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Filtec Omnivision 1000 Series Upgrade Installation Manual

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Omnivision Upgrade
Installation Manual
Document 45277-0805

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Summary of Contents for Filtec Omnivision 1000 Series

  • Page 1 Omnivision Upgrade Installation Manual Document 45277-0805...
  • Page 2 Industrial Dynamics Company, Ltd.   Filtec and Industrial Dynamics are registered trademarks of Industrial Dynamics Company, Ltd. All other trademarks are the property of their respective owners.
  • Page 3 Document 45277-0805...
  • Page 4 Omnivision Upgrade Installation Manual Document 45277-0805...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Installation Overview ..........1-1 Qualifying a Machine For Upgrade .
  • Page 6 LCM Installation ........1-27 •...
  • Page 7 Inspection Head Power Supply Check 1-55 Final installation of parts/assemblies ......1-55 Powering up the Electronic Chassis......1-55 Replacing Doors/Panels .
  • Page 8 Omnivision Upgrade Installation Manual Document 00805...

  • Page 9: Installation Overview

    Installation Overview Qualifying a Machine For Upgrade All of the Omnivisions that are candidates for upgrade will require an engineering evaluation to determine if the machine can be upgraded with the basic upgrade package or will need additional components to ensure compatibility. Refer to EDS document P/N 43187 for additional information and criteria for machine qualification.

  • Page 10: Upgrade Schedule

    Upgrade Schedule The OV Upgrade kits have been designed to allow a machine upgrade to be completed within three days by a factory trained engineer and an assistant. Work should be organized so that one person works on the upper portion of the machine and the other works on the base cabinet and Inspection head.
  • Page 11 In Inspection Head • All optics/cameras (remove Servo Adapter from base) • Trigger blocks and terminal strip • Finish Strobe • Servo Control card Mounting plate (if parts exists) In Base Cabinet: • Wiring troughs • All Base Strobe transformer and rectifier parts (Remove strobe unit for re-installation later) •...

  • Page 12: Day 2 - Ac Power Wiring/Cable Harness Installation

    The base cabinet is prepared and the AC Distribution panel is installed. Day 2 - AC Power wiring/Cable harness installation All power wires are routed through the Base Cabinet and routed up to the upper cabinet. The upper power supply plate is installed and the ac cables are routed to all supplies.

  • Page 13: Machine Preparation

    Machine Preparation Column Labeling The columns are identified by a number and a color. The number/color designation facilitates the installation process as each of the harness has a corresponding color. 4 - Yellow 1- Red 3 - Blue 2 - White 2 - White 3 - Blue 4 - Yellow...

  • Page 14: Electronic Cards

    • A/C unit on top of the Omnivision including the supporting plate • The keypad from the operator side of the machine. The side to be used will have to be decided by the customer. • Air Gauge panel • Circuit Breaker Panel and Power Switch •...
  • Page 15 Echain Machine Preparation Document 45277-0805...

  • Page 16: Ov-900/1200 Series 3000 Upper Cabinet

    OV-900/1200 Series 3000 Upper Cabinet Each of the electronics cages can be taken out of the system by removing the retaining bolts from lower and upper brackets. Retain all of the bolts from the chassis. These retaining bolts will be used to secure portions of the upgrade. “Plate 2”...
  • Page 17 Yellow Column Red Harness BLUE COLUMN White Column Plate 2 Location Machine Preparation Document 45277-0805...

  • Page 18: Junction Box Mounting (Sb1 & Sb3)

    Junction Box Mounting (SB1 & SB3) Parts/Kits Required: • 45265, Kit, SB1 (Packed in Lower Cabinet Kit 45252) • 45268, Kit, SB3 (Packed in Lower Cabinet Kit 45252) Tools required: • 7/16 Allen Wrench • 13/64 drill bit • 25/64 drill bit •...
  • Page 19 Upstream Side (SB1) Downstream Side (SB3) 13/64 Drill (3x) Drilling Guide 25/64 Drill Alignment Pins Placement on Base Cabinet Exterior Place a 41204 gasket underneath the junction box and use the included screws to attach the junction box. Junction Box Mounting (SB1 & SB3) Document 45277-0805...

  • Page 20: Power Connections

    Power Connections The upgrade will require installation of a new power switch (Packed in Lower Cabinet Kit P/N 45252). The power switch is pre-wired and will have to connect to the motor starter and transformers. Check the following table for the appropriate drawing and refer to the corresponding drawing.
  • Page 21 Column 4 (Yellow) Install the motor controllers and their corresponding plate onto the side of the lower cabinet. Place the AC Breaker panel on top of the motor controller plate. The AC breaker will need to have the wires bundled to the side of the mechanical assemble as is it being placed into location.

