SmartScope CNC-Flash 250 Service and Maintenance Manual

Inc.
Optical Gaging
Products, Inc.
A QUALITY VISION INTERNATIONAL COMPANY
This document was produced by the Marketing Communications Group of Optical Gaging Products, Inc.
850 Hudson Ave., Rochester, New York 14621-4896 USA. Telephone: 585-544-0400. FAX: 585-544-0131.
E-mail: sales@ogpnet.com or service@ogpnet.com. Internet: http://www.ogpnet.com.
Warranty
Optical Gaging Products, Inc. (OGP company) warrants each new SmartScope Video Measuring System to be
free from defects in material and workmanship for a period of one year from the date of shipment. OGPs
obligation under this warranty is expressly limited to the replacement and installation of a part or parts found to be
defective by our inspection. This warranty is valid only if the system is given normal and proper usage, and is
operated and serviced according to the technical documentation supplied with the system. The information in this
manual is subject to change without notice.
OGP does not warrant that the operation of the system software will be uninterrupted or error-free. This warranty
does not apply to defects resulting from customer supplied or configured computer equipment, operating systems
or software, unauthorized alteration or misuse, or operation outside the environmental specifications for the
product.
THESE WARRANTIES AND OGPS LIABILITY HEREUNDER, ARE THE SOLE AND EXCLUSIVE
WARRANTIES AND ARE EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE. IN NO EVENT SHALL OGP BE LIABLE FOR ANY DIRECT, INDIRECT,
SPECIAL, CONSEQUENTIAL, INCIDENTAL OR OTHER DAMAGES INCLUDING, AND NOT BY
WAY OF LIMITATION, LOSS OF PROFITS, AND WITHOUT REGARD TO THE FORM OF THE
ACTION OR THE NATURE OF THE CLAIM WHICH IS MADE.
Please Note
The information contained herein is based on the experience and knowledge relating to the subject matter gained
by OGP prior to publication. No patent license is granted by this information. OGP reserves the right to change
this information without notice and makes no warranty, express or implied, with respect to this information. OGP
shall not be liable for any loss or damage, including consequential or special damages, resulting from the use of
this information, even if loss or damage is caused by negligence or other fault on the part of OGP.
Caution
This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in
accordance with this documentation, may interfere with radio communications. Operating this equipment in a
residential area may cause unacceptable interference to radio and TV reception, requiring the operator to take
whatever steps are necessary to correct the interference.
AccuCentric, Avant, Basic Bench, Cobra, DRS, Contour Projector, Feather Probe, FeatureFinder, Flare, Flash,
Focus, GageFit, IQ 2000, Intelligent Qualifier 2000, MeasureFit, MeasureMenu, MeasureMind, MeasureMind 3D
MultiSensor, Measure-X, MicroTheta, MSR, OGP, OQ-30B, Projectron, QC-Calc, Q-Check, QL-20, QL-30,
Q-SEE, Quest, Rainbow Probe, Scan-X, SmartCAD, SmartCheck, SmartFit, SmartRing, SmartReport,
SmartScope, SoftGage, TeleStar, Top Bench, Vantage, and Zoom 10 are registered trademarks or trademarks of
Optical Gaging Products, Inc.
Due to the nature of this material, a number of hardware and software products may be mentioned by name. In
most, if not all, cases these product names are claimed as trademarks by the companies that manufacture the
products. It is not our intent to claim these names or trademarks as our own.
2007 Optical Gaging Products, Inc. All rights reserved. Printed in USA.
No part of this document may be reproduced or disclosed in any form or for any purpose, other than personal use,
without the written permission of Optical Gaging Products, Inc.
Part No. 790451
Second Printing 06-2007
Table of Contents
About This Manual
Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Who Should Read This Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Prerequisite Knowledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Documentation Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Special Symbols Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Technical Support and Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
If You Need Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
For Your Safety

Safety Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Power and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Covers and Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Stage Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Unsafe Operating Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Safety Markings on OGP Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Location of External Safety Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
SmartRing Light Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
Laser Safety Guidelines (Applies Only to Systems Equipped with a Laser) . . . . . . . . . . . . . xiii
Laser Safety Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
For More Laser Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Lockout Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Restoring a Machine to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
SmartScope CNC/Flash 250 Service and Maintenance Manual Table of Contents
Section 1: Introduction
What is the SmartScope CNC/Flash 250 System? . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Section 2: Operating Environment

Workbench Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Equipment Dimensions and Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Electrical Supply Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Power Source Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cabling Major System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Section 3: System Description

Overall System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Motherboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
QVI Video Capture Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Video/Motion Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
DSP Multi Axis Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SmartRing Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Lights Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Section 4: Preventive Maintenance

Recommended Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cleaning the SmartScope CNC/Flash 250 System . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Tools and Materials Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Stage Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
External Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
File and Hard Disk Drive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Backing Up Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Deleting Obsolete Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Hard Disk Drive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Backing Up System Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Cleaning the SmartRing Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
If SmartRing Light LEDs Fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Cleaning the Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Zoom Lens and Lens Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Maintaining the XYZ Transports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Cleaning and Lubricating the X Axis Rails . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Lubricating the X Axis Drive Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Cleaning and Lubricating the Y Axis Rails . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Lubricating the Z Axis Lead Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Calibration and Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Section 5: Diagnostics
System Boot Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Normal System Boot Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Abnormal System Boot Sequences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
If the Machine Misses an Index Pulse . . . . . . . . . . . . . . . . . . . . . . . . 5-6
If the Machine Powers Up On a Limit . . . . . . . . . . . . . . . . . . . . . . . . 5-7
If the Machine is Equipped with a Touch Probe . . . . . . . . . . . . . . . . . . . 5-8
If the Machine is Equipped with a Retractable Laser.... . . . . . . . . . . . . . . . . 5-8
Diagnostic Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Diagnostic Routines (Measure-X Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Accessing Basic Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Accessing Advanced Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Diagnostic Routines (MeasureMind 3D Systems) . . . . . . . . . . . . . . . . . . . . . . 5-27
Board and Control Panel Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Video, Optics and Stage Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
DSP Multi Axis Board Diagnostic LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . 5-34
DSP Multi Axis Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Quadrature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
E-Stop Codes (DS7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Magnetic Limit Codes (DS7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
DSP Multi Axis Board Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Interconnect Board Diagnostic LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Accessing the Diagnostic LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . 5-42
Interconnect Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
System Indicator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Stop LED (DS5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Interconnect Board Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
LED Driver Board Diagnostic LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . 5-51
LED Driver Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
LED Driver Board Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Measuring the Resistance of the Drewire Terminations . . . . . . . . . . . . . . . . . . . . . . . 5-54
Power Supply Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Section 6: Troubleshooting
Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting the SmartScope CNC/Flash 250. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Start-Up Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Illumination Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Motion Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Video Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Troubleshooting the System Computer and User-Interface Components . . . . . . . . . . . . . . 6-24
Start-Up and General Performance Problems. . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Joystick Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Troubleshooting the Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Keyboard Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Monitor Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Troubleshooting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Section 7: Replacing Electrical Components

Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Replacing the DSP Multi Axis Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Replacing the LED Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Replacing the Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Replacing the Universal Multi-Sensor Board (If Equipped) . . . . . . . . . . . . . . . . . . . . . 7-9
Replacing the Micro Theta Control Board (If Equipped) . . . . . . . . . . . . . . . . . . . . . . 7-11
Replacing the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Replacing the Exhaust Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Section 8: Replacing Imaging Components

Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Removing the Optics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Replacing the SmartRing Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Replacing the Video Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Replacing the Zoom Lens Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Section 9: Replacing Transport Components

Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Replacing the Z Axis Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Replacing the Z Axis Read Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Replacing the X Axis Read Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Replacing the Y Axis Read Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Section 10: Spare Parts

How To Order Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Parts List Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Appendix: Service Log
This page was left blank intentionally.
Welcome!
Optical Gaging Products (OGP) has produced this Service and Maintenance
Manual as part of its ongoing effort to provide users with useful, comprehensive
documentation. This manual has been developed using documentation standards
and a design that enhances readability and makes it easier to find information.
We believe this manual will assist you in the service and maintenance of your
SmartScope CNC/Flash 250 system. If you have any questions that are beyond
the scope of this document, please do not hesitate to contact your authorized
OGP representative or OGP directly.
Organization
The SmartScope CNC/Flash 250 Service and Maintenance Manual contains the
following sections:
About This Manual (this section), describes the content and organization of the
manual, defines who should read this manual and the prerequisite knowledge
required to make full use of this information, lists related publications, explains
special symbols used in this manual, and provides information regarding OGP
technical support and customer service.
For Your Safety provides an overview of necessary safety precautions you
should observe whenever operating, installing, or servicing the system.
Section 1, Introduction, provides an overview of the system, and lists its
technical specifications and varying configurations.
Section 2, Operating Environment, defines space and electrical requirements
for installation and discusses environmental considerations.
Section 3, System Description, provides a functional description of how the
system operates as an overall system. Major subsystem functions and
interactions are also included in this section.
Section 4, Preventive Maintenance, provides a detailed description of
preventive tasks necessary to keep the system operating at peak efficiency.
About This Manual
About
This Manual
About This Manual
Section 5, Diagnostics, describes several means of diagnosing problems which

may be exhibited by the system, including diagnosing system boot problems,
use of the metrology software diagnostic routines, and use of diagnostic
indicator LEDs resident on the DSP Multi Axis board, LED Driver board, and
Interconnect board.
Section 6, Troubleshooting, provides a means of determining the probable
causes of system performance anamolies, and suggests solutions to improve the
performance of the machine.
Section 7, Replacing Electrical Components, includes replacement procedures
for the system electrical components, including the DSP board, LED Driver
board, Interconnect board, Universal Multi-Sensor board, Micro Theta Control
board, power supply, and exhaust fan.
Section 8, Replacing Imaging Components, specifies the replacement
procedures for the system imaging components, including the SmartRing Light,
video camera, and zoom lens assembly.
Section 9, Replacing Transport Components, defines the replacement
procedures for the system transport components, including the Z axis motor, Z
axis read head, X axis read head, and Y axis read head.
Section 10, Spare Parts, provides a comprehensive list of spare parts and/or
assemblies which are available for SmartScope CNC/Flash 250.
Appendix, Service Log, provides a space to help you maintain a history of all
repairs and routine preventive maintenance performed on the system.
Who Should Read This Manual?

Read and familiarize yourself with this manual if you will perform any of the
following tasks related to the SmartScope CNC/Flash 250:
ii
Installation
Preventive maintenance
Service adjustments
Parts ordering and/or replacement
Troubleshooting
About This Manual
Prerequisite Knowledge
Routine use of the SmartScope CNC/Flash 250
Basic electrical and mechanical terminology
Common electro-mechanical repair procedures
How to read and interpret troubleshooting and wiring diagrams
About
This Manual
Before using this manual, you should be familiar with:
Related Publications
SmartScope CNC/Flash 250 Hardware Installation Guide (P/N 790450)
Measure-X FastStart Guide (P/N 790280)
Measure-X Reference Guide (P/N 790230)
MeasureMind 3D MultiSensor FastStart Guide (P/N 790321)
MeasureMind 3D MultiSensor Reference Guide (P/N 790322)
SmartScope Flash/Flare Calibration and Alignment Manual (Measure-X

Systems) (P/N 790260)
SmartScope Flash/Flare Calibration and Alignment Manual (MeasureMind

Systems) (P/N 790345)
Touch Probe Users Guide (P/N 790380)
DRS Laser Users Guide (P/N 790309)
DRX Laser Users Guide (P/N 790356)
Standard Part for Measurements (P/N 790012), also known as FastStart, for
testing and self-training
Wiring Diagram, Interconnect, for SmartScope CNC/Flash 250

(P/N 031779-2)
Application training to use and run SmartScope CNC/Flash 250
Service training for preventive maintenance, calibration, troubleshooting

and repair
For a complete list of OGP documentation, contact your local authorized OGP
Sales or Service Representative.
About This Manual
iii
Documentation Conventions
To help you locate, interpret, enter or select information easily, this manual uses
consistent visual cues and standard text formats. These documentation
conventions are explained in the following table.
Type Style or
Symbol
Used for
Bold or italic
Emphasized words
Do not repeat this step

Select the highest magnification
level
Bold, sans-serif
typeface
Commands to be typed
Keys to be pressed
Type exit
Type the following command,
then press Enter
Select Reset from the System
pull-down menu
Press the Stop button
Menu items to be selected

Buttons to be pressed
Pull-right menus
Select Calibration
Non-Linear in the System
pull-down menu
System message
SELECT THE CORNER WITH

THE LEFT MOUSE BUTTON.
Initial caps
Proper nouns
Product names
Sections; Figures
Use the Measure function

SmartScope CNC/Flash 250
See Section 3
ALL CAPS
Acronyms
ASCII; OGP
Bold, all caps,

sans-serif, centered
typeface
iv
Examples and
Explanations
About This Manual
Throughout this manual, you will find special information and symbols set apart
from the body text as Warnings, Cautions, and Notes. These terms and symbols
are explained below.
WARNING: Warns you of the possibility of personal injury due to electrical
shock when performing a task related to the use or servicing of the system.
WARNING: Warns you of the possibility of other personal injury when

performing a task related to the use or servicing of the system.
For either of the above two warnings, follow all instructions precisely to ensure
your safety.
CAUTION: Alerts you to the potential for damage to the hardware or software
in the system. Special instructions may be included for minimizing this risk.
CAUTION: Alerts you to the potential for damage to parts and assemblies
sensitive to electrostatic discharge. Keep these parts in their protective anti-static
packing when not in use. Use a conductive wrist strap to provide grounding
between you and the machine chassis whenever you are handling these parts.
Perform all work on these parts at an approved anti-static workstation.
Note: Provides additional information related to the topic being discussed.
About This Manual
About
This Manual
Special Symbols Used in this Manual
Technical Support and Customer Service

OGP offers service and support contracts that are tailored to meet your specific
needs and protect the value of your investment:
Hardware service contracts for cleaning, general inspection, preventive

maintenance and certification includes a discount on replacement parts
and emergency service labor rates.
Software support contracts with updates of software products, application

assistance, and a discount on new software products.
For more information, call (585) 544-0400.
If You Need Help

If you need help, contact your local authorized OGP Service Representative
first. If he or she cannot solve your problem, you may contact us
vi
By phone at (585) 544-0400
By FAX at (585) 544-8092 (Sales) or (585) 544-4998 (Service)
By e-mail at sales@ogpnet.com or service@ogpnet.com
On the Internet at http://www.ogpnet.com
About This Manual
For Your Safety
For
Your Safety
For your personal safety, please review the following safety precautions. They
are provided for your protection, and to prevent damage to the system. This
safety information applies to anyone who comes in contact with the system.
Safety Guidelines
Power and Grounding
The system operates from a power source that will not apply more than the
rated voltage (specified on the machine identification/name plate) between
the supply conductors or between either supply conductor and ground.
The system is grounded through the power cord. To avoid electric shock,
plug the power cord into a properly wired receptacle with an earth ground
connection.
Without a protective ground connection, all accessible conducting parts

of the system are potential shock hazards. This includes knobs and
controls that may appear insulated.
WARNING: A protective ground connection is essential for safe operation

of the system.
Power Cord
Follow these general safety rules regarding the power cord for the system:
For Your Safety
Use only the power cord and connector specified for your machine. If an
extension cord is used, make sure that it is grounded and is of the proper
type and wire gage.
Do not operate the system if the power cord is damaged.
Position the power cord so that it is not tripped over, pulled on, or in contact
with a hot surface.
vii
Fuses
WARNING: To avoid a fire hazard, use only fuses that meet all ratings
specified by OGP.
Covers and Panels

System covers and panels should only be removed by qualified personnel.
WARNING: To avoid personal injury, do not operate the system without
covers and panels properly installed.
Stage Glass
The stage glass is not designed to withstand excessive weight or rough handling.
The load capacity specified in the system data sheet refers to the maximum
amount of weight that can be fixtured to the stage, not the amount of weight that
the stage glass can support.
WARNING: The stage glass is not shatterproof. To avoid personal injury, do
not drop anything on the stage glass.
Before Servicing
System servicing should only be performed by qualified personnel.
WARNING: Unplug the power cord and follow the standard lockout
procedure (see Page xv) before servicing the system.
viii
For Your Safety
Liquids
WARNING: Keep water and other liquids away from the system, to reduce
the risk of spillage and electrical shock.
WARNING: Do not use any accessory attachments other than those

provided or approved by OGP. Improper accessories can cause fire, electric
shock, and/or personal injury.
Unsafe Operating Environments

Do not operate the system in the following environments, where specific
regulatory compliances are required.
Medical
WARNING: Do not operate the system in hospitals, clinics, or laboratories,
where sensitive patient monitoring equipment may be affected.
Radioactive (Nuclear)
CAUTION: The system electronics are not radiation-hardened. Do not operate
the system in a radioactive environment.
Explosive Atmosphere
WARNING: Do not operate the system in environments where flammable
gases and vapors or explosive dust are present. These could be ignited by
the heat or sparks the system may generate.
For Your Safety
ix
For
Your Safety
Accessories
Safety Markings on OGP Equipment
When affixed to OGP equipment, the following terms mean
CAUTION indicates a potential personal injury hazard or a hazard

to property, including the machine itself, and
DANGER indicates an immediate personal injury hazard.
When affixed to OGP equipment, the following symbols mean
Symbol
Meaning
Symbol
Meaning
Electrical
Danger
Do Not Lift
Caution
Do Not
Touch
Hot
Surface
Earth
Electrical
Ground
Pinch
Hazard
Connector
Electrical
Ground
Electrical
Shock
Hazard
Chassis
Electrical
Ground
For Your Safety
Location of External Safety Markings
For
Your Safety
(One on rear door and

one on lower-rear panel)
(One on each
side of the stage)
For Your Safety
xi
SmartRing Light Safety Guidelines

The SmartRing Light is a Class 2 LED product. Do not stare into the illuminated
LED beams or view them directly with optical instruments. Prolonged viewing
of direct LED beams may be hazardous to the unprotected eye. However,
momentary viewing (0.25 seconds) is not considered hazardous.
WARNING: Follow the standard lockout procedure before removing the

SmartRing Light. Make sure that the main power switch is OFF and the
power cord is unplugged.
xii
For Your Safety
Laser Safety Guidelines

(Applies Only to Systems Equipped with a Laser)
WARNING: Use of controls or adjustments or performance of procedures

other than those specified herein may result in hazardous radiation
exposure.
The laser uses a laser diode as the laser source. The laser energy is not
dangerous to exposed skin. However, if viewed directly or from a reflection of a
specular (mirror-like) surface, the emitted light from the source may be harmful
to the human eye.
The laser sensor conforms to laser safety regulations set forth by the Code of
Federal Regulations 21 (CFR 21) and submitted to the Center for Devices and
Radiological Health (CDRH). The laser also conforms to IEC-825 (1993) laser
safety regulations specified by the International Electrotechnical Commission
(IEC).
The laser sensor meets Class II requirements of the CFR 21 standard and Class 2
requirements of the IEC-825 European standard.
For Your Safety
xiii
For
Your Safety
WARNING: Read the laser safety information carefully and follow all safety
precautions to prevent hazardous radiation exposure to your eyes.
Laser Safety Markings

The following laser safety labels appear on the laser and indicate its compliance
with CDRH and IEC-825 regulations.
Safety Label
Meaning
International Laser Symbol
IEC-825 Laser Safety

Classification
CDRH Laser Safety

Classification
Laser Aperture Warning
For More Laser Safety Information

For information on the location and function of the laser indicator LED on the
system, refer to the user manual for your laser.
For more information on laser safety, contact the Laser Institute of America
(lia@laserinstitute.org) and ask for ANSI specification number Z136.1-1993.
The Laser Institute of America also offers other booklets and information on
laser safety.
xiv
For Your Safety
Lockout Procedure
Before servicing the system, you must unplug the power cord and lock out the
system. This will protect you and others from unintended system operation,
which could cause personal injury. No one should attempt to defeat a lockout
while the system is being serviced.
For Your Safety
1.
Notify all affected employees that you are going to disconnect and lock out
the system, as well as the intended reason for the lockout.
2.
If the system is running, perform a normal System Shutdown by
Exiting the metrology software and closing all programs.
Shutting down Windows and turning off the computer (this turns off
the machine).
3.
Disconnect the power cord.
4.
Lock the plug into an appropriate energy isolating device, such as the one
shown here:
5.
After making sure that no personnel are exposed to danger, operate the
joystick or other controls to ensure that all power is disconnected from the
system. Once you are satisfied that the system is locked out and secure, you
may service or adjust the system.
xv
For
Your Safety
Lockout Sequence
Restoring a Machine to Normal Operation
xvi
1.
Check the area around the system to ensure that no one is exposed to
danger.
2.
Once you have determined that it is safe, unlock the main power plug.
3.
Plug the main power plug into an appropriate outlet.
4.
Turn on the main power for the system.
5.
Operate the system to ensure that power has been restored.
For Your Safety
Section 1
Introduction
This introductory section provides an overview of the SmartScope CNC/Flash
250 system.
The SmartScope CNC/Flash 250 system is an automated benchtop non-contact

measuring system. It incorporates a high precision XYZ stage assembly with
joystick control, a motorized auto-calibrating zoom lens, integral illuminators,
and a high resolution video system. Computer interface is provided by an
industry-standard PC, running the Measure-X or MeasureMind 3D graphical
metrology software.
The SmartScope CNC/Flash 250 system features full field of view processing,
an integrated self-optimizing image analysis that uses all available pixel data to
set critical image processing parameters. FeatureFinder an all-in-one
software tool that extrapolates identified points to build likely geometric
constructions is also standard.
See the SmartScope CNC/Flash 250 Technical Data Sheet (P/N 790349) for
technical specifications.
Introduction
1-1
Introduction
What is the SmartScope CNC/Flash 250 System?
System Components
Machine
Probe
Interface
Unit
Monitor
(If Equipped)
Computer
Remote
E-Stop
Joystick
Keyboard
Mouse
Figure 1-1. System Components
1-2
Introduction
Section 2
Operating Environment
This section defines SmartScope CNC/Flash 250
Workbench requirements
Space requirements for installation
Electrical requirements
Environmental considerations
Workbench Requirements
Two workbenches (recommended), each one a minimum of 92 cm (36")

long and 75 cm (31") deep. One bench must be capable of steadily
supporting 200 kg (445 lbs) for the SmartScope CNC/Flash 250, test
fixtures, accessories, parts being measured, and everything else on its
surface. The other bench must be able to support 40 kg (90 lbs) for the
system computer, monitor, peripherals, and everything else on its surface.
OR
One workbench capable of fully supporting 240 kg (535 lbs) for the
SmartScope CNC/Flash 250, system computer, monitor, test fixtures,
accessories, parts being measured, and everything else on its surface. The
minimum size of this workbench is 183 cm (72") long and 75 cm (31")
deep.
Make sure there is enough space around the system components to allow room
for servicing and to provide an unobstructed air flow to the cooling fans. Refer
to Figure 2-3 on page 2-3.
For effective measuring, the workbench must be stable during system stage
motion with no movement or vibration. We recommend using a professional
granite base workstation for the best results.
2-1
Operating
Environment
Locate the system in a permanent place, away from direct overhead lighting,
heating, and cooling. You can position the system components on:
Equipment Dimensions and Space Requirements

63.5 cm
(25.0")
20.5 cm
(8.0")
System
PC
73.5 cm
(29.0")
SmartScope
Top View
80.0 cm
(31.5")
System
PC
SmartScope
43.5 cm
(17.0")
Front View
Figure 2-2. Dimensions and Recommended Placement of

Major Components of SmartScope CNC/Flash 250
2-2
We recommend a 60 cm (24") clearance for service access, as shown below.

