Page 1 Perceptron, Inc.

IPNet Troubleshooting Reference Manual Part Number 009-0315 Rev. D November, 2000 Planeación Mantenimiento Brenda Sánchez. Ext. 8730

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PERCEPTRON INFORMATION NOTICE The information presented herein provides general operating instructions, engineering data and maintenance procedures for Perceptron equipment. Perceptron assumes no obligation or liability for the information presented herein or the use of the same, all such information being utilized at the recipient's own risk. In no event shall Perceptron be liable for any direct, consequential, incidental or other damages of any kind resulting from the use of this information, including, but not limited to, loss of profits or revenues, loss of use of, or damage to, the equipment, or other property damage or injuries to persons. The availability, presentation and conveyance of such information by Perceptron to non-Perceptron personnel does not constitute an explicit or implicit endorsement of, promotion of, or liability for such information. Except that which may be expressly provided for in service manuals or other written instructions, the recipient is cautioned against unauthorized attempts at maintenance of Perceptron equipment and related activities and that such actions could result in serious damage to such equipment, the malfunction of such equipment, injury to persons or damage to property. In the event that unauthorized maintenance, installation, service, disassembly, adjustments and/or repairs to such equipment are conducted by anyone other than Perceptron personnel without prior written authorization from Perceptron, the warranty provided by Perceptron with respect to the equipment shall be voided, and product performance may be adversely affected. Perceptron makes no representations or guarantees that improvements, upgrades or changes will not occur. In the interest of technical progress, the information in this manual is subject to change without notice. The examples and diagrams in this document are included solely for illustrative purposes and may vary from those which actually appear on your system. TriCam, TriLite, VeriStar, DDM, OCF, LASAR, Wheelworks, ScanWorks, IPNet, and Perceptron are registered trademarks of Perceptron, Inc. and DataCam, Micro-Flash, Visual Fixturing, Sensing the Future, Optiflex, and InterSystems are trademarks of Perceptron, Inc.. The hardware, software, and processes described herein may be protected under one or more of the following patents: US 4541721; US 4645348; US 4647208; US 4666303; US 4745469; US 4841460; US 4862598; US 4899218; US 5006721; US 5078496, US75/728,106, EP 0543900; CA 1294427; CA 1304932; EP 280941; EP 306731; DE P3875984.5; DE P3877655.0; Case # 4226-200037 and Case # 4226-200038. Copyright ∧ 2000 by PERCEPTRON, INC. ALL RIGHTS RESERVED Printed in the United States of America. No part of this publication may be reproduced, distributed, stored in a retrieval system, or transmitted in any form or by any means by media now known or hereafter discovered, including, and without limitation, print, electronic, mechanical, photocopying, electrocopying, recording or otherwise, as well as the right to display and transmit this work publicly on-line without prior permission from Perceptron, Inc. This documentation contains proprietary and confidential technical information. This document and the information in it are for the sole use of the customer and facility to which it has been assigned. Transfer of this material to unauthorized personnel or business entities is in violation of Perceptron’s rights under the United States Copyright Act.

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Revision History Date Revision Description July, 1999 A Initial Release May, 2000 B Removed reference to light pen: Section 1.9, 2.5.10, 3.5.7, 3.6.3. Removed Section 2.6 Power Supply. Removed Error column in 3.2.1, LEDs. Added Hub Card information Section 1.3 & 1.4.1; updated 2.4.4 PPI Hub Card. Ethernet Hub Card information changed in Section 1.9. Added steps to Section 2.5.2.2 Replacing Primary Hard Drive & Section 2.5.3 Secondary Hard Drive. Added steps to Section 2.5.6 PPI Ethernet Hub Card replacement. Updated images in reference to all above changes. August, 2000 C Added Appendix A, I/O Configuration Signals and Input/Output Summary information. November, 2000 D New Output Signal: ALL ALARMS SET, and timing diagram. Updated Support and About help images (Section 1.7.1 & 1.7.3). New C3 Enclosure figures: Figure 1-3, 2-6, 5-6.

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Page 5 Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Contents � i

Contents 1. General Information 1 1.1 Introduction..........................................................................................................................1 1.2 Manual Overview.................................................................................................................1 1.3 Features ................................................................................................................................1 1.4 Specifications .......................................................................................................................2 1.4.1 Perceptron IPNet Controller................................................................................2 1.4.2 Perceptron IPNet Monitor Specifications ...........................................................3 1.4.3 C3 Enclosure Specifications ...............................................................................3 1.4.4 Cooling Requirements ........................................................................................3 1.5 Physical Dimensions ............................................................................................................4 1.6 Functional Description .........................................................................................................7 1.7 Customer Support.................................................................................................................7 1.7.1 Hardware Support ...............................................................................................8 1.7.2 Software Support ................................................................................................8 1.7.3 Software Version Number Locations..................................................................9 1.8 Additional Support Information ...........................................................................................9

1.8.1 Part List...............................................................................................................9 1.8.2 Connector Signals .............................................................................................10 1.9 Related Documentation......................................................................................................11 2. Hardware & Replacement 13 2.1 Introduction........................................................................................................................13 2.2 Unpacking Instructions ......................................................................................................13 2.3 Mounting Options for the Perceptron IPNet ......................................................................14 2.3.1 Main Controller.................................................................................................14 2.3.2 C3 Enclosure.....................................................................................................17 2.4 Computer............................................................................................................................17 2.4.1 PCI Card ...........................................................................................................17 2.4.2 PPI Hub Card....................................................................................................18 2.5 Hardware Replacement ......................................................................................................19 2.5.1 Removing the Computer from the Enclosure....................................................19 2.5.2 Hard Drive Replacement...................................................................................20 2.5.3 Secondary Hard Drive Replacement.................................................................22 2.5.4 Floppy Drive Replacement ...............................................................................23 2.5.5 CD-ROM Drive Replacement...........................................................................24 2.5.6 PPI Ethernet Hub Card Replacement................................................................25 2.5.7 Monitor Replacement........................................................................................28 2.5.8 Keyboard...........................................................................................................28 2.5.9 Mouse ...............................................................................................................30 2.6 Laser Printer (Optional) .....................................................................................................31 2.6.1 Basic Troubleshooting for the Laser Printer ....................................................31 2.6.2 Replacing the Laser Printer Toner Cartridge ....................................................32 2.6.3 Cleaning the Laser Printer.................................................................................32

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ii � Contents Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 3. Operation & Maintenance 35 3.1 Introduction........................................................................................................................35 3.2 Indicators............................................................................................................................35 3.2.1 LEDs During Normal Operation.......................................................................36 3.3 Controller Switches: Power, Reset, and Fuses ..................................................................36 3.3.1 Main Controller Power .....................................................................................36 3.3.2 Isobar Protection ...............................................................................................36 3.3.3 Computer Power ...............................................................................................36 3.3.4 Cooling System Power......................................................................................37 3.3.5 C3 Enclosure Power..........................................................................................37 3.3.6 Sensor Power ....................................................................................................37 3.4 C3 Enclosure ......................................................................................................................37 3.4.1 Power Supply....................................................................................................37 3.4.2 Fuses .................................................................................................................37 3.4.3 C3 (Cable Converter Card) ...............................................................................37 3.5 Other External Controller Connections..............................................................................38 3.5.1 Serial Port Connections.....................................................................................39 3.5.2 Parallel Printer Port Connection .......................................................................39 3.5.3 Color Video Monitor Connection .....................................................................39 3.5.4 Keyboard...........................................................................................................39 3.5.5 Mouse ...............................................................................................................39 3.5.6 Ethernet Hub Card ............................................................................................40 3.6 Periodic Maintenance.........................................................................................................40 3.6.1 Cleaning Digital TriCam Sensor Lenses...........................................................40 3.6.2 Cleaning the Cooling System............................................................................40 3.6.3 Cleaning the Monitor, Light Pen, Keyboard and Mouse Roller........................41 4. Digital TriCam & TriLites 43 4.1 Introduction........................................................................................................................43 4.2 Indicators............................................................................................................................43 4.2.1 Digital TriCam Sensor ......................................................................................43 4.2.2 Digital TriLite ...................................................................................................45 4.2.3 Cable Drop........................................................................................................45 5. Schematics & Wiring 47

5.1 Introduction........................................................................................................................47 5.1.1 Power Distribution Panel and Terminal Block Locations.................................47 5.2 Schematic and Layout ........................................................................................................49 5.2.1 System Power ...................................................................................................50 5.3 C3 Enclosure ......................................................................................................................51 Appendix A. I/O Configuration 53 A.1 I/O Signal Descriptions and Timing Diagram...................................................................53 A.1.1 Input / Output Summary...................................................................................53 A.1.2 Inputs................................................................................................................54 A.1.3 Outputs.............................................................................................................56 A.1.4 Timing Diagram - No Phases...........................................................................61 A.1.5 Timing Diagram - With Phases........................................................................62 Index 63

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 1. General Information � 1

1. General Information 1.1 Introduction This manual addresses hardware and software troubleshooting techniques for the Perceptron IPNet system and IPNet applications.

