MODEL 396/398 ELECTRON BEAM SOURCE ROTARY CRUCIBLE INDEXER INSTRUCTION MANUAL Software version 3.10.18030 Copyright ª TELEMARK, 1995-2018 All rights reserved March 2018 telemark.com Brand and product names are trademarks or registered trademarks of their respective companies. Current version of this manual can be found at https://telemark.com/electron-beam-sources/e-beam-accessories-andupgrades/indexers/
WARRANTY The 396/398 Electron Beam Source Crucible Indexer is guaranteed against faulty materials, function and workmanship for a period of 12 months after delivery from Telemark. Components which are purchased by Telemark from other manufacturers will be guaranteed for any lesser time that such manufacturer warrants its products to Telemark. This warranty is valid only for normal use where regular maintenance is performed as instructed. This warranty shall not apply if repair has been performed or an alteration made by anyone other than an authorized Telemark representative or if a malfunction occurs through abuse, misuse, negligence or accident. No charge will be made for repairs made under warranty at Telemark s facilities. Freight costs both ways will be at customer s expense. Telemark reserves the right for final warranty adjustment. USER RESPONSIBILITY The user is responsible for proper operation and ordinary maintenance of the equipment, following procedures described in this manual, including reference documents. Proper operation includes timely replacement of parts that are missing, broken or plainly worn. If the user has a reasonable doubt about understanding the use or installation of a component, Telemark Technical Service should be called. It is vitally important that the user properly install the equipment as described in Chapter 3 (Installation) of this manual. The warranty will be void if the equipment is improperly installed. Alteration of the design or any function of the equipment voids the warranty and is entirely the responsibility of the user. SAFETY WARNING General Precautions: Human contact with the voltages present within the power supply and vacuum system can be fatal. Make sure that the input power is turned off before opening the doors or removing panels. Short all HV feedthroughs connections with a grounding hook before accessing the indexer main body. 2
3.10.18030 Changed Improved signal processing. 3.8.18006 Added CHANGE LOG Added to system config screen Standard Stall and "SSC Stall" for the 398 model. 3.2.17335 Fixed Fixed problem of REMOTE mode flicking screen when pocket changes after first changing pocket. 3.0.17280 Changed Motor is now permanently braked when stopped. Motor speed minimum is 5. Banana speed minimum is 5. Banana speed maximum is 25. 2.14.17241 Added In-vacuum in-position option added 1.19.16319 Added Added one second debounce on remote pocket selection. Changed Updated stall reversing to allow three stall/reverse attempts, the forth stall generates a stall timeout alarm. A stall timeout alarm is generated if after one second from initiating a reverse the indexer is still stalled. 3
TABLE OF CONTENTS 1 UNPACKING 5 2 DESCRIPTION 6 Specifications 7 3 INSTALLATION 8 Required components 8 Setting Up 8 Motor Cables 9 Inputs - J3 9 Outputs J2 10 Host - J5 11 Motor Assembly 11 Optional In-vacuum In-pocket Switch 12 List of Accessories or Supplies 14 4 CONFIGURATION 15 Unlocking 15 Configuration 16 5 OPERATION 22 Power Up 22 Rotary Operation 22 Banana and Continuous Rotation Control 23 Banana 23 Continuous 23 Remote Operation 24 Error Codes 24 4
1 UNPACKING Your Model 396/398 electron beam source crucible indexer is packed into a specially designed double strength box surrounded with rigid foam padding. Since packaging the indexer for safe shipment is otherwise difficult, please save the box in the event that the indexer may ever need to be returned for servicing. We cannot be held liable and may not be able to fix without charge indexers which are damaged in transit as a result of improper packaging. Contents of shipping box: Indexer mechanism Controller Power cord Indexer motor cable Indexer control cable 5
