QX500 Hardware Manual - Compressed

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QX500
Hardware Manual
Notice
The QX500 is an inspection device intended for use in SMT production environment. Use of this
equipment in a manner not specified in the operating instructions may impair safe operation.
Information in this document is subject to change without notice. CyberOptics Corporation may make
improvements or changes in the products described in this publication at any time.
Trademarks
The following are trademarks or registered trademarks in the United States and other countries:
CyberOptics, Statistical Appearance Modeling (SAM), QX500 are owned by CyberOptics Corporation;
Microsoft and Windows are owned by Microsoft Corporation; Acronis is owned by Acronis Inc.
Warranty, License, and Terms of Sale

The warranty, software license and other terms and conditions of sale covering CyberOptics products are
set forth in CyberOptics Standard Terms and Conditions of Sale and License available at www.cyberoptics.com
or by calling CyberOptics at 1-800-526-2540 and requesting a copy.
QX500 Hardware Manual (Original Instructions)

Part Number 8015676, Revision B
April 2010
©2010 CyberOptics Corporation. All Rights Reserved.
Table of Contents
preface vii
Prerequisite Knowledge vii
Documentation vii
Manual Change Request vii
Technical Support ix
1 Safety 1
Safety Guidelines two
General Guidelines two
Emergency Stop 3
QX500 4 Lockout
Safety Interlocks on the Top Cover 5
Indicator Lights 6
Compliance 6
Disposal Waste 7
Preparing machine for disposal 7
Disposal of individual components 7
Safety and Conformity Labeling 8
Optical Radiation Safety Labels 8
Mechanical Safety Labels 9
Electrical Safety Labels 11
Manufacturing Information Compliance 13
2 System Overview 15
QX500 System 16
QX500 Unit 16
QX500 Rear View 18
QX500 Internal Parts 19
Main Electrical Panel 21
Conveyor 23
System Specifications 24
System Requirements 25
Performance Specifications 26
Computer Requirements 26
dimensions 27
3 Installation 29
Packing the QX500 System 30
Unpacking the QX500 System 33
Choosing a Location 34
Installing the System 35

Installing the Light Pole 35
Positioning / Leveling the QX500 System 36
CyberOptics Corporation
Contents
Installing the Sensor (SIM Module) 40

Wiring QX500 for Power 43
Turning on System Power 45
Connecting SMEMA Cables 46
Connecting to a Network 47
Conveyor Adjustment 48
Manually Adjusting the Conveyor Width 48
Adjusting the Conveyor Width Automatically 49
Aligning the QX500 System 56

Shutting Down the System 59
Moving the QX500 System 60
Disconnecting Utilities from the System 60
Bypassing the QX500 System 60
4 Replacing Components and Preventive Maintenance 61

Maintenance Schedule 62
Replacing Electrical Cables 65
Replacing the AC Main Circuit Breaker 66
Replacing the Fuses 68
Replacing Fans 70
Preventive Maintenance 71
Processor Components 73
Replacing Cards 73
Software Upgrades 74
Restoring system disk using Acronis 75
Conveyor Components 83
Replacing the Conveyor Belts 83
Replacing the Tensioner Pulley 87
Replacing the Conveyor Motors 89
Other Components 92
Replacing the Safety Interlock Switch 92
Replacing Leveling Feet 94
5 Troubleshooting 95
Safety Circuit Block Diagram 96
AC and DC Distribution Block Diagram 97

SMEMA Connector Pinout 98
Appendix 99
EU Declaration of Conformity 100
Microstep Driver Setting Diagram 101
QX500 I/O List 102
iv QX500 Hardware Manual

Contents
Index 105
CyberOptics Corporation v
Contents
saw QX500 Hardware Manual

preface
preface
This QX500 Hardware Manual is intended to provide comprehensive information about the
QX500 system.
If you have any questions that are not answered by this guide, contact CyberOptics Customer
Service and Support. Refer to “Technical Support” on page ix.
Prerequisite Knowledge
• Moderate computer experience
• Moderate Windows® experience
Documentation
Documentation for the QX500 Automated Optical Inspection system consists of the following
information:
• QX500 Hardware Manual
Provides an overview of QX500 components, instructions for how to install and maintain the
QX500 system, parts replacement information, and system specifications.
• QX500 Programmer Online Help
Provides task-based, step-by-step procedures and descriptions of the software controls for the
Programmer application.
• QX500 Inspection Online Help
Provides task-based, step-by-step procedures and descriptions of the software controls for the
Operator and Reworker applications.
Manual Change Request

Every effort has been made to provide complete and accurate information for operating and
maintaining the QX500 system. If you have suggestions for improvements or find an inaccuracy,
please complete the manual change request form on page viii and forward your suggestions to
CyberOptics.
Note: Include a copy of the change request form on the following page and, if applicable, a copy
i of the page with the error marked.
CyberOptics Corporation vii

Manual Change Request
Originator: Gives you:
Company Name:
Address:
City/State/
Province:
Zip/Postal Code:
Country:
machine Serial Number Software Version
Manual Revision/Date Page No. or Figure No.
Check if page is attached
Suggestion:
Fax or email to:

CyberOptics Corp.
Attn: Service
Fax: +1-763-542-5100
service@cyberoptics.com
viii QX500 Hardware Manual

Technical Support
Technical Support
If you have problems operating the QX500, first check the product documentation for more information.
If you still need assistance, or you discover problems with the documentation, please telephone, send e-
mail, or fax CyberOptics Service and Support. • Include your serial numbers in all e-mail messages and
faxes.
• Have the product serial numbers ready when you telephone CyberOptics.
CyberOptics guarantees a response to all messages during the next CyberOptics business day.
International Technical Support Center

+1-800-526-2540
Fax: +1-763-542-5100
Email: service@cyberoptics.com
Website: www.cyberoptics.com/support
If available in your area, the toll-free number above (+1-800) is answered 24 hours a day, every day of the
week. Where toll-free access is not available, please contact the regional office closest to you:
North America
Minneapolis, MinnesotaUSA
+1-763-542-5000
Asia-Pacific
CyberOptics Singapore, Ltd.
Singapore
+65-6595-0328
Europe
CyberOptics Ltd.
United Kingdom
+44-(0)-1756-700-330
China
CyberOptics China Company Ltd.
Shanghai
+86-21-6375-6777
Corporate Headquarters
Minneapolis, MinnesotaUSA
+1-763-542-5000
Website: www.cyberoptics.com
CyberOptics Corporation ix
x QX500 Hardware Manual

1 Safety
Safety Guidelines two
compliance 6
Safety and Conformity Labeling 8
Chapter 1: Safety
Safety Guidelines
The QX500 system is an Automated Optical Inspection equipment intended for use in SMT
production environment.
Use of this equipment in a manner not specified in the operating instructions may impair safe
operation which may cause serious injury.
General Guidelines
• Read and follow instructions provided with all other manufacturer's documentation.
• Be alert and use common sense when operating any machinery.
• Be sure that you understand the safety considerations and follow the regulations in your
manufacturing facility.
• Do not place liquids or heavy objects on or in the QX500 unit.
• Always wear a static control wristband to prevent damage due to static electricity. The QX500
has an electrostatic discharge plug on the front of the machine by the power buttons to plug
the wristband into.
• Be sure the QX500 is properly grounded through the power connection. To avoid electric
shock, provide an earth ground connection.
• Do not lean on the safety enclosure or the safety enclosure frame.
• Do not remove the safety enclosure or disable the safety interlock mechanisms.
• Do not run the system with panels removed.
• Do not attempt to disassemble or repair any QX500 component without first contacting your
CyberOptics representative.
• Use the QX500 system indoors only.
• To avoid electrical shock, always turn off the power using the AC main circuit breaker before
servicing the unit.
• Only personnel trained by a CyberOptics' representative are recommended to operate the
QX500 because of the system's moving parts.
• Parts replacement and maintenance should be performed by trained maintenance personnel,
CyberOptics Representatives and CyberOptics Service and Support.
• CyberOptics recommends to close the side openings of the QX500 system after final
installation with other machines to prevent access to hazardous moving parts.
• System operation should be performed by trained operators.
• During maintenance or repair, all power sources to equipment or machinery shall be
removed and locked or tagged on the de-energized position.
• Locks to assure against inadvertent energizing of the equipment or machinery.
Caution: The system processor contains lithium batteries. There is danger of battery damage if
the battery is incorrectly replaced. Replace only with the same or equivalent type battery
recommended by the manufacturer (CR2032). Dispose of used batteries according to the
manufacturer's instructions. Recommended that only CyberOptics' personnel can perform the
replacement of lithium batteries.
two QX500 Hardware Manual

Safety Guidelines
Emergency Stop
Stop all movement on the QX500 system by using the Emergency Stop (E-Stop) button. Motion
will also stop when a safety interlock is disengaged.
Caution: Always press the Emergency Stop button before clearing a conveyor malfunction,
before performing machine maintenance, or before reaching inside the machine for any reason.
Using the Emergency Stop Button (E-Stop)
The E-Stop button is located on the front, right side of the QX500 system. When the E-Stop
button is pushed all motion into the system stops and power is removed from their circuitry.
The E-Stop on this machine is designed to meet the harmonized European standard for safety of
machinery—electrical equipment EN 60204-1 and EN 954-1 Category 4.
E-Stop
Figure 1. Emergency Stop Button
ÿ To operate the E-Stop

1. Push the red E-Stop button to stop the conveyor.
2. Twist and pull the E-Stop button to disengage.

3. Press the Reset/Start button.
4. The system can be restarted.

When the E-Stop button is pressed, or an interlock is broken, the alarm will sound and the
red tower light will blink. After clearing the E-Stop button or securing the interlock, the red light
turns off and the alarm will go off.
CyberOptics Corporation 3
Chapter 1: Safety
QX500 lockout
The lockout label is located at the rear of the QX500 above the AC Main Circuit Breaker. Lockout
of the machine is to prevent unexpected energization or startup of machinery and equipment, or
the release of hazardous energy during service or maintenance activities.
ÿ To lockout for QX500
1. Turn off all electrical power to the system. For more information, refer to the section
“Shutting Down the System” on page 59.
Caution: Turn the AC main circuit breaker to OFF to shut down all electrical power to the
QX500 before starting any replacement operations. For more information, refer to the section
2. Ensure that all energy sources which could activate the machine must be locked out.
3. Insert a padlocking facility into the slot on the Main AC Circuit Breaker located at the rear of
the QX500. (See Step 1 in Figure 2)
4. Push the latch of the padlocking facility down. (See Step 2 in Figure 2)
5. Attach a padlock or a tag to the padlocking facility. (See Step 3 in Figure 2)
two
Padlocking Facility
padlock
Figure 2. Lockout Component
4 QX500 Hardware Manual

Safety Guidelines
Padlocking Facility
Figure 3. Lockout at the rear of QX500
Safety Interlocks on the Top Cover
The QX500 is equipped with one safety interlock switch on the top enclosure (hood). The safety
interlock is located on the top cover. When the safety interlock is engaged, all motion in the system
stops.
Caution: It is recommended that the machine should only be run in this way by a trained
technician.
When the hood is not securely closed or the switch is defeated in another way (such as putting the
key in the switch) all machine motion is disabled. Refer to Figure 4 for the location of the safety
interlock.
Safety Interlock Key
Safety Interlock Switch
Figure 4. Location of Safety Interlock switch on QX500
ÿ To re-engage the safety interlocks

1. Remove the key from the switch, if applicable.
2. Close the safety enclosure securely.
3. Twist and pull the E-Stop button to disengage.
4. Press the Reset/Start button to re-engage the system.
Chapter 1: Safety
Indicator Lights
In the Inspection software application, you can specify the conditions that turn on the indicator
lights on the QX500 light pole. Refer to the QX500 System Software User Guide or Online Help
for these procedures. Refer to Safety of Machinery EN 60204-1:1998, section 10.3 Indicator lights
and displays, Table 3 for standard indicator light definitions.
The lights also indicate that the power up sequence for the system is complete. Refer to “Turning
on System Power” on page 45.
compliance
This product complies with the requirements of:
• EC Machinery Directive (2006/42/EC)
• EC Directive of Electromagnetic Compatibility (2004/108/EC)
standard classification Description

EN 60204-1:2006 Safety Of Machinery—Electrical Equipment Of
Machines – Part 1: General Requirements
EN 954-1:1996 Category 4 Safety Of Machinery—Safety-related Parts Of
Control Systems – General Principles For
design
EN ISO 12100-1:2003 Safety Of Machinery—Basic Concepts,
General Principles for Design – Part 1: Basic
Terminology, Methodology
EN ISO 12100-2:2003 Safety Of Machinery—Basic Concepts,
General Principles for Design – Part 2:
Technical Principles
EN ISO 14121-1:2007 Safety Of Machinery—Risk Assessment—
Part 1: Principles
EN 12198-1:2000 Safety Of Machinery—Assessment and
Reduction of Risks Arising From Radiation
Emitted By Machinery. General Principles
EN 61000-6-4:2007 Electromagnetic Compatibility (EMC) Part 6-2:
Generic Standards. Emissions for industrial
environments.
EN 61000-6-2:2005 Electromagnetic Compatibility (EMC) Part 6-2:

Generic Standards. Immunity for industrial
environments.