1.2 Manual Overview Chapter 1 - Provides the General Information of the IPNet system, such as list of features, dimensional diagrams, and functional description at the block level. Also provides the user with Support Information. Chapter 2 - Explains how to replace different pieces of Hardware, such as, the controller, monitor, keyboard, mouse, drives, power supplies and air filters. Information also includes general instructions for unpacking, mounting and power connections. Chapter 3 - Explains Operation of LED descriptions during normal start up and operation, description of system controls, and information concerning external connections. And, details information on Periodic Maintenance. Chapter 4 - Details installation of System Drives and Expansion Cards, jumper configuration, and instructions for each card in the IPNet controller. Chapter 5 - Describes the Digital TriCam Sensors and TriLites used with the IPNet system. Chapter 6 - This section contains the Power Schematics and Wiring Diagrams for the system cabinet.

1.3 Features Features of the basic Perceptron IPNet system: � Can accommodate up to 128 Digital TriCam sensors. � High resolution color graphics system. (1024 x 768 pixels, Super VGA compatible video output). � Keyboard and mouse operated user interface, with optional light pen available. � Up to 9 Gigabyte SCSI hard disk storage system for measurement information and program storage.

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2 � 1. General Information Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 � Three and a half inch floppy disk drive for program update and data transfer. � CD-ROM drive.

� Onboard Ethernet connection. � Additional dual function hub card for remote laptop connection. � Two RS-232C serial ports that can be used to: receive part information; send measurement information or part positional information; and connect to programmable logic controllers or a plant communications network. � Nema 12 industrial enclosure with cooling equipment and power conditioning. � Optional Laser printer.

1.4 Specifications 1.4.1 Perceptron IPNet Controller Characteristics Specifications Power requirements 120 VAC, 20A, 50/60Hz, single phase, non- welding bus Processor Single Pentium II (slot 1) with auto-selection of bus frequency. 100MHz Front Side Bus (FSB) frequency with 350-450MHz CPUs. 66MHz FSB frequency with 233-333MHz CPUs. Memory capacity 128MB (standard), expandable to 1 GB I/O Ports Serial: Parallel: Ethernet: USB: 2 Male DB-9 RS-232C serial port Parallel I/O printer port 1 onboard 10/100 Base-T port; 4 additional 10/100 Base-T ports. 2 USB ports Hard disk drive Two 9.1 GB, 3.5 inch SCSI drives Floppy disk drive 1.44MB, 3.5 inch disk CD-ROM SCSI CD-ROM drive Operating Temperature 0° to 40° C Regulatory Class A CE, Class A FCC part 15, UL-1950, CSA-950, VDE en 60 950/IE 950

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 1. General Information � 3

1.4.2 Perceptron IPNet Monitor Specifications Characteristics Specifications CRT display tube 17", 0.25mm mask pitch, 100° deflection Display area (Factory settings) Horizontal: Vertical: 12.4 inches (315mm) 9.3 inches (236mm) Resolution

Horizontal: Vertical: 31kHz to 92kHz 55Hz to 160Hz Operating temperature: Humidity: Altitude: +10°C to +35°C 30% to 80% 0 to 10,000 ft Storage temperature: Humidity: Altitude: -20°C to +60°C 10% to 90% 0 to 45,000 ft Physical dimensions Height: Depth: Width: 16.6 inches (422mm) 15.0 inches (380mm) 15.9 inches (403mm) 1.4.3 C3 Enclosure Specifications Characteristics Specifications Power Requirements 120 VAC, 10A, 50/60Hz, single phase, non-weld bus Power supplied 24VDC, 480 Watt, 20A Operating temperature 0° to 50°C 1.4.4 Cooling Requirements The Perceptron IPNet controller is specified, designed and tested to operate with an ambient air temperature range of 0° to 50°C. Different cooling options are available, depending on ambient conditions. There are three cooling options available. Each option is integrated into the rear door assembly of the enclosure. 1.4.4.1 Fan/Filter Cooling This option uses a NEMA-12 rated fan/filter system. This option is recommended for relatively clean environments with an average ambient temperature below 85° F.

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4 � 1. General Information Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 1.4.4.2 Heat Exchanger Cooling This option uses a NEMA-12 rated heat exchanger assembly. This option does have a filter on the intake and is recommended for relatively dirty environments. This option should be used with ambient temperatures below 85° F. 1.4.4.3 Air Conditioner Cooling This option uses a NEMA-12 rated air conditioner. This option should be used when average ambient conditions will be greater than 85° F, thus requiring cooling to below ambient conditions. Each of the above options are equipped with an air filter assembly which must be cleaned on a regular basis.

1.5 Physical Dimensions The following figure displays physical dimensions for the Perceptron IPNet system. Figure 1-1. IPNet full enclosure

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 1. General Information � 5 Figure 1-2. IPNet pedestal enclosure

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6 � 1. General Information Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Figure 1-3. C3 Enclosure measurements Note: Wall mounting is optional.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 1. General Information � 7

1.6 Functional Description This section provides the functional description of the Perceptron IPNet at the block level. The block diagram of the system is shown in Figure 1-4. Figure 1-4. Digital TriCam System Components

1.7 Customer Support This section identifies the questions the user will need to answer when calling for hardware or software support. Customer support can be reached Monday through Friday from 8am to 5pm Eastern Standard time, at (800) 333-7753.

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8 � 1. General Information Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315

1.7.1 Hardware Support When hardware problems arise requiring customer support, the user will need to provide the following information: � A detailed description of the problem and if more than one system is in the plant, which system is causing the problem. � The part number and serial number of the hardware in question. � If the hardware is not under warranty, the user must have a purchase order number for repair or replacement. � Under the IPNet Help / Support menu there is information unique to the plant. This will help Perceptron identify the project number, system mode and type, and identify warranty features. 1.7.2 Software Support When software problems arise requiring customer support, the user will need to provide the following information: � The system software version number. � The version numbers of all other applications running in the system. � What was the user attempting to do when the error occurred, and is this a repeatable occurrence?

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 1. General Information � 9

1.7.3 Software Version Number Locations When calling for system support, the user may be asked to identify the version number of the system's software. To locate this information, refer to the Help / About IPNet menu.

