Agilent Technologies Medalist i3070 5i Series Manual
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Agilent Technologies Medalist i3070 5i Series Manual

Inline ict system
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Summary of Contents for Agilent Technologies Medalist i3070 5i Series

  • Page 1 Medalist i3070 Series 5i Inline ICT System i3070 Series 5i Help Agilent Technologies...
  • Page 2 Agilent disclaims all practice, or the like that, if not correctly Agilent Technologies, Inc. as governed by warranties, either express or implied, with performed or adhered to, could result in United States and international copyright...

  • Page 3: Table Of Contents

    Contents 1 Getting Started Safety Information Warning and Hazard Labels Emergency Stop Overview System Hardware Manual Control Panel System Software Medalist i3070 Software LCDTouch Panel Program Starting the Medalist i3070 Series 5i Shutting Down the Medalist i3070 Series 5i 1-11 2 Touch Panel Functions Modes of Operation Maintenance Mode...
  • Page 4 Service and Maintenance 5 Maintenance Calibration General Cleaning Lubrication Procedures Press: Ballscrew and Ballscrew Nut Press: Linear Shafts Press: Runner Blocks Zone 1 Conveyor: Leadscrew and Spline Shaft Zone 1 Conveyor: Bevel Gears and Chain Zone 2 Conveyor: Runner Blocks 5-10 Drawer: Guide Shafts 5-11...
  • Page 5 Replacing Servo Motor 7-27 Replacing Press Components 7-31 Replacing Zone 1 Conveyor Belt 7-35 Zone 1 Conveyor Belt (Movable Side) 7-35 Zone 1 Conveyor Belt (Fixed Side) 7-37 Replacing Zone 2 Conveyor Belt/Spring 7-39 Zone 2 Conveyor Belt (Movable Side) 7-40 Zone 2 Conveyor Belt (Fixed Side) 7-42...

  • Page 7: Getting Started

    Medalist i3070 Series 5i Inline ICT System i3070 Series 5i Help Getting Started Safety Information Overview System Hardware System Software Starting the Medalist i3070 Series 5i Shutting Down the Medalist i3070 Series 5i 1-11...

  • Page 8: Safety Information

    Getting Started Safety Information Warning and Hazard Labels Pay attention to the following labels when they appear on the equipment. Table 1-1 Warning Labels on the Equipment Label Description DANGER: High Voltage Do not detach the protective covers. Operating this equipment without covers may cause electric shock.

  • Page 9: Overview

    Getting Started Overview Agilent's Medalist i3070 Series 5i Inline In- Circuit Test (ICT) system is designed to bring all the industry- leading ICT technologies into a fully automated manufacturing line. It comes with a full suite of Agilent ICT solutions, including: •...

  • Page 10: System Hardware

    Getting Started System Hardware • Testhead The two- module testhead contains the hardware resources required to execute tests. Each module in the testhead holds the following cards: • A Mother Card • A Module Control Card • An ASRU Card •...
  • Page 11 Getting Started Figure 1-2 Zone 1 – Front View Zone 1 Conveyor Crank for Conveyor Width Adjustment PDU On/Off Switch Air Regulator DUT Power Supplies System Card Controller i3070 Series 5i Help...
  • Page 12 Getting Started Figure 1-3 Zone 2 – Front View Manual Control Panel Electrical Panel Press Assembly Zone 2 Conveyor Drawer Card Cage Anti-Rotation Guide Bar Figure 1-4 Rear View Guided Probe with Cradle Debug Ports RJ45 Coupler Mains Disconnect Switch Power Outlets i3070 Series 5i Help...

  • Page 13: Manual Control Panel

    Getting Started Manual Control Panel Open the Zone 2 door to access the manual control panel. Figure 1-5 Manual Control Panel Table 1-2 Manual Control Panel Button/Switch Description MAINTENANCE KEY SWITCH Off – Enable Production Mode. On – Enable Maintenance/Debug Mode; allows system to operate with the doors open.

  • Page 14: System Software

    Getting Started System Software Medalist i3070 Software The Medalist i3070 software release 08.30si provides the test development environment as well as the Operator Interface for production testing. Test Development to get started on the test development process. LCDTouch Panel Program The LCD touch panel lets you select the mode of operation.

  • Page 15: Starting The Medalist I3070 Series 5I

    Getting Started Starting the Medalist i3070 Series 5i Start the system following the sequence below. See Figure 1- 1 Turn the Main Power Switch to ON. The LCD touch panel will display the Main page. 2 Press Reset to reset the safety relays. Open the controller pod cover to access the following switches: 3 Turn ON the PDU on/off switch that enables power to the testhead.
  • Page 16 Getting Started Figure 1-6 Power Up Sequence Main Power Switch PDU On/Off Switch Reset button DUT Power Supply Controller Table 1-3 Agilent Medalist ICT system users User Name Default Password Definition and Permissions operator Resetme1 For operators who are using the Operator Interface to test boards.

  • Page 17: Shutting Down The Medalist I3070 Series 5I

    Getting Started Shutting Down the Medalist i3070 Series 5i 1 From the Medalist i3070 software, select File > Exit. 2 Unboot the testhead: a Open a Korn Shell window and type dgn at the command line. b In the DGN window, select Testhead Functs and unboot the testhead using Testhead Power Off.
  • Page 18 Getting Started 1-12 i3070 Series 5i Help...

  • Page 19: Touch Panel Functions

    Medalist i3070 Series 5i Inline ICT System i3070 Series 5i Help Touch Panel Functions Modes of Operation Maintenance Mode Debug Mode...

  • Page 20: Modes Of Operation

    Touch Panel Functions Modes of Operation On the LCD touch panel, the Main page appears when the system is powered on. Select the mode of operation from the Main page. A password is required for both Debug and Maintenance modes. The default password is 1263.

  • Page 21: Maintenance Mode

    Touch Panel Functions Maintenance Mode On the LCD panel’s Main page, press Maintenance to access Maintenance Mode. A password is required. In Maintenance Mode, navigation buttons are provided at the right side of the page where needed, as shown in the following examples. Return to Main Page.
  • Page 22 Touch Panel Functions Table 2-2 Maintenance Menu Option/Description Zone 1 Zone 1 Motor FWD – Start forward movement of Zone 1 conveyor. REV – Start reverse movement of Zone 1 conveyor. Stop – Stop Zone 1 conveyor. Zone 1 Stopper On –...

