7. Push-Up
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Rear right side


of the Topaz
Figure 6-19 Push-up and air solenoid valve

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Figure 6-19a PCB supporter pins

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6 - 14 PA 1309/10 01.05
PCB Transport Systems

Figure 6-20 Output monitor, activate push-up

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CAUTION
When 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.

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01.05 PA 1309/10 6 - 15
PCB Transport Systems

6.8. PCB Detection Sensors


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SQ53 SQ57 SQ54 SQ51 SQ52

PCB

SQ52 SQ51 SQ54 SQ57 SQ53

PCB

Figure 6-21 PCB detection sensors

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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

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6 - 16 PA 1309/10 01.05
PCB Transport Systems

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Figure 6-22 PCB sensors detection errors

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[ESC] : Command Lists Moving Speed : 100
NL09 SET POSITION
DETECT 1

NAME OUT NAME IN

Conveyor NL09-16 10000000

Figure 6-23 Input monitor

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01.05 PA 1309/10 6 - 17
PCB Transport Systems

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Figure 6-24 Adjusting the position of the PCB detection sensor

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6 - 18 PA 1309/10 01.05
PCB Transport Systems

6.9. Conveyor Errors


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

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01.05 PA 1309/10 6 - 19
PCB Transport Systems

Intentionally left blank.

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6 - 20 PA 1309/10 01.05
Component Transport Systems

CHAPTER 7 Component Transport Systems

7.1. Introduction
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7.2. Head Assembly


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Head descent movement Check that each head descends smoothly


Head lower end detection Check that the lower end is correctly detected when each
head descends.
Vacuum generation Check that the vacuum ejector provides adequate vacuum
levels.
Vacuum sensor function Check that the vacuum sensor display levels are correct.
Machine coordinates (position) These coordinates include the stand-by point for the head
and discard point for components
Pick and mount vacuum levels The reference vacuum pressure (suction) is used to
determine whether each head has picked up or mounted a
component.
R-axis absolute accuracy offset* Angular offset for the R-axis that rotates each nozzle shaft.
Nozzle correction* This is used to correct an off-center nozzle shaft when it
rotates by 180 degrees.
Head offset* The position of the heads related to fiducial camera

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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


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Note1:
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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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 7- 3
Component Transport Systems

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<COMMAND_LIST> A/CHANGE_CONDITION

VACUUM SENSOR LEVEL

CURRENT MAXIMUM MINIMUM HEAD


137 187 3 A1
135 186 2 A2


Figure 7-2 Vacuum level display

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Service Manual Topaz 5322 871 63606


7-4 PA 1309/10 01.05
Component Transport Systems

7.2.2. Machine Coordinates


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Figure 7-3 Machine coordinates editing screen

A) Fine angle
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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
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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 7- 5
Component Transport Systems

C) Locate pin
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D) Edge clamp
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E) Wait point
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Service Manual Topaz 5322 871 63606


7-6 PA 1309/10 01.05
Component Transport Systems

F) Discard point
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NOTE:
It is also possible to teach the height on the fixed conveyor rail surface, which is
basically the same height as the PCB surface.

5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 7- 7
Component Transport Systems

H) Dual recognition offset


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I) Simultaneous pickup area


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L) Retry limit
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M) Dump point
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N) Moving height
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Service Manual Topaz 5322 871 63606


7-8 PA 1309/10 01.05
Component Transport Systems

7.2.3. Pickup and Mount Vacuum Levels


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Editing Object Vacuum Level

Head No. Low level High level


Head 1 141 160
Head 2 137 162
Head 3 10 150
Head 4 10 150
Head 5 10 150
Head 6 10 150
Head 7 10 150
Head 8 10 150

Figure 7-4
Current vacuum levels

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A) Pick level adjustment:


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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 7- 9
Component Transport Systems

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<<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

Head Target
ALL Pick
Vacuum Level
Key in 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. • • •

1 2 3 4 5 6 7 8
Level XXX XXX 0 0 0 0 0 0
Max. XXX XXX 0 0 0 0 0 0
Current XXX XXX 0 0 0 0 0 0
Result XXX XXX 0 0 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


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<<<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

Head Target
ALL Pick
Vacuum Level
Key in 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. • • •

1 2 3 4 5 6 7 8
Level XXX XXX 0 0 0 0 0 0
Min. XXX XXX 0 0 0 0 0 0
Current XXX XXX 0 0 0 0 0 0
Result XXX XXX 0 0 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


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WKHFRPSRQHQW:KHQ\RXVHOHFW$VHOHFWWDUJHW!´5D[LVDFFXUDF\µ
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<<MODE>> 2/MCH_DATA

Editing Object R Axis Accuracy

Head No. 0deg. 180deg. 90deg. -90deg.


Head 1 0.00 0.07 0.00 0.00
Head 2 0.00 0.20 0.00 0.00
Head 3 0.00 0.00 0.00 0.00
Head 4 0.00 0.00 0.00 0.00
Head 5 0.00 0.00 0.00 0.00
Head 6 0.00 0.00 0.00 0.00
Head 7 0.00 0.00 0.00 0.00
Head 8 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”

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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


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([DPSOHLV4)33/3UHVVWKHHPHUJHQF\EXWWRQDQGDWWDFKD4)3
QR]]OH W\SH WRHDFKKHDG

Calibrating the R-axis accuracy


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7.2.5. Nozzle Correction


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<<<APPLICATION>>> 3/MAINTE/M
<<MODE>> 2/MCH_DATA

Editing Object NozzleCorrection

Head No. X Y
Atbl Head 1 -0.03 0.03
Atbl Head 2 0.00 0.00
Atbl Head 3 0.00 0.00
Atbl Head 4 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


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<<<APPLICATION>>> 3/MAINTE/M
<<MODE>> 2/MCH_DATA

Editing Object Head Offset

Head No. HeadType X Y Z nozzle


Head 1 AutoNzlChg. 0.00 0.00 0.00 TYPE-31
Head 2 AutoNzlChg. 25.00 12.00 0.95 TYPE-32

Head 7 None 0.00 0.00 0.00 TYPE-31


Head 8 None 0.00 0.00 0.00 TYPE-31

Figure 7-9

Note
This offset is automatically corrected when you execute mount feedback. Since
the position of Head 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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Figure 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


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EHORZ

Figure 7-11 Nozzle sensor amplifier

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Out Monitor [↑↓←→] : Select [Enter] : Exec Selected Arm : MAIN XY


[ESC] : Command Lists Moving Speed : 100
TP02 FRONT NOZZLE STATION CLAMP
CLAMP 0 / OPEN 1
(NP14= 1 / NP14= 0)

NAME OUT NAME IN

Nzl Clamp/Spare TP01-08 01000000

Nzl Clamp/Spare NP09-16 00000100

Figure 7-12 Nozzle clamp in output monitor

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7 - 16 PA 1309/10 01.05
Component Transport Systems

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In Monitor [↑↓←→] : Select [Enter] : Exec Selected Arm : MAIN XY


[ESC] : Command Lists Moving Speed : 100
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

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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


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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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7 - 18 PA 1309/10 01.05
Component Transport Systems

Out Monitor [↑↓←→] : Select [Enter] : Exec Selected Arm : MAIN XY


[ESC] : Command Lists Moving Speed : 100
TP02 FRONT NOZZLE STATION CLAMP
CLAMP 0 / OPEN 1
(NP14= 1 / NP14= 0)

NAME OUT NAME IN

Nzl Clamp/Spare TP01-08 01000000

Nzl Clamp/Spare NP09-16 00000100

Figure 7-14

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Caution
When moving the head assembly, do not push on the camera or head shaft.
The settings for the coordinates may become unreliable.

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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.

