Zeiss Corona process User manual

Service manual
Carl Zeiss Spectroscopy GmbH
Lamp replacement and calibration
Corona process

2Lamp replacement and calibration - Corona process | Service manual | EN_40_070_0010I
Lamp replacement and calibration Corona process
Users must be familiar with this manual to operate the device. Therefore, please familiarize yourself with the
contents. In particular, make sure to follow the instructions explaining how to handle the device safely. Subject to
change in the interest of technical development. The user manual is not subject to updates by revision services.
© Forwarding and reproduction of this document and the use and communication of its contents are prohibited,
unless explicit permission has been granted. Violations of this copyright notice will result in claims for damages.
All rights are reserved in case a patent is granted or a sample is registered.
Caution
GENERAL RISK
Please read the notes in the “Corona process” User Manual;
publication number: UM Corona process / E.
Note
Further information regarding proper use of the measuring system is available in the
“Corona process” User Manual.
Carl Zeiss Spectroscopy GmbH
Carl-Zeiss-Promenade 10
07745 Jena, Germany
Service: + 49 3641 64-3200
Phone: + 49 3641 64-2838
Email: [e-mail]
www.zeiss.com/spectroscopy
EN_40_070_0010I | 2020-06
Design, scope of delivery and technical progress subject to change without notice. © Carl Zeiss Spectroscopy GmbH

3EN_40_070_0010I | Service manual | Lamp replacement and calibration - Corona process
Lamp replacement and calibration Corona process
Table of contents
1 Laser safety 5
2 Preparing for the lamp replacement 8
3 Determining the device version 9
4 Replacing halogen lamps 16
4.1 General tasks 16
4.2 Determining the lamp type 21
4.3 Removing halogen lamps – lamp type A 22
4.4 Removing halogen lamps – lamp type B 25
4.5 Installing new halogen lamps 28
5 Sensor calibration 32
6 Accessories and spare parts 42

4Lamp replacement and calibration - Corona process | Service manual | EN_40_070_0010I
Lamp replacement and calibration Corona process
List of figures
Fig. 1 Warning and information labels on the Corona process spectrometer 6
Fig. 2 Description of laser beam fields and paths 7
Fig. 3 Selecting the device 9
Fig. 4 Entering or scanning the IP address 10
Fig. 5 Opening the “Get device information” context menu 10
Fig. 6 Selecting the device (measuring system) 11
Fig. 7 Reading the device information 12
Fig. 8 Applying a firmware update 13
Fig. 9 Firmware version warning notification 14
Fig. 10 Notification to start the firmware update 14
Fig. 11 Firmware update is being carried out 15
Fig. 12 Confirming successful firmware update 15
Fig. 13 Removing the system cables 18
Fig. 14 Removing the Corona process from the mounting bracket 18
Fig. 15 Removing the base of the device from the device cover 19
Fig. 16 Installation positions of the halogen lamps 20
Fig. 17 Determining the lamp type 21
Fig. 18 Disconnecting the lamp cable – lamp type A 22
Fig. 19 Unscrewing the lamp holder – lamp type A 22
Fig. 20 Remove lamp holder – lamp type A 23
Fig. 21 Removing the halogen lamp – lamp type A 24
Fig. 22 Disconnecting the lamp cable – lamp type B 25
Fig. 23 Unscrewing the lamp holder – lamp type B 26
Fig. 24 Removing the lamp holder – lamp type B 26
Fig. 25 Removing the halogen lamp – lamp type B 27
Fig. 26 Guiding lamp cables through lamp holder 28
Fig. 27 Aligning the halogen lamp 29
Fig. 28 Installing the clamping ring 29
Fig. 29 Mounting the Corona process on the calibration device 32
Fig. 30 Selecting the measuring system 33
Fig. 31 Selecting the lamp 33
Fig. 32 Resetting the lamp counter 34
Fig. 33 Specifying the white standard 35
Fig. 34 Selecting the *.csv file 35
Fig. 35 Mounting the white standard 36
Fig. 36 Confirming the alignment 36
Fig. 37 Positioning the white standard 37
Fig. 38 Continuing the white calibration 37
Fig. 39 Positioning the black standard 38
Fig. 40 Continuing the black calibration 38
Fig. 41 Continuing the distance correction 39
Fig. 42 Saving the distance correction 40
Fig. 43 Selecting the spare lamp 40
Fig. 44 Creating the new *.ini file 41

