CTC Documentation

7/26/2019 CTC Documentation

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Conveyor Control

08/22/2002

Machine Vision Products, Inc.Conveyor Control

Table of Contents

I. Auto Inspector 1-Stage

II. Auto Inspector 3-Stage

III. Repair Station Single Lane

IV. Repair Station Dual Lane

V. General Information

Sections I IV will be formatted as follows:

1. Front Panel

2. Registers

3. Modes of Operation

4. Board Loading Description

5. Jam Recovery/Alarm Routines

6. E-Stop Recovery

7. Diagram


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I. Auto Inspector ~ 1-Stage Page 1

I. Auto Inspector ~ 1-StageUL1STDxx

1. Front Panel

RUN BELT- this allows you to manually move all belts in the direction of the arrow

RAIL WIDTH- this allows you to adjust the width of the rails, either narrower or wider.

RESET ENTER

o RESETwill reset the controller.

o ENTERor RESUMEbutton. This will allow for normal functions to begin at the start of day, or resume operation after a boardjam or e-stop si tuat ion.

MAINT/NORMAL/PASS

o MAINT- This is normally used for testing and debugging database programs. This mode is also used for Manual loading ofboards into the AOI. Upstream SMEMA signaling is ignored. This will also keep boards from loading into the AOI

o NORMAL AOI is ready to inspect boards and conveyor will operate using SMEMA signaling.

o PASS AOI is not ready to inspect and conveyor will pass boards through the AOI using SMEMA signaling

INPUTS and OUTPUTS LED descriptions

CTCOUT

AI DIGIN

OUTPUT BITS CTCIN

AI DIGOUT

INPUT BITS

1 ENGAGE INSPECTION STN HARDSTOPS 1 1 INSPECTION COMPLETE

2 0 READY TO INSPECT (LED ONLY) 2 3 REJECT STATUS

3 2 NOT BUSY TO UPSTREAM (SMEMA) 3 RESET SWITCH4 ENGAGE LOAD STN HARDSTOPS 4 LOAD HARDSTOP CLEAR

5 CONVEYOR MOTOR (INSPECTION) 5 BOARD AT INPUT (PS1)

6 CONVEYOR MOTOR SLOW SPEED 6 9 INSPECTION STN PHO-DET (PS2)

7 INSPECTION STN PHO-DET LED OFF 7 2 BAR CODE OK AND PASS THRU SWITCH (IN1A AND IN7A)

8 3 RAILS CLEAR, OK TO ADJUST 8 NOT BUSY FROM DOWNSTREAM (SMEMA)

9 BOARD AVAIL TO DOWNSTREAM (SMEMA) 9 BOARD AVAILABLE FROM UPSTREAM (SMEMA)

10 1 REJECT BOARD RELAY TO DOWNSTREAM (SMEMA) 10 MAINT MODE SWITCH

11 BOARD CROWDERS ON 11 SPARE

12 FRONT LIFTER 12 8 "INSPECTION ACTIVE"

13 SPARE 13 SPARE14 AUDIBLE ALARM 14 INSPECTION HARDSTOP CLEAR

15 REVERSE BELT MOTORS 15 E-STOP DETECTED

16 STATUS LED (FLASH RED TOWER LIGHT) 16 ENTER SWITCH


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2. Registers

Reg#DefaultValues Purpose

501 100 Time to delay (sec/100) before rechecking that the board has unloaded successfully from PS2. (In13 is clear.)

502 0 0 = Unclamp during inspection; 1 = Clamps on during inspection

503 0 0 = Normal L to R conveyor feed; 1 = R to L feed

508 0 Greater than 0 skip Smart Purge and Not Busy from downstream check to unload

509 Time to wait in seconds/100 before turning off BA and REJ to downstream after sending BA.

510 1 0 = Do not beep when barcodes are not received; 1 = Beep when barcodes are not received.

511 0 1 = do not respond to BA from upstream until Barcode OK; IN7 lit.

512 0 When=0, standard MVP "NOT BUSY" response to BA; when 1, always NOT BUSY when belt empty.

516 0> 0 = Unload boards as REJECT if no bar code OK by the time the board reaches the Inspect Station. Extendthe wait time by the value in R516 in increments of 0.01 seconds.