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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 7- 19
Component Transport Systems

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 FRRUGLQDWHV\RXPDGHDQRWHRILQ6WHSDORQJWKH´1]O6WDWLRQµURZ

Editing Object Nozzle Station

Nzl.Station No. X Y Z R Nzl.Type HeadNo.


Nzl. Station 1 13.78 57.33 74.62 -59.44 TYPE-34 Head1
Nzl. Station 2 20.13 32.33 74.54 -57.95 TYPE-3F Head1
Nzl. Station 3 -29.50 19.00 69.0 -57.21 TYPE-33 Head1
Nzl. Station 4 19.44 5.72 74.63 -59.71 TYPE-3F Head1
Nzl. Station 5 -29.50 -6.00 69.00 -57.21 TYPE-3F Head1
Nzl. Station 6 6.75 39.40 76.64 -57.97 TYPE-3F Head2
Nzl. Station 7 -43.50 34.00 69.00 -18.36 TYPE-3F Head2

Nzl. Station 14 31.21 23.41 72.08 -18.39 TYPE-31 Head2


Nzl. Station 15 31.16 11.07 71.99 -18.51 TYPE-31 Head1
Nzl. Station 16 -43.50 -6.00 69.00 -18.36 TYPE-32 Head1

Figure 7-15 Nozzle station coordinates screen

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3UHVVWKH>(6&@NH\WKHQVHOHFW^$6$9( 48,7`RU^$6$9(`DQG
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 &KHFNWKDWWKHQR]]OHFDQEHH[FKDQJHGVPRRWKO\
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$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


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VWDWLRQ

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Service Manual Topaz 5322 871 63606


7 - 20 PA 1309/10 01.05
Component Transport Systems

7.4. Feeder Plates


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PDFKLQHGDWDLQRUGHUWKDWHDFKKHDGSURSHUO\SLFNVXSDFRPSRQHQW$OVR
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SDUWRIWKLVFKDSWHUH[SODLQVKRZWRDGMXVWWKHIHHGSLWFKDQGVSHHGRIWKHWDSH
IHHGHUV

7.4.1. Feeder Plate Parallel Adjustment


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IHHGHUEORFNSRVLWLRQV 0RXQWWZRIHHGHUEDUDGMXVWPHQWEORFNVRQWKH
IHHGHUEDUDWWKHHQGDQGEHJLQQLQJ

Figure 7-16 Feeder plates (top view)

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VHFXULQJWKHIHHGHUSODWH IRUH[DPSOHRUSRLQWVLQVLGHWKHERWKHQGVRI
WKHIHHGHUSODWH 

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01.05 PA 1309/10 7- 21
Component Transport Systems

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SRVLWLRQV

7.4.2. Feeder Block Positions


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DUHSURYLGHG7KHVHSLFNXSSRVLWLRQVDUHGLYLGHGLQWRVHYHQIHHGHUEORFNVSHU
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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 104.

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<<<APPLICATION>>>1/OPERATION/M 2/DATA/M 3/MAINTE/M
<<MODE>> 1/MCH-CONFIG 2/MCH_DATA
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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 Y
FeederPlate 1 51.50 3.53
FeederPlate 2 179.50 3.51
FeederPlate 3 307.50 3.35
FeederPlate 4 435.50 3.51
FeederPlate 5 563.50 3.53

Figure 7-18 Feeder plate offset editing screen

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 3UHVVWKH>)@NH\WZLFHWRSHUIRUPWHDFKLQJ

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01.05 PA 1309/10 7- 23
Component Transport Systems

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 3HUIRUPWKHFRPSRQHQWSLFNXSWHVWWRFKHFNWKHVHWWLQJV7KLVWHVW
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VHFWLRQ&RPSRQHQWSLFNXSWHVW ,IDQ\RIIVHWLVIRXQGFRUUHFWLW
RQWKHIHHGHUSODWHRIIVHWVFUHHQ

7.4.3. Component Pickup Test


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 5HIHUDOVRWRILJXUHVDQG

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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.

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01.05 PA 1309/10 7- 25
Component Transport Systems

7.4.4. Feeder Plate Maintenance


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7 - 26 PA 1309/10 01.05
Component Transport Systems

7.5. Component Feeders


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7.5.1. Tape Feeders


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DGMXVWHGFRUUHFWO\.

Adjustment item Tape feeder type


Feed pitch All feeder except 8mm and 32 mm tape
feeder
Feeder speed 16 mm, 24 mm, 32 mm and 44 mm tape
feeders
Tape peeling load 8 mm and 12 mm tape feeders
Lock lever position 32 and 44 emboss tape feeders
Figure 7-21

Tape feeder pitch


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GHSHQGLQJRQW\SHRIFRPSRQHQWV7KHWDSHIHHGSLWFKRQWKHWDSHIHHGHUPXVW
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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

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01.05 PA 1309/10 7- 27
Component Transport Systems

8mm (for 0402 chip) and 12mm tape feeders


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Figure 7-23 8mm (0402 chip) tape feeder

Figure 7-24 12mm tape feeder

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7 - 28 PA 1309/10 01.05
Component Transport Systems

16mm, 24mm, 32mm, 44mm tape feeders


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Figure 7-25 16mm, 24mm, 32mm, 44mm tape feeders

Feeder speed (for 12 LP, 16, 24, 32 and 44mm tape feeders)
7KHVSHHGDGMXVWHUOLQNHGWRWKHDLUF\OLQGHURIWKHWDSHIHHGHUDOORZV\RXWR
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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


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7KHWRSWDSDQGFDUULHUWDSRIDWDSHUHHODUHJOXHGZLWKDGKHVLYH,IWKLV
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Figure 7-27

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Figure 7-28 Adjusting the lock lever position

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7 - 30 PA 1309/10 01.05
Component Transport Systems

7.5.2. Minimum Timer / Load Timer / Down Timer


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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
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WKDWWKHQR]]OHLQWKHORZHUHGSRVLWLRQFDQSLFNXSDFRPSRQHQWZLWKRXWIDLO
7KHWLPHLVH[SUHVVHGLQKXQGUHGWKVRIDVHFRQG

Load timer
7KHORDGWLPHULVWKHWLPHIURPZKLFKWKHDLUF\OLQGHULVWXUQHGRIIXQWLOWKH
QH[WFRPSRQHQWLVVHFXUHO\GHOLYHUHGWRWKHSLFNXSSRVLWLRQ7KLVLVH[SUHVVHG
LQKXQGUHGWKVRIDVHFRQG.

Down timer
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EHLQJORZHUHGRQWRWKHFRPSRQHQW LQWKRXVDQGWKRIDVHFRQG

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
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DUHDYDLODEOH

3$ PP7DSH)HHGHUPPSLWFK5HHO
3$ PP7DSH)HHGHUPPSLWFK5HHO
3$ PP7DSH)HHGHUPPSLWFK5HHO
3$ PP7DSH)HHGHU5HHO
3$ PP7DSH)HHGHU5HHO
3$ PP7DSH)HHGHU
3$ PP7DSH)HHGHU
3$ PP7DSH)HHGHU
3$ 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

every Daily Weekly Monthly > 1/2 million > 2 million


Item
feeder
change indexes indexes

Tape waste
clean
Cleanliness
check
Tape path
clean
Transport assy
clean
Top cover assy
clean
Moving parts
lubricate
Top foil wheel
replace
Bottom surface
check

Figure 7-30 Preventive Maintenance Schedule

b) Recommended Materials:

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9DFXXPFOHDQHU IRUPDLQWHQDQFHFORVHWRWKH7RSD]
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3DLURIWZHH]HUV
6PDOOEUXVKHV
4WLSV
/LQWIUHHWLVVXHSDSHU
,VRSURSDQRO
/LJKWPDFKLQHRLO HJ6KHOO7HOOXV
6FUHZGULYHU3KLOLSVQR
IHHOHUJDXJHVRIPPWKLFN
6HDOORFNDJHQW /RFNWLWH
3XQFKPD[LPDOGLDPPP
$OOHQNH\PP
6FUHZGULYHU 7RUFQR7
+DPPHU VPDOO

