Page 1 Polar FT100/RITS500s Flying Probe Test System FT100/RITS500s Service Manual Polar Instruments Ltd. Polar Instruments Ltd. Garenne Park St. Sampson Guernsey Channel Islands GY2 4AF ENGLAND Fax: +44 (0) 1481 252476 Email: mail@polarinstruments.com Web: www.polainstruments.com MAN 184–0110...
Page 3 FT100s/RITS500s Service Manual Comment Sheet Please copy this master sheet and use it to help us to improve this service manual. We would like you to tell us about its accuracy, format and quality. Please give specific references i.e. page numbers or headings and attach examples wherever possible.
Page 5 FT100/RITS500s FLYING PROBE TEST SYSTEM SERVICE MANUAL POLAR INSTRUMENTS LTD. HARDWARE WARRANTY Product Warranty. Product hardware is warranted to be free from defects in material and workmanship during the Warranty Period (as defined below). Product hardware is warranted to conform substantially to Polar’s then current (as of the date of Polar’s product shipment) published user documentation during the...
Page 7 DECLARATIONS European Community Directive Conformance Statement Refer to the Operator Manual to determine conformance with European Community Directives. DECLARATIONS • • • • i FT100s/RITS500s SERVICE MANUAL...
Page 8 WARNING — MAINS VOLTAGES The LIVE and NEUTRAL lines are BOTH fused. When the unit is connected to its supply, the opening of covers or removal of panels is likely to expose dangerous voltages. ii • • • • SAFETY FT100s/RITS500s SERVICE MANUAL...
Page 9 Changing the line voltage settings on this instrument must only be performed by a skilled electronics technician. Instructions for changing the line voltage settings are contained in LINE VOLTAGE AND FUSE CHANGING. SAFETY • • • • iii FT100s/RITS500s SERVICE MANUAL...
Page 10 Use only the accessories (e.g. test probes and clips) provided by Polar Instruments. The instrument must be maintained and repaired by a skilled electronics technician in accordance with the manufacturer’s instructions.
Page 11 SYMBOLS The following symbols are used in this instrument. REFER TO MANUAL Rear panel connectors are for Polar Instruments accessory cables, linking to external equipment as specified in the Operator Manual only. INTERLOCK OVERRIDE When the key is in this position the hood may be opened while the machine is operating.
Page 12 SD12 Stepper drive Boards Logic 1A F FCA131 (Cards 6,7) Drive 3.15A F FCA136 For continued protection against electric shock and fire hazards, replace only with fuses of identical specification. vi • • • • FUSES FT100s/RITS500s SERVICE MANUAL...
Page 13 SECTION 1 — PERFORMANCE CHECK MAINTENANCE AND CALIBRATION OF INSTRUMENTS .... 1 Performance Check................. 1 Calibration Procedure..............1 Recommendations for Routine Maintenance ........1 FT100s PERFORMANCE CHECK Equipment required: ................ 3 Setup....................3 Connections ..................4 Power up ..................4 Z Axis sensor test................
Page 14 Check the hood safety interlock switches ......26 Hood safety interlock electrical test........27 CAMERA ..................28 PROBE HEAD ................29 Removing the FT100s Probe Head ........29 Removing the RITS500s Probe Head......... 30 Z BREAKOUT BOX ............... 30 Z-AXIS ASSEMBLY............... 31 X DRIVE BELT AND PULLEYS.............
Page 15 SECTION 4 – ADJUSTMENT PROCEDURES DISC ADJUSTMENT..............61 Home Position check............61 X DISC................62 Y DISC................63 CAMERA ADJUSTMENT .............. 63 FT100s ................63 RITS500s................64 HOOD SAFETY INTERLOCK ............64 PROBE ADJUSTMENT..............65 FT100s ................65 RITS500s................66 Calibrate Probe Height Sensor ...........
Page 16 SAFETY/EMC CRITICAL PARTS ..........99 MECHANICAL PARTS ..............100 BASIC FT100s/RITS500s SERVICE KIT (ACC223) ....101 ACC228 FT100s FULL SERVICE KIT (includes ACC223)..103 ACC279 RITS500s FULL SERVICE KIT (includes ACC223) ..104 SECTION 9 – SCHEMATIC DIAGRAMS SECTION 10 – EXPLODED MECHANICAL DRAWINGS x •...
Page 17 SECTION 1 — PERFORMANCE CHECK MAINTENANCE AND CALIBRATION OF INSTRUMENTS For most of Polar Instruments’ products there are two maintenance procedures — the Performance Check and the Calibration. Some instruments may have a single (combined) procedure. Performance Check The Performance Check (or Checkout Procedure) is used to verify the basic functions of the instrument.