Maximum Stage Translation
KEEP THIS AREA CLEAR!
Clearance Area Required

for Service Access (Shaded)
60 cm (24")
Minimum
60 cm (24")
Minimum
Remote System
PC
E-Stop
30 cm
(11")
SmartScope
Mouse
5 cm
(2")
Joystick
Operating
Environment
20 cm (8")
Recommended
20 cm
(8")
Figure 2-3. Clearance Area Required for Service Access
2-3
Electrical Requirements
This subsection defines system
Electrical supply cable requirements
Power source circuit breakers
Fuse requirements
Major system components cabling
Electrical Supply Cable Requirements

The system is supplied with an IEC power strip (P/N 037545), a power cord
(P/N 019978) that connects the machine to the power strip, and an external
power cord that connects the IEC power strip to the external power source.
External power cord characteristics vary depending on the country that the
machine is used in, as defined in the table below.
Country
Power
Part
Number
Type
AWG
(US)
Wire Cross
Section
(CE)
US
120 VAC,
50/60 Hz
019938
3-Conductor
18
1.19 mm2
Japan
100 VAC,
50 Hz
019938
3-Conductor
18
1.19 mm2
UK
240 VAC,
50 Hz
019971
3-Conductor
18
1.19 mm2
Italy
220 VAC,
50 Hz
019972
3-Conductor
18
1.19 mm2
Denmark
220 VAC,
50 Hz
019974
3-Conductor
18
1.19 mm2
Switzerland
220 VAC,
50 Hz
019975
3-Conductor
18
1.19 mm2
Other European
Countries
220 VAC,
50 Hz
019973
3-Conductor
18
1.19 mm2
WARNING: Always use the IEC power strip and the external power cord
that is supplied with your machine. Use of an inappropriate power
connection could lead to equipment damage and/or electrical shock.
2-4
Power Source Circuit Breakers

We recommend connecting the system to a dedicated circuit. Follow these
precautions and guidelines in selecting/installing power source circuit
breakers
Make sure the appropriate size and type of circuit breakers are selected, in
compliance with the power requirements stated on the back of the machine.
Current overload/circuit breaker protection must be selected and installed

by a qualified and fully licensed electrician, in compliance with all
national and local electrical codes in force in the country of installation.
Operating
Environment
WARNING: Equipment damage and/or personal injury may be caused by

the installation of inappropriate or inadequate current overload protection.
2-5
Cabling Major System Components

Figure 2-4 illustrates SmartScope CNC/Flash 250 system cabling, and Table 2-1
on the next page provides further detail. All OGP-supplied cables are clearly
marked regarding function, and also which end connects to which system port.
Note: For more detailed information about system cabling, see the SmartScope
CNC/Flash 250 wiring interconnect (P/N 031779-2).
Workstation
System PC
VIDEO IN
LPT1
Monitor
MONITOR
KEYBOARD
MOUSE
Power Cord
Receptacle
CAMERA OUT
PARALLEL PORT
JOYSTICK
PROBE
(optional)
Probe Interface
Unit (optional)
Power Cord
Receptacle
E-STOP
Power Cords
IEC Power Strip
To External
Power Source
Figure 2-4. System Cabling
2-6
Cable
From
To
Part Number
Video cable
CAMERA OUT on
machine
VIDEO IN on
system computer
039742
Parallel cable
PARALLEL PORT
on machine
LPT1 on system
computer
049082.01
Remote E-Stop
Remote E-Stop
E-STOP on
machine
039836
Joystick
Joystick
JOYSTICK on
machine
021041
Mouse
Mouse
MOUSE on system
computer
Keyboard
Keyboard
KEYBOARD on
system computer
Monitor
Monitor
MONITOR on
system computer
Included with
monitor
[Optional] Touch
Probe cable
TOUCH PROBE
on machine
PICS IN on Probe
Interface Unit
038426
Power Cords
Monitor power cord

receptacle
IEC power strip
Included with
monitor
Machine power
cord receptacle
019978
Probe Interface
Unit (if equipped)
power cord
receptacle
Included with
Probe Interface
Unit
IEC power strip
Main power source
Operating
Environment
PICS OUT on
Probe Interface
Unit
See the table on

page 2-4
Table 2-1. System Cabling
2-7
Environmental Considerations
To ensure a long service life and continued accuracy for the system, observe the
following
Install the system in an environment where it is surrounded by fresh, clean

air. The air should not contain airborne dust or other particulate matter, or
oil mist. Airborne contaminants can adhere to the system electronics and
optics, compromising its measurement accuracy.
Keep the parts you are measuring, as well as the system itself and its
immediate surroundings, clean. This will prevent migration of contaminants
to sensitive system components.
Eliminate or minimize any external vibration sources. Vibration transmitted

to the system may compromise its measuring ability.
Make sure that all major components are installed on a sturdy bench or
benches, capable of fully supporting the full weight of the system (see
Workbench Requirements on page 2-1 for more information). This will
prevent bench collapse and machine damage, and also help dampen
vibration.
Do not operate the system in a medical, radioactive (nuclear), or

explosive-atmosphere environment. See the Safety section for more detailed
information.
Installation
For detailed installation instructions, refer to the system Hardware Installation
Guide.
2-8
Section 3
System Description
This section provides a functional description of SmartScope CNC/Flash 250
system operation, including major subsystem functions and interactions.
Overall System
The overall system, as shown in Figure 3-1, consists of:
Pentium class computer
3-axis joystick with variable controls which allow variable speeds of stage
travel
The following optional computer packages are also available (or must be user
supplied):
Computer Accessory Package 1 includes:
3-button mouse
Keyboard
Computer Accessory Package 2 includes:
System Description
Flat panel 15" LCD monitor
Flat panel 20" LCD monitor

3-button mouse
System
Description
Keyboard
3-1
Figure 3-1. System Block Diagram
3-2
System Description
Computer
The system computer is the central controller for the SmartScope CNC/Flash
250 system, processing instructions for all subsystems (see Figure 3-2). This
Pentium class computer has a minimum speed of 1.7 GHz. It has a 32-bit bus
structure and a minimum of 512 megabytes of RAM. System software,
diagnostic programs, and measurement routines are stored on a 40 gigabyte
(typical) hard drive. A 3", 1.44 megabyte floppy drive and CD-ROM drive are
provided.
System
Description
Note: Due to increasing performance characteristics of computer components

today, specifications mentioned are the minimum for your system.
Figure 3-2. System Computer Block Diagram
System Description
3-3
Motherboard
The computer motherboard contains:
Serial port COM1
Parallel port LPT1, which communicates with the DSP Multi Axis board
Disk controller, which manages all data transfers for the hard drive, the
floppy drive, and the CD-ROM drive
PS/2 ports for keyboard and mouse
USB ports for USB printers
LAN port for a network connection
QVI Video Capture Card

The QVI video capture card (P/N 11540-505) acts as a video input/output
interface.
3-4
The card receives SVHS video in signals from the camera, processes the
signals and sends them to the monitor via the graphics device.
System Description
Video/Motion Subsystem
The video/motion subsystem (see Figure 3-3) controls
All three axes of stage motion
The video camera
All illumination controls
The optional touch probe
The optional laser sensor
The following subsections detail the video/motion subsystem and its

components.
System
Description
X SCALE
Y SCALE
Z SCALE
Figure 3-3. Video/Motion Subsystem Block Diagram
System Description
3-5
DSP Multi Axis Board

The DSP (Digital Signal Processor) Multi Axis board contains the servo
amplifiers and control circuitry to drive the X, Y, Z, and Zoom motors (see
Figure 3-4). Servo circuits drive the servo amplifiers on this board. These servo
circuits are software-selectable through addressable decoding circuitry. The
tach/encoder units generate motor speed signals, which are communicated to the
servo amplifiers to complete the servo loop, ensuring precise motion. The glass
scales generate X, Y, and Z positions, and these signals are digitized and sent to
the system computer.
Figure 3-4. Theory of Operation, DSP Multi Axis Board

When a part is measured, the CPU portion of the DSP board sends point entry
and light level data to the parallel I/O card in the system computer. The
computer stores this data in a part routine. When the routine is played back, the
computer reverses this process and sends the routine to the DSP board. The DSP
board interprets the routine instructions and outputs servo commands.
In addition to software control, the DSP board accepts manual input from the
joystick, the optional trackball, and the control panel. The DSP board also
communicates with the LED Driver board, SmartRing Light, optional touch
probe, and optional laser sensor.
3-6
System Description
SmartRing Light
The patented (# 5,690,417) SmartRing Light has an LED array which consists
of eight rings divided into eight sectors. Each ring features independent intensity
control with 255 levels plus off. In addition, each sector of each ring, may be
turned on and off. These 64 different LED strings, allow for precise illumination
adjustments.
Due to the slight power dissipation required, this lighting system incorporates
two small fans for cooling. The fans are intelligently controlled and their
settings can be read and changed in the software. For safety purposes, the LEDs
are forced off if the internal temperature of the SmartRing Light rises above the
factory set level of 65C (149F) to protect the equipment from possible thermal
damage.
The system also monitors a switch that closes when the SmartRing Light comes
in contact with an object. When the pressure switch is activated, the system
enters Stop Mode. The Stop LED viewed through the Optics Cover will blink
slowly. Remove the obstruction from the SmartRing Light area and press the
Stop/Start button to restore the system to normal operation.
System
Description
Note: For more information about the system Stop LED, see Stop LED (DS5)
on page 5-47.
System Description
3-7
Lights Shutdown Mode

The lights shutdown mode turns off all the lights when the machine is not being
used. This extends the life of the lights and prevents them from burning out
prematurely.
The lights are shut off automatically after the machine has been idle for a
specified amount of time.
A fast blinking of the green Power ON LED (visible through the Optics
Cover) indicates that the lights are in shutdown mode.
The automatic shutoff is controlled by the WATT_WATCHER_TIMEOUT

parameter in the HARDWARE CFG file (MeasureMind 3D Systems) or the
Lights Section in the Configuration Editor (Measure-X Systems). The time
is specified in seconds. The default value is 0, which means that this mode
is disabled.
To get the machine out of the lights shutdown mode, do any of the following:
Press the Enter button on the joystick (recommended). However, this does
not change the state of the machine.
Move the stage with the joystick or change the zoom position with the
joystick or zoom slider.
Change any of the light settings with the light knobs on the joystick or the
sliders in the Illumination Control window.
Start to run a routine.
Change and save the value of the WATT_WATCHER_TIMEOUT

parameter.
Press the Start/Stop button on the joystick to put the machine into Stop
Mode and come back out of Stop Mode.
Note: Moving the mouse does not get the machine out of the lights shutdown
mode.
3-8
System Description
Section 4
Preventive Maintenance
The SmartScope CNC/Flash 250 system is designed to provide years of
trouble-free service. To ensure that the system is operating at peak efficiency,
follow the preventive maintenance procedures outlined in this section.
Recommended Maintenance Schedule

As with any industrial equipment, preventive maintenance intervals depend on
the environment where the system is installed and used. For example, some
maintenance items may need to be performed more often if the system is located
in a harsh environment. Airborne contaminants such as dirt and oil can have a
significant effect on the image quality of any optical instrument, and systems in
this type of environment will require more frequent cleaning.
Preventive
Maintenance
The table on the next page lists the preventive maintenance tasks and their
recommended frequencies.
4-1
Frequency
Preventive Maintenance Task
Normal
Environment
Harsh
Environment
weekly
daily
Clean stage
bi-monthly
monthly
Clean external surfaces
bi-monthly
monthly
Clean stage glass
Perform file maintenance

Perform hard disk drive maintenance
Clean SmartRing Light
monthly
bi-monthly
monthly
monthly
weekly
Clean zoom lens and/or lens

attachments
as needed
Clean/lubricate X axis rails
bi-monthly
monthly
Lubricate X axis drive rod
bi-monthly
monthly
Clean/lubricate Y axis rails
bi-monthly
monthly
Clean/lubricate Z axis lead screw
bi-monthly
monthly
Perform calibration and alignment
every 6 months
every 3 months
Note: You may need to perform the various maintenance tasks more or less
frequently, depending on the severity of the environment in which the system
will be used.
4-2
Cleaning the SmartScope CNC/Flash 250 System

It is important to maintain the cleanliness of the system to prevent contaminants
from migrating to the optics, computer equipment, and other vulnerable system
components.
Tools and Materials Required

Soft, lint-free toweling
A can of pure compressed air
Any commercial glass cleaner
Warm water mixed with a mild detergent, or a commercial surface cleaner
2 mm hex key (Allen) wrench
Preventive
Maintenance
4-3
Stage Glass
Cleanliness of the stage glass can be affected by local environmental conditions.
For example, electrostatic charges attract dust and dirt, and airborne
contaminants and oil can coat the stage glass.
To clean the stage glass
1.
Use a 2 mm Allen wrench to loosen (but do not remove) the two set screws
on the front of the stage that hold the glass in place (see Figure 4-1).
2.
Lift the stage glass carefully off the stage and clean both sides with glass
cleaner and soft, lint-free toweling.
CAUTION: Do not spray the stage glass with glass cleaner while it is mounted
within the stage. If you do not plan to remove the stage glass before cleaning it,
we recommend that you spray the toweling with glass cleaner and then wipe the
stage glass.
Note: When cleaning the stage glass, do not remove the orientation markings
from the edge of the glass.
3.
After cleaning the stage glass, place it into the stage recess in accordance
with the orientation markings on the edge of the glass.
Stage Glass
Set Screws
Figure 4-1. Removing the Stage Glass

4.
4-4
Tighten the stage glass set screws.
Stage
The stage has a hard coat anodized finish and requires no lubrication or
maintenance. If the stage becomes dusty or soiled, wipe it down with a soft, dry
cloth. You may also clean the fixturing holes with gentle air pressure.
CAUTION: Do not use water to clean the stage.
External Surfaces
The system is finished with a highly durable enamel. It can be cleaned with
warm water and a mild detergent, or with a household surface cleaner.
WARNING: Do not allow water to get into the machine while cleaning it.
Water can cause internal damage to the optical system, and can cause
electrical shorts and/or fires with the subsequent risk of personal injury.
Always apply the cleaning solution to the cloth. Do not apply the cleaning
solution directly to the machine.
Preventive
Maintenance
CAUTION: Do not use solvents or paint thinners to clean the external surfaces.
This may damage or remove the paint.
4-5
File and Hard Disk Drive Maintenance

To keep the system running at peak efficiency, you should perform routine file
maintenance to back up important files and delete obsolete ones. It is equally
important to maintain the physical integrity of the system hard drive.
Backing Up Files
For your own protection, back up important part routines and related files to
removable, write-protected media on a routine basis. This will help guard
against accidental data loss or corruption. We also recommend backing up files
before deleting them because there is no undelete function.
To back up files, select Save or Save as in the Measure-X or MeasureMind
3D (as applicable) File menu.
Deleting Obsolete Files

Over time, you will accumulate many files which may become obsolete.
For example
4-6
It is common practice when creating part routines (.MXI or .RTN, as

applicable) to save incremental versions of the evolving routine under
different names or revision numbers. Normally, only the final one or two
versions are useful.
You may accumulate a large number of obsolete print (.PRT) files

associated with old routines.
The system software creates files during normal operation which are only
temporarily useful. These may include data stream (.DAT) files, temporary
(.TMP) files, and statistical text data (.TXT) files.
You should regularly delete obsolete files from your hard drive, paying
particular attention to the contents of the C:\partrtn directory (Measure-X
systems) or the C:ogpmm\partrtn directory (MeasureMind 3D systems). This
will free up space on the hard drive and create room for more inspection
routines. It will also reduce disk access time, and allow the system to run faster.
CAUTION: Unless you are positive that a particular file has no further use, back
it up to removable media before deleting it. There is no undelete function.
Note: You cannot delete write-protected files. The software displays a message
if you try to delete such a file.
Hard Disk Drive Maintenance

In order to maintain the integrity of the data on the system hard disk drive,
periodically run the Windows system tool programs Disk Defragmenter and
ScanDisk or a disk-optimization tool such as Norton Disk Doctor, to determine
free hard disk space, correct any disk errors, and compact data onto one part of
the hard disk drive.
Note: Contact your local authorized OGP Service Representative for
recommended anti-virus and/or disk optimization programs that you may install
on the system computer.
Backing Up System Parameters

For your own protection, back up system parameters and calibration files on a
routine basis. This will help restore a previous configuration if inadvertent
changes are made.
Measure-X SystemsC:\OGP\MEASUREX\CONFIG
MeasureMind 3D SystemsC:\OGPMM\CONFIG
Preventive
Maintenance
From Windows Explorer, copy the contents of the CONFIG directory to

removable, write-protected media.
4-7
Cleaning the SmartRing Light

You may clean the fresnel lens on the SmartRing Light with soft, lint-free
toweling and a mild commercial glass cleaner.
WARNING: Be sure that the system main power is off, and the SmartRing
Light components are completely cool before handling them.
WARNING: Do not allow glass cleaner to get into the SmartRing Light
while cleaning it. This can cause internal damage, and can also cause
electrical shorts and/or fires with the subsequent risk of personal injury.
Always apply the glass cleaner to the clothdo not spray it directly onto
the SmartRing Light.
CAUTION: Do not use solvents, paint thinners, or acetone to clean the fresnel
lens. They will damage the lens.
CAUTION: Do not attempt to disassemble the SmartRing Light.
If SmartRing Light LEDs Fail

Individual SmartRing Light LEDs cannot be replaced in the field. Please contact
your local authorized OGP Service Representative or the OGP Service
Department for a replacement SmartRing Light.
4-8
Cleaning the Optics

It is important to maintain the cleanliness of the system optics to ensure the best
possible imaging. You should regularly clean the zoom lens and/or lens
attachments
Camel hair brush
Cotton balls or commercially available lens tissues
99% isopropyl alcohol (reagent grade)
A can of pure compressed air
Zoom Lens and Lens Attachments

The exterior element of the zoom lens and the lens attachments can be affected
by local environmental conditions, particularly airborne dust.
To clean the zoom lens and lens attachment(s), follow the steps below.
CAUTION: Do not use solvents, paint thinners, or acetone to clean any lens.
They leave a film on the lens element and may also damage any plastic parts that
the solvent inadvertently touches.
CAUTION: Do not use commercially available lens tissues that have been
impregnated with any kind of cleaning solution, such as eye glass cleaning
solution.
If a lens attachment is installed on the zoom lens, unscrew it and then:
Brush both surfaces of the attachment with a camel hair brush to

remove any loose dust from the lens elements. (You may alternately use
compressed air to do this.)
CAUTION: When using air to clean a lens, always blow gently across the
surface of the lens, not at it.
If the outside lens element is dirty, moisten it with breath vapor and
wipe it gently in one direction with a clean lint-free tissue. Repeat as
necessary using a new tissue each time.
4-9
Preventive
Maintenance
1.
2.
Clean the recessed lens of the zoom assembly with a camel hair brush
and/or compressed air.
Note: Store lens attachments where protected from the environment, including
dust.
Maintaining the XYZ Transports

It is important to regularly clean and lubricate the stage and optics transport
systems to ensure smooth stage/focus movement.
You should regularly maintain the
X axis stage transport
Y axis stage transport
Z axis transport
4-10
NYE Synthetic Oil 176H
NSK #2 lubricant
A soft, lint-free cloth
Cleaning and Lubricating the X Axis Rails