5EN_40_070_0010I | Service manual | Lamp replacement and calibration - Corona process
Laser safety
Lamp replacement and calibration Corona process
1 Laser safety
A laser class 2 distance meter is integrated into the Corona process
spectrometer. This laser instrument serves to measure the distance between lens
and sample in order to adjust the measurement results regarding the variability of
the distance.
Laser class 2 comprises low-power and low-risk lasers. Follow the operating
instructions below.
The following laser type is used in the Corona process:
Laser Class Rated power
Laser 655 nm 2< 1 mW
Laser safety instructions
When used properly, the Corona process spectrometer does not pose any laser
beam risks for the operating or service personnel. However, please observe the
following warnings:
Caution
RADIATION ENERGY HAZARD
Emissions display: The laser is active if the control LED is flashing in
blue.
Never look directly into the measurement and laser beam. The focused
light of the halogen lamp and the laser may cause eye damage.
Prevent scattered radiation: Do not position any reflective or focusing
optical items in the beam path.
The system may only be operated or maintained by trained personnel.
The personnel must be informed of the possible risks in dealing with
laser class 2 systems.
The staff commissioned with operating or maintaining the device must
be aware of the space and clothing specifications applicable on site
and must act accordingly.
Notes on the handling of laser components

6Lamp replacement and calibration - Corona process | Service manual | EN_40_070_0010I
Laser safety Lamp replacement and calibration Corona process
Warning and information labels on the Corona process spectrometer
The warning and information labels on the Corona process spectrometer
must be obeyed. Check whether all labels shown in the following diagram are
provided. If any labels are missing, please contact ZEISS Germany or one of the
service agencies.
Fig. 1
Carl Zeiss Microscopy GmbH
Carl-Zeiss-Promenade 10
07745 Jena, Germany
LASER APERTURE
XY
000000-1940-639
000000-2112-782
Revision label
Emission indicator
000000-1940-564
000000-2373-910
000000-2374-145
Warning and information labels on the Corona process spectrometer

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Laser safety
Lamp replacement and calibration Corona process
Description of the laser beam fields and paths
Beam path laser triangulation sensor SICK DT20 Hi
for Corona process (000000-2074-398)
• Laser class: II
• Radiation strength: < 1 mW (0.35 ... 0.9 mW)
• Wavelength: 655 nm
• Window transmission: 91%
• Light spot size: 3 x 6 mm
• Distance to Cp 0 ... 580 mm
Fig. 2
SICK
DT20 Hi
Window transmission: 91%
3 x 6 mm
0 ... 580 mm
Description of laser beam fields and paths

8Lamp replacement and calibration - Corona process | Service manual | EN_40_070_0010I
Preparing for the lamp replacement Lamp replacement and calibration Corona process
2 Preparing for the lamp replacement
Before starting the lamp replacement, some preparatory tasks must be
accomplished. Please read chapters 1 and 2 carefully in this regard.
Note
IMPORTANT NOTE ON THE IP address area
Ensure that you are working within the same IP address area when
connecting the device to the test computer.
• Prepare the following tools:
– Corona process calibration assembly, order no. 000000-2211-998
Delivery package:� Calibration device
� certified white standard with corresponding certificate
(accompanying CD)
� Black standard
� Tools for the lamp change
� Associated instructions
� Storage box
– Ethernet cable, order no. 000000-2036-573
– Lab power supply, order no. 000000-2045-548
• Review the white and black standard
Caution
SENSITIVE SURFACES
Do not touch the surface of the white standard.
Make sure that the white and black standard are clean. Clean the
standards with compressed air as necessary.
Note
Ensure that the white standard certification is still valid.
The corresponding certificate can be found on the CD included in the delivery
package. If no CD drive is available on the test computer the certificate must
be copied to another storage device. The certificate is mandatory.
Requirements