Page 18 2 • • • • FT100s PERFORMANCE CHECK FT100s/RITS500s SERVICE MANUAL...
Page 19 FT100s PERFORMANCE CHECK Equipment required: PC running current version of FT100s Prober software. (FSW153) Test Demo Board (MSA154 or MSA190) Warning: This procedure requires the safety hood to be raised when the interlock is set to override. The probe head and table can be accessed while in motion.
Page 20 Safety Interlock Key to override position. Mount the Test Board on the FT100 table using the top slot in the board supports. Set the stop at position 6. Connect power cord and check FT100s is set to correct line voltage. Power up Switch on.
Page 21 Check the ‘Y Limit –’ box is checked. Drive the Y axis until the table stops at the front. Check the ‘Y Home’ and ‘Y Limit +’ boxes are checked. FT100s PERFORMANCE CHECK • • • • 5 FT100s/RITS500s SERVICE MANUAL...
Page 22 Adjust the camera focus and iris for a clear display. Adjust the iris ring (above light ring) to almost maximum. Adjust focus ring(below light ring) for clear display. Adjust iris ring for maximum light without distortion. 6 • • • • FT100s PERFORMANCE CHECK FT100s/RITS500s SERVICE MANUAL...
Page 23 Safety system test Check the Safety Interlock key is set to the INTERLOCK OVERRIDE position. Check the ‘Interlock Override’ box is ticked. Check 40V ‘Motor Power Sensor’ box is ticked. FT100s PERFORMANCE CHECK • • • • 7 FT100s/RITS500s SERVICE MANUAL...
Page 24 Click ‘Home’ and press the EMERGENCY STOP switch whilst the axis are in motion. Check the FT100s comes to an immediate halt. Clear the error message. Check ‘40V Motor Power Sensor’ box is not ticked. Release EMERGENCY STOP switch. Close the FT100S cover.
Page 25 Align these carefully as instructed. Check board passes. Check Red Operational LED is on during probing. Check Green or Yellow Power LED is on all the time unit is powered by mains. FT100s PERFORMANCE CHECK • • • • 9 FT100s/RITS500s SERVICE MANUAL...
Page 26 Stop the test and select slow home from the Menu bar. Close the FT100s program and shut down the PC. Remove all connections from the FT100s. 10 • • • • FT100s PERFORMANCE CHECK...
Page 27 PC card. (Continue at Connections if PC already configured). Observing static precautions, set the DIP switches on Compumotor AT6400 indexer PC card as shown below. Power down the PC. Install the Compumotor AT6400 indexer card. RITS500s PERFORMANCE CHECK • • • • 11 FT100s/RITS500s SERVICE MANUAL...
Page 28 UTILITIES and enter RITS DIAGNOSTICS. Click CONFIG button, then CYCLE POWER and then CONFIG again. Machine should “hiss”. Check no errors flagged on the diagnostics screen. Check OPERATING LED goes out. 12 • • • • RITS500s PERFORMANCE CHECK FT100s/RITS500s SERVICE MANUAL...
Page 29 Check the ‘Y Limit –’ box is checked. Drive the Y axis until the table stops at the front. Check the ‘Y Home’ and ‘Y Limit +’ boxes are checked. RITS500s PERFORMANCE CHECK • • • • 13 FT100s/RITS500s SERVICE MANUAL...
Page 30 Check that the camera is visually square to the Z Axis. Using the Joystick, check that the cross-hair can be positioned beyond the center target area of the 50 ohm air line PCB adapter by at least 100 counts. 14 • • • • RITS500s PERFORMANCE CHECK FT100s/RITS500s SERVICE MANUAL...
Page 31 Check the ‘Interlock Override’ box is ticked. Check 40V ‘Motor Power Sensor’ box is ticked. Click ‘Home’ and press the EMERGENCY STOP switch whilst the axis are in motion. Check the FT100s comes to an immediate halt. Clear the error message.
Page 32 Open the cover while the axis are in motion and check the FT100s comes to an immediate halt. Clear the error message. Check 40V ‘Motor Power Sensor’ box is not ticked. Close the cover and click ‘Configure’ button. Check the 40V ‘Motor Power Sensor’ box is checked.
Page 33 NB The signal pin is furthest from the touch sensor. Press the button again. Move to a clean place on the compound and repeat for each signal pin of each probe. RITS500s PERFORMANCE CHECK • • • • 17 FT100s/RITS500s SERVICE MANUAL...
