Exelis TSB Carts

Instruction M anual

Main
Menu

M ain M enu
Machine Layout
Tower Device
Layout
HMI Screen
Layout
HMI Screen
Details
TSB Leveling
Operations
Drive Error Codes

Cover
Page

Exelis TSB Carts

M achine Layout

Tow er 1
X-D RIVE200
Y-D RIVE145

LED Light Tower

Main
Menu

ES509
Cart Alignm ent
PE Array

Tow er 3
X-D RIVE400
Y-D RIVE345

ES547

Tow er 2
X-D RIVE300
Y-D RIVE245

ES570

Tow er Layout
E-Stop Pushbutton
Internal Sensors
Y-Axis Upper HW
Limit PX
X-Axis Upper HW
Limit PX

Y-Axis
D RIVE145
D RIVE245
D RIVE345

Main
Menu

X-Axis
D RIVE200
D RIVE300
D RIVE400

X-Axis Lower HW
Limit PX
Y-Axis Lower HW
Limit PX

Tower 1 Only
Cart Alignment PE Array

H M IScreen Layout
M ain Screen

Main
Menu

Auto M ode

M anualControl

E-Stop Screen

Cart Alignm ent

D rive Error
Settings

D rive Position
Settings

H om ing
System Status

D rive I/O Status

Main
Menu

H M IScreen D etails
Main Screen

Settings

Auto Mode

Drive Settings
Drives)
Drive Settings
(DRIVE145)
Drive Settings
DRIVE345)
System
Status
Homing

Manual Control
Cart Alignment
E-Stop
Drive Error

X-Axis (All
Y-Axis
Y-Axis (DRIVE245 &
Drive I/O
Status

TSB Leveling

1. Prepping the TSB Cart

Align cart
Verify cart ID # and cart color
In Auto Mode, screen begin a load process
Once the process has reached step 18, exit auto mode and go to the settings screen to
continue
Using the machine center move to tower 1 to begin leveling process
Use the machine centers vertical value as your zero
This can be achieved by using the machine center and a calibration tool
Manually drive the machine center to touchdown at the center of the TSB near tower 1
(DRIVE145)
Record the vertical position of the TSB at tower 1
2. Manually drive the machine center to the closest point near tower 2 on the TSB
Calculate the difference between your zero point and point #2
Adjust the towers vertical position in the drive settings screen (DRIVE245)
Press and hold the Execute Position Upper PB on the Drive Settings screen to automatically
move the tower to the new desired position
Once the In Target Light illuminates, release the PB and verify the position using the
machine center
Repeat until tower 2 is at the correct vertical position to be level with the zero point
3. Move the machine center back to your zero point (Tower 1) to verify that the zero point has not
changed due to tower 2 or 3 adjustments
4. Repeat steps 2 &3 on tower 3 (DRIVE345)
5. Once the three points on the TSB are level navigate to the manual control screen and use these
controls to place the cart back on the ground and unclamped
Note: Tower 1 (DRIVE145) vertical position setting moves all three towers when changed
This can be used to adjust overall height of the TSB cart

Main
Menu

M ain Screen

HMI Screen
Details

Open screen selection buttons.

Auto Select to open the Auto Mode screen. Which is used during
standard production operations.
Settings Select to open the drive settings screen (Adjust drive
positions and speeds).
Manual Select to open control screen for manual operations.
Status Select to open the screen to view the system and drive I/O
statuss.
Drive Error Select to open the error handling screen.
Homing Select to open homing operations screen.
Cart Alignment Select to open the cart alignment viewing screen.

Status displays on Main Screen

(Each display shows Green if the status is good and Red if bad)
E-Stop Status Displays current emergency stop status. If ready for
operation it will be GREEN, if not it will be RED.
System OK Displays the system error status (Drive Errors and Drive
Safetorque OFF).
Drives Ready Displays the homing status of the drives.
Cart ID Displays the current loaded carts ID #.
X Y Positions Displays the current drive position.
Each tower has a Green/Red display on them to show the current EStop pushbutton status for the corresponding button.
Additionally, an error message banner will display a drive error if one
is active.

Auto M ode

HMI Screen
Details

Command Pushbuttons
Back Select to return to previous screen.
Load Press to start or Pause the auto load operation.
Unload Press to start or Pause the auto unload operation.

