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Pick and Place Handler Model 8000 User Manual

Version 2.6 February 28, 2011

Exatron, Inc.
2842 Aiello Drive San Jose, California 95111 (408) 629-7600 Tel (800) exa-tron Tel (408) 629-2832 Fax www.exatron.com

Copyright Notice
Copyright 2011 Exatron This document contains proprietary information which is protected by copyright. All rights are reserved. EXATRON MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. The information contained in this document is subject to change without notice.

Table of Contents
List of Figures Chapter 1: Safety, Support and Options
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Exatron Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Lock-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Facilities Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Air Conditioning and Environmental Requirements . . . . . . . . . . . . . . . . . 1-6 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Vacuum/Pneumatic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Uncrating the Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Installing the Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Customer In-House Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Offshore Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Exatron Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Warranty and Support Contracts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Service Contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Preventive Maintenance Contract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Customer Service Support Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 End-of-Life Handler Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Significance of This Manuals Version Number. . . . . . . . . . . . . . . . . . . . . . 1-23 Typographical Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . 1-24 Terms Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Photo Gallery of Optional Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 Optional Accessories and Peripherals Available with Handler . . . . . . . . 1-31

Chapter 2: System Description


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Distinguishing Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Stacker Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Handler Movement Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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Model 8000 Manual

Chapter 2: System Description continued


System Overview continued Stacker Movement Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Tray Loading Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Photographic Display of Tray Loading Process . . . . . . . . . . . . . . . . . 2-6 Tray Unloading Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Key Positions and Distances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 X, Y, and Z Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Home Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Numbering Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Graphic Display of X, Y, and Z Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 How X and Y Distances Are Measured . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Measuring X Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Measuring Y Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 How Z Distances Are Measured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Mechanical Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Lead Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Tray Carriages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Tray Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Smart Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Anti-Vibration Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Main Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 HALT and RUN Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 PC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Serial Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Light Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Pneumatic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Main Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Auxiliary Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 Vacuum Generator with Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 Air Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Support, Lifter, and Tray Clamp Pins. . . . . . . . . . . . . . . . . . . . . . . . 2-37 Gantry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 Mechanical Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 Pneumatic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 Pickup Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Thermal Test Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
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Chapter 2: System Description continued


Tape-and-Reel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Override Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 CE Marking Standard Practice and Options . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Chapter 3: Hardware Setup


Setting Up Your New Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Leveling Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Changing Device Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Replacing the Pickup Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Installing and Aligning the Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Rotating the Laser Umbilical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 How the Adapter Plate and Deck Work to Align the Laser . . . . . . . . . . . . 3-8 Attaching the Laser to the Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Adjusting the Laser Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Adjusting the Laser Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Loading Trays or Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Powering Up the Handler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Powering the Laser System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Shutting Down the Handler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Calibrating Stack Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Calibrating Lifter Bar Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Aligning Carriage with Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Calibrating and Loading a Detaper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Loading the Detaper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Aligning the Detaper with the Path of the Pickup Head . . . . . . . . . . . . . 3-34 Using the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Setting Up a Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Changing Taper Changeover Kit for Different Device Sizes. . . . . . . . . . 3-39 Mounting a Takeup Reel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Mounting a Supply Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Replacing the Tape Track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Loading the Carrier Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Loading the Sealing Tape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 Adjusting the Position of the Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 Adjusting Seal Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 Understanding Blade Sizes and Orientation . . . . . . . . . . . . . . . . . . 3-53 Changing Seal Head Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 Adjusting Seal Heads Lateral Position . . . . . . . . . . . . . . . . . . . . . . 3-56 Adjusting Seal Heads Downward Pressure . . . . . . . . . . . . . . . . . . 3-58 Adjusting Speed of Seal Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 Setting Temperature for Heat Seal Head . . . . . . . . . . . . . . . . . . . . . . . . 3-60

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Model 8000 Manual

Chapter 4: Handler Software Setup


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Switching Between System Computers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Passwords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Windows Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Handler Software Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Changing the Handler Software Password. . . . . . . . . . . . . . . . . . . . . . . . 4-3 Getting Acquainted with the Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Managing Job Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Verifying the Factory-Installed Job File. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Copying the Job File for Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Opening a Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Checking the Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Windows Accessed in Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Settings Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 SettingsWork Mode Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Input Operation Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Job Information Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Run Mode Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 AutoRun Mode Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Tester Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Tester Operation Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Tester Mode Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Rotation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Inspection Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Function Enabling Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Results of Rotation Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 SettingsMotor Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 General Motion Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Home Sequence Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 PID Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 SettingsDelay Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 SettingsSetup Trays Window (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Enable/Disable Input and Output Trays Group Boxes . . . . . . . . . . . . . . 4-31 Tray Setting Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Head Mode Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 SettingsTray Sort Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Double Test Mode Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Tray Setting Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Stop-On-Fail Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Example Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

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02/2011

Chapter 4: Handler Software Setup continued


SettingsThermal Window (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Hot Thermal Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Cold Thermal Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Defrost Thermal Omega Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Understanding Tray and Waffle Pack Numbering . . . . . . . . . . . . . . . . . . . . 4-42 Setting the Number of Rows and Columns in Trays . . . . . . . . . . . . . . . . . . 4-43 Fine Tuning Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 Disabling Pickup Heads and/or Test Sites . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 Calibrating Stacker Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 Calibrating Lifter Bar Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49 Aligning Carriage with Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 Calibrating Positions for Auto Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 Order of Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 Example of Calibrating Distances for Two JEDEC Trays . . . . . . . . . . . . 4-55 Defining X Distances for JEDEC Trays . . . . . . . . . . . . . . . . . . . . . . 4-55 Defining Y Distances for JEDEC Trays . . . . . . . . . . . . . . . . . . . . . . 4-57 Distances Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59 Setting Tray Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60 Calibration Order for Tray Pockets . . . . . . . . . . . . . . . . . . . . . . . . . 4-60 Setting the Pickup Heads X Distance to a Tray Pocket . . . . . . . . . 4-61 Setting the Trays Y Distance for a Tray Pocket . . . . . . . . . . . . . . . 4-63 Comparing the Z Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64 Setting the Z-Put Distance to a Tray Pocket . . . . . . . . . . . . . . . . . . 4-65 Setting the Z-Get Distance to a Tray Pocket . . . . . . . . . . . . . . . . . . 4-67 Setting Test Site Distances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68 Setting the Pickup Heads X Distance to a Test Site Socket . . . . . . 4-68 Setting the Z-Put Distance to a Test Site Socket. . . . . . . . . . . . . . . 4-70 Setting the Z-Get Distance to a Test Site Socket . . . . . . . . . . . . . . 4-71 Setting the Thermal Heads X Distance to a Test Site Socket. . . . . 4-72 Saving the Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Chapter 5: Auto Run


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Halt, Run, and EMO Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Operator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Input Operation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Job Information Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Run Mode Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 AutoRun Mode Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Tester Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Tester Operation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Tester Mode Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
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Contents-5

Model 8000 Manual

Chapter 5: Auto Run continued


Operator Settings continued Rotation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Inspection Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Function Enabling Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Auto Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Window Features Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Statistics Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Auto Run Status Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Time and Count Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Thermal Test Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Wafer to Tray 1 Only Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Process Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Process Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Process for Two Pickup Nozzles and One Test Site . . . . . . . . . . . . 5-19 Process for Two Pickup Nozzles and Two Test Sites . . . . . . . . . . . 5-20 Process for Tester with Multiple Sockets . . . . . . . . . . . . . . . . . . . . . 5-21 Managing Processed Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Ending Auto Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Viewing the Log File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Examples of Auto Run and Log File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Chapter 6: Diagnostics
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Keeping Your Original Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Diagnostics Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 DiagnosticsSensors/Solenoids Check Window . . . . . . . . . . . . . . . . . . . . . 6-3 Pickup Head X Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Trays Y Input/Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Inputs/Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Outputs/Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Light Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Test Socket Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Test Socket Clamp Air Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . 6-15 Thermal Heads Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Thermal Head Air Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Tape Input/Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Taper Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Loading an Inspection File to the Camera . . . . . . . . . . . . . . . . . . . . 6-20 Taper Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Taper Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Tube Input/Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Laser Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
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Chapter 6: Diagnostics continued


DiagnosticsStacker Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Stacker Motor List Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Motor Settings Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Load Sequence Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Home Sequence Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 DiagnosticsZ Motors Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Motor List Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Motor Settings Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Home Sequence Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Test Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 DiagnosticsRotation Motors Window (Optional) . . . . . . . . . . . . . . . . . . . 6-38 DiagnosticsX and Y Motors Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Motor List Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Motor Settings Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Status Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Home Sequence Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Test Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 DiagnosticsGolden Unit Window (Optional). . . . . . . . . . . . . . . . . . . . . . . 6-43 Golden Unit Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Left Pick Head Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Right Pick Head Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Testing Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Testing Status Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 DiagnosticsTray Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 Tray and Z Head List Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 First Pocket Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Last Pocket Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Pick Head Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Test Fine Tune Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Teach Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 I/O Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55 Home Motors/Motors Go To Zero Position Group Box. . . . . . . . . . . . . . 6-55 DiagnosticsTester Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56 Tester Fine Tune Group BoxSelection Area . . . . . . . . . . . . . . . . . . . . 6-57 Tester Fine Tune Group BoxHorizontal Tester Calibration Area . . . . 6-58 Tester Fine Tune Group BoxVertical Tester Calibration Area. . . . . . . 6-60 Rotation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62 Tray Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62 Golden Parts and Precisor/Bucket Group Box . . . . . . . . . . . . . . . . . . . . 6-63 Testing Status Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66 Test Auto Run Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66 Test Auto Run Group BoxAlternate Version . . . . . . . . . . . . . . . . . . . . 6-67
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Contents-7

Model 8000 Manual

Chapter 6: Diagnostics continued


DiagnosticsTester Window continued I/O Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69 Motor Home/Motors Go To Zero Position Group Box. . . . . . . . . . . . . . . 6-69 Cylinders Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70 DiagnosticsThermal Window (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 6-71 Hot Thermal Omega Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72 Cold Thermal Julabo Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73 Ambient Thermal Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74 Defrost Thermal Omega Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74 Calibrate Cold Chiller Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75 Calibrate Room Chiller Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76 DiagnosticsAir Pressure Window (Optional) . . . . . . . . . . . . . . . . . . . . . . 6-78 DiagnosticsCamera Inspection Window (Optional) . . . . . . . . . . . . . . . . . 6-80 Inspection Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 Rotation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83 Tray Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83 Status Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84 First Pocket Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85 Last Pocket Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86 Check Fine Tune Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86 DiagnosticsLaser Window (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87 Set Variable Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87 Mark Position Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88 Status Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90 Mark Testing Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90 DiagnosticsDetaper Window (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91 Fine Tune Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91 Detaper Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93 DiagnosticsTape and Reel Window (Optional) . . . . . . . . . . . . . . . . . . . . 6-94 Fine Tune Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94 Motor Home Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96 Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96 Tape Reel Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97 Test Auto Run Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100 DiagnosticsTube Window (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102 Input Tube Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102 Output Tube Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104 Test AutoRun (Apply Rotation) Group Box. . . . . . . . . . . . . . . . . . . . . . 6-105 Vacuum and Rotation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107 Recovering from Device Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108 DiagnosticsWafer Input Window (Optional) . . . . . . . . . . . . . . . . . . . . . . 6-109 Fine Tune Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109 Wafer Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-110