5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 7- 33
Component Transport Systems

c) Checking the Cleanliness


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5HTXLUHGWLPH KU SHUIHHGHU
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 &OHDQ WKH IHHGHU ZLWK FRPSUHVVHG DLU RU ZLWK D
YDFXXPFOHDQHUWRUHPRYHDOOGXVW

d) Tape Path Cleaning


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FRPSRQHQW GHEULV DGKHULQJ WR WKH WDSH WUDYHOOLQJ
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SDWK DUHD XQGHUQHDWK WKH WRS FRYHU SODWH &OHDQ LI
QHFHVVDU\ ZLWK WKH UHFRPPHQGHG HTXLSPHQW DQG
PDWHULDOV

e) Tape Transport Cleaning


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5HTXLUHGWLPH KU SHUIHHGHU
3URFHGXUH  &KHFN LI WKHUH LV DQ\ GLUW RQ WKH VSURFNHWV RI WKH
VSURFNHW ZKHHO RQ WKH WZR SDZOV WKH SDZO ZKHHO
DQGLQEHWZHHQWKHZKHHOV

&OHDQLIQHFHVVDU\ZLWKWKHUHFRPPHQGHGHTXLSPHQWDQGPDWHULDOV1HYHUXVHD
VROYHQWRWKHUZLVHWKHJUHDVHLQVLGHWKHWUDQVSRUWDVV\ZLOOEHGLVVROYHG

f) Top Cover Plate cleaning


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3URFHGXUH  8QORFNWKHORFNOHYHU  VRWKDWWKHWRSFRYHUSODWH
 LVOLIWHG
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VOLGLQJVPRRWKO\
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VPRRWKO\WKHQWKHWRSFRYHUSODWHPXVWEHUHSODFHG
 &KHFNLIWKHWRSFRYHUSODWHLVQRWEHQWHOVHUHSODFH
WKH WRS FRYHU 5HIHU WR VSDUH SDUW VHFWLRQ IRU RUGHU
QXPEHUV
 &KHFNLIWKHWRSFRYHUSODWHLVQRWEHQWHOVHUHSODFH
WKHWRSFRYHU)RURUGHUQXPEHUVUHIHUWRWKHVSDUH
SDUWVVHFWLRQRIWKLVPDQXDO

Service 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. 7-31)


3URFHGXUH
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WKHWRSRIWKHIHHGHUVRWKHVKDIW  DQGWKHWRSFRYHUSODWHFDQEHUHPRYHG

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WKHVSULQJHQGIDOOVLQWRWKHVOLWRIWKHVKDIW$OVRSD\DWWHQWLRQWKDWWKHOHYHU 
LVSXOOHGDZD\

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FRUUHFWVOLW

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SRVLWLRQ6HFXUHWKHVKDIWZLWKWKHVRFNHWVHWVFUHZ'XULQJURWDWLRQRIWKHVKDIW
SXVKWKHFRYHUSODWH ZLWKDVPDOOIRUFH RQWRWKHERG\

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IHHGHUIURQWRIWKHPPIHHGHUVVKRXOGQRWH[FHHGPP7KHWRWDOZLGWKRI
WKHIHHGHUIURQWRIWKHPP PHFKDQLFDODLU GULYHQIHHGHUVDQGWKHPP
DLUIHHGHUVKRXOGQRWH[FHHGPP

Remark:
If the spring (12) is deformed, the complete top-cover plate must be replaced
(assembly). The spring is good if the spring ends face each other 180 degrees ± 10
degrees (visual inspection).

h) Replace Gear Wheel (Small)


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5HTXLUHGWLPH PLQXWHV
5HTXLUHG0DWHULDO ['ULYHWRSIRLOZKHHO

3URFHGXUH
Π/RRVHQ WKH FRXQWHUVXQN VFUHZ DQG UHPRYH WKH IODQJH DQG JHDU ZKHHO E\
XVLQJD3KLOLSVVFUHZGULYHUQR
Π0RXQWDQHZJHDUZKHHOLQWKHUHYHUVHGLUHFWLRQ0DNHVXUHWKDWWKHJHDU
ZKHHOPRYHVIUHHO\LIWXUQLQJLWFORFNZLVH VHHDUURZ 

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
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Procedure:
Check if the bottom surface of the feeder is clean and free of mechanical
damage.

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j) Lubrication
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5HTXLUHGWLPH KU SHUIHHGHU

3URFHGXUH
Π&OHDQWKHSRLQWVWKDWKDYHWREHOXEULFDWHG ILJ DQGUHPRYHDOOGXVW
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.

$GGRLOEHWZHHQWKHSDUWVDVVKRZQ E\DUURZV LQILJXUH


/XEULFDQW7HOOXVIURP6KHOO KDVWREHSXUFKDVHGORFDOO\ 
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 Tape out of specification Replace tape


to high (diam. sprocket holes 1.6
(number of re-pick mm
actions) max, play component in
pocket 0.5 mm max)

Feeder not placed correctly


Clean feeder-bar
Feeder interface damaged Clean feeder bottom

Tape or cover tape path not Send feeder back for repair
correct or obstructed
Correct path and/or
Speed air-cylinder too low remove obstructions

Index mechanism polluted


Check adjustment

Clamping lever of feeder to


the left presses against Clean index mechanism
Feeder does not index index mechanism
correctly
Tighten clamping lever to
Index mechanism damaged the feeder body

Cover plate not completely


closed

Cover plate damaged Send feeder back for repair

Index force extremely high Remove obstructing


components
Spring (left-pulley)
broken/absent
Replace cover plate
Spring (top-foil)
broken/absent 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 Spring (set-up) Replace
correctly broken/absent

Pick position wrong See index problems Check pick position


with Tape
Feeder Adjustment
Tool
PA 2849/10
Tape not inserted
Cover tape does not peel back from correctly Insert tape according
carrier tape instructions

Tape stuck between Insert tape again,


wheels make sure the
scrapers are close to
the wheels and the
double guiding is
straight

Replace spring
Spring (left pulley)
broken/absent
Replace spring
Spring (top-foil)
broken/absent
Replace spring
Spring (set-up)
broken/absent
Check for
Reel/tape stuck obstructions

Replace small wheel


Top foil wheel (small)
rotates during upward
stroke
Check if the spring is
Set up spring incorrect set onto the correct
mounted fixing pin
Cover tape does not peel back from
the carrier tape at the appropriate
timing (specially paper tape)

Service Manual Topaz 5322 871 63606


7 - 40 PA 1309/10 01.05
Axes Systems

CHAPTER 8 Axes Systems

8.1. Introduction

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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

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IROORZLQJSDUDPHWHUVPXVWEHVHWFRUUHFWO\

Parameter Axis
Machine reference W, Z, X, Y, R
Secondary limit X, Y
Software limit W, Z, X, Y, R
Initial position W, R
Initial movement Z
Table 8-2 Adjustment parameters of moving axes

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)


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LVFRPSOHWH
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Figure 8-1 Machine reference

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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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DWWDFKHGWRWKHPRYDEOHUDLO

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QHHGHGIRUPDFKLQHVGHVLJQHGIRUPDQXDODGMXVWPHQWRIFRQYH\RUZLGWK

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 5HWLJKWHQWKHEROWWRVHFXUHWKHRULJLQGRJDIWHUWKHPDFKLQHUHIHUHQFH
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Figure 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


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RULJLQLVSHUIRUPHGWKH=D[LVWUDYHOVDWORZVSHHGXSDJDLQVWWKHXSSHUHQG
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WKH=D[LVPDFKLQHUHIHUHQFHIROORZWKHVHVWHSV

