Xinspect 3500ic Operating Instructions - Version 1.0 May 2010

Version 1.0

Operating Instructions

Automated Integrated String Tester

Xinspect 3500ic

Version 1.0

Published by: Komax Solar, Inc. 20 Innovation Drive York PA, 17402

Phone 717.755.6800

Fax 717.757.6470

International

Tel. +41 41 455 0 455

Fax. +41 41 450 1 579

E-mail service [email protected] Internet www.komaxsolar.com

Reproduction of these instructions in part or whole is not permitted without express written permission from the publisher.

Komax Solar, Inc. reserves the right to make technical changes to the machine that may diverge from the information contained herein.

Revision/Version History

All revisions to this manual are listed below. Revisions are listed by Section, from first release to the most recent release.

Version Date Issued Sections Revised Description

1.0 May 2010 n/a First Release

Version 1.0 Table of Contents TOC-1

Xinspect 3500ic Operating Instructions

1. Manual Overview ...................................................................................................................... 1-1

1.1 Audience ............................................................................................................................................1-1

1.2 Scope .................................................................................................................................................1-1

1.3 Structure ............................................................................................................................................1-1

1.4 Updates and Versions ........................................................................................................................1-1

2. Product Description ................................................................................................................. 2-1

2.1 Application .........................................................................................................................................2-1

2.2 Technical Specifications ....................................................................................................................2-2

2.2.1 Xinspect 3500ic Technical Specifications .................................................................................2-2

2.2.2 String Technical Specifications .................................................................................................2-3

2.3 Conformity .........................................................................................................................................2-3

3. Safety ......................................................................................................................................... 3-1

3.1 Explanation of Safety Symbols ..........................................................................................................3-1

3.2 Safety Hazards ...................................................................................................................................3-2

3.3 Safety Features ..................................................................................................................................3-3

4. Transport ................................................................................................................................... 4-1

4.1 Packaging ..........................................................................................................................................4-1

4.2 Handling .............................................................................................................................................4-1

4.3 Corrosion Protection ..........................................................................................................................4-2

4.4 Incoming Inspection ..........................................................................................................................4-2

5. Installation ................................................................................................................................. 5-1

5.1 Installation Site ...................................................................................................................................5-1

5.2 Basic Unit Setup ................................................................................................................................5-1

5.2.1 Installation and leveling of the machine ...................................................................................5-1

5.2.2 Internal Connections ................................................................................................................5-2

5.2.3 Release of moving parts ...........................................................................................................5-8

5.3 Connecting the machine ....................................................................................................................5-9

5.3.1 Robot .........................................................................................................................................5-9

5.3.2 Power Supply ............................................................................................................................5-9

5.3.3 Air supply .................................................................................................................................5-10

5.4 Final Procedures ..............................................................................................................................5-10

6. Machine Overview and Functions ........................................................................................... 6-1

6.1 Overall Machine .................................................................................................................................6-1

Xinspect 3500ic Operators Manual Table of Contents



6.2 External Assemblies ............................................................................................................................6-2

6.2.1 Frame External Assemblies .......................................................................................................6-2

6.2.2 Electrical Cabinet External Assemblies .....................................................................................6-3

6.3 Internal assemblies overview ..............................................................................................................6-4

6.4 Internal Assemblies in the Frame ........................................................................................................6-5

6.4.1 Probe Assembly ........................................................................................................................6-5

6.4.2 Probe Axis .................................................................................................................................6-6

6.4.3 Camera and its Support ............................................................................................................6-7

6.4.4 Camera Axis ..............................................................................................................................6-8

6.4.5 Backlight ....................................................................................................................................6-9

6.4.6 I-V curve measurement ...........................................................................................................6-10

6.4.7 Electrical Equipment located in the Frame ..............................................................................6-11

6.4.8 Mask ........................................................................................................................................6-12

6.5 Internal Assemblies in the Electrical Cabinet ....................................................................................6-13

6.5.1 Computers ...............................................................................................................................6-13

6.5.2 Front Electrical Equipment ......................................................................................................6-14

6.5.3 Rear Electrical Equipment .......................................................................................................6-15

7. Machine Operation ................................................................................................................... 7-1

7.1 Pre-Startup Checks ...........................................................................................................................7-1

7.2 Machine Initial Start Up ......................................................................................................................7-2

7.3 Machine Operation ............................................................................................................................7-3

7.4 Recovery from Emergency Stop ........................................................................................................7-3

7.5 System Shutdown ..............................................................................................................................7-3

8. Software Operation .................................................................................................................. 8-1

8.1 Definition of User Levels ....................................................................................................................8-1

8.2 User Interface Description .................................................................................................................8-2

8.2.1 General Menu ............................................................................................................................8-3

8.2.2 Cell Thumbnails .........................................................................................................................8-4

8.2.3 Full Size View ............................................................................................................................8-4

8.2.4 I-V Curve View ...........................................................................................................................8-5

8.2.5 Process Information ..................................................................................................................8-6

8.2.6 Recipe Information ....................................................................................................................8-6

8.3 Language Selection ...........................................................................................................................8-7

8.4 Machine and Software Configuration ................................................................................................8-7

8.4.1 Vision .........................................................................................................................................8-8



8.4.2 DAQ Agilent ...............................................................................................................................8-9

8.4.3 Change User ............................................................................................................................8-10

8.4.4 About (Software Versions) .......................................................................................................8-11

8.5 System Informations ........................................................................................................................8-11

8.6 Configuration Process .....................................................................................................................8-13

8.6.1 String / Cells Definition ............................................................................................................8-14

8.6.2 Robot Calibration ....................................................................................................................8-15

8.6.3 PLC Configuration / Troubleshoot ...........................................................................................8-16

8.6.4 DAQ Agilent Configuration ......................................................................................................8-18

8.7 Management of Alarms (Reports) ....................................................................................................8-19

8.8 Visualization of test Results (History) ...............................................................................................8-21

9. Maintenance ............................................................................................................................. 9-1

9.1 Important Maintenance Notes ...........................................................................................................9-1

9.1.1 Cleaning ...................................................................................................................................9-1

9.1.2 Solvent......................................................................................................................................9-1

9.2 Maintenance Task Summary ..............................................................................................................9-2

9.2.1 Preventive Maintenance Schedule ...........................................................................................9-2

9.2.2 Corrective Maintenance ...........................................................................................................9-2

9.3 Maintenance Procedures ...................................................................................................................9-3

9.3.1 Frame .......................................................................................................................................9-3

9.3.2 Probe Assembly .......................................................................................................................9-4

9.3.3 Camera Axis .............................................................................................................................9-5

9.3.4 Camera and its Support ...........................................................................................................9-6

9.3.5 Backlight ...................................................................................................................................9-7

9.3.6 I-V curve measurement (optional feature) ................................................................................9-8

9.3.7 Mask 12 cells and Mask 6 cells (optional feature) ..................................................................9-10

9.3.8 Electrical Cabinet ...................................................................................................................9-11

9.3.9 Electrical Equipment ...............................................................................................................9-12

10. Product Changeover / Tooling Replacement & Adjustment ............................................. 10-1

10.1 Setting of the machine at first use .................................................................................................10-1

10.2 New Production .............................................................................................................................10-2

10.3 Production Change ........................................................................................................................10-2



Version 1.0 Manual Overview 1-1


1. Manual Overview

1.1 Audience

These Operating Instructions are intended for the following audience:

Operators ■ - anyone who is to operate and/or program the machine.

Installers ■ - anyone responsible for the installation and/or setup of the machine.

Service Technicians ■ - trained personnel that are to perform service or maintenance to the machine.

1.2 Scope

These Operating Instructions are valid for all Xinspect 3500ic machines.

1.3 Structure

This manual is made up of three separate parts, each intended for a specific audience:

Part A - Product Safety, Description and Installation - covers information that will usually be referenced only once. The Safety chapter covers all safety warnings and should be read at least once by all users.

Part B - Operation Instructions - covers instructions on the operation and setup of the machine. It is intended for operators.

Part C - Maintenance - covers maintenance and machine settings. It is intended for service technicians.

Each part consists of several chapters numbered consecutively. Pages are numbered based on chapter, and so are unique to that chapter only. For example, page 4-11 exists only in chapter 4 on the 11th page of that chapter. Page numbers are located in the lower-outside margins of the page.