2 DESCRIPTION The indexer positions the crucibles of a rotary turret-type E-beam source. It also has a position-indicating function. The indexer features a high torque motor. It is equipped with a coupling to accommodate a feedthrough drive shaft of a ¼ inch (6.35 mm). The model 396 is for standard EB sources, the model 398 with a larger motor is designed for the model 295 EB source. The electron beam source crucible indexer s most notable features are the following: Color LCD touch screen for graphical and numerical display, providing an intuitive and user friendly operator interface Material names can be displayed on the screen Can index up to 30 pockets Automatic recover from pocket jams by reversing and approaching from the opposite direction when in bi-direction mode. No clutch needed for pocket jams due to automatic motor current sensing Includes Rotary, Banana and Continuous modes. Automatically rotates the shortest distance to the desired pocket (can be turned off to only rotate in CW or CCW rotation.) Mounts available for 1 inch bolt, 1.25 inch bolt, and 2-3/4 CFF Speed control from 0.25 to 5 rpm Remote pocket selected by optically isolated inputs, up to 6 direct and up to 30 binary (software selectable active or passive) Relay isolated outputs In position up to 6 pockets directly and up to 30 pockets using binary, Mode signal and General In position signal 6
Specifications Number of pockets: 4 to 30 Controller dimensions: 19-inch rack 2U, 3 1/2 high x 9 3/8 deep Motor Assembly Dimensions: 5.83 (148mm) x 4.60 (117mm) x 2.50 (64mm) Inputs: 8 optically isolated, active (4 to 24V DC or AC), or passive (contact closure) Outputs: 8 relay contacts NO/NC @ max 1A, 24 DC or AC Power Input: 90-260VAC, 50-60 Hz SHAFT Ø.250 6.34 2.500 63.50 3.670-5.620 [93.23-142.75] 5.834 148.18 Figure 2-A 4.600 116.84 INCH [mm] Motor Assembly Reference Dimensions 3.48 [88.4] POWER POCKET INDEXER CONTROLLER Figure 2-B 19.00 [482.6] INCH [mm] Controller Reference Dimensions 7
3 INSTALLATION Required components The following is the minimum list of components required for setting up the indexer for safe operation. Electron beam source. Source rotation must be in working order. Vacuum system with adequate external room for indexer mounting. 19-inch rack with 115/230VAC, 50/60 Hz power to house the controller. Cable from ground on chamber to ground stud indexer controller. Setting Up There are many different ways to set up the indexer. The best location and drive connection for your application can only be made after analyzing all the factors. The determining factors for the location of the indexer are: source type (side or bottom drive), Free space in the chamber as well as under the chamber. The preferred way is a direct drive on each side of the feedthrough eliminating the problems associated with gear and chain drive. However, the locating holes and bolts of the feedthrough, source and indexer must be precisely predetermined so that the indexer can function properly. The feedthrough bracket makes it easy to bolt the indexer to the bottom of the chamber with the nut of a 1 inch or 1.25 inch feedthrough or a 2-3/4 CFF. J1 MOTOR J4 MOTOR CONTROL J2 OUTPUT J3 INPUT J5 HOST POWER 90-264 VAC, 47-63 Hz 3A SLO-BLO FUSE Figure 3-A Rear Chassis 8
Motor Cables J1 (Motor) on the chassis goes to J1 on the Motor Assembly. J4 (Motor Control) on the chassis goes to J2 on the Motor Assembly. Inputs - J3 Inputs are software selectable to be active or passive from the configuration screen. Passive TTL level inputs activated by a short across input pins. Active inputs activated by 12 to 24 volts DC across the input pins. The optically isolated input 25 pin female connector on the back of 396/398 indexer controls the following: 1. Remote pocket selection, up to 6 pockets directly and up to 30 pockets using binary code 2. Remote control start/stop of the continuous/banana rotation Figure 3-B Active Input Connections 9
Figure 3-C Passive Input Connections Outputs J2 The outputs are on a 25 pin male connector on the back of 396/398, isolated SPST relays, 50VDC max, 2A max. Outputs are: 1. Pocket signal, up to 6 pockets directly and up to 30 pockets using binary. These signals can be used in conjunction with a XY sweeper to select a sweep pattern. 2. Remote Mode signal, signal when the indexer is in remote mode. 3. In position signal, when the motor has stopped when the pocket is in position. 10
4. Error signal, when there is an error such as a motor jam. Figure 3-D Output Connections Host - J5 The host port is for upgrading the indexer software. Motor Assembly Connectors J1 and J2 connect to the chassis with the supplied cables. Connector J3 is for an optional connection to an in-vacuum in-pocket switch. Figure 3-E Motor Assembly Connections 11
Optional In-vacuum In-pocket Switch Optional in-vacuum in-pocket confirmation kits are available for Telemark models 271, 274 and 294. When enabled from the touch screen, the software will check that the crucible is in-pocket and count the number of pockets it goes past. This provides confirmation to the optical encoder and home switch inside the motor assembly to makes sure that no slippage has happened between the motor assembly and the e-beam source. This requires an e-beam source bearing housing (hub) that matches the number of pockets in the e-beam source crucible and two pins on a feedthrough. The switch assembly mounts in the empty side drive hole on the side arm. This only works with CW Rotation and CCW Rotation. Supplied Kapton wires are wired to the comm and normally closed terminals of the switch and to an electrical feedthrough. The atmosphere side is wired to the supplied cable that comes with a 9 pin D connector, which is plugged into J3 of the motor assembly. Figure 3-F In-vacuum In-pocket Switch Assembly Figure 3-G Ebeam Source Bearing Housing 12
