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Axometrics, Inc. 103 Quality Circle, Suite 215 Huntsville, AL 35806 Phone: (256) 704-3332 Fax: (256) 704-6002 E-Mail: [email protected] Website: http://www.axometrics.com
AXOSTEP-APM-65H
AxoStep Panel Mapper for 65” Horizontal
Samples
HARDWARE MANUAL
©2015 Axometrics, Inc. All rights reserved. AxoStep, AxoView, Axometrics and the Axometrics logo are trademarks of Axometrics, Inc.
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CONTENTS 1 Safety Information .................................................................................................................... 3
1.1 Safety System Markings ..................................................................................................... 3 1.2 System Nameplate ............................................................................................................. 5 1.3 EC Declaration of Conformity ............................................................................................. 5 1.4 Electrical ............................................................................................................................. 6 1.5 Excepted Circuits ................................................................................................................ 6 1.6 Spare Parts List .................................................................................................................. 6 1.7 Environmental Conditions ................................................................................................... 7 1.8 Explosive Atmosphere ........................................................................................................ 7 1.9 Air Pressure ........................................................................................................................ 7 1.10 Safety Devices .................................................................................................................... 9 1.11 Hazards Associated with Misuse ...................................................................................... 10 1.12 Audible Hazards ............................................................................................................... 10 1.13 Documentation ................................................................................................................. 10
2 System Moving ....................................................................................................................... 11 3 Unpacking and Setup ............................................................................................................. 12
3.1 Unpack the Crate .............................................................................................................. 12 3.2 Level the Machine ............................................................................................................ 12 3.3 Excepted Circuit Components .......................................................................................... 12 3.4 Install the LCD, Keyboard, and Mouse ............................................................................. 14 3.5 Attach the Signal Tower ................................................................................................... 14 3.6 Install Bulbs in Light Source ............................................................................................. 14 3.7 Finished ............................................................................................................................ 15
4 Turning On the System .......................................................................................................... 16 4.1 Power Input....................................................................................................................... 16 4.2 Computer System ............................................................................................................. 16 4.3 Button Panel ..................................................................................................................... 16
5 Introduction ............................................................................................................................. 18 5.1 Overview of the APM Fixture type .................................................................................... 18 5.2 Software Architecture ....................................................................................................... 19
6 System Components .............................................................................................................. 20 6.1 Utilities Input ..................................................................................................................... 20 6.2 Uninterruptible Power Supply (UPS) ................................................................................ 21 6.3 Motion Controllers ............................................................................................................ 21 6.4 Computer System ............................................................................................................. 23
6.4.1 AxoStep Control Units ............................................................................................... 23 6.4.2 AxoStep Network ....................................................................................................... 23
6.5 Button Panel ..................................................................................................................... 24 6.6 Lamp Hour Meter .............................................................................................................. 25 6.7 Ionizer Bar ........................................................................................................................ 26 6.8 Safety Devices .................................................................................................................. 26
6.8.1 Door Open Switch ...................................................................................................... 26 6.8.2 Safety Light Curtain ................................................................................................... 27
6.9 Emergency Off Switches (EMO’s) .................................................................................... 28 6.10 Safety Interlocks ............................................................................................................... 29
7 Operation ................................................................................................................................ 30 7.1 Warm-up ........................................................................................................................... 30 7.2 Running Software ............................................................................................................. 30 7.3 Signal Tower ..................................................................................................................... 30 7.4 Calibration Standard and Coordinate System .................................................................. 31
8 Objective Changer .................................................................................................................. 32 9 Sample Holder ........................................................................................................................ 34
9.1 Concept ............................................................................................................................ 34
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9.2 Panel Support Rails .......................................................................................................... 34 9.3 Film Holder Plate (Optional) ............................................................................................. 34
10 Focus Stages ......................................................................................................................... 36 10.1 Overview ........................................................................................................................... 36 10.2 Interface ............................................................................................................................ 36 10.3 Communication with AxoStep Engine. ............................................................................. 39 10.4 Configuration Mode. ......................................................................................................... 40
11 Machine Vibration Damping System ...................................................................................... 41 11.1.1 Pneumatic Dampers (Vibration Isolation System) ................................................. 41
12 Computer Network ................................................................................................................. 43 12.1 Setup ................................................................................................................................ 43
12.1.1 LAN 1 – AxoStep Network ..................................................................................... 43 12.1.2 LAN 2 – User’s Local Network ............................................................................... 43
13 Troubleshooting and Service.................................................................................................. 45 13.1 Troubleshooting ................................................................................................................ 45
13.1.1 Robots Do Not Operate ......................................................................................... 45 13.2 Service .............................................................................................................................. 45
13.2.1 Arc Lamp Bulb Replacement ................................................................................. 45 13.2.2 Wiring ..................................................................................................................... 46 13.2.3 Linear Guides Lubrication ...................................................................................... 46 13.2.4 Pneumatics ............................................................................................................ 46 13.2.5 Head Replacement / Optical Alignment ................................................................. 46
14 Backup and Restore ............................................................................................................... 49 14.1 AXOSTEP PC ................................................................................................................... 49 14.2 WS Safety Controller and PLC Software .......................................................................... 49 14.3 Mitsubishi Q Series PLC. .................................................................................................. 50
15 PLC Restore Procedure – FTP Option ................................................................................... 51 15.1 Information ........................................................................................................................ 51 15.2 Connection........................................................................................................................ 52 15.3 File Description ................................................................................................................. 52 15.4 Procedure ......................................................................................................................... 52
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1 SAFETY INFORMATION
1.1 Safety System Markings
Protective Earth: Disconnection of this conductor will impede the electrical safety afforded to the system
Earth Terminal: Disconnection of this conductor will impede the electrical safety afforded to the system
Push button: This button will latch ON
Caution, do not operate without guards in place. Possible pinch/crush hazards exist
Warning, risk of electric shock present
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Warning, disconnect power before servicing
Caution, door is interlocked. Do not open during operation
Caution, light curtain in use
Warning, excepted circuits remain energized (orange wire)
Emergency Off
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European Conformity Assessment mark
1.2 System Nameplate
1.3 EC Declaration of Conformity
Manufacturer Information: Axometrics, Inc. 103 Quality Circle, Suite 215 Huntsville, AL 35806 USA Representative Information: Matthew H. Smith, Ph.D. 103 Quality Circle, Suite 215 Huntsville, AL 35806 USA Product Information: Polarimeter System AxoStep Imaging System Model Axostep-APM-65H
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Declaration of Compliance: This product fulfills all the relevant provisions of the Machinery Directive (2006/42/EC) and EMC Directive (2004/108/EC) Applied Standards:
2006/4/EC o EN 60204-1:2006 o EN ISO 12100:2010 o EN ISO 13849-1:2008
2004/108/EC o EN 55011:2009/A1:2010 o EN 61000-6-2:2007
1.4 Electrical
CAUTION – Disconnect all power before servicing
NOTICE – Supplied electrical service must include adequate surge protection / lightning strike protection
1.5 Excepted Circuits
When the main circuit breaker is OFF some circuits will remain energized. These circuits are indicated by orange wiring and include:
Power Indicator Lamp
Lights and Fans inside Electrical Power Panels
Door Switches for Electrical Power Panels
Electrical Disconnect
Switching Mode Power Supply (IDEC PS5R-SC24)
Temperature Alarm
To perform repair or maintenance on any circuit, the facility electrical supply to the machine must be disconnected. The following circuits will remain energized due to the UPS when the main power is disconnected:
1. AxoStep PC 2. LCD Monitor 3. Q-PLC 4. Ethernet switch
To perform repair or maintenance on any of the above identified circuits, power to that circuit must be removed from the UPS.