Status Displays
(Each display shows Green if the status is good, Red if bad and Grey if off)
Auto Mode Active Logic is active for auto Load/Unload operations.
Auto Mode Paused Press Load/Unload to resume Displays the current
operations pause status.
E-Stop Status Displays current emergency stop status.
System OK Displays the system error status (Drive Errors and Drive
Safetorque).
Drives Ready Displays the homing status of the drives.
Load Complete The Load operation has completed and the TSB is
ready for Machine operation.
Machine Interlock Displays the output status to the Fooke machine
center to enable machine operations.
Tower Movement Locked Input from Fooke machine displaying tower
lockout status (Machine in operation).
Cart ID Displays the current loaded cart ID #.
X Y Positions Displays the current drive position.
Each tower has a Green/Red display on them to show the current E-Stop
pushbutton status for the corresponding button.
Each screen will show the current loaded cart and the carts color based
on the cart ID #, if the cart ID is 0 then it will display No Cart
Loaded.

M anualControl

HMI Screen
Details

Command Pushbuttons
Back Select to return to previous screen.
All Towers Up Manually engage all Y-axis drives in positive travel
direction.
All Towers Down Manually engage all Y-axis drives in negative travel
direction.
All Towers Clamp Manually engage all X-axis drives in positive travel
direction.
All Towers Up Manually engage all X-axis drives in negative travel
direction.
(Tower 1) UP Engage DRIVE145 positive direction
(Tower 1) DW Engage DRIVE145 negative direction
(Tower 1) CLAMP Engage DRIVE200 positive direction
(Tower 1) UNCLAMP Engage DRIVE200 negative direction
(Tower 2) UP Engage DRIVE245 positive direction
(Tower 2) DW Engage DRIVE245 negative direction
(Tower 2) CLAMP Engage DRIVE300 positive direction
(Tower 2) UNCLAMP Engage DRIVE300 negative direction
(Tower 3) UP Engage DRIVE345 positive direction
(Tower 3) DW Engage DRIVE345 negative direction
(Tower 3) CLAMP Engage DRIVE400 positive direction
(Tower 3) UNCLAMP Engage DRIVE400 negative direction

Status Displays
X Y Positions Displays the current drive position.
Additionally, an error message banner will display a drive error if one is
active

Cart Alignm ent

HMI Screen
Details

Command Pushbuttons
Back Select to return to previous screen

Status Displays
(Each display shows Green if the status is good, Red if bad and Grey if off)
LED Red Light tower stack light (E-Stop/Drive Error)
LED Amber Light tower stack light (Cart alignment indication)
LED Green Light tower stack light (System status, on if status is good)
Cart ID - Displays the current cart ID #
PE Array (Used to determine cart ID #)
1- DRIVE145 DI:3
PE517
2- DRIVE145 DI:4
PE520
3- DRIVE145 DI:5
PE522
4- DRIVE145 DI:6
PE524
5- DRIVE200 DI:3
PE527
6- DRIVE200 DI:4
PE529
Each screen will show the current loaded cart and the carts color based
on the cart ID #, if the cart ID is 0 then it will display No Cart
Loaded.
Additionally, an error message banner will display a drive error if one is
active

D rive Error

HMI Screen
Details

Command Pushbuttons
Back Select to return to previous screen.
(DRIVE145) Reset Error Resets DRIVE145s current error.
(DRIVE245) Reset Error Resets DRIVE245s current error.
(DRIVE345) Reset Error Resets DRIVE345s current error.
(DRIVE200) Reset Error Resets DRIVE200s current error.
(DRIVE300) Reset Error Resets DRIVE300s current error.
(DRIVE400) Reset Error Resets DRIVE400s current error.