  • Page 23: Test Settings

    Touch Panel Functions Table 2-2 Maintenance Menu Option/Description Top Jig Top Jig Clamp Lock – Lock top fixture Unlock – Unlock top fixture. Presser Presser Up – Move the Press up. Down – Move the Press down. Origin – Move the Press to origin (start) position. Slow –...
  • Page 24 Touch Panel Functions Table 2-3 Settings Option Description Setting 1 Scanner Bypass – Skip the action. Press Non-Bypass – Perform the action. Long Probe This is set via the testplan (except for the Press setting). Retest Scan Timeout Time (in seconds) to wait for scan result from the controller before triggering an error.

  • Page 25: Debug Mode

    Touch Panel Functions Debug Mode On the LCD panel’s Main page, press Debug to access Debug Mode. A password is required. Use Debug mode to quickly move the Press to the various taught positions and check that they are set correctly. 1 On the Debug page, press Origin to intialize the Press to the start position.
  • Page 26 Touch Panel Functions i3070 Series 5i Help...

  • Page 27: Test Development

    Medalist i3070 Series 5i ICT System i3070 Series 5i Help Test Development Test Development Overview Fixturing Guidelines Fixture Setup and Debugging 3-15...

  • Page 28: Test Development Overview

    Test Development Test Development Overview Test development on the Medalist i3070 consists of five main tasks listed below. Follow the detailed instructions in the Medalist i3070 online help, which also explains the use of the software tools you can use in each task. During test development, pay attention to the features and requirements for the Medalist i3070 Series 5i as described in this chapter.

  • Page 29: Fixturing Guidelines

    Test Development Fixturing Guidelines • Board Placement and Specifications • Bottom Fixture • Top Fixture • Guide Pin • Top Fixture Height After Compression • ID Block • Optional Signals Board Placement and Specifications The Board Placement task decides the placement of the board on the fixture and creates the fixture files.
  • Page 30 Test Development Figure 3-2 Board Specifications Free Area at Board Edges • No probing allowed in this area. Tooling Pins • Components must not be located in Tooling pin bushing must not be located Minimum clearance or lean into this area. in or lean into free area of board edge 3.0 mm (0.12 in) Tooling Holes...

  • Page 31: Bottom Fixture

    Test Development Bottom Fixture Figure 3-3 Bottom Fixture Specifications Dimensions in mm NOTE: All connectors (Board Align, Board Orientation, VTEP and CET control signals) should be placed at the front of the fixture for easy connection and removal when changing the fixture. i3070 Series 5i Help...
  • Page 32 Test Development Figure 3-4 Bottom Fixture: Maximum Height Figure 3-5 Bottom Fixture: Tooling Pin Bushing The tooling pin bushing should not lean into the conveyor belt area. The bushing should be flush with the probe plate. If any part of the bushing interferes with the conveyor, it must be cut away.

  • Page 33: Top Fixture

    Test Development Top Fixture Figure 3-6 Top Fixture Specifications Dimensions in mm i3070 Series 5i Help...

  • Page 34: Guide Pin

    Test Development Guide Pin Figure 3-7 Guide Pin Position Center of guide pin to center of guide hole Center of guide pin to front edge of bottom fixture Center of top fixture Dimensions in mm i3070 Series 5i Help...

  • Page 35: Top Fixture Height After Compression

    Test Development Top Fixture Height After Compression The overall height from the top plate to the bottom of the PCB must be 184.6 mm (7.27 in) after compression, regardless of the PCB thickness. Figure 3-8 Top Fixture: Front View After Compression  PP 7RS 3ODWH  PP...

  • Page 36: Id Block

    Test Development ID Block The main function of the ID block is to provide the fixture ID for the top fixture. The fixture ID signal (pin 5 to 12 in the first two rows) is used to verify that the top and bottom fixtures match, before the system can go into Production Auto mode.
  • Page 37 Table 3-2 ID Block: Pin Assignment Pin 16 Pin 14 Pin 12 Pin 10 Pin 8 Pin 6 Pin 4 Pin 2 AF11(MSB) Spare + (24V - T) board (Signal 404) (Signal 406) (Signal 408) (Signal 410) (Signal 412) (Signal 414) orientation Pin 15 Pin 13...
  • Page 38 Test Development Figure 3-10 ID Block Location Dimensions in mm 3-12 i3070 Series 5i Help...

  • Page 39: Optional Signals

    Test Development Optional Signals • Board Orientation • Board Sit Board Orientation An optional Board Orientation signal can be used to verify that: • the orientation of the board is correct • the board has stopped at the correct position for testing in Zone 2 This may be achieved by means of a laser beam perpendicular to the board surface.
  • Page 40 Test Development Board Sit An optional Board Sit signal can be used to verify that the board is sitting flat on the support plate. Dry contact sensors are recommended for this. Connect the micro switches in series, and connect them to the fixture connector provided, as shown in Figure 3- 11.