1.6 Spare Parts List
The following spare parts are required for maintaining the machine:
1. 150W Xenon arc lamp for Tunable Visible Light Source
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a. Manufacturer: Axometrics b. Part number: 69061-AXO c. Service: Replace the lamp after 3,000 hours if the lamp is normally turned off after
being used. If the lamp is left running 24 hours a day, replace the lamp every 12 months
2. 5x20mm fast-acting 2A fuse for interior LED lights a. Manufacturer: LittleFuse b. Part number: 0217002 c. Service: Replace if blown
3. 3V lithium battery for PLC CPU (Q02HCPU) memory
a. Manufacturer: Mitsubishi b. Part number: Q6BAT c. Service: Replace every 4 years (service life is 5 years max.)
4. 3.6V lithium battery for motor cables
a. Manufacturer: Yaskawa b. Part number: JZSP-BA01 c. Service: Replace every 5 years as needed (service life is 5 – 9.7 years max.)
1.7 Environmental Conditions
Transportation and Storage o -25°C to +55°C o Not exceeding 70°C over a 24 hour period
Normal System Operating Conditions o 5°C to 40°C o 50% Relative Humidity at 40°C o Higher RH% is allowed at lower temperatures, e.g., 90% at 20°C o Up to 1000 m above sea level o Atmospheric pressure ~ 89-101 kPa
1.8 Explosive Atmosphere
• WARNING – This system must not be used in an explosive environment.
1.9 Air Pressure
Clean dry air (CDA) is required for operation of the Ionizer Bar and Vibration Isolation System.
Air pressure range for operation: 0.5 to 0.6 MPa (5.0 to 6.0 bar)
External pressure relief safety hardware must be supplied by user
There are two Main Regulators installed on the Pneumatic Panel. One Main Regulator is for the Vibration Isolation system. This regulator is set to 0.5 MPa. The Vibration Isolation system can be operated at reduced pressure as needed to meet user requirements. The other Main Regulator is for the Ionizer Bar. This regulator is set to 0.5 MPa. This system can be operated at reduced pressures as needed to meet user requirements. The recommended operating pressures are shown labeled above the regulators. In order to adjust the Main Regulators, lift the adjuster on top of the regulator (grey) and twist left or right to
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reduce or increase the set pressure. The pressure will display in MPa on the digital pressure gauge.
Figure 1: Vibration Isolation System Main Regulator
In order to depressurize the system, send the “DOWN” or “OFF” signal to the Ionizer Bar (press the button on the Operator Station) and slowly decrease main input pressure and allow the systems to vent. This will allow all systems to return to the “DOWN” and “OFF” states. If for some reason the pressure is reduced to the systems without first sending “DOWN” or “OFF” signals and the systems are initially in the “UP” or “ON” states, the Vibration Isolation System and the Ionizer Bars will return to the “OFF” state. The system is designed to supply air to the system via 12mm tubing. However, additional or different fittings may be used in order for the customer to input air to the system as they choose. The CDA input is located on the back of the Pneumatics Panel Cover.
Figure 2: Customer CDA Input
Regulator Adjustment Knob
Digital Pressure Gauge
Customer CDA Input— 12mm Tubing
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A pneumatic ball-valve disconnect is located on the front of the Pneumatics Panel Cover. In order to lock-out the pneumatic disconnect, the user must raise the locking mechanism on the valve and turn the lever to the right.
Figure 3: Pneumatic Disconnect
OSHA approved Lockouts are located next to both Regulators on the Pneumatics Panel. In order to lock-out these Lockouts, the user must turn the knob located on the top of the each Lockout.
Figure 4: OSHA Approved Pneumatic Lockout
1.10 Safety Devices
The following safety related devices have been provided for your protection. Defeating these devices could result in serious injury
Light Curtains / Area Sensors
Door Switches
Safety PLC
Lift Locking Mechanism And Turn Lever Right
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Emergency Stops
Position and Over Travel Sensors
Fixed Machine Guards
Signal Tower and Audible Alarm
Pressure Regulators
Pneumatic Disconnects
Electrical Disconnect Residual risks present after following safety procedures include but are not limited to pinching, minor shock, bumping into machinery, and injury due to dropping objects. Always operate this system with caution. A periodic check of safety functions is recommended for every 3 months. This includes all safety devices listed above. The user should check to make sure each device is properly functioning and that the wiring to each device is sound. Disconnect power before servicing if checking the wiring. Note: Ensure power to the UPS is also removed, otherwise the UPS battery will be drained
1.11 Hazards Associated with Misuse
Operating the system with Machine Guards removed can result in serious injury
Operating the system with Safety Devices disabled can result in serious injury
1.12 Audible Hazards
Maximum sound levels of 85 dB are possible when the Audible Alarm is activated. Personal Protective Equipment must be worn during prolonged exposure to the Audible Alarm.
1.13 Documentation
Documentation in the Official Language of your region will be provided upon request.
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2 SYSTEM MOVING
The main system is equipped with wheels and can be rolled across smooth surfaces. Main system can also be lifted by fork lift. In all cases, the component can be safely lifted from the center of either of two sides. Be sure to use a fork lift with adequate lift capacity, mass, and fork length in order to safely handle the system. CAUTION: Lift the machine with fork lift using only the inside frame. Do not use the outer cosmetic frame for lifting. This can damage the machine and cause injury. NOTE: Do not lift the machine unless the fork lift is clear of all obstructions.
Main Machine Frame o Total system weight is 3425 Kg o System center of mass is approximately +/- 500mm from center of machine
package
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3 UNPACKING AND SETUP
Follow these steps to unpack and setup the AXOSTEP-APM-65H.