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Chapter 7: Servicing and Troubleshooting


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Backing Up the Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Cleaning the Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Cleaning or Replacing Suction Cups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Lubricating the Bearing Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Encoders and Readers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Checking Lead Screw/Coupling Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Master and Slave Cool Muscle Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Setting Up a Cool Muscle Motor Controller . . . . . . . . . . . . . . . . . . . . . . . 7-9 Replacing a Cool Muscle Servo Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Programming a Cool Muscle Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Checking Motor Serial Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Air Regulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Checking Incoming Air from the House Supply . . . . . . . . . . . . . . . . . . . 7-20 Checking the Moisture/Dirt Trap in the Air Regulator . . . . . . . . . . . . . . . 7-20 Checking the Air Regulator Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . 7-23 Automatic Air Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Adjusting Air Pressure on the Regulator. . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Adjusting Auxiliary Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Adjusting Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Adjusting Air Pressure on a Digital Pressure Switch . . . . . . . . . . . . . . . 7-27 Unlocking or Locking a Digital Air Pressure Switch . . . . . . . . . . . . . . . . 7-29 Unlocking or Locking SMC Model ITV . . . . . . . . . . . . . . . . . . . . . . . 7-29 Unlocking or Locking SMC Models ISE40 and ZSE40 . . . . . . . . . . 7-30 Changing Settings on a Digital Air Pressure Switch . . . . . . . . . . . . . . . . 7-32 Changing Settings on SMC Model ITV . . . . . . . . . . . . . . . . . . . . . . 7-32 Changing Settings on SMC Models ISE40 and ZSE40 . . . . . . . . . . 7-36 Setting Minimum Air Pressure on SMC Models ISE40 and ZSE40 . 7-38 Vacuum Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Troubleshooting Vacuum Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Vacuum Generators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Vacuum Switches Used with Vacuum Pump . . . . . . . . . . . . . . . . . . 7-43 Checking and Replacing a Vacuum Air Filter . . . . . . . . . . . . . . . . . . . . . 7-43 Adjusting Pickup Nozzle Blow-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Adjusting Blow-Off for Handler Using In-House Air Supply . . . . . . . 7-45 Adjusting Blow-Off for Handler Using Vacuum Pump Air Supply . . 7-45 Cleaning Vacuum Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47 Checking and Setting the Vacuum Generator . . . . . . . . . . . . . . . . . . . . 7-51 Solenoid Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58 Opening the Computer for Part Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-58
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Chapter 7: Servicing and Troubleshooting continued


Fiberoptic Photoelectric Sensor Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 7-61 Taper Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63 Checking Omega Temperature Controller . . . . . . . . . . . . . . . . . . . . . . . . . 7-64 Laser Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69 Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69 Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69 Setting LAN Connections and Required IP Addresses. . . . . . . . . . . . . . 7-69 Testing Network Communication with Peripherals . . . . . . . . . . . . . . . . . 7-75 Remote Handler Control with WebEx . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78 Replacing Exatron Program File with an Upgrade . . . . . . . . . . . . . . . . . . . 7-80 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82 Motors Move Very Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82 Tray Carriage Alignment Is Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83 Tray Clamp Pins Fail to Secure Trays . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83 System Does Not Pick Up Devices Reliably. . . . . . . . . . . . . . . . . . . . . . 7-84 System Noise When Y Gantry Moves . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86 Software Responds With Error Message When Motor Commanded to Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86 Suspended Tray Falls Crooked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88

Chapter 8: Parts List


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Suction Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Vacuum Generator Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Z Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Hose Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Motor Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Guide to the Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Exatron (Part Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Part Quantity Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 List of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Chapter 9: Prints

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Appendix A: Test Interfaces


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Components of Test Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 DUT InterfaceHardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Control InterfaceMethod of Communication . . . . . . . . . . . . . . . . . . . . 10-2 TCP/IP Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 TTL Handler Port Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Start Test Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Sort Test Result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 End of Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Sort to Bin Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Handler Port Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Handler Port Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Serial Port Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Exatron RS-232 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Beginning the Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Starting the Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 After the Test Is Completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Cycle Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Exatron Plus RS-232 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Command Set Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Serial Commands for Multiple Test Sites with One Serial Port . . . . . . . . . 10-18 Command Set Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 Multiple Sockets in Multiple Sites. . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Request for Tester Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 GPIB Test Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 If the Tester Controls the Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 If the Handler Controls the Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 Decimal-Hexadecimal-Binary-ASCII Conversion Table . . . . . . . . . . . . . . 10-25 Setting Up HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 Configuring a Connection Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 Testing Communication Between Handler and Tester . . . . . . . . . . . . . 10-32

Appendix B: System Backup and Recovery


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Setting a Computer to Boot from CD-ROM . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Creating a Secure Zone on the Hard Disk . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 Backing Up a Hard Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 Copying Archive Files to CDs or DVDs . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28 Restoring a Disk or Partition Backup from CD-ROM. . . . . . . . . . . . . . . . . 11-28 Restoring a Backup Under Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40

Index
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List of Figures
Figure 1-1: Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-2: HazardsFingers Near Lifter Pins (Left), Support Pins (Right) . . . . . . . . . . . . . . . Figure 1-3: HazardFingers Near Tray Clamp Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-4: HazardsFingers Near Lifter Underside (Under Main Table) . . . . . . . . . . . . . . . . . Figure 1-5: Air RegulatorIn ON Position (Left), in OFF Position (Center), in OFF Position with Lock (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-3 1-3 1-4 1-5

Figure 1-6: Lockable Disconnect SwitchIn ON Position (Left), in OFF Position with Lock (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Figure 1-7: Context Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Figure 1-8: Drop-Down Arrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 Figure 1-9: Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 Figure 1-10: Input Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 Figure 1-11: Model 8000 with Programmer, Detaper, Lead/Ball Inspection, Laser, and Taper. Figure 1-12: Model 8000 with Thermal Test Sites on the Left . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-13: Model 8000 with Taper on the Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-14: Model 8000 with Preheating Tray and Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-15: Preheating Tray Moving on Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-16: Refrigerated/Heating Circulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-17: Customer-Ordered Tester Moving on Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-18: Another Customer-Ordered Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-19: Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-20: Multiple Pickup Heads; Multiple Inspection Sites . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-21: Lead/Ball Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-22: Device with Balls to Be Inspected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-23: Two Designs of Lead/Ball Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-24: Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-25: Detaper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 1-28 1-29 1-30 1-31 1-31 1-32 1-32 1-34 1-35 1-35 1-36 1-37 1-37 1-38

Figure 1-26: Barcode Reader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38 Figure 2-1: Model 8000-3 with 3 Lanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Figure 2-2: Model 8000-5 with 5 Lanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Figure 2-3: Position of Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Figure 2-4: Pickup Head Over Working Input Tray Separated From Waiting Trays . . . . . . . . . . 2-5 Figure 2-5: Position Before Loading Begins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-6: Lifter Bars Lowered Below Support Height (Step 1) . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-7: Trays Lifted Above Support Pins (Step 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-8: All Trays Lowered to Carriage (Step 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-7 2-7 2-8

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Model 8000 Manual

Figure 2-9: Lifter Pins Retracted; Clamp Pins Extended (Step 4). . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Figure 2-10: Lifter Pins Extended Above Lowest Tray (Step 5). . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-11: Lifter Bars Raised to Lift Extra Trays (Step 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-12: Support Pins Extended (Step 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Figure 2-13: Lifter Pins Retracted (Step 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Figure 2-14: X AxisPickup Heads Moving From Trays to Tester . . . . . . . . . . . . . . . . . . . . . 2-13 Figure 2-15: Z AxisPickup Nozzle Moving to and from Trays or Tester . . . . . . . . . . . . . . . . Figure 2-16: Z AxisStackers Moving Trays to and From Carriage. . . . . . . . . . . . . . . . . . . . . Figure 2-17: Y AxisTrays Moving From Loading to Unloading Stackers . . . . . . . . . . . . . . . Figure 2-18: X Motor Distances Diagram for 3-Tray Handler with 9 Waffle Packs . . . . . . . . . Figure 2-19: Y Motor Distances Diagram for 3-Tray Handler with 9 Waffle Packs . . . . . . . . . Figure 2-20: Suction Cup at Z-Get (Pick Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-21: Suction Cup at Z-Put (Put Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-22: Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-23: Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-24: Linear Motor Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-25: Lead Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-26: Tray Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-27: Waffle Pack with Outline Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-28: Smart BucketsTop View (Left); Front View (Right) . . . . . . . . . . . . . . . . . . . . . Figure 2-29: Anti-Vibration FootTop (Left), Bottom (Right) . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-30: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-31: EMO (Emergency Stop Button) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-32: HALT and RUN Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-33: 24-Volt DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-34: CPU Power Supply Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-35: ATX Power Supply Switched to 115 Volts (Left) and 230 Volts (Right) Input . . Figure 2-36: Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-37: Location of Jumpers and Connectors for PCM-8152 Motherboard . . . . . . . . . . . . Figure 2-38: PET-C06 I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-39: 5000-M42 Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-40: 8000-D14 I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-41: Serial Adapter (Left); Ethernet Switch (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-42: Pickup Assembly Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-43: Light PolesWithout Laser (Left); With Laser (Right) . . . . . . . . . . . . . . . . . . . . Figure 2-44: Main Air Regulator Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2-14 2-14 2-16 2-17 2-18 2-18 2-19 2-20 2-20 2-21 2-22 2-22 2-23 2-24

2-24 2-25 2-25 2-26 2-26 2-27 2-27 2-28 2-29 2-30 2-30 2-31 2-31 2-32 2-33

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List of Figures

Figure 2-45: Air Pressure Switch with Digital Display (Left) and Vacuum Wand Attachment (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-46: Auxiliary Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-47: Vacuum Generators for Multiple Pickup Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-48: Dirty Filter (Left) Versus Clean Filter (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-49: Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-50: Support Pin Retracted (Left) and Extended (Right) . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-51: Lifter Pin Retracted (Left) and Extended (Right). . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-52: Tray Clamp Pin Retracted (Left) and Extended (Right). . . . . . . . . . . . . . . . . . . . . Figure 2-53: X-Axis Linear Motor Track for Pickup Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-54: Reader Head over Gold Strip Encoder for Linear Motor . . . . . . . . . . . . . . . . . . . . Figure 2-55: Cable Chain to Pickup Head (Left); Lead Screw Driving Pickup Head (Right) . . Figure 2-56: Pickup Heads with Infinite Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-57: Multiple Z Pickup Heads on One X Gantry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-58: Preheating Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-59: Left Thermal Head Assembly with Hot, Cold, and Ambient Heads (Left); Right Thermal Head Assembly in Reverse Order (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-60: Hot and Cold Thermal Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-61: Undersides of Thermal Heads with Purge Enclosures (Hot Head on Left, Cold Head on Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-62: Hot Head Descending to Test Site (Left); Hot Head at Test Site (Right) . . . . . . . Figure 2-63: Cold Head Descending to Test Site (Left); Cold Head at Test Site (Right). . . . . . Figure 2-64: Thermal Head Air Pressure Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-65: Reels on Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-66: Tape Track with Sensors and Pickup Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-67: Pressure Roller Block, Seal Head, and Image Sensor . . . . . . . . . . . . . . . . . . . . . . Figure 2-68: Pressure Roller Block (Left); Pinch Roller on Pressure Roller Block (Right) . . . . Figure 2-69: Taper Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-34 2-34 2-35 2-36 2-36 2-37 2-37 2-38 2-39 2-39 2-40 2-41 2-42 2-42 2-43 2-43 2-44 2-44 2-45 2-45 2-46 2-47 2-47 2-48 2-49

