TR7700 SIII Plus High-Speed Automated Optical Inspection System User Guide – Hardware Ver 1.0 Jan 13, 2015 Original Instructions Test Research, Inc TR7700 SIII Plus Automated Optical Inspection System User Guide – Hardware Original Instructions Copyright © 2015 Test Research, Inc All rights reserved This document may be printed or photocopied only by customers or authorized agents of Test Research, Inc (TRI) for sole use by their employees working with TRI test systems Any other use of this document must be approved by TRI The following are trademarks or registered trademarks of Test Research, Inc The absence of a product or service name or logo from this list does not constitute a waiver of TRI’s trademark or other intellectual property rights concerning that name or logo All other trademarks and trade names are the property of their owners Specifications and software are subject to change without notice TRI will make all best efforts to let existing customers know of any product upgrade, change or phase-out For any comments/corrections to this guide, please address them to – sales@tri.com.tw with “TR7700 SIII Plus Series User Guide – Hardware” in the Subject field www.tri.com.tw TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc WARNING: Risk of electric shock and mechanical injury Only fully trained persons should be allowed to take part in the installation process WARNING: Do not reach in the machine when it is operating WARNING: When TRI created the test system software CD, it contained no known viruses The software on the TRI CD was checked by the latest anti-virus software before being copied to the disk Customers should use a good, up-to-date virus checker on this TRI software, and any other file you import from an outside source before using the software Please also ensure your virus checker’s data files are up to date TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc Table of Contents INTRODUCTION OF MACHINE 1.1 Front View 1.2 Left View 1.3 Right View 1.4 Rear View 1.5 Interior of Front Cover CONTROL PANEL FUNCTIONAL SETTINGS _ 3.1 CONVEYOR _ 20 4.1 Structures & Functions 20 4.2 Sensor Adjustment and Replacement 21 4.3 Unloader and Loader Connections 22 4.3.1 Unloader Connection Link 23 4.3.2 Loader Connection Link 24 ELECTRIC PANEL _ 25 5.1 PLC Interface Description 3.1.1 Control 3.1.2 Lane Width 18 Structures & Functions 25 5.1.1 Interior Allocation of Front Door 25 5.1.2 Interior Allocation of Rear Door 26 APPENDIX 28 6.1 XY Stage Servo Motor Drivers Error Code Table 28 6.2 IP Connection of PLC 31 TR7700 SIII Plus Series User Guide – Hardware i Test Research, Inc Table of Figures Figure 1: The Front View of TR7700 SIII Plus Figure 2: The Left View of TR7700 SIII Plus Figure 3: The Right View of TR7700 SIII Plus Figure 4: The Rear View of TR7700 SIII Plus Figure 5: Interior of the Front Cover Figure 1: TR7700 SIII Plus Operating & Storage Environment Figure 2: TR7700 SIII Plus Control Panel Figure 3: PLC Control Ribbon Figure 4: PLC Interface Figure 5: PLC Control Ribbon 10 Figure 6: Signal Tower and Buzzer Settings 10 Figure 7: I/O Monitor 10 Figure 8: PLC Pages – Barcode Settings 11 Figure 9: PLC Pages–Light and Buzzer Diagnostic 12 Figure 10: PLC Pages–Light and Buzzer Diagnostic 13 Figure 11: PLC Pages–Board In and Board Out 14 Figure 12: PLC Pages–Operation Mode 15 Figure 13: PLC Pages–Conveyor 16 Figure 14: PLC Pages–PC_PLC IO Diagnostic 16 Figure 15: PLC Pages–Control Center 17 Figure 16: PLC Pages–General Settings 17 Figure 17: Conveyor Setting 18 Figure 18: Manual Board Width Adjustment Calculation Message 19 Figure 19: Adjusting the Feeding Belt Wheel 20 Figure 20: Sensor Adjustment 21 Figure 21: SMEMA to SMEMA Connection Cable 22 Figure 22: SMEMA to Color Lines Connection Cable 22 Figure 23: I/O Port Position 23 Figure 24: Diagrammatic Sketch of Loader and Loader Ports 23 Figure 25: SMEMA Standard Signal Connection Diagram 24 Figure 26: Front Door Allocation 25 Figure 27: Rear Door Allocation 26 Figure 28: Air Pressure Regulator 27 Figure 29: PLC IP Setting 31 ii TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc INTRODUCTION OF MACHINE This chapter will introduce the machine appearance and interior allocation 1.1 Front View Signal Tower Monitor Control Panel Front Cover Emergency Stop Power Switch Keyboard Mouse Front Door Front Door Lock Floor Stand Figure 1: The Front View of TR7700 SIII Plus TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc 1.2 Left View Fans Board in/out Conveyor Figure 2: The Left View of TR7700 SIII Plus TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc 1.3 Right View Maintenance Openings