TR7700 SIII 3D

High-Speed Automated Optical Inspection System

User Guide – Maintenance

Ver 2.0
Jan 12, 2015
Original Instructions
 Test Research, Inc.

TR7700 SIII 3D – Automated Optical Inspection System

User Guide – Maintenance
Original Instructions

Copyright © 2015 Test Research, Inc. All rights reserved.

This document may be printed or photocopied only by customers or authorized agents of

Test Research, Inc. (TRI) for sole use by their employees working with TRI test systems.
Any other use of this document must be approved by TRI.

The following are trademarks or registered trademarks of Test Research,

Inc.

The absence of a product or service name or logo from this list does not
constitute a waiver of TRI’s trademark or other intellectual property rights
concerning that name or logo.
All other trademarks and trade names are the property of their owners.

Specifications and software are subject to change without notice. TRI will make all best
efforts to let existing customers know of any product upgrade, change or phase-out.

For any comments/corrections to this guide, please address them to –

sales@tri.com.tw
with “TR7700 SIII 3D User Guide – Maintenance” in the Subject field.

www.tri.com.tw

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WARNING: Risk of electric shock and mechanical injury. Only fully

trained persons should be allowed to take part in the installation
process.

WARNING: Do not reach in the machine when it is operating.

WARNING: When TRI created the test system software CD, it

contained no known viruses. The software on the TRI CD was checked
by the latest anti-virus software before being copied to the disk.
Customers should use a good, up-to-date virus checker on this TRI
software, and any other file you import from an outside source before
using the software. Please also ensure your virus checker’s data files
are up to date.

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Table of Contents
1 INTRODUCTION OF MACHINE ______________________________________5
1.1 Front View ............................................................................................. 5
1.2 Left View ............................................................................................... 6
1.3 Right View ............................................................................................. 7
1.4 Rear View.............................................................................................. 8
1.5 Interior of Front Cover ........................................................................... 9
1.6 Interior of Front Door ........................................................................... 10
1.7 Interior of Rear Door ........................................................................... 11
2 SAFETY LABELS _____________________________________________12
3 DAILY MAINTENANCE __________________________________________15
3.1 Checking Signal Tower Lighting and Buzzer ....................................... 15
3.2 Checking Environment ........................................................................ 16
3.3 Checking Main Power Connection ...................................................... 16
3.4 Checking Fans Operation ................................................................... 17
3.5 Cleaning Machine Interior ................................................................... 17
3.6 Checking Emergency Stop Function ................................................... 18
4 WEEKLY MAINTENANCE ________________________________________19
4.1 Checking Motor and Sensor Connections ........................................... 19
4.2 Checking Key Switch Emergency Stop Function ................................ 21
4.3 Cleaning Conveyor Feed Belt ............................................................. 21
4.4 Checking Air Pressure Regulator ........................................................ 21
5 MONTHLY MAINTENANCE _______________________________________23
5.1 Cleaning Filters on the Front/Rear Doors ............................................ 23
5.2 Cleaning Conveyor Shafts .................................................................. 23
5.3 Cleaning and Testing the Sensors ...................................................... 24
5.4 Lubricating Linear Guide ..................................................................... 25
5.5 Lubricating Ball Screws ....................................................................... 27
5.6 Cleaning Rear Fans ............................................................................ 28
5.7 Checking Gray Level of Lighting ......................................................... 29
5.8 Cleaning LCD Monitor ......................................................................... 29

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6 QUARTERLY MAINTENANCE _____________________________________30

6.1 Lubricating Ball Screws ....................................................................... 30
6.2 Checking the Feed Belt Elasticity ........................................................ 30
6.3 Lubricating Conveyor Spring ............................................................... 30
7 HALF YEAR MAINTENANCE ______________________________________31
7.1 Check if the Conveyor Belts are Loosened or Hardened .................... 31
8 ANNUAL MAINTENANCE ________________________________________32
9 MAINTENANCE CHECK TABLE ____________________________________33