1.4 Updates and Versions

In the lower-inside margin of each page, you will see a version number. This number consists of a main version number and a subordinate number. For example, in Version 1.0, “1” is the main number, and “0” is the subordinate. There are two types of updates that can be made to these Operating Instructions: Chapter updates and Full Document updates.

Chapter Updates - when an update is made to a chapter, only that individual chapter must be replaced. The subordinate number will be increased each time a chapter revision is released (i.e. 1.1).

Full Document Updates - when the entire manual is re-released due to major structural or content changes, all chapters must be replaced. The main version number will be increased (i.e. 2.0). It is essential that all chapters have the same main version number.

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Version 1.0 Manual Overview 1-2


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Version 1.0 Product Description 2-1


Figure 2.1.1 - Xinspect 3500ic

2. Product Description

The Xinspect 3500ic is an automated string tester designed to check strings composed of traditional monocrystalline and polycrystalline cells. It is fully integrated to a production line where it interacts with a robot for string loading and string unloading steps. The Xinspect 3500ic has two main functions:

to check the string in order to accept it for further processing (installation on matrix) or reject it from ■the production line in case of poor quality,

to measure position of the string in regard to the robot for accurate installation on matrix. ■

2.1 Application

A robot with an integrated cover in the gripper places a string in the Xinspect 3500ic machine.

A camera mounted on a servo axis takes two images of each cell of the string:

the first with a backlight which allows to measure position and broken parts, ■

the second based on electroluminescence which allows detecting defects such as finger breaks, ■micro cracks or inactive areas.

The Xinspect 3500ic is able, through its image processing component, to accept the tested string for further processing or reject it from the production line if the quality is under acceptance criteria.

An optional IV curve measurement, allowing a monochromatic illumination, evaluates the electrical performance of the string: identification of I-V curve, maximum peak power, fill factor, open-circuit voltage, short-circuit current and estimated results on the sun simulator.

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2.2 Technical Specifications

2.2.1 Xinspect 3500ic Technical Specifications

Table 2.2.1 - Xinspect 3500ic Technical Specifications

Parameter Value/Range

Size of Frame (L x W x H) 2500 x 470 x 1150 mm (98.43 x 18.50 x 45.28 in)

Size of Electrical Cabinet (L x W x H) 556 x 600 x 1320 mm (21.89 x 23.62 x 51.97 in)

Weight of Frame Standard 320 kg (706 lb)

Optional 350 kg (772 lb)

Weight of Electrical Cabinet 140 kg (309 lb)

Electrical Connection 1 x 230 VAC - 50/60 Hz

Electrical Power Consumption 1 kW

Electrical Protection 16 A circuit breakers

Compressed Air Connection 6 to 10 bar (87 to 145 psi) Minimum 5 bar (72.5 psi)

Air Consumption 20 NL/min (5.28 Ngal(U.S.)/min)

Radiative Intensity 200 to 500 W/m² (0.129 to 0.323 W/in²)

Process Time (product dependant) 6 cells: 7 s 8 cells: 9 s 10 cells: 11 s 12 cells: 13 s

Noise Level < 72 dBa

Relative Humidity Operating Environment 10 to 90%, non condensing

Ambient Temperature 15 to 35 °C (59 to 95 °F)

Figure 2.1.2 - Example of string

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2.2.2 String Technical Specifications

Table 2.2.2 - String Technical Specifications

Parameter Value/Range

String Length Range 760 to 2004 mm (29.92 to 78.90 in)

Minimum Ribbon Tab Length 33 mm (1.30 in)

Maximum Ribbon Tab Length 80 mm (3.15 in)

Cell Size 125 mm (4.92 in) and 156 mm (6.14 in) square, pseudo square (round opt), 45 ° corners

Cell Thickness 160, 180 and 200 microns (0.00630, 0.00709, 0.00787 in)

Number of Interconnect Ribbons 2 ribbons (125 mm² and 156 mm² cells) 3 ribbons (156 mm² cells)

2.3 Conformity

The Xinspect 3500ic is in conformity with the following standards provided it is operated in accordance with the operating documents and specifications including operation with solely the stated protective, safety and operating devices (see chapter 3 for safety information):

NF EN ISO 60204-1 (Electrical standard) ■

NF EN ISO 12100 (Machinery Directive - Design) ■

NF EN ISO 14121 (Machinery Directive - Safety) ■

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Version 1.0 Safety 3-1


3. Safety

ALWAYS Observe the following safety rules:

This machine is a part of a complete production line. The Frame of the machine is located in a safety area controled by an upstream machine. Observe all safety rules related to the upstream machine and to the complete process.

Before starting the machine: check that all doors are installed on the Frame, check that the safety door of the Electrical Cabinet is closed. The safety requirements are met only if all safety devices are functioning properly.

Operate the machine only in accordance with its intended scope of application and technical data. The machine must not be used for any other purpose other than the application described in these instructions.

Processing of unspecified materials does not guarantee safety or protection from damage. Process ONLY the materials specified in the technical data.

Do not operate, maintain or repair the machine unless you are authorized and trained to do so.

Do not enter a command that will put individuals working on the machine in danger. Safety is guaranteed ONLY for the machine operator. Anyone executing movements on the machine becomes an operator and is thus responsible for the safety of personnel working near the machine.

If you have reason to believe that the machine can no longer be operated safely, you must take it out of operation and secure it against unintentional switch-on.

Observe all warnings, cautions and notes in these instructions as well as locally valid rules of safety and accident prevention.

Use the appropriate personal protective equipment when using any cleaning agents, solvents or lubricants during maintenance procedures.

3.1 Explanation of Safety Symbols

Important information is displayed next to a special icon. An icon indicates the type of note. The following symbols are used in these instructions:

Indicates a procedure that MUST be followed to prevent injury of the operator or surrounding persons AND to prevent possible damage to the machine.

Indicates a procedure that MUST be followed to prevent damage to the machine.

Indicates time saving tips or other useful information that will not result in injury or damage if disregarded.

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3.2 Safety Hazards

Electrocution Hazard

Touching live parts may result in electrocution. DO NOT open the safety door of the Electrical Cabinet unless it is stopped and the power is switched OFF. Only trained personnel should remove doors of the Frame to perform adjustments and maintenance. The entire system MUST be switched off and secured against unauthorized switch-on before any installation, maintenance or repair work is carried out.

Figure 3.2.1 - Electrical Cabinet



3.3 Safety Features

The Xinspect 3500ic is built using state of the art safety engineering. It has the following safety and protection devices as standard equipment:

Main Switch1. - disconnects the power supply from the entire electrical system. In the OFF position, power is switched off to all devices. This switch must be turned OFF before performing maintenance or modifications to the machine.

Power Indicator2. - indicates if power is supplied to the actuators. If the indicator is OFF, air pressure is removed and servo axis deenergized.

Emergency Stop Button3. - turns machine power off (motor power and air pressure) and stops all machine movements.

Safety Door with Lock4. - protects electrical equipment located inside the Electrical Cabinet and prevents operator from electrocution hazard.

ONLY an authorized personnel has the key to open the Electrical Cabinet Safety Door.

Figure 3.3.1 - Safety Features

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Version 1.0 Transport 4-1


4. Transport

Correct transportation of the Xinspect 3500ic is essential to prevent damage to the machine. Follow all procedures outlined in this chapter.

4.1 Packaging

The Xinspect 3500ic is delivered in a solid wooden crate unless special arrangements have been made with the customer.

Table 4.1.1 - Shipping Crate Dimensions

Dimension (L x W x H) Weight

2780 x 1380 x 1500 mm (109.4 x 53.3 x 59.1 in) 690 kg (1522 lb)

4.2 Handling

Always pay attention to the handling symbols on the package. These symbols are shown in the example below.

Failure to observe to package handling symbols may result in damage to the machine.

This side UP1. Protect against moisture2. Location of lift points3.

When handling/transporting the system, always observe the following:

Pay attention to the handling symbols on the crate. ■

Make sure that all parts are securely fastened. ■

Check delivery notes attached to the outside of the crate. These should be located in a highly visible ■position.

Figure 4.2.1 - Handling Symbols

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Version 1.0 Transport 4-2


4.3 Corrosion Protection

Desiccant bags and anti corrosion foam provide corrosion protection to the Xinspect 3500ic machine during transport.