Figure 3: The Right View of TR7700 SIII Plus TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc 1.4 Rear View Signal Tower Rear Cover Emergency Stop Left Rear Fans Right Rear Fans Network Port Rear Door Mains Power Socket Air Pressure Regulator Breaker I/O Ports Figure 4: The Rear View of TR7700 SIII Plus TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc PLC pages – Control center: Figure 15: PLC Pages–Control Center Enable control center: The control center allows one repair station to review multiple test results When the test result is “Pass” in the repair station, the board will be sent to the unloader If the test result is “Fail”, the board will be sent to magazine (optional device) Enable buffer conveyor: If there is an unloader behind the AOI, please check to enable the buffer function PLC pages – General settings: Figure 16: PLC Pages–General Settings Conveyor synchronization: Enable the conveyor synchronization function When the item is checked, the system will send the board in signal to request the next board during the time when the test board is sending out This function should work with the function “Read barcode before board in” Unloader: Enable to use buffer conveyor If there is no buffer conveyor, the test boar will stop in the sensor position and wait for taking away by operators Enable IACS (Intelligent Auto Conveyor System): When this function is enabled, the system will automatically move to the optimized location on the conveyor based on the optical calculation by camera − Enable IACS delay time: Set the delay time for clamping the board in IACS Support pin (Pneumatic): Enable to use pneumatic support pin TR7700 SIII Plus Series User Guide – Hardware 17 Test Research, Inc 3.1.2 Lane Width Figure 17: Conveyor Setting 18 Measurement: Select a measurement unit Project information: Displays the saved board width in the project Adjust method − Vision: Use the optical holes on the conveyor in the frame and frame to calculate the current lane width without resetting the frame Conveyor information − PCB width: Displays the board width The top one displays the current board width, and the bottom one displays the wanted board width − Conveyor tolerance: Set the tolerance between the real board size and Manual: Enable to adjust the board width manually After checking the box, you can use board width adjustment wheel to adjust the board width manually After you complete the adjustment process and click [OK], the camera will move and calculate the current board width by lane marks on the frame and frame During the calculation, a message will appear as figure below TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc Figure 18: Manual Board Width Adjustment Calculation Message TR7700 SIII Plus Series User Guide – Hardware 19 Test Research, Inc CONVEYOR 4.1 Structures & Functions The function of the conveyor is to transport the test board For long term operation, the feeding belt probably will drop off the wheels So, it is recommended to check if the belt is located on the wheels before running the conveyor If users want to replace a new feeding belt, loosen the wheel indicated in the figure below and take the belt away Then, put a new belt on the wheel and adjust the wheel position to optimize the conveyor operation Adjust the wheel position to optimize the conveyor operation Figure 19: Adjusting the Feeding Belt Wheel 20 TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc 4.2 Sensor Adjustment and Replacement 1) Sensor and Sensor 4(Board In and Board Out Control): Use a Philips screw driver to adjust the sensitivity of the sensor Generally, when a board is above the sensor, the indicate light on the sensor will turn on Otherwise, the indicate light will turn off in the normal situation So, users have to find out the best position of the screw by rotating the screw driver slightly 2) Sensor and Sensor (Board Deceleration and Board Stop Control): Use the same approach as description above to adjust the sensor 3) Sensor and Sensor (Front and Rear Board Clamping Control): Use the same approach as description above to adjust the sensor 4) Replacement Procedure: When the sensor does not work, try to adjust the sensor sensitivity first If it still does not work, just replace a new sensor directly instead of repairing it The replacement method is, pull out the connection cable and take away the broken sensor first, then, replace a new sensor and adjust the sensor sensitivity Figure 20: Sensor Adjustment TR7700 SIII Plus Series User Guide – Hardware 21 Test Research, Inc 4.3 Unloader and Loader Connections There are an input and an output port