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Table of Figures
Figure 1: The Front View of TR7700 SIII 3D .......................................................5
Figure 2: The Left View of TR7700 SIII 3D..........................................................6
Figure 3: The Right View of TR7700 SIII 3D .......................................................7
Figure 4: The Rear View of TR7700 SIII 3D ........................................................8
Figure 5: Interior of the Front Cover ....................................................................9
Figure 6: Interior of the Front Door ....................................................................10
Figure 7: Interior of the Rear Door ....................................................................11
Figure 8: Mechanical Caution Label ..................................................................12
Figure 9: Mechanical Hazard Label ...................................................................12
Figure 10: Specific Voltage Sign .......................................................................13
Figure 11: Entanglement Hazard Sign ..............................................................13
Figure 12: Laser Radiation Sign ........................................................................13
Figure 13: Electrical Grounding Signs ...............................................................14
Figure 14: Loading Caution Sign .......................................................................14
Figure 15: Light and Buzzer Diagnostic Page in HMI ........................................15
Figure 16: Checking the Signal Tower Light ......................................................16
Figure 17: Checking the Power Cables .............................................................16
Figure 18: Checking the Rear Fans...................................................................17
Figure 19: Cleaning the Machine Interior ..........................................................17
Figure 20: Emergency Stop Positions ...............................................................18
Figure 21: Checking If the Emergency Stop Works ...........................................18
Figure 22: Checking the Front Panel Connections ............................................19
Figure 23: Checking the Rear Panel Connections ............................................19
Figure 24: Checking the Sensor/ Motor Cord Connections ...............................20
Figure 25: Checking the Key Switch Emergency Stop Function .......................21
Figure 26: Checking the Air Pressure Regulator ...............................................22
Figure 27: Wiping the Conveyor Shafts .............................................................23
Figure 28: Cleaning the Sensors .......................................................................24
Figure 29: Yamada Grease Pump .....................................................................25
Figure 30: NSK Grease .....................................................................................25
Figure 31: Grease Nipples on X Axis (Left) .......................................................25
Figure 32: Grease Nipples on X Axis (Right) .....................................................26
Figure 33: Grease Nipples on Y Axis (Left) .......................................................26
Figure 34: Grease Nipples on Y Axis (Right) .....................................................26
Figure 35: Grease Nipples on X Axis Ball Screws .............................................27
Figure 36: Y Axis Ball Screws ...........................................................................28
Figure 37: Cleaning Rear Fans .........................................................................28

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Figure 38: Cleaning Rear Fans .........................................................................29

Figure 39: Cleaning LCD Monitor ......................................................................29
Figure 40: Lubricating Conveyor Spring ............................................................30

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1 INTRODUCTION OF MACHINE
For maintenance purpose, this chapter will introduce the machine appearance and interior
allocation.

1.1 Front View

Signal Tower

Monitor
Control Panel

Front Cover Emergency Stop

Power Switch

Keyboard
Mouse

Front Door
Front Door Lock

Floor Stand

Figure 1: The Front View of TR7700 SIII 3D

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1.2 Left View

Fans

Board in/out
Conveyor

Figure 2: The Left View of TR7700 SIII 3D

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1.3 Right View

Maintenance
Openings

Figure 3: The Right View of TR7700 SIII 3D

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1.4 Rear View

Signal
Tower

Rear
Cover
Emergency
Stop

Left Rear Fans Right Rear

Fans

Network
Port

Rear Door Mains Power

Socket

Air
Pressure
Regulator Breaker

I/O Ports

Figure 4: The Rear View of TR7700 SIII 3D

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1.5 Interior of Front Cover

Optical
X Axis System

3D Laser
Devices
Y Axis

Gray Card

Conveyor
Motor Conveyor Width
Adjustment
Wheel

Figure 5: Interior of the Front Cover

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1.6 Interior of Front Door

The front door allocation is shown as figure below.

Lighting
Control
Box

Main
PC

Power Supply

Figure 6: Interior of the Front Door

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1.7 Interior of Rear Door

The front door allocation is shown as figure below.

Stepper Motor Drivers XY Stage Servo Motor

Drivers

Terminal

PLC

EMI Filter

Air Pressure
Regulator

Contactor Copper Plate Grounded Module Board

Figure 7: Interior of the Rear Door

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2 SAFETY LABELS
To protect the personal safety and smooth operation of the machine, the safety labels are
stuck on the machine. The meaning of each label is described below.

 Caution Sign, "Watch Your Head": Warns operators of hazardous situations that, if not
avoided, could result in severe injury.

Figure 8: Mechanical Caution Label

 Warming Sign, “Mechanical Hazard”: Warns hazardous shock will cause severe injury
or death. Turn off power and lock out before approaching robot.

Figure 9: Mechanical Hazard Label

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 Specific Voltage Sign: Warns there is 24 ~240 Volts DC or AC in this area. Contact may
cause electrical shock and injury. Disconnect power before servicing.