Disposal Waste
Disposal Waste
Preparing machine for disposal

DANGER
High Voltage, heavy current.

Death of very severe injuries.
• Work on the electrical equipment of the machine may be entrusted only to a CyberOptics
trained and qualified technician. The work has to be carried out according to the rules for
electrical engineering.
• Detach machine from any external energy feed (current, cooling water).
Disposal of individual components

CAUTION
Reusable raw materials and problem materials.

Environmental pollution.
• Protect the environment by correctly disposing of and recycling raw materials and problem
materials.
The. Machine frame and all mechanical machine components are made of steel, light metals
and plastics. These materials are recyclable.
B. Take non-reusable difficult waste, example: lubricants and batteries, to the appropriate
waste disposal point.
Chapter 1: Safety
Safety and Conformity Labeling
Optical Radiation Safety Labels

• The optical radiation risk label is placed on the front of the SIM (Strobe Inspection Module).
Caution: Staring at source of light in operation may be harmful to the eyes or to people susceptible
to epileptic seizures – DO NOT stare at exposed lamp in operation.
Figure 5. Optical Radiation Risk Label
• A hazardous voltage inside warning label is placed at the front of the SIM The label text
says:
WARNING : Hazardous Voltage Inside. Only authorized personnel may service this equipment.
Figure 6. Hazardous Voltage Inside Label

Mechanical Safety Labels

• Pinch points are also clearly labeled on each side of the machine near the conveyor openings
and on the front of the machine. The label text says:
WARNING! Moving parts can crush and cut. Do not operate with guard removed.
Lockout/tagout before servicing.
Figure 7. Pinch Point Warning Labels and Locations
Chapter 1: Safety
• The read technical manual label is located on the back electrical panel. The label text says:
WARNING! To avoid injury, you MUST read and understand technical manual before
servicing this machine.
Figure 8. Read Manuals Label and Location
• The power switch caution label is located on the front of the machine above the power switch.
The power switch does not remove all power from the system. Turn off the AC Main circuit
breaker before servicing the processor.
Power Switch
Figure 9. Power Switch Caution Label

Electrical Safety Labels

• The AC input rating label is located on the back electrical panel.
Figure 10. AC Input Rating Label
• A hazardous voltage label is located on the power connector on the back electrical panel. The
label text
says: WARNING! Hazardous Voltage. Risk of electric shock or burn.
Turn off and lock out system power before servicing.
Figure 11. Hazardous Voltage Labels near Power Connector and AC Main Circuit Breaker
Chapter 1: Safety
• The ESD earth ground label is located near the ESD grounding plug on the outside of the
system.
Figure 12. ESD Earth Ground Label
• The protective earth ground label is located near the PE terminal on the conveyor and on the
YEA .
Figure 13. Protective Earth Ground Label

• The lockout label is located at the rear of the machine above the AC Main Circuit Breaker.
Figure 14. Lockout Label
Manufacturing Information Compliance

The system has two Manufacturing Information and Conformance labels: one is located on the
outside of the machine on the lower right side; the second label is located at the rear of the
machine next to the rear fans.
The label shows the system compliance with European Conformity (CE), UL and RoHs
requirements. In addition, the printed EU Declaration of Conformity is shipped with each system.
If a new copy is required, contact CyberOptics Customer Service (See “Technical Support” on
page ix.).
Figure 15. Manufacturing Label
Chapter 1: Safety
QX500 Right Side of Machine
QX500 Rear of Machine
Figure 16. Locations of Manufacturing Labels

two System Overview
QX500 System 16
System Specifications 24
Performance Specifications 26
Computer Requirements 26
dimensions 27
Chapter 2: System Overview
QX500 System
The QX500 is an in-line Automated Optical Inspection system for pre-reflow or post-reflow
inspection system and helps to prevent production problems by notifying operators when
electronic components defects are detected. It is also intended to help Process Engineers to
establish process control.
The following pages describe the main components of the QX500 and show their location.
QX500 Unit
The QX500 system controls and indicators are located on the outside of the unit as shown in
Figure 17 and described below.
Table 1. QX500 System Components

Component Description
Control Buttons The buttons on the front panel control system operation as follows:
• E-Stop: Stops all of the system's moving parts.
• Mode Control Switch: Enables switching between three
system modes (Pass Through, Inspection and Offline).
• Reset/Start: Resets the system to the initial stage or to start the
system.
Mode Control Switch Enables switching between three system modes (Pass Through,
Inspection and Offline).
Emergency Stop (E-Stop) Stops all of the system's moving parts.
ESD Grounding Plug For connecting ESD wrist strap to prevent damage from
electrostatic discharge.
Keyboard and Trackball Placed on a tray that is mounted on a pivoting arm attached to the
machine frame which can be folded.
Leveling Feet Adjustable to level the unit.

Monitor 19-inch flat-panel display mounted on a pivoting arm attached to the
machine frame.
Power Switch The power switch removes all power from the system with the
exception of the processor power. The switch can be locked in the
off position to ensure safety from moving parts while servicing the
machine.
Signal-Light Pole Indicates the QX500 system status based on user configuration.

QX500 System
signal-light pole
safety
enclosure
hood
Control panel
flat panel (see below)
display
Keyboard
and trackball
tray
leveling feet
Control Panel
ESD wrist strap connection
Power Switch
E-Stop
Mode Control Switch
Reset/Start
Figure 17. Front View
QX500 Rear View

System connections such as power and ports are accessed at the rear of the machine as shown in
Figure 18 and shown below.
Table 2. QX500 System Components

AC Circuit Breaker The main circuit breaker is located on the rear electrical panel; AC
(CB1) power is connected to the circuit breaker through the rear electrical
panel and turns off all system power when activated.
Note: Do not obstruct the rear circuit breaker
Cooling Fans Draw air out of the system to cool internal electronics
Ethernet Port Connection to local area network (10/100 Mb Fast ethernet network
configurations).
SMEMA Connectors Connection for upstream and downstream equipment for conveyor
control.
COM Port Connection for optional devices such as a barcode reader.
Power
access cover
back access cover
COM2 port
ethernet port
SMEMA
cooling fans Upstream
SMEMA
downstream
AC circuit breaker (CB1)

Power cord strain relief
Figure 18. QX500 Rear View

QX500 System
QX500 Internal Parts

Opening the hood, which stops all machine motion, gives you access to the sensor and conveyor.
The lower panel can be removed (by service personnel only) to gain access to internal electrical
components. These parts are described below and shown in Figure 19.
Table 3. QX500 System Internal Components

processor The processor contains two Intelÿÿ5000X chipset, Quad-Core 2.0
GHz CPU, two SATA disk drive (500GB and 1TB) and one DVD
+/- R/W drive.
It provides serial, USB, Ethernet.
Software configuration is Windows XPÿ Professional, 64-bit platform.
Conveyor The conveyor brings the panel into the machine. During inspection,
the panel moves from upstream to downstream depending on the
configuration (Right-to-Left or Left-to-Right). The panel travels in a
non-stop movement towards downstream while the image is
captured.
Main Electrical Panel Contains the electronic components needed to power the system
and control motion.
Sensor (SIM) This is the image capturing device that is used to acquire PCB board
images.
Sensor (SIM)
Conveyor
Main Electrical Panel

processor
Figure 19. Internal Components

QX500 System

The Main Electrical Panel in the QX500 contains the electronic components described in the
following table and shown in Figure 20.
Table 4. Main Electrical Panel Components

Stepper Driver for Conveyor Controls belt and autowidth motors for conveyor motion.
Autowidth and Conveyor Belts
Power Supply, 24V DC, 5 Amp Provide power and auxiliary power to the sensor and
electronics in the system.
Power Supply, 40V DC, 5 Amp Provides power to stepper motor driver.
Circuit Breakers: To control the over current /short circuit for :
CB2 Outlet Processor (6 Amp)
CB3 PS 1 (6 Amp)
CB4 PS 2 (6 Amp)
CB5 spare
Safety Contactor and Safety Relay Allow power to the system only when interlocks are
closed and E-Stop and/or Power Switch are not pressed.
Conveyor Engine Conveyor Width PS1- 5 A

controller Engine Controller PS2- 5 A Safety Relay relays
PS1 PS2
CMD WMD K1 R1 R2 R3 R4 R5
PLC
PS2–24V PS2–0V
Figure 20. Main Electrical Panel

QX500 System
Conveyor
The QX500 receives panels from the upstream conveyor using SMEMA signals to control the
timing. The conveyor transports the panel without stopping until it reaches the exit. The image
is captured while the panel is traveling downstream.
When the inspection is complete, the machine releases the panel to the downstream conveyor
utilizing SMEMA signals for timing. The conveyor contains the major components described in
the following table and shown in Figure 21 on page 23.
Table 5. Conveyor Components

Conveyor Belts The conveyor has belts on both the front and the rear rail to
move panels in and out of the system.
Drive Belts & Motors Provide electro-mechanical drive for the conveyor and for
the automatic width adjustment.
Panel Sensors Entry/Exit Sensors: located on each end of the conveyor
these sensor detect panels entering and exiting the
conveyor. Sensors work in conjunction with SMEMA to bring
boards in.
Adjustment Wheel Can be used to manually adjust the conveyor width.
Rear Conveyor Belt

Movable Conveyor Rail
Conveyor Drive Belt
Conveyor Engine Conveyor Manual Fixed Conveyor Rail Panel Proximity

Adjustment Wheel Sensor (Entry/Exit)
Figure 21. Conveyor – Left to Right board flow configuration
Setting the Conveyor Direction
By default, the QX500 system loads panels from the conveyor to the left of the machine and
unloads them after inspection to the conveyor on the right side of the machine. You can change
the direction of panel flow by accessing conveyor settings using Inspector Cell Editor.
ÿ To set the conveyor direction
1. On the QX500 Launch Pad, click Inspector Cell Editor.
2. In the Inspection Cell Editor, select File>Conveyor Setup ...
3. In the Conveyor Setup dialog box, click on Settings ...
4. In the Miscellaneous conveyor settings section, select the direction of the conveyor motion.
• Left-to-right means that the upstream machine is to the left of QX500 and the
downstream machine is to the right of QX500.
• Right-to-left means that the upstream machine is to the right of QX500 and the
downstream machine is to the left of QX500.
Right-to-left conveyor motion will impact cycle times because the QX500 system can only
acquire images by indexing from left-to-right. When running in the right-to-left direction, the
panel is loaded from the conveyor on the right side of the machine, brought to the left side of
the machine, homed, then indexed left-to-right before being inspected and unloaded to the
conveyor on the left of the machine.
5. Click OK. The settings are saved to the file

D:\QX500\Config\FirmwareConfiguration.xml. To use the same settings on another
system, copy the file to its QX500\Config directory and restart the QX500 application.
System Specifications
Table 6. System Specifications
dimensions
unit height 139 cm (55 in.) excluding signal-light pole and leveling
feet
Unit Width 100 cm (39 in.)
Unit Depth 127 cm (50 in.)
Distance from fixed front rail to back of 92 cm (36 in.)
machine
Conveyor Height 893 to 973 mm (35 to 38 in.)

weight 400 kg (882 lbs.)
Panel Specifications
Panel Size Capacity
• Maximum 457 ÿÿ317.5 mm (18 ÿ 12.5 in.)
• Minimum 50 ÿ 50 mm (2 ÿ 2 in.)
Board Thickness 0.3 to 5.0 mm (0.01 to 0.2 in.)
Board Edge Clearance (mechanical)
• Top 3 mm (0.12 in.)
• Bottom 5 mm (0.19 in.)
Component Clearance
• Topside (above belt) 25 mm (0.98 in.)
• Bottom side 25 mm (0.98 in.)
Maximum Board Weight 3 kg (6.6 lbs.)