behind the AOI They are nearby the power supply The top one is the input port and is designed to connect to the unloader Also, the button one is the output port and is designed to connect to the loader There are two kind connection cables: SMEMA to SMEMA or SMEMA to color lines as figures below Only SMEMA to color connections cable needs to read the following sections Figure 21: SMEMA to SMEMA Connection Cable Figure 22: SMEMA to Color Lines Connection Cable 22 TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc 4.3.1 Unloader Connection Link PORT1 – UP LINE Black (1) / Green (2) Y104 Red (3) / Blue (4) X8A Yellow (5) / White (6) X8B Ready Board Available Spare The input port is designed to connect to the cable which consists of three different type cords, Y104 (black/green), X8A (red/blue), and X8B (yellow/white) The function of Y104 is to deliver a board request signal to the unloader Both X8A and X8B are reserved ports for input signal Normally, users only need to connect Y104 (black/green) to the unloader (TRI AOI follows the SMEMA standards If the unloader uses the different standards, please contact the unloader vendor in order to solve the connection problems.) Connect to unloader Connect to loader Figure 23: I/O Port Position 10 11 12 13 14 10 11 12 13 14 PIN1~PIN6 PIN1~PIN6 10 11 12 13 14 10 11 12 13 14 Figure 24: Diagrammatic Sketch of Loader and Loader Ports TR7700 SIII Plus Series User Guide – Hardware 23 Test Research, Inc 4.3.2 Loader Connection Link PORT2 – DOWN LINE Black (1) / Green (2) X98 Red (3) / Blue (4) Y106 Yellow (5) / White (6) Y105 Ready Board Available OK: Short; NG: Open The output port is designed to connect to the cable which consists of three different type cords, X98 (black/green), Y106 (red/blue), and Y105 (yellow/white) The function of X98 is to receive a board request signal from the loader The function of Y106 is to deliver a board out signal to the loader Moreover, the function of Y105 is to deliver a board test result signal (Pass) to the loader (TRI AOI follows the SMEMA standards If the loader uses the different standards, please contact the loader vendor in order to solve the connection problems The SMEMA standard signal connection diagram is shown below: Figure 25: SMEMA Standard Signal Connection Diagram Remark: All the connections above are dry contacts (No current) 24 TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc ELECTRIC PANEL 5.1 Structures & Functions 5.1.1 Interior Allocation of Front Door The front door allocation is shown as figure below Lighting Control Box Main PC Power Supply Figure 26: Front Door Allocation TR7700 SIII Plus Series User Guide – Hardware 25 Test Research, Inc 5.1.2 Interior Allocation of Rear Door The front door allocation is shown as figure below Auto Conveyor Width Device and Conveyor X and Y Axis Motion Terminal PLC Air Pressure Regulator EMI Filter Figure 27: Rear Door Allocation 26 TR7700 SIII Plus Series User Guide – Hardware Module Board Test Research, Inc 5.1.2.1 Air Pressure Regulator Air Pressure Regulator (Left): provides air for clamping Air Pressure Regulator (Right): provides air for blow module Figure 28: Air Pressure Regulator Blow module is designed to remove the heat vapor from the board after the reflow oven (For post-reflow AOI use) TR7700 SIII Plus Series User Guide – Hardware 27 Test Research, Inc APPENDIX 6.1 XY Stage Servo Motor Drivers Error Code Table 28 TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc TR7700 SIII Plus Series User Guide – Hardware 29 Test Research, Inc 30 TR7700 SIII Plus Series User Guide – Hardware Test Research, Inc 6.2 IP Connection of PLC In default setting, PLC and the main PC connect through enthernet card Therefore, when you click [System]> [Control Setting] but the system cannot work, please check the LNC IP settings in [Control Panel]> [Network and Internet]> [Network and Sharing Center] The correct setting in Internet Protocol Version should be same as figure below Figure 29: PLC IP Setting TR7700 SIII Plus Series User Guide – Hardware 31 ... View of TR7 700 SIII Plus TR7 700 SIII Plus Series User Guide – Hardware Test Research, Inc 1.3 Right View Maintenance Openings Figure 3: The Right View of TR7 700 SIII Plus TR7 700 SIII Plus Series... Front View of TR7 700 SIII Plus Figure 2: The Left View of TR7 700 SIII Plus Figure 3: The Right View of TR7 700 SIII Plus Figure 4: The Rear View of TR7 700 SIII Plus Figure... Cover TR7 700 SIII Plus Series User Guide – Hardware Test Research, Inc TR7 700 SIII Plus Operating & Storage Environment are shown as below: Operating Storage 0~ 40? ?C (32- 104 °F) - 40~ 66°C (- 40~ 151°F)