Figure 3-H In-vacuum In-pocket Home Switch Installation Figure 3-I In-vacuum In-pocket Home Switch Wiring Figure 3-J In-vacuum In-pocket Feedback Configured Available Option Kits that can be shipped with new sources: Assembly 271-0300-4 for model 271 Side Drive E-beam Source, 4 pocket Assembly 271-0300-6 for model 271 Side Drive E-beam Source, 6 pocket Assembly 271-0300-8 for model 271 Side Drive E-beam Source, 8 pocket Assembly 274-0300-4 for model 274 E-beam Source, 4 pocket Assembly 274-0300-6 for model 274 E-beam Source, 6 pocket Assembly 274-0300-8 for model 274 E-beam Source, 8 pocket Assembly 294-0300-4 for model 294 E-beam Source, 4 pocket Assembly 294-0300-6 for model 294 E-beam Source, 6 pocket Assembly 294-0300-8 for model 294 E-beam Source, 8 pocket Add HP to the end of the kit number for existing installations to receive a kit with a bearing housing (Hub), crucible O-ring, pivot shaft O-ring, quad ring, Kapton wire for in-vacuum in-pocket switch and a 9 pin cable assembly for the outside to connect to J3 on the motor assembly. 13
List of Accessories or Supplies Recommended parts: Rotary feedthrough or Right angle rotary feedthrough. 14
4 CONFIGURATION Unlocking To configure the indexer first it must be unlocked. Press the lock to unlock the indexer and enter the password. The default password is 1234. The password can be changed at this time by pressing the Change Password button. Once the indexer is unlocked it will stay unlocked until it is locked by pressing the lock or by turning the power off. 15
Configuration Once the indexer is unlocked then the Config (Configure) button can be pressed. Crucible Type Available types are Rotary, Banana and Continuous. Press button to cycle to the desired type. Rotation Bi-directional Rotation/CW Rotation/CCW Rotation Bi-directional Rotation will enable the indexer to rotate the shortest distance to the selected pocket, clockwise (CW) or counterclockwise (CCW). With CW Rotation and CCW Rotation option the indexer will rotate only one direction. Alignment Alignment sets the pocket one center. For rotation setting CW Rotation and CCW Rotation there is only one step to align the pocket. For Bi-direction rotation setting there are three steps. 16
Step 1: Set the pocket one alignment. There are three speed buttons, Slow, Medium and Fast. They are used so that pocket one is approached with the gear train tight. Use the Fast and Medium speeds till pocket one is almost in position, then use Slow speed to finish the alignment. If you over shot pocket one use the Back Up button to try again. Press Ok when done. For CW Rotation and CCW Rotation you are done. Step 2: For Bi-direction rotation set counter-clockwise pocket one alignment. Press OK when aligned. Step 3: Then the indexer rotates from the other side to set the backlash so that any gear backlash in the gear train is accounted for. Align pocket one and then you are done. 17
Numeric Settings First press the setting to adjust, it will turn red, then press the + and - to adjust the numeric value. PID Adjust - Adjustment for motor, default 1.00 (0.01-2.00). Most sources should use the default value. Only the source model 298 will need fine tuning because of the massive weight. Values less than1will have a slower response and greater than 1 will have a faster response. #Pockets Total number of pockets in crucible (4-30) Speed Maximum rotational speed (0-100%) Scrn Saver (Screen Saver) - Time till indexer goes into screen saver mode and blanks the screen (0-300). Touch the screen to wake screen up. The indexer is always operational if the power is on. Backlash This number is only shown if Bi-direction rotation is selected. The number is automatically generated when Alignment is run, but it can be manual changed to fine tune it. System Config - This button goes to the system configuration sub menu. Pocket Material Names Material names can be added for each pocket. If no name is entered then Pocket will be displayed. Use the up arrow to shift between upper case, lower case and numbers. 18