3.1 Unpack the Crate
Refer to the AXOSTEP-APM-65H Installation Manual for instructions on how to unpack the crate. This includes moving and disassembling the crate, moving the machine to the installation site, removing the hardware, and removing the shipping brackets. Once the machine is safely positioned at the installation site, follow these steps to resume installation:
3.2 Level the Machine
1. Place a steel plate under each leveling leg and lower the legs until they just touch the plate. 2. Put a level on the granite and adjust the leveling legs up and down until the granite is level
left to right and front to back. The installation site must adequately support the weight of the system. 100X100mm weight distribution pads are included with the system. If these are not sufficient in the installation setting for weight support, then larger weight distribution plates or pads must be used. This especially true for use on grated flooring.
Figure 5: Weight Distribution Pad
3.3 Excepted Circuit Components
The Electrical Disconnect is located on the back of the machine, to the right of the smaller electrical panel. A service area of 1m minimum must be left in order for the operator to have adequate access to this disconnect.
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Figure 6: Electrical Disconnect
The Power Meter, Power Indicator, and Temperature Alarm are located below the Electrical Disconnect. The green light on the Power Indicator is on when all Excepted Circuits are hot.
Figure 7: Power Meter, Power Indicator, and Temperature Alarm
The thermocouple for the Temperature Alarm is located inside the smaller electrical panel. The Temperature Alarm display turns amber when the temperature is above 38°C and turns red when the temperature is above 40°C. A Pneumatic Disconnect is also located on the front of the Pneumatic Panel Cover. A service area of 1 m minimum must be left in order for the operator to have adequate access to the Pneumatic Disconnect. A set of tools used for installation and operation will accompany the system. This set includes:
Power Indicator
Temperature Alarm
Power Meter
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Hex Wrench Sets (1 Metric, 1 Inch)
Phillips #1 and #2 Screwdrivers
10’’ Adjustable Wrench
24mm Wrench
Extra Panel Bolts
3.4 Install the LCD, Keyboard, and Mouse
Place the keyboard and mouse on the tray located beneath the computer monitor. The mouse, keyboard, and monitor cables are already inside the AXOSTEP-APM-65H. Attach these cables to their respective devices.
3.5 Attach the Signal Tower
Attach the signal tower to the AXOSTEP-APM-65H. This device is fastened with 3 bolts and is located on the front left corner of the outer frame.
Figure 8: Signal Tower
The cable passes into the AXOSTEP-APM-65H through a small grommet. After the signal tower is attached, route the cable in the cable duct.
3.6 Install Bulbs in Light Source
The bulbs were removed from the light sources for shipment in order to avoid breaking the bulbs. You will need to install the bulbs in the Tunable Visible Sources.
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Figure 9: Light Source CAUTION: Never touch the glass part of the bulb with your fingers. Oil from your fingers will get on the bulb and could cause the bulb to explode when operated. Remove the arc lamp bulb from its package and its protective plastic case. Use your thumb to open the brass clamp and insert the bulb. Make sure the bulb is all the way down and release the clamp with your thumb. Also, make sure that the ‘nipple’ on the bulb is pointed to the side. If the nipple is between the bulb and the mirrors it can reduce the amount of collected light. Attach the white wire to the top of the bulb with the thumb screw and replace the blue cover. Install the Tunable Visible Source back into the AXOSTEP-APM-65H and bolt it to the drawer. Attach the power cables and the serial cables (RS-232 cables) on the back of the Tunable Visible Sources. Place the orange fiber optics back into the light sources and tighten the thumb-screws. NOTE: Make sure the fibers goes all the way into the source or else the optical power will be very low. The thumb-screws must be completely loosened before inserting the fibers or else they will prevent the fibers from going in all the way. NOTE: The power switches on the back of the Tunable Visible Sources must be in the “on” position. After the Light Source has been installed, press the auto exposure button and record the values for the gain and shutter speed. During periodic maintenance, press the auto exposure button again. If the values given are below 50% of the initially recorded values, replace the bulb.
3.7 Finished
No further alignment should be needed. The AxoStep heads were aligned at the Axometrics facility and should not need to be replaced. Your system is now ready to power up and run.
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4 TURNING ON THE SYSTEM
4.1 Power Input
The AXOSTEP-APM-65H wires directly into the utilities input. The required voltage is 220 V and the frequency is 50 Hz. A 3-conductor, 2.5 mm2 (14 AWG), rated 300 V supply cable should be used for onsite installation.
4.2 Computer System
The computer system is located in the drawers on the front of the machine. Make sure the Master Power switch is on. This provides power to the computer and electronics. The Master Power can be left on at all times if desired.
Figure 10: Master PC Next, turn on the Computers and Electronics in any order. Turn on the computer monitor and make sure the computer boots properly into Windows. Sometimes the computers have problems after shipping. The memory, CPU, or other components can vibrate loose. If you experience any problems with the computer, contact Axometrics or your local agent for assistance.
4.3 Button Panel
Separate power switches are provided for the Robot Power, Light Source, Focus Stage, Fans, Ionizer Bar, Interior Lights, and EMO SI Reset.
Figure 11: AXOSTEP-APM-65H Button Panel
Master Power Switch
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NOTE: When powering up the system, turn on the fans first. It is recommended that cooling fans be kept running at all times during system operation. Turn on the light source and the motion controllers only after fans are running. NOTE: If problems are encountered with the robots, do the following:
Power OFF the Motion Controllers using the Robot Power button
Wait 10 seconds
Power ON the Motion Controllers
Wait 30 seconds while the Motion Controllers reboot
This will help clear any errors with the Motion Controllers. The Emergency Stop button will remove power from all motors within the system. Twist the Emergency Stop button clockwise to reset. NOTE: Resetting the Emergency Stop button will not restore power to the motors: E-Stop / SI Reset button must first be pressed to restore motor power.
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5 INTRODUCTION
The AXOSTEP-APM-65H is a system for measuring the polarization parameters of samples of up to 65” diagonal in a laboratory environment. Please read this entire manual before attempting to operate this equipment. Contact Axometrics or your local agent if you need assistance. The system uses a standard AxoStep polarization measurement system and can run most Axometrics software, including: AxoStep Viewer – R&D software for films and other general polarization measurement LCDView – R&D software for learning the parameters of unknown LCD panels LCD Panel Alignment (LPA) – Optional software and camera system for measuring the orientation angle of the LCD panel edge to get the most accurate rubbing direction measurement
Figure 12: AXOSTEP-APM-65H
5.1 Overview of the APM Fixture type
This section discusses the details of the variable tilt / variable rotation AxoStep PanelMapper (AXOSTEP-APM-65H) hardware fixture and the operation of your system. The AXOSTEP-APM-65H consists of an AxoStep PSG and PSA mounted to a fixture that allows ±30° tilting and ±90° rotation of the sensor around a common point on the sample. A standard AxoStep Control Unit and PC control the AxoStep, the APM turret, and the included XY table. Warning: Remove the 100X microscope objective before attempting to operate the Tilt Stage. Failure to comply could result significant damage caused by a collision between the 100X objective and the sample.