  • Page 22: Ac Wire Routing

    AC Wire Routing Lay the AC cables on the floor and route the harnessed cables starting with the longest bundle that runs up column 3 (Blue). PS12-P1 XFM2-P1 PD2-P1 PD2-P2 Air Conditioner Utility Outlet FAN 4-P1 PL1-J5 PL1-J2 MTR1-P1 PL1-J1 MTR2-P1 PL1-J8 FILTER N...

  • Page 23: E-Stops

    Utility Power Air Conditioner PS12-P1 XFM2-P1 PD2-P1 PD2-P2 Upper Cabinet AC Routing E-Stops Remove the old E-stops. Affix the self adhesive backed square plates from the new E-Stop switches(92364; Packed in Lower Cabinet Kit P/N 45252)first. Then install the main body of the new E-Stops through the hole from inside of the machine.

  • Page 24: Mechanical Installation

    Mechanical Installation Air and Water Valve (Packed in Lower Cabinet Kit P/N 45252) Air valve and water valve are located inside at the lower level as shown. Water Valve Air Valve BASE BAR The water valve will need to be completely replaced with P/N 43110.
  • Page 25 Select one side and designate that as the operator side. Remove the keypad from the operator side. Remove the plate underneath the keypad. Save the plate as this will be used later in the upgrade. Column After Keypad Removal Place the plate and gasket in place over the cable hole Gasket Over Plate Mechanical Installation Document 45277-0805...
  • Page 26 Mount the Enclosure unto the column. Mount the Support bracket to the back of the enclosure. Use the slotted end resting on the Omnivision as a guide to mark the column. Remove the support bracket and drill two holes. Use the 8-32 tap to form the holes. Remove the enclosure and mount at the end of the upgrade.

  • Page 27: Cable Harness Installation

    Cable Harness Installation Door Interlock Cable P/N 45207 (Packed in Upper Cabinet Kit P/N 45251) The door interlock cable is included as a separate cable. This cable should be routed as shown on the following diagram. 3 - BLUE COLUMN Interlock cable P/N 45207 in Upper Level The interlock cable should be routed by starting at the four corners.

  • Page 28: Red Harness P/N 45262 (Packed In Upper Cabinet Kit P/N 45251)

    Red Harness P/N 45262 (Packed in Upper Cabinet Kit P/N 45251) The Red Harness references a point called the “First Breakout”. This position on the cable has a special designation and should be located first. The First Breakout position will be placed on top of the starting point in the upper cabinet.

  • Page 29: Yellow & Blue Harness P/N 45264 (Packed In Upper Cabinet Kit 45251)

    Step 1 Step 2 Opening inside upper cabinet Routing a Harness The harness should be routed as one bundle down the column. The best method of routing the harness is to pass the harness through the opening on the side of the column. The bundle should be pulled up and out of the top of the column.

  • Page 30: White Harness P/N 45263 (Packed In Upper Cabinet Kit P/N 45251)

    Separate three of the cables, 41474, 45202 and 45203. These three cables will go down either the yellow or white column, depending on which side the customer prefers to install their operator side. These cables should only be pulled out 12 to 14 inches out of the hole where the touchpad is to be mounted.

  • Page 31: Ups / Power Supply Assembly

    UPS / Power Supply Assembly Upper Cabinet Installations The UPS/Power Supply assembly is mounted vertically on the “B” side of the Omnivision upper cabinet. The assembly requires the replacement of two Allen head screws that hold the grey mounting strip in place Replace the two bolts with the included bolts.

  • Page 32: 45256 Stack Light Installation (Packed In Upper Cabinet Kit P/N 45251)

    45256 Stack Light Installation (Packed in Upper Cabinet Kit P/N 45251) Tools needed: • 3/8 Drill • 3/4” Conduit Punch or 1 1/8” Punch Parts Needed: • 45256 Stack Lamp Kit • Silicone B Side A Side Stack Light Position Options Mark a position close to where the strobe lights were mounted.

  • Page 33: 45261 Upper Cabinet Harness (Packed In Upper Cabinet Kit P/N 45251)

    Spread a ring of silicone on the hole and seat the pin in the hole. Tighten the pin down with the nut inside the upper cabinet. 45261 Upper Cabinet Harness (Packed in Upper Cabinet Kit P/N 45251) Start routing the Upper Cabinet Harness from the center. Monitor cable (45201) as a reference for the center.