Maximum Board Warp ±7 mm

System Requirements
Table 6. System Specifications (Continued)
Operational Specifications
Conveyor Speed Range Up to 375 mm/sec (14.76 in./sec)
Maximum Inspection Area SIM 8: 40 x 308 mm (1.57 x 12.13 in.)
X and Y Pixel Size
• High-resolution 17 µm (0.6 mils)
Temperature Range Recommended 25°C, ± 2°C
Warm Up Time (for repeatability and 30 minutes
accuracy specifications)
Hardware Specifications
processor Quad Core 2.0 GHz CPU
interfaces SMEMA (Per IPC-SMEMA-9851), Ethernet, USB,
Digital I/O, air, power
RAM 8 GB recommended
Available Disk Space 750 GB (to accommodate quilt image for 20 x 20 in.
panel)
video card
• Minimum 256 MB memory
• Recommended 512 MB memory, OpenGL acceleration
a There is an option for upgrading the system processor. Contact CyberOptics for more information.
System Requirements
Table 7. System Requirements
humidity
• Operating 20–80% RH non-condensing
• Storage 10-90% RH non-condensing
temperature
• Operating (Ambient) 15°–35°C (59°–95°F)
• Storage -20°–70°C (-4°–158°F)
Altitude Up to 2000 m
Insulation Coordination Pollution degree 2
Installation Category Category III

(overvoltage category)
Power Requirements 100–130/220–240V, 50/60Hz, 10–15 amps

(Hard-wired, single phase)
Permitted Voltage Drops 90V for 100–130VAC

200V for 220–240 VAC
Peak Operating Current 12 amps @ 100V–130V

6 amps @ 220V–240V
Fuses on Internal Branch Circuit three, 6 amp
breakers One, 10 amp
noise declaration 66 dB (A)
Performance Specifications
The most current performance specifications are found on the product page of the CyberOptics
Web site at http://www.cyberoptics.com.
Computer Requirements
You can run the QX500 application on a desktop computer that meets the following minimum
requirements:
Table 8. Desktop Computer Minimum Requirements
processor Intelÿ Pentiumÿ 4 processor minimum

RAM 4 GB recommended, 2 GB minimum
Available Disk Space 50 GB (to accommodate quilt image for 20 x 20 in. panel)
video card
• Minimum 32 MB memory
Monitor Resolution 1024x768, 24-bit color (minimum)
Operating System Windows XP 32/64 bit Professional recommended

dimensions
dimensions
490cm
(19 in)
139cm
134cm
(55 in)
(53 in)
100cm
(39 in)
Figure 22. Front View
Adjustable*
86 – 104 cm
(34 – 41 in.)
92 cm
(36 in.)
127
cm (50 in.)
Figure 23. Side View

3 Installation
Packing the QX500 System 30
Unpacking the QX500 System 33
Choosing a Location 34
Installing the System 35
Wiring QX500 for Power 43
Connecting SMEMA Cables 46
Connecting to a Network 47
Conveyor Adjustment 48
Aligning the QX500 System 56
Shutting Down the System 59
Moving the QX500 System 60
Bypassing the QX500 System 60
Chapter 3: Installation
Warning: Only CyberOptics' service personnels shall perform the installation procedures in this
Chapter.
Packing the QX500 System

These instructions describe how to pack the QX500 in its original wooden shipping crate for
shipment. It is recommended to save the shipping crate and all of the packing materials in case you
need to ship the QX500 back to CyberOptics.
Performing this procedure requires a drill with a 13 mm socket attachment, hex head bolts, a
forklift, and a pallet jack.
Warning: Make sure the QX500 system power and AC main circuit breaker is off before
packing. Perform visual inspection of the machine for any dirt or damages before crating.
ÿ To prepare the base crate
2. Ensure that the AC main circuit breaker (CB1) located at the rear of the machine is turned
Off.
3. Ensure that there are no incoming power cables connected.
4. Prepare the crate base as shown.
Crate Panels
floaters
Accessory sponge
compartment
Required Tools
13 mm socket attachment hex head bolt

Packing the QX500 System
ÿ Packing Accessories
1. Place foam padding between the keyboard, flat screen display and front cover of machine.
2. Place one moisture barrier and two desiccant clay packets at the rear and the stage of the
machine and seal as shown.
Note: The machine should be at room temperature before placing the moisture
i barriers.
blend
Barrier x 1
Desiccant clays x 2
Sealing the machine
3. Place all accessories in the accessory compartment. Use export packaging if required. The
minimum requirement is to shrink wrap the machine and the accessories.
ÿ To crate the QX500

1. Make sure that the forklift forks fit into the slots at the rear of the crate base.
Note: The forks must properly support both crossbeams from the rear of the machine. If not, the
i machine may tip over while being moved.
2. Lift the QX500 system using the pallet reach truck.
3. Move the machine over the platform. Manually raise each of the leveling feet and ensure that
it is not touching the base crate. Hand-tighten the leveling feet.
Leveling Foot
floater
4. Position the machine so that its frame aligns with the platform floaters. Slowly lower the
machine until it rests on the platform floaters. There should be no gap between the machine
and the sponge placed at the front of the machine.
5. Slowly drive forklift out from under the machine.
6. Using the drill, the 13 mm socket attachment and hex head bolts, secure the lockdown plate
over each of the leveling foot.
7. Shrink wrap the machine and the accessories.
ÿ Closing the Crate
1. Slide the front and back panels onto the platform. Secure with hex head bolts. Numbered the
front panel with numbers 1 and 4, back panel with numbers 2 and 3.
2. Place the side panel onto the crate and secure with hex head bolts. Numbered the panel with
numbers 1 and 2.
3. Place the other side panel onto the crate and secure with hex head bolts. numbered the panel
with numbers 3 and 4. Close the machine ID cover.
4. Cover the crate with a top cover and secure with hex head bolts.
ÿ Markings for the Crate
1. Mark the bolts in blue as shown after the crate is ready for shipment.
Machine ID
cover

Unpacking the QX500 System
Unpacking the QX500 System

These instructions describe how to unpack the QX500 system from its shipping crate. It is
recommended to save the crate and all of the packing materials. For packing instructions, contact
CyberOptics for more details.
Performing this procedure requires a drill with a 13 mm socket attachment, a forklift, and a pallet
jack. Capacity of forklift: (450 kg, 185 cm for QX500).
ÿ To unpack the QX500 system
1. Using the drill and the 13 mm socket attachment, remove all the hex head bolts marked in blue
from the panel where there is a label indicating “To uncrate remove blue bolts” as shown.
13 mm socket attachment
2. Remove the panel with the label indication from the platform or skid/pallet.
3. Slide out the remaining crate pocket off the platform.
4. Using the drill and socket attachment, remove the hex head bolts from the lockdown plate
located at each of the leveling feet.
5. Removes the packing material, moisture barriers, desiccant clays and accessories around the
unit.
Note: The machine should be at room temperature before removing the moisture barriers.
i
6. From the rear of the machine, ensure the forklift's forks are supporting both crossbeams
under the system before lifting.
Note: The forks must properly support both crossbeams from the rear of the machine. If not, the
i machine may tip over while being moved.
7. Lift the machine off the base crate.
8. Lower the leveling feet sufficiently to allow the forks of a pallet jack or a forklift under the
machine.
9. Using a pallet jack or forklift, move the machine to a desired location.
Choosing a Location
The QX500 system must be level and aligned with incoming and outgoing conveyor sections to
allow for smooth movement of panels.
Choose a location for the QX500 that meets the following requirements:
• System has easy access to power
• Conveyor is level • Conveyor
movement is smooth • System is
not exposed to extreme ambient vibration

Installing the System
Caution: The QX500 is a precision inspection system. To ensure optimum performance of your
QX500, a trained CyberOptics service representative is required to install the system.
Installing the QX500 system consists of the general steps listed below. Each step is described in
more detail on the following pages.
• “Installing the Light Pole” on page 35
• “Positioning / Leveling the QX500 System” on page 36
• “Installing the Sensor (SIM Module)” on page 40
Installing the Light Pole

ÿ To install the light pole
1. Loosen and remove two spring loaders along the upper rear panel to remove the panel from
the system.
2. Remove the attaching nut from the light pole and slide it off the cable.
3. Place the light pole in an upright position and insert the threaded end of the pole into the hole
on top of the enclosure.
4. Tighten the bolt inside the enclosure so that the light pole is firmly attached to the unit.
5. Connect the light pole cable to the available cable connector that is tied to the frame.
6. Replace the rear panel.
Connect light pole cable to

cable inside frame
Slide nut onto cable and

tighten underneath frame
Figure 24. Light Pole Installation
Positioning / Leveling the QX500 System
Adjust the height of the system to align with incoming and outgoing conveyor sections. System
height can be configured to a standard height or can be lowered 5 cm (2 inch) by repositioning the
leveling foot block. Both methods are described in the following section.
Note: Do not bolt the QX500 conveyors to incoming and outgoing conveyor sections. Vibrations
i from other machines may impact QX500 performance.
Standard Conveyor Height
The standard height configuration allows the QX500 conveyor to be positioned from 91–104 cm (36–
41 inch) high.
ÿ To adjust the system height (standard height)

1. Ensure that the floor is free of debris and the area provides adequate clearance on all sides of
the unit.
2. Push the QX500 unit into position, lining up the front rails of the incoming and outgoing
conveyor sections.
3. To adjust the leveling feet, loosen the locking nut with a wrench and then turn the
adjustment nut.
• Turn the nut clockwise to raise the unit
• Turn the nut counter-clockwise to lower the unit
locking nut
adjustment nut
Figure 25. Leveling Foot
4. Use a level or machine height measurements to make sure that the system is level.
5. Manually slide a panel through the incoming and outgoing conveyor sections to make sure that
the QX500 conveyor rail is properly aligned. The panel should pass from the upstream conveyor
through the QX500 system and on to the downstream conveyor without any resistance.
6. After adjusting the leveling feet, tighten the locking nuts.