Page 34 Air line calibrate was successful no error messages will be displayed and the test is complete. 18 • • • • RITS500s PERFORMANCE CHECK FT100s/RITS500s SERVICE MANUAL...
Page 35 When lubricating the positioning screw shafts use only Polar supplied lead screw lubricant (Polar part number MPA197) available from Polar Instruments Ltd or your local distributor Lubrication of Y-axis lead screw and slide rails Remove the deck plate (see REMOVAL AND REPLACEMENT SECTION).
Page 36 Caution: do not over lubricate — excess lubricant can cause contamination of the sensors. Replace the Z-slide cover and then the camera (see REMOVAL AND REPLACEMENT SECTION). 20 • • • • SECTION 2 — PERIODIC MAINTENANCE FT100s/RITS500s SERVICE MANUAL...
Page 37 Visual inspection Inspect the machine for damage, loose or missing parts, etc., and rectify as necessary. SECTION 2 — PERIODIC MAINTENANCE • • • • 21 FT100s/RITS500s SERVICE MANUAL...
Page 39 The duster in the service kit is ideal for this. REMOVE THE MAINS CONNECTOR FROM THE BACK OF THE MACHINE BEFORE PERFORMING ANY OF THESE OPERATIONS. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 23 FT100s/RITS500s SERVICE MANUAL...
Page 40 The Main Panels The diagram below illustrates the locations of the main panels. The RITS500s panels Most panels may be removed by simply removing their securing screws. 24 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 41 Tighten up the screws, lower the hood, check it’s alignment and if necessary raise and realign. NEVER LOOSEN OR REMOVE THE HOOD SECURING SCREWS IN THE LOWERED POSITION. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 25 FT100s/RITS500s SERVICE MANUAL...
Page 42 The actuator must be located within, but not touching, the detent cutout of the hinge bar assembly cam. 26 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 43 Ensure the SAFETY HOOD is closed. Release EMERGENCY STOP switch. Set the Safety Interlock key switch to OPERATE position. Enter FT100s/RITS500s diagnostics (Section 7). Click CONFIG button, then CYCLE POWER and then CONFIG again. Check the 40V supply check box is ticked.
Page 44 AXIS ASSEMBLY. Lift the camera away from the Z-AXIS ASSEMBLY. Re-assembly is the reverse of the above procedure. Leave the four top securing screws finger tight. 28 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 45 Refer to Section 4 — FT100s or RITS500s CAMERA ADJUSTMENT for camera alignment routines. PROBE HEAD Removing the FT100s Probe Head Remove the two 25-pin D-connectors from the Side Chain Assemblies. Remove the 4 screws securing the Probe Head Assembly to the Front Plate.
Page 46 The breakout box is located behind the camera, on the X-carriage and contains a PCB that distributes the connections from the main chain to the camera and Z- axis systems. 30 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 47 D socket. Remove the four 6mm hex head screws “A” holding the Z-axis assembly onto the X carriage. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 31 FT100s/RITS500s SERVICE MANUAL...
Page 48 D-connectors. Secure the main chain D-connector assembly to the Z- axis breakout board with a cable tie. 32 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 49 Ensure the lead screw pulley spacer is in place. Insert the grub screws into the pulleys with a small quantity of thread retainer (Polar part number SECTION 3 — REMOVAL AND REPLACEMENT • • • • 33 FT100s/RITS500s SERVICE MANUAL...
Page 50 Wipe away any surplus retainer from pulleys and clamp. If other parts of the machine have been dismantled reassemble first and then refer to Section 4 — DISC ADJUSTMENT (X DISC). 34 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 51 Remove the two screws from the center of the X-axis carrier block. X-axis carrier block Release the locking grub screw holding the left-hand bearing, access being from the front. Left hand lead screw bearing SECTION 3 — REMOVAL AND REPLACEMENT • • • • 35 FT100s/RITS500s SERVICE MANUAL...
Page 52 When reassembling the nut onto the screw shaft, first fit the main part of the nut, and then try the second nut without the spring to find the best fit. The 36 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 53 Clean and lubricate the lead screw and slide rails (Section 2 —PERIODIC MAINTENANCE). Check the X- slide moves freely left and right across the X-axis. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 37 FT100s/RITS500s SERVICE MANUAL...
Page 54 From the front, remove the two screws holding the X carriage to the nut carrier assembly. Carefully slide the X carriage off the rails. 38 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 55 Re-assembly is the reverse of the above but take care not to displace the linear bearing when engaging the rails. TABLE Removing the FT100s table Undo the four thumbscrews, remove the two dowels and lift off the work-holder plate. Remove the four countersunk screws then pry up the IDC plug from the recessed socket in the table.