1.
With the system running, use the joystick to move the stage to either the left
or right limit of travel, so the ends of the outboard X axis rails are exposed
(see Figure 4-2).
Outboard
X Axis Rails
Figure 4-2. Accessing the Outboard X Axis Rails
2.
Press the Stop/Start button on the joystick.
CAUTION: Only apply NYE Synthetic Oil 176H to the X axis rails. Applying
anything else could permanently damage the ball slides.
CAUTION: Apply NYE Synthetic Oil 176H sparingly to the rails. If too much
oil is applied, it will trap dust and may permanently damage the ball slides.
Wipe out the exposed outboard X axis rails with a soft, clean, lint-free cloth.
Then apply a small amount of NYE Synthetic Oil 176H to each outboard
rail.
Preventive
Maintenance
3.
4-11
4.
Locate the inboard X axis rails beneath the stage, as shown in Figure 4-3.
Inboard
X Axis Rails
Figure 4-3. Accessing the Inboard X Axis Rails
4-12
5.
Repeat Step 3 for the inboard X axis rails. (Be sure to comply with the two
CAUTIONS listed before Step 3).
6.
7.
Use the joystick to move the stage from side to side along the full length of
the X axis several times to distribute the oil evenly along the rails and ball
slides.
Lubricating the X Axis Drive Rod

1.
2.
Use a 5 mm Allen wrench to remove the two X Axis Drive Cover screws.
Then remove the cover by sliding it to the left.
Mounting
Screws
(Qty 2)
Remove
X Axis Drive
Shaft Cover
Figure 4-4. Removing the X Axis Drive Cover
CAUTION: Only apply NSK grease to the X axis drive rod. Applying anything
else could permanently damage the X axis transport.
3.
Apply a very small amount

(approximately 0.5 mm) of NSK
grease evenly to the X axis drive rod.
4.
Re-install the X Axis Drive Cover.
5.
Press the Stop/Start button on the

joystick.
6.
Use the joystick to move the stage

from side to side along the full length
of the X axis several times to spread
the grease evenly along the X axis
drive rod.
Preventive
Maintenance
CAUTION: Apply a thin coating of NSK grease to the X axis drive rod.
Applying too much grease could damage the X axis transport.
Figure 4-5. Visual Reference of

Grease Applied to Drive Rod
4-13
Cleaning and Lubricating the Y Axis Rails

1.
With the system running, use the joystick to move the stage forward (to the
end of travel), so the outboard Y axis rails are exposed (see Figure 4-6).
Outboard
Y Axis Rails
Figure 4-6. Accessing the Outboard Y Axis Rails
2.
CAUTION: Only apply NYE Synthetic Oil 176H to the Y axis rails. Applying
anything else could permanently damage the ball slides.
CAUTION: Apply NYE Synthetic Oil 176H sparingly to the rails. If too much
oil is applied, it will trap dust and may permanently damage the ball slides.
4-14
3.
Wipe out the exposed outboard Y axis rails with a soft, clean, lint-free cloth.
Then apply a small amount of NYE Synthetic Oil 176H to the rails.
4.
5.
Use the joystick to move the stage back (to the end of the travel), so the
inboard Y axis rails are exposed (see Figure 4-7).
Inboard
Y Axis Rails
Figure 4-7. Accessing the Inboard Y Axis Rails
7.
Repeat Step 3 for the inboard Y axis rails. (Be sure to comply with the two
CAUTIONS listed before Step 3.)
8.
9.
Using the joystick, move the stage along the full length of the Y axis several
times to distribute the machine oil evenly along the rails and ball slides.
Preventive
Maintenance
6.
4-15
Lubricating the Z Axis Lead Screw

Note: This procedure assumes that there are no parts, fixtures, or other objects
on the stage.
1.
Use the joystick to lower the Z Axis Assembly to the lower limit of travel.
2.
Perform the lockout procedure outlined on page xv.
3.
Remove the Z Axis Cover as described on page 8-2 to reveal the Z Axis
Lead Screw (see Figure 4-8).
Z Axis
Lead Screw
Figure 4-8. Location of Z Axis Lead Screw
4.
Apply a small amount of NSK #2 lubricant to the Z axis lead screw.
CAUTION: Do not apply anything heavier than NSK #2 to the Z axis lead
screw. Also, be sure to apply the NSK #2 sparingly. If too much lubricant is
used, or if the viscosity of the lubricant used is too heavy, the Z transport
mechanism may be permanently damaged.
4-16
5.
Re-install the Z Axis Cover.
6.
Power up the system and launch the metrology software.
7.
Use the joystick to raise and lower the Z Axis Assembly along the full
length of the Z axis travel several times to distribute the lubricant evenly
along the transport mechanism.
Calibration and Alignment
Preventive
Maintenance
The system requires regular calibration and alignment, at the intervals specified
on page 4-2. Refer to the Calibration and Alignment Manual for your system for
complete details.
4-17
4-18
Diagnostics
This section describes the following means of diagnosing problems which may
be exhibited by the system:
Diagnosing system boot problems
Using diagnostic routines
Using diagnostic LED DS7 on the DSP Multi Axis board
Using diagnostic LEDs and test points on the Interconnect board
Using diagnostic LEDs and test points on the LED Driver board
Measuring the resistance of the Drewire terminations
System Boot Diagnostics

In this subsection, we will define:
Diagnostics
A normal system boot sequence for systems equipped with the Measure-X
software
A normal system boot sequence for systems equipped with the

MeasureMind 3D software
Abnormal system boot sequences, along with recommended actions
5-1
Diagnostics
Section 5
Normal System Boot Sequence

Figure 5-1 illustrates a normal boot sequence for systems equipped with the
Measure-X software.
Figure 5-1. Normal Boot Sequence (Measure-X Systems)
5-2
Diagnostics
Diagnostics
Do not click Yes until the
touch probe is set up and
the ports are calibrated (see
the Touch Probe Users Guide,
P/N 790380, for more information)
Diagnostics
5-3
Figure 5-2 illustrates a normal boot sequence for systems equipped with the
MeasureMind 3D software.
Figure 5-2. Normal Boot Sequence (MeasureMind 3D Systems)
5-4
Diagnostics
Diagnostics
Do not click Yes
until the touch probe
is set up and the
ports are calibrated
(see the Touch Probe
Users Guide, P/N 790380,
for more information)
Diagnostics
5-5
After a normal boot sequence, the system displays either the Measure-X or
MeasureMind 3D screen (as applicable).
Note: If the system deviates from a normal boot sequence, go to the next
subsection.
Note: If the system appears to boot normally but still malfunctions, go to
Section 6, Troubleshooting.
Abnormal System Boot Sequences

Possible abnormal boot sequences, and recommended actions, are described
below and on the following pages.
If the Machine Misses an Index Pulse

An index pulse function uses scale counts to determine a precise offset from the
initial stage home to set a new stage home whenever the machine is powered up.
The index pulse function can be turned On or Off within the HARDWARE.INI
file (Measure-X systems) or HARDWARE.CFG file (MeasureMind 3D
systems).
If the USE_INDEX_PULSE parameter is set to 0 - do not use the index

pulse (Off, default), stage home is set conventionally using the X, Y, and Z
limit switches.
If the USE_INDEX_PULSE is set to 1 - use index pulse on X Y and Z

(On), and the system misses an index pulse during the stage home process,
something similar to the following is displayed:
To fix this problem, click OK, reset the index pulse offset parameters
(X_INDEX_OFFSET, Y_INDEX_OFFSET, and Z_INDEX_OFFSET) to
0.00000 in the HARDWARE.INI or HARDWARE.CFG file (as applicable).
Then exit and re-launch the software.
Note: For information about accessing and changing system parameters, see the
Reference Guide for your metrology software.
5-6
Diagnostics
If the Machine Powers Up On a Limit

The machine is equipped with magnetic scale limits for the X, Y, and Z axes. If
the machine is powered down while located on a magnetic scale limit or with a
Z limit switch on, when it is powered back up, it will still be on the limit. Upon
power up, when the system invokes the stage home command, the following
dialog box appears:
The system cannot move the stage or the optics because the servos have not yet
been initialized. To fix the problem, follow the steps below.
1.
Press the Stop/Start button and use the joystick to move the stage/optical
assembly off the limit.
2.
When you are satisfied that the stage/optical assembly is off the limit, click
OK in the dialog box shown above.
The system continues with the normal boot sequence; you do not need to
perform the remaining steps in this procedure.
OR
If the stage/optical assembly is still on the limit, the following dialog box
appears. Continue with Step 3.
Diagnostics
3.
Press the Stop/Start button and use the joystick to move the stage/optical
assembly off the limit.
4.
When you are satisfied that the stage/optical assembly is off the limit, click
OK in the dialog box shown above and re-launch the software.
5-7
Diagnostics
Note: If this does not solve the problem, contact your local authorized OGP
Service Representative or the OGP Service Department for more information.
If the Machine is Equipped with a Touch Probe

If the machine is equipped with a touch probe, you may occasionally power up
the system with the PI200 box turned off. If this happens, something similar to
the following appears:
To fix the problem, simply turn on the PI200 box and click OK.
If the Machine is Equipped with a Retractable Laser....

If the machine is equipped with a retractable laser and you power up the system
with the laser out of position, something similar to the following appears:
To fix the problem, simply re-seat the laser by rotating it until it snaps back into
the correct position and click OK.
Note: The laser mount is spring loaded, which makes it easy to realize when
you have reached the correct sensor mount positionit will snap into
position.
5-8
Diagnostics
Diagnostics
If the machine is equipped the MeasureMind 3D software and a retractable laser

and you power up the system with the laser cable disconnected, something
similar to the following appears:
To fix the problem:

1.
Click OK and follow the normal power-up sequence.
2.
Exit the software and power down the system.
3.
Connect the laser cable to the laser.
4.
Power up the system and launch the software.
Diagnostic Routines
This section covers the use of the different diagnostic tools available in the
Measure-X software and the MeasureMind 3D software.
CAUTION: There are two main subsections (one for Measure-X systems and
another for MeasureMind 3D systems), so be sure you are referring to the
correct section for your system.
Diagnostics
5-9
Diagnostic Routines (Measure-X Systems)

You can easily access basic and advanced diagnostic routines from within the
Measure-X software. The following subsections describes how to access and use
both the basic and advanced diagnostic routines.
Accessing Basic Diagnostics

To access the basic diagnostics from within Measure-X, select System /
Diagnostics Basic.
5-10
Diagnostics
Diagnostics
The Basic Diagnostics dialog box appears.
Figure 5-3. Basic Diagnostics Dialog Box
The Basic Diagnostics dialog box includes the following two sections:
Diagnostics
Enable Graphics For Tools
AccuCentric Light Level
5-11
Enable Graphics for Tools

The following table defines the Enable Graphics For Tools selections
contained within the Basic Diagnostics dialog box. All three check boxes are
used to enable graphics for the selected software tools to do a more detailed
analysis of measurements with those tools.
Selection
Result(s)
Focus check box
Turns on graphics displayed when you use the

autofocus tool. Two types of graphics are enabled:
- Points plotted in a bell shaped curve that appear
within a box in the lower right portion of the image
window. The points indicate the contrast level. The
peak of the curve and two points on either side are
submitted to the autofocus algorithm. These 5 points
should occupy the upper 2/3 of the curve. If they are in
the upper 1/2 or less, the step size is too small. If they
take up the upper 3/4 or more, the step size is too
large.
- Measured and calculated focus results that appear in
the upper left portion of the image window.
Weak Edge check box
Turns on graphics displayed when you use a weak edge

point tool. The weak edge measurement displays two
sets of weak edge points:
- Actual (selected) weak edge points, which are larger
and have the same color as the tool
- All other possible points, that were used to calculate
the actual weak edge, which are smaller and shown
with another color.
Strong Edge check box
Turns on the display of a contrast curve when you use

the Strong Edge Point tool.
Note: Selecting a check box only enables the selection. You must apply your
selection. See the Dialog Box Buttons topic on the next page.
5-12
Diagnostics
The AccuCentric Light Level slider controls the LED illuminating the
AccuCentric reticle. The slider is disabled if the AccuCentric reticle is not
installed on the system.
This feature is used during the procedures to manually align and focus the
reticle. Refer to the LED Reticle Alignment procedure in the Calibration and
Alignment Manual for your system.
Dialog Box Buttons

After making any changes in the Basic Diagnostics dialog box, you can either
apply these changes or cancel them and return to the original settings.
Selection
Result(s)
OK button
Applies your selections, closes the dialog box, and

returns you to normal operation.
The changes you made are now available for use.
Cancel button
Cancels all settings and displays invoked in this session,

closes the dialog box, and returns you to normal
operation.
When you open the dialog box again the original
settings will be selected.
Diagnostics
5-13
Diagnostics
AccuCentric Light Level
Accessing Advanced Diagnostics

To access the advanced diagnostics, select System / Diagnostics
Advanced.
5-14
Diagnostics
Diagnostics
The Advanced Diagnostics dialog box appears.
Figure 5-4. Advanced Focus Dialog Box

The Advanced Diagnostics dialog box includes tabs for the following sections:
Focus
Servos
Video
Stage
SmartRing
Click on the appropriate tab to view each section. All four sections and their
associated selections, buttons, and diagnostics are described on the following
pages.
Diagnostics
5-15
Focus
When you click the Focus tab, a dialog box similar to the one shown in
Figure 5-4 on the previous page appears.
This dialog box lists the Position, Step Size, and SC (S-curve) correction factors
for all 25 calibrated zoom settings. Positions are listed from 1, which is the
lowest magnification, to 25 which is the highest magnification.
Step Size in microns, is the distance traveled in Z, between video frames during
an autofocus. The step size is an approximate representation of the depth of field
at that magnification when multiplied by four.
Note: We strongly recommend that you consult your local authorized OGP
Service Representative or the OGP Service Department before changing the step
size.
The matching S-curve correction, which is also in microns, compensates for
variations in timing when the focus data was collected. Normally, it is not
necessary to change this value. However if the step size is changed significantly,
the correction factor may also need to be changed. The recommended correction
factor is 3.5% to 4% of the step size.
To change a value
1.
Double-click the desired value.
2.
Type in the new value.
3.
Press Enter to accept, or Esc to cancel.
4.
Click OK to save the changes. (Click Cancel to ignore the changes.)
Note: The changes take effect immediately.
5-16
Diagnostics
When you click the Servos tab, a dialog box similar to the one shown in
Figure 5-5 appears.
Note: We strongly recommend that you do not change any of the servo
parameters. These parameters were set at the factory and changing them could
negatively affect system performance.
Figure 5-5. Servos Dialog Box
The dialog box displays the X, Y, Z, and Zoom parameters for the selected servo
type. To select a servo type, select the desired type from the Servo Type list.
The values automatically change to correspond with your selection.
Diagnostics
5-17
Diagnostics
Servos
Servo types include:
AutoGo: values used by the computer only (automatic positioning)
Joystick: values used by the joystick (manual positioning)
Trackball: track ball is not available; values are also used by the mouse
To change a value, double-click the desired value and type the new value. The
new values automatically update. Values of N/A mean that the parameter is not
available for that servo.
Video
When you click the Video tab, a
dialog box similar to the one
shown in Figure 5-6 appears.
The Video dialog box includes
the following sections:
Standard Test
Noise Test
Intensity Histograms
Screen Intensity
Each section is described on the

following pages.
Figure 5-6. Video Dialog Box
5-18
Diagnostics
In the Standard Test section of the Video dialog box, you can observe actual
readings within an active test box in the Image window. Movement of the box
within the window is controlled by the mouse, and readings are updated almost
immediately when you position the test box.
Selection
Description
Width and Height

fields
Allows you to change the width and/or height of the standard test
box using the up and down arrows. The size can be changed
from 20 to 100 pixels.
Start button
Starts the standard test diagnostic. When you click the Start
button, the standard test target appears attached to the mouse
curser in the Image window.
Advanced diagnostics reads the values within the test box
based on its position in the Image window. The system
automatically updates the Red, Green, Blue, Light Meter, Peak
Contrast, and Avg. Contrast fields immediately with the results.
- Red displays the percent red of the camera RGB value
- Green displays the percent green of the camera RGB value
- Blue displays the percent blue of the camera RGB value
To check the RGB values, place white paper on the stage,
select coaxial white light at 70%, and high magnification.
Start the test and check the RGB fields. Red, Green, and
Blue values should all be approximately the same as you
move the box in the Image window.
- Light Meter displays the average light level inside the box.
The value should be approximately the same as the light
level displayed in the lower left corner of the Image window.
- Peak Contrast displays the highest contrast calculated
within the box. Also called the dust test, it provides a
numerical value of camera dust contamination on the CCD if
any exists.
- Average Contrast displays the contrast value within the
entire box. For example on a uniform contrast surface, this
value could be used to test for optical lens sharpness
uniformity over the field of view of the optics.
Stop button
Stops the Standard Test. The test box no longer displays in

the Image window and all the fields are greyed out.
Remember to click Stop before clicking on another tab.
Diagnostics
5-19
Diagnostics
Video Standard Test
Video Noise Test

The Advanced Diagnostics Noise Test displays the amount of noise in the video
signal and characterizes the frequency of the noise. The noise is given in percent
of total dynamic range of the video signal and is expressed in decibels (dB).
The fixed pattern noise test is only valid when nothing is in focus in the Image
window. The illumination must be uniform, with a suggested light level of 70%.
Selection
Description
Start button
Starts the video noise test. Measured and calculated

information displays in the Image window for both Fixed
Pattern Noise and Temporal Pattern Noise.
- The signal to noise ratio (S/N) values shown should be
above 40 dB. If they are lower, the camera frame buffer,
camera, or cabling may be faulty. In addition, if the
difference between the fixed noise value (displayed at the
top of the image window), and the temporal noise value
(displayed at the bottom of the image window) exceeds 5
dB, this may be an indication of a faulty camera.
- The Recommended Focus Pixel Noise field displays the
calculated result that should be included in the
configuration file. It should be between 3.0 and 4.0.
Stop button
Stops the Noise Test. The values no longer display in the

Image window. The Recommended Focus Pixel Noise field is
greyed out.
5-20
Diagnostics
The Advanced Diagnostic Intensity Histograms display oscilloscope-like images

of the video signal in the Image window.
Selection
Description
X Intensity radio
button
Enables the display of the X or horizontal video signal image.

A single line of video data is taken off the horizontal center line
of the Image window.
Data is graphed at near real-time, with dark at bottom of graph
and light at top.
Y Intensity radio
button
Enables the display of the Y or vertical video signal image.

Same as X Intensity, except the single line of video data is
taken off the vertical centerline of the Image window.
Average radio
button
Enables the display of the X or horizontal video signal image,

except the video data is averaged using more than one frame
determined by the EDGE_FRAME_AVERAGES number
resident in the HARDWARE.INI file.
Start button
Starts the Intensity Graph display. The selected oscilloscope

image appears in the Image window, in between two straight
lines. The lines indicate the upper and lower limits.
Stop button
Stops the Intensity Graph display. The lines no longer appear

in the Image window.
Diagnostics
5-21
Diagnostics
Video Intensity Histograms
Video Screen Intensity

The Advanced Diagnostic Screen Intensity Test displays an array that shows the
distributions of the light intensities in the Image window.
Selection
Description
Start button
Starts the video Screen Intensity Test. The software covers

the video image with small patch boxes, and calculates the
average intensity inside each box.
Stop button
Stops the Screen Intensity Test.

These diagnostic tests can be used for several applications such as:
Making sure that the PC can acquire video data for edge detection
Start the test and then increase and decrease the lights and verify that the
graph reflects the light changes accurately.
Checking that the illumination is even across the entire length and width of
the Image window
Check that the signal image is straight and not tipped or bowed in the
center.
Visual check for video noise
Checking for dark current

Turn off all lights and check that there is still a minimum video signal above
the lower limit.
5-22
Diagnostics
Stage
Diagnostics
When you click the Stage tab, a dialog box similar to the one shown in
Figure 5-7 appears.
Figure 5-7. Video Dialog Box

The Advanced Diagnostics Stage dialog box includes check boxes for the
system X, Y, and Z drives. Error and Counts fields for each of these selections,
actively record the results during the Torture Test.
The Stage dialog box, allows you to torture the system by constant motion of
its X, Y, and Z drive systems. You can exercise the X, Y, and Z individually by
selecting only one box, or together by checking more than one box.
Diagnostics
5-23
Refer to the following table for a description of each selection.
Selection
Description
X check box
Enables the system to move the stage back and forth

indefinitely along its X axis.
Y check box
Enables the system to move the stage forward and backward

indefinitely along its Y axis.
Z check box
Enables the system to move the Z axis assembly up and

down indefinitely along its Z axis.
Zoom check box
Enables the system to move the zoom from zero to the

maximum counts and back indefinitely.
Output results to
file check box
When this check box is checked, the Smart Torture test

results are stored in the RANDOM.TXT file (see note below),
which is located in the configuration directory. The file can be
printed out for later analysis.
Smart Torture
moves checkbox
When this check box is checked the system will perform

irregular type motions in the selected axes. This is an effort to
better simulate customer applications.
When this box is clear (default), the system performs
repeated regular motion cycles.
Start button
Starts the torture test. The two fields become active.

- Errors: displays the total number of errors incurred.
- Counts: displays the number of cycles completed.
Stop button
Stops the test at the end of the current cycle. The two fields
are greyed out.
Note: After several runs, the RANDOM.TXT file may become quite large. If
the file size becomes too large, simply back it up and then delete it. The file is
automatically re-created during the next test.
5-24
Diagnostics
When you click the SmartRing tab, a dialog box similar to the one shown in
Figure 5-8 appears.
Figure 5-8. SmartRing Light Dialog Box
Diagnostics
5-25
Diagnostics
SmartRing
Selection
Description
Interval field
Allows you to specify the interval (duration) of the test in

seconds.
Output results to
file
Click Browse to send the test results to a specific file.
Start button
Starts the temperature test.
Stop button
Stops the test at the end of the current cycle. The two fields
are greyed out.
5-26
Diagnostics
You can access two separate groups of MeasureMind 3D diagnostic routines:
Potentiometer and Servo Diagnostics
Video, Optics, and Stage Diagnostics
Board and Control Panel Diagnostics

The system was shipped with special diagnostic routines that run as a separate
application, distinct from the MeasureMind 3D software itself. This diagnostic
software package includes routines to check the potentiometers and servos.
Diagnostics
5-27
Diagnostics
Diagnostic Routines (MeasureMind 3D Systems)
Accessing Potentiometers and Servo Diagnostics

1.
If necessary, exit the MeasureMind 3D software.
Note: You cannot access the board and control panel diagnostics while the
MeasureMind 3D software is open.
2.
From the Windows desktop, select Start Programs Optical

Gaging Products MeasureMind 3D Diagnostics.
3.
When prompted, press the Stop/Start button on the joystick.