1.8 Additional Support Information This section contains additional information useful in supporting the Perceptron IPNet controller: connector signals, power connectors, jumper configurations, and internal DC power distribution. 1.8.1 Part List Part Number Description Includes 926-0088 Main enclosure assembly 726-0137: Envirosealed IPNet system enclosure 726-0141: IPNet 120V power distribution panel 340-0039: Keyboard 340-0069: Microsoft wheel mouse 390-0037: 17" NEC E750 short depth CRT 345-0060: IPNet engineering Motorola Maverick industrial PC assembly

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10 � 1. General Information Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 926-0105 IPNet Printer enclosure base 520-0023: HP LaserJet printer 310-0447: Mold 10' Cable 525-0007: Laser printer paper (ream) 926-0093 DTC/STC Sensor distribution 120V 495-0249-01: C3 for J-Box mounting assembly 835-0059: Flanged 50.8 OD tubing clamp 726-0138 Two legged pedestal base 1.8.1.1 Fuses and Circuit Breakers Controller QOU120 Square D Primary Circuit Breaker 20 Amp 120VAC input QOU110 Square D C3 Enclosure Circuit Breaker 10 Amp 120 VAC GMC-1 Bussman Fan/Heat Exchange Cooling fuse 1 Amp 120 VAC GMC-8 Bussman Air Conditioning fuse 8 Amp 120 VAC C3 Enclosure GMC-5 Bussman Power supply fuses 5 Amp 120 VAC 195210002

Wickmann C3 10 Amp 120 VAC *Extra fuses are supplied with each system. These are located in the spare fuse holders on the power panel. 1.8.2 Connector Signals 1.8.2.1 Serial Port Interconnects The two serial ports on the Perceptron IPNet controller are male 9-pin D- Subminiature connectors. Both ports have identical signals. Pin No. Signal Mnemonic Signal Name and Description 1 DCD DATA CARRIER DETECT – Used to indicate that the modem device is on-line and ready for transmission. 2 RD RECEIVE DATA – Serial data is received by the controller on this line. 3 TD TRANSMIT DATA – Data to be transmitted is furnished on this line to the device from the controller. 4 DTR DATA TERMINAL READY – Indicates that the computer or terminal is ready to accept incoming transmission.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 1. General Information � 11 5 GND SIGNAL GROUND 6 DSR DATA SET READY – Used by a modem device to indicate that it is prepared to operate. 7 RTS REQUEST TO SEND – Supplied by the controller to the device when it is permissible for the device to transmit a message to the controller. 8 CTS CLEAR TO SEND – A function supplied to the controller by the device, and indicates that it is permissible to begin transmissions of a message. 9 RI RING INDICATOR – Signal that transitions from on to off whenever the modem device recognizes an incoming ring.

1.9 Related Documentation Computer: Motorola Computer Group, 2900 S. Diablo Way, Tempe AZ 85282; 1-800-759-1107 (US), (512) 434-1526 (outside US).

CRT (Monitor): Technical Support (800) 632-4662, fax (978) 742-7049. Keyboard: IBM, Hardware Service Support (800) 426-7378. Mouse: Refer to the IntelliPoint Online User's Guide or the Readme.txt file, for information. If the answer cannot be located, contact your computer supplier. Ethernet Hub Card: Trendware International Inc., 3135 Kashiwa St., Torrance CA 90505; (310) 891-1100, fax: (310) 891-1111 (see computer for onboard Ethernet). Printer (optional): Hewlett Packard, HP First fax (800) 333-1917 (US). Microsoft NT Workstation: For product support, contact your PC manufacturer. Refer to the system manual that came with your PC for technical support telephone number.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 2. Hardware & Replacement � 13

2. Hardware & Replacement 2.1 Introduction This chapter provides basic troubleshooting information for the following Perceptron IPNet hardware components: computer, monitor, keyboard, mouse, light pen (optional feature), power supplies, fuses and printer (optional feature). Figure 2-1. Basic IPNet computer system

2.2 Unpacking Instructions Unpack each item from its shipping carton. Check each item for damage as it is unpacked. Verify the contents of each shipping carton against the packing list, and save all packing material for any future storing and shipping. Caution: Avoid static discharge. Static discharge can damage circuits.

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14 � 2. Hardware & Replacement Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315

2.3 Mounting Options for the Perceptron IPNet The IPNet system consists of the main system enclosure, as well as one or more C3 (Cable Converter Card) enclosures. The number of C3 enclosures is dependant on the number of sensors on the system and the physical layout of the measurement stations. 2.3.1 Main Controller 2.3.1.1 Main Controller The Perceptron IPNet system is available with two different mounting bases: a two legged pedestal base or a full size enclosure base. Figure 2-2. Two-legged pedestal base

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 2. Hardware & Replacement � 15 Figure 2-3. Enclosure base unit (doors not shown) Both bases are stationary. Both bases have holes located in the bottom to be used for mounting the base to the floor. Both bases are designed for cable

entry through the bottom of the cabinet or through the top, with the use of cable grommets. The pedestal base does not allow for the addition of printer and/or larger I/O options. If these components are required the full size base should be used. 2.3.1.2 Connecting AC Power AC power should be run to the IPNet controller via a conduit. Although routing will differ for each application, conduit holes are provided in the top of the enclosure and are recommended for power entry.

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16 � 2. Hardware & Replacement Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Figure 2-4. AC Power Connection Power protection for sensitive electronic components are provided by a surge suppresser and line noise filter for the computer cabinet and peripherals. The surge suppresser contains a 12 AMP resetable circuit breaker, located on the isobar on the inside rear of the system cabinet. The voltage suppresser starts at 140 VAC RMS and can handle up to 110V, 13K AMP spikes. Noise suppression is limited to a minimum of 20 DB up to 100 MHz. Figure 2-5. Location of power connection 2.3.1.3 Electromagnetic Interference The Perceptron IPNet controller and all other Perceptron IPNet components were designed or selected to limit RF emissions. It is important that the following guidelines be followed in order to limit RF emissions from and into the system. 1. Use shielded cables on all external I/O ports. 2. Cable shields should be connected to earth ground via metal connectors on the controller chassis. 3. Be sure all internal expansion board screws are properly tightened.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 2. Hardware & Replacement � 17 4. Make sure all external panel and chassis screws are properly tightened and connected to earth ground. 2.3.2 C3 Enclosure 2.3.2.1 C3 Enclosure The C3 Enclosure is designed to be mounted either from the top by 2" diameter tubing or from the rear using wall mounting feet. Figure 2-6. C3 Mounting options 2.3.2.2 Connecting AC Power One fully loaded or two half loaded C3 Enclosures can be powered from the main system enclosure. Holes are provided on the side of the enclosure for routing power cables through a cable grommet. If several C3 enclosures are being used or are located a great distance from the main controller, the AC power should be supplied remotely.

2.4 Computer This section describes basic computer hardware troubleshooting. The computer, accessed through the front and rear doors of the IPNet, houses the processor, drives and peripheral boards that make up the IPNet system. 2.4.1 PCI Card The PCI Host Controller is a circuit board which plugs into a vacant Peripheral Component Interconnect (PCI) slot of a personal computer. It provides the means for a personal computer to communicate with

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Perceptron's Digital TriCam sensors. It is fully compliant with PCI specification 2.1, and has plug-and-play capabilities. 2.4.1.1 RJ Connections The board has two RJ45 connectors (Port 0 & 1) which support up to four sensor "channels" (two channels per port connector). The board also has two RJ11 connectors which provide synchronization capability with additional PCI-HC or other external circuitry. Diagnostic indicator LEDs are provided and are viewable from outside the PC the card is installed in. Figure 2-7. PCI card RJ Connectors and Diagnostic LED locations

2.4.2 PPI Hub Card The PPI Hub Card is a four port 10/100 Mbps autosensing Ethernet PCI Adapter card. The main purpose of this card is to provide a network link between the computer and an external laptop. The hub card has four outputs, each can be connected to a remotely located C3 Enclosure via a category 5 Ethernet cable. This connection allows a user to access the IPNet controller remotely from a laptop through an Ethernet connection in the C3 Enclosure.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 2. Hardware & Replacement � 19 LED Indicators on the PPI Card: LED Indicators Descriptions Link 1, 2, 3, 4 Indicates that a link with the network has been established on the appropriate port.

2.5 Hardware Replacement 2.5.1 Removing the Computer from the Enclosure To replace certain boards, the user will need to remove the computer from the system cabinet. Figure 2-8a. Front view of IPNet system Figure 2-8b. Rear view of IPNet system To remove the computer: 1. Shut down the operating system and disconnect system power. 2. Open the back door of the system and remove all cables connected to the rear of the computer (Figure 2-8b). 3. Next, remove the 4 screws from the front of the computer then slide out the computer through the front of the enclosure. To replace the computer: 1. Insert the computer through the front of the enclosure and replace the 4 screws from the front of the computer. 2. Reconnect all the cables to the rear of the computer, then close the rear door. 3. Power up the system.

