View Benchmark 450 User manual

VIEW Engineering, Inc.
Benchmark™450
Service Manual

VIEW Engineering, Inc.
Benchmark™ 450
Service Manual
Copyright © 2009 View Engineering, Inc., a Quality Vision International
Company.
All rights reserved. Printed in the U.S.A.

Part No. 799014, Revision B, 09/09
Information in this document is subject to change without notice and
does not represent a commitment on the part of VIEW Engineering, Inc.
Benchmark, VIEW, and the Benchmark and VIEW logos, are trademarks
of VIEW Engineering, Inc. All other trademarks mentioned in this
manual are property of their respective owners.
Benchmark equipment is made in the U.S.A.

Service Manual 799014, Revision B, 09/09 Pagei
Table of Contents
Important System Labels vii
1 About This Manual 1
1.1 What This Chapter Contains 1
1.2 Who Should Read This Manual 1
1.3 Required Knowledge 2
1.4 What’s in This Manual? 2
1.5 Where to Read More 3
1.6 Where to Get Help 4
2 General Description 5
2.1 What This Chapter Contains 5
2.2 What is the Benchmark 450 System? 5
2.3 Benchmark 450 System Main Components 6
2.4 Coaxial Light, Programmable Ring Light, & Backlight 7
2.5 Dual Magnification Optical System 8
2.6 Computer & User-Interface Components 9
2.6.1 Mouse 9
2.6.2 Keyboard 9
2.6.3 Joystick 9
3 Safety Information 11
3.1 What This Chapter Contains 11
3.2 Emergency Stops 11
3.3 System Status LEDs 12
3.4 System Power 13
3.5 System Lockout 14
3.6 Safety Guidelines 15

Page ii 799014, Revision B, 09/09 Benchmark450
4 Installation 17
4.1 What This Chapter Contains 17
4.2 Choosing an Installation Site 18
4.3 Benchmark 450 System Layout 19
4.4 Receiving, Unpacking, & Inspecting the System 20
4.5 Moving & Installing the System 21
4.6 Connecting the System 22
4.7 Powering Up the System & Launching the VMS Software24
4.8 Operation Checks 25
4.9 Post Installation Checklist 26
4.10 Shutting Down the System 27
4.11 Installing the X, Y, & Z Shipping Restraints 28
4.12 Fixture Mounting Holes 32
5 Principles of Operation & Interconnections 33
5.1 What this Chapter Contains 33
5.2 Overview of Operation 34
5.3 Image Acquisition, Processing, & Display 35
5.4 Motion Control 36
5.4.1 X- & Y-Axis Motion 36
5.4.2 Z-Axis Motion 37
5.5 Illumination Sources 38
5.6 Optional LED Grid Projector 39
5.7 Optional Ronchi Shuttle Grid Assembly 40
5.8 Optional AccuCentric Assembly 41
5.9 Zeroing the Stage 41
5.10 Benchmark 450 Schematic Diagram 41
6 Preventive Maintenance 45
6.1 What This Chapter Contains 45
6.2 Preventive Maintenance Schedule 46
6.3 Cleaning the User Components 47
6.3.1 Cleaning the Joystick 47
6.3.2 Cleaning the Mouse 47
6.3.3 Cleaning the Flat Panel Display 47
6.3.4 Cleaning the Keyboard 47
6.4 Cleaning the Stage, External Surfaces, & Stage Glass 48
6.4.1 Cleaning the Stage 48
6.4.2 Cleaning External Surfaces 48
6.4.3 Cleaning the Stage Glass 49
6.4.4 Leveling the Stage Glass 50

Service Manual 799014, Revision B, 09/09 Pageiii
6.5 Cleaning & Lubricating the X-Axis and Y-Axis Rails 56
6.5.1 Cleaning & Lubricating the X-Axis Rails 57
6.5.2 Cleaning & Lubricating the Y-Axis Guide Rails 59
6.6 Cleaning the Magnification Lens 61
6.7 Cleaning the LED Programmable Ring Light (PRL) 63
6.8 Checking for Dirt in the Images of the Video Cameras 64
6.9 Verifying Proper System Operation 64
7 Troubleshooting 65
7.1 What This Chapter Contains 65
7.2 Before You Begin 66
7.3 DSP Multi Axis PCBA Diagnostic LEDs & Test Points 67
7.3.1 DSP Multi Axis PCBA Diagnostic LEDs 67
7.3.2 Magnetic Limit Codes (DS7) 72
7.3.3 DSP Multi Axis PCBA Test Points 73
7.4 Dual Mag Optics PCBA Diagnostic LEDs & Test Points 75
7.4.1 Dual Mag Optics PCBA Diagnostic LEDs 75
7.4.2 Dual Mag Optics PCBA Test Points 78
7.5 Z Brake Control PCBA Diagnostic LEDs & Test Points 80
7.5.1 Z Brake Control PCBA Diagnostic LEDs 80
7.5.2 Z Brake Control PCBA Test Points 83
7.6 LED Driver PCBA Diagnostic LEDs & Test Points 85
7.6.1 LED Driver PCBA Diagnostic LEDs 85
7.6.2 LED Driver PCBA Test Points 87
7.7 Measuring the Resistance of the Drewire Terminations 89
7.8 Identifying Problems With the Benchmark 450 System 90
7.8.1 Start-Up Troubleshooting 90
7.8.2 Illumination Troubleshooting 91
7.8.3 Motion Troubleshooting 95
7.8.4 Video Troubleshooting 104
7.9 Identifying Problems with the System Computer &
User-Interface Components 106
7.9.1 Start-Up & General Performance 106
7.9.2 Communications 107
7.9.3 Joystick 107
7.9.4 Troubleshooting the Joystick 108
7.9.5 Keyboard 112
7.9.6 Flat Panel Display 112
7.10 Recovering from Unexpected Z-Axis Contact 114