Observe the following to prevent corrosion:

Make sure the crate has no damage. Otherwise, seal any damaged areas of the crate immediately. ■

Do not open the crate until you wish to make use of its contents. ■

To check the contents of the crate, you may open the covering briefly. After checking, check the ■condition of dessicant bags and anti corrosion foam, replace them if necessary and immediately reseal the crate.

4.4 Incoming Inspection

The following steps must be taken upon arrival of the shipment:

Check the completeness of the delivery against the delivery notes attached to the package.1.

Examine the crate for damage. If the crate is damaged, DO NOT OPEN. First, take several 2. photographs of the crate damage. Be sure to get photographs from multiple angles. The photographs will serve as a record in case damage has been done to the machine.

After opening the crate, ensure all packages were delivered.3.

Check the machine for damage such as corrosion, dents and broken parts. If the crate was 4. delivered by boat, be sure to check for water that may have leaked in during shipment.

If any damage is found, immediately call Komax service to report the damage. Take photographs of 5. the damage for future reference.

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Version 1.0 Installation 5-1


5. Installation

Read this chapter thoroughly before beginning installation. Failure to observe this information may result in poor functioning of the Xinspect 3500ic. There are several steps in the installation process. First, the installation site must be verified. The machine must then be installed and leveled, internal connections must be made, blocked moving parts must be released and finally all pneumatic (only applicable with optional I-V curve measurement) and electrical connections must be made.

5.1 Installation Site

The installation site must be verified before beginning. Ensure that the installation site meets the following requirements:

Table 5.1.1 - Installation Site Requirements

Requirement Description/Range

Floor Structural Characteristics Level, stable surface free of vibration

Floor Load Capacity Xinspect 3500ic max. weight = 350 kg (772 lb)

Relative Humidity 10 to 90%, non condensing

Ambient Temperature 15 to 35 °C (59 to 95 °F)

Compressed Air Connection 6 to 10 bar (87 to 145 psi)

Air Consumption 20 NL/min (5.28 NGal(U.S.)/min)

Power Connection 1 x 230 VAC - 50/60 Hz

5.2 Basic Unit Setup

When installing the machine, always observe general rules of safety and accident prevention. An experienced Komax technician MUST install and put the machine into operation.

5.2.1 Installation and leveling of the machine

During installation, BE CAREFUL to electric cables of the Frame and Electrical Cabinet.

To install and level the machine (see figure 5.2.1):

Safely remove cover from the pallet.1.

Detach all protective straps and remove the packaging materials.2.

Take all boxes and loose machine parts off of the pallet and put them to one side.3.

Use a winch to lift the Frame of the machine by its lift rings (item 1) or use a fork lift to lift the 4. Frame of the machine by its fork openings (item 3).

An optional wheel kit is available to make easy the Frame movement.

While the Frame is on the lift, screw on the leveling pads (item 2) to adjust the dimension “A” to 5. 70 mm (2.76 in).

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5.2.2 Internal Connections

All electrical work MUST be done by a qualified technician. Komax assumes no responsibility for injuries due to electrical adjustments if this warning is disregarded.

Refer to electrical drawing reference STTC61000# for all details about internal connections.

Figure 5.2.1 - Lift and Level Points on the Frame

6. Make sure the surface on which the Frame will rest is clean. Place the Frame in the intended setup location.

7. Level the Frame using a spirit level and by adjusting the leveling pads (item 2). The load should be equally distributed among all leveling pads.

8. Use a fork lift to lift the Electrical Cabinet of the machine.

9. Make sure the surface on which the Electrical Cabinet will rest is clean. Place the Electrical Cabinet in the intended setup location.

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To make all internal connections:

Connect W02 orange cable (power) from the electrical motor to X13 connector of the A3 1. servodrive (item 3, figure 5.2.2).

Connect W03 green cable (resolver) from the electrical motor to X12 connector of the A3 2. servodrive (item 2, figure 5.2.2).

Connect aux. encoder cable from the magnetic probe to X11 connector of the A3 3. servodrive (item 1, figure 5.2.2).

Figure 5.2.3 - Camera Cable

4. Connect W08 grey cable from the camera to the camera link on the vision computer (see figure 5.2.3).

Figure 5.2.2 - Electrical Motor Cables

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Figure 5.2.5 - PLC

6. Connect wires from cables W04, W12, W13, W15 and W17 constituting the second bundle to the A2 PLC (see figure 5.2.5).

Figure 5.2.4 - F4, F5-F6, F7 Terminal Blocks

5. Connect wires from cables W22, W23 and W24 constituting the first bundle to the following electrical components (see figure 5.2.4):

Table 5.2.1 - Wires connections for W22, W23 and W24 cables

Wires from Cable Electrical Component

W22 F4 fuse

W23 F5-F6 fuse

W24 F7 fuse



Figure 5.2.6 - X104 Terminal Block

Figure 5.2.7 - X0V, X107 and X108 Terminal Blocks

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7. Connect wires from cables W09, W14, W16, W21 and W31 constituting the last bundle to the following components (see figures 5.2.5 to 5.2.8):

Table 5.2.2 - Wires connections for W09, W14, W16, W21 and W31 cables

Wires from Cable Electrical Component

W09 X108 terminal block

W14 X0V terminal block X107 terminal block PLC A6 backlight controller


W21 A5 current sensor


8. Connect the USB cable from A11 DAQ to the process computer (only applicable with the I-V curve measurement optional feature).

Figure 5.2.8 - A5/A6 Function Blocks



Figure 5.2.10 - Screen, Keyboard and Mouse

9. Connect screen VGA plug, mouse and keyboard USB plugs to the switch (see figure 5.2.10).

9. Connect ground cable to the screw located on the bottom of the Electrical Cabinet. Then secure it with the washer and the nut (see figure 5.2.9).

Figure 5.2.9 - Ground Cable

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5.2.3 Release of moving parts

DO NOT start up the machine before releasing of moving parts.

Figure 5.2.11 - Locked Light Panel

Remove screws locking the light panel of the I-V curve measurement (optional feature) 1. (see figure 5.2.11).

Figure 5.2.12 - Locked Camera

2. Remove all straps locking the camera (see figure 5.2.12).



5.3 Connecting the machine

All electrical work MUST be done by a qualified technician. Komax assumes no responsibility for injuries due to electrical adjustments if this warning is disregarded.

Refer to electrical drawing reference STTC61000# for all details about internal connections.

The machine must be connected to the robot, power supply and pneumatic supply (only applicable with op-tional I-V curve measurement) before operation.

5.3.1 Robot

Figure 5.3.1 - 01X105 Terminal Block

Connect wires from the robot to the X105 terminal block (see figure 5.3.1).

5.3.2 Power Supply

Connect the power cable of Electrical Cabinet to a 230 VAC – 50/60 Hz source.

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5.3.3 Air supply

Figure 5.3.3 - Air supply and exhaust plugs

To connect air supply to the machine (see figure 5.3.3):

Before connecting air supply, make sure that air hoses do not have kinks or are in the vicinity of 1. moving parts (electrical motor or cylinder).

If necessary, secure all hoses in place to prevent them from being abraded or squeezed by 2. moving parts.

Connect air supply to the air inlet plug (item 1).3.

If necessary, connect exhaust hose to the exhaust plug (item 2).4.

5.4 Final Procedures

Perform the following after the machine has been installed:

Dispose of all packaging materials in an environmentally compatible manner. ■

Keep the technical file that contains the operating instructions, technical documentations of ■accessories, mechanical, electrical and pneumatic drawings and spare parts in a suitable place.

For more information on image processing and standard accessories, refer to the specific ■instructions.

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Version 1.0 Machine Overview and Functions 6-1


6. Machine Overview and Functions

This chapter describes the assemblies and functions of the Xinspect 3500ic machine.

6.1 Overall Machine

Figure 6.1.1 - Overall Machine

The Xinspect 3500ic string tester has the two following units:

An Electrical Cabinet 1. – contains computers and electrical equipment.

A Frame2. - contains mechanical and pneumatic equipment.

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6.2 External Assemblies

6.2.1 Frame External Assemblies

Figure 6.2.1 - Frame External Assemblies

The Frame is the primary housing for all mechanical and pneumatic equipment. Few electrical equipment are housed in the Frame (most part of electrical equipment is indeed housed in the Electrical Cabinet).

Lifting Rings1. – allow for maneuverability using a crank during transportation and setup.