Figure 2-70: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 Figure 2-71: Gold Alodine Finish on Interior Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 Figure 2-72: Ferrite EMI Noise Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 Figure 3-1: Anti-Vibration Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Figure 3-2: Screws To Be Loosened When Changing Pickup Head. . . . . . . . . . . . . . . . . . . . . . . 3-4 Figure 3-3: Pickup Heads for Two Sizes of Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-4: Pickup Head Firm Against Tray Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-5: Strain Relief and Umbilical as Shipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-6: Removing Outer Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-7: Rotating Strain Relief 90 Degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-5 3-6 3-6 3-7

Figure 3-8: Strain Relief Mounted at Angle for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

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Model 8000 Manual

Figure 3-9: Laser Adapter Plate and Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Figure 3-10: Laser Attachment Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Figure 3-11: Tightening Laser Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Figure 3-12: Bolts for Height Adjustment on Laser Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Figure 3-13: Laser Head Elevator Crank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-14: Rotational Adjustment Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-15: Dowel on Holder Fits Dowel Hole on Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-16: Tube Held Out Away from Dowel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-17: Tube Snapped Into Place on Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-18: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-19: Front of Computer with Black Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-20: Power Off (Left); Power On (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-21: Shutting Down Windows from the Start Button. . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-22: Selecting the Turn Off Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-13 3-14 3-15 3-15

3-16 3-17 3-17 3-19 3-19

Figure 3-23: Lockable Disconnect SwitchIn ON Position (Left), in OFF Position with Lock (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Figure 3-24: Input/Output Stacker to Stack Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Figure 3-25: Extending Lifter Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Figure 3-26: Calibrating Stack Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Figure 3-27: Checking Lifter Pins/Stack Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Figure 3-28: Input/Output Stacker to Stack Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-29: Calibrating Lifter Bar Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-30: Extending Lifter Pins and Tray Clamp Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-31: Lifter Too Far Out (Left); Lifter Correctly Positioned (Right) . . . . . . . . . . . . . . . Figure 3-32: Lifter Screw Loosened, Lifter Position Adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-33: Tray Carriage REAR Too Far Forward (Left) Versus Correctly Positioned (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-34: Tray Carriage FRONT Too Far Forward (Left) Versus Correctly Positioned (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-35: Input/Output Stacker Lift to Tray Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-36: Aligning Carriage with Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-37: Tape Threading Diagram on Side of Detaper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-38: Detaper Supply Reel Tensioner Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-39: Carrier Tape from Supply Reel Threaded Under Both Rollers . . . . . . . . . . . . . . . Figure 3-40: Tape Window LatchClosed (Left), Opened (Right) . . . . . . . . . . . . . . . . . . . . . . Figure 3-41: Tape Window Raised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-42: Winding Cover Tape Onto Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 3-24 3-25 3-25 3-26

3-26 3-27 3-27 3-28 3-29 3-30 3-30 3-31 3-31 3-32

Figure 3-43: Cover Tape Wound Onto Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Figure 3-44: Tape Sprockets Fitting Over Gear Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

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List of Figures

Figure 3-45: Tape Sprockets Fitting Over Gear Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Figure 3-46: Detaper Locking Screws on Side Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Figure 3-47: Detaper Adjustment Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Figure 3-48: Detaper Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-49: Counting Number of Sprocket Holes Between Pocket CentersBetween Single Pockets (Left), Between Four Pockets (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-50: Model 202 Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-51: Lifting Pressure Roller Arm and Pushing In Keeper Pin . . . . . . . . . . . . . . . . . . . . Figure 3-52: Gap Sensor (Left); Gap Sensor LED Lit (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-53: Locking Hub on Takeup Reel with Alignment Pins. . . . . . . . . . . . . . . . . . . . . . . . Figure 3-54: Center Prongs of Supply Reel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-55: Screws on Side of Tape Track to Be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-56: Tape Track with Part Number and Sample Tape . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-57: Cover Tape Guide Block Assembly Pushed Left . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-58: Guide Block Partly Removed from Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-59: Carrier Tape Under Guide At Bottom Rear of Track . . . . . . . . . . . . . . . . . . . . . . . Figure 3-60: Carrier Tape Under Guide At Top Front of TrackSide View (Left); Top View (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-61: Lifting Pressure Roller Arm and Pushing In Keeper Pin . . . . . . . . . . . . . . . . . . . . Figure 3-62: Tape Under Takeup Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-63: Sealing Tape PlatesOutside (Left), Inside (Right) . . . . . . . . . . . . . . . . . . . . . . . Figure 3-64: Adjustment Collar on Sealing Tape Supply Reel . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-65: Sealing Tape Threaded to Sealing Tape Guide Assembly . . . . . . . . . . . . . . . . . . . Figure 3-66: Model 202 Sealing Tape Threaded to Sealing Tape Guide Assembly (Left); Sealing Tape Threaded Under Guide Block (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-67: Two Widths of Guide BlocksTop View (Left); Bottom View (Right). . . . . . . . Figure 3-68: Placement in Grooves of Guide Blockof Sealing Tape (Left) and Carrier Tape (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-69: Guide Block Partly Removed from Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-70: Guide Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-71: Taper Alignment Knob Above Base Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-72: Two Sizes of Heat Seal Blades: 16mm, Top, and 12mm, Bottom . . . . . . . . . . . . . Figure 3-73: Top Side of Blades As They Slide into Seal Head (Left); Bottom Side of Blades That Contact Tape (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-74: Replacing Heat Seal Head Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-75: Seal Head with Empty Rails for Blade Insertion (Back View) . . . . . . . . . . . . . . . Figure 3-76: Pressure Seal Blade Inserted Partway into RailTop View (Left), Side View (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-77: Six Lateral Adjustment Screws for Seal Head; Thumbscrew for Small Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 3-36 3-38 3-40 3-41 3-42 3-42 3-43 3-44 3-44 3-45 3-46 3-46 3-47 3-47 3-48 3-48 3-49 3-49 3-50

3-50 3-51 3-51 3-53 3-54

3-54 3-55 3-55 3-56 3-57

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Model 8000 Manual

Figure 3-78: Example of Good Tape Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 Figure 3-79: Auxiliary Air Regulator for Seal Head Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 Figure 3-80: Outward-Facing Knob Adjusts Upward Speed; Right Knob Adjusts Downward Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 Figure 3-81: Heater Controller Displaysin Celsius (Left), in Fahrenheit (Right) . . . . . . . . . . 3-60 Figure 4-1: Log On to the Diagnostics Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Figure 4-2: Log On to the Settings Dialog Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Figure 4-3: Changing Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Figure 4-4: Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Figure 4-5: Opening a Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Figure 4-6: Log On to the Settings Dialog Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Figure 4-7: Work Mode Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-8: Work Mode WindowTwo Testers, Two Inspections . . . . . . . . . . . . . . . . . . . . . . Figure 4-9: Work Mode Window3 Inspections at 2 Locations . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-10: Input Operation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-11: Job Information Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-12: Run Mode Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-13: Tester Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-14: Tester Operation Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-15: Tester Mode Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-16: Rotation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-17: Inspection Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-18: Function Enabling Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-19: Motor Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-20: Motor Drop-Down List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-21: Delay Windowwith Thermal Test Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-22: Delay Windowwith Laser and Inspection Options . . . . . . . . . . . . . . . . . . . . . . . Figure 4-23: Delay Windowwith Multiple Input Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-24: Setup Trays Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-25: Enable/Disable Output Trays Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-26: Tray Setting Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-27: Example of Row and Column Layout for Waffle Pack . . . . . . . . . . . . . . . . . . . . . Figure 4-28: Head Mode Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-29: Tray Sort Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-30: Double Test Mode Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-31: Tray Setting Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4-13 4-14 4-14 4-15 4-15 4-16 4-16 4-17 4-17 4-18 4-19 4-22 4-23 4-25 4-26 4-27 4-30 4-31 4-31 4-32 4-32 4-33 4-34 4-34

Figure 4-32: Example of Row and Column Layout for Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Figure 4-33: Stop-On-Fail Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Figure 4-34: Sort Configuration for Three Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

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List of Figures

Figure 4-35: Sort Configuration for Two Trays and Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Figure 4-36: Sort Configuration for Output Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Figure 4-37: Sort Configuration for Multiple Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-38: Sort Configuration for Waffle Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-39: Thermal Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-40: Test Site and Tray Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-41: Waffle Pack Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-42: Tray Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-43: Example of Row and Column Layout for Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-44: Edit Menu Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-45: Z Head and Tester Mode Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-46: Extending Lifter Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-47: Calibrating Stacker Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-48: Checking Lifter Pins/Stacker Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-49: Calibrating Lifter Bar Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-50: Extending Lifter Pins and Tray Clamp Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-51: Lifter Too Far Out (Left); Lifter Correctly Positioned (Right) . . . . . . . . . . . . . . . Figure 4-52: Lifter Screw Loosened, Lifter Position Adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-53: Tray Carriage REAR Too Far Forward (Left) Versus Correctly Positioned (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-54: Tray Carriage FRONT Too Far Forward (Left) Versus Correctly Positioned (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-55: Aligning Carriage with Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-56: X Motor Distances Diagram for 2-Tray Handler . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-57: X Distances for Tray 1 and Head Z1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-58: Y Motor Distances Diagram for 2-Tray Handler . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-59: Y Distances for Tray 1 and Any Pickup Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-60: Order of Calibrating Distances for Multiple Trays. . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-61: First Pocket Group BoxSetting X Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-62: First Pocket Group BoxSetting Y Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-63: Example Z Distances for Test Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-64: Suction Cup at Z-Get (Pick Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-65: Suction Cup at Z-Put (Put Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-66: Pick Head ZSetting Z-Put Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-67: Pick Head ZSetting Z-Get Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-68: Pickup Head X Distance Group BoxWith Socket Grid (Left) and Without (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-69: Z-Put Distance Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-70: Z-Get Distance Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-71: Thermal Heads X Distance Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 4-39 4-40 4-42 4-43 4-43 4-44 4-45 4-46 4-47 4-48 4-48 4-50 4-50 4-51 4-51 4-52 4-52 4-53 4-55 4-56 4-57 4-58 4-61 4-62 4-63 4-64 4-65 4-65 4-66 4-67 4-68 4-70 4-71 4-72

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Model 8000 Manual

Figure 4-72: Saving to a Different File Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73 Figure 4-73: Saving File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74 Figure 5-1: EMO (Emergency Stop) Button (Left); HALT Button Depressed (Right) . . . . . . . . 5-1 Figure 5-2: Work Mode Window in Operator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Figure 5-3: Tester Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Figure 5-4: Tester Mode Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-5: Rotation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-6: Inspection Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-7: Function Enabling Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-8: Lot Information Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5-5 5-5 5-6 5-8