  • Page 41: Fixture Setup And Debugging

    Test Development Fixture Setup and Debugging • Fixture Setup • Verify the Fixture Fixture Setup Follow the procedures in this section to set up a new fixture. Adjust Conveyor Width Load Bottom Fixture Adjust Board Stopper Learn Press Heights Complete the Setup i3070 Series 5i Help 3-15...
  • Page 42 Test Development Adjust Conveyor Width The conveyor width can be adjusted using the hand crank or via the LCD touch panel. Ensure the Maintenance Key Switch is set to ON when adjusting CAUTION the conveyor. Using the Crank Maintenance Key Switch Reset Button 1 Open the controller pod and Zone 2 doors.
  • Page 43 Test Development Using the Touch Panel 1 Select Maintenance mode on the LCD touch panel and press Width. 2 Press Next. 3 Enter the board width in mm and then press Go Pos to move the conveyor rail to the specified width. i3070 Series 5i Help 3-17...
  • Page 44 Test Development Load Bottom Fixture 1 Release the drawer: a Select Maintenance mode on the LCD touch panel. Press Drawer to go to page 4. b Press Unlock, then press UP to move the drawer up. 2 Pull the drawer out by its handles. Drawer Handles 3 Load the bottom fixture on the drawer.
  • Page 45 Test Development 5 On the LCD touch panel, press Down to move the drawer down, then press Lock to lock the bottom fixture. Adjust Board Stopper The board stopper ensures that the board is stopped at the correct position for testing. Adjust the board stopper using a production board. 1 Turn the Zone 2 board stopper on.
  • Page 46 Test Development 7 On the LCD touch panel, turn the stopper off. 8 Go to page 6. Manually jog the Press to check that the board is correctly positioned and can be guided onto the tooling pins. If necessary, use Slow to slow down Press movement during NOTE checking.
  • Page 47 Test Development b On the Maintenance menu select Top Jig to go to page 6 and select Lock. 11 Go to page 6. Manually jog the Press to check that the board is correctly positioned and can be guided onto the tooling pins. i3070 Series 5i Help 3-21...
  • Page 48 Test Development Learn Press Heights The press positions described in Table 3- 5 need to be set according to the fixture/pin design. Follow the procedure below to set these press positions. The taught positions are automatically saved to the 75 mm, 85 mm or 100 mm fixture profile.
  • Page 49 Test Development Table 3-5 Press Positions Calibration Option Press Position Standby Pos Standby position that allows the transfer of the board from Zone 1 to Zone 2. Presser Retrieve Pos Safe position of the Press for removing the fixture or for maintenance. The three 75 mm fixture calibration pages below will be followed by similar pages for 85 mm and 100 mm.
  • Page 50 Test Development Table 3-5 Press Positions Calibration Option Press Position 75mm Jig Long Probe Pos Position where the board is in contact with the long probes only, for dual stage testing. 75mm Board Align Pos Standby position while verifying that the board is seated properly on the tooling pin and support plate.

  • Page 51: Verify The Fixture

    Test Development Verify the Fixture • Use Pushbutton Debug to verify the fixture as described in the Medalist i3070 online help. • Use Debug mode on the touch panel to quickly check the press positions for the fixture. See Debug Mode on page 2- 7.
  • Page 52 Test Development 3-26 i3070 Series 5i Help...

  • Page 53: Production Setup And Testing

    Medalist i3070 Series 5i ICT System i3070 Series 5i Help Production Setup and Testing Production Setup Production Testing...

  • Page 54: Production Setup

    Production Setup and Testing Production Setup Follow these setup procedures on the Medalist i3070 Series 5i whenever there is a change in board model for production. Adjust Conveyor Width. Load Bottom Fixture. Adjust Board Stopper. 4 Select Fixture Profile. a Select Maintenance mode on the touch panel and enter the password. b Press Setting and then Next.

  • Page 55: Production Testing

    Production Setup and Testing Production Testing 1 On the LCD touch panel, select Production mode. 2 Launch the Medalist i3070 software. 3 Load and run the testplan. • When the testplan starts, commumication is established between the controller and PLC. •...
  • Page 56 Production Setup and Testing i3070 Series 5i Help...

  • Page 57: Maintenance

    Medalist i3070 Series 5i ICT System i3070 Series 5i Help Maintenance Calibration General Cleaning Lubrication Procedures...

  • Page 58: Calibration

    Maintenance Calibration All Medalist i3070 ICT systems have been tested and calibrated by Agilent Technologies to ensure that all warranted specifications are met at the time of shipment. For ongoing calibration and performance verification: • ASRU Calibration – Agilent recommends that the ASRU Card in every module of a Medalist i3070 ICT system be calibrated once every six months.

  • Page 59: General Cleaning

    Maintenance General Cleaning The importance of cleanliness cannot be overemphasized. Dirt in the testhead will cause contact problems and overheating. • MINT pins (fixture interface pins) — Dirt will cause high- impedance contacts and pin sticking. • Pin cards, mother cards and vents — Air flow through the system causes a buildup of dirt on pin cards and Mother Cards and clogs air vents in the testhead, contributing to system overheating.

  • Page 60: Lubrication Procedures

    Maintenance Lubrication Procedures Maintenance Schedule It is recommended that the following parts be checked and lubricated monthly: • Press: Ballscrew and Ballscrew Nut • Press: Linear Shafts • Press: Runner Blocks • Zone 1 Conveyor: Leadscrew and Spline Shaft • Zone 1 Conveyor: Bevel Gears and Chain •...

  • Page 61: Press: Ballscrew And Ballscrew Nut

    Maintenance Press: Ballscrew and Ballscrew Nut 1 Open the Zone 2 door to access the Press. The ballscrew and ballscrew nut are found at the side of the Press. Press Ballscrew Ballscrew Nut 2 Use a grease gun to apply a small amount of grease as shown below. Apply grease here using grease gun 3 Close the door.

  • Page 62: Press: Linear Shafts

    Maintenance Press: Linear Shafts The Press has four linear shafts. 1 Open the Zone 2 door to access the Press. Press Linear Shafts 2 Use a grease gun to apply a small amount of grease to the four linear shafts. Linear Bearing Linear Shaft 3 Close the door.

  • Page 63: Press: Runner Blocks

    Maintenance Press: Runner Blocks The Press has vertical guide rails at the four corners, with two runner blocks along each rail. 1 Open the Zone 2 door to access the Press. 2 Use a grease gun to apply a small amount of grease to the four runner blocks at the front.

  • Page 64: Zone 1 Conveyor: Leadscrew And Spline Shaft

    Maintenance Zone 1 Conveyor: Leadscrew and Spline Shaft 1 Open the Zone 1 door to access the Zone 1 conveyor assembly. Zone 1 Conveyor Assembly 2 Use a brush to lightly apply grease to the two leadscrews and the spline shaft.

  • Page 65: Zone 1 Conveyor: Bevel Gears And Chain

    Maintenance Zone 1 Conveyor: Bevel Gears and Chain 1 Open the rear door to access the Zone 1 conveyor assembly. Zone 1 Conveyor Assembly 2 Remove three screws to remove the rear cover of the assembly. Screw Rear Cover 3 Use a brush to lightly apply grease to the two bevel gears and the chain.