Mask Sensors2. – detects mask type mounted on the robot (12 cells or 6 cells) to check robot configuration.

Inspection Doors3. – allow for checks of vertical string position.

Maintenance Door4. – allows for maintenance.

Camera Door5. – allows for camera focus.

Leveling Pads6. – allow for initial setup leveling.

Fork Openings7. – allow for maneuverability using a fork lift during transportation and setup.

Exhaust Plug8. – allows exaust air to escape from the machine.

Air Inlet Plug9. – supplies compressed air to the machine.

Electrical Connection10. – provides electrical connections between the Frame and the Electrical Cabinet.

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6.2.2 Electrical Cabinet External Assemblies

Figure 6.2.2 - Electrical Cabinet External Assemblies

The Electrical Cabinet is the housing for almost all electrical equipment (few electrical equipment are housed in the Frame).

Main Switch1. – connects or disconnects the power supply from the entire electrical system. In the OFF position, power is switched off to all devices. This switch must be turned off before performing maintenance or modifications to the machine.

Power Indicator2. – indicates if machine power is available. If the indicator is OFF, the emergency stop button is pushed and no machine power (motor power and air pressure) is available.

Emergency Stop Button3. – turns machine power off and stops all machine movements.

Lock4. – allows closing the safety door; only an authorized personnel has a key to open the Electrical Cabinet.

Power Cable5. – supplies electrical power to the machine.

Fan6. – evacuates heat from the Electrical Cabinet.

Robot Connection7. - allows communication with the robot.

Electrical Connection8. - provides electrical connections between the Frame and the Electrical Cabinet.

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6.3 Internal assemblies overview

Figure 6.3.1 - Internal Assemblies Overview

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The Xinspect 3500ic string tester has the following internal assemblies:

A Probe Assembly1.

A Probe Axis2.

A Backlight3.

An I-V curve measurement (optional feature)4.

A Camera and its Support5.

A Camera Axis6.

Electrical Equipment in the Frame7.

Mask8.

Computers9.

Electrical equipment in the Electrical Cabinet10.

6.4 Internal Assemblies in the Frame

6.4.1 Probe Assembly

Figure 6.4.1 - Probe Assembly

The Xinspect 3500ic includes two probe assemblies allowing electrical connection between the machine and the string ribbons.

Each probe assembly contains:

Probes1. – inserted in the support at the operator convenience in order to correpond to string ribbon configuration (number and position of ribbons on the string).

A support2. - mounted on the probe axis. It is connected to the machine via a connector allowing the string power supply, I-V curve measurement of the string (optional feature) and sending the probe assembly code to the machine.

It is recommended to use as many probe assemblies as possible string ribbon configurations.

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6.4.2 Probe Axis

Figure 6.4.2 - Probe Axis

The Probe Axis allows an easy adjustment of the probe assemblies to correspond to the string dimension.

String dimension is related to the number of cells, type of cells and spacing between cells.

The Probe Axis contains:

A Graduated Scale1. – indicates the probe assembly position.

Two Mobile Supports2. – receive probe assemblies.

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Figure 6.4.3 - Camera and its Support

The Camera takes step by step images of the string (2 cells at the same time). These images are processed by the vision computer (Refer to paragraph 6.5.1) to measure string position related to the robot and to check the string during electroluminescence test.

The Camera and its Support assembly contains:

An Optical Window1. – protects the camera lens from process debris such as broken cells or ribbon parts.

A Support2. – mounted on the camera axis (Refer to paragraph 6.4.4); contains a magnetic probe to measure the camera position.

A Camera3. – installed on the support; the camera is supplied with 24 VDC and is linked to vision computer and electronic equipment in the Electrical Cabinet.

6.4.3 Camera and its Support

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6.4.4 Camera Axis

Figure 6.4.4 - Camera Axis

The Camera Axis allows camera movement. During the initialization of the machine, the 0 position is initialized. The camera position is accurately measured with a magnetic scale.

The Camera Axis contains:

An Electrical Motor1. – operates the equipped axis and thus the camera; driven by the A3 servodrive located in the Electrical Cabinet.

An Equipped Axis2. – contains axles and belt necessary to move the camera.

A Magnetic Scale3. – allows position measurement of the camera.

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6.4.5 Backlight

Figure 6.4.5 - Backlight

The Backlight allows the camera to take backlight pictures of the string. Cells are shown dark over a white background.

The vision computer processes these pictures to measure accurately the string position in regard to the robot. Three parameters are computed (a two-axis translation and a rotation) and sent to downstream process to properly position the string on the matrix.

The Backlight is composed of 10 LED boards in series. Each LED board contains a red LED which indicates defective lighting.

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6.4.6 I-V curve measurement

The I-V curve measurement assembly is an optional feature.

Figure 6.4.6 - I-V curve measurement

The I-V curve measurement allows the machine to flash the string and measure its response in voltage and intensity. Radiative energy level is adjustable with the software (Refer to chapter 8).

The I-V curve measurement contains:

A Light Panel (here in operation position)1. – illuminates the string with monochromatic radiation; it is composed of 12 LEDs boards driven by 12 drive boards. Each drive board includes a red LED which indicates defective LED on LED board.

Two Cylinders2. – moves the light panel in operation position or in rest position.

An Electro Valve3. – commands the two cylinders.

A Set of Hose4. – connects cylinders and electro valve to air inlet and exhaust plugs.

Electrical Equipment located in the Frame 5. – see section 6.4.7 for more details.

Electrical Equipment located in the Electrical Cabinet (not represented) 6. – contains power supplies and circuit breakers.

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6.4.7 Electrical Equipment located in the Frame

Figure 6.4.7 - Electrical Equipment located in the Frame

The Frame has the following electrical equipment:

A Set of Capacitors and Resistances1. – provides the energy needed by the I-V curve measurement flash.

A DAQ and its interface board2. – control the radiative energy level to apply to I-V curve measurement flash and acquire voltage and intensity measurement.

A Terminal Block3. - used for I/O signals from the Electrical Cabinet.

K1 Relay4. – supplies electrical power to the string or allows connection between the string and the DAQ and its interface board.

K2 Relay5. – controls capacitors charge.

K4 relay6. – adapts to string polarity.

The string acts as a diode. The current flows only in one direction.

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6.4.8 Mask

Figure 6.4.8 - Mask 12 cells

For the production of large size strings (up to 12 cells), the Mask 12 cells provides an adaptation to the robot gripper to ensure complete darkness during measurements.

For small strings (6 cells), there is an optional Mask 6 cells.

The machine automatically detects the mask type with the Mask Sensors located at the left top of the machine (see paragraph 6.2.1). The production line can thus detect a configuration error.

Figure 6.4.9 - Mask Sensors

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6.5 Internal Assemblies in the Electrical Cabinet

6.5.1 Computers

Figure 6.5.1 - Computers

The Electrical Cabinet contains two computers:

Process Computer1. – synchronizes and controls movements of the camera and the light plate of the I-V curve measurement assembly, moreover, it contains the main software used for production configuration.

Vision Computer2. – dedicated to image processing: measure of the string position related to the robot gripper, defect detection during electroluminescence test. Analyzed data allows to accept or to reject the string.

A screen with a keyboard and mouse is connected to the computers via a switch.

A key combination allows to switch from a computer to the other.

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6.5.2 Front Electrical Equipment

Figure 6.5.2 - Front Electrical Equipment

The Electrical Cabinet has the following electrical equipment in its front side:

Two UPS (Uninterruptible Power Supply)1. – allow a proper stop of the computers in case of power failure.

Circuit Breakers and Fuses2. – protects the electrical equipments.

Table 6.5.1 - Circuit Breakers and Fuses

Circuit Breaker / Fuse Protection

QF1 Main power supply

QF3 Fan

QF4 Servo axis

QF5 IV option supplies

QF6 24 VDC power supply

F1 PLC 24 VDC power supply output

F2 I/O 24 VDC power supply output

F3 Auxiliaries 24 VDC power supply output

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3. 24 VDC Power Supply – supplies camera, servodrive and PLC.

4. A PLC – controls I/O; it is connected to the two computers via two Ethernet cables.

5. A5 Current Sensor – detects the string direction.

The string acts as a diode. The current flows only in one direction.

6. A6 Backlight Controller – controls backlight flash.

7. K13 Safety Relay – activates/deactivates the machine when the emergency stop button is pushed, a door in the safety area is open or when air pressure drops.