Lower Conveyor Height Configuration Option
The lower height configuration allows the QX500 conveyor to be positioned to a minimum
height of 86 cm (34 inch). It is still adjustable to a maximum height of 96 cm (38 inch).
To adjust the height when the system is in the lowest height configuration, you will need to
remove the side panels (see Figure 26 below). If the system panels is already in position in the
line with no access to the side, remove the front panel from the electronics area and the right
panel (vertical) from the control panel area (see Figure 27 on page 38).
Note: To achieve the lowest conveyor height configuration of 83 cm to 96 cm (33 inch to 38

i inch), a customized conversion kit is needed. Contact CyberOptics for more information.
ÿ To remove side panels
1. Loosen the two M5 x 8 screws along the top edge of the panel using the 3 mm allen wrench.
2. Lift the upperside panel off the machine.
3. Grasp the lower panel underneath the top edge and lift it up and off the mounting screws.
M5 screws (x 2)
Figure 26. Removing Side Panels
ÿ To remove the front panels
If the side panels cannot be removed, remove both the front panel and the right front (vertical)
panel.
1. Lift the system hood.
2. Ensure that all motion has stopped.
3. Loosen the two M5 screws along the top edge of the lower front panel.
4. Lift the panel off the machine.
5. Remove the power switch from the machine by removing the attaching screw.
6. Loosen and remove four M5 screws from along the inside of the QX500 frame.
7. Lift the right panel off the machine and rest it on the monitor arm.
M5 screws (x 4)
right panel
Power Switch
M5 screws (x 2) front panel
Figure 27. Removing Front Panels

ÿ To adjust the system height (lowest height) configuration

1. Remove the side panels from the unit.
2. If not already configured for the lowest position, use a forklift to raise the unit 0.5–1 meter (2–
3 feet) off the floor.
3. Remove the two M8 screws that secure the plate and foot assembly to the frame.
4. Remove the leveling foot from the block.
5. Orient the block in the cylinder facing upward and the flat foot is down.
machine frame
Leveling foot block oriented

for standard configuration
Leveling foot block
oriented for lowest
conveyor position
leveling foot
M8 Screws
Figure 28. Changing Leveling Foot
6. Reassemble the foot assembly onto the frame.
7. To adjust the leveling feet, loosen the locking nut with a wrench and then turn the
adjustment nut.
• Turn the nut clockwise to raise the unit
• Turn the nut counter-clockwise to lower the unit
locking nut
adjustment nut
8. Use a level or machine height measurements to make sure that the system is level.
9. Manually slide a panel through the incoming and outgoing conveyor sections to make sure
that the QX500 conveyor rail is properly aligned. The panel should pass from the upstream
conveyor through the QX500 system and on to the downstream conveyor without any
resistance.
10. After adjusting the leveling feet, tighten the locking nuts.
Installing the Sensor (SIM Module)
Caution: Make sure the QX500 system power is off before installing the sensor. The sensor
could be damaged if you connect it to the system when power is on. This procedure should be
carried out by a trained CyberOptics Service Personel.
ÿ To uninstall the sensor (SIM Module)

2. Ensure that all motion has stopped and there are no boards on the conveyor.
3. Open the hood on the QX500.
4. Loosen the four bolts at the corners of the SIM mounting bracket with Allen key No. 4.
5. Remove the grounding cable and screw on the SIM module with Allen key No. 2.5.
mounting bracket
Bolts x 4 (Mounting
bracket)
grounding cable
screw
Figure 30. SIM module grounding cable
6. Slide out the SIM module slowly.
7. Remove the two bolts at the front of the SIM adapter bracket and remove the bracket.
YES bracket top view adapter SIM front view bracket adapter
YES bracket adapter Bolts x 2
Figure 31. SIM module with adapter bracket
8. Repeat for the other side of the SIM module.
9. Mount the SIM adapter bracket to the new SIM module.
10. Repeat for the other side of the SIM module.

11. Fasten the two bolts to the SIM adapter bracket. Do not tighten the bolts.
12. Gently slide back the SIM module onto the mounting bracket. Be careful not to pinch the
cables.
ÿ To install the sensor (SIM Module)
1. Turn off all electrical power to the system. For more information, refer to the section “Shutting
Down the System” on page 59.
2. Ensure that all motion has stopped and there are no boards on the conveyor.
4. Attach the bolts onto the T nut on the four corners of the mounting bracket.
5. Attach the grounding cable to the SIM module and tighten the grounding screw.
6. Attach all the cables and connectors back to the SIM module.
7. Power up the machine and restart the system.
8. Refer to “Adjusting the Conveyor Width” on page 50 to adjust the conveyor widths.
9. Refer to “Aligning the Camera Positions” on page 41 to align the camera positions.
10. After adjusting the conveyor widths and aligning the camera positions, tighten the bolts on
the SIM module bracket fully.
11. Perform a final check on the calibration target. Check that the calibration target serial
number matches the calibration assembly. If the serial number does not match, refer to step 10–18 of
“Aligning the QX500 System” on page 56 to re-align the system.
Aligning the Camera Positions

ÿ To align the camera positions
1. On the QX500, turn the Mode Control switch to Off Line mode.
2. Start the application software and log in as a programmer or hardware engineer.
3. On the QX500, press the Reset/Start button.
4. On the Launch Pad, click the Inspection Cell Editor button.
5. In the Inspection Cell Editor, select Conveyor > Adjust Width and adjust the conveyor rails for
the width of the calibration target.
6. Check and ensure that there are no boards on the conveyor and the machine is in Off Line
mode
7. Open the hood of QX500 and bypass the safety interlock switch with a bypass key.
8. From the front of the machine, manually position the calibration target on the QX500
conveyor so that the center rows of roundels (row 5) on the lower glass plate of the target are
accurately aligned.
Figure 32. Calibration Target
9. In the Inspection Cell Editor in the Camera section, click Live. The system displays a live
image of the calibration target.
Note: The sensor will continue to strobe at this mode. This is normal.
10. Align the camera positions as follows:

• Start with camera 4 and 5 first, then followed by the rest of the cameras.
• Line up all cameras on the center roundels of a pattern, as shown in Figure 33.
Figure 33. Camera Alignment
11. After all cameras have been aligned correctly, select File > Save Cell.
12. Once a sensor is installed, alignment is needed. For more information on the alignment
procedures, refer to “Aligning the QX500 System” on page 56.

Wiring QX500 for Power

The QX500 system must be hard-wired into your AC main power. Have a certified electrician to
wire the system.
Caution: Before wiring the system, make sure that the AC main power supply is turned off and
locked off.
Note: You must have a readily accessible power supply and a protective device in the fixed
i wiring for the permanently-connected QX500 system. The power supply, wiring, and any
protective device must be rated at 240 VAC, 10 amps or 110 VAC, 15 amps.
ÿ To connect AC power
1. On the rear of the machine, turn off the AC Main Circuit breaker (CB1).
2. Loosen and remove four screws on the power access cover to remove the cover.
3. Loosen the strain-relief nut at the bottom of the box.
Note: Make sure the strain-relief nut is fully tightened.
Power access cover Screws x 4 (Loosen)

Safety Labels
Main AC circuit breaker

Strain-relief nut
(CB1)
Figure 34. Rear Electrical Panel
4. Feed the incoming power lines through the strain-relief connector.
L (brown)
N1 L1
power cord
(AWG 14–16)
L2 N2 PE PE PE FOOT
NL
N (blue)
GND (yellow)
Screwdriver
Pry open the crimping connector using

a screwdriver and insert the conductor.
striped wire
NOTE: The QX500 does not come with power cord.
Figure 35. Electrical Wiring

5. Connect L (brown) and N (blue) to the connections marked on the lower face of the circuit
breaker.
6. Connect the ground wire to one of the green terminals on the terminal block:
The. Insert a screwdriver to release the crimp-style connector. B.
Insert the stripped portion of the wire into the connector. ç. Removes
the screwdriver, allowing the connector to crimp the conductor.
d. Pull the wire to ensure it is secured.
7. Replace the power access cover and secure with four screws.
Caution: If the ground is not properly connected, the entire machine chassis will float at half the supply
voltage.

Turning on System Power
CyberOptics recommends a 30–60 minute warm up time to ensure the most accurate system
measurements.
ÿ To turn on the system

1. Check to make sure the conveyor is clear of panels and the E-Stop button is engaged.
2. Turn the main AC circuit breaker to ON to turn on power to the entire system.
The breaker is located on the back electronics panel.
i Note: The computer will start automatically.
3. Turn on the power switch on the front of the system.
Note: Do not run any Inspection applications until after the lights on the signal light pole have turned
on and then off. When you first start the QX500 system, the internal processor initializes the system.
i After approximately two minutes the lights turn on, and then several seconds later they turn off,
indicating that the initialization is complete. Also, there is a need to wait for the sensor light to turn
ON.
4. Release the E-Stop button.

5. Press the Reset/Start button to restart.
Main AC circuit breaker (CB1)
Figure 36. Main AC Circuit Breaker Location
Connecting SMEMA Cables

Use the SMEMA connections to facilitate board handling between machines in the SMT line.
The recommended length for SMEMA cable is less than 3 m.
ÿ To connect SMEMA cables
1. Shut down the computer operating system (Windows XP) and then push the E-Stop button
on the front of the unit.
2. Turn off all electrical power to the system. For more information, refer to “Shutting Down the
System” on page 59.
Back Electrical Upstream

SMEMA connector
panel
downstream
SMEMA connector
pinout connector
1 two 3 pins Upstream Cable Downstream Cable
7 4 1-2 -
Machine Ready
11 8
3-4 Board Available Board Available
14 12
7-8 Failed Board Available Failed Board Available
Figure 37. SMEMA Connectors
3. Route the SMEMA cables under the QX500 unit to the connectors on the rear.
4. Connect the upstream cable to the upper connector.

5. Connect the downstream cable to the lower connector.

Connecting to a Network
Connecting to a Network
Connect the QX500 system to the network using the Ethernet port on the rear electrical panel.
The network port can be used for 10Base-T or 100Base-T installations. You will need assistance
from your network administrator to complete this procedure.
ÿ To connect the QX500 system to a network
1. Shut down the computer operating system (Windows XP) and then push the E-Stop button
on the front of the unit.
2. Turn off all electrical power to the system. For more information, refer to “Shutting Down the
3. Connect the network cable to the Ethernet connection located on the back electrical panel.
Ethernet connection
Back Electrical
panel
Figure 38. Network Connection
Configuring the LAN Connection
Use the Windows network tools to complete the Ethernet configuration. This is typically done by
a network administrator and includes the following:
• Adding the protocol
• Assigning the IP address if it is not dynamically assigned via DHCP
• Configuring the Domain Name System (DNS)
Conveyor Adjustment
The QX500 conveyor consists of a fixed rail on the operator side of the machine and an adjustable
rail on the opposite side. CyberOptics recommends that you adjust the conveyor automatically using
the QX500 software. For instructions, refer to the “Wiring QX500 for Power” on page 43.
The QX500 conveyor is controlled by inputs from the sensors. The conveyor moves forward until a
sensor is triggered signifying a panel is present. The conveyor then continues to transport the panel
in a forward direction until an image of the panel is captured and the software has finished inspecting
the panel.
Manually Adjusting the Conveyor Width

You can manually adjust the width of the conveyor using the adjustment wheel located at the front
of the conveyor rail. Manual adjustment is performed before automatic width adjustment. If you adjust
the width manually after you have automatically adjusted the width, you must re home the auto-width
adjuster because the position of the conveyor will have changed independently of the software. For
instructions on using the auto-width adjuster, refer to the “Wiring QX500 for Power” on page 43.
tools
• Adjustment Wheel (Built-in)
• Metric ruler or measuring tape (capable of measuring up to 500 mm)
ÿ To manually adjust the conveyor width
1. Put the QX500 machine in Off Line mode.
2. Turn the adjustment wheel until the conveyor reaches the correct width.
3. Turn the adjustment wheel clockwise to make the conveyor width narrower.
- or -
4. Turn the adjustment wheel counter-clockwise to make the conveyor width wider.
Adjustment Wheel (built-in)
Figure 39. Location of adjustment wheel on conveyor

Conveyor Adjustment
Adjusting the Conveyor Width Automatically
You should always adjust the conveyor automatically using the QX500 software application;
CyberOptics strongly advises against adjusting the conveyor manually with the crank handle. If
the conveyor is manually adjusted, the conveyor must be sent to the home position to be reset.
You should manually adjust the conveyor only if there is a problem.
You can automatically adjust the conveyor width in the Calibrator, Inspection Cell Editor,
Assembly Editor and Inspection Station. When you adjust the conveyor width, you must ensure
that there is sufficient clearance between the conveyor rails and the edge of the board to
accommodate normal variation in board width.
Homing the Auto Width Motor
Homing the conveyor resets the conveyor to its widest cross-width position. If you have
manually adjusted the conveyor width, you must re-home the auto width motor using the
Conveyor Width Adjuster dialog box. As best practice, CyberOptics also recommends that you
re-home the conveyor engaging the Emergency Stop button or defeating the safety interlock
switch to resynchronize the stepper motor controller with the QX500 system.
ÿ To home the conveyor

2. Remove any boards from the conveyor and shut the doors of the QX500 machine.
3. Start the QX500 application and log on as a programmer or hardware engineer.

4. Press the Reset/Start button on the QX500.
Note: If you open the upper door at any time when you are adjusting the conveyor width, you
must restart the stepper motor controller again after you close the door and before interacting
i further with the QX500 software. To restart the stepper motor controller, press Reset/Start
button. If the stepper motor controller is working, the green lamp on the signal tower will illuminate.
5. On the Launch Pad, click Inspection Cell Editor button.
6. In the Inspection Cell Editor, select Conveyor>Adjust Width.