517> 100, stop belt after delay of R517-100 sec or when downstream conveyor goes BUSY (In8B).< 100, unload time extension of belt motor PS2. (sec)

518 IN-OUT MODE 0 = Normal conveyor; 1 = Manual load same side.

519 100 Time (sec/100) to keep running in slow mode after reaching the inspection sensor, IN6.

520 Timeout delay between PS1 and PS2 and when using barcodes time to wait for barcode ok. (sec)

521 Time to wait to turn off NOT BUSY to upstream if board has not reach PS1 (sec/100).

522 0 0=Do not retract stops during inspection; 1=Retract hard stops during inspection.

526 0=use real-time BA signals; 1=OK to use Flags 5 & 9.

527 0 0 = Send the reject signal normally; 1 = Invert reject status being sent downstream.

529 Time to run board when manually unloading after an inspection has completed (sec/100).

530 0 1=Non-SMEMA mode, BA will not be set when unloading board.

531 0 Lifter mode time delay in 1/100 second.

538 >1000; Set REJ by (R538-1000)/100 seconds before setting BA to downstream.

600 0 When > 0, enter exercise mode. SET TO 0 BEFORE SHIPPING!!!

997 Total seconds waiting while DS conveyor BUSY (Average = 997/998)

998 Board counter.

999 131200211 Program version number, MonthDayYearVersion#

*Material handling may not function properly if the timing registers are not set to the proper values. The slow mode speed should be set so that it is greater than 0,depending on the speed that is chosen timing registers may need to be adjusted slightly.


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3. Placing AOI in the different Modes of Operation

o NORMAL Mode

1 On the Board Handler Controlpanel, toggle the MAINT/NORMAL/PASSswitch to theNORMALposition

Ensure there are no boards present in AOI

Move switch to the NORMALposition

The AOI is now in NORMALMode

o PASS Through Mode

1 On the Board Handler Controlpanel, toggle the MAINT/NORMAL/PASSswitch to thePASSposition


Move switch to the PASSposition

The AOI is now in PASS ThroughMode

o MAINT Mode Or Manual Load

1 On the Board Handler Controlpanel, toggle the MAINT/NORMAL/PASSswitch to theMAINTposition

NOTE:SMEMA signaling is ignored, boards must be hand placed over Sensor One


Move switch to the MAINTposition

The AOI is now in MAINTMode

o Manual Loading of Boards using MAINT Mode


NOTE:SMEMA signaling is ignored, boards must be hand placed over PS1

If a board is in the AOI wait for it to be transferred out of the AOI

On the Board Handler Controlpanel, toggle the MAINT/NORMAL/PASSswitch to theMAINTposition

Place board over PS1


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1 Board Jam while loading

Single Beep Register 510=0

Steady Beeps Register 510=1

Place board over PS2 When the board is detected over PS2 it will continue to prepare forinspection by moving slowly to the hard-stop. It will prepare for inspection as normal.

Press ENTER This will cause the loading process to be aborted and the AOI will prepare toaccept a new board.

NOTE:See Conveyor Drawings for approximate placement of Sensors

6. E-Stop Recovery

CAUTION!Pressing the Emergency Stop will disengage the linear motors and conveyors motors. Pressing the E-Stop

button or opening the front hatch panel will activate the Emergency Stop.

E-Stop recovery is not currently supported on this system. Anytime E-Stop is activated the E-Stop is cleared when the E-Stop button isreleased or the front hatch is closed. After the E-Stop is cleared RESET must be pressed and the board should be reloaded.

7. AOI 1 Stage Diagram


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II. Auto Inspector ~ 3-Stage Page 7

II. Auto Inspector ~ 3-StageSoftware Versions 4.5.1 and later

UL3STDxx

1. Front Panel



RESET ENTER button will reset the controller.

o ENTERor RESUMEbutton. This will allow for normal functions to begin at the start of day, or resume operation after a boardjam or e-stop si tuat ion.