8. A Set of Terminals Blocks:

Refer to electrical drawing reference STTC61000# for all details about terminal block connections.

6.5.3 Rear Electrical Equipment

Figure 6.5.3 - Rear Electrical Equipment

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The Electrical Cabinet has the following electrical equipment in its rear side:

An A3 servodrive1. – controls the electrical motor of the camera axis.

Power supplies for the I-V curve measurement (optional feature)2. .

Fuses3. for the I-V curve measurement (optional feature).

Fuses4. - protects power supplies outputs.

A Plug Bar with QF02 Protection5. – allows power supply of computers and other devices.

Power supply6. of the DAQ (optional feature).

A Current Controlled Power Supply7. – supplies the string with a predefined current during electroluminescence test. 6

Version 1.0 Machine Operation 7-1


7. Machine Operation

This chapter describes pre-startup checks, power up, machine operation, recovery and power down for the Xinspect 3500ic machine.

7.1 Pre-Startup Checks

The machine must be in proper condition to ensure safe operation and to prevent damage and/or injury. Always check the machine prior to each startup.

Never operate the machine if its safety devices are not working properly!

Before starting up the machine, check the following:

Electrical Connections1. - make sure that all cables are correctly connected and undamaged. Replace all damaged cables before operating! Contact Komax service if you are unsure how to replace damaged cables.

Air Supply 2. - make sure that the air pressure is set within the proper range. See chapter 2, section 2.2 - Technical Specifications.

Pneumatic Elements (Electro Valve and Cylinders) 3. - make sure that there is no visible damage to the air hoses. Listen for audible air leaks. Repair all damaged hoses before operating! Contact Komax service if you are unsure how to replace damaged hoses.

Optical Window of the Camera4. - make sure the optical window of camera is clean. Otherwise, clean it.

Emergency Stop Button5. - with the main power switched ON, test the Emergency Stop Button. When it is pushed, all machine power must switch off (motor power and air pressure) and the power indicator is lit off.

Procedures to make pre-startup checks are described in chapter 9.

Production must not start before the machine has passed all checks. A properly operating machine will eliminate downtime and save operating cost.

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7.2 Machine Initial Start Up

Figure 7.2.1 - Power Up Controls

To initially power up the machine, perform the following steps (see figure 7.2.1):

Turn on Main Switch (item 1).1.

Make sure the two UPS (item 6) are turned on. If not, turn the two UPS (item 6) on.2.

Release the Emergency Stop Button (item 5) by turning it clockwise until it pops up.3.

Turn process computer (item 2) and vision computer (item 3) on. Softwares starts automatically.4.

Make sure the Power Indicator (item 4) lits. 5.

Once all steps are completed, proceed to Section 7.3 - Machine Operation.6.

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7.3 Machine Operation

The Xinspect 3500ic is an automated string tester, all process steps during a production are indeed automatic and do not require operator actions.

Production configuration is described in chapter 8.

Tooling replacement and adjustment is described in chapter 10.

7.4 Recovery from Emergency Stop

DO NOT turn off the machine using the Main Switch. If an immediate machine stop is required, use the Emergency Stop Button.

An Emergency Stop condition can be invoked by pressing the Emergency Stop Button.

To recover from an Emergency Stop condition:

Determine the reason for the emergency stop, and remedy any problems that may exist.1.

Release the Emergency Stop Button2. by turning it clockwise until it pops up.

Acknowledge alarm message on the process computer (see chapter 8, section 8.7).3.

Make sure the power indicator lits.4.

Machine is now ready to run.5.

7.5 System Shutdown

The Xinspect 3500ic will be powered off if:

The main power supply is switched off: as the Xinspect 3500ic is integrated to a production line, a ■shutdown of the whole production line means a shutdown of the Xinspect 3500ic machine.

The main switch is turned off. ■

To shutdown the system:

Make sure the machine has completed its production cycle. If not, wait for the end of process.1.

Turn the main switch off. The two UPS send a switch off command to the computers.2.

Turn the two UPS off.3.

System shutdown is now complete.4.

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Version 1.0 Software Operation 8-1


8. Software Operation

Process computer software allow the following actions:

Machine and Software configuration (I-V curve activation, user change, parameter visualization). ■

Process Configuration (string definition, robot calibration, troubleshooting). ■

Management of Alarms. ■

Visualization of Test Results (current and history). ■

String Definition must be configured also in the vision computer software.

As the Xinspect 3500ic is an automated string tester, all process steps during a production are indeed automatic and do not require operator actions.

This chapter describes functions and use of the process computer software.

See the specific documentation for more details on functions and use of the vision computer software.

8.1 Definition of User Levels

Two user levels are available: Operator and Supervisor.

The Operator has access to the following functions:

Selection of a string type among predefined types. ■

Management of alarms. ■

Visualization of test results. ■

The Supervisor has access to the following functions:

Creation or modification of a string type. ■

Robot calibration. ■

Troubleshooting. ■

Modification of DAQ parameters (ONLY for the current session). ■

Activation or deactivation of the I-V curve measurement. ■

Management of alarms. ■

Visualization of test results. ■

Table 8.2.1 - Summary of functions per user type

Menu Function Operator Supervisor

Language Selection Language Selection X X

System Information Visualization of System Information X X

Machine Parameters Visualization of Machine Parameters (archive directories, DAQ parameters, software versions)

X X

Machine Parameters Activation/Deactivation of I-V curve measurement

X

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Table 8.2.2 - Summary of functions per user type (continued)

Menu Function Operator Supervisor

Machine Parameters User Change X X

Configuration Process Change of string type X X

Configuration Process Creation or modification of a string type X

Configuration Process Robot Calibration X

Configuration Process Troubleshooting X

Configuration Process Modification of DAQ parameters X

Reports Management of Alarms X X

History Visualization of Test Results X X

8.2 User Interface Description

Figure 8.2.1 - Main Screen

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The main screen has the six following areas:

General Menu1.

Cell Thumbnails2.

Full Size View3.

I-V Curve View4.

Process Information 5.

Recipe Information6.

8.2.1 General Menu

The General Menu gives access to all available commands (machine and software configuration, process configuration, management of alarms, visualization of test results, exit):

Figure 8.1.2 - General Menu

Displays alarms report dialogue box

Closes the software (in case of software crash)

Selects the language through a contextual menu (accessible with right click mouse button)

Selects an archived test and display associated electroluminescence pictures and I-V curve (only applicable with the optional I-V curve measurement)

Closes dialogue boxes and returns to the main screen

Opens process configuration dialogue box

Opens machine parameters dialogue box or system information dialogue box through a contextual menu (accessible with right click mouse button)

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8.2.2 Cell Thumbnails

Figure 8.2.3 - Cell Thumbnails

Cell Thumbnails area displays in single view electroluminescence pictures of all string cells and test results. The user is able to select a cell by left clicking on its picture to show the full size view.

Cell Thumbnails area has the following elements:

Cell Number1. - located in a grey box; this box is outlined in green when the cell is selected by the user.

Electroluminescence picture of the cell2. .

Test Results Bar (not represented)3. - located under cells; it indicates if the string passed or failed, dimensional analysis and positional parameters for installation on matrix.

8.2.3 Full Size View

The Full Size View area displays the full size picture of the selected cell (if no cell has been selected, cell No 1 is displayed by default). The cell number is displayed above the electroluminescence picture.

Figure 8.2.4 - Full Size View

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8.2.4 I-V Curve View

The I-V Curve View is only available when the optional I-V curve measurement is installed.

The I-V curve measurement test can be activated or deactivated using the machine parameters dialogue box (see section 8.4.2). This action requires a supervisor access level.

Figure 8.2.5 - I-V Curve View

The I-V Curve View displays:

I-V curve1. .

Characteristic values2. - maximum peak power, maximum current and voltage, fill factor, open circuit voltage, short circuit current and estimated results on sun simulator.

Archive directory path3. - for current or former test.

I-V curve and characteristic values are related to the whole string.8

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The Process Information area contains button and data that follow:

Actual Machine Status1. - not connected, waiting for power on (case of an emergency stop) and ready.

Error Red Button2. - diplayed when an error occurs.

Management of Alarms is available with the Reports button in the general menu (see section 8.7).

Actual Sub-Process Step3. - detailed steps.

Reset Button4. - allows a quick acknowledgement of errors.