The following menu appears in the upper left corner of the screen; you are
ready to run the diagnostic routines.
5-28
Diagnostics
Run this diagnostic procedure if the system does not respond appropriately to a
lighting potentiometer adjustment or a joystick motion command.
To access the potentiometer diagnostics
1.
Select Quad Axis / Pots.

The Real Time Pot Value Display
dialog box appears:
2.
3.
Operate the pots that correspond to the sliders in the Real Time Pot Value
Display. If the pot and associated cabling is functional, the system will
move the slider for that pot.
Aux Light, Ring Light, and Back Light sliders begin at zero and, as
the joystick knobs are turned, the slider moves in a positive direction.
Z pot, Y pot, and X pot sliders indicate positive/negative direction of

joystick motion, as well as the amount of joystick deflection. These
sliders should be set to 127 5.
The second SPARE slider indicates power supply voltage. (The first
SPARE slider is unassigned.)
Click DECIMAL/HEX to toggle between decimal or hexadecimal

meter readouts.
When ready, click DONE to exit the potentiometer diagnostics.
If the dialog box sliders do not correspond to actual pot changes, you may have
a defective pot, cable, joystick, or DSP Multi Axis board. See Section 6,
Troubleshooting, for more details.
Diagnostics
5-29
Diagnostics
Potentiometer Diagnostics
Servo Diagnostics
Run this diagnostic routine if the system is exhibiting inappropriate X, Y, Z, or
zoom motion.
To access the servo diagnostics
1.
Select Quad Axis / Servos.
The QUAD AXIS dialog box appears.
2.
If you do not want to exercise a specific axis/servo, click X ON, Y ON, Z

ON, and/or Zm ON to toggle off the axis or axes. (You may exercise any
combination of axes.)
CAUTION: Before proceeding further, remove fixtures or other obstructions

from the stage. The optics may crash into staged objects while running a servo
test.
Note: The X LIMP, Y LIMP, and Z LIMP buttons are currently unassigned.
5-30
Diagnostics
3.
Click exercise servos.
Diagnostics
The following dialog box appears:
4.
Click OK.
The DONE button in the QUAD AXIS dialog box changes to STOP, and
the system exercises the specified servos. As the servos are exercised,
observe the indicator buttons at the bottom of the QUAD AXIS dialog box
to see if they correlate with servo commands:
When the X, Y, Z, or zoom lead screw/rod is turning in a clockwise

direction, XCW, YCW, ZCW, or ZmCW lights.
When the X, Y, Z, or zoom lead screw/rod is turning in a

counterclockwise direction, XCCW, YCCW, ZCCW, or ZMCCW
lights.
If the machine scales have magnetic limits and a limit is reached,

X magnetic, Y magnetic, or Z magnetic lights.
To stop exercising the servos, click STOP at the bottom of the dialog box.
Then click DONE to exit the servo diagnostics.
If the indicator buttons do not correspond with actual servo motions, you may
have a defective motor/tachometer, cable, or DSP Multi Axis board. See
Section 6, Troubleshooting, for more details.
Exiting Board and Control Panel Diagnostics

To exit board and control panel diagnostics, select Quit.
Diagnostics
5-31
Video, Optics and Stage Diagnostics

You can also access video, optics, and stage diagnostics from within the
MeasureMind 3D software itself.
Note: This manual corresponds to the MeasureMind 3D software, version
12.24. More or fewer diagnostic tools may be available depending on the
version of software installed on your system.
Accessing Diagnostics in the MeasureMind 3D Software

To access MeasureMind 3D diagnostics, select System / Diagnostics.
The Set Diagnostics dialog box appears:
5-32
Diagnostics
Set Diagnostics Dialog Box Selections
Result(s)
Diagnostics
Selection
Weak Edge Graphics
check box
Turns on advanced analysis graphics for weak edge

measurement.
Displays red boundaries outlining areas where video
data is taken.
Focus Graphics check

box
Turns on diagnostic display of autofocus information and

parameters.
Contrast of video image while passing through focus
(during autofocus process) is graphed. The peak of this
graph and 2 points on either side are submitted to the
autofocus algorithm.
These 5 points should occupy the upper 1/2 of this graph.
If they are in the upper 1/3 or higher, the step size is too
small. If they make up the upper 3/4 of the graph or more,
the step size is too large. Either situation compromises
autofocus repeatability.
Engineering check box
Turns on display of more advanced weak edge graphics

and AccuCentric measurement.
AccuCentric button
Activates a slider that controls LED illuminating the

AccuCentric reticle.
Used to manually align and focus the reticle.
Light Iris button
Not used for SmartScope CNC/Flash 250
Iris Status button
Not used for SmartScope CNC/Flash 250
Align Camera button
Circle Cal - The software measures the angular

difference between the camera horizontal and the stage
(requires a circle be placed in the center of the FOV.)
Line Cal - Same as the Circle Cal (requires a line be
placed in the center of the FOV.)
Interactive Cal - Used for camera alignment.
Save button
Saves all settings and displays invoked in this session.
Cancel button
Cancels all settings and displays invoked in this session.
Diagnostics
5-33
DSP Multi Axis Board Diagnostic LEDs and Test Points

The DSP Multi Axis board (P/N 036405.15) is located in the Electronics Tower
and it is the electronic heart of the SmartScope CNC/Flash 250. The board has
several diagnostic LEDs and test points that are useful in diagnosing system
problems.
Note: This manual documents the diagnostic LEDs and test points on the latest
version of the DSP board (P/N 03640x). If your machine is equipped with an
earlier version of the DSP board, contact your local authorized OGP Service
Representative for information about the LEDs and test points on your board.
DSP Multi Axis Board Diagnostic LEDs
DS7C
DS7D
PROCESSOR
HEARTBEAT
DS8
DS7
DS7B
ZB
DS5C
PROCESSOR
ERROR CODES
DS7A
ZMB
ZA
DS5D
ZMA
DS5B
DS5A
SHAFT
ENCODERS
DS1B
Z-CW
DS1C
Z-CCW
DS1D
DS3B
DS1A
X2B
X2A
ZM-CW
ZM-CCW
DS3A
SCALES
LIMITS
SCALES
SHAFT
ENCODERS
ZB
ZA
DS12D
DS12B
DS12C
DS12A
DS4C
DS4D
XA
XB
DS3C
XB
DS6D
DS3D
XA
DS6C
DS2D
YA
X-CCW
YB
DS2C
DS6B
DS2A
DS2B
X-CW
DS6A
Y-CW
Y-CCW
YB
YA
DS4B
DS4A
LIMITS
1 2 3 4
SCALES
SCALES
FRONT OF
MACHINE
Figure 5-9. Location of Diagnostic LEDs on the DSP Board (P/N 03640x)
5-34
Diagnostics
What It Monitors
Description
DS1 and DS2
X, Y, and Z Axis
Limits
Indicates whether or not a limit has

been encountered:
LED lit: indicates limit not
encountered
LED not lit: indicates limit
encountered
DS3 and DS4
X, Y, and Z Axis
Scales (A and B
channel input states)
Indicates whether or not the scales

are operating properly:
LEDs should indicate
quadrature (see Quadrature on
page 5-36)
DS5
Z Axis Shaft
Encoders (A and B
channel input states)
Indicates whether or not the Z axis

shaft encoders are operating
properly:
LEDs should indicate
quadrature (see Quadrature on
page 5-36)
DS7
E-Stop Codes
See E-Stop Codes (DS7) on page

5-37
DS8
Processor Heartbeat
Indicates when software is running

and CPU is processing data:
LED lit (solid): indicates power
on, but no minibooter loaded
LED lit (fast blink): indicates
minibooter loaded
LED lit (slow blink): DSP.OUT
loaded and running
Diagnostics
5-35
Diagnostics
LED(s)
Quadrature
The diagnostic LEDs that normally indicate quadrature signals include:
DS3 for the Z axis and extra scales (A and B channels)
DS4 for the X and Y axis scales (A and B channels for each axis)
DS5C and DS5D for the Z axis shaft encoders (A and B channels)
In general, quadrature signal is displayed on these LEDs in the following ways:

An appropriate A/B channel pair (like X2A and X2B on DS3) exhibits a
constantly changing On/Off pattern as the stage or Z axis is moved in one
direction or the other, as indicated below.
DS3A
X2A
X2B
LED Change Sequence
X2A
DS3B
X2B
LED Change Sequence
For Motion in
Opposite Direction
DS3A
For Motion in
One Direction
DS3B
Figure 5-10. Example of Quadrature Signal
5-36
Depending on the direction of stage/Z axis motion, the A/B channel LEDs
will appear to roll in one direction or the other.
If the A/B channel LEDs do not track with axis motion as described above
(for example, if one or both remain fixed On/Off, or if both come on or turn
off suddenly when the stage is moved) this indicates a problem.
Remember that the LEDs change with each least count of motion at the
scale or shaft.
Diagnostics
Diagnostic LED DS7 can be useful in diagnosing system anomalies and serves
two purposes:
If your system has entered E-Stop, DS7 indicates the source of the E-Stop.
DS7 indicates when specific scale limits have been encountered.
Important: Be prepared to provide the status of DS7 and DS8 (heartbeat) when
contacting your local authorized OGP Service Representative or the OGP
Service Department for help.
DS7C
DS7
DS7D
DS7A
DS7B
1
2
3
4
In its normal monitoring state, the four LEDs within DS7 roll rapidly back
and forth. If the system enters E-Stop for any reason, the individual LEDs flash
in a specific pattern, as indicated below.
FRONT OF
MACHINE
Figure 5-11. Location of Diagnostic LED DS7
DS7D
2
3
4
DS7D
DS7C
DS7A
Diagnostics
DS7B
DS7
DS7A
DS7B
DS7C
DS7
2
3
4
Flashing LED Pattern
Source of E-Stop
DSP was reset; possible causes:
metrology software was
launchedcheck DS8 (heartbeat),
which should on (steady) if the
software was launched.
+5V out of tolerance
Excess position error, X axis
5-37
Diagnostics
E-Stop Codes (DS7)
Source of E-Stop
DS7
DS7
Loss of motor and/or light power
DS7
Stop/Start button has been pressed
SmartRing Light collision sensor has

been actuated
DS7D
DS7
DS7
Excess position error, Zoom
DS7D
DS7D
DS7D
DS7D
DS7D
DS7
Laser collision sensor has been

actuated
Loss of continuity between pins 1 and

2 on P401
DS7D
Touch probe collision sensor has

been actuated or no power to the
PI200 box
DS7
DS7C
DS7C
DS7C
DS7C
DS7D
DS7C
Excess position error, Z axis
DS7
DS7C
2
3
4
2
3
4
2
3
4
2
3
4
2
3
4
2
3
4
DS7D
2
3
4
DS7C
Excess position error, Y axis
DS7
2
3
4
DS7C
2
3
4
DS7A
DS7B
1
DS7A
DS7B
1
DS7A
DS7B
1
DS7A
DS7B
1
DS7A
DS7B
1
DS7A
DS7B
1
DS7A
DS7B
DS7B
DS7A
5-38
DS7C
DS7A
DS7B
Flashing LED Pattern
Diagnostics
Again, in its normal monitoring state, the four LEDs within DS7 roll rapidly
back and forth. If an integral magnetic scale limit is encountered, the system will
not usually enter E-Stop. However, magnetic limits will cause individual LEDs
to light up in a specific pattern, as indicated below.
Note: If multiple magnetic scale limits are encountered, more than one LED
will light up concurrently.
DS7D
Encountered magnetic limit, Y axis scale
Encountered magnetic limit, Z axis scale
Encountered magnetic limit, extra scale
DS7D
DS7C
Encountered magnetic limit, X axis scale
DS7D
2
3
4
DS7C
DS7
2
3
4
DS7C
DS7A
DS7B
1
DS7A
DS7B
1
DS7A
DS7B
DS7
Diagnostics
Error
DS7D
2
3
4
DS7
DS7A
DS7B
DS7C
DS7
2
3
4
Steady LED
Pattern
5-39
Diagnostics
Magnetic Limit Codes (DS7)
DSP Multi Axis Board Test Points

The illustration below and the table on the next page provide an overview of the
DSP Multi Axis board test points.
JP406
TP4
+12V
TP6
RESET
TP10
PGND
TP5
GND
TP3
-12V
TP7
ZDAC
TP9
+3.3V
TP8
+5V
TP15
GND
TP42
TP43
TP32
TP41
TP34
TP44
TP33
TP24
WSETUP
TP28
YDAC
TP30
XDAC
TP27
ZSETUP
TP29
YSETUP
TP31
XSETUP
Figure 5-12. Location of Test Points on the DSP Board
5-40
Diagnostics
Test Point
What Does It Test?
Function
-12Volt Power Supply Voltage
TP4
12 Volt Power Supply Voltage
TP5
Ground
TP10
Z Axis Motor Power Ground
TP6
Reset
TP7
Z Axis Digital/Analog
Controller
Test Z Axis Digital/Analog

Controller
TP8
Test Voltage
TP9
Logic Power Supply Voltage

(3.3 volt)
TP15
Ground
TP24
Extra Scale
Test Extra Scale Setup
TP27
Z Axis Scale
Test Z Axis Scale Setup
TP28
Y Axis Digital/Analog
Controller
Test Y Axis Digital/Analog

Controller
TP29
Y Axis Scale
Test Y Axis Scale Setup
TP30
X Axis Digital/Analog
Controller
Test X Axis Digital/Analog

Controller
TP31
X Axis Scale
Test X Axis Scale Setup
TP32
X Potentiometer Input to DSP
TP33
Z Potentiometer Input to DSP
Troubleshoot the joystick

(see Troubleshooting the
Joystick on page 6-27)
TP34
Y Potentiometer Input to DSP
TP41
TP42
X Potentiometer Input to A/D

Converter
TP43
Z Potentiometer Input to A/D

Converter
TP44
Y Potentiometer Input to A/D

Converter
Diagnostics
Test Voltage
Diagnostics
TP3
5-41
Interconnect Board Diagnostic LEDs and Test Points

The Interconnect board (P/N 039441) is attached to the front of the optical
assembly and controls the AccuCentric assembly, SmartRing Light, and optional
LED grid projector. The board has several diagnostic LEDs and test points that
are useful in diagnosing system problems.
Accessing the Diagnostic LEDs and Test Points

CAUTION: Whenever handling electrical or electronic components, take the
necessary precautions to prevent the discharge of static electricity.
1.
2.
Remove the Optics Cover, as described on page 8-2.
Note: Before removing the insulator plate, note the set of standoffs between the
Interconnect board and the zoom assembly and the set of standoffs between the
insulator plate and Interconnect board. Both sets of standoffs must be used
during re-assembly.
3.
4.
5-42
While grasping the

Interconnect board
(and insulator plate),
remove the four
mounting screws,
washers, and
standoffs (see
Figure 5-13). Use a
3 mm Allen wrench.
Retain all attaching
hardware.
Set the insulator
plate aside and
re-install the
Interconnect board
and both sets of
standoffs using the
attaching hardware.
Standoff
(Qty 4)
Zoom
Assembly
Insulator
Plate
Mounting
Screws
(Qty 4)
Interconnect
Board
Standoff
(Qty 4)
Figure 5-13. Removing the Insulator Plate
5.
Power up the
system.
6.
When ready, power down the system and re-install the insulator plate.
Diagnostics
Figure 5-14 and the table that starts on the next page, provide an overview of the
Interconnect board diagnostic LEDs.
Note: For more information about the Stop LED (DS5), see the description on
page 5-47.
Jumper
(JP1)
DS22
DS23
Jumper
(JP2)
DS1
Configuration
Switch
DS4
DS7
DS9
DS11
DS13
DS21
DS2
DS3
DS6
DS8
DS10
DS12
DS5
Stop LED
DS14
Power On LED
DS16
DS17
DS15
Laser LED
DS19
DS18
Figure 5-14. Interconnect Board Diagnostic LEDs

Important: The configuration switch and jumpers on the Interconnect board
have been set at the factory for your particular system. Do not adjust either the
switch or the jumpers without consulting the OGP Service Department.
Diagnostics
5-43
Diagnostics
Interconnect Board Diagnostic LEDs
LED(s)
What Does It
Diagnose?
What Does
It Mean
DS1
Surface Illuminator/Grid
Projector LED Intensity
Indicates whether or not the

LED driver for the surface
illuminator or grid projector is
enabled:
LED Lit - indicates LED driver
is enabled
LED Not Lit - indicates LED
driver is not enabled
DS2
Mechanical CCW Limit

mechanical CCW limit has been
encountered:
LED Lit - indicates limit not
encountered
LED Not Lit - indicates limit
encountered
DS3
Mechanical CW Limit

mechanical CW limit has been
encountered:
encountered
encountered
DS4
Heartbeat
When LED is blinking at

approximately 1 flash/second,
logic chip is functioning properly
DS5
Stop LED
Indicates the status of the

machine during operation, see
page 5-47 for further details
DS6
Zoom CCW Limit

Zoom CCW limit has been
encountered:
encountered
encountered
5-44
Diagnostics
What Does It
Diagnose?
What Does
It Mean
Diagnostics
LED(s)
DS7
Zoom CW Limit

Zoom CW limit has been
encountered:
encountered
encountered
DS8 - DS11
Diagnostic LED functions
Used to troubleshoot system

anomalies - contact the OGP
Service Department for more
information
DS12
When LED is lit, 5 volt power

supply voltage is low (less than
4.76 V)
DS13
When LED is lit, 5 volt power

supply voltage is high (greater
than 5.26 V)
DS14
Power On LED
Indicates whether the system

power is on or off:
LED Lit - indicates system
power is on
LED Flashing - system is in
Lights Shutdown Mode (see
Lights Shutdown Mode on
page 3-8)
LED Not Lit - indicates
system power is off
DS15
Laser Indicator LED (only applies

to systems equipped with a laser)
Indicates the status of the laser:

LED Lit - laser power is on
LED Flashing - laser is taking
height measurements
LED Not Lit - laser power is
off
Diagnostics
5-45
LED(s)
What Does It
Diagnose?
What Does
It Mean
DS16
Indicates whether or not logic

power supply voltage is present:
LED Lit - indicates logic
power supply voltage is
present
LED Not Lit - indicates logic
power supply voltage is not
present
DS17
Indicates whether or not 12 volt

LED Lit - indicates 12 volt
present
LED Not Lit - indicates 12
volt power supply voltage is
not present
DS18

present
LED Not Lit - indicates 5 volt
present
DS19
SmartRing Light Power Supply
Indicates whether or not

SmartRing light power supply
voltage is present:
LED Lit - indicates SmartRing
light power supply voltage is
present
LED Not Lit - indicates
SmartRing light power supply
voltage is not present
DS21
Motorized Deployment CCW

Limit

motorized deployment CCW
limit has been encountered:
encountered
encountered
5-46
Diagnostics
What Does
It Mean
DS22
Motorized Deployment CW Limit

motorized deployment CW limit
has been encountered:
encountered
encountered
DS23
Not used
System Indicator LEDs

The system indicator LEDs are visible through the Optics Cover. The top LED
(yellow) is the Stop LED, the middle LED (green) is the Power On LED, and
the bottom LED (blue) is the Laser Indicator LED (only present if system is
equipped with a laser sensor).
Stop
LED (yellow)
Power On
LED (green)
Laser Indicator
LED (blue)
Figure 5-15. System Indicator LEDs
Diagnostics
5-47
Diagnostics
What Does It
Diagnose?
LED(s)
Stop LED (DS5)

The following table gives the status, description, and causes for the various
system conditions. It also includes instructions for recovering from different
E-Stop and Stop conditions.
Stop LED
Description
Status
Cause
To Recover
Off
System is
operating
normally.
Lit
Expected
stop.
Occurs when the

Stop/Start button is
pressed.
Press Stop/Start button.
Lit,
blinking
slowly
Unexpected,
recoverable
stop.
Occurs during a
normal power-up
sequence until you
press the Stop/Start
button.
Press the Stop/Start button

when prompted.
Occurs when the

SmartRing Light
detects a collision.
The sensitivity of
this sensor is
adjustable.
Remove obstruction and press

the Stop/Start button.
Occurs when the

stage or Z axis
encounters an
end-of-travel limit.
Manually push stage off limit

and then press the Stop/Start
button.
Occurs when servo

parameter settings
are incorrect.
Check parameter settings and

adjust if necessary. Then
press the Stop/Start button.
Check LED DS7 on the DSP
board for the source of
E-Stop; see E-Stop Codes
(DS7) on page 5-37.
Occurs when the

remote E-Stop
switch is pressed in.
Turn remote E-stop switch 1/4

turn counterclockwise or until
it "pops" up. Then press the
Stop/Start button.
Occurs when there

is a loss of motor
voltage.
Contact the OGP Service

Department.
Lit,
blinking
rapidly
5-48
Unexpected,
unrecoverabl
e stop.
Diagnostics
Figure 5-16 below and the table on the next page provide an overview of the
Interconnect board test points.
Note: The Interconnect board contains additional test points not shown in the
illustration. These test points are reserved for OGP Engineering use only.
TP2
TP1
TP3
TP4
TP10
TP12
TP13
TP14
TP15
Figure 5-16. Interconnect Board Test Points
Diagnostics
5-49
Diagnostics
Interconnect Board Test Points
Test
Point
TP1
TP2
What Does
It Test?
DWI cable connection to Interconnect
board
TP4
What Is
Its Function?
Test DWI Data IN
Test DWI SYNC
Test DWI Data OUT
TP10, TP13
Common Circuit
TP12
TP3
Logic Power Supply Voltage (3.3 Volts)
Test power supply

voltages
TP14
TP15
SmartRing Light Power Supply Voltage
5-50
Diagnostics
The LED Driver board (P/N 039322.02) is attached to the front inside wall of
the electronics tower and controls the substage illuminator. The board has
several diagnostic LEDs and test points that are useful in diagnosing system
problems.
LED Driver Board Diagnostic LEDs