Status Displays
(Each display shows Green if status is good and Red if bad)
(DRIVE145) Fault Status Shows current fault state.
(DRIVE245) Fault Status Shows current fault state.
(DRIVE345) Fault Status Shows current fault state.
(DRIVE200) Fault Status Shows current fault state.
(DRIVE300) Fault Status Shows current fault state.
(DRIVE400) Fault Status Shows current fault state.
(DRIVE145) Fault Code Displays the current fault numerical code
(DRIVE245) Fault Code Displays the current fault numerical code
(DRIVE345) Fault Code Displays the current fault numerical code
(DRIVE200) Fault Code Displays the current fault numerical code
(DRIVE300) Fault Code Displays the current fault numerical code
(DRIVE400) Fault Code Displays the current fault numerical code
Additionally, an error message banner will display a drive error if one is
active

HMI Screen
BAD)
E-St(THIS
op SCREEN WILL APPEAR AUTOMATICALLY IF THE E-STOP STATUS ISDetails
Command Pushbuttons
Back Select to return to previous screen.
Press to Reset Safety Controller Resets safety outputs of the SC22-3E
safety controller all E-Stop pushbuttons must be cleared.

Status Displays
(Each display shows Green if status is good and Red if bad)
Cart ID Displays current cart ID #.
E-Stop Status Displays current system E-Stop Status (IF all E-Stops are
green safety controller will need to be rest before this status will be
green)
ES509 Displays ES509s current status (If e-stop pushbutton is
depressed then display will be red)
ES547 Displays ES547s current status (If e-stop pushbutton is
depressed then display will be red)
ES570 Displays ES570s current status (If e-stop pushbutton is
depressed then display will be red)
X Y Positions Displays the current drive position.
Additionally, an error message banner will display a drive error if one is
active

System Status

HMI Screen
Details

Command Pushbuttons
Back Select to return to previous screen.
E-Stop Screen Select to go to the E-Stop handling screen.
DRIVE145 I/O Status Select to view DRIVE145s current state and I/O.
DRIVE245 I/O Status Select to view DRIVE245s current state and I/O.
DRIVE345 I/O Status Select to view DRIVE345s current state and I/O.
DRIVE200 I/O Status Select to view DRIVE200s current state and I/O.
DRIVE300 I/O Status Select to view DRIVE300s current state and I/O.
DRIVE400 I/O Status Select to view DRIVE400s current state and I/O.

Status Displays
(Each display shows Green if status is good and Red if bad)
Light Tower Actual Displays Status
Top - LED Red = E-Stop/ Drive Error
Middle - LED Amber = Cart Centering Indication
Bottom - LED Green = System OK
General System Status
E-Stop Status (Safety Controller Status)
System OK (System Error Status)
Drives Ready (Homing)
Auto Mode Active (Displays the current auto mode state, Step number
> 0)
Drives Fault State
Drives Home Done (Drive Home Position Known)
Additionally, an error message banner will display a drive error if one is
active

D rive I/O Status (AllD rives)

HMI Screen
Details

Command Pushbuttons
Back Select to return to previous screen.

Status Displays
(Each display shows Green if status is good, Red if bad and Grey if off)
Digital Inputs Displays the current input status of the drive I/O.
Digital Outputs Displays the current output state of the drive I/O.
Drive Status Displays the status bits of the drive.
Fault Code Displays the current drive error numerical code.
Position Actual Displays the drives actual position.
Additionally, an error message banner will display a drive error if one is
active

Each Drive I/O Screen has the same layout

H om ing

HMI Screen
Details

Command Pushbuttons
Back Select to return to previous screen.
Start Homing (DRIVE145) Engages the homing sequence for
DRIVE145.
Start Homing (DRIVE245) Engages the homing sequence for
DRIVE245.
Start Homing (DRIVE345) Engages the homing sequence for
DRIVE345.
Start Homing (DRIVE200) Engages the homing sequence for
DRIVE200.
Start Homing (DRIVE300) Engages the homing sequence for
DRIVE300.
Start Homing (DRIVE400) Engages the homing sequence for
DRIVE400.