Figure 5-9: Auto Run Window During Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Figure 5-10: Auto Run Window Initial AppearanceHandler Using Inspection and Output Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Figure 5-11: Auto Run WindowHandler Using Thermal Heads . . . . . . . . . . . . . . . . . . . . . . . 5-11 Figure 5-12: Thermal Test Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Figure 5-13: Auto Run WindowHandler Using Tester with Multiple Sockets . . . . . . . . . . . . 5-16 Figure 5-14: Auto Run Window During RunHandler Using Inspection and Output Tubes . . Figure 5-15: Auto Run Window During RunHandler Using Thermal Testing and Multiple Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-16: Auto Run Initial Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-17: Request for Confirmation to Quit Auto Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-18: Opening Windows Explorer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-19: Log File with Serial Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-20: Auto Run Initial Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-21: Messages Showing Start of Auto Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-22: Run Halted After 11 Devices Processed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-23: Log File from First Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 5-18 5-19 5-22 5-23 5-24 5-25 5-26 5-27 5-28

Figure 5-24: Auto Run Re-entered After Going Back to Main Window . . . . . . . . . . . . . . . . . . 5-29 Figure 5-25: List of Log Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Figure 5-26: Log File from Second Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Figure 6-1: Log On to the Diagnostics Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Figure 6-2: Example of Drop-Down Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Figure 6-3: Sensors/Solenoids Check WindowX Input/Output. . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-4: Input/Output Check WindowX Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-5: Vacuum Generators for Z1, Z2, and Z3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-6: Sensors/Solenoids Check WindowY Input/Output. . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-7: Input/Output Check WindowY Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6-6 6-6 6-7 6-8

Figure 6-8: Door Interlock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Figure 6-9: Input Stacker Empty Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

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Figure 6-10: Tray Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Figure 6-11: Tray Present Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Figure 6-12: Thermal Head Car Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Figure 6-13: Sensors/Solenoids Check WindowLight Input/Output. . . . . . . . . . . . . . . . . . . . Figure 6-14: Input/Output Check WindowLight Input/Output . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-15: Pusher Up (Left); Pusher Down (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-16: Slider Retracted (Left); Slider Extended (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-17: Test Site Clamps Air Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-18: Sensors/Solenoids Check WindowThermal Heads Input/Output. . . . . . . . . . . . Figure 6-19: Cylinder (Thermal Head) Up Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-20: Dynamic Socket Pressure Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-21: Input / Output Check WindowPage for Handler with Taper . . . . . . . . . . . . . . . Figure 6-22: Example of Inspection Files with Their Slot Numbers. . . . . . . . . . . . . . . . . . . . . . Figure 6-23: Bit Settings for Inspection Files with Binary Numbers 000, 001, and 010 . . . . . . Figure 6-24: Bit Settings for Inspection Files with Binary Numbers 011 and 100 . . . . . . . . . . . Figure 6-25: Taper Control Panel with Sensor Lights and Override Buttons . . . . . . . . . . . . . . . Figure 6-26: Tape Track with Empty/Out-of-Pocket Sensor and Pickup Head . . . . . . . . . . . . . Figure 6-27: Taper Model 202 with Slack Switch and Heat Sensors . . . . . . . . . . . . . . . . . . . . . Figure 6-28: Slack Switch Sensor Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-29: Seal Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-30: Sensors/Solenoids Check WindowTube Input/Output . . . . . . . . . . . . . . . . . . . . Figure 6-31: Cover LEDs On (Left) and Off (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-32: Tube Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-33: Sensors/Solenoids Check WindowLaser and Light Input/Output . . . . . . . . . . . Figure 6-34: Stacker Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-35: Rear Support Extended but Lift Retracted (Left); Support Retracted but Lift Extended (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-36: Rear Tray Clamp Extended (Left); Retracted (Right) . . . . . . . . . . . . . . . . . . . . . . Figure 6-37: Motor Settings Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-38: Load Sequence Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-39: Home Sequence Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-40: Z Motors Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-41: Z Motor Drop-Down List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-42: Motor Settings Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-43: Test Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-44: Rotation Motors Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-45: Rotation Motor Drop-Down List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-46: X and Y Motors Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-47: X and Y Motor List Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 6-13 6-14 6-14 6-15 6-16 6-17 6-18 6-19 6-20 6-21 6-21 6-22 6-23 6-24 6-25 6-25 6-26 6-26 6-27 6-28 6-29 6-30 6-31 6-31 6-32 6-34 6-35 6-36 6-36 6-37 6-38 6-38 6-39 6-40

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Model 8000 Manual

Figure 6-48: Motor Settings Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-49: Home Sequence Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-50: Home Sequence Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-51: Golden Unit Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-52: Left Pick Head Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-53: Tray Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-54: Tray and Z Head List Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-55: First Pocket Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-56: Pick Head Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-57: Test Fine Tune Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-58: Teach Group BoxTwo Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-59: Teach Tray Dialog Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-60: Distance Between Pickup Nozzles, for LZ4 (Left), and for RZ3 (Right) . . . . . . . Figure 6-61: I/O Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-62: Tester Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-63: Tester WindowAlternate Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-64: Tester Group BoxSelection Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-65: Configuration for Multiple Testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-66: Configuration for Tester with Socket Grid (Multiple Rows and Sockets) . . . . . . . Figure 6-67: Tester Group BoxHorizontal Tester Calibration Area . . . . . . . . . . . . . . . . . . . . Figure 6-68: Tester Group BoxHorizontal Tester Calibration Area for Socket Grid . . . . . . . Figure 6-69: Tester Group BoxVertical Tester Calibration Area . . . . . . . . . . . . . . . . . . . . . . Figure 6-70: Rotation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-71: Tray Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-72: Golden Parts and Precisor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-73: Golden Parts and Bucket Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-74: Testing Status Group BoxThree Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-75: Test Auto Run Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-76: Pickup Nozzles Operating on Alternate Tray Pockets . . . . . . . . . . . . . . . . . . . . . . Figure 6-77: Test Auto Run Group BoxAlternate Version . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-78: I/O Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-79: Cylinders Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-80: Thermal WindowTwo Testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-81: Thermal WindowOne Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-82: Password Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-40 6-41 6-42 6-43 6-44 6-46 6-47 6-48 6-49 6-50 6-51 6-53 6-54 6-55 6-56 6-57 6-57 6-58 6-58 6-58 6-59 6-60 6-62 6-62 6-64 6-64 6-66 6-67 6-68 6-68 6-69 6-70 6-71 6-72 6-76

Figure 6-83: Correlation Table Examplesfor Cold Head (Left & Middle), for Ambient Head (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77 Figure 6-84: Air Pressure Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78 Figure 6-85: Inspection Windowfor Stationary Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80

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Figure 6-86: Inspection Windowfor Moving Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 Figure 6-87: Camera Drop-Down List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 Figure 6-88: Tray Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-89: Status Group Box with Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-90: First Pocket Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-91: Check Fine Tune Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-92: Laser Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-93: Mark Position Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-94: X Offset from Laser Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-95: Mark Testing Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-96: Detaper Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-97: Pickup Z Nozzle Motor Drop-Down List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-98: Tape and Reel Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-99: Motor Home Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-100: Gap Sensor Offset from Pickup Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-101: Leader Pockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-102: Output Tape Slack (Left); Output Tape Taut, Raising Takeup Arm (Right) . . . . 6-83 6-84 6-85 6-86 6-87 6-88 6-89 6-90 6-91 6-91 6-94 6-96 6-97 6-98 6-99

Figure 6-103: Counting Number of Holes Between Pocket Centers. . . . . . . . . . . . . . . . . . . . . . 6-99 Figure 6-104: Test Auto Run Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100 Figure 6-105: Tube Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102 Figure 6-106: Input Tube Drop-Down List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102 Figure 6-107: Output Tube Drop-Down List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104 Figure 6-108: Vacuum and Rotation Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107 Figure 6-109: Device Jammed Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108 Figure 6-110: Wafer Input Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109 Figure 7-1: Fitting for NSK Non-Self-Lubricating Bearing Shaft . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Figure 7-2: Renishaw Reader over Gold Strip Encoder for Linear Motor . . . . . . . . . . . . . . . . . . 7-6 Figure 7-3: Terminal Block and Input Connector on Network Card. . . . . . . . . . . . . . . . . . . . . . . 7-7 Figure 7-4: Slave Boards Powered Through Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Figure 7-5: Slave Boards Powered Through RS-232 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Figure 7-6: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Network Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Figure 7-7: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Figure 7-8: Master Network Card with Interface Card on Top . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-9: Slave Network Card Powered Through Terminal Block . . . . . . . . . . . . . . . . . . . . . Figure 7-10: Slave Network Card Powered Through RS-232 Cable . . . . . . . . . . . . . . . . . . . . . Figure 7-11: New Motor Assembly to Be Installed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-12: Screwing Motor Drive Board in Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 7-12 7-13 7-14 7-15

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Figure 7-13: Adding Grommet and Long Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-14: Sliding Network Card into Cover; Adding Long Spacers . . . . . . . . . . . . . . . . . . . Figure 7-15: Sliding Both Covers Together; Adding Rainbow Cable . . . . . . . . . . . . . . . . . . . . Figure 7-16: Initialize Motors Menu Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-17: Initialize Motors Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-18: Serial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-19: Serial Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-20: SMC Air Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-21: Small Black Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-22: Metal Casing Unscrewed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-23: Clear Glass Casing Snapped Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-24: Large Black Inner Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-25: SMC Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-26: SMC Air Regulator Turned OnAnother Type . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-27: SMC Air Regulator Turned Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-28: Automatic Air Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-29: Auxiliary Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-30: Air Valves with Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-31: OUT Lights Off and Fractional ReadingNo Air Pressure . . . . . . . . . . . . . . . . . Figure 7-32: OUT1 Light GreenNormal Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-33: Control Buttons on Top of Digital Air Pressure Switch. . . . . . . . . . . . . . . . . . . . . Figure 7-34: Display Locked (Left); Unlocked (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-35: Display Locked (Left); Unlocked (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-36: F_1 Alternating with Set Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-37: F_2 Alternating with Set Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-38: P_1 Alternating with Set Value of 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-39: P_2 Alternating with Set Value of 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-40: G.L. Showing Fastest Gain of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-41: S.L. Showing Best Sensitivity of 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-42: Displays of Air Pressure in PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-43: Unit Set to PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-44: Output Mode 1 Normally Open (Left); Output Mode 2 Normally Open (Right). . Figure 7-45: Response Time 2.5 MS (Left); Manual Mode (Right) . . . . . . . . . . . . . . . . . . . . . . Figure 7-46: K15 Vacuum Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-47: Vacuum AssembliesK15 (Top); K35 Switch for Vacuum Pump (Bottom) . . . .