  • Page 66: Zone 2 Conveyor: Runner Blocks

    Maintenance Zone 2 Conveyor: Runner Blocks The Zone 2 conveyor has two horizontal runner blocks and four vertical runner blocks. 1 Open the rear doors to access the Zone 2 conveyor assembly. Zone 2 Conveyor Assembly Horizontal Guide Rail Vertical Runner Block Horizontal Runner Block 2 Use a grease gun to apply a small amount of grease to the runner blocks.

  • Page 67: Drawer: Guide Shafts

    Maintenance Drawer: Guide Shafts The drawer assembly has four guide shafts at the corners. 1 Remove the testhead pod cover to access the guide shafts of the drawer assembly. Guide Shaft 2 Use a brush to lightly apply grease to the two guide shafts at the front. 3 Open the rear doors to lubricate the two guide shafts at the rear.

  • Page 68: Testhead: Spur Gears

    Maintenance Testhead: Spur Gears Power must be connected to begin this procedure. 1 Follow step 1 through step 4 Accessing the Testhead to pull out the testhead. 2 Remove six screws around the spur gear cover. 3 Use a brush to lightly apply grease to the two spur gears. Screws Spur Gears Spur Gear Cover...

  • Page 69: Troubleshooting

    Medalist i3070 Series 5i ICT System i3070 Series 5i Help Troubleshooting System Diagnostics General System Troubleshooting Sensor Calibration and Troubleshooting...

  • Page 70: System Diagnostics

    Troubleshooting System Diagnostics Diagnostics (dgn) is the main troubleshooting tool. You can use it to check the hardware configuration, verify performance, and isolate failures to a field- replaceable unit (FRU). The Diagnostic tests are structured in such a way that the failing part is usually indicted by the first few test failures. Some Diagnostic tests require that a Pin Verification Fixture (PVF, part number E9988- 67901) be installed on the testhead;...

  • Page 71: General System Troubleshooting

    Troubleshooting General System Troubleshooting Tower Light Indications When lit, the tower light color indicates the current status of the system. Table 6-1 Tower Lights Light Possible Conditions Green System is in Auto mode Amber • System has stopped • System is in Maintenance mode or Debug mode Flashing •...

  • Page 72: Error Messages And Remedial Actions

    Troubleshooting Error Messages and Remedial Actions If error messages appear on the LCD touch panel, press OK and take action as described in Table 6- Table 6-2 Error Messages Error Message Cause/Action 1 Release the Emergency Stop switch by turning it clockwise. 2 Press the Reset button.
  • Page 73 Troubleshooting Table 6-2 Error Messages Error Message Cause/Action 1 Install the bottom fixture if it is not present. 2 Check that the air supply is turned on. 3 Check the clamping cylinders and replace if faulty. 4 Check the reed switches on the fixture’s locking cylinders (front: RS-5 and RS-7;...
  • Page 74 Troubleshooting Table 6-2 Error Messages Error Message Cause/Action 1 Check that the air supply is turned on. 2 Check the top fixture’s lock/unlock cylinder and replace if faulty. 3 Check the top fixture’s lock reed switch (RS-3). It should turn on when the top fixture is locked.
  • Page 75 Troubleshooting Table 6-2 Error Messages Error Message Cause/Action The drawer is not in the lowered position. • Check the drawer’s Left Drawer Down Sensor (PHS-23) and/or Right Drawer Down sensor (PHS-21). • Lower the drawer. • Disengage the front safety hook. •...

  • Page 76: Sensor Calibration And Troubleshooting

    Troubleshooting Sensor Calibration and Troubleshooting • Calibrating PHS- 13 (Presser Lower Limit Sensor) • Troubleshooting PHS- 1 to PHS- 7 • Troubleshooting PHS- 12 to PHS- 14, PHS- 24 to PHS- 26 • Troubleshooting PHS- 16 and PHS- 17 See also: Sensor Layout Calibrating PHS-13 (Presser Lower Limit Sensor) The lowest position of the Press is defined by the Presser Lower Limit...
  • Page 77 Troubleshooting 3 Press Origin to move the Press to its start position. 4 If the lower limit sensor is too high: Loosen the two screws securing the sensor bracket (Figure 6- 1) and move the sensor down to allow the Press to move down. 5 Press and hold Down to lower the Press until all the probes are contacting the board.
  • Page 78 Troubleshooting 8 Test the sensor positioning: a On the LCD Touch Panel, press and hold UP to move the Press up. b Press and hold Down to move the Press down until the probes are contacting the board. Check that the lower limit sensor is still off at this point. 6-10 i3070 Series 5i Help...

  • Page 79: Troubleshooting Phs-1 To Phs-7

    Troubleshooting Troubleshooting PHS-1 to PHS-7 These are the Zone 1 and Zone 2 sensors triggered by the board. PHS-1 Zone 1 Inlet Sensor PHS-2 Zone 1 Stopper Sensor PHS-3 Zone 1 Exit Sensor PHS-4 Zone 2 Inlet Sensor PHS-5 Zone 2 Stopper Slow Sensor PHS-6 Zone 2 Stopper Sensor PHS-7...

  • Page 80: Troubleshooting Phs-12 To Phs-14, Phs-24 To Phs-26

    Troubleshooting If the sensor responds 1 Trigger the sensor again and check if the PLC responds (check the PLC I/O indicator). If the PLC responds, it was likely an intermittent failure and no further action is needed. 2 If the PLC does not respond, perform a continuity check on the PLC’s connector signal terminals.
  • Page 81 Troubleshooting If the sensor doesn’t respond Check the sensor response after each step and continue only if the sensor fails to respond. 1 Check the connectors and ensure there is power to the sensor. 2 Replace the sensor. If the sensor responds 1 Trigger the sensor again and check if the PLC responds (through the PLC I/O indicator).

  • Page 82: Troubleshooting Phs-16 And Phs-17

    Troubleshooting Troubleshooting PHS-16 and PHS-17 These sensors detect if the rear and front safety hooks on the Press are disengaged. Figure 6-4 Rear Safety Hook Check the sensor response • Disengage the hook to trigger the sensor and see whether it responds. If the sensor doesn’t respond Check the sensor response after each step and continue only if the sensor fails to respond.