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Figure 13: AxoStep APM Turret The AxoStep polarimeter heads and control software are covered in a separate manual. The system includes an XY robotic stage for measuring the entire area of the sample. The table includes adjustable support rail that can be adjusted to hold LCD panels up to 65” diagonal. An optional plate with 25 mm diameter holes is available for holding film samples.
5.2 Software Architecture
The AXOSTEP-APM-65H measurement system uses modular software architecture in which numerous independent programs share information via TCP/IP communications protocol. These software components all run on the main AxoStep PC, and they communicate to various hardware components via TCP/IP, IEE-1394 (FireWire™), or RS-232 (Serial) as shown in the figure below:
Figure 14: APM-65H System Software Architecture
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6 SYSTEM COMPONENTS
6.1 Utilities Input
The Utilities Input is located on the back of the machine inside the smaller electrical panel.
Figure 15: Power Input The machine requires a 220 V, 50 Hz electrical supply. The machine also must be connected to a minimum 15A branch circuit. A disconnect device must be provided for the electrical supply to the machine. It must located near the machine and be marked to identify it as the machine disconnect. Connect the input power as follows:
Black – Line (L)
White – Neutral (N)
Green – Ground CAUTION: Do not use an incorrect input voltage or the light source and motor controllers will be permanently damaged. There is an ID Plate on the system indicating the proper input voltage.
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Figure 16: ID Plate
6.2 Uninterruptible Power Supply (UPS)
The system is equipped with a Tripp Lite SMX1500LCD Uninterruptible Power Supply (UPS). The UPS is located in the left electronics drawer on the front of the machine. Be sure to turn off the UPS when the system will be without power for extended periods.
Figure 17: UPS
6.3 Motion Controllers
The Focus Stage Controller, AxoStep Controller, and Tilt / Rotation Controller are located behind the doors under the machine.
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Figure 18: Focus MCU and MCU TT
Figure 19: Voltage Driver and MCU XY These motion controllers are all communicate to the AxoStep PC by Ethernet (TCP/IP) on the 10.0.0.x “AxoStep Network”. The IP addresses are shown below:
AxoStep PC – 10.0.0.20
XY controller – 10.0.0.1
Tilt Rotation controller – 10.0.0.2
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Focus stage controller – 10.0.0.40 The network switch connecting these devices is inside the AxoStep Controller.
6.4 Computer System
The entire system is controlled by the AxoStep PC. For system to function properly ensure the Main Power Switch must be ON. The Main Power Switch may be left on at all times as desired. NOTE: In order for system to function correctly, computer and electronics must be powered up. Power up of computer and electronics systems in any order is fine. NOTE: Computers often have problems after being shipped. Memory modules, CPU’s and other components can vibrate loose during transport. If you experience any problems with the computer, contact Axometrics or your local agent for assistance.
6.4.1 AXOSTEP CONTROL UNITS
Refer to the separate User’s Manual for the AxoStep control unit.
6.4.2 AXOSTEP NETWORK
The communication between most hardware components on the system is accomplished using TCP/IP communication protocol. All AXOSTEP TCP/IP communications are routed through the Ethernet Switch on the back of the AxoStep Control Unit shown below.
Figure 20: Network Switch on Back of Axostep Control Unit The Ethernet network port of each component is connected to the Ethernet Switch. Each component has a static IP address that has been set to the following:
AxoStep PC – 10.0.0.20
XY Motion Control Unit – 10.0.0.1
Tilt / Rotation Motion Control Unit – 10.0.0.2
Focus Stage Controller – 10.0.0.40
AxoStep Camera – 10.0.0.50
AxoStep Controller – 10.0.0.30
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Figure 21: Ethernet Switch There are two TCPIP networks configured on the AxoStep PC. The AxoStep Network is the internal control network for the instrument. A second network interface is attached to the master computer to allow it to communicate with an external network. Important: The only network settings that should be configured by the user are the secondary network settings on the master computer (Local Area Connection 2). Do not attempt to change the settings in the AxoStep Network on the master computer.
Figure 22: AxoStep Network Configuration
DO NOT Attempt to change the network settings for the AxoStep Network. Configure company network on second Ethernet card on the master computer
6.5 Button Panel
Separate power switches are provided for the Robot Power, Light Source, Focus Stage, Fans, Ionizer Bar, and Interior Lights.
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Figure 23: Button Panel NOTE: When powering up the system, turn on the fans first. It is recommended that cooling fans be kept running at all times during system operation. Turn on the light source and the motion controllers only after fans are running. NOTE: If problems are encountered with the robots (XY Table or Tip/Tilt fixtures), do the following:
Power OFF the Motion Controllers using the Robot Power button,
Wait 10 seconds
Power ON the Motion Controllers.
Wait 30 seconds while the Motion Controllers reboot. This will help clear any errors with the Motion Controllers. The Emergency Off button will remove power from all motors within the system. Twist the Emergency Off button clockwise to reset. NOTE: Resetting the Emergency Off button will not restore power to the motors: EMO / SI Reset button must first be pressed to restore motor power.
6.6 Lamp Hour Meter
A meter used to record the total time that the lamp has been running is located on the top left of the system console. It is located on the button panel to the left of the Robot Power Switch. This meter is used to time replacement of the Tunable Light Source lamp
Figure 24: Lamp Hour Meter
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NOTE: Lamp Replacement:
If the lamp is turned ON and OFF every day, then the lamp should be replaced after 3,000 hours
If the lamp is left running continuously, then the lamp should be replaced at least once per year
NOTE: To Reset the Hour Meter:
Reset the hour meter after replacing a lamp
With the lamp turned ON, insert a thin non-conducting tool into the hole below the Lamp Hour Meter. This will press a button inside the hole and will reset the counter.
There is also a lamp hour meter on the back side of the Tunable Visible Source. You should reset this meter at the same time.
6.7 Ionizer Bar
The system is equipped with at least one ionizer bar, positioned above the entrance to the machine. Pressurized clean dry air (CDA) is provided to the ionizer bars by a main regulator. The ‘Ionizer’ switch on the button panel applies power to the ionizer and also opens a solenoid to supply air to the ionizer.
Figure 25: Ionizer Bar
6.8 Safety Devices
Various safety devices are placed throughout the AXOSTEP-APM-65H system to monitor its working status. Each safety device is described below.
6.8.1 DOOR OPEN SWITCH
Sensor Type: Mechanical / Magnetic SPST (wired NORMALLY OPEN) switches, OMRON STI CM-S1PC5, wired in series. Purpose: Detect whether doors are OPEN. Status: “ON” (closed circuit) when door is closed The open-circuit “OFF” condition caused by an open door causes a “Safety Interlock” condition to occur.
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Adjustment: User adjustment of door switch is not required.