7-15 7-16 7-16 7-17 7-18 7-18 7-19 7-21 7-21 7-22 7-22 7-23 7-24 7-24 7-25 7-25 7-26 7-27 7-28 7-28 7-29 7-30 7-31 7-32 7-33 7-34 7-34 7-35 7-35 7-36 7-37 7-37 7-38 7-40 7-41

Figure 7-48: Extra Holes in K15 Interface Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 Figure 7-49: K35 Vacuum SwitchUsed with Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . 7-42 Figure 7-50: Blow-Off Adjustment Screw Locationon Vacuum Generator (Left); on Vacuum Switch (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

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Figure 7-51: Dirty Filter (Left) Versus Clean Filter (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Figure 7-52: Blow-Off Adjustment Screw at PS Port When Using In-House Air . . . . . . . . . . . 7-45 Figure 7-53: Blow-Off Adjustment Screw at PD Port When Using Vacuum Pump. . . . . . . . . . Figure 7-54: Various Styles of Vacuum Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-55: Vacuum Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-56: Vacuum Assembly with Four Screws Highlighted. . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-57: Vacuum Assembly with One Solenoid Valve Removed . . . . . . . . . . . . . . . . . . . . Figure 7-58: Vacuum Assembly with Both Solenoid Valves Removed . . . . . . . . . . . . . . . . . . . Figure 7-59: Removing Gasket from Vacuum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-60: Vacuum Assembly with Gasket Still Attached. . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-61: Vacuum Assembly with Both Solenoid Valves and Gasket Removed . . . . . . . . . Figure 7-62: Vacuum Generator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-63: Vacuum Generator Optimal Pressurefor Nozzle with Larger Hole . . . . . . . . . . Figure 7-64: Vacuum Generator Optimal Pressurefor Nozzle with Smaller Hole . . . . . . . . . Figure 7-65: Vacuum and Blow-Off Override Buttons on Vacuum Generator . . . . . . . . . . . . . Figure 7-66: P1 Baseline Value Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-67: P1 Set at Least 8-10 Points Higher Than Baseline . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-68: P2 Set to 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-69: Error Code Set to Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-70: Green Indicator Light with High Number Showing Device Attached . . . . . . . . . . Figure 7-71: Computer Sliding Out of Cabinet on Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-72: Four Computer Base Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-73: Sliding Computer Out of Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-74: Front Bolts Securing Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-75: Top Bolts Securing Lid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-76: Sensor Controller Set to L-ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-77: Green and Red Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-78: Conditions of Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-79: Omega Temperature Controller Display Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-80: Back of Box with Pre-Heat Plug-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-81: Clamp Head for Test Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-82: Current Temperature Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-83: Setpoint 1 Menu Item Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-84: Setpoint 1 Value Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-85: Setpoint 1 Value Increased . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-86: Setpoint 1 Value Saved. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-87: Setpoint 2 Menu Item Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 7-46 7-47 7-47 7-48 7-48 7-49 7-49 7-50 7-51 7-52 7-53 7-54 7-55 7-55 7-56 7-56 7-57 7-59 7-59 7-60 7-60 7-61 7-61 7-62 7-63 7-64 7-64 7-65 7-65 7-66 7-67 7-67 7-68 7-68

Figure 7-88: Configuration Menu Item Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69

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Figure 7-89: LAN Setup Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-90: Local Area Connection Status Dialog BoxGeneral Tab. . . . . . . . . . . . . . . . . . . Figure 7-91: Local Area Connection Properties Dialog BoxGeneral Tab . . . . . . . . . . . . . . . Figure 7-92: Internet Protocol (TCP/IP) Properties Dialog BoxGeneral Tab . . . . . . . . . . . . . Figure 7-93: Local Area Connection Properties Dialog BoxAdvanced Tab. . . . . . . . . . . . . . Figure 7-94: Windows Firewall Dialog BoxExceptions Tab . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-95: Selecting Run Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-96: Opening a DOS Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-97: PING Command with Replies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-98: IPCONFIG Command with Reply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-99: E-mail Invitation to WebEx Meeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-100: WebEx Meeting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-101: Exatron Directory with Job Files, 3 Essential System Files, and Existing Program File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-102: Backup Directory with Job Files, Old Program File, and New Zipped File. . . . . Figure 7-103: Exatron Directory with Job Files and New Program File. . . . . . . . . . . . . . . . . . . Figure 7-104: Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-105: Setscrews for Carriage Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-106: Hub Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-107: Servo Motor Driver Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-70 7-71 7-72 7-73 7-74 7-75 7-76 7-76 7-77 7-77 7-78 7-79 7-80 7-81 7-81 7-82 7-84 7-87 7-87

Figure 7-108: Tray Drop Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88 Figure 8-1: Relays12-Volt (Left); 24-Volt (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Figure 8-2: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Figure 8-3: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Figure 8-4: Linear Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Figure 8-5: Dimensions Listed From Smallest to Largest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Figure 9-1: PET-V84-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Figure A-1: Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Figure A-2: 24-Pin D Connector on Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Figure A-3: TTL 24-Pin Connector with Pin Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Figure A-4: Sort Interface Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-5: Tray Sort Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-6: Eight-Bit LED Checker #3000-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-7: TTL 24-Pin Connector with Pin Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-8: Typical RS-232 Interface Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 10-7 10-8 10-8 10-9

Figure A-9: Work Mode Window in Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Figure A-10: Getting to HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 Figure A-11: Opening the HyperTerminal Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28

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List of Figures

Figure A-12: Naming a New Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 Figure A-13: Selecting the Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Figure A-14: Selecting the Port Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-15: Getting to Connection Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-16: Getting to ASCII Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-17: Displaying Typed Commands Onscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-18: Using Call to Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30 10-30 10-31 10-32 10-32

Figure A-19: Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 Figure B-1: CMOS Setup Opened to Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 Figure B-2: CMOS Setup Changed to Advanced Menu; Advanced BIOS Features Selected . . 11-3 Figure B-3: Advanced BIOS Features Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 Figure B-4: Selecting CD-ROM Drive as Boot Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 Figure B-5: CD-ROM Drive Selected as Boot Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-6: Saving Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-7: Acronis Program Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-8: Acronis Main Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-9: Manage Acronis Secure Zone Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 11-6 11-6 11-7 11-8

Figure B-10: Manage Acronis Secure Zone WizardWelcome . . . . . . . . . . . . . . . . . . . . . . . . 11-8 Figure B-11: Creating Secure Zone in Unallocated and Free Space . . . . . . . . . . . . . . . . . . . . . . 11-9 Figure B-12: Specifying Size of Secure Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 Figure B-13: Activating Acronis Startup Recovery Manager . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11 Figure B-14: Alternate SelectionDo Not Activate Acronis Startup Recovery Manager. . . . 11-11 Figure B-15: Confirming Settings Before Creating Secure Zone . . . . . . . . . . . . . . . . . . . . . . . Figure B-16: Secure Zone Successfully Created . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-17: Reviewing Properties of the Created Secure Zone . . . . . . . . . . . . . . . . . . . . . . . Figure B-18: Backup Disk Shipped with Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-19: Selecting the Backup Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-20: Create Backup WizardWelcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-21: Selecting Entire Disk or Partition Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-22: Alternate SelectionIndividual Files and Folders Backup. . . . . . . . . . . . . . . . . Figure B-23: Selecting Partitions to Back Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-24: Explanation of Differences Between Full and Incremental Backups . . . . . . . . . Figure B-25: Restoration Based On Incremental Backups . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-26: Restoration Based On Differential Backups . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-27: Selecting Backup Storage Destination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-28: Selecting a Full Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-29: Selecting an Incremental Backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12 11-13 11-14 11-15 11-16 11-16 11-17 11-17 11-18 11-19 11-19 11-19 11-20 11-21 11-21

Figure B-30: Selecting a Differential Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22

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Figure B-31: Selecting Backup Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-32: Archive SplittingAutomatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-33: Archive SplittingFixed Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-34: Drop-Down List of Fixed Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-35: Adding Optional Archive Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-36: Confirming Settings Before Creating Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-37: Progress Bar Displayed While Backup Is Created. . . . . . . . . . . . . . . . . . . . . . . . Figure B-38: Successful Completion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-39: Archive Files Created. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-40: Acronis Boot Disk Inserted in Drive (Left); Acronis Splash Screen (Right) . . . Figure B-41: Acronis Main Screen with Restore Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-42: Error Messages Due to Inserting Wrong Backup Disk . . . . . . . . . . . . . . . . . . . . Figure B-43: Restore Image WizardWelcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-44: Selecting Archive File for Restoration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-45: Option to Verify Archive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-46: Selecting Partition or Disk to Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-47: Option to Resize Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-48: Resizing Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-49: Deleting Partitions on Destination HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-50: Option to Restore Additional Partition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-51: Confirming Settings Before Restoring Partition . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-52: Prompts to Insert Series of Recovery Disks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-53: Successful Completion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-54: Selecting the Recovery Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-55: Restore Data WizardWelcome. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-56: Selecting Location of Archive File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-57: Selecting Original or New Location for Restoration . . . . . . . . . . . . . . . . . . . . . . Figure B-58: Selecting Restoration Destination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-59: Selecting Archive Files to Be Restored . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-60: Selecting Restoration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-61: Selecting Restoration Options Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-62: Selecting Whether to Overwrite Existing Files . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-63: Confirming Settings Before Restoring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-64: Progress Bar Displayed While Data Is Restored . . . . . . . . . . . . . . . . . . . . . . . . .

11-22 11-23 11-24 11-24 11-25 11-26 11-27 11-27 11-27 11-28 11-29 11-30 11-30 11-31 11-32 11-33 11-34 11-35 11-36 11-37 11-38 11-39 11-39 11-40 11-41 11-42 11-43 11-44 11-45 11-46 11-47 11-48 11-49 11-50

Figure B-65: Successful Completion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50 Figure B-66: Restored Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50

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Chapter 1: Safety, Support and Options


Chapter Overview
This chapter discusses the following main topics: Topic Exatron Safety Warnings Lock-Out Procedures Facilities Requirements Standard Warranty Exatron Support Services End-of-Life Handler Disposal Warranty and Support Contracts Significance of This Manuals Version Number Typographical Conventions Used in This Manual Terms Used in This Manual Photo Gallery of Optional Configurations Page 1-1 1-5 1-6 1-8 1-10 1-23 1-10 1-23 1-24 1-25 1-27

Please read and understand this entire User Manual before installing or using your Exatron handler. A short glossary of terms used in this manual and other keys to understanding is found at the end of this chapter.

Exatron Safety Warnings


Typically, the handler is simply one part of a complete test system. It is the responsibility of the company purchasing the handler to properly train all handler operators in all of the safety practices required for every component of the test system. The following safety procedures must be followed at all times.

WARNING! Keep fingers, hair, and clothing away from any moving parts on the handler. Its motors are very powerful and can cause severe injury.

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WARNING! Always reset all motors before running the handler. Do not run it without homing the motors. WARNING! Never try to stop an action of the handler with your hands or any other device. To stop the handler, press the EMO (emergency stop) or click Pause on the screen.

Figure 1-1: Emergency Stop Button

WARNING! If your Exatron handler is equipped with safety covers, never operate the handler without them. Never remove the safety covers. Never defeat any electrical interlock switch supplied with the handler. To avoid contact with moving parts, the Model 8000 is equipped with fixed and moving covers. The fixed covers are screwed in place and should never be removed except for maintenance and then only by qualified maintenance technicians. The movable covers are supplied with interlocks. Exatron specifically disclaims responsibility and/or liability for any injury which occurs as a result of any interlock being defeated and/or bypassed, or for any injury which occurs as a result of any fixed cover being removed during operation.