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- 7RGHFUHDVHWKHPDFKLQHUHIHUHQFHURWDWHLQGLUHFWLRQ% XS
 5HWLJKWHQWKHEROWWRVHFXUHWKHFRXSOLQJDIWHUWKHPDFKLQHUHIHUHQFHLV
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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


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DVVHPEO\,WLVGULYHQE\EDOOVFUHZDWDOHDGRIPPSHUWXUQRIWKH
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2. $GMXVWWKHPDFKLQHUHIHUHQFHDVIROORZVORRVHQWKHVFUHZVHFXULQJWKH;
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3. 5HWLJKWHQWKHVFUHZWRVHFXUHWKHRULJLQGRJ0DNHVXUHWKDWWKHPDFKLQH
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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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DVVHPEO\,WLVGULYHQE\EDOOVFUHZDWDOHDGRIPPSHUWXUQRIWKH
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Figure 8-6 Adjusting the Y-axis machine reference

Note:
The machine reference will be adjusted about 10% for every 2mm movement of
the origin dog. Be sure to slide the dog slightly (a maximum of 10mm). If you slide
it too far, a “0” pulse in a different cycle may be received, causing the origin
position to shift

Service Manual Topaz 5322 871 63606


8-6 PA 1309/10 01.05
Axes Systems

8.2.5. R-axis Machine Reference


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WKH5D[LVPDFKLQHUHIHUHQFHIROORZWKHVHVWHSVVHHILJXUH

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 /RRVHQWKHVHWVFUHZIRUWKHGRJULQJ
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 WRHDFKQR]]OHVKDIW8VHDKH[ZUHQFKWRORRVHQWKHVHWVFUHZIRUWKHGRJ
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 7RDGMXVWWKHPDFKLQHUHIHUHQFHVOLJKWO\WXUQWKHGRJULQJ
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 5HWLJKWHQWKHVHWVFUHZWRVHFXUHWKHGRJULQJ0DNHVXUHWKDWWKH
PDFKLQHUHIHUHQFHLVVHWZLWKLQWKHWROHUDQFHUDQJH

Figure 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
PHFKDQLFDO KDUG VWRSSHU $OLJKWLPSDFWPD\RFFXUKRZHYHUGHSHQGLQJ
RQWKHUXQQLQJVSHHG

7KHVHFRQGDU\OLPLWDUHDLVSURYLGHGIRUWKH;DQG<D[HVDQGFDQEH
DGMXVWHGE\VOLGLQJWKHSRVLWLRQRIWKHVHFRQGDU\OLPLWGRJORFDWHGDWWKHERWK
HQGVRIWKHPRYHPHQWUDQJH

8.3.1. X-axis Secondary Limits


8VXDOO\WKH;D[LVVHFRQGDU\OLPLWVDUHVHWWRDSRLQWPPLQVLGHWKH
PHFKDQLFDOVWRSSHU KDUGOLPLW VHHILJXUH

 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
7RGRWKLVRSHQWKHRXWSXWPRQLWRUVFUHHQ RULQSXWPRQLWRUVFUHHQ 
DQGZKLOHREVHUYLQJWKH;FRRUGLQDWHYDOXHLQGLFDWHGRQWKHERWWRPRI
WKHRSHUDWLRQPRQLWRUVWRSWKHKHDGDWDSRVLWLRQDSSUR[LPDWHO\
PPIURPWKHPHFKDQLFDOVWRSSHU LHIURPWKHKDUGOLPLW 7KLV
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
PHFKDQLFDOVWRSSHU KDUGOLPLW 6LQFHWKLVDGMXVWPHQWSURFHGXUHLVH[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. Software Limits


:KHQDQD[LVPRYHVWRDWDUJHWSRVLWLRQWKHVRIWZDUHOLPLWLVXVHGWRUHVWULFW
PRYHPHQWWRDYRLGLQWHUIHULQJZLWKWKHPHFKDQLFDOVWRSSHUVORFDWHGDWWKH
ERWKHQGVRIWKHD[LV,IWKHWDUJHWSRVLWLRQH[FHHGVWKHVRIWZDUHOLPLWWKH
HUURUPHVVDJH´$;,662)7/,0,729(5µDSSHDUVDQGD[LVPRYHPHQWLV
SURKLELWHG,QWKH0DQXDOPRGH\RXFDQXVHWKHMR\VWLFNRQWKH++.
ZLWKLQWKHVRIWZDUHOLPLWUDQJH

8.4.1. W-axis Software Limits


7KH:D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRPPLQVLGHWKHPHFKDQLFDO
VWRSSHUIRUERWKWKH´SOXVµVLGH ZLGWKHQODUJLQJGLUHFWLRQ DQGWKH´PLQXVµ
VLGH ZLGWKUHGXFLQJGLUHFWLRQ 
:KHQWKHVRIWZDUHOLPLWVHWWLQJVDUHFRUUHFWWKLVPHHWVWKHVSHFLILFDWLRQVIRU
WKHPLQLPXP PP DQGPD[LPXP PP ZLGWKVRI3&%VWKDW
FDQEHWUDQVIHUUHG
F A: Structural movable range
3.00mm
B: Allowable movement range
C: “plus” side software limit (rear)
C
D D: Origin position
E: “minus” side software limit (front)
F: Mechanical limit

B A

E
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.

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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>>> 3/MAINTE/M
<<MODE>> 3/MCH_ADJUST
<COMMAND_LIST> 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\

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01.05 PA 1309/10 8 - 13
Axes Systems

8.4.2. Z-axis Software Limits


7KH=D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRPPLQVLGHWKHPHFKDQLFDO
VWRSSHUIRUERWKWKH´SOXVµVLGH ORZHUGLUHFWLRQ DQGWKH´PLQXVµVLGH
XSSHUGLUHFWLRQ 
7KH´SOXVµVLGHPXVWEHVHWDWDSRVLWLRQZKHUHQR]]OHFKDQJHLVQRW
GLVWXUEHGDQGWKH´PLQXVµVLGHDWDSRVLWLRQZKHUHWKHQR]]OHVGRQRW
LQWHUIHUHZLWKWKHEDFNOLJKWXQLW
A: Structural movable range
E
1.00 B: Allowable movement range
C C: “plus” side software limit
D: Origin position
E: “minus” side software limit
F: Mechanical limit

B A

D
1.00
F

Figure 8-14 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
7KLVYDOXHLVWKHPHFKDQLFDOOLPLW KDUGOLPLW 
Editing Object Software Limit

Axis +direct. -direct. Init.Pos Init.Mov

Z1/MAIN 22.90 0.16 0.00 18.72


Z2/MAIN 23.00 0.05 0.00 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´SOXVµVLGH ULJKWGLUHFWLRQ DQGWKH´PLQXVµVLGH OHIWGLUHFWLRQ 
A Mechanical stopper
Mechanical stopper
1 1 B 1 1
A: Structural movable range
B: Allowable movement range
C: Software limit
D: Secondary limit
E: Origin position
F: Mechanical limit

F D C C D F
E

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´SOXVµVLGH ULJKWGLUHFWLRQ DQGWKH´PLQXVµ
VLGH OHIWGLUHFWLRQ 

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 +direct. -direct. Init.Pos Init.Mov

Y/MAIN 699.00 -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\

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8 - 18 PA 1309/10 01.05
Axes Systems

8.4.5. R-axis Software Limits


7KH5D[LVVRIWZDUHOLPLWVKRXOGEHVHWWRDIL[HGYDOXHRIRQWKH
´PLQXVµVLGH FORFNZLVH DQGWRDIL[HGYDOXHRIRQWKH´SOXVµVLGH
FRXQWHUFORFNZLVH 

