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

Service Manual 799014, Revision B, 09/09 Pagevii
Important System Labels
Label: Location: Definition:
Around the remote E-
Stop
Around the E-Stop on
the front of the machine
(Yellow ring
around red
switch)
Emergency stop
Left and right sides of
the Z-axis cover Pinch hazard
Rear panel of the
electronics enclosure,
lower-left corner
Dangerous
voltagepresent;
disconnect
power before
servicing to
avoid electrical
shock
Right side of the
electronics enclosure,
above the power cord
receptacle
Fuse label
Lower-left corner of
Main System ID label System meets the
requirements of
the European
Union (EU)

Chapter
Page viii 799014, Revision B, 09/09 Benchmark450
Front surface of the
base, upper-right corner System model and serial
number
Rear panel of the
electronics enclosure,
lower-left corner
Main system ID
Right side of the laser
(if equipped) International laser symbol
Right side of the laser
(if equipped) Indicates that the laser meets
Class 2
requirements of
the IEC-825
European
standard
Right side of the laser
(if equipped) Indicates that the laser meets
Class II
requirements of
the CFR 21
standard
Right side of the laser
(if equipped) Identifies the laser emitting
aperture
Label: Location: Definition:

Service Manual 799014, Revision B, 09/09 Page1
Chapter
About This Manual
1.1 What This Chapter Contains
This chapter covers the following:
• Who Should Read This Manual
• Required Knowledge
• What’s in This Manual?
• Where to Read More
• Where to Get Help
1.2 Who Should Read This Manual
Read this manual if you will perform any of the following tasks on the Benchmark
450 system:
• Installation
• Preventive maintenance
• Troubleshooting
• Service adjustments
• Parts replacement
For information on programming and configuring, refer to the VMS Fast Start
Guide (P/N 790438) and VMS Reference Guide (P/N 790411).
1

Chapter 1 About This Manual
Page 2 799014, Revision B, 09/09 Benchmark450
1.3 Required Knowledge
To use this manual, you should be familiar with:
• How to maintain and service inspection or industrial automation equipment
• How to use and troubleshoot a computer
• Basic electrical and mechanical terminology and inspection equipment
terminology
1.4 What’s in This Manual?
Note: We recommend that the procedures described in this manual be performed
by trained and authorized personnel.
Chapter Title Contents
2 General Description Defines what the Benchmark 450
system is and familiarizes you with
the basic hardware components.
3 Safety Information Describes the remote Emergency
Stop switch and covers other safety
issues.
4 Installation Describes how to:
• Choose an installation site.
• Unpack, move and install the
Benchmark 450 system.
• Power up the system, verify the
system, and shut down the
system.
5 Principles of Operation &
System Interconnections Describes subsystems and the interconnections within the
Benchmark 450 system.
6 Preventive Maintenance Lists actions you should take to keep
the Benchmark 450 system in good
operating order.
7 Troubleshooting Helps you identify the cause of
possible problems with the
Benchmark 450 system, the system
computer, and the user components.
8 Service Adjustments Describes how to calibrate and align
the system optics.

About This Manual Chapter 1
Service Manual 799014, Revision B, 09/09 Page3
1.5 Where to Read More
For information about using the Benchmark 450 system, refer to the software
manual(s), software release notes, and OEM manuals that shipped with your
system.
9 Parts Repair & Replacement Describes how to replace imaging,
transport, and electrical components.
A VMS System Certification &
Verification 7.02 Describes how to certify and verify the system.
B TTL Laser Calibration Describes how to calibrate the
optional TTL laser.
C Accessing VMS Parameters Describes how to access VMS
parameters.
D Software Installation Describes how to install the VMS
software and Elements software.
Chapter Title Contents

Chapter 1 About This Manual
Page 4 799014, Revision B, 09/09 Benchmark450
1.6 Where to Get Help
If you are faced with a situation you cannot resolve using this manual, contact the
Customer Support HelpDesk, at:
Be ready to provide the following information when contacting us:
• Model and serial number of your system
• Nature of the problem
• Steps you have taken
• Your phone and fax numbers
• Case number if you are calling about an issue that has already been reported
VIEW Engineering, Inc.
1650 N. Voyager Avenue
Simi Valley, CA 93063, USA
Phone: [phone]
Toll free: 877-SOS-VIEW
(877-767-8439)
Fax: [phone]
E-mail: [email protected]
Website: www.vieweng.com

Service Manual 799014, Revision B, 09/09 Page5
Chapter
General Description
2.1 What This Chapter Contains
This chapter covers the following:
• What is the Benchmark 450 System?
• Benchmark 450 System Main Components
• Coaxial Light, Programmable Ring Light, & Backlight
• Dual Magnification Optical System
• Computer & User-Interface Components
2.2 What is the Benchmark 450 System?
The Benchmark 450 system is a non-contact, three-dimensional measurement
system with a full range of vision-based measurement tools and software. It has
450 mm x 450 mm x 150 mm (18" x 18" x 6") XYZ travel.
The system has precision dual magnification optics, coaxial and backlight
illumination, and autofocus circuitry for high-accuracy Z-axis measurements over
a variety of surface textures, finishes, and colors. The LED Programmable Ring
Light (PRL) is optional.
No upgrades are necessary to achieve full automatic inspection.
Note: See the VIEW Benchmark 450 Technical Data Sheet (part number 799003)
for more technical information.
2

Chapter 2 General Description
Page 6 799014, Revision B, 09/09 Benchmark450
2.3 Benchmark 450 System Main Components
The Benchmark 450 system is a large travel, floor standing machine. The X-axis
travels on an overhead bridge above the worktable. Parts are measured by
mounting them on the worktable, which moves in the Y direction. The system has
an integrated workstation for the flat-panel display, 3-axis joystick, keyboard,
mouse, and remote E-Stop switch. The system computer is located on the shelf
attached to the right side of the machine.
There are two Emergency Stops: one is located on the workstation, within easy
reach of the operator, and the other is on the base of the machine.
Figure 2-1 Benchmark 450 System Main Components
System
Computer
Flat Panel
Display
Joystick
Worktable
Front
Cover
E-Stop
Remote
E-Stop
Base

General Description Chapter 2
Service Manual 799014, Revision B, 09/09 Page7
2.4 Coaxial Light, Programmable Ring Light, & Backlight
The LED coaxial light, LED Programmable Ring Light (PRL), and LED backlight
assemblies are used to illuminate the part on the worktable.
The following table describes each feature:
Feature Description
LED Coaxial light (through
the lens) Projects the light straight down through the magnification lens — it is also used in conjunction with the Ronchi grid
(the Ronchi grid is used to focus on very flat, non-textured
parts)
LED Programmable Ring
Light (PRL) Allows you to control illumination via four quadrants at various angles
LED Backlight Projects the light upward through the stage glass, from
below the part under inspection

Chapter 2 General Description
Page 8 799014, Revision B, 09/09 Benchmark450
2.5 Dual Magnification Optical System
The dual magnification optical system uses two monochrome cameras on two
separate optical paths to provide instant magnification switching under software
control. A third optical path is included to provide coaxial (through the lens)
illumination and grid pattern for autofocus.
Figure 2-2 Optical Components (shown with optional LED grid projector)
Low Mag
Camera
High Mag
Camera
High Mag Lens
Assembly
Optical Block
Optional LED
Grid Projector
PRL Assembly
Optional AccuCentric
Assembly