Page 56 Re-assembly is the reverse of this procedure. DECK PLATE Set the table about mid-way before starting. Remove the six countersunk screws retaining the plate and slide it out to the front. 40 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 57 Remove the six countersunk screws in the middle of the sub-table to release the nut carrier assembly. Sub-table/bearing blocks Push the sub-table to the rear of the machine to access the anti-backlash nut assembly. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 41 FT100s/RITS500s SERVICE MANUAL...
Page 58 Remove the two screws securing the nut plate assembly to the nut plate carrier/table support bracket. Replace the nut and plate as an assembly (MSA197). 42 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 59 — do not tighten the screws at this time. Slide the sub-table forward and align the sub-table screw holes with the support plate screw holes; refit the six countersunk screws and tighten fully. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 43 FT100s/RITS500s SERVICE MANUAL...
Page 60 Cut the top cable tie securing the safety interlock cable (14-way orange plug JP2) to the rack assembly, and release the two (reusable) cable ties securing the cable to the main frame. 44 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 61 Take care not to snag the wires under the rear of the deck. Take care when reinserting plug JP2 to seat the plug correctly in the socket. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 45 FT100s/RITS500s SERVICE MANUAL...
Page 62 Remove the four witnessed screws, A, holding the main bearing block at the rear of the Y lead screw. Repeat for the front bearing block. 46 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 63 Y motor and sensor assembly Remove the front bearing block. The motor and screw assembly may now be rotated and removed from the machine. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 47 FT100s/RITS500s SERVICE MANUAL...
Page 64 The pulleys may now be removed as a pair. Use the gear-puller supplied with the service kit to remove the pulleys. If necessary, replace the bearings at this stage. 48 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 65 Rotate the screw shaft with the nut and check that the belt is running true and the pulleys are aligned. Tighten the grub screw in the small pulley. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 49 FT100s/RITS500s SERVICE MANUAL...
Page 66 Apply 1cc of special lead screw lubricant to the lead screw shaft. Move the sub-table back and forth several times to align the front and rear bearing blocks. Move the table to the centre position. 50 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 67 Pull the sub-table to the fully forward position. Replace the main cover, taking care not to snag the ribbon cable assembly on the rear bearing block assembly. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 51 FT100s/RITS500s SERVICE MANUAL...
Page 68 Remove the SAFETY HOOD. Remove the BACK COVER. Note the location of each plug-in card. Each card must be returned to its original slot. 52 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 69 Power Supply & Safety Provides power 2A T Relays distribution and 500mA T contains safety 2A T interlock relays. Remove the plug-in cards. The cable connections are shown overleaf. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 53 FT100s/RITS500s SERVICE MANUAL...
Page 70 Breakout board cable connections 54 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 71 Note: the breakout board assembly must be removed as a unit. Loosen the four nuts securing the assembly to the main chassis. Lift the assembly clear. Re-assembly is the reverse procedure. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 55 FT100s/RITS500s SERVICE MANUAL...
Page 72 Remove the nut and washer and the plastic transformer cover from the transformer. Release the cable ties securing the transformer cables. Remove the power supply and safety card (8). 56 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 73 Unplug the spade terminal connectors from the rear power panel. Remove the transformer through the rear of the machine. Replacement is the reverse procedure. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 57 FT100s/RITS500s SERVICE MANUAL...
Page 74 Y home and limit sensors Remove the MAIN COVER. The Y sensors are located adjacent the left slide rail. Y sensor locations Replace the Y sensor(s) as necessary. 58 • • • • SECTION 3 — REMOVAL AND REPLACEMENT FT100s/RITS500s SERVICE MANUAL...
Page 75 INTERLOCK SAFETY SWITCH Remove the MAIN COVER. Replace the switch as necessary. EMERGENCY STOP BUTTON Remove the MAIN COVER. Replace the emergency stop button as necessary. SECTION 3 — REMOVAL AND REPLACEMENT • • • • 59 FT100s/RITS500s SERVICE MANUAL...
Page 77 The probe head and table can be accessed while in motion. Note: Once the adjustments have been completed it will be necessary to perform the FT100s or RITS500s PERFORMANCE CHECK. DISC ADJUSTMENT...
Page 78 Note the position of the slot in the disc on the rear of the X motor. Turn off the power to the FT100s/RITS500s. Move the X axis until the camera and probe head are clear of the home position to allow access to the X disc.
Page 79 Turn off the power to the FT100s/RITS500s. Loosen the grub screw in the disc collar and rotate the disc until it is in the position shown below.