Figure 5-17 and the table on the next page provide an overview of the LED
Driver board diagnostic LEDs.
DS1
0
1
2
3
4
5
6
7
8
9
Jumpers
(JP1)
DS2
Heartbeat
Jumper
(JP2)
Jumper
(JP3)
DS4-DS11
DS13
DS14
DS12
Figure 5-17. LED Driver Board Diagnostic LEDs

Important: The jumpers on the LED Driver board have been set at the factory
for your particular system. Do not adjust jumper settings without consulting
Department.
Diagnostics
5-51
Diagnostics
LED Driver Board Diagnostic LEDs and Test Points
LED(s)
What Does It
Diagnose?
What Does
It Mean
DS1
Backlight LED Intensity

LED driver for the backlight is
enabled:
LED Lit - indicates LED driver
is enabled
LED Not Lit - indicates LED
driver is not enabled
DS2
Heartbeat
When LED is blinking at

approximately 1 flash/second,
logic chip is functioning properly
DS4-DS11
Diagnostic LED functions
Used to troubleshoot system

anomalies - contact the OGP
Service Department for more
information
DS12
Indicates whether or not logic

LED Lit - indicates logic
present
LED Not Lit - indicates logic
present
DS13

present
LED Not Lit - indicates 5 volt
present
DS14

present
LED Not Lit - indicates 12
volt power supply voltage is
not present
5-52
Diagnostics
Figure 5-18 and the table that starts on the next page provide an overview of the
LED Driver board test points.
TP1
TP4
TP2
TP3
TP5
TP6
TP7
TP8
TP9
Figure 5-18. LED Driver Board Test Points
Diagnostics
5-53
Diagnostics
LED Driver Board Test Points
Test
Point
What Does
It Test?
What Is
Its Function?
TP1
Reserved for Engineering use
TP2
DWI SYNC RX
TP3
DWI DATA RX
TP4
DWI DATA TX
TP5
+12 Volt Power Supply Voltage
TP6
+5 Volt Power Supply Voltage
TP7
Logic Power Supply Voltage (3.3 volt)
TP8
Ground
TP9
LED Power Supply Voltage
Test power supply

voltage
Test power supply

voltages
Measuring the Resistance of the Drewire Terminations

1.
Perform the lockout procedure outlined on page xv. The machine must be
off when measuring the resistance of the terminations.
CAUTION: Do not let the rear door drop. Support it while gently lowering it
into position.
2.
5-54
Use a flat-head screwdriver to loosen the six rear door fasteners and slowly
lower the door until it is perpendicular to the Electronics Tower and is
supported by the rear door retainer.
Diagnostics
3.
4.
5.
Use a Digital Multimeter

(DMM) to measure the
resistance between pins 1
and 3 on connector J403
(connects to P403) or J404
(connects to P404). Record
this reading.
Repeat Step 3 to measure
the resistance between pins
4 and 5 on connector J403
or J404. Again, record this
reading.
Diagnostics
CAUTION: Do not disconnect the cables that are connected to P403 and P404
on the DSP Multi Axis Board.
Pin 1
J404
Pin 1
J403
Be prepared to provide the

recorded resistance readings
if you contact your local
authorized OGP Service
Representative or the OGP
Service Department for help.
P400
Power Supply Diagnostic LEDs

The power supply diagnostic LEDs are visible through the lower-rear panel.
+5VSB
ADJUST +
+5V
On whenever
power is
connected and
system power
switch is on
+12V
+15V
Power
Switch
+24V
+24V MTR
Diagnostics
5-55
5-56
Diagnostics
Section 6
Troubleshooting
Note: Since the DSP Multi Axis board plays such a critical part of SmartScope
CNC/Flash 250 electronics, it often makes sense to rule out the DSP board as a
source of performance variances. Therefore, you may also find the DSP Multi
Axis Board Service Guide (P/N 790168) to be helpful.
Before You Start

WARNING: The risk of electrical shock is present any time the covers are
removed from the machine. Never remove the covers from the monitor or
system power supply, or you expose yourself to high voltage.
CAUTION: Protect the system from electrostatic damage. Perform

troubleshooting at a static-safe workstation and wear a ground strap. If a ground
strap is not available, follow these guidelines:
Work in an uncarpeted area.
Before you touch electronic components, discharge static electricity by

touching a known-grounded object.
Do not touch components on printed circuit boards, except as directed.
Before you begin troubleshooting, note that:
Troubleshooting
If you encounter a problem you cannot address on your own, contact your
local authorized OGP Service Representative or the OGP Service
Department (see If You Need Help on page vi).
This manual does not provide information on the repair of faulty boards,
and we strongly suggest that you do not attempt to repair them. Contact
Department for a replacement board.
6-1
Troubleshooting
This section helps you identify the cause of system problems.
Troubleshooting the SmartScope CNC/Flash 250

This subsection is intended to assist you in solving problems that may arise
while using the system. It is intended as a reference, and it is recommended that
the steps taken to resolve the problem be performed by a factory trained
individual within your facility.
Important: Be sure to review Section 5, Diagnostics, for information on using
the diagnostic LEDs and test points (and associated voltages) on the system
circuit boards.
Contact your local authorized OGP Service Representative or the OGP Service
Department (see If You Need Help on page vi) for assistance and/or training
information.
6-2
Troubleshooting
Start-Up Problems
START
Does
system
boot and invoke
Windows?
No
Troubleshooting
Turn on the
machine and
computer.
Yes
Verify E-Stop
switch(es) are
not pushed in.
Double-click
metrology
software icon
on desktop.
Does
metrology
software
launch?
No
Measure-X systems
MeasureMind 3D systems
Yes
Press
Stop/Start on
joystick when
prompted.
Does
system clear
the stop?
No
D
Yes
Click OK at
Stage Home
prompt.
Check stage
movement,
focus, etc.
Is
machine fully
functional?
No
See illumination
and/or motion
troubleshooting
sections
Yes
END
Figure 6-1. Power-Up Troubleshooting Diagram (Sheet 1 of 5)
Troubleshooting
6-3
Are fans
running and is
green power
LED lit?
No
Is main
power switch
ON and power cord
connected to
outlet?
Yes
Is
monitors
power switch ON
& is power cord
connected to
outlet?
No
Yes
No
Yes
Press
RESET button
on computer.
Yes
Is power
present at AC
outlet?
Turn switch ON
and/or connect
power cord.
Turn switch ON
and/or connect
power cord.
No
Check circuit
breaker or
consult an
electrician.
Does
boot activity
display on
screen?
Yes
Go to START.
Yes
Does
boot activity
display on
screen?
No
No
See the computer

troubleshooting
section
See the computer

troubleshooting
section
Go to START.
6-4
Troubleshooting
The following system

error message is
displayed on the
screen:
Measure-X
The following normal

system download
message is displayed
on the screen:
Downloading .\DSP.OUT...
Click OK
Measure-X
Problem loading configuration

or ???? Data.

error message is
displayed on the
screen:
Measure-X
Initializing hardware failed!
Initializing video board failed!

(Null)
OK
Troubleshooting
When trying to launch

Measure-X,
one of the
following occurs:
OK
System locks up in
download mode, &
above message is
frozen on screen.
Hold down [Ctrl] &
[Alt] keys, & press
[Delete]; then, press
[Enter].
Click OK
Measure-X
Initializing hardware failed!

OK
OK
Click OK
The system returns

to the Windows
desktop.
Click OK
Select File/Exit
Select File/Exit
This will end your session,....
This will end your session,....
OK
OK
Click OK
Click OK
See the computer
troubleshooting
section
Troubleshooting
6-5
C
When trying to launch
MeasureMind 3D,
one of the
following occurs:
The following normal

system download
message is displayed
on the screen

error message is
displayed on the
screen
Downloading .\DSP.OUT...
System locks up in
download mode, &
above message is
frozen on screen
Hold down [Ctrl] &
[Alt] keys, & press
[Delete]; then, press
[Enter]
Click OK
The system returns

to the Windows
desktop
The system returns

to the Windows
desktop
Repeat boot process
Are you
successful?
No
See the computer

troubleshooting
section
Yes
END
6-6
Troubleshooting
Check LED DS7

on DSP board.
No
Note DS7 error

code & contact
OGP Service
Department.
Troubleshooting
Are all
LEDs
flashing?
Yes
Troubleshoot
power supply,
as described
on page 6-25.
Did
you replace
power supply,
cabling, or circuit
board(s)
?
Yes
Go to START
No
Troubleshoot
joystick, as
outlined on
page 6-25.
Double-click
metrology
software icon
on desktop.
Press
Stop/Start on
joystick when
prompted.
Does
system clear
the stop?
No
Contact OGP
Service
Department.
Yes
Click OK at
Stage Home
prompt.
Check stage
movement,
focus, etc.
Is
machine fully
functional?
No
See illumination
and/or motion
troubleshooting
sections
Yes
END
Troubleshooting
6-7
Illumination Problems
Symptom
Dim or no
surface
(coaxial) light.
Possible
Cause(s)
Possible Solution(s)
Dirty optics.
Clean the optics. See Cleaning the Optics on

page 4-9.
Loose or faulty
cabling to the
Interconnect
board.
Observe LED DS1 on the Interconnect board

(see Figure 5-14 on page 5-43) as you adjust
the light level in the software. If the intensity
of DS1 tracks the illumination changes made
in the software, there is a problem with the
surface illuminator or the cabling to the
surface illuminator.
Check that all cable connections (and all
interconnecting cables) to the Interconnect
board and surface illuminator are secure.
Reconnect or replace disconnected or
damaged cables.
System not
configured
correctly.
Contact your local authorized OGP Service

Representative or the OGP Service
Department.
Burnt out LEDs.

Defective surface
illuminator.
Defective
Interconnect
board.
6-8

of DS1 does not track the illumination
changes made in the software, there is a
problem with the Interconnect board or the
cabling to the board.
Check voltages on the Interconnect board
(described on page 5-49).
Check LED DS4 (heartbeat) on the
Interconnect board (see Figure 5-14 on page
5-43). If the LED is off (and cabling is not the
problem), replace defective board. See
Replacing the Interconnect Board on page
7-7.
Troubleshooting
Possible
Cause(s)
Dim or no
surface
(coaxial) light
(continued).
Improper Drewire
terminations (very
rare).
Measure the resistance of the terminations and

contact your local authorized OGP Service
Representative or the OGP Service Department.
See Measuring the Resistance of the Drewire
Terminations on page 5-54.
Dim or no
backlight.
Dirty stage glass.
Clean the glass. See Stage Glass on page 4-4.
Loose or faulty
cabling to the LED
Driver board.
Observe LED DS1 on the LED Driver board

substage illuminator or the cabling to the
substage illuminator.
interconnecting cables) to the LED Driver
board are secure.
damaged cables.
System not
configured
correctly.

Defective LED
Driver board.
Observe LED DS1 on the LED Driver board

problem with the LED Driver board or the
Check voltages on the LED Driver board
Check LED DS2 (heartbeat) on the LED
Driver board (see Figure 5-17 on page 5-51).
If the LED is off (and cabling is not the
problem), replace the defective board. See
Replacing the LED Driver Board on page 7-5.
Defective
substage
illuminator.

Troubleshooting
6-9
Troubleshooting
Symptom
Symptom
Possible
Cause(s)
Dim or no
backlight
(continued).
Improper Drewire
terminations
(very rare).

Department. See Measuring the Resistance of
the Drewire Terminations on page 5-54.
Dim or no
SmartRing
light.
Dirty SmartRing
light.
Clean the SmartRing light. See Cleaning the

SmartRing Light on page 4-8.
Loose or faulty
cabling to the
SmartRing Light
or Interconnect
board.
Check that all cable connections to the

SmartRing light and Interconnect board are
secure.
damaged cables.
System not
configured
correctly.

Department.
Power supply not

connected to the
Interconnect
board.

damaged cables.
Defective power
supply.
Check power supply LEDs and voltages.

Perform the power supply troubleshooting
procedure on page 6-31.
Replace power supply if necessary. See
Replacing the Power Supply on page 7-13.
Defective
Interconnect
board.

7-7.
Improper Drewire
terminations
(very rare).

6-10
Troubleshooting
Optional LED
grid projector/
surface
illuminator does
not operate.
Troubleshooting
Possible
Cause(s)
Loose or faulty
cabling between
grid projector/
surface illuminator
and Interconnect
board.

grid projector/surface illuminator or the
cabling to the grid projector/surface
illuminator.
interconnecting cables) to the Interconnect
board and and grid projector/surface
illuminator are secure.
damaged cables.
Defective LED
grid projector/
surface
illuminator.

6-11
Troubleshooting
Symptom
Symptom
Optional LED
grid projector/
surface
illuminator
does not
operate.
(continued)
6-12
Possible
Cause(s)
Defective
Interconnect
board.

problem with the Interconnect board or the
7-7.
Incorrect
parameter
settings.

Department.
Improper Drewire
terminations
(very rare).

Troubleshooting
Motion Problems
All axes will not

initialize.
Troubleshooting
Possible
Cause(s)
Solution(s)
Emergency Stop
switch has been
pressed.
Check the status of the Stop LED (visible

through the optics cover). If the LED is blinking
rapidly, perform these steps:
1. Clear the stage.
2. Reset the remote E-Stop switch by twisting
it in the direction of the arrows.
3. Press the Stop/Start button on the joystick.
4. Perform the stage home sequence.
Loose or faulty
remote E-Stop
connection to the
machine.
Verify the remote E-Stop is properly (and

securely) connected to the machine.
Motor power
supply not
connected to DSP
board.
Verify power supply connections.

Verify +24V MTR LED on the back of the
power supply is on.
Verify +24V is present on the DSP
boardcheck between the outermost pins on
connector J13 on the DSP board.
Reconnect power supply to the DSP board.
Defective power
supply.

Replace the power supply if necessary. See
Loose or faulty
cabling to the
DSP board.
Check and secure all cable connections.

Replace if necessary.
6-13
Troubleshooting
Symptom
Symptom
Possible
Cause(s)
Solution(s)
All axes will

not initialize
(continued).
Defective DSP
board.
Check LED DS8 (heartbeat) on the DSP

board. The LED should be on (solid or
blinking).
Check LED DS7 on the DSP board for error
codes. See E-Stop Codes (DS7) on
page 5-37.
Check power supply voltages.
Replace DSP board if necessary. See
Replacing the DSP Multi Axis Board on
page 7-2.
Missed index
pulse message
appears on the
screen.
Axis is positioned
between the
index pulse and
end-of-travel limit
at start-up.
Click OK. Then move axis to the center of

travel and perform the stage home sequence.
Note: Not enabled in Measure-X.
One axis will

not initialize.
Axis may be
stuck at the end
of travel.
1. Press the remote E-Stop switch.

2. Manually position the XY stage to the
center of travel.
3. Reset the E-Stop switch by twisting it in the
direction of the arrows.
5. Perform the stage home sequence.
Loose or faulty
cabling to the
DSP board.

Low +12 or -12

voltage.
Check voltage.
Defective
joystick.
Perform the joystick troubleshooting procedure

outlined on page 6-27.
DSP board
offsets not set
correctly.
Refer to the DSP Multi Axis Board Service

Guide (P/N 790168).
Department.
Axis drifts on
power up.
6-14
Troubleshooting
Joystick causes
wrong or
multiple axes to
move.
Axis does not

move in any
direction.
Troubleshooting
Possible
Cause(s)
Solution(s)
Loose or
disconnected
joystick.
Verify that the joystick is connected to the

machine and the connection is secure.
Missing or corrupt
configuration file.

Defective joystick.

Remote E-Stop
switch has been
pressed.

through the optics cover). If the LED is blinking
rapidly, reset the E-Stop switch and press the
Stop/Start button to resume normal operation.
The Stop/Start
button on the
joystick has been
pressed.

through the optics cover). If the LED is on
(steady), press the Stop/Start button to resume
normal operation.
Loose or
disconnected
remote E-Stop
switch.
Verify that the remote E-Stop switch is

connected to the machine and the connection is
secure.
Axis is on
end-of-travel limit.
Move axis off of limit.
DSP.OUT was not

downloaded at
start-up.
Re-launch the metrology software.
Faulty safety
relay.
Check the LEDs on the safety relay; all LEDs

should be on.
If the Power LED is off, check cabling. If
cabling is OK, contact your local authorized
OGP Service Representative or the OGP
Service Department.
If the Channel 1 LED or Channel 2 LED is off,
Department.
6-15
Troubleshooting
Symptom
Symptom
Axis does not
move in any
direction
(continued).
6-16
Possible
Cause(s)
Solution(s)
No motor power
to the DSP
board.
Check voltages at the DSP board.

Check and secure the cable connections to
the DSP board.
Loose or faulty
motor cables.

Loose or faulty
scale cables.
Check for proper scale operation by

observing the corresponding diagnostic LEDs
on the DSP board. The LEDs should indicate
quadrature (as described on page 5-36).
Misaligned read
head.
Check the read head alignment along the full

length of travel; re-align the read head if
necessary.
Defective motor.
Isolate problem axis and then replace the

defective motor.
If the X axis or Y axis motor is defective,
Department.
If the Z axis motor is defective, see Replacing
the Z Axis Motor on page 9-2.
Defective read
head or read
head cable (LED
DS7 on the DSP
board indicates
excess position
error).
Check for proper scale operation by observing

the corresponding diagnostic LEDs on the DSP
board. The LEDs should indicate quadrature
(as described on page 5-36).
If the X axis read head is defective, see
Replacing the X Axis Read Head on
page 9-9.
If the Y axis read head is defective, see
Replacing the Y Axis Read Head on
page 9-14.
If the Z axis read head is defective, see
Replacing the Z Axis Read Head Assembly
on page 9-4.
Troubleshooting
Axis does not

move in any
direction
(continued).
Axis only moves

in one direction.
Axis runs to a
hard stop.
Troubleshooting
Possible
Cause(s)
Solution(s)
Defective power
supply.

Replace power supply if necessary. See
Defective DSP
board.

blinking).
page 5-37.
page 7-2.
Incorrect or
missing tuning
parameters.

Loose or faulty
cabling to the
DSP board.

Defective joystick.

Defective DSP
board.

blinking).
page 5-37.
page 7-2.
Loose or faulty
cabling to the
DSP board.

6-17
Troubleshooting
Symptom
Symptom
Axis runs to a
hard stop
(continued).
Axes run
away at
power up.
Note: If you
encounter this
problem,
contact the
OGP Service
Department
and provide as
much detail as
possible.
6-18
Possible
Cause(s)
Solution(s)
Defective DSP
board.

blinking).
page 5-37.
page 7-2.
Incorrect tuning
parameters.

Department.
DSP board not

loaded correctly.
Exit the metrology software and reboot.
Loose or faulty
cabling to the
DSP board.

Loose or faulty
scale cable
connections.
Misaligned read
head.
Check the read head alignment along the full

length of travel; re-align the read head if
necessary.
Scales not
functioning
properly.

page 9-9.
page 9-14.
Replacing the Z Axis Read Head on
page 9-4.
Troubleshooting
Possible
Cause(s)
Solution(s)
Axes run away

at power up
(continued).
Defective DSP
board.

blinking).
page 5-37.
page 7-2.
Squealing,
knocking, or
hard clicks.
Incorrect tuning
parameters or the
acceleration set
too high.

Loose axis
hardware or
damaged Z axis
ball screw.
Check for loose hardware and re-secure if

necessary.
Remove the Z axis cover and check for
defective ball screw.
Department.
Defective read
head on the
problem axis.

board. The LEDs should indicate quadrature (as
described on page 5-36).
page 9-9.
page 9-14.
page 9-4.
Incorrect tuning
parameters.

Axis does not

finish moves or
hesitates when
finishing move.
Troubleshooting
6-19
Troubleshooting
Symptom
Symptom
Oscillations.
6-20
Possible
Cause(s)
Solution(s)
Loose axis
hardware.
Check for loose hardware and re-secure if

necessary.
Department.
Loose or
defective motor
coupling.

Department.
Loose or
defective motor.
Isolate problem axis and then replace defective

motor.
If the X axis or Y axis motor is defective,
Department.
If the Z axis motor is defective, see Replacing
the Z Axis Motor on page 9-2.
Defective read
head on the
problem axis.

page 9-9.
page 9-14.
page 9-4.
Loose or faulty
cabling to the
DSP board.

Troubleshooting
Oscillations
(continued).
Unexpected
contact between
the optics and
part/fixture on
the stage.
Possible
Cause(s)
Defective DSP
board.

board. The LED should be on (blinking or
solid).
page 5-37.
page 7-2.
Incorrect tuning
parameters.