9EN_40_070_0010I | Service manual | Lamp replacement and calibration - Corona process
Determining the device version
Lamp replacement and calibration Corona process
3 Determining the device version
1 Connecting the device to test computers and power supply
Connect the device to the measuring computer via the ethernet cable.
Establish the power supply for the device via the lab power supply.
2 Opening OSIS software
Start the OSISManagementConsole.exe under:
⇒C:\Program Files (x86)\ZEISS\InProcess
⇒C:\Program Files (x86)\ZEISS\InProcess\OSIS\ManagementConsole\
3 Selecting the device
Select the Corona process measuring system.
Fig. 3 Selecting the device
4 Enter the IP address of the measuring system or carry out a scan
Under Hardware settings > IP address, enter the IP address of your device or
carry out an address scan via the Scan button.
Ensure that you are working within the same IP address area when
connecting the device to the test computer.
Procedure
up to InProcess Version 2.9:
starting from InProcess
Version 2.10:

10 Lamp replacement and calibration - Corona process | Service manual | EN_40_070_0010I
Determining the device version Lamp replacement and calibration Corona process
Fig. 4 Entering or scanning the IP address
5 Open the “Get device information” context menu
Right-click Corona process, then select Get device information...
Fig. 5 Opening the “Get device information” context menu

11EN_40_070_0010I | Service manual | Lamp replacement and calibration - Corona process
Determining the device version
Lamp replacement and calibration Corona process
6 Select the device (measuring system)
Under “Please select one entry...” select Corona process, as necessary.
Fig. 6 Selecting the device (measuring system)

12 Lamp replacement and calibration - Corona process | Service manual | EN_40_070_0010I
Determining the device version Lamp replacement and calibration Corona process
7 Read the device information
Determine the hardware revision version by choosing “Device Info”.
Example: Hardware revision 2.
Fig. 7 Reading the device information
8 Decide on subsequent procedure
If Hardware revision 1 is displayed, you may not carry out the lamp replace-
ment by yourself. The device must be sent back to Carl Zeiss Spectroscopy
GmbH directly for lamp replacement, service, maintenance or repair.
If Hardware revision 2 is displayed, you may replace the lamps. Regardless of
the lamp type already installed, lamp type B must be mounted (see paragraph
“4.2 Determining the lamp type” on page 21).
In order to then operate the replaced lamps, you must additionally carry out a
firmware update (see step 10 in this chapter).
If Hardware revision 3 is displayed, you may replace the lamps. Regardless of
which lamp type is installed, lamp type B may be mounted (see paragraph “4.2
Determining the lamp type” on page 21).
If Hardware revision 4 is displayed, you may replace the lamp.
Lamps of the current lamp type B are already mounted on your device.
Hardware revision 1Hardware revision 1
Hardware revision 2
Hardware revision 3
Hardware revision 4

13EN_40_070_0010I | Service manual | Lamp replacement and calibration - Corona process
Determining the device version
Lamp replacement and calibration Corona process
9 Generate *.ini file
Under “Device info”, click on the Export details button.
An *.ini file is created. Save this file.
10 Carry out firmware update – starting from Hardware revision 2
Repeat the work steps from 5 to 7.
Starting from Hardware revision 2, a firmware update has to be performed.
Under “Device info”, click on the Update device button.
Fig. 8 Applying a firmware update
– For Hardware revision 2: V02.04_02xx.fwx
– For Hardware revision 3: V03.04_03xx.fwx
– For Hardware revision 4: V04.01_04xx.fwx

14 Lamp replacement and calibration - Corona process | Service manual | EN_40_070_0010I
Determining the device version Lamp replacement and calibration Corona process
If you try to install incorrect firmware or firmware which is already installed, the
following warning message will be shown.
Fig. 9 Firmware version warning notification
If you have selected the correct firmware, the following window appears. To start
the firmware update, click OK.
Fig. 10 Notification to start the firmware update
Note
IMPORTANT NOTIFICATION ON THE FIRMWARE UPDATE
Do not switch off the device or interrupt the network connection to
the test computer during the update under any circumstances.