 2SHQWKHVRIWZDUHOLPLWVFUHHQ
6HOHFW0$,17(0!!!0&+B$'-867!!%6$9(
48,7!^%$'-8677$5*(7`µ6RIWZDUH/LPLWµDQGSUHVVWKH
>(17(5@NH\
8VHWKHDUURZNH\VWROLQHXSWKHFXUVRUZLWK´GLUHFWµRU´GLUHFWµ
LQWKH´50$,1µ RU´50$,1 URZ\RXZDQWWRDGMXVW
2) (QWHUWKHVRIWZDUHOLPLW
(QWHUIRUWKHVRIWZDUHOLPLWRQWKH´SOXVµVLGHZKLOHRQ
WKH´PLQXVµVLGH

Editing Object Software Limit

Axis +direct. -direct. Init.Pos Init.Mov

12 R-NO1 360.00 -360.00 80.00


13 R-NO2 360.00 -360.00 -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. Initial Position and Initial Movement


7KLVVHFWLRQH[SODLQVKRZWRDGMXVWWKH:D[LVDQG5D[LVLQLWLDOSRVLWLRQDQG
=D[LVLQLWLDOPRYHPHQW

8.5.1. 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]]OHVDUHDOLJQHGZLWKWKHGLUHFWLRQRIFRPSRQHQWV WKHQR]]OHKROGHU
VOHDI
VSULQJVDUHVHWSDUDOOHOZLWKWKH;D[LV 

 ([HFXWHWKH´&+$1*(12==/(µFRPPDQGWRDWWDFKDQR]]OH IRU
H[DPSOH7\SH WRDKHDG
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 &KHFNWKDWWKHQR]]OHKROGHU
VOHDIVSULQJVDUHVHWSDUDOOHOZLWKWKH;
D[LV ,IQRWSDUDOOHOZLWKWKH;D[LVDGMXVWE\URWDWLQJWKHQR]]OHVKDIW
0RYLQJWKH5D[LVEHOWE\KDQGDOORZVHDV\DGMXVWPHQW
 6HWWHDFKLQJFRQGLWLRQV
 3UHVVWKHHPHUJHQF\EXWWRQ
 $WWDFKDW\SHQR]]OHWRKHDG
 &KHFNWKDWWKHQR]]OHKROGHU·VOHDIVSULQJVDUHVHWSDUDOOHOZLWKWKH;
D[LVLIQRWURWDWHWKH5D[LVXQWLOWKH\GR
 6HWWHDFKLQJFRQGLWLRQVE\VHOHFWLQJ%!DQGSUHVV(17(5
 3HUIRUPWHDFKLQJIRUWKH5D[LVLQLWLDOSRVLWLRQ6HOHFW%!
´6RIWOLPLWµDQGSUHVV(17(58VHWKHDUURZNH\VWROLQHXSWKH
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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 360.00 -360.00 138.00


R2/MAIN 360.00 -360.00 138.00

Figure 8-23 R-axis initial position setting screen

8.5.3. Z-axis Initial Movement


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Service Manual Topaz 5322 871 63606


8 - 22 PA 1309/10 01.05
Axes Systems

  3HUIRUPWHDFKLQJIRUWKH=D[LVLQLWLDOPRYHPHQW
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Figure 8-24 Software setting screen (for initial movement)

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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 8 - 23
Axes Systems

8.6. Axes Assembly, Disassembly, Adjustments and Maintenance


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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
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8.6.1. Adjustment of the X- and Y-motor Encoder Position

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Service Manual Topaz 5322 871 63606


8 - 24 PA 1309/10 01.05
Axes Systems

8.6.2. Head Replacement


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8.6.3. X-axis Assembly


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8.6.3.1. X-axis: Replacement X-motor Only


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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 8 - 25
Axes Systems

8.6.3.2. X-axis: Ball Screw Replacement


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Figure 8-25 X-axis ball screw

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Service Manual Topaz 5322 871 63606


8 - 26 PA 1309/10 01.05
Axes Systems

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8.6.3.3. X-axis: Linear Guide Replacement


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8.6.4. Y-axis Assembly


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8.6.4.1. Y-axis: Replacement Y-motor Only


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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 8 - 27
Axes Systems

8.6.4.2. Y-axis: Removing Y-axis Ball Screw Generation 2


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Figure 8-26 Y-axis ball screw generation 2

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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


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Figure 8-27 Y-axis ball screw generation 3

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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


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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

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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.


nd rd
The difference between the 2 and 3 generation ball screw assembly is found in
the Bearing holder (34), Sleeve bearing (32) and thrust bearing(36). In the 3rd
generation these have been changed for a new Bearing holder (20) and new Thrust
bearing (25) only. See figure 8-28.

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Figure 8-29 alignment tool of the Y-axis ball screw

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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)


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Figure 8-30 Adjusting the pre-tension

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 0D[SUHWHQVLRQDGMXVWPHQWLVOHVVWKDQGHJUHHVWXUQ
 7LJKWHQWKHVHWVFUHZ ZDWFKIRUWKHFRSSHUFKLS RIWKHORFNQXWVHHILJXUH

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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5HPDUN )RUWKH7RSD]WKHOHIW GULYHQVLGH OLQHDUJXLGHLVGLIIHUHQWIURPWKH


ULJKW GULYHVLGH OLQHDUJXLGH 6HHVSDUHSDUWVOLVW 

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JXLGHVLVGRQHDVIROORZV
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 )RUWKHIURQWEROWV,IWKH;D[LVLVPRYHGDOOWKHZD\WRWKHIURQWWKHQ
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JXLGH

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01.05 PA 1309/10 8 - 33
Axes Systems

8.6.5. Z-axis Assembly


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Z-axis: Z-Motor replacement


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GLVFRQQHFWWKHPRWRUDQGHQFRGHUFDEOHIURPFRQQHFWRUSODWHLWHPLQILJXUH

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  $VVHPEOHLQUHYHUVHRUGHU

Z-axis: Z-bearing replacement


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LVDOVRGHWHUPLQHGE\PHDQVRIILWWLQJSLQV7KHYHUWLFDOSRVLWLRQRQSODWHLWHP
PD\VKLIWDOLWWOHDVPXFKDVWKHKROHVDOORZ

8.6.6. R-axis Assembly


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7KH7RSD]XVHVDEHOWGULYHZKLOHWKHHQFRGHUDSDUWLVRIWKH5PRWRUDVVHPEO\

R-Axis: Replacing the Nozzle Holder


1) 5HPRYHWKHOHDIVSULQJVLWHPE\PHDQVRIVFUHZWDNHFDUHQRWWRORRVH
WKHZDVKHULWHP
2) 5HPRYHWKHSLQLWHP·LQILJXUHD7KHSLQKDVWREHGULYHQRXWRIWKH
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&KHFNWKHOHDIVSULQJVLIWKH\FDQKROGWKHQR]]OHZHOOLIQRWUHSODFHWKHVSULQJV

Service Manual Topaz 5322 871 63606


8 - 34 PA 1309/10 01.05
Axes Systems

R-axis: Replacing the Spline Shaft


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R-axis: Replacing and Maintaining the Piston and Plugs Assy’s


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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 8 - 35
Axes Systems

Intentionally left blank.

Service Manual Topaz 5322 871 63606


8 - 36 PA 1309/10 01.05
Vision Systems

 CHAPTER 9 Vision Systems

9.1. Introduction
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9.2. Vision Systems


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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


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9.3. Moving Camera


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ILGXFLDOPDUNVDQGSHUIRUPWHDFKLQJ7KHOLJKWLQJOHYHODQGWKHVFDOHRIWKH
PRYLQJFDPHUDFDQEHDGMXVWHG

9.3.1. Adjusting the Focus and Field Of View


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VRPHWKLQJRQWKH3&%WKDWSURYLGHVJRRGFRQWUDVWVLPSO\PRYHWKHFDPHUDXS
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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).