A message prompts you to ensure that there are no boards in the machine and that the
system is in Off Line mode.
7. Verify that the machine is in Off Line mode and that there are no boards in the machine and
then click OK.
8. In the Conveyor Width Adjuster dialog box, click the Fine-Tune button.
The Additional Movements section appears.
9. Click the Go Home button.
10. If a confirmation message appears asking if you want to return the conveyor to the home
position, click Yes.
The adjustable conveyor rail moves to its home position.
11. Click Close to close the Conveyor Width Adjuster dialog box.
The conveyor belts move as the system attempts to locate a board, and a message appears
telling you to make sure to put the QX500 in Inspect mode before starting an inspection in line.
12. Click OK.
The conveyor belts move as the system again attempts to locate the board.
Adjusting the Conveyor Width
After the system width is aligned and you are ready to operate in-line, you must adjust the
conveyor width to the width of the boards to be inspected.
ÿ To adjust the conveyor width for boards
1. Using a metric ruler or tape measure, measure the width of the board you want to inspect.
Note: If the board has both a top side and a bottom side, measure the end of the board that will
i enter the conveyor first.
3. Remove all boards from the conveyor.
4. If the stepper motor controller is not powered (the green lamp on signal tower is not
illuminated), press the Reset/Start button on the QX500. The controller is reset and the
amber lamp on the signal tower flashes.
Note: If the controller is already receiving power (the green lamp on the signal tower is
i illuminated) and the amber lamp is flashing, pressing the Reset/Start button causes the system to try
to locate a board on the conveyor, even though there is on the board on the conveyor.

Conveyor Adjustment
5. Open the Assembly Editor, Calibrator, Inspection Cell Editor, or Inspection Station.
6. In the Assembly Editor, select Inspection Cell > Adjust Width.

- or -
In the Calibrator, Inspection Cell Editor, or Inspection Details window, select Conveyor > Adjust
Width.
A message prompts you to ensure that there are no boards in the machine and that the machine
is in Off Line mode.
then click OK.
The Conveyor Width Adjuster dialog box opens and displays the conveyor width during the
previous session.
8. In the New Width text box, type the width of the board, in millimeters. If you are adjusting
the conveyor width for the calibration target type 460.
9. Click Go To.
10. After the system has adjusted the conveyor rails, verify that the width is correct.
The. Though the opening on the right-hand side of the machine (the downstream side),
carefully insert the board and place it onto the conveyor. For the calibration target, the upper
plate of the target should be to your left as you look at the front of the machine.
Note: If you open the door of the QX500 to insert the board, you must ensure that the stepper
motor controller is receiving power before continuing.
B. Gently moves the board along the conveyor. The board should fit snugly between the
conveyor rails and move smoothly without catching.
11. If the conveyor is at the correct width, leave the board in the machine and skip step 12.
- or -
If the conveyor width is incorrect, perform the following steps.

The. Estimate how much wider or narrower the conveyor rails should be.
B. From the opening on the right-hand side of the machine, remove the board from the
conveyor.
Note: If you open the door of the QX500 to remove the board, you must ensure that the stepper motor
controller is receiving power before continuing. If the green lamp on the signal tower is not lit, press the
i Reset/Start button to re-establish communication to the software application.
The amber lamp on the tower should begin flashing.
ç. In the Conveyor Width Adjuster dialog box, click the Fine-Tune button.
The Additional Movements section appears.
d. Click the Widen by 0.5 mm or the Narrow by 0.5 mm button to widen or narrow the
conveyor width by one-half millimeter until the conveyor is at the correct width.
12. Click Close to close the Conveyor Width Adjuster dialog box.
13. If a message appears telling you to make sure to put the machine in Inspect mode before
inspecting in-line, click OK.
If required, you can now turn the Mode Control switch to Inspect mode. The conveyor will
automatically reset itself.
Fine-Tuning the Conveyor Width
ÿ To fine-tune the conveyor width
2. Remove all boards from the conveyor.
3. If the stepper motor controller is not powered (the green lamp on the signal tower light is not
illuminated), press the Reset/Start button on the QX500. The controller is reset and the amber
lamp on the signal tower flashes.
Note: If the controller is already receiving power (the green lamp on the signal tower is
i illuminated) and the amber lamp is flashing, pressing Reset/Start button causes the system to try to
locate a board on the conveyor, even though there is no board on the conveyor.
4. Open the Assembly Editor, Calibrator, Inspection Cell Editor, or Inspection Station.
5. In the Assembly Editor, select Inspection Cell > Adjust Width.

- or -
In the Calibrator, Inspection Cell Editor, or Inspection Details window, select Conveyor >
Adjust Width.
machine is in Off Line mode.
then click OK.

Conveyor Adjustment
7. In the Conveyor Width Adjuster dialog box, click Fine-Tune. The Additional Movements
section appears.
8. Click the Widen by 0.5 mm or the Narrow by 0.5 mm button to widen or narrow the
conveyor width by one-half millimeter.
The value in the New Width text box changes accordingly.
9. Repeat step 8 until the width of the conveyor is correct and then click the Close button.
The message appears telling you to make sure to put the QX500 in Inspect mode before
starting an inspection.
10. Click OK.
Re-calibrating the Conveyor Auto-Width Adjuster
CyberOptics calibrates the conveyor auto-width adjuster on the QX500 before the machine is
shipped. After the machine has been installed in-line, you should re-calibrate the auto-width
adjuster. Thereafter, you should not typically need to re-calibrate the auto-width adjuster unless
you move the machine to a different location.
ÿ To re-calibrate the auto-width adjuster
2. On the Launch Pad, click the Inspection Cell Editor button.
3. In the Inspection Cell Editor, select Conveyor > Adjust Width.

Ensure that there are no boards in the machine and that the system is in Off Line mode.
4. In the Conveyor Width Adjuster dialog box, click the Fine-Tune button. The Additional
Movements section appears.
5. Click the Re-Calibrate button.
The Conveyor Width Calibration Wizard — Step 1 of 3 dialog box opens.
6. To begin adjustment, click Next.

The conveyor rail moves out to its home position (generally, though not always, the widest
cross-width setting), and the Conveyor Width Calibration Wizard — Step 2 of 3 dialog box
opens.
7. Using a metric ruler or tape measure, accurately measure the width of the gap between the
inside edges of the both rails of QX500 conveyor. Measure the gap towards the middle of the
machine, including visible part of the conveyor belts in the measurement, as shown.

Conveyor Adjustment
8. In the Conveyor Width text box, type in the width, in millimeters, and click Next. The
Conveyor Width Calibration Wizard — Step 3 of 3 dialog box opens.
9. Click Finish to save the changes and close the Conveyor Width Calibration wizard.
10. The system returns you the Conveyor Width Adjuster dialog box and displays the
recalibrated width in the New Width text box.
11. To verify the setting, click the Go To button. There should be no response from the conveyor,
meaning that the conveyor rails are at the designated width.
12. Click Close.
The conveyor belts move the system tries to locate a possible board, and a message appears
telling you to return the QX500 to Inspect mode before inspecting in-line.
13. Click OK, but leave the machine in Off Line mode. The conveyor belts move as the system
tries to locate a possible board.
Aligning the QX500 System

CyberOptics recommends alignment should be performed once a month. You may also want to
align the cameras if you are experiencing false out-of-position errors or if a SIM module has been
replaced.
The QX500 system is aligned in Off Line mode using a glass calibration target and a specific
calibration assembly file. Before you start alignment, you should ensure that the glass plates of
the calibration target are fitted snugly against the left and bottom stops of the target's support
frame.
If the glass plates feel loose, finger-tighten the plastic buttons and the cap screws to secure the
plates into position. Over-tightening the capscrews can cause distortion or lead to fractures in
the glass plates.
Caution: Do not disassemble the calibration target. System alignment and performance are
dependent on a correctly assembled calibration target.
ÿ To align the QX500 system
1. On the QX500, turn the Mode Control switch to Off Line mode and allow the conveyor to
reset itself.
2. Remove all panels from the conveyor.
Note: If you open the upper door of the QX500 to check for boards, after you close the door, you
i will need to restart the stepper motor controller before continuing with alignment.
3. Press the Reset/Start button on the QX500 and allow the conveyor to reset itself.
The amber light on the signal tower should flash.
4. On the Launch Pad, click Calibrator.
5. If the system has not been aligned before, a message appears asking if you want to adjust the
conveyor width. Click Yes. If the conveyor width is already correct, go to step 8.
machine is in Off Line mode.
then click OK.
The Conveyor Width Adjuster dialog box opens and displays the width entered the last time
the dialog box was opened.
7. Adjust the conveyor as described in “Adjusting the Conveyor Width” on page 50, using the
calibration target width (460 mm).
8. Position the calibration target on the conveyor at the left side of the SIM module.
The system draws the calibration target into the machine, indexes the target as it captures the
images.
9. The message appears prompting you to put the machine in Inspect mode before inspecting
in-line. Click OK, but leave the machine in Off Line mode.
The Calibrator opens the calibration assembly used in the previous session and displays the
name of the assembly in the title bar.
10. Verify that the name of the calibration assembly matches the serial number printed on the
calibration target. If the name of the assembly does not match, open the correct assembly.

Aligning the QX500 System
11. In the Calibrator, select Image > Live.

The system resets the cell, indexes the calibration target and then displays the image of the
lower plate. Make sure that the machine is not bumped or vibrating excessively during the
image acquisition process.
Calibrator title bar
Calibration Statistics
panel
Graphical Calibration
browser
12. Select Calibration > Start.
The QX500 system takes approximately five minutes to finish the alignment and display a
message stating whether the alignment passed or failed. During the process, each camera is
checked, one at a time on each plate (upper and lower).
• If the alignment passed, the QX500 system displays green squares around all the
roundels. The message board passed should also appear in the Status Bar.
• If the alignment failed, the QX500 system displays red squares around the failed
roundels.
13. In the Calibration Statistics panel, verify the results of the alignment. The mean should
be 0.2 or less and the standard deviation should be 4.0 or less.
14. Select View > Image > Raised to view the results for the upper plate of the calibration target.
Verify the results in the Calibration Browser and Calibration Statistics panel. Both plates must
pass calibration for the QX500 system to capture images correctly.
Note: To view the alignment results in more detail, select View > Results to open the Results
i Window.
15. If the alignment is not successful, check the camera setup and correct any problems.
16. After a successful alignment, select File > Save Calibration.

17. Select File > Exit to close the Calibrator.
18. Carefully remove the calibration target from the conveyor and store it in a safe place.