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Exatron Safety Warnings

Figure 1-2: HazardsFingers Near Lifter Pins (Left), Support Pins (Right)

WARNING! Keep your fingers and other body parts away from the pins on the stackers while the handler is operating.

Figure 1-3: HazardFingers Near Tray Clamp Pins

WARNING! Keep your head, fingers, and other body parts away from the underside of the lifters (underneath the main table) on the stackers while the handler is operating.

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Figure 1-4: HazardsFingers Near Lifter Underside (Under Main Table)

WARNING! Keep your fingers away from the internal cabinet shutter and camera shutter while the handler is operating. WARNING! Never open/disassemble the pressurized air springs that support the upper cabinet doors. The only hazardous waste associated with any Model 8000 handlers is the circulatory fluid used in chillers, for handlers using cold testing. For MSDS, see the suppliers recommendations. WARNING! If your Exatron handler is equipped with a thermal circulator or chiller, dispose of the circulatory fluid in accordance with local or federal regulations. Using compressed air can be hazardous. It is the responsibility of the company purchasing the handler to properly train all handler operators in every aspect of the safety practices associated with the use of compressed air. WARNING! Never operate any Exatron system that requires compressed air without an approved air regulator and shutoff valve, such as that originally supplied with your system. WARNING! Never unplug a pressurized air hose while the air regulator is turned on.

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Lock-Out Procedures

If your handler is equipped with a laser, follow all the federal and state safety regulations for safely operating the laser. Follow the safety warnings in the laser manufacturers manual. WARNING! Only a qualified in-house laser safety officer (LSO) should service the laser, if the handler is equipped with a laser.

Lock-Out Procedures
Lock-out/tag-out procedures should be followed when servicing or repairing the handler. This prevents an operator from turning on the handler when it may be partially disassembled and thus prevents damage or injury. Before servicing or repairing your handler, turn off the air regulator and lock it in the OFF position as shown in Figure 1-5. Then, if you have to leave the handler in an inoperable or unsafe condition, no one can turn it on by mistake. NOTE: Locking devices such as padlocks are provided by you, the customer. WARNING! Turn off the air regulator and lock it in the OFF position before servicing.

Figure 1-5: Air RegulatorIn ON Position (Left), in OFF Position (Center), in OFF Position with Lock (Right)

The handler has a lockable disconnect switch (Figure 1-6) that shuts off all AC power to the handler and computer(s). When using lockout procedures, turn off and lock this switch also.

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Figure 1-6: Lockable Disconnect SwitchIn ON Position (Left), in OFF Position with Lock (Right)

Facilities Requirements
Air Conditioning and Environmental Requirements
The Model 8000 handler should be installed in a temperature-controlled, dust-free environment to preclude dust and dirt particles from contaminating its moving parts, especially those parts which come into contact with the devices being tested. The life of your handler is greatly enhanced by keeping it as clean as possible. See Chapter 7 for instructions. Handlers equipped with laser markers must have a smoke extraction/filter system. If no laser is present, there are no special ventilation requirements.

Electrical Requirements
The power supplies for handlers shipped either within the United States or offshore have builtin switching electrical supply capability for 100-volt AC to 240-volt AC, 50Hz to 60Hz, at usually 5-15 amps. For more information see "Power Supplies" on page 2-26. However, the handler is wired for either 100-120-volt AC, 50/60 Hz, at 3 amps; or 220-240-volt AC, 50/60 Hz, at 2 amps. You must specify your choice when you order the handler. Tapers, if included, can be wired for either 100-120-volt AC, 60 Hz; or 220-240-volt AC, 50 Hz. You must specify your choice when you order the handler. If the handler is to be used in an electrically noisy environment or near large electromechanical equipment, Exatron recommends the use of a reliable power conditioner to filter line noise, surges, and spikes which can cause the handler to operate improperly or become damaged. CAUTION: Connect the power cord to earth-grounded power outlets only.

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Facilities Requirements

Vacuum/Pneumatic Requirements

Service calls made to the customer facility to correct problems caused by improper electrical supply are not covered by the Exatron warranty.

Vacuum/Pneumatic Requirements
The Model 8000 system requires a supply of pressurized air at a minimum of 80 PSI at 2 to 5 CFM (depending on the number of vacuum generators), filtered for proper operation. The air supply must be clean (containing no particulate matter greater than 5 microns in size), oil-free, and dry (having a dew point of 36 degrees F to 38 degrees F) to operate correctly. Dirty, oily or wet air will cause the vacuum generator to malfunction and will make your system unreliable. If the handler is equipped with a taper, add 0.5 CFM of shop air to the CFM required for the handler itself. The external air source should be attached to the air regulator mounted on the handler base. Before turning on the air regulator and using the handler, make certain the compressed air line is attached to the air regulator fitting. Check to make sure the air regulator gauge on the external regulator measures the air pressure at 80 PSI, and adjust if necessary. To maintain these levels of pressurized air quality, replace the air filter (Exatron part #GPA-97075) in the air regulator of your handler after every 6000 hours or 12 months of operation, whichever comes first; or if your air regulator registers a pressure drop of 15 PSI. Moisture of any kind will travel through external and internal air lines. This moisture will coat these air lines and the insides of the handler's cylinders, causing them to stick or to stop functioning altogether. The best defense against this kind of contaminate is to prevent it from occurring in the first place by maintaining the clean air supply described above. If the air lines are allowed to become discolored or the moisture traps become overfilled, damage to the system will occur. The only corrective action to take at that point is to replace all of the air lines and to completely clean all of the solenoids supplied by those air lines. Handler damage due to improper air supply is not covered by the Exatron warranty.

Internet Access
It is strongly recommended that your handler be equipped with Internet access. This is to facilitate remote troubleshooting by Exatron engineers as necessary, and to save you larger onsite costs, the details of which are itemized in the "Customer Service Support Guide" on page 1-17. See Chapter 7 and especially "Remote Handler Control with WebEx" on page 7-78 for how we can help you troubleshoot remotely. Exatron strives to maintain low capital acquisition costs and low service costs for our customers. A key part of this strategy is the use of the Internet to provide software updates and perform remote service on our systems. Software support in the field can be extremely expensive to the end user, so high-speed connections are an excellent money-saving tool. We encourage our customers to put our systems on their networks and provide remote access to the system through the Internet. Exatron reserves the right to bill the customer for any on-site warranty work that otherwise could have been accomplished remotely.

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Uncrating the Handler


The Model 8000 handler will usually come in a wooden crate which will require some disassembly to remove the handler. Please inspect the system when it is removed from the crate for any obvious damage which may be the result of shipping. Contact Exatron and the shipping company immediately if you see any damage.

Installing the Handler


For seismic safety, once the handler is installed in its designated location, do not leave it on unlocked wheels. Lock its wheels, then extend the leveling feet. See "Leveling Feet" on page 3-1 for instructions. Additionally, if local regulations require it, an optional tie-down kit is available from Exatron. This will permanently attach the handler to the floor so it cannot be moved. See page 9-2 in Chapter 9. Call for a quote.

Standard Warranty
All Exatron products are under warranty for one year from the date of purchase. Exatron agrees to repair any mechanical or electrical assembly, subassembly, or entire unit that fails during normal use within its first year. The customer agrees to follow the recommended maintenance procedure as defined in this User Manual. Exatron does not warrant test contactors. Handler test contactors are fragile and may be easily ruined by operator abuse. Exatron uses the finest materials available in our contactor designs. Exatron does not warrant the following: Damage caused by improper packaging of equipment returned to Exatron for repair Damage caused by the shipping company Damage caused by natural catastrophes: flood, fire, earthquake, etc. Damage caused by equipment connected to improper power line voltages Damage caused by equipment connected to improper air supply: contaminated with oil, water, dirt, etc. Damage caused by operator abuse or improper practices cautioned against in this manual Damage caused by interface hardware not manufactured by Exatron Damage or malfunction caused by customer modifications Test contactors

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Customer In-House Service

Customer In-House Service


Except in the case of laser marking systems, Exatron encourages customer in-house equipment service and tries to make in-house service as easy as possible to perform. There are no "Void Warranty" warning stickers on Exatron handlers. By using the built-in diagnostic software and diagnostic tools, it is usually possible for the operator to isolate a problem quickly and effect a repair. The customer is responsible for all cost of in-bound shipping expenses. Standard out-bound shipping expenses will be paid by Exatron. In such cases where the customer requests specific out-bound shipping methods be used, the customer is responsible for all shipping costs and any additional related charges.

Offshore Warranty Service


An Exatron handler purchased in the United States and then shipped offshore will be warranted through Exatron in California. Replacement parts are furnished for a period of one year from date of purchase with the exception of replacement contactors. In most cases, it will not be necessary to return the worn part from the offshore user location. To receive offshore service support, the handler must be purchased through your local Exatron representative or an extended warranty agreement must be purchased directly from your local Exatron representative. Please supply the following information when requesting offshore service or replacement parts: The part number(s) required. If the part number is not known, photocopy or take a photo of the part and fax it to Exatron. The model number of the handler The type of device being run by the handler, such as: DIP, SOIC, SOJ, PLCC, LCC, SIP, PGA, PCB, ZIP, etc. The handlers serial number The full shipping address Any special shipping or customs instructions Method of shipment, such as: Federal Express, UPS, DHL, U.S. Mail, or the name of your chosen shipping company In most cases, faxed requests and shipment of replacement parts orders are processed within twenty-four hours of receipt by Exatron.

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Exatron Support Services


For factory technical support, you can contact us in several ways. Call 1-800-EXA-TRON or 1-408-629-7600, between 8:00 A.M. and 5:00 P.M. Pacific time, Monday through Friday. E-mail us anytime at service@exatron.com. Fax us at 1-408-629-2832. When contacting us, please have your Exatron equipment close at hand, along with the following information: The model number of your handler with all its options (taper, tubes, etc.) The exact wording of any messages that appeared on your handler display. A description of what happened and what you were doing when the problem occurred. A description of how you tried to solve the problem.

Warranty and Support Contracts


The following three sample contracts show details of what is covered. They may be changed without notice.