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2.5.2 Hard Drive Replacement The primary hard drive is located in the internal drive bay located to the left of the floppy drive. It is connected to the system via the SCSI bus, which is a ribbon cable connected to the SCSI breakout on the system motherboard. 2.5.2.1 Hard Drive Troubleshooting If the system appears not to be booting correctly, it could potentially be a hardware problem if: � Hard Drive Access LED remains constantly lit (for more than 60 seconds). To troubleshoot the hard drive, the user will generally need to note the

information that is being displayed on the monitor during the boot sequence. If the system appears to be partially booting, the user can examine the boot sequence for specific error messages or deviations from a normal boot sequence. 2.5.2.2 Replacing the Primary Hard Drive Replacing the hard drive does require removal of the computer from the system cabinet. When the hard drive fails, use the following procedure to replace the drive. 1. Remove the top cover of the computer 2. Disconnect all the cables from all disk drives in the drive assembly. 3. Remove the four screws from the front of the computer holding the drive assembly in position (Figure 2-9a). Slide out the assembly (Figure 2-9b). Figure 2-9a. Remove screws then . . .

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 2. Hardware & Replacement � 21 Figure 2-9b. Slide out assembly 4. Remove the four screws holding the drive in place and remove the hard drive. Figure 2-10. Remove screws to remove the hard drive 5. Insure that the new drive is jumpered for the SCSI ID 0. 6. Replace the new drive into the brackets and secure in place.

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22 � 2. Hardware & Replacement Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 7. Re-install the four screws holding the drive in place. 8. Slide in the assembly. Screw in the four screws to the front of the computer. 9. Reconnect all the cables to the disk drive in the drive assembly. 10. Replace the top cover of the computer. 2.5.3 Secondary Hard Drive Replacement 1. Remove the top cover of the computer 2. Disconnect all the cables from all disk drives in the drive assembly. 3. Remove the four screws from the front of the computer holding the drive assembly in position. Slide out the assembly. (Figure 2-9a & 2-9b.) 4. Remove the four screws holding the drive in place and remove the secondary hard drive. The secondary hard drive is located in the expansion bay directly below the CD-ROM drive. Figure 2-11. Removing the secondary hard drive (upside down) 5. Insure that the new drive is jumpered for SCSI ID 1. 6. Replace the new drive into the brackets and secure in place. 7. Re-install the four screws holding the drive in place.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 2. Hardware & Replacement � 23 8. Slide in the assembly. Screw in the four screws to the front of the computer. 9. Reconnect all the cables to the disk drive in the drive assembly. 10. Replace the top cover of the computer. 2.5.4 Floppy Drive Replacement The floppy drive is located in the center the computer, as shown in Figure 2-12.

Figure 2-12. Location of Floppy Drive, CD-ROM and Primary Hard Drive 2.5.4.1 Replacing the Floppy Drive Replacing the floppy drive does require removal of the computer from the system cabinet. When the floppy drive fails, use the following procedure to replace the drive. 1. Remove the top cover of the computer 2. Disconnect all the cables from all disk drives in the drive assembly. 3. Remove the four screws from the front of the computer holding the drive assembly in position. Slide out the assembly. (Refer to Figure 2-9a & 2-9b.)

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24 � 2. Hardware & Replacement Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 4. Remove the four screws holding the drive in place and remove the floppy drive. Figure 2-13. Remove screws to remove floppy drive 5. Replace the new drive into the brackets and secure in place. 6. Re-install the four screws holding the drive in place. 7. Slide in the assembly. Screw in the four screws to the front of the computer. 8. Reconnect all the cables to the disk drive in the drive assembly. 9. Replace the top cover of the computer. 2.5.5 CD-ROM Drive Replacement 1. Remove the top cover of the computer 2. Disconnect all the cables from all disk drives in the drive assembly. 3. Remove the four screws from the front of the computer holding the drive assembly in position. Slide out the assembly. (Refer to Figure 2-9a & 2-9b.) Note: To get to the screws holding the CD-ROM in place, you must first remove the hard and floppy drive.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 2. Hardware & Replacement � 25 4. Remove the four screws holding the drive in place and remove the CD-ROM. Figure 2-14. Removing the CD-ROM 5. Replace the new drive into the brackets and secure in place. 6. Re-install the four screws holding the drive in place. 7. Slide in the assembly. Screw in the four screws to the front of the computer. 8. Reconnect all the cables to the disk drive in the drive assembly. 9. Replace the top cover of the computer. 2.5.6 PPI Ethernet Hub Card Replacement The PPI (Perceptron Personal Interface) is designed to allow the user to interface to the controller remotely at the location of a C3 enclosure. This configuration will allow the user to display images on a P.C. inside the work station for aiming sensors and verifying images. The PPI is facilitated through an add-on PCI bus Ethernet hub card. This card is installed in the PCI expansion slot nearest the power supply. No jumper settings are required for this card, all addressing and interrupts are automatically configured.

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26 � 2. Hardware & Replacement Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315

Removing the card: 1. Remove the hub card drives in NT. 2. Remove computer from enclosure. 3. Remove top cover of computer. 4. Remove screws holding card to computer chassis. 5. Remove card from PCI slot. Replacing the card: 1. Place the new card into the PCI slot. 2. Replace the screws to hold the card in the computer chassis. 3. Replace the cover of the computer. 4. Place the computer in the enclosure. 5. Reinstall the hub card drivers in NT. 2.5.6.1 Serial Interface Card (Optional) As an option to the system, a serial communication card can be added to the system. This card has RS-422 capability and resides on the ISA expansion bus. The card is located in slot 7, the furthest slot from the power supply. The available ports can be used for communication with the I/O racks and other peripheral devices. The card should be jumpered as shown in Figure 2-15.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 2. Hardware & Replacement � 27 Figure 2-15. Jumper Settings Removing the card: 1. Remove computer from enclosure. 2. Remove top cover of computer. 3. Remove screws holding card to computer chassis. 4. Remove card from PCI slot. Replacing the card: 6. Place the new card into the PCI slot. 7. Replace the screws to hold the card in the computer chassis. 8. Replace the cover of the computer. 9. Place the computer in the enclosure.

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2.5.7 Monitor Replacement This section provides instructions for replacing a failed system monitor. Replacing the Monitor: 1. Open the front access door of the monitor using the key latch. 2. Turn off monitor power. 3. Disconnect the power cable from the rear of the monitor. 4. Disconnect the video cable from the rear of the computer and remove it from the wireways. 5. Remove the monitor from the enclosure by lifting it off of the support rails and pulling out through the front of the enclosure. Loosen the upper rear support bracket as necessary for removing the monitor. Installing a New Monitor into the Cabinet: 1. If not already done, remove the tilt/swivel base from the monitor. 2. Slide the monitor onto the support rails from the front of the enclosure. 3. Securely position the monitor in the support rails. Slight adjustments of the bottom rails may be needed. 4. Secure the upper rear support rail to the monitor as required. 5. From the back of the cabinet, reconnect the power cable and video signal cable. 6. Turn on the power to the monitor.

7. Use the controls on the front of the monitor to adjust the screen size, position and brightness as necessary for use. 8. Close and lock the monitor access door. 2.5.8 Keyboard Removing the keyboard: 1. Shut down the operating system and disconnect the system power. 2. Cut the ty-rap securing the keyboard cable to the drawer.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 2. Hardware & Replacement � 29 Figure 2-16. Location of ty-rap 3. Disconnect the keyboard cable from the rear of the computer. Figure 2-17. Keyboard cable location on rear of computer 4. Remove the wire grommet in the rear of the keyboard compartment. 5. Remove keyboard.

