CyberOptics SE500ULTRA User manual

SE500ULTRA
Hardware Manual

Notice
The SE500ULTRA is a measuring device intended for use in SMT production environment. Use of this
equipment in a manner not specified in the operating instructions may impair safe operation.
Information in this document subject to change without notice. CyberOptics Corporation may make
improvements or changes in the products described in this publication at any time.
Trademarks
The following are trademarks or registered trademarks in the United States and other countries:
CyberOptics and SE500ULTRA are (owned by CyberOptics Corporation); Windows (owned by Microsoft
Corporation).
Warranty, License, and Terms of Sale
The warranty, software license and other terms and conditions of sale covering CyberOptics products are
set forth in CyberOptics Standard Terms and Conditions of Sale and License avai lable at
www.cyberoptics.com or by calling CyberOptics at 1-800-526-2540 and requesting a copy.
Disclaimer
The system drawings contained in this manual are current at the time of release. The system drawings
subject to change without notice and may not identically represent your system.
SE500ULTRA Hardware Manual
Part Number 8020206, Revision C
November 2013
©2013 CyberOptics Corporation. All Rights Reserved.

CyberOptics Corporation
Table of Contents
Preface vii
Prerequisite Knowledge vii
Documentation vii
Manual Change Request vii
Technical Support ix
1System Overview 1
SE500ULTRA 2
SE500ULTRA Unit 2
SE500ULTRA Rear View 4
SE500ULTRA Internal Parts 6
Main Electrical Panel 8
Conveyor 10
System Specifications 15
System Requirements 16
Performance Specifications 17
Computer Requirements 17
Dimensions 18
2Installation 21
Packing the SE500ULTRA 22
Unpacking the SE500ULTRA 25
Choosing a Location 26
Installing the System 27
Installing the Light Pole 27
Positioning / Leveling the SE500ULTRA 28
Installing the Sensor 32
Wiring SE500ULTRA for Power 34
Turning on System Power 36
Connecting the Air Supply 37
Connecting SMEMA Cables 38
Connecting to a Network 39
Connecting to an External Device 40
Wago PLC Assembly 41
Manually Adjusting the Conveyor Width 42
Configuring the Pressure Gauge Display 43
Setting Up System Security 45
Adding Users to the System 46
Assigning Secure Areas 48
Verifying System Accuracy 50

Contents
iv SE500ULTRA Hardware Manual
Shutting Down the System 52
Moving the SE500ULTRA System 53
Disconnecting Utilities from the System 53
Bypassing the SE500ULTRA System 53
3Replacing Components and Preventive Maintenance 55
Maintenance Schedule 56
Main Electrical Panel 57
Replacing Electrical Cables 60
Replacing the AC Main Circuit Breaker 61
Replacing the Fuses 63
Replacing the Air Regulator 65
Replacing Fans 66
Preventive Maintenance 67
Processor Components 71
Replacing Cards 71
Software Upgrades 72
Restoring system disk using Acronis 73
Preventive Maintenance 90
Conveyor Components 93
Replacing the Conveyor Edge Strip Guides 93
Replacing the Conveyor Clamp Blade 96
Replacing the Conveyor Clamp Air Fittings 98
Replacing the Conveyor Clamp Hall Effect Switch 99
Replacing the Conveyor Clamp Cylinder 100
Replacing the Conveyor Motors 102
Replacing the Conveyor Belts 104
Replacing the Drive Belts 105
Replacing the Idler Pulleys 107
Replacing the Pulley Drive 109
Replacing the Board Sensors 110
Replacing the Panel Lifter Cylinder and Inductive Sensor 112
Preventive Maintenance 114
Gantry Components 124
Replacing the Gantry Forcer 124
Replacing the Gantry Stator 127
Replacing the X-Axis 130
Replacing the Encoder 133
Preventive Maintenance 134
Adjusting X-Axis Parallelism 141
Adjusting Y-Axis Parallelism 142
Adjusting X-axis and Y-axis Orthogonality 143
Sensor 145
Sensor Replacement 145
Other Components 148
Replacing the Safety Interlock Switch 148
Replacing Leveling Feet 150