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Service Manual Topaz 5322 871 63606


9-2 PA 1309/10 01.05
Vision Systems

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9.3.2. Adjusting the Lighting Level of the Moving Camera


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PRYLQJFDPHUDPXVWEHRSWLPLVHG7RPDNHWKHDGMXVWPHQWDQRSWLRQDO
FXVWRPWRRO OLJKWDGMXVWHUSODWH VKRXOGEHXVHG

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.

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01.05 PA 1309/10 9- 3
Vision Systems

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´2.µLVYHU\FORVHWRWKLVOHYHO

1. Prepare the light adjuster plate.


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DGMXVWHUFDQEHSODFHG3&%ILGXFLDOPDUNVDUHQRWQHFHVVDU\
2. Execute the “Mov.Cam. Light” command.
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>(17(5@NH\
6HOHFW'LDOVFUHZV
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<<<APPLICATION>>> 3/MAINTE/M
<<MODE>> 3/MCH_ADJUST
<COMMAND_LIST> B/SAVE

B1 ADJUST TARGET

Object

Mov.Cam.Light
A650
This procedure adjusts the light intensity of the
moving camera.
The way of . . .

LED Type
0 Dial + 2 screws
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.
(QWHUWKHZLGWK PLOOLPHWUHV RIWKH3&%XVHGLQWKLVDGMXVWPHQW
4. Ensure safety, then press the [ENTER] key again.
7KH:D[LVPRYHVWRVHWWKHVSHFLILHGFRQYH\RUZLGWK
5. Press emergency button, set the PCB & light adjuster plate.
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6. Adjust the conveyor unit.
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7. Cancel emergency stop.
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>5($'<@EXWWRQRIWKH++.
8. Press the [ENTER] key.
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A655
<<<Teaching>>>
Please position the cross hair cursor over the
Light Adjuster …

Figure 9-3 Adjusting light intensity

9. Adjust the camera position.


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FDPHUDVRWKDWWKHOLJKWJUH\DUHDRQWKHOLJKWDGMXVWHUSODWHLVGLVSOD\HGRYHU
WKHHQWLUHILHOGRIYLHZ

OK NG
Figure 9-4 Position the light adjuster tool

10. Adjust the camera lighting level according to the messages.


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RXWHULQQHUDQGFRD[LDO 

5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 9- 5
Vision Systems

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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 Fiducial light adjustment


Inner
Rotary SW Outer Middle (coaxial) Optimum level
0 ❍ ❍ ❍ Normal lighting pattern
1 ❍ ❍ –
2 ❍ ❍ –
3 ❍ 50±5
4 ❍ ❍ –
5 ❍ 50±5
6 ❍ 20±5
7 –
Figure 9-7 Optimum level settings

Service Manual Topaz 5322 871 63606


9-6 PA 1309/10 01.05
Vision Systems

11. Return the rotary switch to "0".


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VZLWFKWR DOO/('·VWXUQHGRQ 
12. Press the [ESC] key to quit the adjustment.
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WKHHPHUJHQF\VWRSEXWWRQUHPRYHWKH3&%7KHUHLVQRPDFKLQHGDWDWR
EHVDYHGLQWKLVDGMXVWPHQW

9.3.3. Adjusting the Moving Camera Scale


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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.'$7$%$6(DQGSUHVVWKH
>(17(5@NH\
&KHFNIRUWKHUHJLVWUDWLRQGDWD&KHFNLQSDUWLFXODUWKDWWKHPDUNVL]H
RIWKH3&%H[DFWO\PDWFKHVWKHUHJLVWUDWLRQGDWD 0DUN2XW6L]H &KHFN
DOVRWKDWWKH6HDUFK$UHDSDUDPHWHULQWKH9LVLRQ,QIRVXEZLQGRZLV
RUODUJHU QRWWRRODUJHEXWDOVRQRWVPDOOHUWKDQ 


Sub-window

<<<APPLICATION>>> 2/DATA/M
<<MODE>> 3/DATABASE

OBJ : MARK DATABASE Mark size Info.


No. MARK NAME COMMENT 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.

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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>>> 2/DATA/M
<<MODE>> 3/DATABASE

OBJ : MARK DATABASE Mark size Info.


No. MARK NAME COMMENT 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&%

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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.

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01.05 PA 1309/10 9- 9
Vision Systems

7KHZLGWKRIWKH3KLOOLSVERDUGLVPPDQGRIWKHJODVV3&%PP
Confirm that “Distance (mm/10) 15” is displayed, and press [ENTER].
1RUPDOO\DPRYHPHQWGLVWDQFHRI´µ LQWHQWKVRIDPLOOLPHWHU LV
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

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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>>> Scale_x = xx.xx
The following data is the result of the adsjustment of Scale_y = yy.yy
the moving camera scales. Angle = rr.rr
To save the result in memory, press the [ENTER] key
(contents are not saved on disk).
To abandon, press the [ESC] key.

Figure 9-13 Start calibration


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

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Vision Systems

9.4. Single Camera Adjustment


7KLVVHFWLRQGHVFULEHVWKHFDOLEUDWLRQRIWKHVLQJOHFDPHUD,IQRWLQVWDOOHGWKDQ
VNLSWKLVVHFWLRQ

9.4.1. Maximum Component Size and Field Of View


7KLVSURFHGXUHH[SODLQVKRZWRDGMXVWWKHPD[LPXPFRPSRQHQWVL]H7KH
PD[LPXPFRPSRQHQWVL]HLVGLUHFWO\UHODWHGWRWKH)LHOG2I9LHZ)RUWKH7RSD]
WKHUHFRPPHQGHG)LHOG2I9LHZLVPPRUODUJHUWKHPD[LPXPFRPSRQHQWLV
PPVTXDUH

7RDGMXVWXVHDWUDQVSDUHQWUXOHUVKHHW WLSFRS\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

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Vision Systems

9.4.2. 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= DQGWKDWWKHFRPSRQHQW IRFXVDGMXVWHU LVUHFRJQLVHGDWWKH
FRUUHFWFDPHUD
•  6HW WKH IRFXV ULQJ RQ WKH OHQV WR WKH ´ µ SRVLWLRQ EHIRUH DGMXVWLQJ WKH
IRFXV

NOTE: 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
$W WKH OHYHO  SRVLWLRQ RI WKH IRFXV
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

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01.05 PA 1309/10 9- 13
Vision Systems

7KH IRFXV DGMXVWPHQW LQIOXHQFHV WKH PD[LPXP FRPSRQHQW VL]H DGMXVWPHQW


VRWDNHFDUHRIWKDWDQGILQGWKHRSWLPXPYDOXHIRUERWKIRFXVDQGPD[LPXP
FRPSRQHQW
NOTE: The focus must be adjusted by moving the camera up or down, not by turning the
focus ring. Only use the focus ring adjustment if no good results can be obtained.
This because it is a very precise adjustment.