MAINT/NORMAL/PASS

o MAINT- This is normally used for testing and debugging database programs. This mode is also used for Manual loading ofboards into the AOI. Upstream SMEMA signaling is ignored. This will also keep boards from loading into the AOI

o NORMAL AOI is ready to inspect boards and conveyor will operate using SMEMA signaling.

o PASS AOI is not ready to inspect and conveyor will pass boards through the AOI using SMEMA signaling


CTCOUT

AI DIGIN

OUTPUT BITS CTCIN

AI DIGOUT

INPUT BITS

1 ENGAGE INSPECTION STN HARDSTOPS 1 1 INSPECTION COMPLETE

2 0 READY TO INSPECT (LED ONLY) 2 3 REJECT STATUS (FROM SMEMA 5-6)

3 2 NOT BUSY TO UPSTREAM (SMEMA) 3 RESET SWITCH

4 CVYR1 MOTOR (INPUT BELT MOTOR) 4 BOARD AT INPUT CVYR1 (PS1)

5 CVYR2 MOTOR (INSPECTION) 5 BOARD AT END OF CVYR1 (PS2)

6 CVYR2 MOTOR SLOW SPEED 6 9 INSPECTION STN (PS5) AND SCAN COMPLETE PULSE

7 INSPECTION STN PHO-DET LED OFF 7 2 BAR CODE OK AND PASS THRU SWITCH (IN1A AND IN7A)

8 3 RAILS CLEAR, OK TO ADJUST 8 NOT BUSY FROM DOWNSTREAM (SMEMA)

9 BOARD AVAIL TO DOWNSTREAM (SMEMA) 9 BOARD AVAILABLE FROM UPSTREAM (SMEMA)

10 1 REJECT BOARD RELAY TO DOWNSTREAM (SMEMA) 10 MAINT MODE SWITCH11 BOARD CROWDERS ON 11 START OF CVYR3 SENSOR (PS4)

12 BAR CODE READER ON 12 8 "INSPECTION ACTIVE"

13 CVYR3 MOTOR (ULOAD BELT MOTOR) 13 BOARD AT END OF CVYR3 (PS5)

14 AUDIBLE ALARM 14 INSPECTION HARDSTOP CLEAR

15 REVERSE BELT MOTORS 15 E-STOP DETECTED

16 STATUS LED (FLASH RED TOWER LIGHT) 16 ENTER SWITCH OR RESUME BUTTON


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2. Registers

Reg#

Default Values

Reg570=0

Default Values

Reg570=1 Purpose

501 20 20 Time to delay (sec/100) before rechecking that the board has unloaded successfully. ( In13 is clear.)

502 0 0 0 = Unclamp during inspection; 1 = Clamps on during inspection

503 0 0 0 = Normal L to R conveyor feed; 1 = R to L feed

506 0 0 1 = Function as a single stage conveyor.

507 0 00 = At RESET any boards that are on the system will not be moved.1= Boards on the belts will be purged at RESET.

508 0 0 0 = Send BA on PURGE; 1 = No BA on PURGE

509 0 0 Lifter Mode when >0. Value determines delay (1/100 sec) between valve actuations.

517 200 200 Unload time extension of BA and/or REJ after unload sensor. (1/100 sec)

519 100 100 Time (sec/100) to keep running cvyr 2 in slow mode after reaching the inspection sensor, IN6.

520 4 4 Timeout delay between In4 and In6. (sec)

522 0 0 0=Do not retract stops during inspection; 1=Retract hard stops during inspection.

530 0 0 1=Non-SMEMA mode, BA will not be set when unloading board.

533 10 10 Time to run cvyr1 after reaching IN4, in order for the board to reach the end of cvyr1. (sec/100)

534 0 0 Time extension (sec/100) to run cvyr3 after reaching unload sensor, In13.

536 3 3 Timeout delay between IN5 and IN4. (sec)

541 50 50 Delay sending BUSY to upstream after board reaches IN5 (sec/100).

551 1 10=Recover from an unload jam by placing board on ILAG.1=Recover from an unload jam by placing board over end sensor(IN13).

570 0 10= will work w/ systems that have 5 sensors(In5,4,6,11,13).1= will work w/ systems that only have 4 sensors(In5,4,6,13).

600 0 0 When > 0, enter exercise mode. SET TO 0 BEFORE SHIPPING!!!

710 0 0 0=No Bar Code Trigger; >0=Trigger then wait for BCOK for seconds in 710.

900 1 1 0= Message panel available; 1= No message panel available.