Page 80 Run the Calibrate Probes command before running any program. HOOD SAFETY INTERLOCK Close the Safety Hood Loosen the two screws securing each Safety Interlock switch. 64 • • • • SECTION 4 – ADJUSTMENT PROCEDURES FT100s/RITS500s SERVICE MANUAL...
Page 81 Calibrate Probe dialog box is displayed. The Calibrate Probe dialog box Centre the camera on the Calibration Block and click the Save button — the FT100s will record the cross-hair SECTION 4 – ADJUSTMENT PROCEDURES • • • • 65 FT100s/RITS500s SERVICE MANUAL...
Page 82 Sensor until the Probe Height Sensor LED just lights. Rotate in the opposite direction so that the LED just extinguishes. This procedure must be carried out when the probe board is replaced. 66 • • • • SECTION 4 – ADJUSTMENT PROCEDURES FT100s/RITS500s SERVICE MANUAL...
Page 83 Adjust the joystick so that the camera cross-hair is precisely positioned on the indentation made by the signal pin of the probe and press Save. Repeat for each signal pin in the Probe Head. SECTION 4 – ADJUSTMENT PROCEDURES • • • • 67 FT100s/RITS500s SERVICE MANUAL...
Page 85 The remaining connections go to the power supply card slot 8. The outer winding connections, TX44 A and B are switched by the safety relays and return as SECTION 5 – CIRCUIT DESCRIPTION • • • • 69 FT100s/RITS500s SERVICE MANUAL...
Page 86 K2 will latch if KEYOP1 is connected to ground through The Emergency stop button contacts and either the RH lid switch or the key switch in the override position. 70 • • • • SECTION 5 – CIRCUIT DESCRIPTION FT100s/RITS500s SERVICE MANUAL...
Page 87 GATETOUCH is high (from J22 p17) This allows the touch sensor to use the instant braking of the limit command if an unexpected object is encountered as the Z axis is lowered. SECTION 5 – CIRCUIT DESCRIPTION • • • • 71 FT100s/RITS500s SERVICE MANUAL...
Page 88 VREF1 and the motor current to its quiescent holding level. The hold period after a pulse is about 0.5S 72 • • • • SECTION 5 – CIRCUIT DESCRIPTION FT100s/RITS500s SERVICE MANUAL...
Page 89 U5C, D and U3B perform no useful function in this application. Q1 keeps F1 low unless 40V is absent or F1 blows. SECTION 5 – CIRCUIT DESCRIPTION • • • • 73 FT100s/RITS500s SERVICE MANUAL...
Page 90 The PC connecting cable may be taken direct to this board. The joystick cable may also go direct to this board. 5V power is supplied direct to this board from J19. 74 • • • • NOTES ON COMPUMOTOR ASSEMBLIES FT100s/RITS500s SERVICE MANUAL...
Page 91 PC Card Bit Switch Settings CARD 6 & 7 SD12 Motor Driver Card Link Settings NOTES ON COMPUMOTOR ASSEMBLIES • • • • 75 FT100s/RITS500s SERVICE MANUAL...
Page 93 When replacing the fuse always use the type and rating stated in SPECIFICATIONS. Reconnect the power cord. CAUTION: Serious damage will result if a 110V instrument is connected to a 240V supply. SECTION 6 – LINE VOLTAGE AND FUSE CHANGING • • • • 77 FT100s/RITS500s SERVICE MANUAL...
Page 95 Click Yes in the next dialog box. The following screen should appear. Which boxes are ticked will depend on the status of the RITS500s as the diagnostics were entered. RITS500s diagnostics screen SECTION 7 – FAULT DIAGNOSIS • • • • 79 FT100s/RITS500s SERVICE MANUAL...
Page 96 FT100s To enter the diagnostic routine, the FT100s must be powered and the application running on the PC. Click on FT100s Diagnostics in the Utilities pull down menu. Click “Yes” in the next dialog box. Enter the password FT100. A screen similar to that shown below should appear.
Page 97 This function raises the Z slide to the Home position. Video On (RITS500s only) Turns on video camera. Camera up (Ft100s only) Switches between Target and View cameras. Touch Z This function lowers the probe into contact with the test PCB.
Page 98 This is not a fault. Status The X, Y, and Z boxes show the distance from Home in steps. 82 • • • • SECTION 7 – FAULT DIAGNOSIS FT100s/RITS500s SERVICE MANUAL...
Page 99 Z touch sensor Ticked if probe tip lifted. Home and limit Show status of the home and limit switches Fine Show the status of the disc sensors SECTION 7 – FAULT DIAGNOSIS • • • • 83 FT100s/RITS500s SERVICE MANUAL...