  • Page 34: Electronic Card Chassis Installation

    Electronic Card Chassis Installation OV-900/1200 Series 1000/2000 Installation The installation of the chassis in the 900 will require the bracket PN 43055 (Packed with Card Cage P/N 45231)to mount the electronics chassis. Do not use brackets P/N 43072, whose parts are only for Series 3000 upgrades.

  • Page 35: Ov-900/1200 Series 3000 Installation

    OV-900/1200 Series 3000 Installation The OV-1200 will require the Electronic chassis to sit on top of two brackets PN 43072 (Packed with Card Cage P/N 45231). These brackets fasten to the Omnivision by using the retaining bolts that held the older electronics housing. Do not use brackets P/N 43055, whose parts are only for Series 1000/2000 upgrades.

  • Page 36: Lower Cabinet Harness Routing

    Lower Cabinet Harness Routing Red Harness Cable Routing Route the red harness in the base cabinet as shown in the following drawing. RED HARNESS 40465-3 (VLV1-P1) 45211(SW4-P1) Panel 1 Cables 40475-3 (PL1-J1,J2) 45205 (PL1-J3) 40577-2 (PL1-J10) 45206 (PL1-J9) 45211 (VL3-P1) 45240 (PL1-J11) 45211 (VLV10-P1) 45199 (PL1-J13)

  • Page 37: White Harness Cable Routing

    YELLOW HARNESS 40456-7 (SB2-J9) 40456-8 (SB3-J9) Inspection Head Cables 45219 (CBC-P11; MTR1-P3) 45210 (S6-P1) 40549-4 (SCC2-P1) 45208 (FIC-P1) 45228 (IRLD-P500) 40549-3 (SCC1-P1) 45228 (STR2-P1) Yellow Harness Lower Cabinet Routing Route the Yellow harness as shown above. White Harness Cable Routing Locate the two cables (45209, 45196-1) and route them through the scan head pole and into the inspection head.

  • Page 38: Blue Harness Cable Routing

    Route the rest of the white harness as shown in the diagram. Blue Harness Cable Routing Take the loose cable (45207) and plug it into the sensor Junction Box #2. BLUE HARNESS 45207 (SB2-P3) 40467-5 (PL3-J3) Blue Harness Lower Cabinet Routing Route the rest of the remaining cables as shown.

  • Page 39: Plc /Osw/Comm Interface Installation

    PLC /OSW/Comm Interface Installation Parts/Kits Required: • 45272, Kit, Intfc Plate(Packed in Lower Cabinet Kit 45252) • Ethernet ADT Cable(95289) (2) (Located in 45272 Kit) • D-Sub Jack-Post Assembly (26061) (5) (Located in 45272 Kit) Cable Listing: • 45233 (J5, J2, J1, J8; from AC Brkr Assy 45269) •...

  • Page 40: Plc /Comm / Osw Interface Plate Cable Connections

    IDC NET DSW LAMPS POW SUPPLIES SENSOR 220 VAC OSW CAMERA ETHERNET RS 232 120 VAC MODULE PLC PLC Interface PN 45272 PLC /Comm / OSW Interface Plate Cable Connections Connect all of the cables onto the plate. Where necessary, use jack-post kits P/N 26061 located in Upgrade Kit P/N 45272.

  • Page 41: Mounting Sb2 Signal Junction Box On Plate 2

    Mounting SB2 Signal Junction Box on Plate 2 Parts/Kits Required: • 45266, Kit, SB2 (Packed in Lower Cabinet Kit 45252) PLATE #2 Junction Box PN 40458 Mounting Bracket PN 43108 Plate 2 Assembly Mount the sensor junction box on Plate 2 using mounting bracket (PN 43108).
  • Page 42 White Column SB2 PLATE Red Column XMFR5-P2 STR1-P5 Inspection Head INTERLOCK SWITCH S5P1 TRIG-P2 STR2-P5 SB2 Harness Routing Omnivision Upgrade Installation Manual Document 45277-0805...