Status Displays
(Each display shows Green if status is good, Red if bad and Grey if off)
Home Done Displays the drives home known status.
Drive Busy Displays the current operation status of the drive (Drive is
running)
Pos Act Displays the drives current location (If the home is unknown
then the drive position will display incorrect values)
Additionally, an error message banner will display a drive error if one is
active

Settings

HMI Screen
Details

Command Pushbuttons
Back Select to return to previous screen.
Tower 1 X Axis Drive200 Select to view the position settings for
DRIVE200.
Tower 1 Y Axis Drive145 Select to view the position settings for
DRIVE145.
Tower 2 X Axis Drive300 Select to view the position settings for
DRIVE300.
Tower 2 Y Axis Drive245 Select to view the position settings for
DRIVE245.
Tower 3 X Axis Drive400 Select to view the position settings for
DRIVE400.
Tower 3 Y Axis Drive345 Select to view the position settings for
DRIVE345.
Save And Exit Select this to save the current position values.
Exit Without Save Select this to exit this screen without performing a
save operation (The settings that have been entered will stay active
until the system is powered down then they will be replaced with the
previously saved values)
Discard Change And Exit Select this to read the previous position
values from the save file.
Status Displays
(Each display shows Green if status is good, Red if bad and Grey if off)
Pos ACT X/Y Displays the drives current position.
Home Done Displays the drives home known status.
IN Target Displays the drive in target status.

HMI Screen
Details

D rive Position Settings

Command Pushbuttons
(X-Axis D rives)
Back Select to return to previous screen

Manual UnClamp Engage Drive in negative direction

Manual Clamp Engage Drive in positive direction
Selected Cart # - Numeric entry box to select the cart number of the
positions to change
Drive Torque % - Numeric entry box to select the drives torque percent
(Drive torque entry can only be set in a range of 50-100%)
(Negative travel position) Numeric entry box to enter the new drive
Unload position for the selected Cart ID
(Positive travel position) Numeric entry box to enter the new drive
Load position for the selected Cart ID
Manual/Auto Speed Numeric entry box for the drive Manual/Auto
control speed (Drive speed is measured on a scale of 0-15000 with
15000 being 100%)
Manual/Auto Accel/Decel - Numeric entry box for the drive Manual/Auto
control acceleration and deceleration (Drive Accel/Decel is measured on
a scale of 0-1500 with 1500 being 100%)
Position Execute Upper This engages the auto movement for the drive
to the selected upper target position
Position Execute Lower This engages the auto movement for the drive
to the selected Lower target position
Status Displays
Drive Position Actual Displays the drive Current Location
Additionally, an error message banner will display a drive error if one is
active

HMI Screen
Details

D rive Position Settings

Command Pushbuttons
(Y-Axis D RIVE145)
Back Select to return to previous screen

Manual Down Engage Drive in negative direction

Manual UP Engage Drive in positive direction
Selected Cart # - Numeric entry box to select the cart number of the
positions to change
Drive Torque % - Numeric entry box to select the drives torque percent
(Drive torque entry can only be set in a range of 50-100%)
(Negative travel position) Numeric entry box to enter the new drive
Unload position for the selected Cart ID
(Positive travel position) Numeric entry box to enter the new drive
Load position for the selected Cart ID
Manual/Auto Speed Numeric entry box for the drive Manual/Auto
control speed (Drive speed is measured on a scale of 0-15000 with
15000 being 100%)
Manual/Auto Accel/Decel - Numeric entry box for the drive Manual/Auto
control acceleration and deceleration (Drive Accel/Decel is measured on
a scale of 0-1500 with 1500 being 100%)
Position Execute Upper This engages the auto movement for the YAxis drives to the selected upper target position
Position Execute Lower This engages the auto movement for the YStatus Displays
Axis drives to the selected Lower target position
Drive Position Actual Displays the drive Current Location
Additionally, an error message banner will display a drive error if one is active
IN Target This displays the current drive position in target value (If the drive is currently in the desired target position this
will illuminate Green)
Individual Y-Axis Drive IN Target Displays - This displays the current drive position in target value (If the drive is currently in