Figure 10: Specific Voltage Sign

 Entanglement Hazard Sign: Warns moving parts can crush and cut. Do not operate with
guard removed. Lockout/tagout before servicing.

Figure 11: Entanglement Hazard Sign

 Laser Radiation Sign: Warns users not to stare at the light to prevent the visual damage.

Figure 12: Laser Radiation Sign




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 Electrical Grounding Sign: Indicates protective earth ground in this area.

Figure 13: Electrical Grounding Signs

 Loading Caution Sign: Warns users do not sit in this area. The overweight loading will
cause the damage of machine.

Figure 14: Loading Caution Sign

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3 DAILY MAINTENANCE

3.1 Checking Signal Tower Lighting and Buzzer

After turning on the power, double click under the TRAOI main program folder
to enter the human machine interface (HMI). In HMI, choose page [light and buzzer
diagnostic] and then check color to see if the corresponding light works properly.

Figure 15: Light and Buzzer Diagnostic Page in HMI

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Figure 16: Checking the Signal Tower Light

3.2 Checking Environment

Check the environment and remove any dangers (for example, water, exposed cords, screw,
etc.) Moreover, check if the voltage, temperature and humidity are normal.

3.3 Checking Main Power Connection

Check if all the wires and power cables are connected properly.

Figure 17: Checking the Power Cables

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3.4 Checking Fans Operation

Check if all the fans on the rear doors operate properly and are not blocked.

Figure 18: Checking the Rear Fans

3.5 Cleaning Machine Interior

Confirm there is no foreign matter or interference which will influence the inspection inside
the machine.

Figure 19: Cleaning the Machine Interior

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3.6 Checking Emergency Stop Function

Press the front and rear emergency stops to test if the emergency stop function works
properly. When the emergency stop button is pressed, the red light on the signal tower and
the alarm will be triggered. After the function has been tested, turn the emergency stop
button clockwise to reset it, and then press [Reset] button on the control panel to return to
the standby mode.

Figure 20: Emergency Stop Positions

Figure 21: Checking If the Emergency Stop Works

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4 WEEKLY MAINTENANCE
Warning: Except for the specific parts mentioned in the manual, the power MUST be
turned off during the maintenance. Incorrect actions could induce the severe
mechanical or electrical injury

4.1 Checking Motor and Sensor Connections

Check if the cords and sockets in the front panel and rear panel are properly connected.

Figure 22: Checking the Front Panel Connections

Figure 23: Checking the Rear Panel Connections

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Figure 24: Checking the Sensor/ Motor Cord Connections

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4.2 Checking Key Switch Emergency Stop Function

Test if the key switch on the front door works properly. Turn the lock key to [Enable], close
the front and rear doors, and start to run the machine. If the protection system works
properly, the machine will stop inspection while the doors are opening. Moreover, the signal
tower should display in red color, the buzzer should be alarmed, and the HCI should show
the red screen. After checking all the devices work normally, press [Reset] on the control
panel. The system will return to the operation status.

Figure 25: Checking the Key Switch Emergency Stop Function

4.3 Cleaning Conveyor Feed Belt

Clean dirty and residual flux on the conveyor feed belt by a dry, clean and soft cloth.

4.4 Checking Air Pressure Regulator

Check if the air pressure is higher than 0.4MPa. (The upper limit is 0.6MPa.)

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Figure 26: Checking the Air Pressure Regulator

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5 MONTHLY MAINTENANCE
Warning: Except for the specific parts mentioned in the manual, the power MUST be
turned off during the maintenance. Incorrect actions could induce the severe
mechanical or electrical injury

5.1 Cleaning Filters on the Front/Rear Doors

Use an air gun or a vacuum cleaner to remove out the dust on the filters.

5.2 Cleaning Conveyor Shafts

Turn off the power and remove the dust on the conveyor shafts and wheels. Moreover, use
scouring oil to clean the shaft and wheel surface.

Figure 27: Wiping the Conveyor Shafts

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5.3 Cleaning and Testing the Sensors

Clean sensors 1, 2, 3, and 4 and test if the sensitivity is adjusted properly.

Figure 28: Cleaning the Sensors

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5.4 Lubricating Linear Guide

Use Yamada grease pump and NSK grease to lubricate the X and Y linear guides by filling
the grease to the grease nipples.