Figure 9-18 Nozzle back plate sides visible

9.4.3. Lighting Level Adjustment


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 6HOHFW%$GMXVWWDUJHW6LQJOH&DP/LJKW!DQGSUHVV(QWHU!
l (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
l (QWHU WKH IHHGHU VHW QXPEHU DQG SUHVV WKH (QWHU! NH\ :KHQ WKH
VHOHFWHGFRPSRQHQWLVUHJLVWHUHGDVDWUD\FRPSRQHQWWKLVGLDORJER[
GRHVQRWDSSHDU

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Vision Systems

R
IVE
DR
1

Figure 9-19 Led driver board

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7KH KHDG DVVHPEO\ PRYHV WR DERYH WKH VLQJOH YLVLRQ FDPHUD DQG
PHDVXUHPHQWRIEULJKWQHVVDURXQGWKHQR]]OHZLOOVWDUW
 $GMXVWWKHVLQJOH YLVLRQ FDPHUD OLJKWLQJ OHYHO ZLWK SRWPHWHU 95 RQ WKH
/('GULYHUERDUG VHFRQGSRWHQWLRPHWHUIURPWKHERWWRP DWWKHULJKWVLGH
RI WKH 0&; FRQWUROOHU $GMXVW WKH ´$YH*UD\/HYHO RQ WKH XSSHU ULJKW
FRUQHURIWKHVFUHHQWR,IWKLVYDOXHFDQQRWEHUHDFKHGSOHDVHDGMXVW
WKHDSHUWXUHULQJDOLWWOHDQGWU\DJDLQ
 3UHVV(VF!RU(QWHU!WRTXLWWKHDGMXVWPHQW7KHUHLVQRPDFKLQHGDWDWR
EHVDYHGLQWKLVDGMXVWPHQW

2SWLRQDODGMXVWPHQWPHWKRG
 6HOHFW%6LQJOH&DPHUDOLJKWLQJ6LQJOH&DPHUD)URQWOLJKW!
 )ROORZWKHH[SODQDWLRQRQWKH9,26
PRQLWRUDQGDGMXVWWKH/('GULYHU
ERDUGSRWHQWLRPHWHU95
 8VHWKH/LJKWDGMXVWHUWRRO

 $GMXVWWKHSRWHQWLRPHWHUVRWKDW
WKHERUGHUEHWZHHQGDUNDQG
EULJKWLVRQHIXOOVFDOH OHYHOV 
VHHILJ
Full 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.

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01.05 PA 1309/10 9- 15
Vision Systems

9.4.4. Camera Scale Adjustment


)RUDFFXUDWHUHFRJQLWLRQRIFRPSRQHQWVVXFKDV4)3·VWKHOLJKWLQJOHYHODQG
WKHVFDOHRIWKHVLQJOHYLVLRQFDPHUD IL[HGFDPHUD PXVWEHDGMXVWHGFRUUHFWO\
7KHVLQJOHYLVLRQFDPHUDVFDOHUHSUHVHQWVDQDFWXDOPHDVXUHPHQW LQXQLWVRI
PLFURQV HTXLYDOHQWWRRQHSL[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
PLFURQV ZLOOEHDGMXVWHG

<<MODE>> 3/MCH_ADJUST
A377 Camera = 1
<<<Result>>> Distance = 5.00
The results of calculating the scales of the single Scale_x = 83.33
vision camera are as follows. Scale_y = 83.97
To save the result in memory, press the [ENTER] key Cam.posx = 0.00
(the results are . . . Cam.posy = 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 .

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• 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

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9 - 16 PA 1309/10 01.05
Vision Systems

WKDQ1RWKHQHGLWWKLVGDWD)RULQVWDQFHWKHIROORZLQJVWHSVDUH
H[SODLQHGLQFDVHVZKHUHDFRS\LVPDGHRQWRUHJLVWUDWLRQ1R
• 2SHQWKHVXEVFUHHQ9LVLRQIRUWKHFRPSRQHQWRIUHJLVWUDWLRQ1R
• (GLWWKHGDWDRQ6HDUFK$UHDPP
• 8VHWKHQXPHULFNH\VWRVHWWKHQRUPDOYDOXHWR
PD[LPXPVHWWLQJ 7KLVLVIRURIIFHQWHUSLFNXSRIWKH4)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

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01.05 PA 1309/10 9- 17
Vision Systems

Figure 9-23 Procedure of scale adjustment

 &RQILUPWKDWGLVWDQFH PP LVGLVSOD\HGDQGSUHVVWKH>(17(5@NH\
1RUPDOO\DPRYHPHQWGLVWDQFHRI PLOOLPHWUHV LVUHFRPPHQGHG

 (QWHUWKHFRPSRQHQWGDWDEDVH1RDQGSUHVVWKH>(17(5@NH\
 +HUHHQWHUWKHGDWDEDVH1R\RXKDYHHGLWHGSUHYLRXVO\

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Service 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.

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<<MODE>> 3/MCH_ADJUST
A377 Camera = 1
<<<Result>>> Distance = 5.00
The results of calculating the scales of the single Scale_x = 83.33
vision camera are as follows. Scale_y = 83.97
To save the result in memory, press the [ENTER] key Cam.posx = 0.00
(the results are . . . Cam.posy = 0.00
Cam.posr =180.19
Rate =0.9923

Figure 9-25 Scale parameters

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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).

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9.4.5. Camera Optical Axis Angle Adjustment

Introduction
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FDPHUDVDUHXVHG

Service Manual Topaz 5322 871 63606


9 - 20 PA 1309/10 01.05
Vision Systems

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Measurement Principles
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Single Camera
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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 9- 21
Vision Systems

Line Array Camera


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LQIRUPDWLRQ &$0&25 

Required Tools and Supplies


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 7KLQVKLPV UDQJLQJIURPPPWRPP
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Single Camera Adjustment


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REC_COM
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Service Manual Topaz 5322 871 63606


9 - 22 PA 1309/10 01.05
Vision Systems

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Evaluating the Results


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([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

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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 9- 23
Vision Systems

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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. Line Array Camera Adjustment


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9.5.1. Maximum Component Size and Field Of View


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9.5.2. Adjusting the Focus and Aperture


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Focus ring
Aperture ring
Knurled ring
(complete lens)

Figure 9-28
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Figure 9-29

5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 9- 25
Vision Systems

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LEVEL:80

Figure 9-30

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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 !

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Service Manual Topaz 5322 871 63606


9 - 26 PA 1309/10 01.05
Vision Systems

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5HFKHFNWKHIRFXVDIWHUWLJKWHQLQJ

9.5.3. Adjusting the Lighting Level of the Line Array Camera(s)


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Figure 9-31

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EXWWRQRQWKH++.

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Full Scale

Figure 9-32

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5322 871 63606 Service Manual Topaz


01.05 PA 1309/10 9- 27
Vision Systems

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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.

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9.5.4. Adjusting the Line Array Camera Scale


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Setting up for the line array camera


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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

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Adjusting the line array camera scale


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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

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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

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<<<APPLICATION>>> 3/MAINTE/M
<MODE>> 3/MCH_ADJUST
A542 Camera = 1
<<<Result>>> Distance = 5.00
The results of calculating the scales of the Scale_x = 58.59
multi-vision camera are as follows. Scale_y = 73.28
……… Cam.posx =328.96
Cam.posy =111.88
Cam.posr = 0.03
Div_x = 0.00
Div_y = 0.43
Cam.corx = -1.80
Cam.cory = 1.48
Rat =0.5969

Figure 9-36

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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 Cam. cor X


MultiCam2 Position Error MaltCam1 : -18.61
Position(angle) of MltCam2 is not correct. MaltCam2 : 0.00
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.

A712 Cam. cor X


Adjusting Method of MltCam2 MaltCam1 : -18.61
When you see the machine from front, MaltCam2 : 0.00
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.
Figure 9-37

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01.05 PA 1309/10 9- 31
Vision Systems

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Figure 9-38
Multi-camera 2

Camera stay

Adjusting cam coor. X

Camera stand
B

Adjusting cam coor. Y


(insert a shim)

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9 - 32 PA 1309/10 01.05
Vision Systems

9.5.5. Adjusting the Dual Recognition Offset


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Figure 9-37

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01.05 PA 1309/10 9- 33
Vision Systems

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9.5.6. Replacement of the Line Array Camera


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Figure 9-38 Multi-camera 1 and 2 positions

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9 - 34 PA 1309/10 01.05
Vision Systems

9.6. Cleaning the Optical Systems


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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. Recognition Errors


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9.7.1. Chip Components

Symptom Possible cause Corrective action


Recognition error Dust or dirt on the camera Whip the lens surface
frequently occurs with lens. with its special cleaner.
almost all components
Recognition error The shape data in the Check the shape data and
frequently occurs with component information width make adjustments by
specific components is not correct, or the nozzle using the adjust assistant.
is picking up the component If the pickup position is
by the edge. off center of the
component check the
tape feeder for operation.
Recognition error The buffing part of the nozzle Generate a negative
frequently occurs with a does not move smoothly, or pressure for all heads in
specific head, specific dirt is on the nozzle tip. the manual mode and
components cannot be move the nozzles.
recognized
The shape data in the If any incorrect value is
component information is not entered for the shape
properly supplied. data the component is
supplied in a wrong
direction, this also results
in recognition errors. For
components to be
supplied laterally specify 0
degree in the database.
While specifying 90
degrees for lengthwise
supply.