Page 100 Trouble shooting procedures Accuracy Problem X or Y axis Perform FT100s/RITS500s Accuracy Check (Section 7) Perform Periodic Maintenance (Section 2) Check Probe Head for damage and replace if required (Section 3) Check X or Y Anti-backlash Nut Is securely fitted to Nut...
Page 101 Error messages FT100 Limit Error Z or Touch Probe Sensor Error Enter FT100s/RITS500s Diagnostics and test operation of Probe Head (Section 1 and 7) Replace Probe Head (Section 3) Unable to Cycle Power If J2 14 way orange plug has been removed from the...
Page 102 FT100s and RITS500s Compumotor Board Set Checkout Procedure The Compumotor Board set comprises two boards, the Auxiliary Breakout Board located in the FT100s or RITS500s, and the PC Control Board located in the PC. The following procedure will isolate a fault on either of these boards.
Page 103 This check will help to identify loss of probe accuracy in the X or Y-axis due to mechanical resistance. Enter the FT100s or the RITS500s Diagnostics. Select ‘Home’ from the diagnostic window. When the X and Y-axis have come to a complete stop, check the co-ordinates in the diagnostics window.
Page 104 6800 15600 6400 15200 6000 14800 5600 14400 5200 14000 4800 13600 4400 13200 4000 12800 3600 12400 3200 12000 2800 11600 2400 11200 2000 10800 1600 88 • • • • SECTION 7 – FAULT DIAGNOSIS FT100s/RITS500s SERVICE MANUAL...
Page 105 -400 8400 -800 8000 -1200 7600 -1600 7200 -2000 6800 -2400 6400 -2800 6000 -3200 5600 5200 4800 4400 4000 3600 3200 2800 2400 2000 1600 1200 SECTION 7 – FAULT DIAGNOSIS • • • • 89 FT100s/RITS500s SERVICE MANUAL...
Page 106 This check will help to identify loss of probe accuracy in the X or Y-axis caused by loose or damaged drive components. Enter the FT100s or the RITS500s Diagnostics. Select ‘Joystick Mode’. Select ‘Camera Up’ until the cross-hair is displayed.
Page 107 F3 on the PSU card (8) and ground then remove cards one by one and the D-connectors of the main chain, and also the D-plug of the “white“ harness to the Distribution Board. SECTION 7 – FAULT DIAGNOSIS • • • • 91 FT100s/RITS500s SERVICE MANUAL...
Page 108 Pins Colours Estop out Estop in Operate Override Lid up Lid down Any twin Any twin Blk/Brn 10,11 Yel/Grn 6,13 Blu/Mve Brn/Red 7,10 Or/Yel 92 • • • • SECTION 7 – FAULT DIAGNOSIS FT100s/RITS500s SERVICE MANUAL...
Page 109 X and Y motor drivers The power distribution is outlined in the diagram above. The contacts shown are actually several contacts of the safety relays in series. SECTION 7 – FAULT DIAGNOSIS • • • • 93 FT100s/RITS500s SERVICE MANUAL...
Page 110 Similarly the B socket only goes to the card 1 socket. (On earlier machines probe sockets 2 and 3 link to pins on the card 1 socket.) 94 • • • • SECTION 7 – FAULT DIAGNOSIS FT100s/RITS500s SERVICE MANUAL...
Page 111 J1 of the main chain. The signal passes through another co-axial cable in the chain, but this does not go to the back-plane, going straight to the output BNC on the back panel. SECTION 7 – FAULT DIAGNOSIS • • • • 95 FT100s/RITS500s SERVICE MANUAL...
Page 113 Instruments distributor to ensure continued safe operation. A Basic Service Kit for servicing the instrument may be ordered as part number ACC223. A Full Service Kit may be ordered as ACC228 (FT100s) ACC279 (RITS500s). The contents of these kits are detailed in this section.
Page 114 EXCHANGE SUB-ASSEMBLIES Description Part Number Dual Camera (FT100s) MSA165 Probe Head (FT100s) MSA150 Probe Head (RITS500s) MSA192 Z axis slide, without camera or probe MSA155 X slide with bearings MSA156 Single Camera (RITS500s) MSA164 ELECTRICAL ASSEMBLIES Description Part Number Power supplies and safety relays...
Page 115 Fuse 5A T FCA126 Fuse 3.15A T FCA134 Fuse 2A T FCA127 Fuse 1A F FCA131 Fuse 3.15A F FCA136 Fuse 500mA T FCA113 Fuse 1A T FCA137 SECTION 8 – REPLACEMENT PARTS • • • • 99 FT100s/RITS500s SERVICE MANUAL...
