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Universal GSM 2

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Got a failure while starting up our GSM, and hoping you guys... - Oct 09, 2014 by robgd3  

#72868

Universal GSM 2 | 9 October, 2014

Got a failure while starting up our GSM, and hoping you guys have an easy fix that we're not seeing.

We're getting a Timeout waiting for nozzle changer vacuum buildup.

It seems to be occurring on head 2, during nozzle change. We've reseated all of the nozzles, and redone the nozzle inventory (as we found that it was incorrect). We were able to get head 1 to change it's nozzles after fixing this, but, head 2 doesn't want to change.

There is no obvious air leak that we can detect; the changer does pop up for the change.

Any thoughts as to things we should check?

Thanks, ..rob

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#72870

Universal GSM 2 | 10 October, 2014

First, plug all holes with nozzles or plugs. Then use I/O diagnostics to fire changer up and activate vacuum. Then try to remove each of the nozzles and see if the vacuumm holds. If it does, check vacuum detector switch (mounted on changer side). There's a LED indicator and you can adjust vacuum detection level. If you can't obtain propper holding force, ne of possible issues is faulty rubber gasket(s), which are easily replaceable.

And, by the way, for propper operation changer MUST have 6 of 7 holes plugged - either by a nozzle or a plug.

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#72874

Universal GSM 2 | 13 October, 2014

Deni,

Thanks. I managed to do pretty much exactly that. I was able to get the changers to pop up, and check the vacuum on the nozzles. The first two nozzles are very well sealed into the changer (can't move them), but, the balance of the nozzles are a bit looser. However, I verified that this condition exists on all four changers; and changers 3 and 4 on head 1 were able to change nozzles with no issues.

I swapped some nozzles around, wondering if the issue might be gasketing between the nozzles and the changer, no luck.

It finally occurred to me that the problem might be in the head, and not in the changer. So, I got into the manual screen, and manually lowered the spindles. No issues with head 1, all 4 spindles lower per norm. However, when I got to head 2, I found an issue! x and y movements of the head work fine. When lowering the spindles, I get an error telling me that the z axis was not mounted.

Hmm. So I checked out the configuration pages, made sure that all of the spindles are checked off as mounted. And, made sure that head 2 is checked off as mounted. Even tried unmounting the head (in software), rebooting, then re-mounting the head, rebooting; thinking it might just be a software flag somewhere. All with no luck.

So, my current state is that head 2 will not change nozzles...and, when trying to lower the spindles in the manual move screen, the reported error is that the z-axis is not mounted.

Thanks, ..rob

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#72875

Universal GSM 2 | 13 October, 2014

Check in Machine setup -> parameters -> axis that z axis for head2 is also enabled ("axis mounted" must be 1)

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#72876

Universal GSM 2 | 13 October, 2014

Deni,

Yep, we found that one the other day, too. And, yes, axis mounted is set to 1.

We tried setting it to 0, saving, then back to 1 (again, hoping to clear a software flag/fault, if that's what it is).

Thanks, ..rob

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#72878

Universal GSM 2 | 13 October, 2014

So...today, we were able to get rid of the z axis not mounted error. It looks like we did so by modifying the settings in axes location (matched them to the beam 1 settings).

Now, when we try to lower the nozzles, we can hear a relay or switch click; but, the nozzles don't go down. By moving the z-motor manually, we can cause the nozzles to travel up or down.

I think I'm down to either a motor failure, or a z-axis amplifier failure.

As it looks like a pain to pull out the motor to test it on the bench, I was thinking it would be useful if I could swap the z-axis amp cards from beam 1 to beam 2, to see if the failure follows the cards. Is this bit of isolation troubleshooting a possibility on the GSM? I'm working on figuring out where the card might be, but, it's not conveniently labeled on the machine.

Thanks, ..rob

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#72881

Universal GSM 2 | 13 October, 2014

Hey rob, make sure you do the changer setup. That procedure looks at the fiducials on the changer and adjust the position for nozzle change. It is in system setting. Motor or amp is not easily go bad. I have machine from 92 and never had problem with motor or amp. Just teach nozzle changer and try.

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#72884

Universal GSM 2 | 14 October, 2014

Z axis drivers are located in co-salled LP servo bay. It is 19" rack mounted in lower left part of the machine. Head1 z axis driver is in slot 4 and head2 driver is in slot 6

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#72887

Universal GSM 2 | 14 October, 2014

Thanks, Deni,

I discovered the servo control box, but, noticed that it was a sealed unit (and a third party unit, at that)! I wasn't sure if I should muck about with digging into it.

But...now that you've identified the driver slots for me, we might think about trying it out. I wonder if I can swap cables on the back of the box, rather than opening the box up and swapping cards (if they're even swappable inside the box).