994 Number of boards that were reviewed when the last E-Stop was activated.

995 Board counter since last E-Stop.

996 E-Stop activated counter.

998 Reviewed board counter.

999 102200253 102200253 Program version number, MonthDayYearVersion#



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3. Placing AOI in the different Modes of Operation

o NORMAL Mode




The AOI is now in NORMALMode

o PASS Through Mode




The AOI is now in PASS ThroughMode






The AOI is now in MAINTMode




Wait for all boards in AOI to complete inspections and are transferred out of the AOI

On the Board Handler Controlpanel, toggle the MAINT/NORMAL/PASSswitch to the

MAINTposition


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the board, OUT-10 will be sent downstream. If the board does not reach sensors IN-11 or IN-13 within 3 seconds the AOI will alarmthat there is a jam on conveyor 3.

Board unloading to downstream equipment

If the downstream equipment is NOT BUSY, IN-8 lit, the AOI will turn on conveyor 3 belts and unload the board downstream. To extendthe time period that the belts run and Board Available remains active after the board leaves IN-13 extend the time stored in register517, sec/100.


o NORMAL and MAINT Mode

1 Audible Alarms for Board Jam conditions

Single Beep Place board over Sensor One and press ENTER/RESUME

Two beeps Place board over Sensor Three and press ENTER/RESUME

Three beeps Place board over Sensor Five and press ENTER/RESUME

Four beeps Place board downstream and press ENTER/RESUME


o PASS through Mode

1 Audible Alarms for Board Jam conditions

Single Beep Place Board over Sensor One then press ENTER/RESUME

Three Beeps Move board to Sensor Five then press ENTER/RESUME



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6. E-Stop Recovery

CAUTION!Pressing the Emergency Stop will disengage the linear motors and conveyors motors. Pressing the E-Stop

button or opening the front hatch panel will activate the Emergency Stop.

In most cases recovery from an E-Stop will only require releasing the E-Stop button or closing the front hatch panel, then pressingENTER/RESUME.

Recovering when a board is being inspected:

If a board is in the inspection bay and a scan is in progress when E-Stop is activated, deactivate E-Stop then press ENTER/RESUME.The board will be repositioned in the inspection bay by reversing conveyor 2 then moving the board forward again and being re-clamped. At this point the board will be scanned again.

If a board is in the inspection bay and the scan complete has been given, pulse IN-6, the software will continue to process the

information and send Inspection Complete. When E-Stop is cleared then ENTER/RESUME is pressed the board should move to the endof conveyor 3 as it normally would.

Recovering after Board Available, OUT-9 and Reject, OUT-10 have been sent downstream. In this case BA, OUT-9 will be deactivatedwhen E-Stop is detected.

If E-Stop is activated after BA and reject status have been sent and a NOT BUSY, IN-8 from downstream is detected while in E-Stop theAOI wi ll have an unloading jam rout ine. Clear the E-Stop and press ENTER/RESUME, the E-Stop wi ll clear but the system wi ll be in thefour beeps jam routine. Place the board downstream and press ENTER/RESUME on the AOI in order to clear this jam.

If the downstream system does not send a NOT BUSY, IN-8 during the E-Stop after clearing the E-Stop and pressing

ENTER/RESUME the BA and Reject Status, OUT-9 and OUT-10 will be reasserted and the system will unload the boardnormally after receiving a NOT BUSY from downstream.


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7. AOI 3 Stage Diagram


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III. Repair Station ~ Single Lane Page 14

III. Repair Station ~ Single LaneSoftware Versions 4.5.1 and later

ILAGAWxx

1. Front Panel



RESET ENTER

o RESET button will reset the controller. If review station is running when RESETis pressed, you must QUIT then RESTARTreview.

o ENTERor RESUMEbutton will resume operation after a board jam or e-stop situation.

MAINT/NORMAL/PASS

o MAINT- This is normally used for testing and debugging database programs. Boards must be manually loaded into theILAGAW when running in this mode. Upstream SMEMA signals will be ignored.

o NORMAL ILAGAW will accept boards and conveyor will operate using SMEMA signaling.

o PASS ILAGAW is not ready to inspect and conveyor will pass boards through using SMEMA signaling


