me220 system configuration and alignment - covaris · 2020. 4. 6. · pn 210054 (optional) note:...

Document Number: 440244 Rev E of 34 Title: ME220 System Configuration and Alignment Covaris Confidential

Notice UNCONTROLLED IN PRINTED FORM UNLESS STAMPED IN RED

ME220 System Configuration and Alignment

Rev. DCO # Author Change History Date Training

required A 021632 D. Kerikas Release to production 8/23/2016 Y

B 021728 I. Tsinteris Officially released Macro Alignment procedure and tooling 1/11/2017 Y

C 021710 L. LaBranche Updating ManField information 2/9/2017 D 021932 J. Maeir Updating ManField screenshots 12/12/2017 N

E 022334 R.DiBiase Moving Macro Alignment section to ME220 Mechanical Base Assembly Procedure

4/09/2019 Y


Contents 1. Purpose: ....................................................................................................................... 3 2. Definitions and Acronyms ........................................................................................... 3 3. Associated Documents: ............................................................................................... 3 4. Records: ....................................................................................................................... 3 5. Training: ...................................................................................................................... 3 6. Disassembly before Calibration ................................................................................... 3 7. Roll/Pitch/Yaw Alignment .......................................................................................... 5 8. Adjusting the Home Limit Sensors ........................................................................... 14 9. X, Y & Z Center Position Calibration ....................................................................... 17 10. Water Level Sensor Calibration ................................................................................ 24 11. Sliding Weight Alignment ......................................................................................... 26 12. Instrument Leveling ................................................................................................... 29 13. Assemble Trim Pieces ............................................................................................... 30 14. Appendix A (Printer setup) ........................................................................................ 34


1. Purpose:

This document describes the process for aligning and calibrating the motion system, calibrating the water level sensor, and adding the final trim pieces to the ME220 instrument.

2. Definitions and Acronyms

3. Associated Documents: 3.1. Internal Documents

PN 420240 – ME220 Fab File PN 210054 – ManField application

3.2. External Documents

4. Records:

None

5. Training:

Read procedure, observe and practice with a trainer.

6. Disassembly before Calibration

6.1. If working with a fully assembled ME220, some disassembly will be required before performing these steps. If building up a new ME220, none of these items will be in place yet, and you can skip this section.

6.2. Take the laptop off from the ME220 Cover and set it aside.

6.3. Remove the M4 BHCS that secure the Skin to the Baseplate.

6.4. Carefully Slide the Skin up and off the ME220 Instrument and set it aside.

6.5. Remove the 4 items indicated with red arrows. Carefully set them aside with their screws.


Parts to be Removed

Instrument after Removal


7. Roll/Pitch/Yaw Alignment

7.1. Equipment

7.1.1. Alignment Indicator Plate – PN 901105 7.1.2. ME220 Dial Indicator – PN 901210 7.1.3. ME220 Motion Handwheels – PN 901262 (Optional) 7.1.4. ManField application- PN 210054 (Optional)

NOTE: All stage motion for the following process steps can be achieved by manually moving the stages or by powering up the machine and having software move it. Most people find the process quicker when moving the stages manually, especially with the ME220 Motion Handwheels installed (PN 901262) on both stages. Or use the ManField application (PN 210054) for the following sections: (8.2 – 8.3.10)

7.2. Roll Alignment

7.2.1. Adjust the tip of the ME220 Dial Indicator (PN 901210) so that it is near flat.

7.2.2. Place the ME220 Dial Indicator on the Alignment Indicator Plate (PN 901105). It will snap on with magnets. Slide it around on the Plate so that


the tip of ME220 Dial Indicator will touch the top surface of the Rack Holder as shown below.

7.2.3. Jog the Rack Holder with the software in the X direction until the ME220 Dial Indicator rests on the right side of the Rack Holder as shown.

7.2.4. Jog the height of the Rack Holder until the needle of the ME220 Dial Indicator is pointing straight back at you.

7.2.5. Twist the ring of the ME220 Dial Indicator so that 0 is centered on the needle of the Indicator.

7.2.6. Move the Rack Holder to the right 63mm. If you are manually driving the

stages, this is the equivalent of moving ¾ of the length of the Rack Holder.