Shutting Down the System
Shutting Down the System

ÿ To shut down the system
1. Stop the inspection process.
2. Press the E-Stop button.
3. Exit the inspection application.
4. On the taskbar, click Start and then click Shut Down to shut down the system processor.
Caution: Turning off power at the power switch does not remove power from the processor and
AC Main circuit breaker. The AC main circuit breaker must be turned OFF to remove power
completely from the machine.
5. Turn off the power switch on the front of the unit. This removes all power from the system with
the exception of the processor power.
Power Switch
Figure 40. Shutting Down the System
ÿ To remove power entirely

1. Turn off the power switch on the front of the unit.
2. On the rear of the machine, turn the AC main circuit breaker to OFF.
Moving the QX500 System
Caution: The QX500 unit weighs approximately 400 kg (882 lbs.). To avoid injury, always use
a forklift or a pallet jack to move the unit. The forklift's forks need to securely hold both cross
beams under the unit. Otherwise the forks may damage the electronics undercarrage.
Disconnecting Utilities from the System

Use the following procedure as a checklist to make sure that all of the external connections to
the QX500 system are disconnected before you move the system.
ÿ To disconnect the system
1. Shut down the QX500 as described in “Shutting Down the System” on page 59.
2. Disconnect the AC wiring from the breaker on rear of the machine.
3. Disconnect any additional external connections to the processor, such as USB connections.
4. Disconnect external connections to the rear electrical panel, such as the network, SMEMA,
or cables, if used.
Bypassing the QX500 System

The QX500 bypass mode allows panels to run through the machine without inspection. In the
event of certain hardware failures, the system can be temporarily bypassed.
Failures include defective conveyor motor, defective SIM module (Camera).
ÿ To engage bypass mode

1. Turn the Mode Control switch located at the front of the machine to “PASS THROUGH” to
bypass the system.
Mode Control Switch
Figure 41. Location of Mode Control Switch for bypassing the system

4 Replacing Components and

Preventive
maintenance
Maintenance Schedule 62
Processor Components 73
Other Components 92
Chapter 4: Replacing Components and Preventive Maintenance
Maintenance Schedule
Perform the maintenance procedures in this section as specified in the maintenance schedule
below. Perform maintenance more frequently as required, based on machine usage.
Warning: To prevent the risk of injury, turn the AC main circuit breaker to OFF to shut down all
electrical power to the QX500 before starting any replacement operations. For more information,
refer to the section “Shutting Down the System” on page 59.
Table 9. Maintenance Schedule

Frequency
maintenance monthly annually Page
Cleaning Rear Fans every 3 months 71
Cleaning Inside the Enclosure every 3 months 72
Cleaning Main Electronics Panel every 3 months 72
Cleaning Inside the Processor every 3 months 81
Cleaning the Panel Sensors every 3 months 91
Replacing the Conveyor Belts once a year 83
Replacing the Tensioner Pulley Every 3 years 87
Backing Up Data once a month 79


This section contains procedures for maintenance and replacing the following electrical panel
components:
• Conveyor Motors
• Safety Relay and Contactor
• Power Supplies
• Circuit Breakers
• Electrical Cables
• Fuses
Warning: To prevent the risk of injury, turn the AC main circuit breaker to OFF to shut down all
electrical power to the QX500 before starting any replacement operations. For more information,
refer to the section “Shutting Down the System” on page 59.
ÿ To replace DIN rail-mounted components
4. Gain access to the main electrical panel by removing two screws that secure the lower front
panel to the machine frame.
5. Identify the part to replace (see Figure 43 on page 64) and disconnect the wires from the
terminals.
6. If present, remove attaching screws from the component.
7. Insert a flat blade screwdriver underneath the component and press down on the tab to
release it from the rail.
Releasing from DIN rail Latching onto DIN rail
Figure 42. DIN Rail Mounting
8. Hook the component onto the upper edge of the DIN rail and press downward to latch it onto
the rail.
Conveyor Engine Conveyor Width PS1- 5 A

controller Engine Controller PS2- 5 A Safety Relay relays
PS1 PS2
PLC
PS2–24V PS2–0V
Figure 43. Main Electrical Panel

Replacing Electrical Cables

The following diagram contains origin, destination, and general routing information for
electrical cable replacement. Route replacement cables exactly the same as the originals.
' ! ! %= 1 4 >?
1/
"
%
*+ 0-
'')
$ %&'( '-!., /%0
--!
## #
(#
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%= 4 "
#
#
##
(((
# #(
(#
( (((
%=
4
" %*+
%*+'
" 560 ' 7 8'
0
< 23)
%&'( %&' 0- %&' )% 23) ((( 9-
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$ )% / '4- '')
)% /
'-!.,
/%0
--! %*+' # 1 -
%;4
/% # /% 7 8' # 78:; -
(two,% # (two,% ' ' 9- !8
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1 - # %*+
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( 78:; - #
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,% /0 #
((( )% 23)
' 4- (
/4-04 /
560
560' 4- #(
%, #(
# 23)
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Figure 44. Main Electrical Cable Route Diagram
Replacing the AC Main Circuit Breaker
parts
AC Main Circuit Breaker
i Note: For Parts Replacement, contact CyberOptics for part numbers.
Warning: Hazardous voltages may be present. Make sure that power is disconnected from the mains before
replacing the AC Main circuit breaker.
ÿ To replace the AC main circuit breaker

1. Turn off all electrical power to the system. For more information, refer to the section “Shutting Down
the System” on page 59.
2. Verify that AC main power is off and locked off. Use the voltmeter to verify that the power is
Off.
3. Loosen the four screws and remove the Power access cover (see Figure 45 on page 67).

4. Gently pull out the wires to disconnect the outside line power (L and N) and the system
power. Remove and replace the circuit breaker on the DIN rail.
Back Electrical Panel Power access cover (Loosen) screws (x 4)
Main AC
circuit
breaker
strain
relief
nut
L (brown)
N1 L1
power cord
(AWG 14–16)
L2 N2 PE PE PE FOOT
NL
N (blue)
Screwdriver
GND (yellow)
striped wire
Pry open the crimping

connector using a
screwdriver and insert the
conductor.
NOTE: The QX500 does not come with the power cord.
Figure 45. Replacing the Circuit Breaker

5. Reconnect the wires for outside line and system power.
The. Insert a screwdriver to release the crimp-style connector.
B. Insert the stripped portion of the wire into the connector.
ç. Remove the screwdriver to allow the connector to crimp the conductor.
d. Pull the wire to ensure it is secured.
6. Place the power access cover back onto the panel and secure in place with four screws.
7. Turn the AC main circuit breaker to ON.
Replacing the Fuses
parts
Fuse 10 A
Fuse 6 A
Warning: Hazardous voltages may be present. Make sure that power is disconnected from the mains before
replacing the fuse.
Caution: Recommended that only trained service personnel perform this operation.
ÿ To replace the fuse

1. On the rear of the machine, turn the AC main circuit breaker to OFF.
2. Verify that AC main power is off and locked off. Use the voltmeter to verify that the power is
Off.
3. Pull out the faulty fuse and replace with a new fuse of the same rating. Refer to Table 10 for
more information.
4. Turn the AC main circuit breaker to ON.
Table 10. Fuse Listings

Circuit Breaker Rating Purpose
CB2 6.0 A To protect the processor outlet
CB3 6.0 A To protect PS1
CB4 6.0 A To protect PS2
CB5 10.0 A spare

Conveyor Width PS1- 5 A

Conveyor Motor Controller Engine Controller PS2- 5 A Safety Relay relays
PS1 PS2
PLC
PS2–24V PS2–0V
fuses
6.0 A 6.0 A 6.0 A 10.0 A
Replacing Fans
parts
8009605 Fan
ÿ To replace the fan

Back Electrical Panel

Cooling Fan M4 screws x 4
Figure 46. Location of Fans
2. Remove the metal fan guard by removing four M4 x 40 screws on each fan.
3. Remove the fan.
4. Disconnect the cable from the fan.
5. Connect the new fan to the cable. Orient the fan so the air flows out of the machine.
6. Secure the fan in place with the screws.
7. Secure the metal fan guard with four M4 x 40 screws.

Preventive Maintenance
Cleaning Rear Fans
Perform this procedure monthly or more frequently if required.
ÿ To clean rear fans
2. Locate the fans on the back electrical panel.

Back Electrical Panel
Cooling Fans
Figure 47. Rear Fans
3. Using a dry cloth, remove any dust covering the fans and wipe off the remaining dust from
the outside of the air intakes.
4. On the inside check the fans for dust buildup. Remove dust buildup using dry cloth.
Keep away from the system so the dust will not get into the electronics panel.
5. Set the AC main circuit breaker to ON.
Cleaning Inside the Enclosure

ÿ To clean the inside of the enclosure
Warning: Make sure the AC main circuit breaker is turned OFF and power is disconnected from
the mains before starting on any procedure.
2. Lift the system hood.
4. Use a dry cloth to wipe debris off the inside of the hood, conveyor rails, the gantry, etc.
Note: For residue such as solder paste, it removes the substances from inside the system with
i clean, dry cloth.
Cleaning Main Electronics Panel

ÿ To clean the main electronics panel
4. Remove two screws that secure the lower front panel to the machine frame.
5. Using clean, dry, compressed air, remove the dust buildup from the main electronics panel.
Keep away from the system so the dust will not get into the electronics panel.
6. Replace the lower font panel.
7. Close the QX500 hood.

Processor Components
QX500 before starting any replacement operations. For more information, refer to the section
Replacing Cards
Use the following procedure to replace circuit cards in the QX500 processor. Refer to Figure 48 on
page 74 for circuit card locations.
Caution: The circuit cards contain components that can be damaged by static electricity. Use
the ground strap when handling circuit cards to prevent damage to sensitive components.
ÿ General card replacement procedures
4. Remove the lower front panel by removing two screws along the top edge of the panel.
5. Remove all the cables to release the processor from the system frame.
6. Gently place the processor on the ground in front of the machine, being careful not to strain
the cable connections on the rear of the processor.
7. Remove processor cover by sliding the cover plate back toward the rear connectors.
8. Disconnect any internal cables from the card.
9. Remove the screw holding the card to the processor case.
10. Gently slide the card out of the processor case.
11. Slide the new card into the processor case, gently pushing it into place until it seats firmly in
the backplane connector.
12. Secure the card in place with the screw.

13. Reconnect cables to the card.
14. Slide the processor back into the machine frame.
USB Ports
Serial Port RS-232

(COM1)
Video Port
(on board)
Ethernet Ports
USB Ports
Serial Port RS-232

(COM2)
Parallel Port
Figure 48. Card Locations in Processor
Software Upgrades
The QX500 software can be upgraded or re-installed from the DVD-R/W drive. Keep all
software media in a safe and accessible place.
ÿ To install software
1. Place the installation Disk in the DVD-R/W drive.
2. By default, the installation setup should auto-run by itself. If it doesn't, navigate to and
double-click on the Setup.exe file located on the Disk.
3. Follow the on-screen prompts to install the System Software. There is a selection for
choosing to install QX500 configuration.
4. After installing the software, restart the processor.

Restoring system disk using Acronis
Use this procedure to restore the system disk if the system hard drive is replaced or if the operating
system becomes corrupt. The system drive on QX500 machines is the C drive and holds the Windows
operating system.
i Note: This procedure restores the system to the configuration shipped from the factory.
The system disk can be restored either from a Secure Zone located on the disk itself, or from a disk image
CD shipped with the system. This section provides instructions for both methods.
• Use the Acronis™ Boot Disk and Secure Zone: when the operating system does not work properly,
but the hard drive can be accessed. (In some cases you can still boot from the hard drive – see “Starting
the Acronis Recovery Program” below.)
• Use the Acronis Boot Disk and the QX500 Recovery Disk: when the hard drive has been
accessed, or the hard drive cannot be replaced.
Starting the Acronis Recovery Program
The system disk can be restored wither from a secure zone located on the disk itself, or from a disk image
CD shipped with the system. This document provides instructions for both methods.
• Use the Acronis™ OEM Zone: when the operating system does not work properly, but the hard drive
can be accessed – see “To Boot from the Hard Drive” on page 75.
• Use the Acronis Boot Disk and the QX500 Recovery Disk: when the hard drive has been replaced, or
the hard drive cannot be accessed – see “To Boot from the Acronis Boot CD” on page 76.
ÿ To Boot from the Hard Drive
If the hard drive is still accessible, boot from the OEM Zone on the hard drive. To do this:
1. Start the computer and watch the screen for the Starting Acronis Loader … Acronis Backup Recovery
Manager prompt.
2. Press F11.
3. At the Windows/Acronis screen, select the option for Acronis True Image (Full Version)
and press Enter.
4. At the password prompt enter dontPanic.
ÿ To Boot from the Acronis Boot CD
If the computer will not start, boot from the Acronis Boot CD. To do this:
1. Insert the Acronis Boot CD into the computer.
2. Start the computer.
3. At the Acronis Rescue Media Screen, select Acronis True Image (Full Version).
Recovering the Disk Image
When booting into Acronis, the True Image screen opens as shown below.
1. Click Recovery to start the Restore Data Wizard.
2. If you are restoring data from the QX500 Recovery disk, remove the boot CD (if used) and
replace it with the QX500 Recovery Disk.
3. In the Restore Data Wizard Welcome screen click Next.

4. In the Archive Selection screen, select the location from which to recover data. you can
choose only one archive to restore. If the hard drive is not accessible, you must choose to
restore the *.tib file from the Acronis Media CD (QX500 recovery disk).
Restore from OEM Zone
Restore from Boot Disk
5. Click Next.
6. Click OK at the Warning prompt.