Page 116 M5 x 12 Torx head (Hood and main MNS263 cover) M5 x 25 Torx head (Camera) MNS262 M3 x 6 Csk Torx (Deck plate) MNS267 M4 x 6 Torx (Rear cover) MNS265 100 • • • • SECTION 8 – REPLACEMENT PARTS FT100s/RITS500s SERVICE MANUAL...
Page 117 BASIC FT100s/RITS500s SERVICE KIT (ACC223) Description Part Number 1.5mm Hex key ACC208 Duster ACC215 Safety test plug ACC216 2mm Hex key ACC217 2.5mm Hex key ACC218 3mm Hex key ACC219 4mm Hex key ACC220 5mm Hex key ACC221 Parts box...
Page 118 Fence end stop ACC196 COM clip lead ACC198 Fence thumb screw MNS215 PCB clip thumb screw MNS216 Table thumb screw MNS217 Connector MQX386 Table Dowel QT5-1152 Linear bearing QT7-1199 102 • • • • SECTION 8 – REPLACEMENT PARTS FT100s/RITS500s SERVICE MANUAL...
Page 119 ACC228 FT100s FULL SERVICE KIT (includes ACC223) FT100 SPARES KIT ACC223 CARD EXTENDER ACC262* LEADSCREW LOCK TOOL ACC263 Service Manual MAN173 TOUCH-UP PAINT MPA203* Lock’N’Seal MPA204 POWER SUPPLY CARD MSA133 PROBE HEAD MSA150 X or Y Nut with Nut Plate...
Page 120 PULLEY END BEARING FOR X or Y QT50016 SCREW FAR-END BEARING FOR X SCREW QT50017 FAR END BEARING FOR Y SCREW QT51193 BEARING FOR Z SCREW QT61167 GAS STRUT, SINGLE QT1850 Cables WMA326 104 • • • • SECTION 8 – REPLACEMENT PARTS FT100s/RITS500s SERVICE MANUAL...
Page 121 Photocopy a part of the panel identification drawing or the exploded parts drawing, circle the location of the part and give a description of it, then fax these with order. SECTION 8 – REPLACEMENT PARTS • • • • 105 FT100s/RITS500s SERVICE MANUAL...
Page 123 SECTION 9 – SCHEMATIC DIAGRAMS SECTION 9 – SCHEMATIC DIAGRAMS • • • • 107 FT100s/RITS500s SERVICE MANUAL...
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Page 125 SECTION 10 – EXPLODED MECHANICAL DRAWINGS SECTION 10 – EXPLODED MECHANICAL DRAWINGS • • • • 109 FT100s/RITS500s SERVICE MANUAL...
Page 126 POWER INPUT CIRCUIT WHITE BLACK PINK WHITE LINE POWER SWITCH LINE IEC filter WHITE SELECTOR BROWN GREY LIMIT SWITCH ASSY MSA129 MAUVE BLUE ORANGE 230V GREEN 115V 270R NEUTRAL YELLOW OPTOSWITCH 10uF Z AXIS LIMIT ASSY MSA128 OPTOSWITCH 270R 270R OPTOSWITCH 10uF 10uF...
Page 127 TX30A TX30A PCUT HER602 HER602 VSAFE 4700uF KEYOP1 WORKING TX30B TX30B R3 4K7 KEYOP4 RESET-SAFE HER602 HER602 2N3904 +40V +40V +24V +24V R1 37K4 LM2575-ADJ +24v 680uH TX44A TX44A 100uF CTRL TX44B TX44B MBR760 470uF Lo ESR TX44BSW TX44BSW TX44ASW TX44ASW TX44A TX44B...
Page 128 Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands BIT5 BIT1 Inst. Title MSA136 Relay Matrix BIT6 BIT2 BIT7 BIT3 BIT8 BIT4 +24V +24V BIT2 BIT1 BIT5 BIT6 BIT7 BIT8 TABLE3 TABLE1 BIT3 BIT4 TABLE4 TABLE2 PROBE1 74HC374 PROBE2 ULN2803 ULN2803 ULN2803...
Page 129 These connections are on the backplane schematic Lid Switch RH SW1A e/stop SW3C switch/keyop To J1 a6 "KEYOP1" SW3A To J1 a8 "KEYOP4" switch/keyop To J1 a4 "VSAFE" To J1 c4 "OPLAMP" HEADER 14 SW3B Lid switch LH switch/keyop GREEN SW1B e/stop Polar Intruments Ltd...