D rive Position Settings

(Y-Axis D RIVE245 & D RICommand
VE345)
Pushbuttons

HMI Screen
Details

Back Select to return to previous screen

Manual Down Engage Drive in negative direction
Manual UP Engage Drive in positive direction
Selected Cart # - Numeric entry box to select the cart number of the
positions to change
Drive Torque % - Numeric entry box to select the drives torque percent
(Drive torque entry can only be set in a range of 50-100%)
(Negative travel position) Numeric entry box to enter the new drive
Unload position offset for the selected Cart ID
(Positive travel position) Numeric entry box to enter the new drive
Load position offset for the selected Cart ID
Manual Speed Numeric entry box for the drive Manual/Auto control
speed (Drive speed is measured on a scale of 0-15000 with 15000
being 100%)
Manual Accel/Decel - Numeric entry box for the drive Manual/Auto
control acceleration and deceleration (Drive Accel/Decel is measured on
a scale of 0-1500 with 1500 being 100%)
Position Execute Upper This engages the auto movement for the YAxis drives to the selected upper target position
Status Displays
Position Execute Lower This engages the auto movement for the Y Drive Position Actual Displays the drive Current Location
Axis drives to the selected Lower target position
Drive Current Position Offset This will display the drives offset position from tower 1 (DRIVE145)
Additionally, an error message banner will display a drive error if one is active
IN Target This displays the current drive position in target value (If the drive is currently in the desired target position this
will illuminate Green)
Individual Y-Axis Drive IN Target Displays - This displays the current drive position in target value (If the drive is currently in

0
11
19
23
25
26
27
31
35
40
44
45
84
26
54
100
101
102
103
104
105
106
107
2818
2819
2820
2822
4864
-5C
4865
4866
4867
4876

D rive

Next
Main
Error Codes
Page5981 ot2: Speed controller
Screen
4879 oH3: Motor temperature (X106) triggered
output limited

No error
Supply voltage
Temperature
Motor management/encoder
I/O integrated
Axis bus
Extension module slot 1
Integrated CAN general
CAN PDO
Device configuration
Parameter set
Device firmw. - internal errors
MotionControlKernel
Device hardware defective
Fieldbus
User error 1
User error 2
User error 3
User error 4
User error 5
User error 6
User error 7
User error 8
Su02: A mains phase is missing
Su03: Too frequent mains switching
Su04: CU is supplied insufficiently
Su06: Mains input overload
oH4: Heatsink temp. > shutdown temp.

oH1: Heatsink overtemperature

oH7: Motor temperature resolver >= C121
oH9: Motor overtemperature resolver
Sd6: Error thermal detector resolver

4884
C121
4885
4886
4914
5889
5895
5902
5903
5904
5905
5912
5914
5915
5916
5917
5918
5919
5920
5921
5944
5945
5946
5947
5948
5949
5950
5953
5959
5962
5963
5978

oH6: Motor temperature MultiEncoder >=

oH12: Motor overtemperature MultiEncoder

Sd12: Error thermal detector MultiEncoder
oC5: Ixt overload
ot1: Maximum torque reached
oC7: Motor overcurrent
oU: DC bus overvoltage
LU: DC bus undervoltage
oC1: Power section - short circuit
oC2: Power section - earth fault
Sd2: Resolver open circuit
Sd7: Error encoder communication
Sd4: MultiEncoder open circuit
Sd9: Status message Hiperface
Sd14: Position invalid Hiperface
oC10: Maximum current reached
oC17: Clamp sets pulse inhibit
oS1: Maximum speed limit reached
oS2: Max. motor speed
Id2: Motor data identification error
Id1: Motor data identification error
Id3: CINH identification
Id4: Resistance identification error
Id7: Motor control different motor data
Id8: Speed sensor not adjusted
Sd8: Encoder angular drift monit.
oC12: I2xt brake resistor overload
oC11: Clamp operation active
Id5: Pole position identification error
Id6: Resolver ident error
oC13: Maximum current for Fch exceeded

5982 FC01: Switching frequency reduction

5983 FC02: Maximum speed for Fchop
5984 oC14: Direct-axis current controller limitation
5985 oC15: Cross current controller limitation
5986 oC16: Torque controller limitation
5987 FC03: Field controller limitation
5993 oC6: I2xt motor overload
6033 LP1: Motor phase failure
6088 Sd10: Speed limit for feedback system 12
6089 Sd11: Speed limit for feedback system 67
6093 Sd3: HTL 2x o.4x open circuit
6094 Sd13: SinCos inexactness
6095 Sd15: HTL 4x open circuit
6096 Sd16: Hiperface-SinCos difference
6401 An01: AIN1_I < 4 mA
6402 An02: AIN2_I < 4 mA
6657 Ab01: Axis bus time out
6658 Ab02: Axis bus-IO fail
6914 CE04: MCI communication error
6927 CE0F: MCI control word
7936 CE4: CAN Bus Off
7942 CA06: CAN CRC error
7943 CA07: CAN Bus Warn
7944 CA08: CAN Bus Stopped
7947 CA0b: CAN HeartBeatEvent
7951 CA0F: CAN control word
8961 CE1: CAN RPDO1
8962 CE2: CAN RPDO2
8963 CE3: CAN RPDO3
8964 CE5: CAN RPDO4
10253
CI01: Module missing/incompatible