• If you are restoring from the OEM Zone, click Proceed at the next prompt and go to step
13.
• If you are restoring from the Boot Disk, click Proceed at the next prompt and continue
with step 7.
7. In the partition or Disk to Restore, select Disk 1, this automatically selects NTFS and MRB
listed below the Disk 1 entry. Click Next.
8. In the Restored Hard Disk Drive Location screen, select Disk 1 and click Next.
9. In the Restored Partition Resizing Screen, select No, I do not want to resize partitions and
click Next.
10. In the Non-Empty Destination Hard Disk Drive screen, select Yes, I want to … and click
Next.
11. In the Next Selection screen, select No, I do not. and click Next.
12. In the Additional Settings screen, leave the checkbox clear and click Next.
The Restore Summary screen opens as shown below.
Restore from OEM Zone
Restore from Boot Disk
13. To change any of the settings, click Back. When the summary information is correct, click
procedure
The program begins the restore process and displays a progress meter, showing the time
remaining. The process takes approximately 10 minutes to complete.
14. When the Restoration Complete prompt appears, remove any disks from the CD tray and
click OK.
The Acronis program closes and the system restarts into the Windows operating system.
15. Shut down the system, then restart the system.

Backing Up Data
It is possible that the hard drive may fail due to wear and tear and hence it is important to
backup the key data files so that data can be recovered and the impact on production is reduced.
If possible, the entire D:\QX500 folder must be backed up as this preserves the entire content of
the QX500 application and ensures data recovery close to 100 percent. However, this requires
a minimum of 150MB of disk space on a newly installed system and can increase to several
Gigabytes in size for a system which has been in use for a long time with many assemblies.
Hence, the most critical folders that need to be backed up are listed in the following tables.
**Backup criticality indicates how critical it is to backup a particular folder with 1 being the
most critical and 5 being the least critical or not necessary.
folders Contents Backup Criticality**
assemblies Contains the assemblies used for 1

inspection. Backup mandatory.
CAD Format Contains CAD formats used for two
creating assembly.
config Contains configuration information and 1

system properties settings
geometries Contains geometry files two
InspectionCells Contains machine calibration files 1
models Contains models used for 1

inspection
Template Contains Unit and Composite 1

template repository
OUI Framework Contains the Operator User 1

Interface (OUI) files as well as the
configuration files for the PREH rework
keyboard
It is also important to backup the following file located in the main directory (D:\QX500).
folders Contents Backup Criticality**
Environments.cfg Environment variables used by 1

QX500 software
If the entire Drive D where QX500 resides needs to be backed up, CyberOptics recommends that
you examine the following folders before backup.
Folders/Files Reason
FullResults Contains the full inspection results. If the operator has reviewed all the
defects produced so far, it is usually deleted after review (depending on
system properties settings).
If the system is not setup to delete these files after review, the content can
be huge. Hence, you need to decide if the entire content needs to be
backed up or not.
XML Contains the full inspection results in XML format and can be huge. If
Process Insight is used to extract data from this folder via XMLWatcher,
this folder is usually small (if XML watcher is setup to delete these files
after extraction) and its size is not a concern. However, it is recommended
that you do a quick check to ensure the contents before creating a huge
backup.
Results Contains results which is used mainly for statistician and does not need to
be backed up, if you are not performing GR&R studies.
images Contains board images. This folder need not be backed up unless
required.

Cleaning Inside the Processor
Warning: Make sure the AC main circuit breaker is turned OFF and power is disconnected from the
mains before starting on any procedure.
ÿ To clean inside the processor
5. Remove two screws at the top of the processor that secure it to the machine frame.
6. Gently slide the processor part way out of the machine, being careful not to strain cables
connected to the rear.
7. Disconnect from the rear of the processor, taking note as to the correct cables connections.
8. Remove the processor cover.
9. Use a dry cloth to clean the dust buildup out of the processor and keep away from the
system, so dust will not be blown into the electronics panel.
10. Replace the processor cover.
11. Reconnect the cables. See Figure 48 on page 74 for cable connections.
12. Slide the processor back into the machine and secure in place with two screws.
ÿ To clean the processor's air filter
Warning: Make sure the AC main circuit breaker is turned OFF and power is disconnected from
the mains before starting on any procedure.
5. Lift the air filter up and out from the front of the processor.
Air Filter
Figure 49. Processor Air Filter

6. Using clean, dry, compressed air to remove the dust buildup from the air filter. keep away
from the system so the dust will not be blown into the electronics panel.
7. Replace the air filter in the front of the processor.


Conveyor Components
Conveyor Components
This section contains procedures for replacing the following conveyor components:
• Conveyor engines • Tension pulleys and conveyor belts
Caution: Turn the AC main circuit breaker to OFF to shut down all electrical power to the QX500 unit
before replacing any parts or components. For more information, refer to the section “Shutting Down the
Warning: Make sure the AC main circuit breaker is turned OFF and power is disconnected from the
mains before working inside the hood. Conveyor motion can pinch or sever objects in its path.
Replacing the Conveyor Belts

Use this procedure to replace the conveyor belts on the fixed or the moveable railsets. This procedure
can be performed with access to the left/right of the machine in production line. This section shows the
procedures performed when the machine is not in the production line.
parts
Conveyor Belts
Required Tools
– No. 2.5 Allen Key wrench
– No. 3 Allen Key wrench
– No. 4 Allen Key wrench
– Threadlock Sealant
ÿ To replace the conveyor belt on moveable rail
2. Make sure the SIM module is at the HOME position without blocking any portion of the
rail.
3. Make sure the widths of the rails are in the “OPEN” position such that it is easy for
performing the replacement of the belts. The recommended width is approximately 50 cm.
4. Remove the two M4 screws attached to the belt guide bar using Allen Key No. 2.5.
Remove the belt guide bar.
M4 x 12 screws
Belt guide bar
Figure 50. Conveyor rails opening

5. Remove the M5 x 30 screw at the end of the moveable rail using Allen key No. 3.
6. Loosen the M6 x 35 screw attached to the tensioner pulley using Allen key No. 4.
M6 x 35 screws
M5 x 30 screws
Figure 51. End bearing screw on moveable rail

7. Remove the M4 screws on the coupling using Allen key No. 2.5.
Note: Make sure the coupling is facing up when removing the screws for easy access
and visibility.
M4 screws x 4
Figure 52. Coupling screws

Conveyor Components
8. Loosen the belt and remove the belt through the opening as shown.
9. Replace with a new belt and route to the pulleys.
10. Tighten the M6 screw to the tensioner pulley at 8NM after applying adequate threadlocking
sealant.
11. Replace the belt guide bar and tighten with the two M4 screws to 2NM.
ÿ To replace the conveyor belt on fixed rail
Tools Required Allen

Key No. 2.5 Allen
Key No. 3 Allen
Key No. 4 Allen
Key No. 5 Spanner
No. 10
2. Ensure that the SIM module is at the HOME position without blocking any portion of the
rail.
3. Make the widths of the rails in the “OPEN” position such that it is easy for performing the
replacement of the belts. The recommended width is approximately 50 cm.
4. Remove the two M4 screws attached to the belt guide bar using Allen Key No. 2.5. remove
the belt guide bar.
5. Remove the M5 x 30 screw at the end of the moveable rail using Allen key No. 3.
6. Loosen the belt.
7. Loosen the nut on the tensioner block with spanner No. 10.
8. Remove the belt from the rail.
9. Replace with a new belt and route the belt to the pulleys.
10. Tighten the nut to the tensioner block at 5NM.
11. Tighten the M5 screw to the end of the fixed rail at 5NM.
12. Replace the belt guide bar and tighten with two M4 screws to 2NM.
M5 screw M4 screws x 2
M6 screw
Belt guide bar
tensioner block
Figure 53. Fixed Conveyor rail

Conveyor Components
Replacing the Tensioner Pulley
Use these procedures to replace the Idler pulleys on the front or rear railsets. This procedure can be
performed with access to the left/right of the machine in production line. This section shows the procedure
performed when the machine is not in production line.
parts
Idler Pulley
Required Tool
– No. 2.5 Allen Key
ÿ To replace the Tensioner pulley

1. Ensure that the SIM module is at the HOME position without blocking any portion of the
rail.
2. Make the widths of the rails in the “OPEN” position such that it is easy for performing the
replacement of the belts. The recommended width is approximately 50 cm.
4. Open the front cover from the machine.
5. Loosen the M6 setscrew using Allen Key No. 4.
6. Remove the tensioner pulley from the rail and replace.
7. Tighten the setscrew to 8NM.

Pulley tensioner
Figure 54. Fixed Conveyor Rail
ÿ To set the belt tension
1. Measure 123 mm from the idler pulley, taking the red line as the reference and make a
marking.
2. Push the bottom belt down by 25 mm at the 123 mm distance away from the idler pulley.
3. Use the push and pull gauge to measure, the reading should read about 40N±2N.
123 mm
bottom belt
Figure 55. Conveyor Fixed Rail
Push the bottom belt by 25 mm
123 mm
Figure 56. Front View of Conveyor Fixed Rail

Conveyor Components
Replacing the Conveyor Motors
Use this procedure to replace the conveyor motors. This procedure can be performed with access to the
front of the machine in production line. This section shows the procedures performed when the machine is
not in the production line.
parts
DC Brushless Motor
ÿ To replace the conveyor motor

2. Remove the mounting screws from the motor.
Mounting screws x 4
3. Remove the motor from the motor bracket and unscrew the drive pulley by using the Allen key No. 2.5
from the setscrew.
4. Transfer the drive pulley to a new motor and tighten it, then replace it at the bracket and tighten
back with screws.
ÿ To replace the width opening motor

2. Remove the handwheel.
3. Remove the mounting screws from the motor.
handwheel
Bracket motor
Mounting screws x 4
4. Remove the motor from the motor bracket and unscrew the drive pulley by using the Allen key
No. 2.5 from the setscrew.
5. Transfer the drive pulley to a new motor and tighten it, then replace it at the bracket and
tighten back with screws.

Conveyor Components
Cleaning the Panel Sensors
The conveyor contains two sensors as shown in Figure 57.
Warning: Make sure the system power is turned off before working inside the hood. Gantry
motion can pinch or sever objects in its path.
ÿ To clean the panel sensors

2. Open the QX500 hood.
4. Use a dry, soft cloth with household glass cleaner.
5. Gently wipe the panel sensors lenses.
i Note: Do not use solvents or abrasives to clean the panel sensor lenses.
Entry/Exit Proximity Sensor
Figure 57. Conveyor
Other Components
This section contains procedures for replacing the following QX500 system components:
• Safety Interlock Switch • Leveling Feet
QX500 unit before starting any replacement operations. See “Shutting Down the System”
on page 59 for this procedure.
Replacing the Safety Interlock Switch

This procedure can be performed with access to the front of the machine in production line.
This section shows the procedure performed when the machine is not in production line.
parts

Safety Interlock Key
ÿ To replace the safety interlock switch
2. Open the QX500 hood.
4. Remove three screws to take off the cover to the safety interlock switch.
Safety interlock switch detail.

Disconnect wires (steps 4 through
7 on 92) before removing the switch.
Figure 58. Safety Interlock Switch Access

5. Disconnect the six wires in the box.
6. Remove the strain relief nut and pull the cable out of the switch.
7. Remove two screws at the top and remove the safety interlock switch.

Other Components
8. Loosely attach the new safety interlock switch onto the bracket with two screws.
9. Re-insert the cable through the strain-relief nut.
10. Reconnect six wires. Refer to the color coding table in Figure 59.
11. Install the cover onto the safety interlock switch.
brown Red black
color sign
black safety relay coil
White safety relay coil
Red safety relay coil
Green Ground
Brown +24V pilot

blue interlock signal
blue green white
Figure 59. Safety Interlock Switch
ÿ To align safety interlock switch
1. Press the green ON button to turn on system power.
2. Close the hood to make sure the pin is lined up with the safety interlock switch socket. To check
the alignment:
• Re-engage the E-Stop.
• Observe the safety circuit relays inside the electronics panel. The LEDs should be turned
on
3. Adjust the switch for correct alignment and tighten the mounting screws.
Replacing Leveling Feet
ÿ To replace leveling feet

1. Using a forklift, raise the QX500 frame off the floor.
2. Remove the two M8 screws that secure the plate and foot assembly to the frame.
3. Replace the damaged leveling foot.
4. Reassemble the foot assembly onto the frame.
5. Repeat steps 1– 4 as required to replace the other leveling feet.
6. Adjust the leveling feet as needed to align the QX500 with the conveyors. for more
information, refer to the section “Positioning / Leveling the QX500 System” on page 36 for
details.
locking nut
adjustment nut

5 Troubleshooting
Safety Circuit Block Diagram 96
AC and DC Distribution Block Diagram 97
SMEMA Connector Pinout 98
Chapter 5: Troubleshooting
Safety Circuit Block Diagram
1-6 /4- 04
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9+1+
)( ( ( ((( (
( (
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!