CTC OUT OUTPUT BITS CTC IN INPUT BITS

1 ENGAGE INSPECTION STN HARD STOPS 1 INSPECTION COMPLETE

2 READY TO INSPECT 2 REJECT STATUS FROM UPSTREAM3 NOT BUSY TO UPSTREAM (SMEMA) 3 RESET SWITCH

4 NOT USED 4 NOT USED

5 CONVEYOR MOTOR ON 5 INPUT SENSOR (PS1)

6 CONVEYOR MOTOR ~ SLOW SPEED 6 INSPECTION SENSOR (PS2)

7 INSPECT SENSOR LED OFF 7 OPTIONAL BOARD REMOVED BUTTON

8 DEFEAT HARD LIMIT (STEPPER) 8 NOT BUSY FROM DOWNSTREAM

9 BOARD AVAILABLE TO DOWNSTREAM (SMEMA) 9 BOARD AVAILABLE FROM UPSTREAM

10 REJECT BOARD RELAY TO DOWNSTREAM (SMEMA) 10 MAINT SWITCH

11 BOARD CROWDERS ON 11 E-STOP DETECTED

12 STEPPER 1 FULL CURRENT 12 NOT USED13 STARVED (FLASHING GREEN TOWER LIGHT) 13 UNLOAD SENSOR (PS3)

14 AUDIBLE ALARM 14 INSPECTION HARD STOP CLEAR

15 REVERSE BELT MOTOR 15 WIDTH CLOSE-TO-HOME

16 STATUS LED 16 ENTER SWITCH OR RESUME BUTTON


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3. Placing the ILAGAW in different Modes of Operation

o NORMAL Mode


Ensure there are no boards present in ILAGAW


The ILAGAW is now in NORMALMode

o PASS Through Mode




The ILAGAW is now in PASS ThroughMode

o

MAINT Mode Or Manual Load


NOTE:SMEMA signaling is ignored, boards must be hand placed over PS1 if Reg570=0 orPS2 if Reg570=1.



The ILAGAW is now in MAINTMode



NOTE:SMEMA signaling is ignored when loading boards, boards must be hand placed overPS1 if Reg570=0 or PS2 if Reg570=1.

Before changing modes, wait for all boards in ILAGAW to complete inspections and be


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transferred downstream.

On the Board Handler Controlpanel, toggle the MAINT/NORMAL/PASSswitch to theMAINTposition

Place board over Sensor (PD1 or PD2). Press the ENTER/RESUMEbutton; board will load to review bay. After completion of

review, board will transfer to downstream conveyor.

4. Board Handling Description

Reg 570 = 0; the system has 3 sensors and a BOARD REMOVED button.

o Loading

The following conditions must be met before a board will load onto the ILAGAW:

No jam, error, or e-stop condition can exist.

Repair should be started and a database selected, th is will set Flag 23 .

Cyc le Stop must not be selected, which will clear Flag 29.

The repair station should be clear of any boards, Flag 2 clear.

In-9 lit board available from upstream.

If all of the previous conditions are met the ILAGAW will start moving its belts, OUT-5, then send a not busy signal to upstream,

OUT-3. If a board is not detected at either PS1 or PS2 within 7 seconds the ILAGAW will alarm for a board jam while loading.Once PS1 detects the board the belt will continue to move at normal speed for the time stored in register 524 sec/100, at whichtime the belts will begin to move in slow mode, OUT-6.

When the board reaches PS2 all boards will be stopped if the value stored in register 522 is equal to 2. Only reject boards will stopif the value stored in register 522 is 1. If the board does not reach PS2 after being detected by PD1 within 4 seconds the ILAGAWwill alarm for a board jam while loading.

Boards that are stopped will remain clamped during review if the value stored in register 502 is equal to 1.

If the board is not stopped for review it will continue to be transferred to PS3. Once reaching PD3 a Board Available signal, OUT-9

will be sent downstream. PS3 must detect the board within 5 seconds after passing PD2 or a board jam alarm state will beactivated.

o Reviewing boards

The board will remain in place to be reviewed and the red tower light will flash until reviewing is completed.

Once review is completed, Flag 32 will be set. The user will be able to select Board Pass or Board Fail.

If the board Passed, Flag 4 will be set and the board will be transferred to PS3. Once reaching PD3 a Board Availablesignal, OUT-9 will be sent downstream. If the board does not reach PS3 within 5 seconds the ILAGAW will go into an alarmstate for a board jam.


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If the board Failed, Flag 4 will be cleared and the board should be manually removed. Once the board has been removedthe Board Removed button must be pressed in order to load another board.

o Unloading

The following conditions must be met for a board to unload:

OUT-9 lit, indicating Board Available to downstream.

