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Studen t Guide HS-50 A dvanced I 06/200 2 Edition 20 App endix 15 Servo on: green LED 20 Normally on w hen the axis ON/OFF swi tch i s in the ON position a nd the axis i s ena bled. The LED for the Dp-axis is on ly on wh…

06/2002 Edition Student Guide HS-50 Advanced I

20 Appendix

20.4.2 Overview of LEDs used throughout the machine

Throughout the machine there are a number of control and monitoring PCBs that have visible

LEDs fitted that indicate the status of various objects. These LEDs are useful when first line trou-

ble shooting as a quick check on the machine status at any one time. Listed below are the various

items that have LEDs visible, together with the normal status of the LED and what it indicates.

Please refer to the machine overview section of this student guide for an indication of the location

of the items within the machine.

20.4.2.1 Axis Control Board

Counting error: red LED 20

Normally off. It lights up In the HS-50, only at the moment of error, then it is off again. This can be

used to isolate the problem to the ribbon cable or a location on the scale. The error can be caused

by: an encoder that is dirty, defective, or not adjusted properly; a dirty scale; a problem with the

feedback system from the encoder; a defective ribbon cable, axis board, or other boards involved.

General error: red LED 20

Normally off. Lights on a system hardware electronics error. Can only be cleared by cycling the

machine off then on. The board or power supply may have a problem if the error does not clear.

Zero pulse: green LED 20

Normally on when the axis is exactly at zero pulse (home) position. The LED will not be lit if the

axis is in any other position than ”home”. The zero pulse is used for the reference run. The count-

ing system of the axis card is initialized by the negative value of the zero-point correction value in

the file achs_ver.ma when the encoder has detected the reference pulse.

Initialized: green LED 20

Normally on. LED lights when its designated axis has successfully run a reference run. The sys-

tem becomes initialized the instant the zero-pulse has been found and the zero-point correction

value has been loaded into the axis card.

End signal: green LED 20

Normally on when an end signal has been received. Off again after the next start signal. The LED

remains off during movement from start to target position. An end signal occurs when the axis has

completed its travel, and is stable about it’s position, after which the LED remains on.

Student Guide HS-50 Advanced I 06/2002 Edition

20 Appendix

Servo on: green LED 20

Normally on when the axis ON/OFF switch is in the ON position and the axis is enabled. The LED

for the Dp-axis is only on when it is engaged to turn the segment. The software switches off the

gantry axes after a predetermined amount of time (approx. 2min.) if operations stop. The LED will

also go off if the gantry axes is moved to the service position. A lit LED does not necessarily indi-

cate a good servo.

20.4.2.2 Anti-crash board

X-axis gantry 1: green LED 20

Normally on. LED will extinguish when the X-axis braking proximity switch on gantry 1 changes

state when the speed is greater than 5. The X-axis is disabled and brought to a very quick stop by

the dynamic brake and the LED is extinguished if the axis exceeds 40% of maximum speed within

8 cm of the stop (in the direction of the small buffer close to the X-motor). The anti-crash board

does not protect the other end of the gantry. A full crash situation may occur offset only by the

large buffer at that end.

X-axis gantry 2: green LED 20

Normally on. LED will extinguish when the X-axis braking proximity switch on gantry 2 changes

state when the speed is greater than 5. The X-axis is disabled and brought to a very quick stop by

the dynamic brake and the LED is extinguished if the axis exceeds 40% of maximum speed within

8 cm of the stop (in the direction of the small buffer close to the X-motor).

Y-axis gantry 1: green LED 20

Normally on. LED will extinguish when the Y-axis braking proximity switch on gantry 1 changes

state when the speed is greater than 4. The Y-axis is disabled and brought to a very quick stop by

the dynamic brake and the LED is extinguished if the axis exceeds 40% of maximum speed within

8 cm of the stop (working in both directions). The same happens to both y-axes if they travel at a

speed more than 10% of maximum speed and have approached each other to less than 10 cm.

Y-axis gantry 2: green LED 20

Normally on. LED will extinguish when the Y-axis braking proximity switch on gantry 2 changes

state when the speed is greater than 4. The Y-axis is disabled and brought to a very quick stop by

the dynamic brake and the LED is extinguished if the axis exceeds 40% of maximum speed within

8 cm of the stop (working in both directions). The same happens to both y-axes if they travel at a

speed more than 10% of maximum speed and have approached each other to less than 10 cm.

06/2002 Edition Student Guide HS-50 Advanced I

20 Appendix

Distance sensor: green LED 20

Normally on. The LED will go off as soon as the gantries have approached each other to less than

4 cm. The anti-crash board monitors the speed of both gantries in this range. All gantry-axes are

disabled and all LED’s of the anti-crash-board are also off if the speed is more than 10% of max-

imum speed while the gantries are moving toward each other. If you run into a ”crash situation” on

gantry 1 to gantry 2, all LED’s are off but the lowest LED may be ON because of the distance the

bumpers create after the ”crash bump.” The gantries will continue in their original course and

crash into each other if the Anti-crash board reset is pressed immediately. Therefore: Press RE-

SET only after pressing an E-stop!

20.4.2.3 Servo Amplifier Boards

Ready: green LED 20

Normally on. Indicates servo system is ready to process.

Output stage release (servo ON): green LED 20

Normally on when the axis ON/OFF switch is in the ON position and the servo is enable. This LED

should light when the Servo ON LED on the Axis Control Board is on.

I r.m.s. Limiting (over current): yellow LED 20

Normally off. Lights when the axis servo system is drawing excessive (maximum) current. The

limit is based on the motor’s capacity and is set on the Servo-board by a fixed resistor. This indi-

cation can be caused by too much p-gain; a short-circuit in the motor or servo amplifier; or a nozzle

on the head which is too long (Z axis).

Fault: red LED 20

Normally off. Lights when axis servo system has incurred a fault such as an over voltage or under

voltage condition.

20.4.2.4 Ballast card

Over current: yellow LED 20

Normally off. LED will light when current is being shunted to the ballast card. A feedback effect

from the motor raises power supply levels of the servo amplifier during deceleration. The ballast

card compensates for this effect by channeling the extra current into a bank of large resistors and

dissipating it in the form of heat. On S23/S20/S15 it is used to stabilize the power supply for the

y-axis, and depending on machine type the X-axis too, during deceleration. On F3/F4/F5 it is used

to stabilize the power supply for both axes. The X-axis is included because the gantry has more

inertia due to carrying both the revolver and IC heads. The HS 50 uses this on the X and Y axes

because all 4 gantries are on the same power supply. A feed back effect to the power supply may

occur turning ”ON” the ballast board switch if more than 1 axis is decelerated at the same time.