Actual Process Step5. - global steps.

Actual process and sub-process steps are given for information purpose and may be useful during troubleshooting.

8.2.6 Recipe Information

Figure 8.2.6 - Process Information

8.2.5 Process Information

Figure 8.2.7 - Recipe Information

The Recipe Information area contains the following text areas:

Job ■ - allows entering the job name (batch) for archiving test data.

Recipe ■ - allows entering a recipe name (production type) for archiving test data.

String ref. ■ - indicates the string reference used for this recipe (see section 8.6.1 for more details on string definition).

Counter ■ - indicates the number of strings already processed in the job. When the job is changed, the counter is set to zero. Counter reset may also be done manually by clicking the right trackball button.

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8.3 Language Selection

The user can select a language among three languages : French, English and German. The changing is done in real time.

Right click on the language selection menu: ■

Select the desired language. ■

8.4 Machine and Software Configuration

To access to the machine and software configuration:

Right click on the configuration menu: ■

Select the “Application configuration” command. The Machine Parameters dialogue box appears with ■the default tab (“Vision” tab).

Figure 8.4.1 - Machine Parameters dialogue box

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This dialogue box contains six tabs allowing to view and set the following machine and software parameters:

Vision ■ - allows to visualize archive repertories for current and former tests.

DAQ Agilent ■ - allows to activate or deactivate I-V curve measurement (only applicable if the optional I-V curve measurement is installed).

Simulation ■ - not used (available only during factory settings).

Options ■ - not used (available only during factory settings).

Change User ■ - allows changing user levels.

About ■ - gives software versions.

An exit button located at the bottom right of the dialogue box allows the operator to close the dialogue box.

8.4.1 Vision

This tab indicates directory paths for archiving data:

Vision data directory1. - directory path on the disk used to store current test data. At the end of the test, test files are moved to the history directory.

Image history directory2. - directory path on the disk used to store former test data.

Directory paths are defined during factory settings and are given for information purpose only.

Figure 8.4.2 - Machine Parameters - “Vision” tab

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8.4.2 DAQ Agilent

Click on the “DAQ Agilent” tab in the Machine Parameters dialogue box. ■

Figure 8.4.3 - Machine Parameters - “DAQ Agilent” tab

This tab allows to activate or deactivate the optional I-V curve measurement by selecting or deselecting the related radio button.

This action requires a supervisor access level.

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8.4.3 Change User

Click on the “Change User” tab in the Machine Parameters dialogue box. ■

Figure 8.4.4 - Machine Parameters - “Change User” tab

This tab contains button, text areas and data that follow:

Current user level1. - indicates the current user level: Operator or Supervisor.

User name2. - allows the user to enter the user name with its related access level.

Password3. - allows the user to enter the password related to the user name.

Validation button4. - allows the user to validate entered user name and password.

If user name or password is wrong, no action is performed and the current user level (item 1) does not update.

Current XP user5. - indicates the current user of the Windows XP session.8

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8.4.4 About (Software Versions)

Click on the “About” tab in the Machine Parameters dialogue box. ■

Figure 8.4.5 - Machine Parameters - “About” tab

The dialogue box indicates versions for the following softwares:

String Tester software release1. - complete String Tester software.

Graphical User Interface (zenOn)2. - process computer software.

EL inspection software3. - vision computer software.

EL interface (activeX)4. - software providing the link between process and vision computers.

PLC software5. - software controlling the PLC.

8.5 System Informations

To access to the System Informations dialogue box:

Right click on the configuration menu: ■8

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Figure 8.5.1 - System Informations dialogue box

The System Informations dialogue box indicates:

Remaining free memory1. - in percentage.

Free disk size2. - in KiloBytes and percentage. When the free disk space decreases to a level within 12 and 30% (pink area), the software triggers an alarm and a caution symbol is displayed on the dialogue box. When the free disk space decreases to a level less than 12% (red area), a warning symbol is displayed on the dialogue box.


Select the “System informations” command. The System Informations dialogue box appears. ■

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8.6 Configuration Process

To access to the Production Configuration general menu:

Click on the configuration button in the menu. The general menu of the Configuration Process ■appears.

The general menu of Configuration Process contains:

String / Cells definition button1. - allows the operator to change string type and the supervisor to create or modify a string type.

Calibration Robot button2. - allows the supervisor to calibrate the robot. Calibration needs also the utilization of vision process computer.

PLC Configuration / Troubleshoot button3. - allows the supervisor to operate independantly each actuator and perform a fault analysis.

DAQ Agilent configuration button4. - allows the supervisor to modify, for the current session only, DAQ parameters such as flash intensity, flash time...(only applicable with the optional I-V curve measurement).


Figure 8.6.1 - General Menu of Configuration Process

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8.6.1 String / Cells Definition

Click on the “String / Cells Definition” button to open the String Definition dialogue box. ■

Figure 8.6.2 - String / Cells Definition dialogue box

The String / Cells Definition dialogue box contains the following areas:

String Parameters Area1. - allows to define a string.

String Management Area2. - allows to select, create or modifiy a string.

Cell Position Area3. - characteristic positions for camera movement. It is given for information purpose only.

The string parameters area (item 1) contains:

Cell n°1 position (in mm) ■ - defines the first cell position in regard to the 0 position robot (theoretically the 0 position on graduated scale). This value is equal in first approximation to string length/2 + camera offset. Accurate value is obtained using vision computer software (see specific documentation for more details).

Cells step (in mm) ■ - defines the cell size added of the gap between two cells.

Cells nb ■ - defines the number of cells in the string.

String length (in mm) ■ - defines the length of the string.

Quality ■ - defines the quality of the string among two values (A and B). The quality is included in the name of test data file stored on the disk and may be useful for statistical treatment.

Class ■ - defines a quality or finishing parameter. The class is included in the name of test data file stored on the disk and may be useful for statistical treatment.

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The string management area (item 2) contains:

A Scroll Bar ■ - allows the operator to select a string type among predefined string types or allows the supervisor to enter a string type name.

The number of predefined string types is indicated at the bottom right of the area.

Edit String button ■ - allows the supervisor to create a string type according to string parameters entered in the string parameters area and the string name entered in the scroll bar. If a predefined string has been modified, a confirmation action is needed by clicking on the “save modification” button to save definitively string change.

New ■ - allows the supervisor to create a new string type. The supervisor has then to define string parameters in the string parameters area, and enter string name in the scroll bar.

Copy ■ - allows the supervisor to copy a predefined string.

Rename ■ - allows the operator to change the name of a predefined string.

Delete ■ - allows the supervisor to delete a predefined string.

8.6.2 Robot Calibration

Click on the “Calibration Robot” button to open the Calibration Robot dialogue box. ■

Robot Calibration has to be performed during machine installation and for camera change.

Figure 8.6.3 - Calibration Robot dialogue box

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The Calibration Robot dialogue box allows the supervisor to calibrate the robot central position (X and Y positions) in regard to the camera axis. Accurate value of this position is obtained using vision computer software (see the specific documentation for more details).

8.6.3 PLC Configuration / Troubleshoot

Click on the “PLC Configuration / troubleshoot” button to open the Setup PLC dialogue box. ■

BE CAREFUL when using this function. Operation on actuators may damage the machine or wound maintenance personnel.

Figure 8.6.4 - Setup PLC Configuration dialogue box

The Setup PLC dialogue box contains the three command buttons that follow:

Manual mode1. - allows the supervisor to enter manual mode in order to independently operate each actuator and the camera axis for troubleshooting.

2. Automatic mode - allows the supervisor to come back to automatic mode. It is the default mode that initializes all actuators to get an operating machine.

PLC variable test3. - not used (allows controlling variable during factory settings).

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The Manual Mode has the following commands:

Actuator Scrollbar1. - allows the supervisor to select an actuator.

Operation Commands2. - allows the supervisor to move or stop the actuator.

Camera Command3. - allows the supervisor to operate the camera axis.

Figure 8.6.5 - Setup PLC Configuration dialogue box - Manual Mode

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8.6.4 DAQ Agilent Configuration

Click on the “DAQ Agilent Configuration” button to open the DAQ Agilent Configuration dialogue ■box.

This function is only applicable with the optional I-V curve measurement installed.

BE CAREFUL when using this function. DAQ parameters control flash duration, flash intensity and measurement parameters. Modification of DAQ parameters are ONLY valid for the current session. DAQ parameters are indeed re-initialized at every machine start-up.