D rive Error Codes

11265
11266
11267
11268
11271
11272
11273
11274
11534
11535
11544
11545
11546
11553
11554
11555
11570
11571
11572
21505
21506
21509
21511
21512
21519
position
21568
21657
21658
21659
21660
21709
21711

PS01: No memory module

PS02: Par. set invalid
PS03: Par. set device invalid
PS04: Par. set Mci invalid
PS07: Par. mem. module invalid
PS08: Par. device invalid
PS09: Par. format invalid
PS10: Memory module binding invalid
dF14: SW/HW invalid
dF15: DCCOM CU2 error
dF18: BU RCOM error
dF25: CU RCOM error
dF26: Apl. Watchdog
dF21: BU Watchdog
dF22: CU Watchdog
dF10: AutoTrip Reset
dF50: Retain error
dF51: CuCcr error
dF52: BuCcr error
Ck01: Pos. HW limit switch
Ck02: Neg. HW limit switch
Ck15: Error status sig. brake
Ck03: Pos. SW limit position
Ck04: Neg. SW limit position
Ck14: Target position beyond SW limit
Ck16:
Ck05:
Ck06:
Ck07:
Ck08:
Ck09:
Ck10:

Time overflow manual control

Error following error 1
Error following error 2
Travel range limit exceeded
Home position unknown
Positioning mode invalid
Profile data implausible

Previous
Ck11: Operating modePage
invalid

21713
21718
Ck12: Profile no. invalid
21719
Ck13: Error FB MCKCtrlInterface
6665 dH09: EEPROM power section
6672 dH10: Fan failure
6760 dH68: Adjustment data error CU
6761 dH69: Adjustment data error BU
6762 dH70: ControlUnit different to BaseUnit
13824
CI: Communication interface

Main
Screen

O perations
Cart Alignment
Load Operation
Unload Operation
Manual Control
Homing

Main
Menu

Load O peration

This section will explain the loading sequence. Each tower has an X-axis and a Y-axis drive to allow
it to clamp the cart and pick it up off of the ground to a level plain for the Fook machine center.
Each drive has its own position settings to allow the carts to be adjusted to match the needs of the
machine.

Note: Make sure that the position settings have been entered correctly as to ensure there is no
machine damage attempting to lift the cart.
Make sure the cart is aligned and the position settings for the cart have been entered.
Press the Load pushbutton on the touchscreen or on the remote to begin the operation.
Once initiated the towers will begin traveling to their zero positions if they are not already in
them.
When they reach their zero location the X-axis will begin to extend to clamp the cart for lifting
(The location that the X-axis clamps is -0.25 from the load position entered in the drive settings
to ensure that the cart wont bind between the towers during lifting).
Once the X-axis has reached their positions they will stop.
The Y-axis will now begin to lift the cart off the ground to the desired height (The Y-axis works in
unison by following the master drive, once the slave drives are locked on to the master drive
they will begin their ascent).
Once the Y-axis has reached the desired upper position the X-axis will finish moving to the
clamped position.
If all drives are in the desired loaded position, then an electrical relay will notify the Fook
machine center that the cart is in position and ready.
This will be displayed on the touchscreen with a green indication next to Machine Interlock.
Once the machine has been started the towers controls will be locked until the Fook machine
has completed or canceled.

Operatio
ns

Cart Alignm ent

There are six PEs in the array, typically you will start at PE number 1 and work your way through
them in order from north to south. Each cart has a specific reflector setup to determine the cart ID.
It will reflect the PEs in a binary pattern with a total of 16 different combinations.