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30 � 2. Hardware & Replacement Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Installing a new keyboard: 1. Set the new keyboard in the drawer and route the cable through the keyboard compartment to the exit slot and the cable grommet to the rear of the computer. The keyboard drawer can be removed by pushing in on the side tabs and pulling the drawer out firmly. 2. Plug the keyboard cable into the rear of the computer, and replace the wire grommet to the rear of the keyboard compartment. 3. Ty-rap the keyboard cable to the drawer. 4. Reconnect the system power and power up the operating system. 2.5.9 Mouse The mouse that the system is provided with is a IntelliMouse TrackBall. IntelliPoint software must be installed on the system in order to the mouse to respond to the user's command. The wheel works two different ways: � Roll the wheel forwards or backwards to scroll up and down the window. � Press in on the wheel to bring up a two way arrow, that moves the mouse either up or down the screen. To remove the mouse: 1. Shut down the operating system and disconnect system power. 2. Cut the ty-rap that is securing the mouse cable to the drawer. Figure 2-18. Location of ty-rap

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 2. Hardware & Replacement � 31 3. Disconnect the mouse cable from the rear of the computer. Figure 2-19. Mouse cable location on rear of computer 4. Remove wire grommet in the rear of the mouse compartment. 5. Remove mouse. To replace new mouse: 1. Set the new mouse in the drawer and route the cable through the mouse compartment to the exit slot and the cable grommet to the rear of the computer. The keyboard/mouse drawer can be removed by pushing in on the side tabs and pulling the drawer out firmly.

2. Plug the mouse cable into the rear of the computer, and replace the wire grommet to the rear of the mouse compartment. 3. Ty-rap the mouse cable to the drawer. 4. Reconnect the system power and power up the operating system.

2.6 Laser Printer (Optional) 2.6.1 Basic Troubleshooting for the Laser Printer The system has no power: � Is the AC power cord properly connected to the Isobar and the printer? � Is there power to the Isobar? The printer has power but will not print: � Is the error light on? Check to see that the lid is properly closed, the printer is free of paper jams, and the toner cartridge is installed.

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32 � 2. Hardware & Replacement Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 � Are either of the paper tray indicators lit? If so, add paper. � Are the cables securely connected? Print quality is poor: � Does a white streak or faded area appear on the page? The printer toner is probably low. Try removing the toner cartridge, gently rotating it back and forth, and replacing it. (Note that shaking the cartridge redistributes the toner for a temporary improvement of print quality. The user will need to eventually replace the cartridge, as described in the next section.) � Is the printing too light? Try adjusting the printing density, as per the manual's instructions. � Does the toner smear on the leading edge of the printer? The printer may need to be cleaned. 2.6.2 Replacing the Laser Printer Toner Cartridge Periodically, the toner cartridge will need to be replaced. Print quality will be faded or streaked in areas when the toner is running low. How often the cartridge needs to be changed will depend upon printing volume. Note: To temporarily improve printer quality, remove the cartridge and gently rotate back and forth to distribute toner. To replace toner cartridge: 1. Press the top cover release button on the side of the printer to open the printer's top cover. Remove the old cartridge, and discard. 2. Remove the new cartridge from its packaging. Shake the toner cartridge gently back and forth several times to distribute toner. 3. Remove the 12-15 inch clear sealing tape from the cartridge, and discard tape. 4. Insert the cartridge into the printer using the arrows on the toner cartridge and printer. 5. Close the top cover. 2.6.3 Cleaning the Laser Printer 1. Prepare printer: turn printer power off and unplug power cable. Open the printer's top cover by pressing the top cover release button on the side of the printer. Remove the toner cartridge. 2. Clean cartridge cavity and paper path with a dry lint-free cloth, wipe any residue from the paper path area and the toner cartridge cavity. 3. Clean mirror: remove the cleaning brush from the shoulder above the toner cartridge. Insert the brush such as that the flat

Page 39 Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 2. Hardware & Replacement � 33 part is on the shoulder, while the brush is below the shoulder where the mirror is located. Move the brush from side to side several times to clean the mirror. 4. Prepare the printer for operation again: replace the brush and toner cartridge, close the top cover, plug in the power cable, and turn the printer on.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 3. Operation & Maintenance � 35

3. Operation & Maintenance 3.1 Introduction This chapter provides information on the use and maintenance of the physical components of the Perceptron IPNet system. Topics covered are: indicators, switches, connections for external devices (other than for sensors and lights), serial port protocols, and periodic maintenance.

3.2 Indicators The controller has LED indicators for power status, hard and floppy disk access, CD ROM access as shown in Figure 3-1a (front view), and PCI & PPI card status as shown in Figure 3-1b (rear view). Figure 3-1a. Front view for LED indicator locations Figure 3-1b. Rear view for LED indicator location

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3.2.1 LEDs During Normal Operation Indicators Normal Operation Power LED ON when power is on Hard-Disk Drive Access ON when data is written to or read from hard disk drive Floppy Disk Drive Access ON when attempt is made to read or write to the floppy disk drive. (A disk does not have to be in the drive for attempt to be made.) CD-ROM ON when attempt is made to read or write to the floppy disk drive. (A disk does not have to be in the drive for attempt to be made.) PCI Card ON when software is running properly

3.3 Controller Switches: Power, Reset, and Fuses

Warning: To shut-down the system, on the PC select Start / Shut Down. Do NOT physically turn off the system at the base, or all data will be lost. 3.3.1 Main Controller Power A 120V, 20A circuit breaker provides the main power protection for the system enclosure. This circuit breaker is located on the inside of the hinged power panel in the rear of the system enclosure. This breaker should be switched off during any major maintenance procedures on the system. 3.3.2 Isobar Protection The Isobar provides power protection and disconnect means to all electronic components within the system enclosure. The Isobar provides electronic isolation as well as a 12A overload protection circuit. This disconnect should be used if it desirable to disconnect power from the electronic components only. 3.3.3 Computer Power There are two push buttons on the front of the computer unit, Power and Reset. Pushing the power button on the front of the controller will put the system into a powered down state, with only essential power being supplied to the motherboard. Turning off the power switch in the rear of the controller will remove all power from the controller.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 3. Operation & Maintenance � 37 Pushing the reset button will warm boot the computer. Except in rare circumstances, the reset button should only be pressed after proper shutdown procedures of the operating system has been followed. 3.3.4 Cooling System Power A 5x20mm fuse block is located on the back of the hinged power panel and is used to provide overload protection to the cooling units. In the event of a blown fuse condition the orange LED will be illuminated. To replace the fuse, remove the fuse holder and insert a spare fuse from those on the front of the power panel. Disconnecting power from the cooling system can be accomplished by removing the fuse from the fuse block. 3.3.5 C3 Enclosure Power A 120V, 10A circuit breaker is provided for protection and disconnecting power to the C3 enclosure. This circuit breaker is located on the inside of the hinged power panel. This breaker should be switched off when installing and servicing the C3 enclosure. 3.3.6 Sensor Power The power to the sensors can be disconnected using the "sensor power" push button, located on the front of the C3 enclosure, and should turned off when removing or installing the sensors.

3.4 C3 Enclosure The C3 enclosure is located remotely from the main enclosure and is used as a power and communication hub for the sensors. The main components of the enclosure are the 24VDC power supplies and the C3 (Cable Converter Card).

3.4.1 Power Supply The power supply has fused input terminals. The AC power to the supply can also be disconnected by pushing the sensor power push button on the outside of the enclosure. 3.4.2 Fuses There is one fuse block for the incoming power to each power supply. If this

fuse is blown, the orange LED will be illuminated. In this event the fuse should be removed and replaced with one of the spares located inside the enclosure door. 3.4.3 C3 (Cable Converter Card) The C3 is located on the right side panel inside the enclosure. Each channel of the DC supply to the C3 is fused by an onboard fuse. There are status

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38 � 3. Operation & Maintenance Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 LEDs for each channel of the board that can give indication of error conditions present. The descriptions of these LED codes are located on the board and on the schematic inside the enclosure door. If the LED indicates a fuse is blown it can be replaced by removing the fuse holder and inserting a spare from those located on the enclosure door. The LED indicators on the C3 have various meanings. In the following table are the voltages that are known: LED Indicators Description Green / blinking fast 28 to 35V Green / solid 20 to 28V Green / blinking slow 9 to 20V Yellow / solid Below 9V Yellow / blinking Fuse blown Alternating yellow-green Network error - call Perceptron No LEDs No power Note: The fuses on the C3 are replaceable. The part number is 410-0098 and is a 10 Amp, 5x20mm in length.