7.2.7. Look at the ME220 Dial Indicator and how the needle has changed. The needle must have deviated to less than .005” (5 on Dial scale) for it to pass. Record final measured value for Roll in Fab File.


7.2.8. If the ME220 Dial Indicator changed more than or equal to .005” use the following table to determine which set screw needs to be driven inwards.

Roll Alignment Adjustment Table Dial Indicator Change Screw to Drive Inwards

7.2.9. When adjusting the screw, it’s important to know that it will only begin to

have an effect on the alignment once the set screw makes contact with the block. Once the set screw makes contact with the block advance the screw forward only ¼ turn at a time before retesting the alignment. Small turns will have big impact on the alignment.

7.2.10. To retest the alignment repeat steps 8.2.1 – 8.2.9. **NOTE - It’s important that you continue to test the alignment by moving the Rack Holder in the same direction. The Dial Indicator should travel from the right side of the Rack Holder to the left. The table that shows which screws to adjust was written with this direction in mind.**


7.2.11. Once the Roll requirement has been reached, it’s important to back off

either of the 2 set screws on the side of the Arm Mount Plate Potted Assy (PN 190381) so that they are not digging into the carriage of the 30mm Stroke Linear Actuator (PN 340138). This will not cause you to lose any Roll adjustment that you made. Doing this step will allow the Arm Mount Plate Potted Assy (PN 190381) to be free to pivot in the Yaw and Pitch alignment steps.

7.3. Yaw Alignment 7.3.1. Adjust the tip of the ME220 Dial Indicator so that it is bent down 90

degrees.

7.3.2. Place the ME220 Dial Indicator on the Alignment Indicator Plate (PN

901105). It will snap on with magnets. Slide it around on the Plate so that the tip of ME220 Dial Indicator will touch the inside surface of the Rack Holder as shown below.

7.3.3. Jog the Rack Holder with the software in the X direction until the ME220 Dial Indicator rests on the right side of the Rack Holder as shown.


7.3.4. Slide the ME220 Dial Indicator forward or back on the Plate until the needle of the ME220 Dial Indicator is pointing straight back at you.

7.3.5. Twist the ring of the ME220 Dial Indicator so that 0 is centered on the

needle of the Indicator.

7.3.6. Move the Rack Holder to the right 63mm. If you are manually driving the stages, this is the equivalent of moving ¾ of the length of the Rack Holder.

7.3.7. Look at the ME220 Dial Indicator and how the needle has changed. The needle must have deviated to less than .005” (5 on Dial scale) for it to pass. Record final measured value for Yaw in Fab File.

7.3.8. If the ME220 Dial Indicator changed more than or equal to .005” use the

following table to determine which set screw needs to be driven inwards.


Yaw Alignment Adjustment Table

Dial Indicator Change Screw to Drive Inwards

7.3.9. When adjusting the screw, it’s important to know that it will only begin to

have an effect on the alignment once the set screw makes contact with the block. Once the set screw makes contact with the block advance the screw forward only ¼ turn at a time before retesting the alignment. Small turns will have big impact on the alignment.

7.3.10. To retest the alignment repeat steps 8.2.1 – 8.2.9.

**NOTE - It’s important that you continue to test the alignment by moving the Rack Holder in the same direction. The Dial Indicator should travel from the right side of the Rack Holder to the left. The table that shows which screws to adjust was written with this direction in mind.**

7.4. Pitch Alignment

7.4.1. Adjust the tip of the ME220 Dial Indicator so that it is bent down approximately 45 degrees. The tip of the Dial Indicator must be below the bottom edge of the Dial Indicator as indicated by the red line in the image.


7.4.2. Place the ME220 Dial Indicator on the Alignment Indicator Plate (PN 901105). It will snap on with magnets. Slide it around on the Plate so that the tip of ME220 Dial Indicator will touch the top front surface of the Rack Holder as shown. You can do this anywhere along the length of the Rack Holder.