Figure 8.6.6 - DAQ Agilent Configuration dialogue box

The DAQ Agilent Configuration dialogue box allows the supervisor to change DAQ parameter values. Modified values are only applicable for the current session and are re-initialized at the next machine start-up.

These parameters configure:

Flash characteritics. ■

Measurement characteristics. ■

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8.7 Management of Alarms (Reports)

At any time, an error can occured. Errors are indicated by a red button in the process information area (see section 8.2.5). An alarm is also automatically generated and may be visualizated in the Reports dialogue box.

Click on the Reports button in general menu to open the Reports dialogue box: ■

Figure 8.7.1 - Reports dialogue box

The Reports dialogue box contains the three following areas:

Alarm total number and Non Acknowledged Alarm total number1.

Alarm information display 2.

Command buttons3.

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Figure 8.7.2 - Command Buttons

Command Buttons are composed of:

Acknowledge button1. - allows the user to acknowledge the selected alarm.

Acknowledge all button2. - allows the user to acknowledge all alarms displayed on the alarm information display area.

A click on the reset button in the process information area has the same action (acknowledge all alarms).

Filtre ... button3. - allows the user to filter alarms by type, date and hour, acknowledgement or non acknowledgement.

Alarms are displayed in the alarm information display area. They are sorted out using parameters that follow:

Name ■ - alarm name.

Received ■ - date and hour of alarm receipt.

Cleared ■ - date and hour of alarm disappearence (troubleshooting).

Acknowledged ■ - date and hour of alarm acknowledgement.

Text ■ - definitive description of the error related to the alarm.

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8.8 Visualization of test Results (History)

Click on the History button in general menu to open the History dialogue box: ■

Figure 8.8.1 - History dialogue box

This function is unavailable during production. It is only available when the machine is stopped.

The History dialogue box allows the user to select a former test. Tests are included in directories organized in four levels:

First level ■ - Year.

Second level ■ - Month.

Third level ■ - Day.

Fourth level ■ - Time Stamp.

Thus the user has to know year, month, day and hour of the required test. He can simply select it by clicking on the corresponding directories: year, month, day, and finally hour. Test results are displayed in the cell thumbnails, the full size view, the I-V curve view (if applicable) and the recipe information areas of the main screen (see section 8.2).

In the final directory (Hour), test file indicate the following information:

Recipe name. ■

Job name. ■

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String quality. ■

String class. ■

If the exact hour of the required test is inknown, these information may be useful to find the test hour using a tool as Windows Explorer to find the test hour.

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Version 1.0 Maintenance 9-1


9. Maintenance

This chapter describes all maintenance procedures required to keep the Xinspect 3500ic running smoothly. Failure to preform these maintenance tasks may result in poor operation and reduced service life.

9.1 Important Maintenance Notes

Before doing maintenance or repairs, ALWAYS turn the Main Switch OFF and secure against unauthorized switch-on.

Any problems and defects detected during daily production must be remedied immediately to ensure the safety of the machine and personnel. ALWAYS replace damaged parts.

Maintenance MUST be performed at the intervals stated in this chapter to ensure trouble-free operation and long machine service life. The maintenance intervals described in this chapter are meant for three-shift operations. Lighter use may require less maintenance.

DO NOT use compressed air to clean. This will blow minuscule bits of solder debris into the surrounding tooling, increasing wear and impairing accuracy. If you must use compressed air, first remove the parts to be cleaned from the machine.

This machine is a part of a complete production line. The Frame of the machine is located in a safety area controlled by an upstream machine. Use the appropriate personal protective equipment related to the complete process.

Use the appropriate personal protective equipment when using any cleaning agents, solvents or lubricants during maintenance procedures.

Refer to mechanical, pneumatic, electrical drawings and spare parts list for more details on defective part replacement (P/N and installation).

9.1.1 Cleaning

Clean machine parts only with non-fraying, non-linting materials. DO NOT use fraying/linting materials such as cleaning wool.

9.1.2 Solvent

Clean machine parts only with isopropyl alcohol. DO NOT use abrasive solvents such as acetone, benzene or white spirit, especially on protective plastic plates.

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9.2 Maintenance Task Summary

9.2.1 Preventive Maintenance Schedule

The following preventive maintenance schedule is the minimum that should be followed for a three-shift operation. Lighter use may require less maintenance. See Section 9.3 for a detailed list of maintenance tasks.

Table 9.2.1 - Preventive Maintenance Schedule

Component Frequency Maintenance Task

Electrical Equipment Daily Check cables for good condition

I-V curve measurement (optional feature)

Daily Check pneumatic hoses for good condition

Camera and its Support Daily Clean the optical window

Electrical Cabinet Weekly Clean the fan filter

Backlight Weekly Clean protective plastic plates covering boards


Weekly Clean protective plastic plates covering the light panel

Frame Weekly Clean the bottom of the Frame with a vaccum cleaner

Probe Assembly Weekly Check the cleanliness of the probes

Probe Assembly Weekly Check the good condition of the probes

Electrical Equipment Monthly Check safety devices

Frame Every 6 months Check the darkness of the Frame

Camera and its Support Every 6 months Clean the camera lens

Probe Assembly Every 6 months or 106 cycles

Remove and replace probes

Mask 12 cells or Mask 6 cells Every 6 months Remove and replace the foam seal

Frame Yearly Check the maintenance door gasket for good condition

Mask 12 cells or Mask 6 cells Yearly Check the gasket for good condition

Camera Axis Yearly Check the motor belt for good condition

Electrical equipment Yearly Check the good condition of the two UPS

9.2.2 Corrective Maintenance

The following corrective maintenance tasks require attention and a specific procedure.

Other defective parts are of standard maintenance level. Refer to mechanical, pneumatic, electrical drawings and spare parts list for more details on part replacement (P/N, removal and replacement).

Table 9.2.2 - Corrective Maintenance Tasks

Component Maintenance Task

Electrical Equipment Remove and replace a fuse

Backlight Remove and replace a defective LED board


Remove and replace a defective LED board



9.3 Maintenance Procedures

The following procedures are organized by assembly. All maintenance requirements (daily, weekly, every 6 months, monthly, yearly or as required) are listed in parenthesis next to each part.

9.3.1 Frame

BE CAREFUL to Frame Assemblies when cleaning the bottom of the Frame.

Bottom of the Frame (weekly) - carefully clean the bottom of the Frame with a vaccum cleaner.

Maintenance Door Gasket (yearly) - make sure that the gasket for maintenance door (see figure 9.3.1) is in good condition and has no sign of wear or cracks. Otherwise, remove and replace the defective gasket; make sure the gasket covers all the mating surface of the Frame.

Figure 9.3.1 - Frame

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9.3.2 Probe Assembly

Do not apply excessive pressure to the probes.

Probes (weekly) - make sure the probes (items 1) are clean. Otherwise, handly remove dirt from dirty probes or replace the dirty probes if dirt remains.

Support (weekly) - gently push each probe (item 1) and make sure that there is no obstruction to probe movement. If an obstruction occurs:

the probe (item 1) may be defective: make sure that the probe is not twisted. Otherwise, replace ■the probe and check the probe movement again,

the support (item 2) may be defective: replace the complete probe assembly. ■

Probes (every 6 months) - remove and replace the probes (items 1) of probe assemblies.

Figure 9.3.2 - Probe Assembly

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9.3.3 Camera Axis

Figure 9.3.3 - Camera Axis

Motor Belt (yearly) - make sure that the motor belt (see figure 9.3.3) is in good condition and has no sign of wear or cracks. Otherwise replace the motor belt.

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9.3.4 Camera and its Support

Figure 9.3.4 - Camera Lens and Optical Window

BE CAREFUL when cleaning the Camera Lens. Cleaning the camera may RESULT in a wrong adjustment of the camera.

DO NOT clean the inner side of the Optical Window with isopropyl alcohol. The Optical Window is installed on the support with glue. It may RESULT in a glue spreading on the Optical Window.

It is recommended to use Chemtronics Opticwipes C920 dry swabs for Optical Window and Camera Lens cleaning.

Optical Window (daily) - clean the outer side of the optical window (item 1) with isopropyl alcohol and dry swabs. Clean the inner side of the optical window ONLY with dry swabs.