3.5 Other External Controller Connections This section describes connections to external hardware. Digital TriCam sensor and TriLite connections were described in the previous section. The rear of the standard Perceptron IPNet controller contains connectors for two serial ports, parallel printer, color video monitor, Ethernet, USB ports, keyboard and mouse. Figure 3-2. Rear view of external controller connections

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 3. Operation & Maintenance � 39

3.5.1 Serial Port Connections There are two DB-9 serial port connectors located on the motherboard of the Perceptron IPNet controller. The following paragraph applies only to the standard configuration. For information concerning the pin-outs of the serial ports, refer to Section 3.3.1.1. 3.5.1.1 Serial Port Protocol The two serial ports are configured to operate with the RS-232C Protocol specifications. RS-232C protocol is a single-ended protocol that is good for applications where the distance between the two communicating devices are less than 50 feet and there is little chance of electromagnetic interference. 3.5.2 Parallel Printer Port Connection The parallel printer port is a DB-25 pin connector located on the controller

motherboard. A parallel printer connected to the Perceptron IPNet controller provides the capability to print statistical reports, system setup information, and various messages about measurements being made. The hardware protocol for the printer port is a standard parallel interface used in most personal computers. Perceptron sells and supports printers that will accommodate a full range of system capabilities. If you wish to connect a printer other that a Perceptron supplied printer, please contact Perceptron for compatibility requirements for the chosen printer. It is recommended that the cable to the printer not exceed 25 feet in length. 3.5.3 Color Video Monitor Connection The color video monitor connector is a DB-15 connector located on the motherboard. This connector outputs the horizontal and vertical sync and the red, blue, and green color signals to the monitor. The output of this connector conforms to personal computer standards for VGA graphic monitors and is compatible with both VGA fixed frequency monitors and multiscan monitors that are VGA compatible. The video connector from the monitor unit connects into the DB-15 connector. 3.5.4 Keyboard The keyboard connection is a mini-pin connector located on the rear of the controller. This is a standard connection used throughout the PC industry. 3.5.5 Mouse The mouse connection is a mini-pin connector located on the rear of the controller. This is a standard connection used throughout the PC industry..

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3.5.6 Ethernet Hub Card The input to the Ethernet hub card comes from the C3 enclosures, or directly from a remote computer, being used on the system. The purpose of this connection is to provide remote access to the controller at the location of the C3 enclosure or direct from a laptop computer.

3.6 Periodic Maintenance Periodic cleaning / maintenance is necessary for the sensor lenses and the external cooling filters and coils. How often the user should clean a component will depend on how dirty the environment is. Items Should be Lenses Cleaned at least weekly; checked daily External Cooling filter and coils Cleaned at least monthly; checked weekly Monitor, mouse, keyboard, light pen and printer Cleaned as needed; check monitor daily for dust and lint Printer toner cartridge Replaced when toner runs low (print becomes faint or streaked) 3.6.1 Cleaning Digital TriCam Sensor Lenses Warning: Removal of the case and/or internal access to the inside of the lenses will void sensor warranty, and may cause damage or inaccuracy of further measurements. Check sensor lenses daily. To clean lenses: 1. Use a lint-free cloth and a commercial glass cleaner. 2. Moisten cloth with glass cleaner and wipe off dust on external glass surfaces. Do not spray water or cleaner directly onto any

sensor lenses. 3.6.2 Cleaning the Cooling System To clean the Fan filter: 1. Open the rear door of the enclosure. 2. Open the access door to the filter. 3. Remove the filter and blow off any dirt/debris, using compressed air. 4. Re-insert the filter into the holder and close the doors. To clean the Heat Exchanger: 1. Remove the intake filter by removing the two screws holding it to the heat exchange unit.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 3. Operation & Maintenance � 41 2. Blow off any debris/dirt using compressed air. 3. Re-install the filter. To clean the Air Conditioner: 1. Remove the outer grill assembly covering the air filter by sliding it up and pulling out. 2. Remove the filter and blow off any dirt/debris using compressed air. 3. Re-install the filter and grill assembly. To clean the AC copper coils: Check filter and copper foils weekly. Clean filter and copper coils when a fine layer of dust or lint is visible on the surface of the filter. 1. Power down the cooling system. 2. Remove the grill and air filter, and clean the coils. 3.6.3 Cleaning the Monitor, Keyboard and Mouse Roller The monitor, keyboard and mouse roller will require occasional cleaning for proper function. Cleaning the monitor Check the monitor daily. The monitor surface must be lint-free for correct light pen operation. To clean the monitor, wipe with a lint-free cloth moistened with commercial glass cleaner. Cleaning the Mouse If when moving the mouse, it sticks or the cursor does not move, there might be dust or debris on the roller. Simply turn the mouser over, and remove the cap in the direction of the arrow. Remove the roller and wipe off with an alcohol swab. Blow into the cavity to remove dust there. Replace the roller and cap. Cleaning the Keyboard There are two options to cleaning a keyboard. The first option is to tip the keyboard upside down, this will remove any loose particles. Then hold the keyboard and a can of Inert Dusting Gas at a 90° angle, and spray. The second option is to wet a paper towel with rubbing alcohol and wipe off any keys that may have heavy debris on them. Do not spray water or cleaner directly onto the keyboard.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 4. Digital TriCam & TriLites � 43

4. Digital TriCam & TriLites 4.1 Introduction This chapter addresses troubleshooting techniques for the Digital TriCam sensors and Digital TriLites. TriCam and TriLite cabling is designed in a multidrop configuration with quick connect industrial connectors for simplified installation. A signal conditioning terminator is connected to the end of each sensor cable dropline, whether it is a single sensor system or multiple sensor system. All TriCams and TriLites are connected to a C3 Enclosure.

4.2 Indicators 4.2.1 Digital TriCam Sensor On the back of each Digital TriCam sensor there are six LED indicators. The voltage indicators are used to monitor the internal voltage of the sensor, while the S0 and S1 indicators describe the status of the sensor. Refer to Table 4-1 for Status Indicators and Table 4-2 for Blink Patterns. The Laser indicator lights up when the sensor is enabled, and the laser is on. All six LED indicators are viewed through an overlay label on the back of the sensor, as displayed in Figure 4-1. Figure 4-1. Digital TriCam Sensor LED indicators

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44 � 4. Digital TriCam & TriLites Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Table 4-1. Sensor Status Indicators Powered, but not running Green During boot-up, status indicator is solid; if processor locked, solid or off. Amber During boot-up, status indicator will be off; if processor locked, solid or off. Running out of Flash ROM Green Processor Boot "heartbeat", blinking (on 10% of time) Amber Sync "heartbeat", blinking at a rate about 2 Hz rate for 30 Hz sync. Running out of Program RAM Green Processor Main "heartbeat", blinking (on 50% of time) Amber Sync "heartbeat", blinking at a rate about 2 Hz rate for 30 Hz sync. Error condition Green On solid Amber Blink pattern as defined in Table 4-2 Table 4-2. TriCam Status 1 Blink Pattern Definitions Count Description 01 Do not use

02 Illegal memory access 03 Stack and/or heap have overflowed 04 Illegal program instruction 05 Controller serial number is zero and/or HW/SW version mismatch 06 Flash type/size doesn't match what code expects 07 Frame RAM test failed 08 Program RAM test failed 09 Unsupported exception occurred 10 Boot CRC on ROM failed 11 Code error 12 FIFO not ready with receive value

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 4. Digital TriCam & TriLites � 45

4.2.2 Digital TriLite The Digital TriLite is a proprietary LED flood light, that floods the surface of an area of light 70mm x 70mm, allowing the Digital TriLite sensor to locate the feature in space. The back of the Digital TriLite contains three indicator LED switches: +5V, +12V, and ON. The two voltage LEDs indicate that the Digital TriLite is functioning, and the ON LED indicates that the Digital TriLite is on, as shown in Figure 4-2. Figure 4-2. Digital TriLite LED indicators