AC and DC Distribution Block Diagram
AC and DC Distribution Block Diagram
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-two "
!"#
two "
$ %# "'
& ()
!"#
% * +
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( ''#-/&
(,-.#- (&
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-( '' 0 1 ( '' 0
4' 5(
$ two ! $3
Chapter 5: Troubleshooting
SMEMA Connector Pinout

The SMEMA cables allow the QX500 to communicate with the upstream and downstream
conveyors. The recommended length for SMEMA cable is less than 3m. For more information
about SMEMA cables, refer to “Connecting SMEMA Cables” on page 46.
SMEMA Connector
1 two 3
4 7
8 11
12 14
pin Upstream Cable Downstream Cable
1-2 Machine Ready -
3-4 Board Available Board Available
7-8 Failed Board Available Failed Board Available

THE Appendix
EU Declaration of Conformity 100
Microstep Driver Setting Diagram 101
QX500 I/O List 102
Chapter A: Appendix
EU Declaration of Conformity
EU Declaration of Conformity
According to EC Machinery Directive 2006/42/EC
We herewith declare, name : CyberOptics
address : No 21, Ubi Road 1, #02-01, Singapore 408724
that the following machine in our delivered version complies with the appropriate basic safety and health
requirement of the EC Machinery Directive 2006/42/EC based on its design and type, as brought into
circulation by us. In case of alteration of the machine, not agreed upon by us, this declaration will lose its
validity.
Description of the machine/machinery part : QX500

machine type : Automatic Optical Inspection Equipment
Serial Number :
Applicable EC Directives:
EC Machinery Directive (2006/42/EC)
EC Directive of Electromagnetic Compatibility (2004/108/EC)
Applicable Harmonized Standards:
EN ISO 12100-1: 2003 Safety of machinery - Basic concepts, general principles for design -
Part 1: Basic terminology, methodology
EN ISO 12100-2: 2003 Safety of machinery - Basic concepts, general principles for design —
Part 2: Technical principles
EN ISO 14121-1: 2007 Safety of machinery - Risk assessment - Part 1: Principles
EN 954-1: 1996 Safety of machinery - Safety related parts of control systems - Part 1:
General principles for design
EN 60204-1: 2006 Safety of machinery - Electrical equipment of machines - Part 1: General
requirements
EN 12198-1: 2000 Safety of machinery - Assessment and reduction of risks arising from
radiation emitted by machinery - Part 1: General principles
EN 61000-6-4: 2007 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards.
Emission for industrial environments.
EN 61000-6-2: 2005 Electromagnetic compatibility (EMC) – Part 6-2: Generic standards.
Immunity for industrial environments.
Mr. Sean Langbridge is appointed as the responsible person for collecting the technical files.
Address: The High Laithe, Gargrave Road, Broughton Skipton, North Yorkshire BD23 3AQ, United
Kingdom.
This Declaration of Conformity is valid from April xx, 2010.
Date/Authorized Signature:
-------------------------------------------------- -------------------------
Full Name: Chuanqi Chen

Title: Engineering Director
Address: CyberOptics (Singapore) Pte Ltd, No 21, Ubi Road 1,
#02-01, Singapore 408724.
Document Number: 8015902 Review: A Gives you: April xx, 2010

Microstep Driver Setting Diagram
Microstep Driver Setting Diagram
- 4' '6 36 %6 7
+889 . ( 3 3 "9 #
' 6
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. % " :$ 4 '
two 79& &.#

Chapter A: Appendix
QX500 I/O List
Table 1: Input I/O
I/O Description Remarks
X00000 spare
X00001 spare
X00002 Pulse Output 1: Origin Input Sensor Home Sensor for WM
X00003 High-speed Counter 0 (Z-phase/reset)

X00004 spare
X00005 spare
X00006 spare
X00007 spare
X00008 High-speed Counter 0 (A-phase)
X00009 High-speed Counter 0 (B-phase)
X00010 spare
X00011 spare
X00100 spare
X00101 Safety Relay Activate AT THE
X00102 spare
X00103 Left Sensor#L1
X00104 Right Sensor#L1

X00105 Start PB
X00106 Mode 0 Pass Through, Inspection, Off Line

X00107 Mode 1
X00108 SMEMA#L1 - BA From US Board available from US
X00109 SMEMA#L1 - MR From DS Ready to receive from DS

X00110 spare
X00111 spare

QX500 I/O List
Pass Through inspection Off Line
Mode 0 (X00106) on Off Off
Mode 1 (X00107) Off Off on
Table 2: Output I/O
I/O Description Remarks
Y10000 Pulse Output 0 (Pulse) CM
Y10001 Pulse Output 1 (Pulse) WM
Y10002 Pulse Output 0 (Direction) CM
Y10003 Pulse Output 1 (Direction) WM
Y10004 spare
Y10005 spare
Y10006 spare
Y10007 spare
Y10100 Tower Light, Red
Y10101 Tower Light, Amber
Y10102 Tower Light, Green
Y10103 Tower Light, Blue
Y10104 Tower Horn
Y10105 spare
Y10106 spare
Y10107 Disable Width Driver#L1 WM, R1
Y10200 SMEMA#L1 - MR To US Ready to receive Board to US, R2
Y10201 SMEMA#L1 - BA To DS Board available for DS, R3
Y10202 SMEMA#L1 - GB To DS Good Board to DS, R4
Y10203 SMEMA#L1 - BB To DS Bad Board to DS, R5
Y10204 Start PB Green Light
Y10205 spare
Y10206 spare
Y10207 spare

Chapter A: Appendix

Index
THE Cooling fans

AC circuit breaker description 18
location 18 location 18
AC input rating label 11
AC main circuit breaker
location 18 D
Date
replacing 66
acronis backing up 79
diagrams
restoring system disk 75
Safety circuit 96
Adjustment wheel
Digital Inputs/Outputs
description 23
Indicators 98
Aligning
Dimensions 27
safety interlock switch 93
Disconnecting
Aligning the system 36
system 60
Documentation vii
B drive belts
back access cover description 23
location 18 drive motors
Backing Up Data 79 description 23
Belts
conveyor, description 23
AND
drive, description 23
Electronics panel
motor controller description 21
cleaning 72
Email ix
Ç Emergency stopping 3
cables Enclosure
Replacing 65 cleaning 72
Choosing an installation location 34 Engaging
Circuit breaker, replacing 66 safety shield for Machine Maintenance 6
circuit breakers ESD grounding plug
description 21 description 16
cleaning ESD strap connection 17
inside enclosure 72 E-Stop
main electronics panel 72 description 16
rear fan 71 E-Stop button
location 17
COM port
ethernet connector
description 18
Computer requirements 26 description 18
Connecting
power 43
F
signal-light pole 35
fans
SMEMA cables 46
to network 47 replacing 70
Fixed rail motor controller
Contacting CyberOptics ix
control buttons description 21
description 16
Conveyor
I
description 19 I/O channel indicators 98
manual adjustment wheel description 23
indicator lights 6
engines, replacing 89
Indicators, digital I/O 98
Conveyor belts
installing
description 23 sensor 40
system 34
Conveyor width motor controller interlock switch
description 21
Index
aligning 93 R
replacing 92 Read manuals label 10
Rear fan
K cleaning 71
removing power 59
Keyboard
replacing
description 16 AC main circuit breaker 66
location 17
conveyor motors 89 fans 70
Fuses 68
L
labels processor components 73
safety interlock switch 92
AC input rating 11
Replacing Cards 73
Manufacturing Information Conformance 13
Replacing the Conveyor Belts 83
protective earth ground 12 read manuals 10
Requirements
computer 26
Leveling feet
system 25
adjusting 36, 39
Restoring
description 16
location 17 repair system disk using Acronis 75
94
QX500 4 Lockout s
Safety
M guidelines 2
Main Electrical Panel labeling 8
Main 63 Safety circuit block diagram 96
Safety contactor
Main electrical panel
description 21
description 19
maintenance Safety enclosure
location 17
preventive 71
Mode Control Switch Safety interlocks
aligning switch 93
description 16
Monitor replacing switch 92
Safety Interlocks on top cover 5
description 16
location 17 Safety shield
Engine controller engaging 6
Sensor
description 21
description 19
Engine, conveyor (replacing) 89 installation 40
Motors
Sensors, panel
drive, description 23
Movable rail motor controller description 23
Service
description 21 email ix
moving the system 60
Shutting down the system 59
Signal-light pole
No attaching to system 35
Network connection 47 description 16 indicator
lights 6 location 17
P SMEMA connector
Panel sensors description 18
location 18
description 23
Positioning the system 36 pinout 98
Power SMEMA, connecting cables 46
removing 59 Software Upgrades 74
turning on system 45 Specifications
Power access cover performance 26
location 18 system 24
Power supplies System
dimensions 27
description 21
power switch disconnecting 60
description 16 moving 60
location 17 positioning 36
Preventive Maintenance 71 requirements 25
backup data 79 shutting down 59
Conveyor components 91 specifications 24
processor components 79 turning on power 45
Processor unpacking 33
description 19 System processor
replacing components 73 description 19
Protective earth ground label 12 replacing components 73
106 QX500 Hardware Reference

T
Trackball
description 16
location 17
u
unpacking system 33
USB port
location 18
W
website ix
Wiring the system 43

Index
108 QX500 Hardware Reference

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Warranty, License, and Terms of Sale

QX500 Hardware Manual (Original Instructions)

General Guidelines two

Installing the System 35

Installing the Sensor (SIM Module) 40

Aligning the QX500 System 56

4 Replacing Components and Preventive Maintenance 61

AC and DC Distribution Block Diagram 97

Microstep Driver Setting Diagram 101

QX500 I/O List 102

iv QX500 Hardware Manual

saw QX500 Hardware Manual

Manual Change Request

CyberOptics Corporation vii

Manual Change Request

Originator: Gives you:

machine Serial Number Software Version

Manual Revision/Date Page No. or Figure No.

Check if page is attached

Fax or email to:

viii QX500 Hardware Manual

International Technical Support Center

x QX500 Hardware Manual

Safety Guidelines two

Safety and Conformity Labeling 8

two QX500 Hardware Manual

Using the Emergency Stop Button (E-Stop)

Figure 1. Emergency Stop Button

ÿ To operate the E-Stop

2. Twist and pull the E-Stop button to disengage.

4. The system can be restarted.

ÿ To lockout for QX500

5. Attach a padlock or a tag to the padlocking facility. (See Step 3 in Figure 2)

Figure 2. Lockout Component

4 QX500 Hardware Manual

Figure 3. Lockout at the rear of QX500

Safety Interlocks on the Top Cover

Safety Interlock Key

Safety Interlock Switch

Figure 4. Location of Safety Interlock switch on QX500

ÿ To re-engage the safety interlocks

2. Close the safety enclosure securely.

3. Twist and pull the E-Stop button to disengage.

4. Press the Reset/Start button to re-engage the system.

standard classification Description

EN 61000-6-2:2005 Electromagnetic Compatibility (EMC) Part 6-2:

6 QX500 Hardware Manual

Preparing machine for disposal

High Voltage, heavy current.

Disposal of individual components

Reusable raw materials and problem materials.

Safety and Conformity Labeling

Optical Radiation Safety Labels

Figure 5. Optical Radiation Risk Label

Figure 6. Hazardous Voltage Inside Label

8 QX500 Hardware Manual

Safety and Conformity Labeling

Mechanical Safety Labels

Figure 7. Pinch Point Warning Labels and Locations

Figure 8. Read Manuals Label and Location

Figure 9. Power Switch Caution Label

10 QX500 Hardware Manual