Part programming
error.
1. Manually lift the Z axis assembly up, off of

the obstruction.
2. Remove the obstruction.
3. Carefully lower the Z axis assembly.
5. Use the joystick to raise the Z axis
assembly to the upper limit of travel (this
clears the error message displayed on the
screen).
Fixturing problem.
Stage initialization
error.
Unexpected Z
axis movement.
Troubleshooting
Solution(s)
6-21
Troubleshooting
Symptom
Video Problems
Symptom
No live video,
but menus OK.
No live video or
menus.
Live video, but

no stored video.
6-22
Possible Cause(s)
Incorrect color settings.
1. Right-click on the Windows

Desktop and select
Properties.
2. Click the Settings tab and
make sure Colors is set to
24 or 32 bit.
Check for loose or defective

video and camera cables.
Reconnect or replace cables.
Corrupt registry of .ini files.
Copy known good files from

backup disk.
Corrupt inspection routine.
Reload inspection routine.
Defective camera.
Replace the camera. See

Replacing the Video Camera on
page 8-5.
Defective QVI video capture

card.
Contact your local authorized

OGP Service Representative or
the OGP Service Department.
Check for defective monitor

cables.
Replace cables.
If the system boots up on

power, check for defective
monitor.
Replace the monitor.

card.


card.

Troubleshooting
During focus,
video image
moves erratically.
Troubleshooting
Possible Cause(s)
Environmental vibration.
Relocate system.
Misconfigured camera.

Loose Z axis motor.
Verify Z axis motor mounting

screws are secure. Tighten
screws if necessary.
Defective Z axis motor.
Replace the defective motor. See

Replacing the Z Axis Motor on
page 9-2.
6-23
Troubleshooting
Symptom
Troubleshooting the System Computer and User-Interface Components

Before you suspect a serious problem with the system computer, remember that
adding hardware and/or software can affect the existing system. Recheck any
installations you may have recently performed.
Start-Up and General Performance Problems
Symptom
6-24
Possible Cause(s)
System computer does

not turn on when you
press the On/Off switch.
Check for loose or disconnected

power cord. Reconnect the power
cord.
Bios not configured to power on after
a power failure; contact your local
Department.
System unable to write

to the CONFIG
directory (error
message appears).
CONFIG directory is write-protected.

Give restricted users read, write,
execute, and modify permission to the
following:
C:\OGPMM and all subdirectories
(MeasureMind 3D systems)
C:\OGP and all subdirectories
(Measure-X systems)
C:\Temp
Icons in metrology
software turn green or
green bar appears at
the top of the screen.
The hardware acceleration is set too

high.
1. Right-click on the Windows Desktop
and select Properties.
2. Click the Settings tab.
3. Click the Advanced button.
4. Click the Troubleshooting tab.
5. Move the Hardware acceleration
slider one setting to the left of Full.
Troubleshooting
Troubleshooting
Possible Cause(s)
Unable to download to
the DSP board during
start-up.
Parallel cable is loose or defective.

Verify parallel cable is connected to
the machine and PC; replace if
necessary.
Misconfigured parallel port.
- Access the CONFIG directory and
open INPUT.CFG (MeasureMind
3D) or PREFERENCE.INI
(Measure-X). Verify that the
CONFIG LPT_PORT parameter is
set to zero.
- Verify parallel card appears in
Device Manager (Start/Settings/
System/Hardware Tab/Device
Manager). Contact your local
Department for further assistance.
Does not boot from

floppy.
Check associated cables and verify

power to the drive.
Bios not configured to boot from
floppy first; contact your local
Department.
Does not boot from hard

drive.
Verify that there is no floppy disk in

the disk drive.
Check for data corruption on hard
drive.
Check the power and data
connections to the hard drive.
Erratic operation after

booting.
Monitor power supply and check for sags

in voltage. Measure supply voltages with
all cards plugged in.
Does not read floppy

disk.
Suspect floppy disk damaged.

Reformat disk or try new disk.
Check cabling to drive in PC. Replace
floppy drive if needed.
6-25
Troubleshooting
Symptom
Joystick Problems
Note: Perform the joystick troubleshooting procedure on the next page any time
you suspect that the joystick is defective.
Symptom
Possible Cause(s)
No movement.
Remote E-Stop switch has been

pressed. If necessary, reset the
switch by twisting it in the direction
of the arrows.
System is in Stop Mode; press
Stop/Start button on joystick.
Check joystick cabling. Replace
joystick if needed.
Check stage for holding torque.
Stage may have faulted.
Stage moves without input.
Centering switch(es) on joystick is

not locked.
Check the DAC test points on the
DSP board and adjust the offset
potentiometers if necessary (refer
to the DSP Multi Axis Board
Service Guide, P/N 790168).
Joystick is out of calibration. Try to
move the joystick a small amount
to stop the stage motion. Replace
the joystick.
Note: On MeasureMind 3D systems, you can use the diagnostic tools available
in the software to verify that the joystick is working properly. See Section 5,
Diagnostics, for details.
6-26
Troubleshooting
Troubleshooting the Joystick

Note: The following procedures only apply to systems equipped with the DSP
Multi Axis board (P/N 03640x, revision E or higher).
TP42
TP43
TP32
TP41
TP34
TP44
TP33
JP9-1
Troubleshooting
Figure 6-6 shows the test points on the DSP board that are used to troubleshoot
the joystick.
DSP Board
Figure 6-6. Joystick Troubleshooting Test Points
Verifying VREF+ from DSP Board to Joystick

1.
Troubleshooting
Connect the positive (+) lead of a Digital Volt Meter (DVM) to pin 1 on JP9
and connect the negative (-) lead to TP41. The reading (VREF) should be
3.0VDC 10%.
If the reading is within specification, the joystick, interconnecting

cables, and DSP board are all working properly. You do not need to
perform the rest of this procedure.
If the reading is not within specification, continue with the next step in
this procedure.
6-27
2.
Unplug the joystick and re-check VREF+. Again, the reading should be
3.0VDC 10%.
If the reading is within specification, connect the joystick directly to the

DSP board (no interconnecting cables) and re-check.
If the reading is out of specification, replace the joystick.

If the reading is within specification, replace the interconnecting
cables.
If the reading is not within specification, check the power supply

voltages to the DSP board (+5VDC and +12VDC). If the voltages are
OK, perform the next procedure. Otherwise, replace the DSP board.
Verifying Joystick Potentiometer at Input to DSP Board

1.
Make sure the joystick is not deflected and use a DVM to measure the
voltage between the following:
TP41 and TP32
TP41 and TP33
TP 41 and TP34
Each reading should be (VREF/2) 5%.
2.
3.
6-28
If the voltages are within specification, continue with the next step in
this procedure.
If the voltages are not within specification and cabling is not the
problem, replace the joystick.
Connect the negative (-) lead to TP41 and connect the positive (+) lead to:
TP32 to measure the X_POTvoltage should vary from ~0VDC to

VREF(+) when you move the joystick lever in X
TP34 to measure the Y_POTvoltage should vary from ~0VDC to

VREF(+) when you move the joystick lever in Y
TP33 to measure the Z_POTvoltage should vary from ~+1VDC to

+2VDC when you rotate the joystick knob
Move the joystick lever (XY axes) or rotate the joystick knob (Z axis) to
check the different input voltages. The voltages should be within the
specifications specified above.
If the voltages are within specification, perform the next procedure.
If the voltages are not within specification and cabling is not the
problem, replace the joystick.
Troubleshooting
Verifying Joystick Potentiometers at Input to A/D Converter
2.
Connect the negative (-) lead to TP41 and connect the positive lead to:
TP42 to measure the X_POTvoltage should vary from ~0VDC to

VREF (+) when you move the joystick lever in X
TP44 to measure the Y_POTvoltage should vary from ~0VDC to

VREF (+) when you move the joystick lever in Y
TP43 to measure the Z_POTvoltage should vary from ~0VDC to

VREF (+) when you rotate the joystick knob
Move the joystick lever (XY axes) or rotate the joystick knob (Z axis) to
check the different input voltages. The voltages should be within the
specifications specified above.
If the potentiometer voltages are within specification, the joystick,

interconnecting cables, and DSP board are all working properly.
If the voltages are not within specification, replace the DSP board.
Keyboard Problems
Symptom
Possible Cause(s)
No response.
Make sure the computer is on.

Faulty keyboard or cabling.
Replace keyboard if necessary.
Some keys do not work or

they stick.
Clean all internal surfaces of the

keyboard. Replace keyboard if
necessary.
CAUTION: Never connect or unplug the keyboard (or mouse) from the PS2
port while the computer is on. Doing so could damage the motherboard in the
system computer.
Troubleshooting
6-29
Troubleshooting
1.
Monitor Problems
Symptom
6-30
Possible Cause(s)
No video.
Make sure the monitor is on.

Make sure the system computer boots and cables
are connected properly.
Check the video acquisition and memory cards for
failure.
No video, or high pitched

squeal and no video.
Internal circuit or high-voltage breakdown.
Color shift or image not

straight.
Degauss the monitor.

Reduce proximity to nearby magnetic field.
Noise in image or noisy

(floating) image.
Reduce proximity to nearby electric field, including

a second monitor.
Screen adjustment pots could be dirty. Turn all pots
several times from end to end to clean wipers.
Fixed bars or striped

pattern on screen (live
video window).
Re-install .ini files from backup diskette.

Confirm that all display settings and drivers are
correct.
No live video (metrology

software running and
system Power LED is
on).
See if lights are turned off or if lighting is too low for

the part.
Check for defective camera cable.
Image appears choppy

during stage motion.
This is normal and can be minimized by increasing

the monitor refresh frequency.
1. Right-click on the Windows desktop.
2. Select Properties from the context menu.
3. Click the Settings tab and click the Advanced
button.
4. Click the Monitor tab and select a refresh
frequency of 75 Hertz or higher from the
Refresh Frequency list. (We recommend
selecting the maximum refresh frequency.)
Circles appear elliptical.
Incorrect monitor aspect ratio. Replace with monitor

that has a native aspect ratio of 4:3.
Troubleshooting
Troubleshooting the Power Supply

WARNING: This procedure requires that power be applied to the system
with the rear door open. Exercise caution whenever operating the system in
this state.
Power down the system.
into position.
2.
3.
Disconnect the cables connected to J300, J301, and J302 (if applicable)
on the top of the power supply.
J312
AC OUT/MOTOR IN
J300
LOGIC & CONTROL 1
J301
LOGIC & CONTROL 2
J310
MOTOR OUTPUT
J302
LOGIC & CONTROL 3
CONTROL J311
Figure 6-7. Power Supply (Top View)
Troubleshooting
4.
Verify that the power cord is connected to the back of the power supply and
that AC power is present.
5.
Verify that the machine power switch on the back of the power supply is on
and then turn on the system computer.
6.
Observe whether or not the power supply turns on, as indicated by the
Power ON LED on the power supply.
If the power supply turns on, a problem exists with the cabling or
connected circuit boards. Contact your local authorized OGP Service
Representative or the OGP Service Department for more information.
If the power supply does not turn on, continue with the next step.
6-31
Troubleshooting
1.
7.
Shut down the system computer (do not turn off the machine power switch).
8.
Disconnect the cable connected to J311on the top of the power supply.
CAUTION: When installing a jumper on the pins indicated in the next step, be
sure to install the jumper on the correct pins to avoid damaging the power
supply.
9.
Apply +5V to pin 13 on connector J311 by installing a jumper between

pins 11 and 13 or pins 12 and 13.
J312
AC OUT/MOTOR IN
Pin 13
12 11
J300
LOGIC & CONTROL 1
J301
LOGIC & CONTROL 2
J310
MOTOR OUTPUT
J302
LOGIC & CONTROL 3
CONTROL J311
Figure 6-8. Location of Pins 11, 12, and 13 on Connector J311
10. Observe whether or not the power supply turns on, as indicated by the
Power ON LED on the power supply.
If the power supply turns on, a problem exists with the cabling or QVI
Video Capture Card. Contact your local authorized OGP Service
Representative or the OGP Service Department for more information.
If the power supply does not turn on, replace the power supply. See
11. When finished, re-connect all cables and close the rear door.
6-32
Troubleshooting
Section 7
Replacing
Electrical Components
DSP Multi Axis board
LED Driver board
Interconnect board
Universal Multi-Sensor board (if equipped)
Micro Theta Control board (if equipped)
Power supply
Exhaust fan
Note: The procedures described in this section assume that a qualified service
technician has properly identified the component being replaced to be the cause
for the system anomaly. If this is not the case, please contact your local
authorized OGP Service Representative before performing any of the
procedures.
Before You Start

Before servicing the system, please review the Safety section at the beginning of
this manual, and the following important safety precautions.
WARNING: Before beginning any work, turn off the main power switch
and disconnect the power cord from the power source. Remove rings,
watches, neckties, and loose jewelry before servicing the machine.
CAUTION: Use the correct tools for the job. Improper tools may damage
components. Use only authorized OGP parts. Other replacement parts may not
be of the same rating or duty cycle and may damage the system.
Replacing Electrical Components
7-1
Replacing Electrical
Components
This section describes how to replace the following electrical components:
Replacing the DSP Multi Axis Board

The DSP Multi Axis board is the located in the Electronics Tower and it is the
electronic heart of the system.
Important: Before performing the following procedure, verify that the
replacement DSP board has the same part number as the old DSP board. If the
part numbers on the two boards are different, contact your local authorized OGP
Service Representative or the OGP Service Department.
Note: If there are any daughter boards installed on the DSP board, you will
have to remove them before removing the DSP board.
Flat-head screwdriver
Phillips-head screwdriver
Plastic, anti-static bag
Replacement DSP Multi Axis board
Replacing the DSP Multi Axis Board

1.
into position.
2.
7-2
3.
Locate the DSP Multi Axis board, which is mounted on the rear door.
Components
Rear Door
Retainer
DSP
Board
Figure 7-1. Location of the DSP Multi Axis Board
4.
If there are any daughter boards mounted on the DSP board, remove them
before continuing.
If the system is equipped with a laser sensor or more than one probe,
see the Universal Multi-Sensor Board Replacement procedure on
page 7-9.
If the system is equipped with a rotary indexer, see the Micro Theta
Control Board Replacement procedure on page 7-11.
7-3
5.
Disconnect all external connections from the DSP board. Refer to

Figure 7-2.
Note: Be sure to disconnect the Chassis Ground (J31) from the DSP board
because a new one is not supplied with the replacement board.
RS-485
DWI
(P403)
ZOOM
(J12)
RS-485
DWI
(P404)
CRASH
(J406)
EXPANSION
(P400)
Z-AXIS
(J14)
CHASSIS
GND (J31)
JOYSTICK
(P20)
MOTOR
PWR (J13)
POWER
(J81)
Y-AXIS
(J11)
PC
PARALLEL
(P1)
X-AXIS
(J10)
RS232-A
(P406)
RS232-B
(P407)
RS232 Y-SCALE X-SCALE

DEBUG
(J303)
(J304)
(P405)
Z-SCALE
(J302)
FRONT OF
MACHINE
Figure 7-2. DSP Multi Axis Board, External Connections
CAUTION: Do not let the rear door drop. Support it while removing the screw
that secures the rear door retainer to the rear door.
7-4
6.
Use a Phillips-head screwdriver to remove the mounting screws around the

perimeter of the DSP board.
7.
Remove the old DSP Multi Axis board and place it in a plastic, anti-static
bag.
8.
Reverse the above procedure to install the replacement DSP Multi Axis
board. Be sure to re-install the rear door retainer during re-assembly.
Replacing the LED Driver Board

The LED Driver board is located in the Electronics Tower and it controls the
LED backlight assembly.
replacement LED Driver board has the same part number as the old LED Driver
board. If the part numbers on the two boards are different, contact your local
authorized OGP Service Representative or the OGP Service Department.
Replacement LED Driver board
Components
Replacing the LED Driver Board

1.
into position.
2.
7-5
3.
Locate the LED Driver board, which is mounted to the front-inside wall of
the Electronics Tower.
4.
Disconnect all external cables from the board (see Figure 7-3).
Mounting
Screw (Qty 4)
J701
J706
J708
J707
Figure 7-3. Removing the LED Driver Board
7-6
5.
Use a 3 mm Allen wrench to remove the four mounting screws.
6.
Carefully remove the LED Driver board from the Electronics Tower and
place it in a plastic, anti-static bag.
7.
Reverse the above procedure to install the replacement LED Driver board.
Replacing the Interconnect Board

The Interconnect board is attached to the front of the optical assembly and it
controls the AccuCentric assembly, SmartRing Light, and optional LED grid
projector.
replacement Interconnect board has the same part number as the old
Interconnect board. If the part numbers on the two boards are different, contact
Department.
Set of Metric hex key (Allen) wrenches
Replacement Interconnect board
Components
Replacing the Interconnect Board

1.
2.
Remove the Optics Cover, as described on page 8-2.
CAUTION: Do not unplug any cables from the Interconnect board if the system
is powered up. Doing so could permanently damage the Interconnect board
and/or other components.
CAUTION: If any of the cables are not labeled, make and attach labels before
disconnecting them. Connecting cables to the wrong connectors could
permanently damage the Interconnect board and/or other other components.
3.
With power removed from the machine, disconnect all accessible external
connections from the Interconnect board (see Figure 7-4 on the next page).
7-7
Note: Before removing the Interconnect board, note the set of standoffs
between the Interconnect board and the zoom assembly and the set of standoffs
between the insulator plate and Interconnect board. Both sets of standoffs must
be used during re-assembly.
4.
While grasping the Interconnect board (and insulator plate), remove the
four mounting screws, washers, and standoffs (see Figure 7-4). Use a 3 mm
Allen wrench. Retain all attaching hardware.
Standoff
(Qty 4)
Insulator
Plate
Zoom
Assembly
Interconnect
Board
Mounting
Screws (Qty 4)
Standoff
(Qty 4)
Figure 7-4. Removing the Interconnect Board
5.
Disconnect any remaining cables from the Interconnect board. Then remove
the board and place it in a plastic, anti-static bag.
6.
Reverse the above procedure to install the replacement Interconnect board.
Note: During re-assembly, be sure to:
7-8
Re-install both sets of standoffs (removed in Step 4).
Re-connect all cables to the Interconnect board.
Re-install the insulator plate.
Replacing the Universal Multi-Sensor Board (If Equipped)

If the system is equipped with a laser sensor or more than one touch probe, the
Universal Multi-Sensor board will be installed on the DSP board (connected to
P400).
replacement Universal Multi-Sensor board has the same part number as the old
Universal Multi-Sensor board. If the part numbers on the two boards are
different, contact your local authorized OGP Service Representative or the OGP
Service Department.
2.5 mm hex key (Allen) wrench
Replacement Universal Multi-Sensor board
Components
Replacing the Universal Multi-Sensor Board

1.
into position.
2.
7-9
3.
Locate the Universal Multi-Sensor board, which is mounted to the DSP

board (connected to P400).
4.
Disconnect all external cables from the Universal Multi-Sensor board.
DRS Laser (top)

or
QVI TTL Laser
(bottom)
Mounting Screws
(or Standoffs)
Multi-Probe
P/N
REV
Figure 7-5. Removing the Universal Multi-Sensor Board
7-10
5.
Use a 2.5 mm Allen wrench to remove the four mounting screws.
6.
Carefully remove the Universal Multi-Sensor board and place it in a plastic,

anti-static bag.
7.
Reverse the above procedure to install the replacement Universal

Multi-Sensor board.
Replacing the Micro Theta Control Board (If Equipped)

If the system is equipped with a rotary indexer, the Micro Theta Control board
will be installed on the DSP board (connected to P400).
replacement Micro Theta Control board has the same part number as the old
Micro Theta Control board. If the part numbers on the two boards are different,
contact your local authorized OGP Service Representative or the OGP Service
Department.
Replacement Micro Theta Control board
Components
Replacing the Micro Theta Control Board

1.
into position.
2.
3.
If the system is equipped with a laser sensor or more than one probe,
remove the Universal Multi-Sensor board. See the Universal Multi-Sensor
Board Replacement procedure on page 7-9.
7-11
4.
Disconnect all cables from the Micro Theta Control board.
Power
Connector
Mounting Screws
(or Standoffs)
J400
MTR Connector
MSR Connector
Figure 7-6. Removing the Micro Theta Control Board
5.
Use a 2.5 mm Allen wrench to remove the mounting screws or standoffs.
Note: If the system has a Universal Multi-Sensor board, you will remove
standoffs instead of screws.
6.
Carefully remove the Micro Theta Control board and place it in a plastic
anti-static bag.
7.
Reverse the above procedure to install the replacement Micro Theta Control
board.
Note: If the system has a Universal Multi-Sensor board, be sure to re-install it

during re-assembly.
7-12
Replacing the Power Supply

The power supply is located in the lower portion of the Electronics Tower.
Replacement power supply

1.
2.
Use a flat-head screwdriver to remove the lower-rear panel.
into position.
3.
4.
Disconnect all external cables from the top of the power supply.
J312
AC OUT/MOTOR IN
J300
LOGIC & CONTROL 1
J301
LOGIC & CONTROL 2
J310
MOTOR OUTPUT
J302
LOGIC & CONTROL 3
CONTROL J311
Figure 7-7. Top View of Power Supply
7-13
Components
Replacing the Power Supply
CAUTION: Do not let the power supply drop. Support it while removing the
mounting screws.
5.
While grasping the power supply, remove the four mounting screws
(accessed from outside of the tower). Use a Phillips-head screwdriver.
Mounting
Screws
Lower-Rear Panel
Power Supply
Figure 7-8. Removing the Power Supply
6.
7-14
Remove the power supply from the Electronics Tower and reverse the above
procedure to install the replacement power supply.
Replacing the Exhaust Fan

The electronics exhaust fan is located in the upper portion of the Electronics
Tower and removes hot air from the tower, cooling the electronic components.
Replacement exhaust fan
Replacing the Exhaust Fan