  • Page 83: Sensor Layout

    Troubleshooting Sensor Layout Table 6- 3 lists the sensors in the system, together with their IDs and signals to the PLC. The following figures show the locations of the sensors in a left- to- right system. The sensor ID will be marked on labels in the system.
  • Page 84 Troubleshooting Table 6-3 Sensors Sensor Signal to PLC Top Press Assembly Rear Safety Hook Detect Sensor PHS-16 Top Jig Lock SV5,1014 RS3,110 Top Jig Unlock SV6,1015 RS4,111 Top Jig Fully In Detect Sensor PHS-19 Front Safety Hook Detect Sensor PHS-17 Table 6-4 Motors and Controls Motor/Control...
  • Page 85 Troubleshooting Figure 6-5 Sensor Locations in Left-to-Right System 3UR[LPLW\ VHQVRU 'LIIXVH VHQVRU 6ROHQRLG YDOYH 3+6 )LEHU RSWLF VHQVRU *DS VHQVRU 3+6 5HHG VZLWFK 3+6 3+6 69 3+6 69 ELW 7RS -LJ ,QSXW 3+6 8%$  3+6 3+6 3+6 3+6 69 3+6 '%$*  69...
  • Page 86 Troubleshooting Figure 6-7 Zone 1 and Press Sensors Zone 1 Inlet Sensor Zone 1 Stopper Sensor Zone 1 Exit Sensor PHS-1 PHS-2 PHS-3 Presser Upper Limit Sensor PHS-12 Presser Front Safety Hook Detect Sensor Home Sensor PHS-17 PHS-14 Presser Lower Limit Sensor PHS-13 Rear Safety Hook Detect Sensor PHS-16...
  • Page 87 Troubleshooting Figure 6-8 Zone 2 Sensors Zone 2 Stopper Slow Sensor PHS-5 Zone 2 Exit Sensor Zone 2 Stopper Sensor PHS-6 PHS-7 Zone 2 Inlet Sensor PHS-4 Conveyor Conveyor Conveyor Right Limit Sensor Origin Sensor Left Limit Sensor PHS-25 PHS-24 PHS-26 i3070 Series 5i Help 6-19...
  • Page 88 Troubleshooting 6-20 i3070 Series 5i Help...

  • Page 89: Replacement Procedures

    Medalist i3070 Series 5i ICT System i3070 Series 5i Help Replacement Procedures Accessing the Testhead Replacing Cards in the Testhead Replacing i-System Card Replacing Runner Blocks 7-10 Replacing Module Power Unit (MPU) 7-21 Installing DUT Power Supply 7-23 Replacing Servo Motor 7-27 Replacing Press Components 7-31...

  • Page 90: Accessing The Testhead

    Replacement Procedures Accessing the Testhead 1 Unload the bottom fixture: a Select Maintenance mode on the LCD touch panel. Press Drawer to go to page 4. b Press Unlock to unlock the bottom fixture, then press UP to move the drawer up.
  • Page 91 Replacement Procedures 6 Use the hand crank to rotate the testhead. The direction depends on the part being replaced. Figure 7-1 Accessing the Testhead Guide Bar Latch Handle Hand Crank Star Knob Install hand crank to rotate testhead i3070 Series 5i Help...
  • Page 92 Replacement Procedures Figure 7-2 Stowing the guide bar Guide Bar i3070 Series 5i Help...

  • Page 93: Replacing Cards In The Testhead

    Replacement Procedures Replacing Cards in the Testhead Follow this procedure to replace the ASRU Card (slot 1), Module Control Card (slot 6), or any of the pin cards in the testhead. Removal 1 Follow the instructions in Accessing the Testhead. 2 Turn the hand crank counterclockwise to rotate the testhead 120 degrees until the blower door is facing you (Figure 7-...
  • Page 94 Replacement Procedures Installation To prevent electrostatic discharge (ESD) from damaging sensitive components on CAUTION module/slot cards, wear a tested, grounded, anti-static wrist strap while performing this procedure. Connectors for the wrist strap are provided at the front of the system 1 Remove the new card from the ESD- safe bag.
  • Page 95 Replacement Procedures 5 Tighten the retaining screw on each side of the card. If the screws do not thread properly, reseat the card in the connector. If the retaining screws are not tightened, the card will be pushed CAUTION out of its connector when a test fixture is pulled down, possibly damaging the system.

  • Page 96: Replacing I-System Card

    Replacement Procedures Replacing i-System Card The i- System Card is installed in the controller pod. Removal 1 Open the rear door to access the back of the i- System Card Assembly. Disconnect the cables. 2 Open the controller pod door. 3 Remove the four dress screws securing the i- System Card Assembly and remove the assembly.
  • Page 97 Replacement Procedures 3 Open the rear door to reconnect the cables to the i- System card. To Module 3 To Module 2 i3070 Series 5i Help...

  • Page 98: Replacing Runner Blocks

    Replacement Procedures Replacing Runner Blocks • Testhead Runner Blocks • Press Lower Runner Block • Press Upper Runner Block • Zone 2 Conveyor Runner Block (Up/Down) • Zone 2 Conveyor Runner Block (Width Adjustment) Replace runner blocks one at a time. NOTE Remove the fixture before replacing parts in the Press assembly.
  • Page 99 Replacement Procedures Removal 1 Follow the instructions in Accessing the Testhead. 2 Turn the hand crank clockwise to rotate the testhead about 90 degrees. 3 Open the rear doors to access the runner blocks from the rear of the system. Runner Blocks Runner Blocks Runner Blocks...

  • Page 100: Press Lower Runner Block

    Replacement Procedures Press Lower Runner Block The Press has four guide rails with two runner blocks on each rail. Figure 7- 6 shows the runner blocks visible from the front of the system. Figure 7-6 Front Runner Blocks for Press Upper Runner Blocks Lower Runner Blocks Removal...
  • Page 101 Replacement Procedures 2 Open the Zone 2 door and rear doors to access the Press. Lock the front and rear hooks on the Press. Front Hook Locked Rear Hook Locked 3 Turn off the PDU on/off switch. 4 Remove the lower runner block to be replaced: a Remove two screws below the Screws runner block stopper and remove...
  • Page 102 Replacement Procedures Installation 1 Slide the new runner block up the guide rail. Align the screw mounting holes and secure with the four screws. 2 Install the runner block stopper and secure with the two screws. 3 Unlock the front and rear hooks. 4 Close all doors.