Figure 29: Yamada Grease Pump

Figure 30: NSK Grease

Figure 31: Grease Nipples on X Axis (Left)

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Figure 32: Grease Nipples on X Axis (Right)

Figure 33: Grease Nipples on Y Axis (Left)

Figure 34: Grease Nipples on Y Axis (Right)

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5.5 Lubricating Ball Screws

Use Yamada grease pump and NSK grease to lubricate X axis ball screw by filling the
grease to the grease nipples, and use a dry, clean and soft cloth with grease to wipe Y axis
ball screws.

Figure 35: Grease Nipples on X Axis Ball Screws

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Figure 36: Y Axis Ball Screws

5.6 Cleaning Rear Fans

Use an air gun or a brush to clean the dust on the rear fans, and then wipe them with a dry,
clean, and soft cloth.

Figure 37: Cleaning Rear Fans

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5.7 Checking Gray Level of Lighting

Figure 38: Cleaning Rear Fans

5.8 Cleaning LCD Monitor

Turn off the power and wipe the LCD monitor gently with a dry, soft and clean cloth.

Figure 39: Cleaning LCD Monitor

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6 QUARTERLY MAINTENANCE
Warning: Except for the specific parts mentioned in the manual, the power MUST be
turned off during the maintenance. Incorrect actions could induce the severe
mechanical or electrical injury

6.1 Lubricating Ball Screws

Use Yamada grease pump and NSK grease to lubricate X axis ball screw by filling the
grease to the grease nipples, and use a dry, clean and soft cloth with grease to wipe Y axis
ball screws. Please refer to 5.5.

6.2 Checking the Feed Belt Elasticity

Check if the feed belt can transport the test board smoothly. When the feed belt elasticity is
too loose or tight, please adjust its elasticity to meet the transport need.

6.3 Lubricating Conveyor Spring

Use a dry, clean and soft cloth with grease to wipe conveyor spring.

Figure 40: Lubricating Conveyor Spring

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7 HALF YEAR MAINTENANCE

7.1 Check if the Conveyor Belts are Loosened or Hardened

Check if conveyor belts are loosened and influence the board transport. When conveyor
belts are hardened, please replace them immediately.

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8 ANNUAL MAINTENANCE
Annual maintenance includes adjustment and calibration of the optical system. The
maintenance has to be conducted by a TRI-certified engineer using the TRI-issued standard
calibration procedure. This procedure is not introduced in this manual, and is only available
through TRI Field Application Engineering (FAE).

Notice: Moving the machine could cause the inspection inaccuracy. Please contact TRI FAE
to do the optical calibration procedure after the move.

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9 MAINTENANCE CHECK TABLE

In this chapter, we provide a maintenance check table for users to run the maintenance in
different time period mentioned above. Following the maintenance check table to run the
maintenance can protect the personal safety and smooth operation of the machine.

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 TR7700 SIII 3D AOI MAINTENANCE RECORD
Line: Month:
NO Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 Check Signal Tower Lighting and Buzzer
2 Check Environment
3 Check Main Power Connection
Daily

4 Check Fans Operating

5 Clear Objects Inside Machine
6 Check Emergency Stop Procedure
1 Check the Motor and Sensor Connection

2 Check the Key switch Process

Weekly

3 Clean the belts on Conveyer

4 Clean Air Filter

1 Clean Filters on Front doors
2 Check and Clean Wheels of Conveyor
3 Clean the Sensors
Month

4 Lubricate Linear Guide

5 Clean and Lubricate ballscrews (7500)
6 Clean Fans
7 Check the Optical Gray Level
8 Clean LCD Monitor

Prepared Technician

Approve Leader or Enginner

Remark 1.TECHNICIAN NEED TO CHECK THE ITEM BEFORE WORKING 2.MARK: V OK X NG △ PAY ATTENTION
 AOI MAINTENANCE RECORD
Line: Year:
NO Item 1 2 3 4 5 6 7 8 9 10 11 12 Note

1 Clean and Lubricate ballscrews

2 Check Elasticity of Conveyer Belts

3 Check Conveyer spring and lubricate

5
Quarter

10

11
Check if the Conveyer Belts are hardened or loosened.
1
Half an Year

(Change for new belts)

2 Check the Shock absorbers

1 Annual Maintenance (TRI)

Annual

Moving Machine ( Please Contact the TRI

2
Calibration)

Prepared Technician

Approve Leader or Enginner

Remark 1.TECHNICIAN NEED TO CHECK THE ITEM BEFORE WORKING 2.MARK: V OK X NG △ PAY ATTENTION