IN-8 lit, indicating Not Busy from downstream.

Once the previous conditions have been satisfied OUT-5 will be lit moving the belts once again. The belts will continue to run andBoard Available OUT-9 will remain on for the time stored in register 535 in seconds/100 after passing PS3.

Reg 570 = 0; the system has 1 sensor and noBOARD REMOVED button.

o Loading

The following conditions must be met before a board will load onto the ILAGAW:

No jam, error, or e-stop condition can exist.

Repair should be started and a database selected, th is will set Flag 23 .

Cyc le Stop must not be selected, which will clear Flag 29.

The repair station should be clear of any boards, Flag 2 clear.

In-9 lit board available from upstream.

If all of the previous conditions are met the ILAGAW will start moving its belts, OUT-5, then send a not busy signal to upstream,OUT-3. When the board reaches PS2 all boards will be stopped if the value stored in register 522 is equal to 2. Only reject boardswill stop if the value stored in register 522 is 1. If a board is not detected at PS2 within 7 seconds the ILAGAW will alarmindicating a board jam while loading.

Boards that are stopped will remain clamped during review if the value stored in register 502 is equal to 1.

If the board is not stopped for review it will continue to be transferred towards the end of the belt for the time duration stored inregister 535 seconds/100. After this time period has elapsed the belts will stop and a Board Available signal, OUT-9 will be sentdownstream.

o Reviewing boards

The board will remain in place to be reviewed until reviewing is completed.

Once review is completed, Flag 32 will be set. The user will be able to select Board Pass or Board Fail, in either case a BoardAvai lable signal , OUT-9 will be sent downstream.

o Unloading

The following conditions must be met before a board will unload:

OUT-9 lit, indicating Board Available to downstream.


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IN-8 lit, indicating Not Busy from downstream.

Once the previous conditions have been satisfied OUT-5 will be lit moving the belts once again. The belts will continue running andBoard Available OUT-9 will remain on for the time stored in register 535 in seconds/100.


o NORMAL or MAINT Mode ~ Reg 570 = 0

NORMAL Operational mode

1 If a board jams before PS1; (Single Beeps)

NOTE:The AOI might also be in an alarm state (Four Beeps)

Remove board from AOI conveyor


Press the ENTER/RESUMEbutton

If the AOI is alarming with four beeps, press ENTER/RESUMEon the AOI to clear thejam there.

2 If a board jams betweenPS1 and PS2; (Single Beeps)



3 If a board jams between PS2and PS3; (Rapid Beeps)



4 If a board jams over PD3while unloading; (Rapid Beeps)

Place board over PD3


o PASS Through Mode ~ R570 = 0

PASS Through mode1 If a board jams before PS1; (Single Beeps)


Clear board jam

Place board over PS2 on the ILAGAW

Press ENTER/RESUME



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2 If a board jams betweenPS1 and PS2;



3 If a board jams between PS2and PS3;



4 If a board jams over PS3while unloading;



o NORMAL or MAINT Mode ~ Reg 570 = 1

1 If a board jams before PS2; (Single Beeps)


Remove board from AOI conveyor



If the AOI is alarming with four beeps, press ENTER/RESUMEon the AOI to clear the

jam there.

2 If a board jams after PS2; (Rapid Beeps)

The ILAGAW has no way of knowing that the board did not make it to the downstreamconveyor, therefore no alarm state will be activated. The board should still be moveddownstream.

o PASS Through Mode ~ R570 = 1

1 If a board jams before PS2; (Single Beeps)NOTE:The AOI might also be in an alarm state (Four Beeps)

Place board over PS2 on the ILAGAW

Press ENTER/RESUME



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2 If a board jams afterPS2;

The ILAGAW has no way of knowing that the board did not make it to the downstreamconveyor, therefore no alarm state will be activated. The board should still be moved

downstream.

6. E-Stop Recovery

CAUTION!Pressing the Emergency Stop button will remove power to the Laser motors, Indexers and conveyor motors. It

will NOT remove power from the Material handling controls. The Review Station will loose communication

with the motors.

In order to recover after E-Stop has been activated, the E-Stop button will need to be released then ENTER/RESUME mustbe pressed. If the board was not in the review bay or waiting to unload the ILAGAW will probably be in a jam state, the

jam should be cleared us ing the methods described in Jam Recovery/Alarm Routines.