  • Page 43: Inspection Head Assembly

    Inspection Head Assembly The Inspection Head upgrade will fall into two types; 1000 Series (2 Tower Camera) and 3000 Series (Triple Tower) upgrade. 1000 Series Inspection Head Parts Removal Remove the Power supply located above the Finish Strobe Power Supply. Clear any tie-wrap mounts from the rear wall to allow the new brackets to be mounted.
  • Page 44 Slide the cover into place and place the upper nuts into place and tighten. Place the mounting standoff (PN 39929) on the bracket to form a triangle. This will allow the IR card cover to snap into place easily. Snap the IR RLD Amplifier Card (PN 35486) into place with the two DB9 connector facing the outside of the inspection head.
  • Page 45 Mount the IR RLD Shield (PN 43126) onto the bracket. GND Wire Connect the IR-RLD Ground wire (PN 36179) onto the IR-RLD card and attach to the inspection head. Mount three Support Spacers (PN 37148-2) onto the side of the Inspection head.
  • Page 46 Place the Mounting Bracket (PN 43119) on the spacers and place the Servo Adapter Board (PN 41777) inside the bracket. Place the Quad Pin Buffer card (PN 31195) onto the Mounting bracket. Place the Trigger Card Label (PN 36364) on the Finish Strobe Power Supply.

  • Page 47: Optional Items

    Optional Items The following items may be needed and depends on the serial number of the machine and if it has been upgraded in the past. Servo Adapter Plate The Servo Adapter card (PN 36672) can be mounted on the back of the servo mounting using the Servo Adapter Plate (PN 43127).

  • Page 48: 3000 Series Inspection Head

    3000 Series Inspection Head Parts Removal Remove the Power supply located above the Finish Strobe Power Supply. Clear any tie strap mountings from the rear wall to allow the brackets to be mounted. Initial Bracket Mounting 2 Tower Inspection Head (Cameras Removed for Clarity) Bracket Installation Note: Bracket P/N’s 43127 is not used for Series 3000 machines...
  • Page 49 Place the mounting standoff (PN 39929) on the bracket to form a triangle. This will allow the IR card cover to snap into place easily. Snap the IR RLD Amplifier Card (PN 35486) into place with the two DB9 connector facing the outside of the inspection head. Inspection Head Assembly Document 45277-0805...

  • Page 50: Optional Items

    Mount the IR RLD Shield (PN 43126) onto the bracket. GND Wire Connect the IR-RLD Ground wire (PN 36179) onto the IR-RLD card Place the Quad Pin Buffer card (PN 31195) onto the Mounting bracket. Replacement Servo Adapter Card The Servo Adapter card (PN 36672) can be mounted on the base of the optics triple tower using two #4-40x5/8”...
  • Page 51 Support Spacers Place the Mounting Bracket (PN 43119) on the spacers and place the Servo Adapter Board (PN 41777) inside the bracket. Place the Quad Pin Buffer card (PN 31195) onto the Mounting bracket. Place the Trigger Card Label (PN 36364) on the Finish Strobe Power Supply.
  • Page 52 LED Finish interface Card mounting Some OV1200/3000 units may have LED Finish. If so, attach bracket 43120 to the studs on the Universal RLD plate which was installed on the back wall of the Inspection Head. Attach standoffs P/N 41441(qty 4) to the studs on bracket 43120 and mount the FInish Interface Card (P/N 40578)to the bracket.

  • Page 53: Inspection Head Cable Connections And Adapters

    Inspection Head Cable Connections and adapters The following list describes the part number and where the cable or adapter connects. Cable Number From 45210 Rej. Ver. Cable Reject Verifier Yel/Blu harness 45264 45237 IR Cable IR Preamp IR-RLD Card 45228 IR RLD Cable IR-RLD Card Yel/Blu harness 45264...

  • Page 54: Adapter List - Kit P/N 45291

    Adapter List - Kit P/N 45291 The 1000 series Omnivision may have some slight connector differences and the kit includes several adapters to accommodate the differences. The machine being updated may or may not need several of the following adapters. Cable Part Number Adapter Name Application...

  • Page 55: Servo Adapter Card Connections

    Servo Adapter Card Connections Connect the Inspection Head Servos to their appropriate location on the servo adapter card. Base Finish Brightness Brightness Brightness Brightness Base Finish Zoom Zoom Zoom Zoom Servo Adapter Card Connections Inspection Head Assembly Document 45277-0805...

  • Page 56: Touch Pad Assembly

    Touch Pad Assembly Hardware needed: • Touch Pad PN 43070 • 10-32 x 3/8 bh (2) • #10 lock washer (2) • 8-32 x 3/8 bh (2) • #8 lock washer (2) • #8 flat washer (2) • 6-32 x1/2 bh (10) •...