Figure 26: Magnetic Safety Door Switch (OMRON PN: CM-S1PC5)
6.8.2 SAFETY LIGHT CURTAIN
Sensor Type: Keyence SL-V type Purpose: Detect if a human is standing in the machine, safety Status: Sensor is ‘ON’ (green) when nothing is blocking the beam. If the beam is blocked or if the alignment is bad, the sensor turns ‘OFF’ (red).
Figure 27: Safety Light Curtain ON/OFF Demonstration
Location: At the system entrance door Adjustment: If all of the lights are red, then make sure that nothing is blocking the beam. But if only the bottom red light is on (the other red lights are turned off) then the light curtain is not properly aligned. You may need to rotate the emitter or receive to get proper alignment.
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6.9 Emergency Off Switches (EMO’s)
EMO Switches – There is one EMO switch installed in this machine. This switch will light up when it is pressed. Rotate the EMO switch clockwise 90° to restore it to a normal position. The system’s emergency stop circuit will engage if this switch is pressed.
Figure 28: EMO Switch EMO Active – The Emergency Off circuit will engage if the following scenario occurs
Pressing the Emergency Off button Safety Interlock Active – The Safety Interlock will engage if the following scenarios occur
Interrupt the Safety Light Curtain
Door Open EMO / SAFETY INTERLOCK Reset – After the EMO circuit has been activated, press the reset button on the button panel in order to restart operation.
Figure 29: Emergency Off/ Safety Interlock Reset Button The Emergency Off button completely shuts down power to the XY Table and the Tip-Tilt Fixture. When no power is applied, if fixtures must be moved, they can be moved by hand.
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You should generally only press the Emergency Off button in an emergency. Pressing this button will always require you to restart the software and turn the ‘Robot Power’ button off and then back on. NOTE: When the Emergency Off button is pressed, the following reset procedure must be performed to restore the AXOSTEP-APM-65H to normal operation.
1. You will need to reset the E-Stop button: To reset the button, twist the red button clockwise 90° and it will ‘pop’ back out.
2. You will need to press the E-Stop Reset Button. 3. You will need to restart all software controlling the AXOSTEP-APM-65H
6.10 Safety Interlocks
The Safety Light Curtain and Door Switch are configured as safety interlocks on the AXOSTEP- APM-65H system. Breaking the Safety Light Curtain or opening the door will trigger a “Safety Interlock” condition. The Safety Interlock will prevent the robots from moving until the door is closed again and the Safety Light Curtain is no longer blocked. On this AXOSTEP-APM-65H system the EMO Reset and Safety Interlock Reset are combined into one button.
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7 OPERATION
7.1 Warm-up
No warm-up time is required; the system can be operated immediately after start-up.
7.2 Running Software
Follow These Steps to initialize the software on the AXOSTEP-APM-65H:
1. Clear any E-stop of Safety interlocks on the control panel and turn on the Light source, Motion Controllers, and Fans.
2. Turn on the Robot Power, Light Source, and Fans pushbuttons. a. Ionizer and Interior Lights are optional
3. Run the Objective Control Software by double clicking the icon on the desktop
a. 4. Run the AxoStep Engine by double clicking the icon on the desktop.
a. b. The Focus Stage software will automatically initialize c. The Robots and the light source will initialize
5. Once the AxoStep Engine has fully initialized, run the AxoStep Viewer software.
a. Refer to the AxoStep Viewer User’s Manual for details about running software on the AXOSTEP- APM-65H.
7.3 Signal Tower
The signal tower on the AXOSTEP-APM-65H is controlled using the AxoStep Engine Software and the PLC. The following meanings have been assigned to the Signal Tower.
Red (Flashing) – Alarm The system is in an alarm state (an audio alarm might also be sounding). The alarm requires a user acknowledgement in software.
Red (Steady) – Down The system experienced an Alarm that has been acknowledged, or an alarm that does not require software reset.
Yellow – Ready The system is in Stand-By Mode and is ready to make measurements.
Green – Active: The AXOSTEP-APM-65H is currently making an automated measurement. The XY Table and Tip-Tilt Fixture could be moving. Opening the doors or breaking any light curtain while the system is running may result in an Emergency Stop Condition.
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7.4 Calibration Standard and Coordinate System
A CAL-VIS-1 retardation reference and a CAL-VIS-2 polarizer standard are permanently installed on the sample holder of the AXOSTEP-APM-65H. These standard is used for calibrating the AxoStep polarimeter. See the appropriate Users Manuals for more information. The CAL-VIS-1 defines the true-zero angle of the AxoStep system. The retarder within the CAL-VIS-1 is aligned to within +/-0.05° of true zero. The CAL-VIS-2 is used to define the 0 degree orientation of the system when measuring polarizers. The coordinate system is shown below. The same coordinate system is used for all orientation measurements, for rubbing direction, and for XY locations.
Figure 30: AxoStep Coordinate System for All Polarization and XY Measurements
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8 OBJECTIVE CHANGER
The AxoStep Objective Changer for APM-systems is shown below. This allows users to change Microscope objectives on the AxoStep APM system without needing to enter the machine. Included are 5X, 10X, 20X, and 100X lenses. Starting with the closest objective mounting position, the first slot is for the 5x, second is for the 10x and the third is for the 20x.
NOTE: Whenever the microscope objective is changed, Axometrics strongly recommends recalibration of the AxoStep Heads. Please see the AxoStep Viewer Software Manual for detailed information about calibration.
Figure 31: Objective Changer
The Objective Changer is a slide with three positions for objectives. Its associated software is simple. There are three positions to select from and those positions can be set and the names of them edited from the Objective Control Advanced Settings screen (navigated to by the menu item: Options> Settings).
Figure 32: Objective Controller Software Interface
Objective Changer
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The Objective Changer has been configured and aligned prior to shipment. If necessary, Axometrics will provide detailed instructions for aligning and configuring the Objective Changer.
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9 SAMPLE HOLDER
9.1 Concept
The system includes an adjustable sample holder for supporting up to 65” samples. There are two options for supporting the sample during measurement.
9.2 Panel Support Rails
Horizontal and Vertical panel support rails are provided.
Figure 33: Panel Support Rails The panel support rails are designed to lock into the small support fingers around the edge of the sample holder
Figure 34: Panel Support Rail locking mechanism Install support rails to minimize panel bending and to allow measurement at desired locations on the sample
9.3 Film Holder Plate (Optional)
An optional plate is available for supporting film samples inside the system. The film plate includes a series of 25 mm diameter holes on 50 mm centers. Reference edges are included along the x- and y-axes.