CyberOptics Corporation v
Contents
4Troubleshooting 151
Safety Circuit Block Diagram 152
AC and DC Distribution Block Diagram 153
SMEMA Connector Pinout 154
System Error Messages 155
Solder Paste Failure Causes 156
SOS 158
5System Drawings 159
8015066 ASSY, MAIN ELECTRICAL PANEL, SE500ULTRA 160
Drawing 160
8016704 Conveyor SE500ULTRA 166
Drawing 166
Index 175

Contents
vi SE500ULTRA Hardware Manual

CyberOptics Corporation vii
Preface
Preface
This SE500ULTRA Hardware Manual is intended to provide comprehensive information about the
SE500ULTRA.
If you have any questions that are not answered by this guide, contact CyberOptics Customer
Service and Support. Refer to “Technical Support” o n p a g e i x .
Prerequisite Knowledge
●Moderate computer experience
●Moderate Windows®experience
Documentation
Documentation for the SE500ULTRA Solder Paste Inspection system consists of the following
information:
● SE500ULTRA Hardware Manual
Provides an overview of SE500ULTRA components, instructions for how to install and
maintain the SE500ULTRA system, parts replacement information, system specifications, and
system drawings.
● SE Series Solder Paste Inspection Software User Guide and Online Help
Provides task-based, step-by-step procedures and descriptions of the software controls for the
Solder Paste Inspection Applications—Engineering Interface.
● SE Series Inspection User Guide and Online Help
Provides task-based, step-by-step procedures and descriptions of the software controls for the
Solder Paste Inspection Applications—Operator Interface.
● SE Series Solder Paste Inspection Safety User Guide
Provides safety guidelines, safety symbols and their meanings to help prevent personal
injury and equipment damage when operating SE500ULTRA system. Read, understand and
follow safety messages and instructions in this user guide.
Manual Change Request
Every effort has been made to provide complete and accurate information for operating and
maintaining the SE500ULTRA system. If you have suggestions for improvements or find an
inaccuracy, please complete the manual change request form on page viii and forward your
suggestions to CyberOptics.
i
Note: Include a copy of the change request form on the following page and, if applicable, a copy
of the page with the error marked.

viii SE500ULTRA Hardware Manual
Manual Change Request
Date:
Zip/Postal Code:
City/State/
Province:
Address:
Company Name:
Originator:
Machine Serial Number Software Version
Manual Revision/Date Page No. or Figure No.
Suggestion:
Fax: [phone]
CyberOptics Corp.
[email protected]
Attn: Service
Fax or e-mail to:
Check if page is attached
Country:

CyberOptics Corporation ix
Technical Support
Technical Support
If you have problems operating the SE500ULTRA, first check the product documentation for more
information.
If you still need assistance, or you discover problems with the documentation, please telephone,
send e-mail, or fax CyberOptics Service and Support.
●Include your serial numbers in all e-mail messages and faxes.
●Have the product serial numbers ready when you telephone CyberOptics.
CyberOptics guarantees a response to all messages during the next CyberOptics business day.
International Technical Support Center
[phone]
Fax: [phone]
Email: [e-mail]
Website:www.cyberoptics.com/support
If available in your area, the toll-free number above (+1-800) is answered 24 hours a day, every
day of the week. Where toll-free access is not available, please contact the regional office closest to
you:
North America
CyberOptics Corporation
Minneapolis, Minnesota USA
[phone]
Asia-Pacific
CyberOptics Singapore, Ltd.
Singapore
[phone]
Europe
CyberOptics Ltd.
United Kingdom
[phone]
China
CyberOptics China Company Ltd.
Shanghai
[phone]
Corporate Headquarters
CyberOptics Corporation
Minneapolis, Minnesota USA
[phone]
Website: www.cyberoptics.com

xSE500ULTRA Hardware Manual
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CyberOptics Corporation
1System Overview
SE500ULTRA 2
System Specifications 15
Performance Specifications 17
Computer Requirements 17
System Requirements 16
Dimensions 18