4.2.3 Cable Drop The Digital TriCam sensor cables are industrial grade, molded cables fitted with 6-pin connectors. All connector cables, PCI to C3 and C3 to Sensor, are available in several lengths. Each power supply within the C3 Enclosure can support a total combination of 16 TriCam sensors and TriLites. A signal conditioning terminator is required at the end of the sensor line to balance the sensor signals. Available cable lengths: 310-0785-XX PCI to C3 Cable in meters 310-0784-XX C3 to Sensor Cable in meters -01 -25 -01 -05 -30 -03 -10 -35 -05 -15 -40 -10 -20

-50 -25

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46 � 4. Digital TriCam & TriLites Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Figure 4-3. Typical cable drop for the sensor and flood lights Note: To verify that the sensors are responding to the system, go to the Sensor Configuration screen (path: Station image, Context Menu, Sensor Configuration). All the sensors should be listed and running.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 5. Schematics & Wiring � 47

5. Schematics & Wiring 5.1 Introduction This chapter contains an example system schematic and wiring diagram for a basic IPNet system, containing no special boards or hardware. The schematics displayed in this section may vary from those delivered with the system. For accurate schematics and wiring diagrams refer to the print package delivered with the system. 5.1.1 Power Distribution Panel and Terminal Block Locations The power distribution panel and terminal block are located in the rear of the system cabinet, above the computer, as displayed in Figure 5-1. The power distribution wiring schematic is located inside of the IPNet system. Figure 5-1. Power Distribution Panel and Terminal Block

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48 � 5. Schematics & Wiring Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 The 120V power distribution panel distributes power to all the subsystems, and filters power through the isobar. The CRT, Printer, Ethernet Hub, Computer, Light Pen and I/O are connected to the isobar. Figure 5-2. 480V, 3KVA Power Distribution Panel and Terminal Block

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 5. Schematics & Wiring � 49 Figure 5-3. 480V, 5KVA Power Distribution Panel and Terminal Block

5.2 Schematic and Layout The following pages contain an example power distribution panel and terminal block layout and wiring schematics. The schematics displayed in this section may vary from those delivered with the system. Refer to the print package distributed with the system for accurate wiring schematics and power distribution and terminal block layout.

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5.2.1 System Power In the U.S., power (120 Volts, single phase, AC, 20 Amps) then passed through a main 20A circuit breaker and distributed to the system. Figure 5-4 displays an example wiring schematic and Figure 5-5 an example power distribution panel and terminal block.

Figure 5-4. Rear view of terminal block Figure 5-5. Front view of Distribution Panel

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 5. Schematics & Wiring � 51

5.3 C3 Enclosure Figure 5-6. Schematic for the C3 Enclosure.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Appendix A. I/O Configuration � 53

Appendix A. I/O Configuration A.1 I/O Signal Descriptions and Timing Diagram This section describes the preferred method and signals required that enable the Perceptron IPNet Gauge Controller (IPNetGauge), to communicate with a programmable logic controllers (PLC). Perceptron uses an OLE for Process Control (OPC) client for interfacing with line PLC's. The connection from the IPNet Gauge Controller and the PLC is defined by the end user. A.1.1 Input / Output Summary The following is a list of the INPUTS to the IPNetGauge: MODEL START (One bit for each model) JSN STRINGS (JSN/VIN) (optional, one per station) AUX ID STRINGS (optional) MODEL COMPLETE ACKNOWLEDGE (optional, up to one bit per model) PHASE START (optional, one per model and phase) PHASE COMPLETE ACKNOWLEDGE (optional, one per model and phase) *SENSOR RESET (optional component, one per station) The following is a list of OUTPUTS from the IPNetGauge: STATION READY (one bit per station) ALARM (optional, up to one bit per axis) SENSOR ERROR ALARM (optional, up to one bit per checkpoint) MODEL START ACKNOWLEDGE (optional, up to one bit per model) ALL DATA ACQUIRED (optional, up to one bit per model) ALL ALARMS SET (optional, up to one bit per model) MODEL COMPLETE

(optional, up to one bit per model) PHASE START ACKNOWLEDGE (optional, one per model and phase) PHASE COMPLETE (optional, one per model and phase)

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54 � Appendix A. I/O Configuration Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Note: The IPNetGauge will only accept the signal to start a cycle as long as the STATION READY output is high. STATION READY is an "on- line" signal generated by the IPNetGauge controller. *Note: This input is only available at installation time. A.1.2 Inputs SIGNAL NAME: MODEL START PURPOSE: STARTS the measurement cycle of a specific model for the part in station. SOURCE: Station PLC FORMAT: Bit CONDITIONS: Sent when a part is present in the measurement station and it is clamped in the inspection position. In a non-phased system, this signal should be set low when the signal MODEL START ACK is set high by the IPNetGauge. In a phased system, this signal must remain high until the PLC has finished running all of the phases. COMMENTS: There is a MODEL START bit for each model defined in the IPNetGauge. Only one model can cycle at a time. If the PLC attempts to start more than one model at a time, it will not receive the MODEL START ACKNOWLEDGE signal. SIGNAL NAME: JSN STRINGS PURPOSE: (Optional) Used to record and store measurement data with an externally generated VIN number or part ID number. (AVI, Bar code, etc.) SOURCE: Station PLC FORMAT: String file COMMENTS: The string MUST be set before sending the MODEL START bit. This string can contain any number of alpha-numeric characters.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Appendix A. I/O Configuration � 55 SIGNAL NAME: AUX ID STRINGS PURPOSE: (Optional) Typically used on a multiple framer or respot line to indicate the IPNetGauge from which

framer or respot line the current part came. They are sometimes used to indicate which carrier a part is mounted on. SOURCE: Station PLC FORMAT: String COMMENTS: The string MUST be set before sending the MODEL START bit, unless the option to "Read Aux ID's at Cycle Complete" is selected on the Aux ID configuration screen. This string can contain any number of alpha-numeric characters. SIGNAL NAME: MODEL COMPLETE ACKNOWLEDGE PURPOSE: (Optional) Acknowledge the MODEL COMPLETE BITS from IPNetGauge SOURCE: Station PLC FORMAT: Bit CONDITIONS: Sent when the PLC accepts the Model Complete bit for the model just measured. COMMENTS: There can be one Model Complete ACK bit for each model defined in the IPNetGauge, or one bit for the entire station. SIGNAL NAME: PHASE START PURPOSE: (Optional) Start a measurement phase SOURCE: Station PLC FORMAT: Bit CONDITIONS: Sent by the PLC after it has sent MODEL START and it has received MODEL START ACKNOWLEDGE COMMENTS: Only one phase can be running at a time. If the PLC attempts to start more than one phase, it will not receive the PHASE START ACKNOWLEDGE signal.

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56 � Appendix A. I/O Configuration Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 SIGNAL NAME: PHASE COMPLETE ACKNOWLEDGE PURPOSE: (Optional) Acknowledge the PHASE COMPLETE signal. SOURCE: Station PLC FORMAT: Bit CONDITIONS: Sent when the PLC accepts the Model Complete bit

for the model just measured. SIGNAL NAME: SENSOR RESET PURPOSE: (Optional Component) Reset all sensors and reload with binary code when the system is not gauging. SOURCE: Station PLC FORMAT: Bit CONDITIONS: Sent by the PLC to reload the sensors with code following a power down condition. This input may be required for lockout conditions where sensor power is removed when a gate is opened. The reset will occur after a measurement cycle is completed. A.1.3 Outputs SIGNAL NAME: STATION READY PURPOSE: Indicates the IPNetGauge is ready to accept a MODEL START signal from the station PLC. The system must be placed in the Automatic Cycling mode. SOURCE: IPNetGauge FORMAT: Bit CONDITIONS: HIGH: when IPNetGauge has been placed in ACTIVE mode by operator action. LOW: when IPNetGauge is taken out of AUTOMATIC mode by operator action or power failure.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Appendix A. I/O Configuration � 57 SIGNAL NAME: ALARM PURPOSE: (Optional) Indicates that a checkpoint measurement has exceeded preset limits. The IPNetGauge has limits to indicate if a checkpoint is Trending, Outside of its Specification Limits, or if it is outside of its Reject Limits. SOURCE: IPNetGauge FORMAT: Bit CONDITIONS: HIGH: when a limit is exceeded and the IPNetGauge MODEL COMPLETE is high. LOW: when NO limits are exceeded and the IPNetGauge MODEL COMPLETE is high. COMMENTS: Measurement reject limits can be set by a system operator that has proper password assignment. These signals are set low when a MODEL COMPLETE ACK is received from the PLC.