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Service Contract

Service Contract

2842 Aiello Drive, San Jose, CA 95111

www.exatron.com 408-629-7600

SERVICE CONTRACT Rev H


for Customer TBD Street Address City, State, Zip
Please see our Customer Service Support document for detailed warranty details This contract shall commence on Starting Date for a period of twelve (12) months and shall be renewed only upon receipt of new purchase order for a new 12 month period. Exatron shall provide service by way of prompt, reliable technical consultation and service coordination with respect to Customers Exatron built products located at their TBD facility, full address. Please see section Product Movements, below, for more information regarding the location of the Exatron products covered by this contract.. This Service Contract" includes: Perform Preventive Maintenance procedures as defined in the Exatron Manual. Clean, align and inspect handler for worn and/or damaged parts. Examine handler for signs of wear and notify the Customer. A list of required replacement parts will be supplied to the customer during each visit. Purchased parts may be installed during the next visit. 1 year factory labor Installation of any update and diagnostic software as might be available Best effort response time, 1 to 3 business days typical Typical same day shipment of spare parts Toll free 800-EXA-TRON support service phone line What is NOT covered by this Service Contract: All actual travel costs, see below The cost of all spare parts The cost of consumables and test contacts Any OEM equipment warranty/service costs (non-Exatron products) Operator and/or service training of customer personnel Shipping damage of any kind Acts of God

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Acts of war Power line problems and damage Air supply problems and damage Ongoing camera & laser application support Any other Exatron products not specifically listed on this contract

Service performed on Exatron-built products only: Service is strictly limited to the Exatron portions of a given system Service work on any OEM subsystem is to be purchased directly from the OEM This includes, and not limited to, bowl feeders, chillers, camera/vision systems, customer supplied equipment, label printers, laser markers, smoke extractors, and any large OEM subsystem used in the overall Exatron system Please note: All laser markers require professional service. Improper service will void the OEM warranty and could result in personal injury and/or serious damage to the laser.

This contract does NOT extend the Exatron product warranty. This contract does NOT provide for any additional service work beyond the limits of this contract.
Service Contract Schedule Exatron will make every effort to have a service engineer at the customers facility with in 1 to 3 business days of the call for service. There are no service response time guaranties. We do offer a 1 business day turn around service on a per occurrence basis. Please contact Exatron for details and quotation. PM Product Movements Preventive maintenance contracts are priced to specific locations. With the exception of movements between buildings on the same campus, any movement of the Exatron product covered by this contract during the period of this contract may result in a change in the price of the preventive maintenance contract, and the contract must be requoted. The value of any unused portion of this contract will be applied towards the new contract price. Exatron reserves the right to refuse service for machines which are moved to parts of the world considered unstable or dangerous. Service Operating Hours Preventive Maintenance service work shall be performed 8:00 AM to 5:00 PM, local time, Monday through Friday, excluding weekends and local public holidays. Availability of Products Any spare parts at site shall be made freely available by Customer to Exatron's engineer to enable remedial work to be carried out. In the event spare parts must be obtained from the factory in San Jose, California, the engineer may return to the customer facility to complete the work. Return to the customer facility will be determined by mutual agreement between Exatron and the customer. Price Call for a quotation. There is a substantial cost increase for customers who do not have and/or allow our service engineer to connect the Exatron Product to the internet allowing for remote diagnostics. Spare Parts 25% discount on all Exatron spare parts, except consumables, during the life of the contract. Spare parts for OEM subsystems should be purchased directly from the OEM vendor. If purchased through Exatron, there is an additional markup and no discounts are available. Terms Call for a quotation.

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Service Contract

All actual travel expenses are NOT included and will be billed at the time: These include as a minimum the following expenses: Air fare as required Rental car and/or cab fees Lodging Per-diem food allowance Equipment and/or spare parts express shipping costs Travel expenses to the customer are waived if within 50 miles of Exatron, San Jose, California. Site Medical Facilities Site medical facilities will be made freely available to Exatron's engineer(s) as needed for emergency medical treatment. Limitation of Liability During the initial warranty period of a system covered by this contract, Exatrons entire liability and customer's exclusive remedy will be repair or replacement of an assembly not meeting Exatron's standard warranty. Following the warranty period, Customer is responsible for any and all costs associated with repairs, replacement parts, etc. In no event will Exatron be liable to the customer for any damages including lost profits, cost saving, or other incidental or consequential damages arising out of the use or inability to use Exatron products referred to herein even if Exatron has been advised of the possibility of such damages, or of any claim by any other party. Customer will indemnify Exatron against any damage to Customers property and against any claims for loss or injury to any person or to the property of any person by reason of the Customers negligence or of any act or omission on the part of the Customers employees, subcontractors, assignees or agents arising out of this contract. Excuse of Performance Neither party shall be liable to the other party for any delay due to causes beyond its reasonable control, including but not limited to faulty instructions, lack of instructions, travel or shipping delays due to weather or other factors outside their control, shipper's error, acts of God, or strikes or other labor disputes. Law The validity, interpretation, and performance of this agreement, and any dispute connected therewith will be governed and construed in accordance with the laws of the State of California. IN WITNESS WHEREOF, the parties have executed this Agreement by their duly authorized representatives as of the date and year stated at the top of this document. Customer TBD EXATRON

_____________________________________________________________________ By ___________________________By _David Ledezma______________ Title __________________________Title _Customer Service Manager____ Customer contact person(s) Phone number(s) Email(s) EXATRON PRODUCTS COVERED UNDER THIS P.M. CONTRACT Serial # Serial #

Handler Model Exatron PC

Original Customer PO# :__________________ Original Ship date#:______________________

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Preventive Maintenance Contract

2842 Aiello Drive, San Jose, CA 95111

www.exatron.com 408-629-7600

PREVENTIVE MAINTENANCE CONTRACT Rev J


for Customer TBD Street Address City, State, Zip
Please see our Customer Service Support document for detailed warranty details This contract shall commence on Starting Date for a period of twelve (12) months and shall be renewed only upon receipt of new purchase order for a new 12 month period. Exatron shall provide service by way of prompt, reliable technical consultation and service coordination with respect to Customers Exatron built products located at their TBD facility, full address. Please see section Product Movements, below, for more information regarding the location of the Exatron products covered by this contract. This "Preventive Maintenance Contract" includes: Perform Preventive Maintenance procedures as defined in the Exatron Manual. Clean, align and inspect handler for worn and/or damaged parts. Examine handler for signs of wear and notify the Customer. A list of required replacement parts will be supplied to the customer during each visit. Purchased parts may be installed during the next visit. Installation of any update and diagnostic software as might be available Scheduled PM visits only, as listed below Typical same day shipment of spare parts Toll free 800-EXA-TRON support service phone line What is NOT covered by this "Preventive Maintenance Contract": All actual travel costs, see below The cost of all spare parts The cost of consumables and test contacts Un-scheduled service calls Any OEM equipment warranty/service costs (non-Exatron products) Operator and/or service training of customer personnel Shipping damage of any kind Acts of God Acts of war Power line problems and damage Air supply problems and damage Ongoing camera & laser application support Any other Exatron products not specifically listed on this contract Service performed on Exatron-built products only: Service is strictly limited to the Exatron portions of a given system Service work on any OEM subsystem is to be purchased directly from the OEM This includes, and not limited to, bowl feeders, chillers, camera/vision systems, customer supplied equipment, label printers, laser markers, smoke extractors, and any large OEM subsystem used in the overall Exatron system

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Preventive Maintenance Contract

Please note: All laser markers require professional service. Improper service will void the OEM warranty and could result in personal injury and/or serious damage to the laser.

This contract does NOT extend the Exatron product warranty. This contract does NOT provide for any additional service work beyond the limits of this contract.
Preventive Maintenance Visit Schedule There will be two (2) preventive maintenance visits each year. The timing of each visit shall be mutually agreed upon by Exatron and the customer to prevent unnecessary disruption of Customer's plant operation. The dates of the mutually agreed semi-annual visits must be determined at least 30 days prior to its occurrence. One engineer will be dispatched to carry out the preventive maintenance work. PM Product Movements Preventive maintenance contracts are priced to specific locations. With the exception of movements between buildings on the same campus, any movement of the Exatron product covered by this contract during the period of this contract may result in a change in the price of the preventive maintenance contract, and the contract must be requoted. The value of any unused portion of this contract will be applied towards the new contract price. Exatron reserves the right to refuse service for machines that are moved to parts of the world considered unstable or dangerous. Service Operating Hours Preventive Maintenance service work shall be performed 8:00 AM to 5:00 PM, local time, Monday through Friday, excluding weekends and local public holidays. Availability of Products Any spare parts at site shall be made freely available by Customer to Exatron's engineer to enable remedial work to be carried out. In the event spare parts must be obtained from the factory in San Jose, California, the engineer may return to the customer facility to complete the work. Return to the customer facility will be determined by mutual agreement between Exatron and the customer. Price The PM contract is priced by the day. We recommend a minimum of 2 PM visits per year. We recommend a maximum of 4 PM visits per year. Prices DO NOT include any travel costs and/or spare parts if applicable. 2 PM visits per year at $1200 per visit ($2400 Contract Cost) 3 PM visits per year at $1100 per visit ($3300 Contract Cost) 4 PM visits per year at $1000 per visit ($4000 Contract Cost) Spare Parts Spare parts for OEM subsystems could be purchased directly from the OEM vendor and/or Exatron. Exatron manufactured spare parts to be purchased through Exatron only. Terms Call for a quotation. All actual travel expenses are NOT included and will be billed at the time: These include as a minimum the following expenses: Air fare as required Rental car and/or cab fees Lodging Per-diem food allowance Equipment and/or spare parts express shipping costs Travel expenses to the customer waived if within 50 miles of Exatron, San Jose, California. Site Medical Facilities Site medical facilities will be made freely available to Exatron's engineer(s) as needed for emergency medical treatment.

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Limitation of Liability During the initial warranty period of a system covered by this contract, Exatrons entire liability and customer's exclusive remedy will be repair or replacement of an assembly not meeting Exatron's standard warranty. Following the warranty period, Customer is responsible for any and all costs associated with repairs, replacement parts, etc. In no event will Exatron be liable to the customer for any damages including lost profits, cost saving, or other incidental or consequential damages arising out of the use or inability to use Exatron products referred to herein even if Exatron has been advised of the possibility of such damages, or of any claim by any other party. Customer will indemnify Exatron against any damage to Customers property and against any claims for loss or injury to any person or to the property of any person by reason of the Customers negligence or of any act or omission on the part of the Customers employees, subcontractors, assignees or agents arising out of this contract. Excuse of Performance Neither party shall be liable to the other party for any delay due to causes beyond its reasonable control, including but not limited to faulty instructions, lack of instructions, travel or shipping delays due to weather or other factors outside their control, shipper's error, acts of God, or strikes or other labor disputes. Law The validity, interpretation, and performance of this agreement, and any dispute connected therewith will be governed and construed in accordance with the laws of the State of California.