Page iv 799014, Revision B, 09/09 Benchmark450
8 Service Adjustments 117
8.1 What This Chapter Contains 117
8.2 Benchmark 450 Service Adjustments 118
8.3 Integrated Workstation Adjustment 119
8.4 Dual Magnification Optical System Adjustments 120
8.4.1 Component Location 120
8.4.2 Sequence of Optical Adjustments 122
8.4.3 Ronchi Shuttle Window Position Adjustment 123
8.4.4 Ronchi Shuttle Opto Switch Flag &
End Limits Adjustment 124
8.4.5 Ronchi Grid Rotation Adjustment 126
8.4.6 Camera Parfocal Adjustment 127
8.4.7 Camera Parfocal Adjustment
(Systems Equipped with Ronchi Grid) 130
8.4.8 LED Grid Projector Focus Adjustment 134
8.4.9 Camera Par-Center (Coaxial) Adjustment 136
8.4.10 Camera Rotation Adjustment 139
8.5 Lens Calibration 141
8.6 AccuCentric Assembly Alignment 143
8.7 LED Programmable Ring Light (PRL) Adjustments 146
8.7.1 Centering the PRL 147
8.7.2 Adjusting the PRL Height 150
8.7.3 Setting Up the PRL Lights 153
8.7.4 Checking the PRL Light Setup with the
Light Test Part Program 157
9 Parts Repair & Replacement 159
9.1 What This Chapter Contains 159
9.2 Repairing & Replacing Parts on Your System 160
9.3 Removing the Benchmark 450 Covers 162
9.3.1 Removing the Front Cover and Z-Axis Cover 162
9.3.2 Removing the Rear Bridge Cover 163
9.3.3 Removing the Lower Bridge Cover 164
9.3.4 Removing the Electronics Enclosure Panel 165
9.4 Replacing the Magnification Lens 166
9.5 Replacing the High & Low Mag Cameras 167
9.6 Replacing the Programmable Ring Light (PRL) 169
9.7 Replacing the AccuCentric Assembly 171

Service Manual 799014, Revision B, 09/09 Pagev
9.8 Replacing the Scale Reader Heads 173
9.8.1 Replacing the X-Axis Scale Reader Head 174
9.8.2 Replacing the Y-Axis Scale Reader Head 178
9.8.3 Replacing the Z-Axis Glass Scale and Reader Head 181
9.9 Replacing the Motors 184
9.9.1 Replacing the X-Axis Motor 185
9.9.2 Replacing the Y-Axis Motor 187
9.9.3 Replacing the Z-Axis Motor 190
9.10 Replacing the Main Power Fuse(s) 194
9.11 Replacing the PCBAs 195
9.11.1 Replacing the DSP Multi Axis PCBA 196
9.11.2 Replacing the Z Brake Control PCBA 198
9.11.3 Replacing the LED Driver PCBA 200
9.11.4 Replacing the Dual Mag Optics PCBA 202
9.11.5 Replacing the Universal Multisensor PCBA 204
9.11.6 Replacing the Micro Theta Control PCBA 206
9.12 Replacing the Power Supplies 208
9.12.1 Replacing the 24 Volt Power Supply 209
9.12.2 Replacing the 48 Volt Power Supply 212
9.12.3 Replacing the ATX Power Supply 215
9.13 Replacing the Fans 218
9.13.1 Replacing the Exhaust Fan 219
9.13.2 Replacing the Intake Fan 221
A VMS System Certification & Verification 7.02 223
A.1 What This Appendix Contains 223
A.2 General Guidelines 223
A.3 Handling & Cleaning Grid Plates, Scales, & Lenses 224
A.4 Wringing Gage Blocks 224
A.5 System Certification 226
A.5.1 Certification Setup 227
A.5.2 XY Certification 231
A.5.3 Z Certification 235
A.6 System Verification 245
A.6.1 Verification Setup 246
A.6.2 XY Verification 250
A.6.3 Z Verification 254
B TTL Laser Calibration 265
B.1 What This Appendix Contains 265
B.2 TTL Laser Alignment 266
B.3 TTL Laser Calibration 278
B.4 TTL Laser Verification 280

Page vi 799014, Revision B, 09/09 Benchmark450
C Accessing VMS Parameters 281
C.1 What This Appendix Contains 281
C.2 Accessing Basic Parameters 282
C.3 Accessing Advanced Parameters 283
C.4 Loading Parameters 284
D Software Installation 285
D.1 What This Appendix Contains 285
D.2 VMS Software Installation 286
D.3 Elements Software Installation 291
Index 295