Any of these bits "ON" at the end of the gauging cycle indicates that the IPNetGauge has detected a measurement CRITICAL condition in the build process. SIGNAL NAME: SENSOR ERROR ALARM PURPOSE: (Optional) Indicates that a designated checkpoint was not able to take a valid measurement of the part in the station. This alarm can be set from a hardware or algorithm error. SOURCE: IPNetGauge FORMAT: Bit CONDITIONS: HIGH: when one or more checkpoints assigned to the alarm failed to take a valid measurement. LOW: when ALL designated checkpoints have taken valid measurement. COMMENTS: These signals are set low when a MODEL COMPLETE ACK is received from the PLC. Any of these bits "ON", at the end of the gauging cycle, indicates that the IPNetGauge has detected that a "SENSOR ERROR ALARM", exists. THE GENERATION OF THIS SIGNAL COULD MEAN THAT THE PART BEING MEASURED IS OUT OF THE FIELD OF VIEW OF THE

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58 � Appendix A. I/O Configuration Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 SENSOR(S). THIS COULD INDICATE A SEVERE OUT OF TOLERANCE CONDITION OR A PART LOCATING PROBLEM. A SENSOR ERROR ALARM can also mean that a sensor is failing to communicate with the IPNetGauge controller and is therefore not taking any measurements of its assigned part feature. This FAULT indicates that human intervention is required at the measurement station to determine the cause. SIGNAL NAME: MODEL START ACKNOWLEDGE PURPOSE: (Optional) Used to acknowledge the MODEL START bits from the PLC SOURCE: IPNetGauge FORMAT: Bit CONDITIONS: HIGH: When IPNetGauge receives the MODEL START bit for a specific model. LOW: When the PLC drops the MODEL START bit SIGNAL NAME: ALL DATA ACQUIRED PURPOSE: (Optional) Indicates that the required data from all sensors has been acquired and the part is free to leave the station. Additional time is required to process the

data and set ALARM bits, etc. SOURCE: IPNetGauge FORMAT: Bit CONDITIONS: HIGH: When the IPNetGauge has acquired all of the data from the sensors, and any other external devices. In a phased system, this will occur during every phase. LOW: In all system, when IPNetGauge MODEL COMPLETE bit transitions to low. In a phased system, when the PHASE COMPLETE ACK bit is received. COMMENTS: There is one ALL DATA ACQUIRED bit for each model defined in the IPNetGauge.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Appendix A. I/O Configuration � 59 SIGNAL NAME: ALL ALARMS SET PURPOSE: (Optional) Indicates that all checkpoint limits have been evaluated and alarms, if any are defined, have been set. This can be used to release the part form the station. Additional time is required to update status screens and write measurements to the database. SOURCE: IPNetGauge FORMAT: Bit CONDITIONS: HIGH: When all checkpoint limits have been evaluated and alarms, if any are defined, have been set. LOW: In all systems, when IPNetGauge MODEL COMPLETE bit transitions to low. In a phased system, when the PHASE COMPLETE ACK bit is received. COMMENTS: There is one ALL ALARM SET bit for each model defined in the IPNetGauge. SIGNAL NAME: MODEL COMPLETE PURPOSE: Indicates the IPNetGauge has completed the measurement cycle, ALARM signals are valid, and the data has been written to the database. SOURCE: IPNetGauge FORMAT: Bit CONDITIONS: HIGH: When the IPNetGauge first starts. Optionally, this signal can be set to come up low on startup. In a non-phased system, when the IPNetGauge has completed its cycle after receiving a MODEL START from the station PLC and GAUGE

READY is high. In a phased system, after the PLC has dropped the MODEL START bit. LOW: When the IPNetGauge is not cycling the model OR after MODEL COMPLETE ACK is received from the PLC. COMMENTS: This signal also indicates that the FAULT signals (critical measurement fault, and Sensor Error fault) are now valid for the part just measured, and the measurement data has been written to the database.

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60 � Appendix A. I/O Configuration Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 SIGNAL NAME: PHASE START ACKNOWLEDGE PURPOSE: (Optional) Used to acknowledge the PHASE START bit from the PLC. SOURCE: IPNetGauge FORMAT: Bit CONDITIONS: HIGH: When IPNetGauge receives the PHASE START bit for a specific phase. LOW: When the PLC drops the PHASE START bit. COMMENTS: If the PLC does not receive this signal, then it indicates that the system is in-active, the model has not started, or a different phase is already running. SIGNAL NAME: PHASE COMPLETE PURPOSE: Indicates the IPNetGauge has completed the phase and ALARM signals are valid for that phase. SOURCE: IPNetGauge FORMAT: Bit CONDITIONS: HIGH: When the IPNetGauge has completed its phase after receiving a PHASE START from the PLC and GAUGE READY is high. LOW: When the IPNetGauge is not cycling the phase OR after PHASE COMPLETE ACK is received from the PLC. COMMENTS: This signal also indicates that the FAULT signals (critical measurement fault, and Sensor Error fault) are now valid for the phase just measured, but the measurement data has not been written to the database.

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Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Appendix A. I/O Configuration � 61

A.1.4 Timing Diagram - No Phases

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62 � Appendix A. I/O Configuration Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315

A.1.5 Timing Diagram - With Phases

Page 69 Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315 Index � 63

Index A Additional Support Information 9 B Basic Troubleshooting for the Laser Printer 31 C C3 Card 37 C3 Enclosure 37 C3 Enclosure Schematic 51 Cable Drop 45 CD-ROM Drive 24 Cleaning Digital TriCam Sensor Lenses 40 Cleaning the Laser Printer 32 Cleaning the Monitor, Light Pen and Mouse Roller 41 Computer 17 Connection Color Video Monitor 39 Ethernet Hub Card 40 Keyboard 39 Mouse 39 Parallel Printer Port 39 Connector Signals 10 Cooling Requirements 3 Customer Support 7 D Digital TriCam Sensors and TriLites 43 F Floppy Drive 23 Fuses 37 Fuses and Circuit Breakers 10 H Hard Drive 20 Hard Drive Troubleshooting 20 Hardware Introduction 13 Hardware Support 8 I I/O Configuration Inputs 54 Outputs 56 Timing Diagram - No Phases 61 Timing Diagram - With Phases 62 I/O Signal Descriptions and Timing Diagram 53 Indicators 35, 43 Digital TriCam Sensor 43 Digital TriLites 45 Input / Output Summary 53 IPNet Features 1 Functional Description 7 Mounting Options 14 Physical Dimensions 4 Specifications 2 K Keyboard 28 L Laser Printer 31 LEDs During Normal Operation 36 M Manual Overview 1

Monitor Replacement 28 Mouse 30 O Operation & Maintenance Introduction 35 Other External Controller Connections 38 P Part List 9 PCI Card 17 Perceptron IPNet Controller 2 Perceptron IPNet Monitor Specifications 3 Periodic Maintenance 40 Power Distribution Panel and Terminal Block Locations 47 Power Supply 37 PPI Ethernet Hub Card 25 PPI Hub Card 18 R Related Documentation 11 Removing the Computer from the Card Cage 19 Replacing the Floppy Drive 23

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64 � Index Perceptron, Inc. IPNet Troubleshooting Reference Manual, Rev. D, 009-0315