7. ILAGAW Diagram


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IV. Repair Station ~ Dual Lane Page 22

IV. Repair Station ~ Dual LaneSoftware Versions 4.5.1 and later

DLAGAWxx

1. Front Panel

RUN BELT- This allows you to manually move all belts in the direction of the arrow. There are two RUN BELT buttons one willoperate the Bypass conveyor, the back conveyor, and the other will run the Review conveyors, the front conveyors.

RAIL WIDTH- This allows you to adjust the width of the rails, either narrower or wider. Both conveyors will be adjusted at the sametime so that they are both the same width.

RESET ENTER

o RESET button will reset the controller. If review station is running when RESETis pressed, you must QUIT then RESTARTreview.

o ENTERor RESUMEbutton will resume operation after a board jam or e-stop situation.

MAINT/NORMAL/PASS

o MAINT- This is normally used for testing and debugging database programs. Boards must be manually loaded into the DLAGwhen running in this mode. Upstream SMEMA signals will be ignored.

o NORMAL DLAG will accept boards and will operate using SMEMA signaling.

o PASS DLAG is not ready to inspect and conveyor will pass boards through using SMEMA signaling


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2. Registers

Reg# Typical Value Purpose

5010=Always unload reviewed boards to DS.1=Manually remove FAILED boards with the BOARD REMOVED button.

502 1 0=Unclamps during inspection; 1=Clamps on during inspection

503 0 0=Normal L to R conveyor feed; 1=R to L conveyor feed

504 220 Rail width (in. x 100) at home switch. Manually set at factory or by field maintenance.

505 0 New width (in. x 100) set by software when adjusting. 0=home only function.

506 0 Last width set. Used to compare to new width to avoid changing rails if new is the same as old.

511 0 0=No Stepper Motor; 1=Stepper Motor Installed

512 800 Stepper base speed (steps per second) (Used by stepper motor PROFILE command)

513 1580 Stepper max speed (steps per second) (Used by stepper motor PROFILE command)

514 10 Stepper acceleration (Used by stepper motor PROFILE command)

515 5 Stepper deceleration. (Used by stepper motor PROFILE command)

517

0 = Inspection did not complete before reset.

1 = Inspection completed before reset.

524Time in seconds/100 to run cvyr4 after the board reaches PS5, In6 before stopping cvyr4 to stop and clamp.This value should be less than or equal to 100, if not within this range the default value is 100.

525 15000 Set the time (ms) to wait before sending starved warning. Must be >=5000

527 00=Allow LCD messages to be sent during REVIEW.1=Do NOT allow LCD messages to be sent during REVIEW.

528 0 1=Only allow 1 board on review conveyor at a time.

560 0 0=Wait for BA before sending Not Busy; 1=Send Not Busy unless Busy

995 Board counter since last E-Stop.

996 E-Stop activated counter.

997 Varies Counts the number of GOOD boards that have gone through the bypass lane.

998 Varies Counts the number of boards that have been reviewed.

999 422200220 Version of CTC: MonthDayYearVersion#



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3. Placing the DLAG in different Modes of Operation

o NORMAL Mode


Ensure there are no boards in DLAG

Move the switch to the NORMALposition

The DLAG is now in NORMALMode

Load boards using SMEMA signals.

o PASS Through Mode


Ensure there are no boards present in DLAG

Move the switch to the PASSposition

The DLAG is now in PASS ThroughMode

Load boards using SMEMA signals.



NOTE:SMEMA signaling is ignored, boards must be hand placed over PS1 or PS7 .

Ensure there are no boards present in DLAG


The DLAG is now in MAINTMode

To load boards place a board over PS1 or PS7

Press the ENTER/RESUMEbutton. If the board was place on PS1 it will load to thereview bay. After completion of review, board will transfer to downstream conveyor. Ifthe board was on the PS7 the board will move down the bypass conveyor and unload whendownstream is not busy.


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IV Repair Station Dual Lane Page 28


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PASSED boards going to the bypass lane.

o Loading to the bypass lane.

In order to load a board onto the bypass lane the following conditions must be met:

No jam, error, or e-stop conditions can exist.

Cyc le Stop must be inactive, which will clear Flag 29.

IN21 and IN29 must be off indicating that no board is on PS7 or PS8.

IN25 should be lit signaling Board Available to bypass conveyor from upstream.