  • Page 103: Press Upper Runner Block

    Replacement Procedures Press Upper Runner Block Follow this procedure to replace an upper runner block (Figure 7- 6) on the Press. Removal Follow this procedure to replace a lower runner block. Power must be connected to begin this procedure. 1 Select Maintenance mode on the LCD touch panel.
  • Page 104 Replacement Procedures 4 Remove the runner block that is below the runner block to be replaced: a Remove two screws below the Screws runner block stopper and remove the stopper. Lower Runner Block b Remove four screws securing the runner block. c Slide the runner block down the guide rail to remove it.

  • Page 105: Zone 2 Conveyor Runner Block (Up/Down)

    Replacement Procedures Zone 2 Conveyor Runner Block (Up/Down) Follow this procedure to replace the up/down runner blocks for the Zone 2 conveyor assembly. Runner Block (Up/Down) Vertical Guide Rail Zone 2 Conveyor Assembly Horizontal Guide Rail Runner Block (Width Adjustment) Removal 1 Follow the Removal...
  • Page 106 Replacement Procedures c The guide rail with runner block can now be removed from the system. Slide the runner block off the guide rail. Runner Block Guide Rail Installation 1 Slide the new runner block onto the guide rail. 2 Reinstall the guide rail in the system. 3 Secure the runner block to the conveyor with two screws.

  • Page 107: Zone 2 Conveyor Runner Block (Width Adjustment)

    Replacement Procedures Zone 2 Conveyor Runner Block (Width Adjustment) Follow this procedure to replace the runner blocks for the Zone 2 conveyor’s two horizontal guide rails. Movable Rail Assembly Runner Block (Up/Down) Vertical Guide Rail Zone 2 Conveyor Assembly Horizontal Guide Rail Runner Block (Width Adjustment) Removal 1 Remove the right side cover.
  • Page 108 Replacement Procedures 3 To remove the runner block: a Remove four screws to remove the movable guide holder. b Remove 10 screws securing the guide rail to the system. Spring and Spring Guide Screw Screws Guide Rail Runner Block Movable Guide Holder c Slide the runner block off the guide rail.

  • Page 109: Replacing Module Power Unit (Mpu)

    Replacement Procedures Replacing Module Power Unit (MPU) There is a Module Power Unit (MPU) for each module in the testhead. Removal 1 Follow the instructions in Accessing the Testhead. 2 Turn the hand crank counterclockwise to rotate the testhead 90 degrees until the MPUs are facing up.
  • Page 110 Replacement Procedures Installation 1 Secure the new MPU with the screws removed earlier. 2 Connect the MPU cable to the motherboard. Be sure to align the connectors properly. 3 Plug in the power cable. 4 Rotate the testhead back into position and stow the hand crank. Replace the guide bar and fasten the latches.

  • Page 111: Installing Dut Power Supply

    Replacement Procedures Installing DUT Power Supply Figure 7-7 DUT Power Supply in Controller Pod Dress Screws i-System Card Assembly DUT Power Supply (Module 3) Controller DUT Power Supply (Module 2) Dress Screws Installation 1 Open the controller pod door. 2 Slide the DUT power supply along the support rails into the system. 3 Secure it with four dress screws.
  • Page 112 Replacement Procedures 4 Open the rear door to connect the ground cable at the back of the DUT power supply. 5 Connect the cables F, G, H, and J. Ground Cable 6 Tidy the unused cables (K and L) and secure with cable ties. 7 If two DUT power supplies are installed, connect the GPIB cable between the two GPIB ports.
  • Page 113 Replacement Procedures 8 Connect the GPIB interface cable between the GPIB port on the DUT power supply and a USB port on the controller. GPIB Interface Cable 9 Connect the AC power cord from the DUT power supply to the PDU outlet box.
  • Page 114 Replacement Procedures Update config Files The power supply connections must be declared in the system and standard files. config Example 7-1 bank 2 module 2 ………… supplies ps6751 5 to 8 asru channels 1 to 4 supplies hp6634 19 asru channels 5 supplies hp6634 20 asru channels 6 ports ext3, ext4 end module...

  • Page 115: Replacing Servo Motor

    Replacing Servo Motor Safety Precautions for Removal For your safety, follow these steps before removing the Press servo motor, coupling, and ballscrew. Power must be connected to begin this procedure. 1 Select Maintenance mode on the LCD touch panel. a Press Presser to go to page 6. b Press Origin to move the Press to its origin position.
  • Page 116 3 Open the rear door. 4 Loosen the two screws on the set collar and push the set collar against the linear bearing. Tighten the screws on the set collar. Do the same for the other set collar. Linear Bearings Set Collar Set Collar 7-28...
  • Page 117 Remove Servo Motor 1 Open the Zone 2 door and remove the side cover. 2 Remove the Press servo motor: a Loosen the screw that secures the coupling to the motor shaft. b Unplug the electrical connectors. c Remove four screws securing the servo motor. The motor can now be removed.
  • Page 118 Install Servo Motor 3 Install the new servo motor. The shaft of the motor must be properly aligned for it to go into the coupling. Secure the motor with the four screws. 4 Plug in the electrical connectors. 5 Tighten the screw on the coupling. Reposition Set Collars 6 Loosen the screws on the set collars and move them back into position, 30 mm to 50 mm from the end of the shaft.

  • Page 119: Replacing Press Components

    Replacing Press Components • Ballscrew • Tapered roller bearing (on either side of the bearing block) • Coupling Remove the fixture before replacing parts in the Press assembly. NOTE Ballscrew Coupling Bearing Block Tools required • Metric Allen key • Philips screwdriver •...
  • Page 120 Removal 1 Follow the Safety Precautions for Removal. 2 Open the Zone 2 door. 3 Loosen the screw securing the coupling to the ballscrew. Then loosen the locknuts. Screw Locknuts 4 Remove four screws securing the bearing block. Screws on this side of the bearing block Bearing Block 5 Remove six screws securing the ballscrew collar.
  • Page 121 Keep the rubber washer in place; it prevents the ballscrew nut from sliding off the ballscrew. Collar Ballscrew Rubber Washer Do not drop the bearing block when removing the collar and CAUTION ballscrew. If replacing the tapered roller bearing: The bearing block is released and the tapered roller bearing can now be replaced.
  • Page 122 10 Tighten the locknuts and the screw on the coupling. Screw Locknuts Reposition Set Collars 11 Loosen the screws on the set collars and move them back into position, 30 mm to 50 mm from the end of the shaft. Tighten the screws on the set collars.