1.
into position.
2.
7-15
Components
CAUTION: Do not let the heatsink baffle drop. Support it while removing the
mounting screws.
3.
While grasping the heatsink baffle, remove the three button-head screws
and two Phillips-head screws.
Phillips-Head Screws
Heatsink
Baffle
Button-head Screws
Figure 7-9. Removing the Heatsink Baffle
7-16
4.
Carefully lower the heatsink baffle out of the way.
5.
Unplug the fan power connector from the bottom of the fan.
CAUTION: Do not let the fan drop. Support it while removing the mounting
screws.
CAUTION: Do not let the rear door drop. Support it while removing the screw
that secures the rear door retainer to the machine.
6.
While grasping the fan, remove the four mounting screws (accessed from
outside of the tower) and hex nuts securing the fan mounting plate (and
attached fan) to the tower. Use a Phillips-head screwdriver.
Components
Mounting Screws,
Washers, and Hex
Nuts (4 places)
Fan Mounting
Plate
Fan Power
Connector
Rear Door
Retainer
Figure 7-10. Removing the Electronics Fan
7-17
7.
Remove the fan from the Electronics Tower.
8.
Remove the fan from the mounting plate.
9.
Remove the finger guard from the old fan and install it on the replacement
fan.
Mounting
Plate
AIR
FLOW
Finger
Guard
Fan
Figure 7-11. Removing the Fan from the Mounting Plate
10. Reverse the above procedure to install the replacement fan, paying
particular attention to the following details:
Make sure the air flow is in the direction indicated by the arrow shown
in Figure 7-11.
Make sure you reconnect the fan power connector so the red wire (the
positive side) lines up with the positive plug on the fan (see
Figure 7-12). Do not reverse polarity.
Black wire
is Negative
AIR
FLOW
Red wire
is Positive
Figure 7-12. Connecting the Fan Power Connector
7-18
Section 8
Replacing
Imaging Components
This section includes replacement procedures for the following imaging
components:
SmartRing Light
Video Camera
Zoom Lens Assembly
Before You Start

this manual, and the following important safety precautions.
Replacing Imaging Components
8-1
Replacing Imaging
Components
procedures.
Removing the Optics Cover

With the Optics Cover removed, you can access the Video Camera, optical
components, and SmartRing Light. You also need to remove the Optics Cover in
order to perform the mechanical calibration adjustments.
Shock absorbing material
Removing the Optics Cover

CAUTION: The equipment under the Optics Cover includes components
sensitive to damage from electrostatic discharge. Exercise caution to prevent
damage during this procedure.
1.
2.
Place a piece of shock absorbing material on the stage glass to protect it.
3.
Remove the Z Axis Cover by lifting it straight up.
Z Axis Cover
Lift Cover
Straight
Up to
Remove
Optics Cover
(Under Z Axis Cover)
Figure 8-1. Removing the Z Axis Cover
8-2
4.
Do one of the following, depending on whether or not the system is

equipped with the QVI TTL Laser:
If the system is equipped the QVI TTL Laser, use a 2.5 mm Allen
wrench to remove the four Optics Cover screws. Then carefully
remove the cover without scraping the paint.
If the system is not equipped with the QVI TTL Laser, use a 2.5 mm
Allen wrench to loosen the four Optics Cover screws. Then pull the
cover forward to remove it.
Optics Cover
Replacing Imaging
Components
Mounting
Screw (Qty 4)
Figure 8-2. Removing the Optics Cover (Z Axis Cover Removed)
5.
When ready, reverse the above procedure to re-install the Optics Cover and
Z Axis Cover.
8-3
Replacing the SmartRing Light

The SmartRing Light is mounted to the bottom of the Z axis assembly.
Replacement SmartRing Light
Replacing the SmartRing Light

Note: This procedure assumes that there are no parts, fixtures, or other
obstructions on the stage. If there are, please remove them before continuing.
CAUTION: The SmartRing Light includes components sensitive to damage
from electrostatic discharge. Exercise caution when handling the assembly.
1.
2.
Place a piece of shock absorbing material on the stage glass and remove the
Optics Cover, as described on page 8-2.
3.
Grasp the SmartRing Light by its outside edges and fully loosen the three
thumb screws (see Figure 8-3).
Connector
Thumbscrews
(Qty 3)
SmartRing Light
Figure 8-3. Removing the SmartRing Light
8-4
4.
Lower the SmartRing Light and gently place it on top of the stage.
5.
Unplug the connector from the back of the light (see Figure 8-3).
6.
Reverse the above procedure to install the replacement SmartRing Light.
Replacing the Video Camera

The Video Camera is mounted to an adjustment plate, which is attached to the
top of the optical assembly.
Hex key (Allen) wrenches: 1.5 mm, 2 mm, and 5 mm
Replacement Video Camera
Replacing the Video Camera
1.
2.
3.
Disconnect J4 (green/blue cable), J5 (red cable), and J6 (yellow/orange

cable) from the top of the camera (see Figure 8-4).
4.
Use a 1.5 mm Allen wrench to remove the upper two camera mounting
screws and a 2.5 mm Allen wrench to remove the lower two mounting
screws. Then remove the camera.
5.
Reverse the above

procedure to
install the
replacement Video
Camera.
6.
Perform the
required
calibration and
alignment
procedures
outlined in the
Calibration and
Alignment Manual
for your system.
J6
J4
J5
Upper Mounting
Screws
Lower Mounting
Screws
Video Camera
Figure 8-4. Removing the Video Camera
8-5
Replacing Imaging
Components
Note: This procedure assumes that there are no parts, fixtures, or other
obstructions on the stage. If there are, remove them before continuing.
Replacing the Zoom Lens Assembly

The Zoom Lens Assembly is located inside the Optics Housing. The assembly is
mounted to the housing and not the camera, so replacing the zoom lens
assembly without touching the camera should minimize the calibration and
alignment necessary after installing the new Zoom Lens Assembly.
Hex key (Allen) wrenches: 2 mm, 3 mm, and 5 mm
Replacement Zoom Lens Assembly
Replacing the Zoom Lens Assembly

1.
2.
3.
With power removed from the system, disconnect P643, P607, P15,
P601, P610, and P620 from the Interconnect Board (see Figure 8-5).
4.
While grasping the front plate, remove the four screws (and washers)
securing it (and attached Interconnect Board) to the Optics Housing (see
Figure 8-5). Use a 3 mm Allen wrench.
Front Plate Mounting

Screws (Qty 4)
P643
P607
P15
P601
Interconnect
Board
P620
P610
Figure 8-5. Removing the Front Plate & Interconnect Board
8-6
5.
Disconnect the remaining cables from the Interconnect board and set the
board and front plate aside.
6.
Grasp the Zoom Lens Assembly as you remove the three screws and
washers securing it to the Optics Housing (see Figure 8-6). Use a 3 mm
Allen wrench.
Optics
Housing
Zoom
Assembly
Figure 8-6. Removing the Zoom Lens Assembly
7.
Grasp the Zoom Lens Assembly and lift it up, rotate the bottom out of the
Optics Housing, and remove.
8.
Reverse the above procedure to install the replacement Zoom Lens

Assembly.
9.
Perform the required calibration and alignment procedures in the

Calibration and Alignment Manual for your system.
8-7
Replacing Imaging
Components
Mounting
Screws
(Qty 3)
8-8
Section 9
Replacing
Transport Components
This section includes replacement procedures for the following transport
components:
Z axis motor
Z axis read head
X axis read head
Y axis read head
procedures.
X and Y axis motor and drive assemblies
Z axis drive assembly
Before You Start

this manual, and observe the following important safety precautions.
Replacing Transport Components
9-1
Replacing Transport
Components
The following replacement procedures are not documented in this manual, and
should only be performed by an authorized OGP service technician:
Replacing the Z Axis Motor

The Z Axis Motor is located behind the Z Axis Slide Assembly.
Hex key (Allen) wrenches: 5/64-inch, 2.5 mm, and 3 mm
Replacement Z Axis Motor
Replacing the Z Axis Motor

1.
2.
Place a piece of shock absorbing material on the stage glass to protect it.
into position.
3.
4.
Unplug the Z Axis Motor Power and Z Axis Motor Tachometer connectors
(see Figure 9-1) and push both connectors through the cable access hole in
the front wall of the Electronics Tower.
Cable
Access
Hole
Z Axis
Motor
Tachometer
Z Axis
Motor
Power
Figure 9-1. Disconnecting the Z Axis Motor Connectors
9-2
5.
Remove the Z Axis Cover by lifting it straight up.
Refer to Figure 9-2 as you perform the remaining steps in this procedure.
6.
Use a 5/64-inch Allen wrench to loosen (but do not remove) the four motor
mounting screws slightly. Then grasp the Z Axis Motor Pulley and pull it
forward to release the tension on the Z Axis Drive Belt. Remove the drive
belt and set it aside.
7.
Use a 2.5 mm Allen wrench to remove the four sets of bracket mounting
screws and washers, and set them aside.
8.
Lift the Z Axis Motor, bracket, and pulley straight up and out of the Z Axis
Motor Housing.
Z Axis Drive Belt
Pulley Set Screws
Bracket Mounting
Screws & Washers
(4 places)
Motor Mounting
Screws (Qty 4)
Figure 9-2. Removing the Z Axis Motor
9.
Use a 5/64-inch Allen wrench to loosen (but do not remove) the two pulley
set screws. Then slide the pulley off of the Z axis motor shaft.
10. Use a 5/64-inch Allen wrench to remove the four motor mounting screws
holding the Z Axis Motor to its bracket.
11. Reverse the above procedure to install the replacement Z Axis Motor.
Note: When re-installing the Z Axis Drive Belt, adjust the motor mounting
screws and pulley set screws so the drive belt is snug and centered within the Z
Axis Motor Pulley.
9-3
Replacing Transport
Components
Z Axis
Motor
Replacing the Z Axis Read Head

The Z Axis Read Head is mounted on the left side of the Z Axis Assembly.
9-4
Small flat-head screwdriver
Wire cutters and cable tie wraps
Replacement read head (package includes orange and blue spacers)
Replacing the Z Axis Read Head

1.
Place a piece of shock absorbing material on the Stage Glass and perform
the lockout procedure outlined on page xv.
2.
Remove the Optics Cover as described on page 8-2 to reveal the Z Axis
Slide Assembly. Note the location of the read head on the left side of the Z
Axis Slide (see Figure 9-3).
Z Axis
Read
Head
Cable Guide
Assembly
Mounting
Plate
Replacing Transport
Components
FRONT OF
MACHINE
Figure 9-3. Location of Z Axis Read Head
into position.
3.
9-5
4.
Disconnect the Z Scale Cable from J302 on the DSP Multi Axis Board (see
Figure 9-4).
Cable
Access
Hole
Z Scale
(connects
to J302)
DSP
Board
Figure 9-4. Disconnecting the Z Scale Cable
5.
9-6
Cut any necessary cable tie wraps to free the Z Axis Scale Cable. Then feed
the cable through the cable access hole in the front wall of the tower and
remove it from the Cable Guide Assembly.
CAUTION: Avoid scratching the tape scale when removing the Z Axis Read
Head.
6.
Use a 2.5 mm Allen wrench to remove the mounting plate and attached read
head (see Figure 9-5).
Tape
Scale
Read Head
Mounting
Plate
7.
Use a 2.5 mm Allen wrench to remove the two screws that secure the read
head to the mounting plate.
8.
Attach the mounting plate to the replacement read head.
CAUTION: Avoid scratching the tape scale when inserting and removing the
orange and blue spacers.
9.
Loosely install the replacement Z Axis Read Head, using the orange spacer
to align the read head to the tape scale.
10. Remove the orange spacer and insert the blue 0.8 mm spacer between the
read head and the tape scale. Slightly push the read head toward the tape
scale and tighten the mounting plate screws. Then remove the spacer.
Note: Refer to the Installation Guide provided with the new read head for more
information about adjusting the read head.
11. Feed the Z Scale Cable into the Electronics Tower and connect it to J302
on the DSP Board (see Figure 9-4 on page 9-6 for reference).
9-7
Replacing Transport
Components
Figure 9-5. Removing the Z Axis Read Head
12. Re-install any previously removed cable tie wraps to secure the Z Scale
Cable.
WARNING: The next step involves powering up the system with covers
removed. Exercise caution whenever operating the system in this state.
13. Power up the system and launch the metrology software.
14. Use the joystick to raise and lower the Z Axis Assembly the full length of Z
travel while observing the lamp on the Z Axis Read Head.
The lamp should remain green through the entire Z travel.
If the lamp remains green through the entire travel, no adjustment is

necessary. Power down the system and re-install the Optics Cover and
the Z Axis Cover.
If the lamp illuminates yellow or red, even for a short period of time,
power down the system and re-adjust the read head spacing. Repeat
Steps 13 and 14 until the lamp remains green through the entire travel.
Note: The lamp may illuminate yellow or red if the read head is too close to the
scale, too far away from the scale, or not parallel to the scale.
9-8
Replacing the X Axis Read Head

The X Axis Read Head is located behind the stage.
Replacing the X Axis Read Head

1.
2.
Use a 2.5 mm Allen wrench to remove the two button-head screws securing
the Post Y Axis Cover to the Electronics Tower (see Figure 9-6). Remove
the cover and set it aside.
3.
Use a small flat-head screwdriver to remove the four flat-head screws

securing the Y Axis Cover to the machine. Remove the cover and set it
aside.
Post Y
Axis Cover
Button-head
Screw (Qty 2)
Replacing Transport
Components
Flat-head
Screw (Qty 4)
Y Axis
Cover
Figure 9-6. Removing the Y Axis Covers
9-9
4.
Locate the X Axis Read Head, which is mounted below the back of the
stage (see Figure 9-7).
Cover Support
Plate Mounting
Screws (Qty 3)
Stage
X Axis
Read Head
Cable Tie
Wraps
Cover
Support
Plate
Figure 9-7. Removing the Cover Support Plate
5.
Use a 3 mm Allen wrench to remove the three socket-head cap screws that
secure the Cover Support Plate to the machine.
6.
Remove the Cover Support Plate and set it aside. Then cut and remove any
cable tie wraps securing the read head cable to the machine.
CAUTION: Do not let the rear door drop. Support it while lowering it into
position.
7.
9-10
Use a flat-head screwdriver to loosen the rear door fasteners and slowly
8.
Disconnect the X and Y scale connectors from J304 and J303 on the DSP
Multi Axis Board (see Figure 9-8).
Y Scale
(connects
to J303)
X Scale
(connects
to J304)
DSP Board
Figure 9-8. Disconnecting the X and Y Scale Connectors

9.
Cut any necessary cable tie wraps to free the cables and drop the cables into
the lower portion of the tower.
10. Use a flat-head screwdriver to remove the Lower Rear Panel.
Replacing Transport
Components
11. Unlatch the upper and lower cable clamps (see Figure 9-9) and pull the flex
cable tubingcontains the X and Y scale cablesout of the lower clamp
and straight back toward you.
Upper Cable
Clamp (hidden)
Lower Cable
Clamp
Flex Cable
Tubing
Figure 9-9. Lower Electronics Compartment
9-11
CAUTION: Avoid scratching the tape scale when removing the X Axis Read
Head.
12. Use a 2.5 mm Allen wrench to remove the two socket-head cap screws that
secure the X Axis Read Head to the Read Head Mounting Bracket (see
Figure 9-10).
Tape
Scale
Read Head
Mounting
Bracket
Mounting
Screw (Qty 2)
Figure 9-10. Removing the X Axis Read Head

13. Remove the X Axis Read Head. The flex cable tubing should be free to
follow the read head.
14. Remove the X Scale Cable from the flex cable tubing, while leaving the Y
Scale Cable inside the tubing. Discard the defective X Axis Read Head.
15. Loosely install the replacement X Axis Read Head, using the orange spacer
scale and tighten the mounting screws. Then remove the spacer.
17. Feed the X Scale Cable into the flex cable tubing, next to the Y Scale Cable,
and route the flex cable tubing back through the lower and upper
Electronics Compartments.
9-12
18. Reconnect the X and Y scale connectors to J304 and J303 on the DSP
Board.
19. Refer to the previous steps and complete the re-assembly process by:
Installing any previously removed cable tie wraps
Re-installing the Lower Rear Panel (see Step 10)
Closing the rear door (see Step 7)
Re-installing the Cover Support Plate (see Steps 5 and 6)
21. Use the joystick to move the stage along the full length of X travel while
observing the lamp on the X Axis Read Head.
The lamp should remain green through the entire X travel.

necessary. Power down the system and re-install the Y Axis Cover and
Post Y Axis Cover (see Steps 2 and 3).
Replacing Transport
Components
9-13
Replacing the Y Axis Read Head

The Y Axis Read Head is located under the Y Axis Cover.
Replacing the Y Axis Read Head

1.
2.
Use a 2.5 mm Allen wrench to remove the two button-head screws securing
the Post Y Axis Cover to the Electronics Tower (see Figure 9-11). Remove
the cover and set it aside.
3.
Use a small flat-head screwdriver to remove the four flat-head screws

securing the Y Axis Cover to the machine. Remove the cover and set it
aside.
Flat-head
Screw (Qty 4)
Post Y
Axis Cover
Button-head
Screw (Qty 2)
Y Axis
Cover
Figure 9-11. Removing the Y Axis Covers
9-14
4.
Locate the Y Axis Read Head (see Figure 9-12).
Cover Support
Plate Mounting
Screws (Qty 3)
Stage
Y Axis
Read
Head
Cable Tie
Wraps
Cover
Support
Plate
5.
Use a 3 mm Allen wrench to remove the three socket-head cap screws that
secure the Cover Support Plate to the machine.
6.
Remove the Cover Support Plate and set it aside. Then cut and remove any
cable tie wraps securing the read head cable to the machine.
CAUTION: Do not let the rear door drop. Support it while lowering it into
position.
7.
Use a flat-head screwdriver to loosen the rear door fasteners and slowly
9-15
Replacing Transport
Components
Figure 9-12. Removing the Cover Support Plate
8.
Disconnect the X and Y scale connectors from J304 and J303 on the DSP
Multi Axis Board (see Figure 9-13).
Y Scale
(connects
to J303)
X Scale
(connects
to J304)
DSP Board
Figure 9-13. Disconnecting the X and Y Scale Connectors

9.
Cut any necessary cable tie wraps to free the cables and drop the cables into
the lower portion of the tower.
10. Use a flat-head screwdriver to remove the Lower Rear Panel.

11. Unlatch the upper and lower cable clamps (see Figure 9-14) and pull the
flex cable tubingcontains the X and Y scale cablesout of the lower
clamp and straight back toward you.
Upper Cable
Clamp (hidden)
Lower Cable
Clamp
Flex Cable
Tubing
Figure 9-14. Lower Electronics Compartment
9-16
CAUTION: Avoid scratching the tape scale when removing the Y Axis Read
Head.
12. Use a 2.5 mm Allen wrench to remove the two socket-head cap screws that
secure the read head to the mounting bracket (see Figure 9-15).
Mounting
Screw (Qty 2)
Mounting
Bracket
Read
Head
Figure 9-15. Removing the Y Axis Read Head

13. Remove the Y Axis Read Head. The flex cable tubing should be free to
follow the read head.
15. Loosely install the replacement Y Axis Read Head, using the orange spacer
scale and tighten the mounting plate screws. Then remove the spacer.
17. Feed the Y Scale Cable into the flex cable tubing, next to the X Scale Cable,
and route the flex cable tubing back through the lower and upper
Electronics Compartments.
9-17
Replacing Transport
Components
14. Remove the Y Scale Cable from the flex cable tubing, while leaving the X
Scale Cable inside the tubing. Discard the defective Y Axis Read Head.
18. Reconnect the X and Y scale connectors to J304 and J303 on the DSP
Board.
19. Refer to the previous steps and complete the re-assembly process by:
Installing any previously removed cable tie wraps
Re-installing the Lower Rear Panel (see Step 10)
Closing the rear door (see Step 7)
Re-installing the Cover Support Plate (see Steps 5 and 6)
21. Use the joystick to move the stage along the full length of Y travel while
observing the lamp on the Y Axis Read Head.
The lamp should remain green through the entire Y travel.

necessary. Power down the system and re-install the Y Axis Cover and
Post Y Axis Cover (see Steps 2 and 3).
9-18
Section 10
Spare Parts
This section provides a comprehensive list of spare parts and/or assemblies
available for the system.
How To Order Parts

It is usually most convenient and efficient to contact your local authorized OGP
Sales Representative if you need to order spare parts for the SmartScope
CNC/Flash 250. Your local OGP representative is familiar with the entire OGP
line, and can provide you with parts and/or answer common service-related
questions on a quick-turnaround basis.
There are times, however, when your local OGP Sales Representative does not
have the correct part in stock, or when you need specialized expertise. In those
cases, do not hesitate to contact the OGP Service Department directly, at:
Spare Parts

Service Department
850 Hudson Avenue
Rochester, New York 14621-4896
Phone 1-585-544-0400, Extension 214
Fax 1-585-544-4998
E-mail service@ogpnet.com
Internet http://www.ogpnet.com
Spare Parts
10-1
Parts List Format

The remainder of this section consists of SmartScope CNC/Flash 250 spare
parts, in a number of tables.
Each table consists of parts that fall into general categories, e.g.,
Electrical/Electronic Parts.
Though the tables differ in content, the headings are consistent in each one.
Table headings include:
Item Designation. This is the nomenclature of the part or assembly,

e.g., Camera.
Type Designation. This refers to defining technical characteristics of

the item, e.g., Color CCD with 768 x 494 pixel array.
Qty. This specifies the quantity of that specific part/assembly normally

installed in one SmartScope CNC/Flash 250.
Part Number. This is a six-digit part number assigned by OGP.