15EN_40_070_0010I | Service manual | Lamp replacement and calibration - Corona process
Determining the device version
Lamp replacement and calibration Corona process
The firmware update is being installed. This may take a few minutes.
Fig. 11 Firmware update is being carried out
The update was installed successfully.
Close the notification by clicking OK.
Fig. 12 Confirming successful firmware update
The preparation tasks for the lamp replacement are now completed.
Go to Chapter “4 Replacing halogen lamps” on page 16 and read through
the safety instructions. Carry out the lamp replacement in accordance with
the following work steps.
Result

16 Lamp replacement and calibration - Corona process | Service manual | EN_40_070_0010I
Replacing halogen lamps Lamp replacement and calibration Corona process
4 Replacing halogen lamps
4.1 General tasks
Warning
DANGER DUE TO ELECTRICAL ENERGY
Ensure that the power supply is interrupted – the entire measuring
system must be off the power grid.
Secure the measuring system against unintentional power supply by
third parties.
Caution
GENERAL HAZARDS
All activities listed may only be carried out by service staff of
CarlZeissSpectroscopyGmbH or trained personnel.
Caution
HAZARD DUE TO THERMAL ENERGY
Allow the halogen lamp being replaced to cool down for
approx. 10 minutes before removal.
Caution
SENSITIVE OPTICAL COMPONENTS
Work on optical components may only be carried out in a very clean
work environment.
Ensure that you wear cotton gloves at all times when touching the
glass halogen lamp.

17EN_40_070_0010I | Service manual | Lamp replacement and calibration - Corona process
Replacing halogen lamps
Lamp replacement and calibration Corona process
1 Closing the control software
Close the InProcess control software.
2 Cut off the power supply
Cut off the power supply to the Corona process measuring system.
3 Set up ESD work station
Carry out the activities described below at an ESD work station.
4 Prepare spare parts
Prepare the following spare parts:
– Spare lamps, 2x, order no. 000000-2219-967
– Cable connector, screw-on, 1x
Note
Always replace both halogen lamps at once.
5 Prepare tools and materials
Prepare the following tools and materials:
– the tools belonging to the Corona process calibration device
ȩ8 mm spanner
ȩTX10 and TX25 screwdrivers
– additionally necessary tools and materials:
ȩ22 mm spanner
ȩ6 mm hex wrench
ȩPhillips screwdriver PH2 (for older device versions)
ȩCotton gloves
Procedure

18 Lamp replacement and calibration - Corona process | Service manual | EN_40_070_0010I
Replacing halogen lamps Lamp replacement and calibration Corona process
6 Removing the system cables
Loosen the union nuts of the connected plugs by hand (or using a 22 mm
spanner) and remove the cables from the device.
Fig. 13
3
2
1
Removing the system cables
“ETHERNET” port
“Digital IN OUT” port
“POWER 12 – 24 V DC” port (power supply)
7 Removing the Corona process from the mounting bracket
Loosen both clamping screws 1on the mounting bracket using a 6 mm hex
wrench.
Remove the Corona process 2from the mounting bracket.
Fig. 14
2
1
Removing the Corona process from the mounting bracket
1
2
3

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Replacing halogen lamps
Lamp replacement and calibration Corona process
8 Removing the base of the device from the device cover
Loosen the four hexagonal screws 1of the housing with a 8 mm spanner.
(Phillips screws may be installed in older device versions. Loosen these using a
PH 2 Phillips screwdriver.)
Caution
RISK OF COMPONENT DAMAGE
Risk of damaging the FBG filter board while removing the device base
from the cover.
Carefully lift up the base and watch out for stuck parts.
Carefully lift the device base 2out of the device cover 4by the handle
3. Avoid jamming any parts whilst removing.
Rotate the base of the device by 180° – the internal assemblies are now on
top and the handle on the bottom – and carefully place it at an ESD work
station.
Fig. 15
3
12
4
Removing the base of the device from the device cover

20 Lamp replacement and calibration - Corona process | Service manual | EN_40_070_0010I
Replacing halogen lamps Lamp replacement and calibration Corona process
9 Installation positions of the halogen lamps
When looking at the base of the device from the direction of the connector
panel, the default lamp L1 is on the left hand side of the device base and
the spare lamp L2 on the right. The corresponding labeling is also on the
base of the lamp.
Fig. 16
Spare lamp
Default lamp
L1 L2
Installation positions of the halogen lamps
Note
Always replace both halogen lamps at once.
Note
The replacing procedure of the default lamp is described in the
following steps. Replacing the spare lamp is performed accordingly to
the default lamp.