  • Page 123: Replacing Zone 1 Conveyor Belt

    Replacing Zone 1 Conveyor Belt • Zone 1 Conveyor Belt (Movable Side) • Zone 1 Conveyor Belt (Fixed Side) Zone 1 Conveyor Belt (Movable Side) Removal 1 Open the Zone 1 door to access the access the Zone 1 conveyor assembly.
  • Page 124 Installation 1 Install the new belt. 2 Slide the tensioner bearing in the direction shown and tighten the screw. Tensioner Bearing Belt 3 Close the door. 7-36 i3070 Series 5i Help...

  • Page 125: Zone 1 Conveyor Belt (Fixed Side)

    Zone 1 Conveyor Belt (Fixed Side) Removal 1 Open the Zone 1 door to access the access the Zone 1 conveyor assembly. Zone 1 Conveyor Assembly 2 Loosen the screw on the tensioner bearing to release tension on the belt. 3 Slide the tensioner bearing in the direction shown and release the belt.
  • Page 126 Installation 1 Install the new belt. 2 Slide the tensioner bearing in the direction shown and tighten the screw. Belt Tensioner Bearing 3 Close the door. 7-38 i3070 Series 5i Help...

  • Page 127: Replacing Zone 2 Conveyor Belt/Spring

    Replacing Zone 2 Conveyor Belt/Spring • Zone 2 Conveyor Belt (Movable Side) • Zone 2 Conveyor Belt (Fixed Side) • Compression Spring (Movable Side) • Compression Spring (Fixed Side) i3070 Series 5i Help 7-39...

  • Page 128: Zone 2 Conveyor Belt (Movable Side)

    Zone 2 Conveyor Belt (Movable Side) Removal 1 Open the Zone 2 door to access the Zone 2 conveyor assembly. Zone 2 Conveyor Assembly 2 Loosen the screw on the tensioner bearing to release tension on the belt. 3 Slide the tensioner bearing in the direction shown and release the belt. Note how the belt is routed.
  • Page 129 Installation 4 Install the new belt. Slide the tensioner bearing in the direction shown and tighten the screw. Belt Tensioner Bearing 5 Close the door. i3070 Series 5i Help 7-41...

  • Page 130: Zone 2 Conveyor Belt (Fixed Side)

    Zone 2 Conveyor Belt (Fixed Side) Removal 1 Open the Zone 2 door to access the Zone 2 conveyor assembly. Zone 2 Conveyor Assembly 2 Loosen the screw on the tensioner bearing to release tension on the belt. 3 Slide the tensioner bearing in the direction shown and release the belt. Note how the belt is routed.
  • Page 131 Installation 1 Install the new belt. Slide the tensioner bearing in the direction shown and tighten the screw. Belt Tensioner Bearing 2 Close the door. i3070 Series 5i Help 7-43...

  • Page 132: Compression Spring (Movable Side)

    Compression Spring (Movable Side) Follow this procedure to replace the springs for the Zone 2 conveyor (movable side). Movable Rail Assembly Spring Zone 2 Conveyor Assembly Removal 1 Remove the right side cover. 2 Remove the movable rail assembly: a Remove six screws securing one side of the rail assembly. 2 screws Movable Guide Holder 4 screws around...
  • Page 133 3 The spring can now be removed. Spring and Spring Guide Installation 1 Insert the spring guide and new spring. 2 Reinstall the movable rail assembly. On each side, tighten the four screws at the base and make sure the rail assembly is properly aligned before tightening the two screws at the top.

  • Page 134: Compression Spring (Fixed Side)

    Compression Spring (Fixed Side) Follow this procedure to replace the springs for the Zone 2 conveyor (fixed side). Spring Fixed Rail Assembly Spring Zone 2 Conveyor Assembly Removal 1 Remove the right side cover. 2 Remove the fixed rail assembly: a Remove two screws securing one side of the rail assembly.
  • Page 135 3 To remove the spring from the fixed rail assembly: a Remove the screw securing the spring guide from below. b Remove four screws securing the support plate. Spring Guide Screw Support Plate The support plate, spring, and spring guide can now be removed. Installation 1 Assemble the new spring, spring guide, and support plate.

  • Page 136: Replacing Conveyor Motors

    Replacing Conveyor Motors • Zone 1 Conveyor Motor • Zone 2 Conveyor Motor (Movable Side) • Zone 2 Conveyor Motor (Fixed Side) Zone 1 Conveyor Motor Removal 1 Open the rear door to access the Zone 1 conveyor assembly. Zone 1 Conveyor Assembly 2 Remove three screws to remove the rear cover of the assembly.
  • Page 137 3 The conveyor motor is mounted on a bracket. Remove the two screws securing the bracket to the assembly. Screws on this side 4 Remove the conveyor motor from the bracket: a Loosen two setscrews securing the bevel gear and remove the bevel gear.

  • Page 138: Zone 2 Conveyor Motor (Movable Side)

    Zone 2 Conveyor Motor (Movable Side) Removal 1 Follow the Removal instructions in Zone 2 Conveyor Belt (Movable Side) to remove the belt on the movable side of the Zone 2 conveyor. 2 Remove the four mounting screws securing the conveyor motor. Screw 3 Loosen the two setscrews that mount the pulley on the conveyor motor and remove the pulley.

  • Page 139: Zone 2 Conveyor Motor (Fixed Side)

    Zone 2 Conveyor Motor (Fixed Side) Removal 1 Follow the Removal instructions in Zone 2 Conveyor Belt (Fixed Side) to remove the belt on the fixed side of the Zone 2 conveyor. 2 Loosen the two setscrews that mount the pulley on the conveyor motor and remove the pulley.
  • Page 140 7-52 i3070 Series 5i Help...