When these conditions are met the bypass conveyor will begin to run, OUT29, then Bypass Lane Not, OUT19 lit, will be sentupstream. When the board is detected at PS7 OUT19 will be turned off, indicating that the Bypass Lane is busy to upstream.Board Available to downstream from the bypass lane, OUT25 is sent when the board is detected at PS8. The board will

continue to unload is downstream is not busy to bypass lane is set, IN24 lit. Otherwise the board will stop and wait for notbusy from downstream. If the board does not arrive at PS7 within 6 seconds or PS8 within 12 seconds after reaching PS7 analarm state will be activated with 5 beeps.

o Unloading from the bypass conveyor

The bypass conveyors will unload the board from PS8 as soon as downstream not busy to bypass lane is received, IN24 lit. Thebelts will continue to run for 1 second after the board has left PS8. If the board is stuck over PS8 for 3 seconds the board willgo into an alarm routine with five beeps.


Instructions for all jam situations will be given on the LCD panel when register 527 is equal to 0.

o NORMAL or MAINT Mode

1 If a board jams before PS1, loading to conveyor 1; (Single Beeps)

Remove board from upstream conveyor

Place board over PS2.

Press the ENTER/RESUMEbutton.

2 If a board jams betweenPS1 and PS2, while on conveyor 1; (Single Beeps)



3 If a board jams between PS2and PS3, transferring from conveyor1 to conveyor 2; (TwoBeeps)



IV Repair Station ~ Dual Lane Page 29


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IV. Repair Station Dual Lane Page 29

4 If a board jams between PS3and PS4, transferring from conveyor2 to conveyor 3; (ThreeBeeps)



5 If a board jams between PS4and PS5, transferring from conveyor3 to conveyor 4; (FourBeeps)



6 If a board jams between PS5and PS6, transferring from review bay to the end conveyor 4;(Four Beeps)



7 If a board jams over PD6while unloading; (Four Beeps)

Place board downstream.


8 If a board jams before PS7, loading to bypass conveyor; (Five Beeps)




9 If a board jams between PS7and PS8, transferring on the bypass lane; (Five Beeps)



10 If a board jams over PD8while unloading; (Five Beeps)



o PASS Through Mode

PASS Through mode

1 If a board jams before PS1, loading to conveyor 1; (Single Beeps)






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IV. Repair Station Dual Lane Page 30

2 If a board jams betweenPS1 and PS2, while on conveyor 1; (Single Beeps)



3 If a board jams between PS2and PS3, transferring from conveyor1 to conveyor 2; (TwoBeeps)



4 If a board jams between PS3and PS4, transferring from conveyor2 to conveyor 3; (ThreeBeeps)



5 If a board jams between PS4and PS5, transferring from conveyor3 to conveyor 4; (FourBeeps)



6 If a board jams between PS5and PS6, transferring from review bay to the end conveyor 4;(Four Beeps)



7 If a board jams over PD6while unloading; (Four Beeps)



8 If a board jams before PS7, loading to bypass conveyor; (Five Beeps)




9 If a board jams between PS7and PS8, transferring on the bypass lane; (Five Beeps)



10 If a board jams over PD8while unloading; (Five Beeps)





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p g

6. E-Stop Recovery

CAUTION!Pressing the Emergency Stop button will remove power to the Laser motors, Indexers and conveyor motors. It

will NOT remove power from the Material handling controls. The Review Station will loose communicationwith the motors.

In order to recover after E-Stop has been activated, the E-Stop button will need to be released then ENTER/RESUME must be pressed.If all moving boards had not successfully arrived at the intended location DLAG will probably be in a jam state, the jam should becleared using the methods described in Jam Recovery/Alarm Routines. The LCD panel will instruct the user where each jam hasoccurred.



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7. DLAG Diagram

V. General Information Page 33


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V. General Information

PC to CTC cable construction

V. General Information Page 34


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Cable SMEMA External

Links

http://ctc-control.com/

http://www.ipc.org/html/smemastandards.htm
http://ctc-control.com/http://ctc-control.com/http://www.ipc.org/html/smemastandards.htmhttp://www.ipc.org/html/smemastandards.htmhttp://www.ipc.org/html/smemastandards.htmhttp://ctc-control.com/

CTC Documentation

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Transcript of CTC Documentation