System Config Manual/Automatic Find Pocket On power up operation 1. Manual When the Indexer is powered on a screen will ask to confirm the current pocket is aligned. Press ok if aligned or press Manual Find Pocket to make the indexer move the motor to verify its internal home position. 2. Automatic - When the Indexer is powered on it will automatically make the indexer move the motor to verify its internal home position. In Pocket Feedback/No Pocket Feedback 1. In Pocket Feedback Select this option when using the optional in pocket switch on 271, 274 or 294 EB sources, see chapter for installation instructions. This setting only works with CW Rotation and CCW Rotation 2. No Pocket Feedback Normal operation Passive/Active Input Input can be configured two ways 3. Passive TTL level inputs activated by a short across input pins. 4. Active inputs activated by 12 to 24 volts DC across the input pins. Input Selecting a pocket from a PLC or other device can be done by using the optically isolated indexer inputs. See table below for binary code. 1. Binary 1=00000 - up to 30 pockets 19
2. Binary 1=00001- up to 30 pockets 3. Individual - up to 6 pockets directly Output - Relay isolated outputs up to 6 pockets directly and up to 30 pockets using binary, these signals can be used to connect to a XY sweep to select a sweep pattern. 1. Binary 1=00000 - up to 30 pockets 2. Binary 1=00001- up to 30 pockets 3. Individual - up to 6 pockets directly Binary 1=00000 Pocket Number Binary 1=00001 Pocket Number Binary Bit 4 Binary Bit 3 Binary Bit 2 Binary Bit 1 1 1* 0 0 0 0 0 Binary Bit 0 2 1* 0 0 0 0 1 3 2 0 0 0 1 0 4 3 0 0 0 1 1 5 4 0 0 1 0 0 6 5 0 0 1 0 1 7 6 0 0 1 1 0 8 7 0 0 1 1 1 9 8 0 1 0 0 0 10 9 0 1 0 0 1 11 10 0 1 0 1 0 12 11 0 1 0 1 1 13 12 0 1 1 0 0 14 13 0 1 1 0 1 15 14 0 1 1 1 0 16 15 0 1 1 1 1 17 16 1 0 0 0 0 18 17 1 0 0 0 1 19 18 1 0 0 1 0 20 19 1 0 0 1 1 21 20 1 0 1 0 0 22 21 1 0 1 0 1 23 22 1 0 1 1 0 24 23 1 0 1 1 1 25 24 1 1 0 0 0 26 25 1 1 0 0 1 27 26 1 1 0 1 0 28 27 1 1 0 1 1 29 28 1 1 1 0 0 30 29 1 1 1 0 1 Not used 30 1 1 1 1 0 Not used Not used 1 1 1 1 1 * Note: For Binary 1=00001 00001 and 00000 both equal pocket one. 20
Banana To use Banana mode set rotation to Bi-direction rotation. In banana mode pocket one is always the start of the banana. Banana end is the end pocket of the banana relative to the nominal crucible number. Banana Spd (Banana Speed) is the speed at which the crucible moves when in the banana pocket. Continuous The continuous rotary speed setting is adjustable on the main screen. 21
5 OPERATION Power Up Once alignment has be performed as described in the Configuration chapter 4, the indexer will remember where the pockets are even after power has been turned off and on. On power up the indexer rotate the crucible to find its internal reference home and then return to the last pocket it was at. If for some reason the pocket does not line up repeat the Alignment procedure in chapter 4. Rotary Operation Crucible pockets are selected by pressing the large green button. A list of pockets will display. Press the desired pocket. The up or down arrow will bring up the rest of the list of pockets.
Banana and Continuous Rotation Control The Banana pocket can stop and start rotation. Press the Start Rotate button When the crucible is not moving there is line across the rotate graphic. When the crucible is rotating the graphic will spin. Speed can be controlled by pressing the Banana Speed or Speed button. Banana The banana is always pocket 1. In the case above the banana end pocket is 2 so the next pocket after the banana is pocket 3. Continuous 23
In this mode the crucible rotates continuously (varied by the speed control). This is commonly used with a trough type crucible. Remote Operation All types of crucibles can be operated remotely. Press the Remote On button to activate remote operation. Remote Control On will be displayed when in remote mode. Error Codes These are HARD alarms that force a stop condition and require hardware fix and controller reboot to clear. ** HOME SWITCH NOT FOUND ** EEPROM failure - no acknowledge EEPROM failure - write verify HOME switch EndStop encountered Indexer model unknown MICRO switch EndStop encountered Motor assembly cable disconnected Motor not connected Motor polarity swapped Motor stall timeout OUT OF POSITION PWM shutdown - motor shorted 24
The following alarms are not considered HARD but they do force the entering of a valid value of the variable in question. Use unlock to access the CONFIG screen. Invalid backlash degrees Invalid banana end pocket Invalid banana speed Invalid CCW home offset Invalid CW home offset Invalid crucible Type Invalid current pocket Invalid find pocket type Invalid input coding type Invalid input select type Invalid linear model index Invalid linear size index Invalid mode Invalid motor direction Invalid number of pockets Invalid output coding type Invalid PID factor Invalid position switch count Invalid rotary model index Invalid rotation type Invalid screen saver minutes Invalid speed Invalid system parameters CRC 25
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