In normal operation the load cart sequence starts on the north end of the machine center.
When bringing the cart into the machine center with the tug caddy use the angled floor guides
to align the cart into the center of the towers.
Once the cart has entered the photoelectric sensor array the amber LED on tower 1 will begin to
blink.
Once the cart has triggered PE 2 the amber LED will begin to blink faster, this will continue until
the last PE in the array has been reached.
The amber LED will blink faster and faster the closer the cart is to alignment.
Once PE 6 has been entered the amber LED will go solid to indicate that the cart is properly
aligned with the master tower.
If the cart has passed PE 6 in the array the amber LED will begin to blink again at the fastest
rate.
If the cart continues the amber LED will slow its blink depending on the PE array location of the
cart as it did on entry.
Once the cart is properly aligned and the amber LED is solid the cart ID # will be displayed on
the touchscreen along with the cart color corresponding to the carts ID #.

Operatio
ns

U nload O peration

The unload operation is a mirror image of the load operation it will go backwards through the
load steps until the cart has been successfully set back on the ground.

Once the Fook machine center has released the lock command to the towers the display screen
will then show a green indication next to Tower Movement Locked.
Once the lock has been cleared, you can now use the unload sequence by pressing the Unload
pushbutton on the touchscreen or on the remote.
Once pressed the X-axis towers will release the clamp on the cart by moving -.25 from the load
position.
When the X-axis has completed the move the Y-axis will be engaged.
The Y-axis will begin by locking onto the master tower before beginning descent.
When the Y- axis has reached the lower positions the X-axis will be engaged.
Once engaged the X-axis will finish moving to their unload position so the TSB cart can be
removed from the machine center.

Operatio
ns

H om ing

The homing operation will only be needed if the machine has lost power. If it is needed the
touchscreen will display each drives home known status. Before a homing operation is started, walk
through each tower to make sure that negative travel is clear of obstructions. The homing
operation will lower the drives to the negative HW limit switch to set a zero point for positioning.

Note: Once a homing operation has been done it has the ability to change all of the positions.
Because of the nature of the sensor, it has the ability to trigger at different times during the homing
process. This will cause the positions to change by up to 0.015 of an inch.

Make sure the towers are free of obstructions.

Go to the homing screen and press the Activate Homing pushbutton on the desired drive.
Once pressed the automated process will begin.
The drive will start by moving in the negative travel direction until the lower HW limit has been
reached
Once the HW limit has been triggered the drive will stop and then travel in the positive direction
until it is clear of the negative HW limit switch.
The screen will now display a green indication next to the Home Done.

Operatio
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Operatio
Manual controls can only be used when the touchscreen is in the manual control screen. If a cart is loaded,
you
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M anualControls

will need to take extra caution to not damage the towers or the cart by moving them. The controls are only
limited by the maximum stroke of the ball screws to the hardware limits (Proximity sensors). Each drive has
software limitations (SW Limit) to avoid contact of there corresponding proximity limit sensors. If one of the
hardware limits has been triggered it will fault the drive requiring a reset.

All Towers
All Towers UP Press the corresponding button on the remote or the touchscreen. This will engage all Y-axis
drives in positive travel direction they will stop automatically once they have reached the SW limit.
All Towers DW Press the corresponding button on the remote or the touchscreen. This will engage all Y-axis
drives in negative travel direction they will stop automatically once they have reached the SW limit.
All Towers Clamp Press the corresponding button on the remote or the touchscreen. This will engage all Xaxis drives in positive travel direction they will stop automatically once they have reached the SW limit.
All Towers Unclamp Press the corresponding button on the remote or the touchscreen. This will engage all
X-axis drives in positive travel direction they will stop automatically once they have reached the SW limit.

Individual Tower Controls (Tower selection on the remote is done with the lower left hand dial. To select tower 1
move dial to the A position, for tower 2 move the dial to the B position, for tower 3 move the dial to the A/B
position)

Tower Y-axis The tower can be selected with the remote by turning the dial or by using the touchscreens
individual tower controls.
For positive travel press up arrow on the screen or by pressing the Aux Up on the remote.
For negative travel press down arrow on the screen or by pressing the Aux DW on the remote.
Tower X-axis The tower can be selected with the remote by turning the dial or by using the touchscreens
individual tower controls.
For positive travel press clamp arrow on the screen or by pressing the Aux IN on the remote.
For negative travel press unclamp arrow on the screen or by pressing the Aux Out on the remote.