Page 130 SWITCHES CONNECT TO D TYPE PLUG "B" PROBE TOUCH RED TO D PLUG PIN 11 OPTOSWITCH PROBE DOWN 270R 270R OPTOSWITCH 10uF 10uF ORANGE TO D PLUG PIN 1 BLACK TO D PLUG PIN 13 OPTOSWITCH BROWN TO D PLUG PIN 15 TOP VIEW RED WIRE TO PIN 10 ORANGE WIRE TO PIN 9...
Page 131 VMOTOR 2K2 2W MOTOR1 B+ 0.1uF 0.1uF 1000uF 0.1uF MOTOR1 B- MOTOR1 A- L297 L298N MOTOR1 A+ 3.3nF DIR1 /STEP1 MOTOR1 A+ OUT1 ENABLE1 /SELECT1 SYNC SYNC MOTOR1 A- OUT2 5VLOGIC 12VLOGIC /CLOCK1 CLOCK MOTOR1 B+ OUT3 VMOTOR VMOTOR DIR1 CW/CCW MOTOR1 B- OUT4...
Page 132 270R R2 270R HEADER 4 10uF 0.1uF 74LS86 74LS86 74LS86 HEADER 4 74LS86 270R 270R Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Drawing No Revision Date 19/10/01 RITS500 HEAD SENSOR PLUG Instrument Title...
Page 133 CEXT 0.1uF LM324 LM324 200K Polarity A REXT/CEXT 0.1uF LM324 0.1uF 74HC123 CEXT 200K REXT/CEXT 0.1uF LM324 LM324 Polarity B 0.1uF 0.1uF 74HC123 LM324 LM324 yellow CEXT green blue black 200K REXT/CEXT Joystick 0.1uF Output 74HC123 save left right fine common LM324 Switches...
Page 134 P1UP PROBE2 P2UP PROBE1 P3UP PROBE3 P1TOUCH S1HOME S1LIM+ PROBE SIGNAL S1LIM- S2HOME S2LIM+ S2LIM- S3HOME S1A- S3LIM+ ZLIM+ S1B- S3LIM- ZLIM- S1A+ S4HOME S1B+ S4LIM+ S2B- S4LIM- Z LIMITS S3B+ P1UP SPARE1 S2B+ P2UP S3B- P3UP SPARE3 S2A+ P1TOUCH S3A- S1HOME S2A-...
Page 135 1,000uF 0.1uF 0.01uF 74HC74 0.1uF 0.1uF VREF1 L297 L298N 3.3nF 1N4148 /STEP1 CLOCK1 MOTOR1 A+ OUT1 SYNC 74HC74 MOTOR1 A- 74HC02 OUT2 /CLOCK1 CLOCK MOTOR1 B+ OUT3 DIR1 CW/CCW MOTOR1 B- OUT4 ENABLE1 ENABLE INH1 ENABLEA /CLOCK1 VREF1 Vref INH2 ENABLEB 74HC02 74HC4060...
Page 136 Y Axis X Axis SD12 SD12 Polar Stepper Stepper Stepper PCUT VSAFE OPLAMP KEYOP1 WORKING ZDIR /ZCLK KEYOP4 RESETSAFE ZENABLE +24V +40V +40V +40V TX18A TX44ASW TX18A TX44ASW +40V +40V Transzorb +24V +24V TX18B TX44BSW TX18B TX44BSW LED1 YFAULT XFAULT CAMMV TX44A TX44A...
Page 137 S1/S2 S3/S4 Solenoid Relay Polar Polar Driver Matrix Stepper Stepper BIT1 SOL2- SOL2- S1B+ S1B+ S3B+ S3B+ BIT5 SOL2+ SOL2+ S1B- S1B- S3B- S3B- BIT6 BIT2 BIT3 SOL1- SOL1- S1A- S1A- S3A- S3A- BIT7 SOL1+ SOL1+ S1A+ S1A+ S3A+ S3A+ BIT8 BIT4 DOWN1...
Page 138 VSOLENOID SOLENOID2- VSOLENOID SOLENOID2+ 74HC74 SOLENOID1- 2K2 2W 2200uF 0.1uF L295 SOLENOID1+ 0.1uF PROBE1 VREF1 +24V PROBE2 PRB1 SOLENOID1+ OUTHI1 1N4148 VREF1 SOLENOID1- VREF1 OUTLO1 PROBE1 PRB2 SOLENOID2+ OUTHI2 74HC04 74HC04 VREF2 SOLENOID2- VREF2 OUTLO2 /ENABLE PROBE3 /ENABLE ENABLE FAULT PROBE4 SOLENOID4- 74HC4060...

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