7.4.3. Jog the Rack Holder up or down in the ManField software in the Z

direction until the ME220 Dial Indicator is pointing straight back at you.

7.4.4. Twist the ring of the ME220 Dial Indicator so that 0 is centered on the needle of the Indicator.

7.4.5. Slide ME220 Dial Indicator straight forward on the Alignment Indicator Plate (PN 901105) until the tip of the indicator rests on the back front surface of the Rack Holder.


7.4.6. Look at the ME220 Dial Indicator and how the needle has changed. The needle must have deviated to less than or equal to .003” (3 on Dial scale) for it to pass. Record final measured value for Pitch in Fab File.

7.4.7. If the ME220 Dial Indicator changed more than .003” use the following

table to determine which set screw needs to be driven inwards.


Pitch Alignment Adjustment Table Dial Indicator Change Screw to Drive Inwards

7.4.8. When adjusting the screw, it’s important to know that it will only begin to have an effect on the alignment once the set screw makes contact with the block. Once the set screw makes contact with the block advance the screw forward only 1/8 turn at a time before retesting the alignment. Small turns will have a big impact on the alignment.

7.4.9. To retest the alignment repeat steps 8.4.1 – 8.4.8.

**NOTE - It’s important that you continue to test the alignment by moving the Rack Holder in the same direction. The Dial Indicator should travel from the front to the back of the Rack Holder. The table that shows which screws to adjust was written with this direction in mind.**

7.5. After finishing Pitch alignment, double check Roll and Yaw Alignment to

make sure adjustments that you have made haven’t thrown them out of the .005” spec.


7.6. If you have been using the ME220 Motion Handwheels, remember to remove them from the stages at this point.

8. Adjusting the Home Limit Sensors

8.1. Equipment

8.1.1. PN 901193 – Motion Go NoGo Gauge 8.1.2. PN 901209 – Door Sensor Bypass 8.1.3. PN 210054 – ManField Application (Optional) sections: (9,10 and 11)

8.2. Slip the Door Sensor Bypass (PN 901209) over the door sensor.

8.3. Launch (PN 210054) ManField software and go to the Motion Tab.

8.4. Press the [Home] button to home the instrument.

8.4.1. Verify the [HOMED] indicator transitions from red to green to indicate Homing was successful.

**WARNING – The safety door has been removed and the switch overridden. It is your responsibility to ensure you are out of harm’s way before telling the motion system to move.**

8.5. Save a preliminary center position to instrument as follows:


8.5.1. Use motion jog buttons or Target Position feature to move system to position X=30.0 and Z=0.0.

8.5.2. Under the ‘Center Position’ menu, click [Save Current] button. Verify ‘Center Position’ value changes as expected.

8.5.3. Click X to Exit out of ManField application

8.5.4. Cycle power to instrument, then launch ManField application after 10-20

seconds.

8.5.5. Return to Motion tab and Home instrument.

8.6. Obtain tool ME220 Motion Go/No Go Gauge (PN 901193).

8.7. To calibrate the Z home position, slide the Go/No Go Gauge between the Z axis carriage and endcap as indicated with the black arrow.


Z-Axis Calibration

8.8. The GO end of the Gauge should slide freely between the 2 parts. The NO GO end of the Gauge should not be able to slide between the 2 parts.

8.9. Loosen the 2X M2.5x6 SHCS indicated with red arrows to be able to adjust the sensor up and down.

8.9.1. Adjust the sensor up if the NO GO end can pass between the 2 parts.

8.9.2. Adjust the sensor down if the GO end cannot pass between the 2 parts.

**WARNING – Adjusting the limit sensor too high may cause the stage to crash and stall because the sensor never gets tripped.**

8.10. After making your adjustment to the sensor position, tell the machine to

home again using the software to see what effect your adjustment had.

8.11. Repeat steps 9.7-9.10 until condition 9.8 is satisfied. Once satisfied, tighten down on the 2X M2.5x6 SHCS screws.

8.12. To calibrate the X home position, slide the Go/No Go Gauge between the X

axis carriage and endcap as indicated with the black arrow.