Always refer to this part number when ordering a specific part.
General Characteristics. This is similar to Type Designation, but

referring to item characteristics of a more general nature. (This column
may be blank for certain items.)
Important: If you cannot find a specific OGP part in the following spare parts
list, please contact the OGP Service Department directly.
10-2
Spare Parts
Illumination/Optical Parts
Item
Designation
Type
Designation
Qty
Part
Number
Camera
Color CCD with

768 x 494 pixel
array
036259
SmartRing
Light
Standard
531398
SmartRing
Light
Systems
w/touch probe
(no DRX laser)
531397
SmartRing
Light
Systems
w/DRX laser
(no touch
probe)
531395
SmartRing
Light
Systems
w/touch probe
and DRX laser
531394
Zoom lens
assembly
12x
526280
General
Characteristics
User Components
Item
Designation
Type
Designation
Qty
Part
Number
021041
Remote
E-stop
039836
Spare Parts
Joystick
General
Characteristics
Spare Parts
10-3
Power Cords
Item
Type
Designation Designation
Qty
Part
Number
Power strip,
IEC
037545
Power
cord,
external
019978
Connect machine to IEC

power strip
019938
Connects IEC power strip

to external power source
Qty
Part
Number
Power
cord,
external
120 VAC,
50/60 Hz
General
Characteristics
Transport Parts
Item
Type
Motor, Z
axis
Type 23
030270
X axis read
head
0.5 micron
036797
Y axis read
head
0.5 micron
Z axis read
head
0.5 micron
10-4
0.1 micron
036798
1
0.1 micron
0.1 micron
Optional
036797
036798
General
Characteristics
Optional
036797
036798
Optional
Spare Parts
Electrical/Electronic Parts
Item
Type
Qty
Part
Number
General
Characteristics
Circuit board
DSP Multi Axis

board
036405.15
Circuit board
LED Driver
board
039322.02
Circuit board
Interconnect
board
039441
Circuit board
Universal
Multi-Sensor
board
032881
If system is equipped with a

laser or more than one
probe
Circuit board
Micro Theta
Control board
039192
If system is equipped with

MTR or MSR rotary indexer
Power
supply
24V/15V/12V/
5V/ 855W
026775
020372
Fan
Miscellaneous Parts
Stage glass
Type
Designation
Part
Number
638783
Wiring
diagram,
interconnect
031779-2
Alignment
reticle
623970
FastStart
training part
790012
Spare Parts
10" x 6"
Qty
General
Characteristics
Spare Parts
Item
Designation
10-5
Optional Accessories
Item
Designation
Type
Designation
Qty
Part
Number
Lens, .5x
Attachment
625680
Lens, 1.5x
Attachment
625670
Lens, 2.0x
Attachment
625660
General
Characteristics
Documentation
Item
Designation
Type
Designation
Qty
Part
Number
General
Characteristics
Manual
Hardware
Installation
Guide
790450
Manual
Service and
Maintenance
Manual
790451
This manual
Manual
Service Guide,
DSP Multi Axis
Board
790168
Optional
Manual
Measure-X
Reference
Guide
790230
For Measure-X systems
Manual
Measure-X
FastStart
Guide
790280
For Measure-X systems
Training
Workbook
Measure-X
790276
Optional
Manual
MeasureMind
3D Reference
Guide
790322
For MeasureMind 3D
systems
Manual
MeasureMind
3D FastStart
Guide
790321
For MeasureMind 3D
systems
Training
Workbook
MeasureMind
3D
790295
Optional
10-6
Spare Parts
Service Log
This service log is provided to help you maintain a history of all repairs and
routine preventive maintenance performed on your SmartScope CNC/Flash 250.
Date
Service
Technician(s)
Service
Type
Service
Procedure(s)
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
Service Log
A-1
Service Log
Appendix
Date
Service
Technician(s)
Service
Type
Service
Procedure(s)
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
A-2
Service Log
Service
Technician(s)
Service
Type
Service
Procedure(s)
Service Log
Date
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
Service Log
A-3
Date
Service
Technician(s)
Service
Type
Service
Procedure(s)
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
r Preventive
r Repair
A-4
Service Log
User Feedback
User Feedback
OGPs documentation serves a wide range of users in hardware and software

environments. In an attempt to meet each users needs, we welcome your
feedback.
Three forms are provided for this purpose:
Use the SmartScope CNC/Flash 250 Feedback and Evaluation Form to

express your opinion of our products, technical support and publications.
For the most effective feedback, please complete this form after you have
become familiar with the machine and you have had the opportunity to use
your SmartScope CNC/Flash 250, OGPs technical services, and this
manual.
Use the Documentation Enhancement Request Form to submit your

suggestions for improving the documentation as well as any notifications of
technical or documentation errors/omissions.
Use the System/Software Enhancement Request Form if you have any

ideas or suggestions for enhancing OGP products.
Thank you, in advance, for your cooperation.
User Feedback

SmartScope CNC/Flash 250 Feedback and Evaluation Form
After using your machine for several months, please take a few moments to complete this feedback
and evaluation form, and return it to Marketing Communications, Optical Gaging Products, Inc., 850
Hudson Ave., Rochester, NY 14621. If you want, you may FAX it to us at (585) 544 - 0131. Thank
you!
1.
Please tell us about yourself and your work with SmartScope CNC/Flash 250.
Your job function: _______________________________
How often do you use your machine?
2.
Years of experience: ___________
All/most of the day
Several times/day
Several times/week
Once a week or less
Please provide some background about your experience and training.

Did you receive training on SmartScope CNC/Flash 250?
Yes
No
If yes, how many days? ____
If yes, who provided the training?
Manufacturers representative
OGP employee
Do you consider your training to be sufficient?
Yes
No
If you did not receive any training, how did you learn to use it? ___________________________
Did you have previous experience with this machine or one similar to it?
What is your comfort level in using this machine?
3.
High
Yes
Medium
No
Low
Please indicate how strongly you agree or disagree with the following statements
about SmartScope CNC/Flash 250 and OGP technical support.
Strongly
Agree
Agree
Neutral/
Not Sure
Disagree
Strongly
Disagree

Has the functions I need
Is easy to use
Is easy to learn
User Feedback
User Feedback
Your feedback is very important. We value your opinion of our products, technical support and
publications. Your comments will help us to continually improve our products and services.
Strongly
Agree
Agree
Neutral/
Not Sure
Disagree
Strongly
Disagree
OGP Technical Support

Staff knowledgeable about the product
Responses provided in reasonable time
4.
Please indicate whether you have access to this manual.

Is a copy of the manual available for you to use?
5.
User Feedback
Staff helpful and friendly
Yes
No
Please indicate how strongly you agree or disagree with the following statements about this
manual.
Strongly
Agree
Agree
Neutral/
Not Sure
Disagree
Strongly
Disagree
Provides the information I need

Information is easy to find
Information is accurate
Information is well-organized
Writing is clear
Illustrations are clear
Manual has enough examples
Examples are helpful
Instructions are complete
Manuals quality consistent with product
User Feedback
6.
Please identify which parts of the manual you use the most or least, and what you think is still
needed.
What sections of the manual do you refer to most often? ________________________________
What sections of the manual do you refer to least often?
What topics, if any, should be added to the manual?
________________________________
___________________________________
What kinds of quick-reference cards or checklists would be helpful to you? __________________
7.
Please provide any additional comments or suggestions that you may have.
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
If youd like someone from OGP to contact you regarding your comments, please fill in the
information below.
How would you like us to contact you?
Letter
Phone
Fax
E-mail
Your name: ___________________________ Company name: ____________________________

Address:
_______________________________________________________________________
_______________________________________________________________________
Phone No.: _________________________________
Fax:
____________________________
E-mail Address: _____________________________
User Feedback
User Feedback
Are there any functions of your job that this manual doesnt address? _______________________

Documentation Enhancement Request Form
If you find any errors or omissions, or there is additional information that you would like to see
included in the documentation, please specify them on this form and send the form to:
Date:
User Feedback
Marketing Communications Group

850 Hudson Ave.
Rochester, NY 14621
__________________
Manual Name: _____________________________________________________________________

Your Name: _______________________________________________________________________
Company:
_______________________________________________________________________
Address:
_______________________________________________________________________
_______________________________________________________________________
Telephone: ______________________________
Fax:
_______________________________
E-mail Address: __________________________
Page Number
Error/Omission/Additional Information
__________
________________________________________________________________
__________
________________________________________________________________
__________
________________________________________________________________
__________
________________________________________________________________
__________
________________________________________________________________
__________
________________________________________________________________
__________
________________________________________________________________
Thank you for taking the time to help us in our continuing effort to improve OGP documentation.
User Feedback

System/Software Enhancement Request Form
If you have any ideas or suggestions for enhancing OGP products, please specify them on this form
and send the form to:
Date:
User Feedback
Marketing Communications Group

850 Hudson Ave.
Rochester, NY 14621
__________________
Product Name:
_____________________________________________________________________
Your Name: _______________________________________________________________________
Company:
_______________________________________________________________________
Address:
_______________________________________________________________________
_______________________________________________________________________
Telephone: ______________________________
Fax:
_______________________________
E-mail Address: __________________________

You may describe the enhancement and make any additional comments below. Please be as specific as
possible.
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Thank you for taking the time to help us in our continuing effort to improve OGP products.
User Feedback
Accessories, spare parts, 10-6

Advanced diagnostics, Measure-X systems
Focus, 5-16
Servos, 5-17
SmartRing, 5-25
Stage, 5-23
Video, 5-18
Video intensity histograms, 5-21
Video noise test, 5-20
Video screen intensity, 5-22
Video standard test, 5-19
Cabinet, cleaning, 4-5

Cabling system components, 2-6
Cards, computer
QVI video capture card, 3-4
CAUTION, ESD, definition of, v
CAUTION, marked on OGP equipment,
definition, x
Cover, post Y axis, location, 9-9, 9-14
Cover, Y axis, location, 9-9, 9-14
Customer service, vi
Index
Index
D
B
Backing up parameters, 4-7
Basic diagnostics, Measure-X systems
AccuCentric light level, 5-13
Dialog box, 5-11
Dialog box buttons, 5-13
Enable graphics for tools, 5-12
Block diagram, functional
Computer, 3-3
DSP Multi Axis board, 3-6
System, 3-2
Video/motion subsystem, 3-5
Boot sequence, abnormal
Missed index pulse, 5-6
Powering up on limit, 5-7
Boot sequence, normal, 5-2
Index
DANGER, marked on OGP equipment,

definition, x
Description, system, 3-1
Diagnostics, 5-1
Diagnostics, MeasureMind 3D systems, 5-27
Board and control panel, 5-27
Accessing, 5-28
Potentiometer, 5-29
Servo, 5-30
Video, optics, and stage, 5-32
Accessing, 5-32
Set diagnostics dialog box, 5-33
Diagnostics, Measure-X systems, 5-10
Accessing advanced diagnostics, 5-14
Accessing basic diagnostics, 5-10
Dimensions, 2-2
Documentation conventions, iv
Drewire terminations, 5-54
DS5, 5-48
DS7, 5-37, 5-39

DSP board
Diagnostic LEDs, 5-34
Function within the system, 3-6
Test points, 5-40
E
Electrical components, replacing
DSP Multi Axis board, 7-2
Electronics exhaust fan, 7-15
Interconnect board, 7-7
LED Driver board, 7-5
Micro Theta Control board, 7-11
Power supply, 7-13
Universal Multi-Sensor board, 7-9
Electrical components, spare parts, 10-5
Electrical requirements
Circuit breakers, 2-5
Supply cable, 2-4
Electrostatic Discharge (ESD), v
E-mail address, OGP, vi
Environment, recommended, 2-8
E-Stop codes, 5-37
F
FAX number, OGP, vi
Files, backing up, 4-6
Files, deleting obsolete, 4-6
Format, Parts List, 10-2
Functional description, 3-1
G
General Characteristics, definition,
Parts List(s), 10-2
H
Hard disk drive, maintaining, 4-7
How to
Back up files, 4-6
Clean external surfaces, 4-5
Clean the SmartRing Light, 4-8
Clean the stage, 4-5
Clean the stage glass, 4-4
Clean the Zoom lens, 4-9
Contact OGP, vi
Delete obsolete files, 4-6
Lock out the system, xv
Maintain the hard disk drive, 4-7
Maintain the X axis stage transport, 4-11
Maintain the Y axis stage transport, 4-14
Order parts, 10-1
Remove the optics cover, 8-2
Replace the DSP board, 7-2
Replace the electronics exhaust fan, 7-15
Replace the Interconnect board, 7-7
Replace the LED Driver board, 7-5
Replace the Micro Theta Control board, 7-11
Replace the power supply, 7-13
Replace the SmartRing Light, 8-4
Replace the Universal Multi-Sensor board, 7-9
Replace the video camera, 8-5
Replace the X axis read head, 9-9
Replace the Y axis read head, 9-14
Replace the Z axis motor, 9-2
Replace the zoom lens assembly, 8-6
I
Illumination, spare parts, 10-3
Imaging components, replacing
SmartRing Light, 8-4
Video camera, 8-5
Zoom lens assembly, 8-6
Index pulse, missed, 5-6
Index
Installation, 2-8
Interconnect board, 5-43
Test points, 5-49
Internet address, OGP, vi
Item Designation, definition, Parts List(s), 10-2
J
Joystick, troubleshooting, 6-27
Maintenance, preventive (continued)

SmartRing Light, optional, cleaning, 4-8
X axis stage transport, lubricating, 4-11
Y axis stage transport, lubricating, 4-14
Z axis transport, lubricating, 4-16
Zoom lens, cleaning, 4-9
Manual, intended audience, ii
Manual, use of, prerequisite knowledge, iii
Markings, Safety, on OGP equipment, x
MeasureMind 3D diagnostics, 5-27 - 5-28
Measure-X diagnostics, 5-10
Mechanical, spare parts, 10-4 - 10-5
Micro Theta Control board, replacing, 7-11
Motherboard, computer, 3-4
Laser Institute of America, xiv

Laser safety guidelines, xiii
Lead screw, Z axis, location, 4-16
LED Drive board
LED Driver board
Test Points, 5-53
LEDs, flashing, DSP board, 5-37
Lens attachments, cleaning, 4-9
Lights shutdown mode, 3-8
Lockout sequence, before servicing, xv
M
Magnetic limit codes, 5-39
Maintenance schedule, recommended, 4-1 - 4-2
Maintenance, in harsh environment, 4-1
Maintenance, preventive
Calibration and alignment, 4-17
Files, backing up, 4-6
Files, deleting obsolete, 4-6
Hard disk drive, 4-7
Lens attachments, cleaning, 4-9
SmartRing Light, LEDs, failure of, 4-8
Index
Index
L
O
Operating environment, 2-1
Optics cover, removing, 8-2
Optics, spare parts, 10-3
Options, spare parts, 10-6
Organization, Manual, i
P
Paint thinners, risk of, 4-5
Parameters, backing up, 4-7
Part Number, definition, Parts List(s), 10-2
Parts List format, 10-2
Parts, how to order, 10-1
Parts, spare, 10-1
Phone number, OGP, vi
Post Y axis cover, location, 9-9, 9-14
Power supply, troubleshooting, 6-31
Powers up on limit, dialog box, 5-7
Preventive maintenance, 4-1
Q
Qty, definition, Parts List(s), 10-2
Quadrature, 5-36
R
Read head
X axis, replacing, 9-9
Y axis, replacing, 9-14
Recommended operating environment, 2-8
Related publications, iii
Renishaw limit codes, 5-39
Requirements
Circuit breakers, 2-5
Electrical supply cable, 2-4
Workbench, 2-1
S
Safety guidelines
Accessories, improper, ix
Before servicing, viii
Covers/panels, viii
Fuses, viii
Laser, xiii
Liquids, ix
Operating environments, unsafe
Explosive atmosphere, ix
Medical, ix
Radioactive (nuclear), ix
Power cord, vii
Power/grounding, vii
SmartRing Light, xii
Stage glass, viii
Safety labels
Laser, xiv
On SmartScope CNC/Flash 250, xi
Safety markings, on OGP equipment, x

Service access, recommended, 2-3
Service Department, OGP, contacting, 10-1
Service Log, A-1
Set Diagnostics, dialog box, 5-32
Set screws, stage glass, location, 4-4
Shutdown mode, 3-8
SmartRing Light
Electrical safety, xii
Replacing, 8-4
Safety guidelines, xii
Viewing LEDs, xii
SmartRing Light, LEDs, failure of, 4-8
SmartRing Light, optional, cleaning, 4-8
SmartScope CNC/Flash 250, description of, 1-1
Solvents, risk of, 4-5
Space requirements, 2-2
Spare parts, 10-1
Stage glass, cleaning, 4-4 - 4-5
Static, ESD protection, v
Symbol, CAUTION, v
Symbol, WARNING, v
Symbols, marked on OGP equipment, x
System boot diagnostics, 5-1
System boot sequence, normal, 5-2
System LEDs, 5-48
T
Technical support, vi
Troubleshooting the joystick, 6-27
Transport components, replacing
X axis read head, 9-9
Y axis read head, 9-14
Z axis motor, 9-2
Transport, spare parts, 10-4
Index
Troubleshooting, 6-1
Illumination, 6-8
Motion, 6-13
Power supply, 6-31
Power-up, 6-3
Video, 6-22
Type Designation, definition, Parts List(s), 10-2
Y
Y axis cover, location, 9-9, 9-14
Y axis rails, inboard, accessing, 4-15
Y axis rails, outboard, accessing, 4-14
Y axis stage transport, cleaning/lubricating, 4-14
Z
U
Universal Multi-Sensor board, replacing, 7-9
User components, spare parts, 10-3
Z axis lead screw, location, 4-16

Z axis motor, replacing, 9-2
Z axis transport, lubricating, 4-16
Zoom lens assembly, replacing, 8-6
Zoom lens, cleaning, 4-9
Index
V
Video camera, replacing, 8-5
Video, advanced diagnostics, 5-19
Video/motion subsystem, 3-5
W
Water, risk of spillage, 4-5
Workbench requirements, 2-1
World Wide Web address, OGP, vi
Wrist strap, ESD protection, v
X
X axis rails, outboard, accessing, 4-11
X axis read head, replacing, 9-9, 9-14
X axis stage transport, cleaning/lubricating, 4-11
Index
Optical Gaging Products Inc.

A Quality Vision International Company
World Headquarters and Technology Center

850 Hudson Avenue Rochester, New York 14621-4896 USA
Telephone: 1.585.544.0400 Fax: 1.585.544.0131 Customer Center Fax: 1.585.544.8092
Western USA Regional Office
615 South Madison Drive Tempe, AZ 85281 USA
Telephone: 1.602.882.1600 Fax: 1.480.921.3375
OGP Metechnik GmbH
Nassaustr. 11 65719 Hofheim-Wallau GERMANY
Telephone: 49.6122.9968.0 Fax: 49.6122.9968.20
Optical Gaging (S) Pte Ltd
21 Tannery Road SINGAPORE 347733
Telephone: 65.67.41.8880 Fax: 65.68.46.8998
OGP Shanghai Co, Ltd
17 Lane 593 East Jin An Road Pu Dong New District Shanghai 201204 CHINA
Telephone: 86.21.5045.8383/8989 Fax: 86.21.6845.8800

SmartScope CNC-Flash 250 Service and Maintenance Manual

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Part No. 790451

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For Your Safety

SmartScope CNC/Flash 250 Service and Maintenance Manual Table of Contents

Section 2: Operating Environment

Section 3: System Description

Section 4: Preventive Maintenance

SmartScope CNC/Flash 250 Service and Maintenance Manual Table of Contents

File and Hard Disk Drive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

SmartScope CNC/Flash 250 Service and Maintenance Manual Table of Contents

Section 7: Replacing Electrical Components

Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Section 8: Replacing Imaging Components

Section 9: Replacing Transport Components

Section 10: Spare Parts

Appendix: Service Log

SmartScope CNC/Flash 250 Service and Maintenance Manual Table of Contents

This page was left blank intentionally.

SmartScope CNC/Flash 250 Service and Maintenance Manual Table of Contents

About This Manual

About This Manual

Section 5, Diagnostics, describes several means of diagnosing problems which

Who Should Read This Manual?

Parts ordering and/or replacement

About This Manual

Routine use of the SmartScope CNC/Flash 250

Basic electrical and mechanical terminology

Common electro-mechanical repair procedures

How to read and interpret troubleshooting and wiring diagrams

Before using this manual, you should be familiar with:

SmartScope CNC/Flash 250 Hardware Installation Guide (P/N 790450)

Measure-X FastStart Guide (P/N 790280)

Measure-X Reference Guide (P/N 790230)

MeasureMind 3D MultiSensor FastStart Guide (P/N 790321)

MeasureMind 3D MultiSensor Reference Guide (P/N 790322)

SmartScope Flash/Flare Calibration and Alignment Manual (Measure-X

SmartScope Flash/Flare Calibration and Alignment Manual (MeasureMind

Touch Probe Users Guide (P/N 790380)

DRS Laser Users Guide (P/N 790309)

DRX Laser Users Guide (P/N 790356)

Wiring Diagram, Interconnect, for SmartScope CNC/Flash 250

Application training to use and run SmartScope CNC/Flash 250

Service training for preventive maintenance, calibration, troubleshooting

About This Manual

Do not repeat this step

Menu items to be selected

SELECT THE CORNER WITH

Use the Measure function

Bold, all caps,

About This Manual

WARNING: Warns you of the possibility of other personal injury when

Note: Provides additional information related to the topic being discussed.

About This Manual

Special Symbols Used in this Manual

Technical Support and Customer Service

Hardware service contracts for cleaning, general inspection, preventive

Software support contracts with updates of software products, application

For more information, call (585) 544-0400.

If You Need Help

By phone at (585) 544-0400

By FAX at (585) 544-8092 (Sales) or (585) 544-4998 (Service)

By e-mail at sales@ogpnet.com or service@ogpnet.com

On the Internet at http://www.ogpnet.com