Table 9-3

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9 - 36 PA 1309/10 01.05
Vision Systems

9.7.2. QFP Components

Symptom Possible cause Corrective action

Recognition Incorrect data is entered Check the data on the Component Information,
error for the Component and perform "PARAM. SEARCH" in the
frequently Information. Adjust Assistant.
occurs.
Recognition If the component has Check the "Feeder Pos_X/Y" and "X/Y-
error deviated from the center CompPitch" values in the Component
frequently of pickup position, it may Information, and make the corrections.
occurs. (QFP shift from the center of
is not the monitor, resulting in a
displayed on recognition error.
the vision
monitor.)

Components The direction supplying Component supply data is created for the
cannot be the component is not database, with the lateral supply as standard.
recognized. correct. (If the supply Therefore, when the component is to be
direction is wrong, the supplied in a lengthwise direction, enter "90
number of leads is degrees (-90 degrees)" for the "Pick Angle"
switched between the parameter in the Component Information.
length and width sides,
causing a recognition
error even if the SHAPE
data is correct.)

Table 9-4

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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
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5322 871 63606 Service Manual Topaz 10-1


01.05 PA 1309/10
Software Section

10.2. System Software

10.2.1. Operating System


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10.2.2. Disk Organization


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10-2 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
Software Section

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5322 871 63606 Service Manual Topaz 10-3


01.05 PA 1309/10
Software Section

10.2.3. Installation Disk Contents


:LWKWKHV\VWHPWKHUHZLOOEHDVHWRIGLVNHWWHVVXSSOLHG
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SYSTEM – 1
SM100 .001 1 07-23-97 07:33
INFDSK .V12 381 11-29-95 12:06
INS1 .LZH 1.114.237 21-12-98 08:55

SYSTEM – 2
SM100 .002 1 07-23-97 07:33
INFDSK .V12 56 11-29-95 12:05
INS2 .LZH 995.318 21-12-98 04:54

SYSTEM - 3
SM100 .003 1 07-23-97 07:33
INFDSK .V12 56 11-29-95 12:05
INS3. .LZH 781.441 21-12-98 04:55
VERSION .STS 6 12-14-96 11:47

SYSTEM - DATA
NO0 >SUB_DIR< 98-06-17 15:58
NO1 >SUB_DIR< 98-06-17 15:58
FTABLE .BIN 740 06-09-98 08:33
INFDSK .V12 56 11-29-95 12:06
DATABASE .LZH 29730 06-11-98 04:59
MCXCONF .SYS 2110 05-29-98 01:10
SM100 .DAT 1 07-23-98

VIOS SOFTWARE UTILITY DISK

Name 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(
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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.

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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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10-6 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
Software Section

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CAUTION
This command can be dangerous because it initialises all
machine data on the hard disk. Use this command only in case
the machine data is corrupted or out of date or if there are hard
disk problems.

5322 871 63606 Service Manual Topaz 10-7


01.05 PA 1309/10
Software Section

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10-8 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
Software Section

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5322 871 63606 Service Manual Topaz 10-9


01.05 PA 1309/10
Software Section

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10-10 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
Software Section

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the machine has problems.

5322 871 63606 Service Manual Topaz 10-11


01.05 PA 1309/10
Software Section

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CAUTION
Normally these 2 commands are not used. These commands
requires the VIOS I/O BOARD UTILITY INSTALLATION DISK
for its execution.

10-12 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
Software Section

10.2.5. Installation of a New Version VIOS System Software


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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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5322 871 63606 Service Manual Topaz 10-13


01.05 PA 1309/10
Software Section

9HUVLRQXS)LQLVKHGVXFFHVVIXOO\KLWDQ\NH\

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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
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/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
Software Section

10.2.8. Floppy Disk Problems


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10-16 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
Software Section

10.2.10. Hard Disk Problems


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5322 871 63606 Service Manual Topaz 10-17


01.05 PA 1309/10
Software Section

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10-18 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
Software Section

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5322 871 63606 Service Manual Topaz 10-19


01.05 PA 1309/10
Software Section

10.3. PCB File Handling


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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(' $OO0DFKLQHHTXLSPHQW 237,21B&)*


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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

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10.4. Machine Configuration


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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


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Software Section

,QILJXUHWKHPDFKLQHFRQILJXUDWLRQVLVVKRZQRIWKH9,269[YHUVLRQ7KHUHDUH
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---------------------------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
+------------------------------------------------------------------------------+
¦OPTION CONFIG. ¦
¦ Serial:KM1-632312 M.type:SM100-1/2 ¦
¦ ¦

• /BASIC CONF./ Message English
• Simple Edition Full Itms •
• RS232C CMU Normal •
• Sub Machine Type SM100-2 •
• /SOFTWARE/ Online Optimization None •
• Badmark Function Normal •
• Badmark Distinction Normal •
• Air Consumption No Limit. •
• Alternate Component WithConfirm. •
• Retry Sequence GroupRetry •
• Production Log Use •
• /RECOGNITION/ Laser Alignment Exist •
• Camera Combination 1&2:Single View •
• Camera1 Spec. Fore&Back Light •
• Camera2 Spec. Fore&Back Light •
• • Camera3 Spec. Fore&Back Light •
• Multi Detection Standard •
• MarkLightingControl Exist •
• /CONVEYOR/ Edge Clamp Exist •
• Conveyor Width Axis Normal •
• Conveyor Direction R -> L •
• Conveyor Spec. Line •
• Conveyor Width Exist •
• Precede Pick None •
• /BUFFER CONV/ Buffer Conveyor A-TYPE •
• Buffer Conv. W Axis Reverse •
• /TRAY CHANGE/ Tray Changer Ext.TC-A •
• Ext.TC Trv. Axis Normal •
• • Ext.TC Access Table A table •
• /OPTIONS/ Nozzle Changer Exist •
• Slide Feeder Bar None •
• Co-Planarity Sensor None •
• Dump Station None •
• Dispense Head None •
• Disp. Head R Sensor Single •
• Dot Station None •
• RS232C extension None •
••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••

Figure 10.8 Configuration settings VIOS version V1.2x

5322 871 63606 Service Manual Topaz 10-23


01.05 PA 1309/10
Software Section

10.4.1. Machine Configuration Detailed


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10-24 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
Software Section

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5322 871 63606 Service Manual Topaz 10-25


01.05 PA 1309/10
Software Section

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10-26 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05
Software Section

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5322 871 63606 Service Manual Topaz 10-27


01.05 PA 1309/10
Software Section

10.5. ROM and File Configuration (Version Level)


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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

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<<<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

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Software Section

10.6. System Messages


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02'0(6B(7;7 VHHILJ
33(55B(7;7 VHHILJ
9,60(6B(7;7 VHHILJ

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

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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

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#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

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Software Section

0260(6B(W[W
7KLVILOHFRQWDLQVWKHWH[WILOHVIRUHDFKPRGH ILJ

#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

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#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

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01.05 PA 1309/10
Software Section

10.7. Online Commands


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10-32 Service Manual Topaz 5322 871 63606


PA 1309/10 01.05

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