X-Axis Calibration

8.13. The GO end of the Gauge should slide freely between the 2 parts. The NO GO end of the Gauge should not be able to slide between the 2 parts.

8.14. Loosen the 2X M2.5x6 SHCS indicated with red arrows to be able to adjust the sensor up and down. You will need to move the stage off of home with the software to have better access to the screws.

8.14.1. Adjust the sensor left if the NO GO end can pass between the 2 parts.

8.14.2. Adjust the sensor right if the GO end cannot pass between the 2 parts.

**WARNING – Adjusting the limit sensor too far to the left may cause the stage to crash and stall because the sensor never gets tripped.**

8.15. After making your adjustment to the sensor position, tell the machine to

home again using the software to see what effect your adjustment had.

8.16. Repeat steps 9.12-9.15 until condition 9.13 is satisfied. Once satisfied, tighten down on the 2X M2.5x6 SHCS screws. Check ‘PASS’ in Limit Sensor Position Go/No Go box in Fab File.

9. X, Y & Z Center Position Calibration **NOTE – Before performing this procedure the Home Limit Sensors must be in their correct spot (Section 7) and the Motion System must be aligned in Roll, Yaw, and Pitch (Section 8).**


**NOTE – This procedure can be performed on a fully assembled machine. The disassembly described in Section 6 does not need to be performed prior to performing X, Y, or Z Center Position Calibration.**

9.1. Equipment

9.1.1. ME220 Center Alignment Pin – PN 901108 9.1.2. ME220 XY Calibration Plate – PN 901110 9.1.3. ManField application – PN 210054

9.2. Y-Center Position Calibration

9.2.1. Launch the ManField software

9.2.2. When the splash screen is shown, enter the unlock code “Control-Alt-M”.

9.2.3. Click Motion Tab

9.2.4. Move the Rack Holder up out of the Bath so that it is free to swing open.


9.2.5. Swing open the Rack Holder and place the ME220 Center Alignment Pin (PN 901108) into the center of the bath. The tool should sit flat on the surface of the Xducer.

9.2.6. Swing the Rack Holder shut.

9.2.7. Place the ME220 XY Calibration Plate (PN 901110) into the Rack Holder.

9.2.8. Jog the Rack Holder in the X direction with the software so that the Center Alignment Pin will be able to pass through the HORIZONTAL slot.

9.2.9. Slowly jog the Rack Holder down to see if the Pin will pass through the HORIZONTAL slot.

9.2.9.1. If the pin DOES NOT pass freely through the slot, loosen the 4X M3

SHCS that hold the sliding half of the arm. Slide the Arm forward or


back so that the Center Alignment Pin will be able to pass through the HORIZONTAL slot. Grip the arm as described in Section 8.2.3 so that you don’t lose your pitch alignment. Lightly tighten the 4X M3 SHCS and check to see if the Pin will now pass freely through the HORIZTONTAL slot.

If the pin DOES pass freely though the slot, perform a final tightening of the 4X M3 SHCS that secure the sliding half of the arm. Motion System is now centered in the Y-Axis. 9.2.10. Jog the Rack Holder up off the Pin before telling the instrument to home. 9.2.11. Double check that the Pitch of the instrument hasn’t gone out of

alignment by repeating Section 8.4.

9.3. X-Center Position Calibration

9.3.1. If you haven’t already done it, perform steps 9.2.1 through 9.2.5.

9.3.2. Home instrument.

9.3.3. Jog the instrument in the X-axis until the Center Alignment Pin appears centered on the VERTICAL slot.


9.3.4. Slowly jog the Rack Holder down to see if the Center Alignment Pin will pass through the VERTICAL slot.

9.3.5. Adjust the X-axis position until the Center Alignment Pin passes freely

through the slot. Record the current X-Axis position into the Fab-File. That is the instrument’s X-Axis Center position.

9.3.6. Jog the Rack Holder up off the Pin before telling the instrument to home.

9.3.7. Remove the ME220 XY Calibration Plate (PN 901110) and the ME220

Center Alignment Pin (PN 901108) from the instrument.