  • Page 141: Firmware Update

    Medalist i3070 Series 5i ICT System i3070 Series 5i Help Firmware Update Update PLC Firmware Back Up PLC Firmware Update LCD Touch Panel Firmware Back Up LCD Touch Panel Firmware If a firmware update is available, the files must be copied to a memory card for transfer to the Medalist i3070 Series 5i.

  • Page 142: Update Plc Firmware

    Firmware Update Update PLC Firmware 1 Open the Zone 2 door to access the PLC. Electrical panel and circuit breakers Front View 2 Turn off the power to the PLC by switching off MCB4 (Main Circuit Breaker 4) which is found on the electrical panel. 3 Open the cover of the memory card slot on the PLC and insert the memory card into the slot.
  • Page 143 Firmware Update 4 Open the cover above the memory slot to access the DIP switches. DIP Switches 5 Turn on DIP switch 2 and 7. 6 Switch on MCB4. The program is automatically downloaded to the PLC. 7 Wait for the BUSY and MCPWR lights to go off, then turn the PLC power off.

  • Page 144: Back Up Plc Firmware

    Firmware Update Back Up PLC Firmware 1 Switch off MCB4. 2 Open the cover of the memory card slot on the PLC and insert the memory card into the slot. DIP Switches under this cover Memory Slot 3 Open the cover above the memory slot to access the DIP switches. 4 Turn on DIP switch 7.

  • Page 145: Update Lcd Touch Panel Firmware

    Firmware Update Update LCD Touch Panel Firmware 1 Copy the entire folder ( ) containing the firmware update to an gt_data SD card. 2 Open the Zone 2 door. Insert the SD card into the card slot. card slot 3 On the Setting Mode page, select SD → GT. 4 Select the folder to download and press Copy.

  • Page 146: Back Up Lcd Touch Panel Firmware

    Firmware Update 6 Press OK when completed. Remove the SD card and press ESC to return to the Main menu. Back Up LCD Touch Panel Firmware 1 Open the Zone 2 door. Insert the SD card into the card slot. 2 On the Setting Mode page, press Manual to switch to Automatic mode.
  • Page 147 Medalist i3070 Series 5i ICT System i3070 Series 5i Help Appendix Parts List Electrical Diagrams...
  • Page 148 Parts List Table 9-1 Parts (Level 1) Part Number Description Category Sub-category E9988-21201 Motor Coupling, Oldham Coupling ID15K5 and Top Press Servo System ID19K6 0490-2998 Switch-Reed 40mA 24VAC with Light indicator Top Press Top Fixture Clamp E9988-33602 TU-6 3MM ENDLESS BELT 1000MM Zone 1 Conveyor Rail Assy 5186-2230...
  • Page 149 Table 9-2 Parts (Level 2) Part Number Description Category Sub-category 1990-4262 Photomicrosensor GaAs infrared 940-nm-Peak Top Press Servo System wavelength NPN L-Shape 3101-4356 Switch-push Button SPDT 15A 500VAC Screw Top Press Press Safety Mount Lock 1990-4262 Photomicrosensor GaAs infrared 940-nm-Peak Zone 1 Conveyor Width wavelength NPN L-Shape...
  • Page 150 Table 9-2 Parts (Level 2) Part Number Description Category Sub-category 2090-1086 Display-LCD 4.6-in Monitor with Touchscreen Interface Panel 24VDC 320x120-Pixels 146X74X30-mm 3101-4357 Switch-push Button SPDT momentary 0.5A Interface Panel 24VDC 240VAC/DC Blue illuminated panel-mount 3130-1520 Switch-Guard push-Button rectangular Interface Panel 24VDC 3101-4359 Switch-push Button emergency stop Pushlock...
  • Page 151 Medalist i3070 Series 5i ICT System i3070 Series 5i Help Appendix Electrical Diagrams...

  • Page 152: Electrical Diagrams

    Electrical Diagrams • Sensor Layout 1 • Sensor Layout 2 • Sensor Layout 3 • Sensor Layout 4 • Power Circuit 1 • Power Circuit 2 • Power Circuit 3 • Power Circuit 4 • Power Circuit 5 • Pneumatic 1 •...

  • Page 153: Sensor Layout

    Figure 9-1 Sensor Layout 1...

  • Page 154: Sensor Layout

    Figure 9-2 Sensor Layout 2...

  • Page 155: Sensor Layout

    Figure 9-3 Sensor Layout 3...

  • Page 156: Sensor Layout

    Figure 9-4 Sensor Layout 4...

  • Page 157: Power Circuit

    Figure 9-5 Power Circuit 1...

  • Page 158: Power Circuit

    Figure 9-6 Power Circuit 2...

  • Page 159: Power Circuit

    Figure 9-7 Power Circuit 3...

  • Page 160: Power Circuit

    Figure 9-8 Power Circuit 4...

  • Page 161: Power Circuit

    Figure 9-9 Power Circuit 5...
  • Page 162 Figure 9-10 Pneumatic 1...
  • Page 163 Figure 9-11 Pneumatic 2...
  • Page 164 Figure 9-12 Pneumatic 3...
  • Page 165 Figure 9-13 PLC Input Unit (Channel 0)
  • Page 166 Figure 9-14 PLC Input Unit (Channel 1)
  • Page 167 Figure 9-15 PLC Input Unit (Channel 2)
  • Page 168 Figure 9-16 PLC Input Unit (Channel 3)
  • Page 169 Figure 9-17 PLC Input Unit (Channel 4)
  • Page 170 Figure 9-18 PLC Output Unit (Channel 10)
  • Page 171 Figure 9-19 PLC Output Unit (Channel 11)
  • Page 172 Figure 9-20 PLC Output Unit (Channel 12)
  • Page 173 Figure 9-21 Motor and Communication...
  • Page 174 Figure 9-22 PLC to PC Interface...
  • Page 175 Figure 9-23 Interfacinng Cables...
  • Page 176 Figure 9-24 SMEMA Communication...
  • Page 177 Figure 9-25 Touch Panel...
  • Page 178 Figure 9-26 Servo Motor...
  • Page 179 Figure 9-27 Servo Pin Connection...
  • Page 180 Figure 9-28 Analog Card Interface...
  • Page 181 Figure 9-29 Stepper Motor...

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