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Figure 35: Optional film plate for the 65" sample holder
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10 FOCUS STAGES
10.1 Overview
AxoStep APM systems are equipped with a robotic focus stage. Each turret is designed to move in the entire assembly up and down to refocus the microscope objective on the sample. By moving the entire assembly allows the system to properly focus on the sample while keeping the alignment between the two turrets. Each turret focus motor operates independently (to allow for alignment and proper spacing), however the focus software is designed to move the turrets together as a unit
Figure 36: Turret Focusing System
10.2 Interface
The Turret focus stages are controlled using the AXOSTEP PM FOCUS STAGE CONTROL software engine. The main interface for the Focus Stage Control software is shown below.
Turret Focusing system
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Figure 37: Focus Stage Control Software Interface
If the focus stage software is required for the safe operation of the AxoStep APM system, it will automatically be automatically launched when the AxoStep Engine opened. Otherwise, the focus
stage software can be opened manually by double clicking the icon on the desktop of the AxoStep Computer. The controls on the front panel operate as follows. Current Position (mm): Shows the Current Position of the Focus Stage. Press the Move Button to move the focus stage to a desired focus position.
Pressing the Up and Down Arrows will move the Focus Stage either farther or closer to the sample by the amount entered in the Step (mm) control. Press the Auto Button to open the AutoFocus window shown below:
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Figure 38: Auto Focus User Interface There are two options for performing AutoFocus. Complete Focus is a 2-stage focus procedure that consists of the following 2 steps.
1. Perform a coarse scan over the distance defined in the control “Coarse Range (mm)”. The objective will move in a pre-defined number of steps (default=10) over the Coarse Range (mm), testing the focus at each location.
a. Number of steps for coarse range is defined for each microscope objective and is configured on the diagnostic tab.
2. The Algorithm will find the best focus in the coarse scan, and perform a fine scan that is centered on the best focus from the coarse scan.
3. The fine scan will move a set number of steps (default=5) in increments defined by the Fine Step Size (mm) control.
a. Number of steps for fine scan range is defined for each microscope objective and is configured on the diagnostic tab.
The Quick Focus Button performs only step 3 (from above) starting from the current focus stage location.
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Figure 39: Auto Focus Settings The diagnostic tab allows the user to configure the focus algorithm. The Scan settings (for the current Microscope Objective) are shown in the top control box. The bottom control box, shows the basic settings for the focus algorithm. The Focus engine uses a basic edge detection algorithm to determine the best focus.
Figure 40: Auto Focus Advanced Settings The Advanced tab, shows more advanced focus algorithm settings. Axometrics can provide a detailed description of each of these setting if requested.
10.3 Communication with AxoStep Engine.
The AxoStep PM Focus Control software engine maintains a two-way connection with the AxoStep Engine. When the AxoStep Engine Changes any coordinate (X,Y, Rotation or Tilt), commands are
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sent to the AxoStep PM Focus Control software, to adjust the focus positon to keep the sample in focus during a measurement. Likewise, the focus stage routinely queries the AxoStep Engine for information such as the Current Image, or the Current Objective that is installed. Additionally, Autofocus and focus position commands can be sent from the AxoStep Viewer to the Focus Control Software, to control the focus stage.
10.4 Configuration Mode.
The software also has a configuration mode that can be used to configure the individual focus stage motors independently. To switch to Configuration mode, press Ctrl-Shift-F1, then enter password (default PW: 7043332). To go back to operator mode, Uncheck the box that says “Show Setup” and the software will return to normal operation Mode. Configuration Mode allows Low-Level control of the focus stage motors and should only be used when re-aligning the focus stage motors, after Mechanical disassembly. Serious damage or significant miss-alignment can occur when operating in Configuration Mode. Please contact Axometrics for assistance in using Configuration Mode on the AxoStep APM Focus Control Software.
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11 MACHINE VIBRATION DAMPING SYSTEM
NOTE – Vibration damping is not usually required for the AXOSTEP APM-65H system and will only be installed in cases where severe factory vibration is present. If your system does not include vibration damping, you can ignore this section.
11.1.1 PNEUMATIC DAMPERS (VIBRATION ISOLATION SYSTEM)
Refer to the figure below to view one of four dampers installed in the system. The dampers are located in each of the four bottom corners of the system. Each damper is connected to the pneumatic system via pneumatic (air) line, which is connected to an air pressure regulator on the Pneumatic Control Panel. Note that each damper has a mechanical stop. These must be left in place for protection during earthquakes, and in case of damper overpressure. Overpressure can cause damage to the damper pistons by forcing them out too far. The mechanical stops prevent this. The mechanical stops should be left in place at all times. These are also left in place for shipment, and are used when there is no air pressure applied to the dampers. When air pressure is applied, the system “floats” on the air pressurized dampers. The range of up and down motion of each mechanical stop should be no more than +/- 5mm. NOTE: when first applying air pressure, slowly increase air pressure to 5 bar and observe. Adjust regulator pressure up or down as needed. There are indicators at each corner of the machine near each isolator that physically show current isolator floating position.
CAUTION! -When installing machine you must put the machine weight back on the pneumatic isolators. CAUTION! Do not exceed 10mm or the machine isolators will be permanently damaged. This is done by performing the following steps:
Mechanical Stops -- Use only to remove Pneumatic Isolators
Damper / Shock Isolator
Figure 41: Mechanical Stop Bracket – Used ONLY for Isolator Removal and Installation
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1. Loosen all shipping brace nuts and turn counterclockwise so that there is at least 5mm between the granite and brace
2. Loosen each L bracket from the granite by loosening the bolt 3. Loosen the L bracket nuts at the mounting base at bottom of machine and slide it out so
there is at least 4mm between the surface of the L bracket and the granite. After position is approximately 4mm from granite retighten.
4. Verify each physical brace and L bracket has at least 5mm clearance from granite 5. Add air pressure to the shock isolators, while watching each position measurement on
machine corners. 6. Once machine is “floating” on shock isolators, adjust brackets and shipping braces again
to approximately 3-4mm from granite for earthquake protection as desired, so the machine can still move up and down freely without rubbing the braces or L brackets.
Figure 42: Vibration Isolator Height Gauge (5mm ±2mm)
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12 COMPUTER NETWORK
12.1 Setup
Your AXOSTEP Master computer has two different network cards installed.
12.1.1 LAN 1 – AXOSTEP NETWORK
LAN Connection 1 is used by the AXOSTEP computer to communicate with the Motion Controllers of the Tip/Tilt Fixture. NEVER change these network settings. If you change the LAN 1 network settings, the AXOSTEP will no longer operate correctly.
Figure 43: LAN 1: AXOSTEP Network Connection Properties
12.1.2 LAN 2 – USER’S LOCAL NETWORK
LAN Connection 2 is available for the user to attach the AXOSTEP to a local network. These settings may be changed as required by your network administrator.