9.4. Z-Center Position Calibration

9.4.1. Obtain ME220 Z-Height Gauge Block (PN 901112) and ME220 Z-Height Drop Gauge (901256).

9.4.2. Setup the ME220 Z-Height Gauge Block on a flat surface with the ME220

Z-Height Drop Gauge inside of it.

9.4.3. Zero the Z-Height Drop Gauge.


9.4.4. ManField application under Motion tab Click [Home] button.

9.4.5. Tell the instrument to go to its X-Center position. (See Section 10.3)

9.4.6. Place Z-Height Drop Gauge into the Rack Holder.

9.4.7. Jog the instrument down until the Z-Height Drop Gauge reads less than

0.05mm. Record Drop-gauge value in Fabrication File.


9.4.8. The instrument’s motion system should currently be at its X and Z-Axis Center position. Record the Center Positions in Fab-File. Click the [Save Current]. That sets the values into firmware.

9.4.9. Remove the Z-Height Drop Gauge from the Rack Holder.

9.4.10. Home the instrument.

9.5. X-Axis Range of Travel Verification

9.5.1. Click [Center Position] and verify holder moves to proper position.

9.5.2. Calculate position to travel to which is +34mm from Center Position and

record in Fabrication File.

9.5.3. Use Motion controls to move to the target X location. Verify it successfully reaches this position. Check ‘PASS’ in Fab File if successful.

9.5.4. Click [Home] button and verify instrument homes back to position 0,0.

9.5.5. Calculate position to travel which is -34mm from Center Position and

record in Fabrication File.

9.5.6. Use Motion controls to move to the target X location. Verify it successfully reaches this position. Check ‘PASS’ in Fab File if successful.

9.5.7. Click [Home] button and verify instrument homes back to position 0,0.


10. Water Level Sensor Calibration

10.1. Equipment 10.1.1. WL Sensor Calibration Tool – PN 901211 10.1.2. ManField application – PN 210054

**NOTE – Before performing this procedure the Home Limit Sensors must be in their correct spot (Section 7), the Motion System must be aligned in Roll, Yaw, and Pitch (Section 8), and the X,Y, & Z Center Position (Section 9) must be calibrated.**

**NOTE – This procedure can be performed on a fully assembled machine. The disassembly described in Section 6 does not need to be performed prior to performing the Water Level Sensor Calibration.**

10.2. Remove the WL Sensor cover from the instrument if it is currently in place.

10.3. Make sure the bath of the instrument is drained of water.

10.4. Cycle the power of the instrument.

**NOTE – The “Teach” process for the sensor is automatically disabled 5 minutes after power-up. From this point forward, you will have only 5 minutes to complete this process.**

10.5. Launch the ManField software.

10.6. Press and hold the yellow “Teach-In” button on the front of the sensor for approximately 2 seconds until the LED flashes amber/red. Release button.

10.7. Verify the LED now flashes Red.


10.8. Home the instrument.

10.9. Jog the instrument to the right so that you can fit ME220 Water Level Calibration Tool (PN 901211) into the Rack Holder. The left tip of the tool should be just 1-2mm from touching the left side of the bath.

10.10. Tell the instrument to move down to a z-height of 2.8mm above the Z-Axis Center value.

10.11. Press the yellow “Teach-In” button to set the low water sense level.

10.12. Verify the LED now flashes Yellow.


10.13. Tell the instrument to move up to a z-height of 18.8mm above the Z-Axis Center value. Another way to calculate it is 16.0mm above the low water sense level.

10.14. Press the yellow “Teach-In” button to set the high water level.

10.15. Successful completion of the process is confirmed by both LEDs being on

for approximately 2 seconds.

10.16. After sensor calibration has been completed, move down 8.0mm from current position so holder is 10.8mm above the Z-Axis Center Value.

10.17. In the ‘Water’ Tab, review the average Water Level value displayed to the

right of the water bath image. 10.17.1. Record value in Water Level Sensor Calibration box in Fabrication

File. Check ‘PASS’ box if verified to be within 7.5 to 8.5mm.