Chapter 1:System Overview
2SE500ULTRA Hardware Manual
SE500ULTRA
The SE500ULTRA is an inline Solder Paste Inspection system that inspects solder deposits.
The SE500ULTRA helps to prevent production problems by notifying operators when the print
process moves outside the control tolerances. The SE500ULTRA is intended to help Process
Engineers to establish process tolerances.
The following pages describe the main components of the SE500ULTRA and show their location.
SE500ULTRA Unit
The SE500ULTRA system controls and indicators are located on the outside of the unit as shown in
Figure 1 and described below.
Tab le 1 . SE500ULTRA System Components
Component Description
Air Pressure Gauge The LED gauge, located near the control button panel on the outer
frame of the system, displays the air pressure.
Control Buttons The buttons on the front panel control system operation as follows:
●E-Stop: Stops all of the system’s moving parts.
●Green Start: Starts the inspection. This button is an alternative
to using the button in the software.
●Red Stop: Stops the inspection. This button is an alternative to
using the button in the software.
●Yellow E-Stop Reset: Initializes the system after re-engaging
the E-Stop.
●Yellow Alarm Cancel: Clears system alarms. This button is an
alternative to using the button in the software.
Emergency Stop (E-Stop) Stops all of the system’s moving parts.
ESD Grounding Plug For connecting ESD wrist strap to prevent damage from
electrostatic discharge.
Keyboard and Trackball Placed on a tray that is mounted on a pivoting arm attached to the
machine frame which can be folded.
Leveling Feet Adjustable to level the unit.
Monitor 17-inch flat-panel display mounted on a pivoting arm attached to the
machine frame.
Power Switch The power switch removes all power from the system with the
exception of the processor power. The switch can be locked in the
off position to ensure safety from moving parts while servicing the
machine.
Signal-Light Pole Indicates the SE500ULTRA system status based on user
configuration.

CyberOptics Corporation 3
SE500ULTRA
Figure 1. Front View
Signal-light pole
Keyboard and
trackball tray
Flat-panel
display
Safety
enclosure
hood
Leveling feet
Air pressure gauge
Power Switch
ESD wrist strap connection
Control panel
(see below)
E-Stop E-Stop
Reset
Stop
Start
Control Panel
Alarm
Cancel

Chapter 1:System Overview
4SE500ULTRA Hardware Manual
SE500ULTRA Rear View
System connections such as power, air, and I/O are accessed at the rear of the machine as shown
in Figure 2 and shown below.
Tab le 2. SE500ULTRA System Components
Component Description
AC Circuit Breaker
(Circuit Breaker 1)
The main circuit breaker is located on the rear electrical panel; AC
power is connected to the circuit breaker through the rear electrical
panel and turns off all system power when activated.
Note: Do not obstruct the rear circuit breaker
Air Regulator Regulates compressed air for pneumatic control of the conveyor lift
and clamp.
Cooling Fans Draw air out of the system to cool internal electronics
Digital Input/Output
Connector
Connection for an external device such as a separate conveyor.
Ethernet Port Connection to local area network (10/100 Mb Fast ethernet network
configurations).
SMEMA Connectors Connection for upstream and downstream equipment for conveyor
control.
USB Port Connection for USB devices such as a barcode reader.

CyberOptics Corporation 5
SE500ULTRA
Figure 2. Rear View
Back access cover
Air regulator
Power access
cover
COM1 port
Ethernet port
SMEMA
Upstream
SMEMA
Downstream
Digital I/O
AC circuit breaker
(Circuit Breaker 1)
Power cord strain relief
COM2 port
Cooling fans

Chapter 1:System Overview
6SE500ULTRA Hardware Manual
SE500ULTRA Internal Parts
Opening the hood, which stops all machine motion, gives you access to the sensor, gantry and
conveyor. The lower panel can be removed (by service personnel only) to gain access to internal
electrical components. These parts are described below and shown in Figure 3.
Tab le 3. SE500ULTRA System Internal Components
Component Description
Processor The processor contains two IntelXeonProcessor E5-2620 GHz
CPU, one 500GB + one 1 TB hard drives and one DVD +/- R/W drive.
It provides serial, USB, Ethernet, CANOpen, and CameraLink
Framegrabber connections.
Software configuration is Windows XPProfessional, 64-bit platform.
Conveyor The conveyor brings the panel into the machine, clamps it, and
positions it for inspection. During inspection, the gantry moves as
needed in the X and Y directions, and the Z stage adjusts for height
while the panel remains stationary. The conveyor automatically
adjusts to the width of the panel as specified in the SRFF.
Digital I/O Controller The Digital I/O controller uses programmable logic to control
conveyor motion.
Gantry Moves the sensor along the X and Y axes during inspection.
Main Electrical Panel Contains the electronic components needed to power the system
and control motion.
Sensor Measures the height, volume, and area registration, bridging of the
solder pads defined for a given location. The gantry moves along
both the X and Y axes and the Z stage moves the sensor vertically to
keep it in focus.