Camera Lens (every 6 months) - carefully clean the camera lens (item 2) with isopropyl alcohol and dry swabs.

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9.3.5 Backlight

Figure 9.3.5 - Backlight

DO NOT clean the Plastic Plates with abrasive cleaners such as acetone, benzene or white spirit.

DO NOT clean the Plastic Plates with liquid cleaners. There is a RISK of cleaner infiltration between Plastic Plates and the Diffuser.

Protective Plastic Plates covering Boards (weekly) - clean protective plastic plates (items 1) with dry swabs.

When a LED on Backlight is defective, an alarm message is automatically sent to the process computer software (see chapter 8, section 8.7 for more details on the management of alarms).

LED board (as required) - when a defective backlight LED is reported, do the procedure that follows:

Initiate an image acquisition with the Backlight. In the same time, check each LED board of the ■backlight for a red LED illumination.

Repeat this action as many times as necessary to identify the defective LED board. ■

Loosen and remove the four screws (items 2) which attach the protective plastic plate (item 1) ■covering the defective LED board (item 5).

Loosen and remove the four screws (items 4) wich attach the diffuser (item 3) and the defective ■LED board (item 5) to the Frame.

Loosen and remove the first and second screw of each surrounding board (item 6) to make easy ■the removal of the defective board.

Disconnect the defective LED board (item 5) and remove it. ■

Connect the new LED board to the surrounding boards. ■

Install the new LED board and the diffuser (item 3) with the four screws (item 4). Then install the ■screws (item 6) of the surrounding boards.

Install the protective plastic plate (item 1) with the four screws (item 2). ■

Make sure the alarm disappears. ■

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9.3.6 I-V curve measurement (optional feature)

Figure 9.3.6 - I-V curve measurement Light Panel

Figure 9.3.7 - Locking Screw of Light Panel



Figure 9.3.8 - LED and Drive Boards

DO NOT clean the Plastic Plates with abrasive cleaners such as acetone, benzene or white spirit.

Pneumatic Hoses (daily) - make sure that there is no visible damage to the pneumatic hoses. Listen for audible leaks. Otherwise, replace damaged hoses.

Protective Plastic Plates covering the Light Panel (weekly) - clean protective plastic plates (see figure 9.3.6) with dry swabs.

When LED on I-V curve measurement (optional feature) are defective, an alarm message is automatically sent to the process computer software (see chapter 8, section 8.7 for more details on the management of alarms).

LED board (as required) - when a defective I-V curve measurement LED is reported, do the procedure that follows:

Operate the light panel of the I-V curve measurement to its operation position (see chapter 8, ■section 8.6.3 for more details on troubleshootings). Then install the locking screw (see figure 9.3.7) to maintain the light panel in the operation position.

Initiate an image acquisition with the I-V curve measurement (IL test). In the same time, check ■each drive board (item 3, figure 9.3.8) of the I-V curve measurement for a red LED illumination.

Repeat this action as many times as necessary to identify the defective LED board (item 1, figure ■9.3.8).

Remove the locking screw (see figure 9.3.7) to release the light panel. Then operate the light ■panel of the I-V curve measurement to its rest position.

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9.3.7 Mask 12 cells and Mask 6 cells (optional feature)

Figure 9.3.7 - Mask Gasket and Seal

Mask 6 cells is an optionnal feature. However, maintenance tasks are valid for both masks (12 cells and 6 cells).

Foam Seal (every 6 months) - remove the foam seal (item 2) from the mask. Then, clean the mating surface and make sure there is no residue on it. Install the new sticker foam seal on the mating surface of the mask and make sure the foam seal covers all the mating surface.

Gasket (yearly) - make sure that the gasket (item 2) of the mask is in good condition and has no sign of wear or cracks. Otherwise, remove and replace the defective gasket. Make sure the gasket covers all the mating surface of the mask.

Disconnect the connectors (items 2, figure 9.3.8). Then loosen and remove the four nuts (items ■4, figure 9.3.8) which attach the defective LED and drive boards to the Frame.

Remove the defective LED and drive boards. ■

Install the new LED and drive boards with the four nuts. ■

Connect the new LED and drive boards. ■

Make sure the alarm disappears. ■

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9.3.8 Electrical Cabinet

Figure 9.3.8 - Fan Filter in Electrical Cabinet

Fan Filter (Weekly) - remove the cover from the fan. Then, remove the fan filter (see figure 9.3.8) and clean it with compressed air. If needed, replace the fan filter.

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9.3.9 Electrical Equipment

Electrical Cables (daily) - make sure that all cables are correctly connected and undamaged. Otherwise, replace damaged cables.

Safety Devices (monthly) - check the good condition of safety devices:

Operate an emergency condition on production line (emergency stop button of the upstream ■machine, door opening of the safety area...) and make sure that the safety devices work properly by turning the machine power off. Otherwise, check electrical connection and K13 safety relay, replace it if necessary.

Operate the emergency stop button located on the Electrical Cabinet and make sure that the ■safety devices work properly by turning the machine power off. Otherwise, check electrical connection and K13 safety relay, replace it if necessary.

Disconnect air supply and make sure that the safety devices work properly by turning the ■machine power off. Otherwise, check electrical connection and K13 safety relay, replace it if necessary.

UPS (yearly) - make sure that the two UPS (see figure 9.3.9) are in good condition and work properly (“Defective Battery” LED must not be lit). Otherwise, replace the defective UPS.

Circuit Breakers and Fuses (as required) - remove and replace any defective circuit breaker or fuse.

Refer to electrical drawings for more details about circuit breaker and fuse characteristics.

Figure 9.3.9 - UPS

Version 1.0 Tooling Replacement / Product Changeover 10-1


10. Product Changeover / Tooling Replacement & Adjustment

This chapter describes all procedures necessary to replace and adjust tooling. The three following cases are considered:

Setting of the machine at first use. ■

New production definition. ■

Production change. ■

10.1 Setting of the machine at first use

At machine first use, perform the following settings:

Insert probes in the support of the probe assemblies to correspond to string ribbon configuration 1. (number and position of ribbons on the string).

If necessary, install the probe assemblies on the probe axis with two screws, two washers and two 2. lock washers. Connect the connector.

Position a reference string on the machine with the robot (see the specific documentation of the 3. robot).

Loosen and remove the screws of the two inspection doors, then remove the inspection doors.4.

Figure 10.1.1 - Vertical String Position

5. Using marks on the two probe assemblies (see figure 10.1.1), make sure that the vertical string position is in the correct position: the arrow must be within the two marks. If not, adjust the robot position (see the specific documentation of the robot).

6. Install the two inspection doors with the screws and washers.

7. Using the graduated scale, adjust the probe assemblies’ position at the correct string dimensions.

String dimension is related to the number of cells, type of cells and spacing between cells.

8. Perform a new production setting (see section 10.2).

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Version 1.0 Tooling Replacement / Product Changeover 10-2


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10.2 New Production

The Xinspect 3500ic must be adjusted to the string parameters when starting a new production.


When starting production, perform the following settings:

Adjust the two probe assemblies to correspond to string ribbon configurations with one of the two 1. methods:

Insert probes in the support of the probe assemblies to correspond to the new string ribbon ■configuration.

Or remove and replace the probe assemblies if a set of probe assemblies exists for this ■configuration.

Adjust the probe assemblies’ position at the correct string dimensions.2.

Enter string parameters (cell no 1 position, cell step, cell number, string length and quality 3. parameters if necessary) in the software of the process computer (see chapter 8, section 8.6.1).

Enter string parameters in the software of the vision computer (see specific documentation for more 4. details on fuctions and use of the vision computer software).

10.3 Production Change

The Xinspect 3500ic must be adjusted to the string parameters when changing production.


When changing production, perform the following settings:

Adjust the two probe assemblies to correspond to string ribbon configurations with one of the two 1. methods:

For a rare configuration: insert probes in the support of the probe assemblies to correspond to ■the new string ribbon configuration.

For common configuration: remove and replace the probe assemblies if a set of probe ■assemblies exists for this configuration.

Adjust the probe assemblies’ position at the correct string dimensions.2.

Select a predefined string configuration in the software (see chapter 8, section 8.6.1).3.

Select a predefined string configuration in the vision computer (see specific documentation for more 4. details on fuctions and use of the vision computer software).

Documents

Xinspect 3500ic Operating Instructions - Version 1.0 May 2010