11. Sliding Weight Alignment


11.1. Inspect the Sliding Weight to see if it is out of alignment relative to the Rack Holder.

11.2. Looking from the top down, inspect the gap between the Sliding Weight and the Rack Holder. The gap, indicated in red arrows, should be relatively uniform along the entire length of the Weight and Rack Holder.

11.3. If the Sliding Weight appears crooked from this view perform the following:

11.3.1. Remove the 4x M2X6 FHCS that secure the Barrel to Swing Arm. Set

Barrel and Sliding Weight aside.


11.3.2. Drive the red pair or blue pair of set screws up so that they are proud of the surface slightly. This will kick the Sliding Weight to the right or left when you reattach it.

11.3.3. Secure the Barrel and Sliding Weight back to the Swing Arm using the 4x M2X6 FHCS and look down on the weight see if your adjustments are adequate. If not, repeat steps process.

11.4. Looking from the front, straight on, inspect the gap between the Sliding Weight and the Rack Holder. The gap, indicated in red arrows, should be relatively uniform along the entire length of the Weight and Rack Holder.

11.5. If the Sliding Weight appears crooked from this view perform the following:

11.5.1. Remove the 4x M2X6 FHCS that secure the Barrel to Swing Arm. Set

Barrel and Sliding Weight aside.


11.5.2. Drive the red pair or blue pair of set screws up so that they are proud of the surface slightly. This will kick the Sliding Weight forward or backward when you reattach it.

11.5.3. Secure the Barrel and Sliding Weight back to the Swing Arm using the 4x M2X6 FHCS and look at the weight see if your adjustments are adequate. If not, repeat steps process. When complete, check ‘PASS’ in Sliding Weight Alignment box in Fab File.

12. Instrument Leveling **NOTE – This procedure can be performed on a fully assembled machine. The disassembly described in Section 6 does not need to be performed prior to performing the Water Level Sensor Calibration.**


12.1. If not already on the instrument, install Front Trim Water Bath (PN 101903) with 8X FHCS, M3x6, SST (PN 310642).

12.2. Install Instrument Level (PN 300186) with 2X M2x5 BHCS (PN 310685).

12.3. Look at the bubble of the Instrument Level to determine what adjustment if any is needed to bring the instrument into level left to right.

12.4. The left pair of feet should be locked in place.

12.5. Adjust the right pair of feet up or down to get the bubble of the Instrument Level centered between the 2 marks.

12.6. Lock the right pair of feet in place using a ½” wrench to jam the nut up against the bottom of the base plate. Grip the foot with your finger while performing this operation to ensure it doesn’t spin and cause the instrument to go out of level.

12.7. Check to make sure that all 4 feet of the instrument make contact with the table and that it cannot rock back and forth or side to side. When complete, check ‘PASS’ in Level Instrument box of Fab File.

13. Assemble Trim Pieces

**NOTE – Perform once all calibration procedures have been completed.**

13.1. If not already on the instrument, install Front Trim Water Bath (PN 101903)

with 8X FHCS, M3x6, SST (PN 310642).


13.2. Install Instrument Level (PN 300186) with 2X M2x5 BHCS (PN 310685).

13.3. Install WL Sensor Cover (PN 101923) with 1X M3x6 BHCS (PN 310064).


13.4. Install Door Sensor Cover (PN 101944) with 1X M3x20 BHCS (PN 310654).

13.5. Install Upper Front Trim (PN 101932) with 4X M3x6 FHCS (PN 310642) and 2X M3x6 BHCS (PN 310064).


13.6. If you are performing this in the field, install the Cover back onto the instrument. If building this instrument up from scratch in MFG, refer to the ME220 System Integration Procedure PN 440246.


14. Appendix A (Printer setup) • Enable CEW WiFi • Search field type: \\ops\

• Location WhiteOak • Double click on WhiteOak this will install drivers

• Click on Printer • Scroll down to Properties • Click on [Print test page] button

• Verify a test page was sent to printer • Printer is now setup if print out was successful