Do Not Change the Settings for this Network
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Figure 44: LAN 2: Local User Network Connection Properties
These network settings may be changed in order to attach the AxoStep to
the local network
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13 TROUBLESHOOTING AND SERVICE
13.1 Troubleshooting
In the event of an accident or breakdown, engage the Emergency Stop, power down the system, and clear the obstructions. When the obstructions have been cleared, release the Emergency Stop and reapply power to the system.
13.1.1 ROBOTS DO NOT OPERATE
1) Shut down all Axometrics software. If needed, use Ctrl-Alt-Del and use End Process 2) Make sure all doors are completely closed 3) Make sure nothing is blocking the light curtain 4) Twist the red Emergency Stop button 90° clockwise to make sure it is not engaged 5) Turn off the ‘Robot Power’ on the Button Panel 6) Wait 10 seconds 7) Turn on the ‘Robot Power’ on the Button Panel 8) Wait 30 seconds while the Motion Controllers reboot 9) Start the Axometrics software 10) Repeat this process if needed
13.2 Service
Disconnect the building electrical supply to the machine before performing service or maintenance operations that will require personnel to come in contact with hazardous parts.
13.2.1 ARC LAMP BULB REPLACEMENT
The lamp in the Tunable Visible Source is rated to last 3,000 hours. There is a time meter on the back of the Tunable Visible Source. This lamp will last longer if it is left running continuously. Replace the lamp after 3,000 hours if the lamp is normally turned off after being used If the lamp is left running 24 hours a day, replace the lamp every 12 months. Contact Axometrics or your local agent for replacement lamp. After the Light Source has been installed, press the auto exposure button and record the values for the gain and shutter speed. During periodic maintenance, press the auto exposure button again. If the values given are below 50% of the initially recorded values, replace the bulb.
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13.2.2 WIRING
Every 3 months, check the wiring at the entrance and exit of the flexible cable tracks. Be sure that the wires are securely fixed in the cable clamps. Examine the wire for any signs of damage or wear. Disconnect power before servicing. Note: Also remove power to the UPS or the battery will drain
13.2.3 LINEAR GUIDES LUBRICATION
The system uses THK “LM Guide” rails and blocks, SHS20 or SHS25 model, in several locations. In all cases, THK brand AFE clean-room grease is used. Anti-corrosion coating is applied to both the rail and the block. Either THK AP-C anti-corrosion coating (black) or Armaloy™ think dense chrome coating (grey) is used. The SHS caged ball LM guides have extremely long lifetimes and require very little maintenance. Based on THK calculations, the Nominal Life of these guides exceeds 10,000,000 km. The AXOSTEP-APM-65H will not exceed this distance during its operational lifetime.
1. All moving parts should be physically examined for particulate matter (dirt, metal shavings, etc.) every 3 to 6 months.
2. Small amounts of grease can build up at the end-of-run of each rail. In order to avoid
grease dropping onto the sample, wipe this grease off the ends of the rails every 6 months if present.
1. NOTE: Do NOT wipe down the linear rails with methanol or any other
solvent as this will remove the thin layer of grease on the rail that is needed for correct operation.
13.2.4 PNEUMATICS
Every 3 months, check pneumatic components for filter rot, hose damage, and faulty connections. Be sure that tubing is securely in place. Examine all components. Check, empty, drain, etc. components that may fill up, get clogged, etc. Disconnect power before servicing.
13.2.5 HEAD REPLACEMENT / OPTICAL ALIGNMENT
Optical alignment was performed at the Axometrics factory during system assembly; periodic alignment is NOT Necessary. However if an AXOSTEP PSG head is replaced, perform the following steps to properly align the PSG head. Warning: To perform the optical alignment of the PSG head, the turrets and XY stages must be energized. It is therefore possible that the some AXOSTEP safety devices will need to be defeated when performing this operation to prevent an emergency stop from occurring when the technician enters the machine to perform the alignment. Extreme Caution must be exercised when performing this alignment. Contact Axometrics for detailed instructions. Only AUTHORIZED PERSONNEL who have received ADEQUATE TRAINING shall perform this procedure. NOTICE: To bypass Safety Interlock devices, use the Safety Interlock Bypass Key Switch inside the electrical panel of the AXOSTEP APM-65H. in order to prevent unauthorized
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personnel from engaging the Safety interlock Bypass, the Bypass Key MUST BE KEPT IN A SECURE LOCATION AWAY FROM THE MACHINE. Notice for Key Switch Operation – The following is noted for operation of bypass key switch:
Only authorized personnel should use the safety bypass key switch
Key switch is safe with key removed, and bypassed when operated clockwise with key installed
Put cover back in place before operating machine
Be careful with hands – do not touch any other electrical parts inside the machine
Do not remove terminal block covers
Figure 45: Safety Interlock Bypass Key Switch – in NORMAL position
1. Move the AXOSTEP Heads to a convenient location (e.g. X=100, Y=100)
2. Place a small piece of translucent tape over the entrance to the PSA Head, and mark the location of the beam entering the PSA.
3. Shut down the system
4. Unscrew the fiber entering the PSG Head
5. Remove the PSG Head by removing the two mounting screws on the back of the turret.
6. Remove the entire Spectral Input Adapter from the old PSG head, and mount it to the
new PSG head.
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Figure 46: PSG - Spectral Input Adapter
7. Place the spectral input adapter on the New AXOSTEP PSG Head, and tighten the three
locking screws holding it in place.
8. Attach the new PSG head to the turret and secure it using the two screws that enter from the back.
9. Re-attach the optical fiber to the spectral input adapter.
10. Restart the system
11. Move the AXOSTEP Heads to the same location that was used when marking the beam
location.
12. The beam should be in the same location as the mark that was made previously.
13. If not, small adjustments can be made by loosening the Jam nuts on the mirror mount (use a 6mm open end wrench) on the Spectral input adapter and adjusting the mirror tilt set screws (using a 1.5mm Allen wrench) until the beam is in the previously marked location. Tighten the Jam nuts when complete.
14. Remove the tape from the PSA head.
15. If necessary the PSA head can now be replaced. There is no alignment necessary for the
PSA head.
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14 BACKUP AND RESTORE
14.1 AXOSTEP PC
Backup – All of the Axometrics software and settings are stored in the directory c:\AxoView. Make a copy of all files in order to backup an AXOSTEP PC. Each AXOSTEP PC includes CD- RW drive to allow easy backups. USB ports or a network drive can also be used. Restore – To revert to a previous configuration, replace all of the files and subfolders in c:\AxoView with backed-up copes. Backup & RAID – Each AXOSTEP PC ships with mirrored RAID HDD with software and drivers installed. If the original HDD becomes damaged, use the Recovery CD provided with the machine to restore the computer. This CD has Windows and all drivers and software needed to restore your machine to a working configuration.