CyberOptics Corporation 7
SE500ULTRA
Figure 3. Internal Components
Processor PLC Controller Main Electrical panel
Gantry
Sensor
Conveyor

Chapter 1:System Overview
8SE500ULTRA Hardware Manual
Main Electrical Panel
The Main Electrical Panel in the SE500ULTRA contains the electronic components described in
the following table and shown in Figure 4.
Table 4 . Main Electrical Panel Components
Component Description
Middleman PCB Assembly Collects encoder and sensor information and transfers it
to the processor for analysis.
Servo Amps for X, Y, and Z stages Provide feedback and fine tuning for stage movement.
Motor Controllers for Conveyor
Autowidth and Conveyor Belts (2)
Controls belt and autowidth motors for conveyor motion.
Power Supply, 24Vdc 5 Amp, 3.5
Amp
Provide power and auxiliary power to the sensor and
electronics in the system.
Circuit Breakers:
CB2
CB3
CB4
CB5
CB6
CB7
CB8
Processor Outlet (6 Amp)
PS 1 (6 Amp)
PS 2 (6 Amp)
PS 3 (6 Amp)
X-Axis Servo (10 Amp)
Y-Axis Servo (10 Amp)
Monitor Outlet (6 Amp)
Safety Contactor and Safety Relay Allow power to the system only when interlocks are
closed and E-Stop and/or Power Switch are not pressed.

CyberOptics Corporation 9
SE500ULTRA
Figure 4. Main Electrical Panel
6.0A 6.0A 6.0A 6.0A 10.0A 10.0A 10.0A
MM
PS1 PS2 PS3
K2 K1
TOWER SYSTEM
SMEMA
Z
X
Y
B
Middleman
PCB
Assembly
X-Stage Servo Amp
Y-Stage Servo Amp
Z-Stage Servo Amp
Fixed Rail Motor Belt Motor Controller
PS1–3.5 A
PS2–5 A
PS3–5 A CB2–CB8 Contactor, 18 A
24 VDC, Coil Safety Relay

Chapter 1:System Overview
10 SE500ULTRA Hardware Manual
Conveyor
The SE500ULTRA receives panels from the upstream conveyor using SMEMA signals to control
the timing, it clamps the panel into position and also supports the panels with the lift to hold it
in place during inspection.
When the inspection is complete, the machine releases the panel to the downstream conveyor
utilising SMEMA signals for timing. The conveyor contains the major components described in
the following table and shown in Figure 5 on page 11.
Tab le 5. Conveyor Components
Component Description
Conveyor Belts The conveyor has belts on both the front and the rear rail to
move panels in and out of the system.
Drive Belts & Motors Provide electro-mechanical drive for the conveyor.
Panel Sensors Entry/Exit Sensors: located on each end of the conveyor
these sensor detect panels entering and exiting the
conveyor. Sensors work in conjunction with SMEMA to bring
boards in.
Slow Speed Sensor: A third sensor detects the panel
nearing the inspection position, causing the conveyor to
slow down for final positioning.
Board Stop Sensor: A fourth sensor detects when the panel
is in position to activate the mechanical board stop.
Adjustment Wheel Can be used to manually adjust the conveyor width.
Mechanical Board Stop Provides a physical barrier to stop the panel when it is in
position for inspection.
Board Clamps Hold the panel in position during inspection.
Panel Lifter Rubber magnetic support pins are moved around on the
panel lifter plate. When the panels come in contact with the
support pins, inspection will begin.