Thanks! ..rob

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#72888

Universal GSM 2 | 14 October, 2014

Thanks, Tushar, we might give that a try.

The only reason I'd lean away from it is because I've been able to determine that I can't get the nozzles to move down on head 2 in the manual screen (or move the theta). I may be chasing two problems, but, I don't think the changers will work at all if I can't get the z-axis to respond.

Thanks, ..rob

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#72889

Universal GSM 2 | 14 October, 2014

Deni,

Do you know if the theta axis controlled by the same slots/cards as the z-axis, by any chance? We also can't get theta to work on head 2, so, I'm wondering if the issue is related...

thanks, ..rob

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#72895

Universal GSM 2 | 14 October, 2014

No, each card in LP servo rack drives only one motor. But there is an servo cotnroller board (actually 3 of them) in the VME rack (where all computers are). Third one from the left(slot13) controls head2 theta and z axis. That might be a cause of your problems - maybe only a bad opamp or something like that.

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#72896

Universal GSM 2 | 14 October, 2014

The axis drive cards can be swapped, so if you switch the second and third in the VME, and the problem moves to another axis, there's your answer.

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#72897

Universal GSM 2 | 14 October, 2014

Just be careful to set the jumpers accordingly, if you swap the boards!

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#72928

Universal GSM 2 | 20 October, 2014

Had someone in from the broker that we bought this machine from, and he did some poking around. We've learned some things, but, unfortunately, are still no closer to getting the machine running :(

We discovered (based on double checking other machines), that while nearly everything refers to the head on beam 2 as head 2...the axes may refer to the head as head 3. Or, at least, theta and z 3. In the axes parameter screen, theta 2 and z 2 were listed as mounted, while theta and z 3 were listed as unmounted. Apparently, on a functioning machine, theta and z 2 should be unmounted, and theta and z3 are mounted.

So...we swapped those settings around. Made sure that the axes addresses (through the head parameters screen) were set at 14 and 15 (we had previously matched these settings to head 1). And...now we've got a new set of error messages: Axis Head 3 Z velocity over speed error during Move Home command. Axis Head 3 Z error not recognized during Move Home command.

In the diagnostics screen, I found an axes screen; the statuses reported are that: Head 3 Theta: enabled. Head 3 Z: disabled.

While watching the machine during the zero process, I can observe the theta on head 1 zeroing...then, as the routine moves to the next step (which I suspect is head 2 theta/z zeroing, we get the z axis failures listed above.

On Friday, I swapped cards 2 and 3 in the VME bank, but observed the same failure. This morning, I swapped cards 1 and 2 (and changed the jumpers with each swap). The reported failure is the same...but, now it seems like I can hear a click on head 2 right before the z-axis failures pop up in the status window.

..rob

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#72929

Universal GSM 2 | 20 October, 2014

Progress!!

Somehow, this morning I was able to get things almost working. I swapped cards 1 and 2 back, and then back again, so, in the same state as my last reply...set the default settings for the axes configuration...then, verified the addresses of the axes for good measure. Head 1 should be set at 2 axes, and set as 1: 10; 2: 11; 3:0; 4:0; Head 2 is also 2 axes, 1:12; 2:13; 3:0; 4:0. Head 3 is also 2 axes, 1:14; 2:15; 3:0; 4:0.

Once set like this, I zeroed the machine, and suddenly, everything was working. I believe that those settings are address settings for the various axes, which is probably what got things going for me.

So...I go dry run my first board...everything's going smoothly for the first 10 or so placements; then head 2 goes to change nozzles out of changer 2, and, dies. Timeout waiting for vacuum. Play around a little bit, and, now I've got changer 4 stalling out when nozzles are changed.

There's plenty of vacuum in the changer, as all nozzles are seated, and vacuum pressure can be felt when wiggling the nozzles in their seats.

So close, and yet, so far...

..rob

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#72946

Universal GSM 2 | 23 October, 2014

Hi Rob,

We have a GSM2. We have had that error in several occasions. Assuming you have already verified your vaccuum is good for that spindle, the most common problem is that the machine configuartion is wrong. Match the nozzle on the head to the nozzles in the machine configuration for head 2. Also, match your nozzle changers to the configuration as well. Make sure you leave one empty hole including both changers all together.

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#72949

Universal GSM 2 | 23 October, 2014

Thanks, George.

Yep, we got through all of that. Then went to cleaning the nozzle changers, etc.

Had a tech in the other day from the broker that we bought the machine from, and discovered that the problem in changer 4 is that we don't have any seals, so, the nozzles stick just a little bit in the changer...just enough to defeat the nozzle change routine. We also re-taught changer 2, which then started working.

After they get us the new seals for changer 4, I'm expecting to do a quick re-teach, and, hopefully, resolve the last of my current changer issues.

Thanks! ..rob

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