  • Page 57: Ac Power Check

    AC Power Check Disconnect the Electronic Chassis from the power supply as well as the Power Supply itself. These two items will be the last to be powered up. Basic Power Check 1. Ensure the power going into the machine is disabled. 2.

  • Page 58: Testing Cb1 Circuit

    Testing CB1 Circuit. 1. Turn CB1 ON. 2. Verify that the voltage at CB2, CB3, CB4, CB5 and CB6 is 120 VAC. Testing CB2 Circuit. 1. Locate the following connector and insure it is not connected: • PD2-P1 (AC into PD) 2.

  • Page 59: Testing Cb3 Circuit

    11.Record the voltage at PS5-P2 should be +5VDC. 12.Record the voltage at PS4-P2 should be +12VDC. 13.Turn CB2 OFF and reconnect the connectors that were just checked. Testing CB3 Circuit. 1. Remove the following connectors: • PS12-P1 (UPS Power Supply •...

  • Page 60: Testing Cb4 Circuit

    Testing CB4 Circuit. 1. Remove connector if OSW option is included PL1-J5 (TO OSW DC POWER). 2. Turn CB4 ON. 3. Verify that the voltage at PL1-J5 is 120VAC. 4. Turn CB4 OFF and reconnect the connector PL-P5. Testing CB5 Circuit. 1.

  • Page 61: Testing Cb9 Circuit

    3. Verify the voltage at XFMR3-P1 is 120 VAC. 4. Turn CB8 OFF and reconnect the connector. Testing CB9 Circuit. 1. Disconnect MTR1-P1 (Star Motor Controller) 2. Turn CB9 ON 3. Verify that the voltage at MTR1-P1 is 120VAC. 4. Turn CB9 OFF. Testing CB10 Circuit.
  • Page 62 5. Measure XFMR2-P1 for 220VAC. 6. Turn Off CB12. Omnivision Upgrade Installation Manual Document 45277-0805...

  • Page 63: Inspection Head Power Supply Check

    Inspection Head Power Supply Check 1. Disconnect P1at the Inspection Head Power Supply Card. 2. Make sure the UPS Circuit Breaker is in the Closed position. 3. Turn CB3 ON and measure 24 VDC at PS6-P1 of Inspection Head Power Supply card. See Drawing 41955 for this portion. 4.

  • Page 64: Replacing Doors/Panels

    5. Verify that the system is in “Upgrade Mode” by viewing the “System Operating Mode” status LED’s in the Diagnostics/IO screen (Left column; 1/2 the way down). Both status LED’s should be illuminated. Note:The upgrade mode is automatically detected by the system via the connection of cable P/N 45219 between J33 of the LCM card and J11 of the Clutch Brake Driver Card.

  • Page 65: Osw Upgrade (Optional)

    OSW Upgrade (Optional) Parts Removal Remove the OSW camera box on both sides of the OSW by removing the four large phillips head screws on the bottom plate. Remove the mirror tilt mechanism. OSW Upgrade (Optional) Document 45277-0805...

  • Page 66: Rotator Installation

    Rotator Installation Remove the guide rails and replace with the Universal Rotator Guides. Refer to drawing 43135 (Upper Rotator) and 43148 (Lower Rotator) for installation details. For Single Outer Sidewall (SOSW) machines, refer to drawing 43133 (Upper Rotator) and 43149 (Lower Rotator) for installation details.

  • Page 67: Bottom Plate Assembly

    Insert the OSW conduit (Right Angle) into the OSW and tighten into position. Bottom Plate Assembly Remove the mirror from the Bottom Plate Assembly and mount onto the OSW base plate with 4 phillips head screws. OSW Upgrade (Optional) Document 45277-0805...

  • Page 68: Camera Mount

    Camera Mount Drill the center tunnel with the drill guide. Mount the Top Camera bracket and tighten down the assembly. Replace the bottom plate mirror. Cable Connections PS-8 Remove this PS-10 Power Supply Power Supply Positions Omnivision Upgrade Installation Manual Document 45277-0805...

  • Page 69: Osw Heater

    The cable conduit part number is 45240 and all of the labels on the cables will have that part number on them. The following is a list of connector numbers and where they connect: Connector Number From SCC3-P4 Servo Control Card 27976 Terminator Servo Control Card PS-10 J2...
  • Page 70 Omnivision Upgrade Installation Manual Document 45277-0805...

This manual is also suitable for:

Omnivision 2000 seriesOmnivision 3000 seriesOv-900Ov-1200

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