14.2 WS Safety Controller and PLC Software
The EMO and Safety Interlock circuits on the AXOSTEP-APM-65H are controlled by a Mitsubishi WS series safety-rated PLC controller. This safety controller has software code that can be used to restore it to normal operation should it need replacement. This software image file is located on the included CD at:
CD PATH: \AxoView\Current Version\PLC Files\WSPLC.MEP
Figure 47: AXOSTEP APM-65H – MITSUBISHI WS SAFETY CONTROLLER Backup and Restore – There are no other settings to back up or restore directly on the Mitsubishi WS safety controller. The WS software image file may be restored by using the WS Controller Setting and Monitoring Tool software provided by Mitsubishi as a download. Axometrics software to restore is on the product CD:
CD PATH: \AxoView\Current Version\PLC Files\WSDEV.ZIP
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For logic implementation diagram of WS Controller refer to the AXOSTEP-APM-65H DRAWING PACKAGE.PDF on the CD. The drawing title is SAF0001A. The Mitsubishi WS Safety Controller has a default Administrator password:
WS Controller Administrator Password: MELSECWS
WS Controller Maintenance Password: MELSECWS
14.3 Mitsubishi Q Series PLC.
Figure 48: AXOSTEP APM-65H – MITSUBISHI Q-PLC Machine signaling and button panel on and off commands are provided by a Mitsubishi Q Series Programmable Logic Controller (PLC). This PLC is programmed with appropriate ladder logic code at Axometrics. The Q-PLC software GXWorks2 project file (provided by Axometrics) is located on the CD at:
CD PATH: \AxoView\Current Version\PLC Files\QPLC.GXW
For ladder logic implementation diagram of Q Series PLC refer to the AXOSTEP-APM-65H DRAWING PACKAGE.PDF on the CD. The drawing title is LAD0001A. Q-PLC NOTICE: Ladder logic editing and project restoration can only be performed by using Mitsubishi GX Works2 or GX Developer software. This software is not provided by Axometrics; it can be obtained from Mitsubishi:
MANUFACTURER - MITSUBISHI
PART# - GX-WORKS2-C1
VERSION# - 1.87R Q-PLC PASSWORD: The Mitsubishi Q-Series PLC does not have an Administrator password set by default. No password is needed to access the PLC.
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15 PLC RESTORE PROCEDURE – FTP OPTION
This procedure will show how to restore the main sequence (ladder logic) program and/or the parameter file to the Mitsubishi Q-PLC. NOTICE: Only authorized trained technical or engineering service personnel should attempt this procedure. Failure to follow these steps accurately can make your system fail. Take care to read each step carefully in order to successfully restore file(s) to the Mitsubishi Q-PLC. Refer to the figure below to see an example of how to use Windows FTP with the Mitsubishi Q-PLC. NOTICE: These steps only show restore for the MAIN.QPG file. They are the same for the PARAM.QPA file. The MAIN.QPG file and PARAM.QPA file is located on the product CD:
CD PATH:\AxoView\Current Version\PLC Files\MAIN.QPG
CD PATH: \AxoView\Current Version\PLC Files\PARAM.QPA
Figure 49: PLC FTP Session from Windows Command Line
15.1 Information
You will need the following things in order to use FTP to restore files to the Mitsubishi Q-PLC:
Windows FTP Client (included in Windows XP on your machine PC)
PLC File - MAIN.QPG or PARAM.QPA (available from Axometrics and on install CD)
PLC IP Address – IP is 10.0.0.70
PLC FTP Address – FTP is 10.0.0.70
PLC FTP Port Number – Port number is 21 FTP (default)
PLC Subnet Mask – Subnet Mask is 255.255.255.0
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PLC Username – QJ71E71 (CASE SENSITIVE-USE ALL UPPERCASE LETTERS)
PLC Password – QJ71E71 (CASE SENSITIVE-USE ALL UPPERCASE LETTERS)
15.2 Connection
NOTICE: The computer being used to restore the Mitsubishi Q-PLC files must be on the same physical network as the PLC (10.0.0.1). The best machine to use is the Axometrics PC. The IP settings below are for another PC or laptop or an Ethernet crossover cable can be used directly attached to PLC with different PC or laptop. Settings for different PC or laptop
IP Address of different PC or Laptop: 10.0.0.xxx (Example 10.0.0.213)
Subnet Mask of different PC or Laptop: 255.255.255.0
15.3 File Description
The PLC has internal files that are used for configuration. Each file and its brief description is listed below. The files we will use are MAIN.QPG and PARAM.QPA.
1. Primary PLC Files a. MAIN.QPG – Main sequence (ladder logic) program b. PARAM.QPA – PLC parameters file, for modules, network and settings
2. Other PLC Files
a. Q02.DAT – PLC data file b. SRCINF1.CAB – PLC CAB file c. SRCINF2.CAB – PLC CAB file d. COMMENT.QCD – Ladder / Main Sequence Comments file
15.4 Procedure
NOTICE: The steps below will make the PLC fail if not used properly. Only qualified engineering personnel should perform these steps. It is best to contact Axometrics BEFORE using this procedure to restore the PLC. Take care to read each of the steps and understand before proceeding. See the figure above for a visual representation of FTP login to the Mitsubishi Q-PLC. It is suggested to use PING to make sure PLC is connected. Follow the steps below IN ORDER. This procedure will restore the PLC to Axometrics factory settings: NOTICE: Other FTP programs may work; this has only been tested with Windows FTP Client as shown in this procedure. I. Connect to the PLC network II. Locate the file(s) to restore (MAIN.QPG or PARAM.QPA) III. Place these files in the root directory (C drive) of your machine IV. In Windows XP or Windows 7 use Start Menu - Run and type CMD.EXE
1. In the CMD.EXE window type: FTP 10.0.0.70
2. When it connects type the username (ALL UPPERCASE): QJ71E71
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3. When it shows Password Required type (ALL UPPERCASE): QJ71E71
4. It will now show User Logged In. Type the command: LS
5. It will show a list of files (see Fig. 42). See that MAIN.QPG and PARAM.QPA are listed.
6. Type the command: QUOTE STOP
7. It will show Command Successful. The PLC RUN light will be OFF on the Q-PLC CPU
Module and the PLC will be in STOP mode
8. Type the command: DEL MAIN.QPG
9. It will show MAIN.QPG deleted. Type the command: PUT C:\MAIN.QPG MAIN.QPG
10. It will show Command Successful, Transfer complete. Type the command: QUOTE RUN
11. It will show Command Successful, Transfer complete. The PLC RUN light will be ON on
the Q-PLC CPU Module and the PLC will be in RUN mode.
12. Type the command: BYE
13. The FTP Session will be closed.
14. Physically turn the PLC POWER OFF then ON and verify proper operation.
15. The PLC is now updated with a new MAIN.QPG file.
This is the end of the restore procedure. If there are problems please contact Axometrics or your distributor.