IN WITNESS WHEREOF, the parties have executed this Agreement by their duly authorized representatives as of the date and year stated at the top of this document. Customer TBD EXATRON

_____________________________________________________________________ By ___________________________By _Quang Truong______________ Title __________________________Title _Customer Service Manager____ Customer contact person(s) Phone number(s) Email(s) EXATRON PRODUCTS COVERED UNDER THIS P.M. CONTRACT Serial # Serial #

Handler Model Exatron PC

Original Customer PO# :__________________ Original Ship date#:______________________ PM Contract PO# :__________________ Exatron Invoice# :__________________ NOTE: LASER & LASER PC SERVICE/MAINTENANCE ARE NOT INCLUDED DATES FOR PREVENTIVE MAINTENANCE The Preventive Maintenance procedures will be performed two (2) times semi-annually as scheduled below: (Please fill out and return with signed copy of the contract.) 1: TBD 2007 PM Contract Quote#:______________________

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Customer Service Support Guide

Customer Service Support Guide

2842 Aiello D rive, San Jo se, C A 95111

w w w .exatron.com 408-629-7600

C ustom er S ervice & S upport Rev K


Manager Factory service hours Phone numbers Fax number E-mail Quang Truong (or Eric Hagquist) 8:00AM-5:00PM M-F Pacific Time 408-629-7600 or 1-800-EXATRON 408-629-2832 info@exatron.com or qtruong@exatron.com

Standard Exatron Warranty: 1 year all Exatron parts other than test contacts and consumables 1 year factory labor. Warranty does not cover travel expenses for on-site service. See note, below, regarding Ethernet access for support All parts listed by OEM and in-house part numbers Typical same day shipment of spare parts PC Anywhere remote update and diagnostic software standard Self-service encouraged with on-line documentation and extensive built-in diagnostics Service contracts available See below Toll free 800-EXA-TRON support service phone line Major OEM subassemblies such as bowl feeders, lasers, vision systems, etc., have pass-through OEM warranties ONLY. No additional Exatron warranty Assume OEM warranties do not include on-site labor usually factory only Any unexpected OEM warranty/service costs passed on to customer at Exatron cost What is NOT covered by the Standard Exatron Warranty: On-site operator or in-house service training after install Consumables and test contacts Shipping damage of any kind Improper or lack of preventative maintenance Operator abuse of any kind Acts of God Acts of war Power line problems and damage Air supply problems and damage Any problems with OEM equipment not covered by OEMs warranty Ongoing camera & laser application support (see below) Ongoing Exatron updates added after shipment Problems with non-Exatron supplied system components Please note: All of our products are quoted with factory installation. If this option is not ordered, then problems that arise from "self installation" are not considered covered by our standard warranty Exatron comprehensive manuals: Over the years our documentation has improved greatly. We now offer full color comprehensive manuals. These manuals are installed on the handlers hard disk and can be downloaded from our website anytime. All manuals have fullcolor photos to help get the point across. To keep our costs down, our manuals have grown to cover all possible options and are now considered comprehensive. We then add customized chapters to the comprehensive manual with productspecific electrical schematics, master assembly drawings, and a detailed parts list.

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Self diagnostic support: All Exatron products have substantial built-in self diagnostic software. These diagnostics are well documented in our manuals. Typically every sensor, switch, solenoid, valve, lamp, motor, vacuum can be individually turned on/off and tested quickly. This is a great help with troubleshooting problems. Combine this with remote Internet access and just about all problems can be found quickly and at low cost to everyone. Void warranty stickers: There are no "void warranty" stickers on Exatron products, but there are some on some of our OEM add-ons. We do require that a properly trained service technician perform any service work on Exatron products. Laser self service: Exatron does NOT recommend customer self service for any of our laser products. There are substantial safety issues with lasers and they must be serviced by the OEM laser vendor. In some cases, Exatron can provide basic service work. Laser service work must be quoted on a specific as-needed basis. Any damage, of any kind, to the laser caused by improper service or operator abuse voids any remaining warranty. Factory customer operator and service training: Exatron will train the customers operators and/or service personnel if: The training takes place at Exatron The customer pays all of their own travel / lodging costs Exatron is given at least 30 day notice Exatron will then train on the next best thing we have in-house at that time (best effort) Exatron uses only standard Exatron manuals for training aids Any spare manuals must be purchased by the customer In most cases, we are willing to provide up to two days of training for up to 3 people at no cost during the buy-off of the equipment. Additional factory customer operator service training can be purchased for $600 per day for one person, $200 per additional person all trained at the same time. Typically we would limit our class sizes to 4 people maximum. The number of days required to train depends on the Exatron product(s) and the skill level of the people being trained. On-site training classes: On occasion, Exatron provides our customers with on-site training classes. This can be as simple as a few hours reviewing our standard documentation. Or a more formal class may be required. Exatron will quote on-site training classes based on the customers needs. Spare parts: Most spare parts orders are shipped the same day, if the order is placed before 1pm PST. We do all we can to maintain a good stock of commonly used spare parts. But there will be times when Exatron cannot supply a spare part overnight. The customer must maintain their own stock of spare parts based on their needs. All shipping costs will be charged to the customers account. Please specify shipping method at time of order. Exatron will hold all spare part orders if the customer has any overdue open invoices. Spare test contactors: It is expected that the customer will maintain at least a 60 day inventory of spare test contactors. In many cases, test contactors are custom designed. In many cases, we ship the test contactors as a lot. We do not maintain a stock of spares in these cases. Typical lead time is 3 to 4 weeks; longer is possible for unforeseen reasons. Spare part kits: Exatron offers a well stocked spare parts kit. Call for a quotation. Spare part long-term support: Exatron makes every effort to supply spare parts for the life of the equipment. We manufacture our own machine parts and our ability to find old drawings, for old parts, is excellent. As the handler ages, many of the non-Exatron made parts will no longer be available. In some cases, we may substitute used parts that still have some life in them. If all else fails, we can design in new parts or upgrade around the problem part; this can add substantial extra cost, but will also extend the working life of the handler.

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Customer Service Support Guide

RoHS Lead Free Compliance: Exatron has been building equipment since 1974. We no longer use lead solder in any of our newly designed products. Some of our "newly built" older designs might in fact use older in-stock parts that are not RoHS compliant. We do have older stocks of spare parts that were originally made with lead solder. Some of these older parts will be used in newly built Exatron products that were originally designed years ago. This applies mostly to older PCBs, both bare boards and assemblies. This may also apply to older test contacts & cable assemblies. In the event the customer needs to have all spare parts, including older in-stock parts, the customer's original order must clearly indicate that RoHS compliance is required. Exatron reserves the right to re-quote as needed. There will be substantial price increases. With many of our older spare parts, we will need to generate new documentation, artworks, and buy a minimum number of parts to remanufacture just one spare part that is now RoHS complaint. All of these costs and a much longer lead time will be passed on to the customer within the required re-quote. Product upgrades: As the product ages, there will be a time when Exatron will no longer be able to upgrade the product with new options that are constantly being added to our product line. We will do all we can to support the product to work as well as it did when it originally shipped. Spare computer parts: It is simply a fact that as computers get cheaper, they also become less reliable. Exatron does all we can to buy the highest quality and generic computer parts as possible. This is why we build our own PCs. Please note that computer parts typically DO NOT have long term support. In most cases, but not all, we can swap out one PC vendor with another. It is highly recommended that the customer buy a spare PC at time of order (included in some spare parts kits). We maintain a small stock of older computers, subject to prior sale. Recover disks: All Exatron PC-based handlers are shipped with software recovery disks. We will store a copy as well at Exatron. This disk(s) will allow the customer to fully recover from a catastrophic computer failure. The disk will recover all of the installed software that was on the handlers hard disk at time of shipment. This disk will not always fully recover if the computer itself has to be changed out to a different type or upgraded version of MS Windows. It is up to the customer to maintain backup files for all job files and Exatron updates after the equipment is shipped from Exatron. Please do not make your only backup files on the Exatron computer. Software updates: Some customers ask for improvements that we add to all future versions. Sometimes we even find "bugs" and fix them. We are always making improvements. Exatron provides these generic software updates on request only. We strongly believe in the idea that "if it isnt broken, dont fix it" when it comes to software adding a change to fix one problem can often lead to more and worse other problems, so we specifically do not make software fixes unless really necessary. Should the customer request be considered by Exatron to be an enhancement, we reserve the right to quote as needed. Spare hard drive: Exatron highly recommends adding a spare hard drive to our computers. This can be ordered at time of order. Adding a disk drive after shipment will require an on-site service call and is not covered by our standard warranty. 8-to 5-phone support: Exatron offers toll free (800-EXA-TRON) phone support, 8am to 5pm Pacific Time, Monday Friday, at no extra cost for the life of the equipment. Most questions are answered on the spot. More complicated issues will take longer. At some point Exatron may require the customer to purchase an on-site service call or return the equipment to Exatron for repair. Internet support: Exatron strives to maintain low capital acquisition costs and low service costs for our customers. A key part of this strategy is the use of the Internet to provide software updates and perform remote service on our systems. Software support in the field can be extremely expensive to the end user, so high-speed connections are an excellent money-saving tool. We strongly encourage our customers to put our systems on their networks and give us access to the system over their networks.

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Internet access software is included with every Exatron PC-based handler. In most cases, handlers can be connected to Exatron over any Internet port as long as the customer initiates the connection. There will be substantially higher service and engineering costs to our customers who cannot provide Internet access to our products. OEM equipment: Many Exatron products are systems built with additional third party OEM products. These products include laser markers, chillers, smoke extraction, vision/camera systems, bowl feeders, label printers, and other big ticket non-Exatron products. In every case, Exatron will require the OEM to pass its standard warranty through to the end user. In every case, Exatron will do all we can to correct any system problems. The specific service policy for the non-Exatron product will be determined at time of order. Most of our OEM products do not include on-site support or return shipping costs without a specific additional order at time of the original system order. In the event an OEM product is supplied by the customer, Exatron will only guarantee the initial integration. This integration must be bought off at Exatron prior to shipment. Exatron will not offer any additional warranty from that point in time. Exatron service work on OEM equipment: Service work is typically limited to repair of Exatron products only. We will make every effort to service our OEM partners equipment to the best of our ability. Should the OEM product require service beyond our limited ability, any and all costs required to bring the OEM equipment back to working order will be passed on to the customer. ONGOING CAMERA AND LASER APPLICATION SUPPORT: Exatron systems that require machine vision (cameras) and/or laser markers include the initial application development only. Depending on how the system is used, ongoing application support may be required. We encourage customers to develop sufficient in-house familiarity with the vision and laser systems to accomplish this themselves. However, in the event that additional application support is needed, Exatron considers this not to be covered by warranty. Applications support is available from Exatron at a price to be determined on a case-by-case basis. Exatron customers are also encouraged to seek applications support directly from the camera and/or laser vendor(s). Third-party service: Exatron has working relationships with qualified third-party service providers in Asia and Europe. Please see our web site for contact information. The customer is free to directly contact any of these service providers. Each has their own pricing structures. Returned to the factory repair turn-around times: Exatrons in-house repairs are billed at $75 per hour, 1 hour minimum. All products sent in to Exatron for repair must have an RMA number. If there is no RMA number, turn-around times can be significantly longer. Work performed 8am-5pm Pacific Time, normal business days only Standard service turn-around time (with RMA#) ...typically the next day, best effort Rebuilds & engineering turn-around times...to be determined as needed 1 business day response subject to availability at the time (see below) Field upgrades and service call turn-around times: On-site turn-around time: We will make our best effort to provide on-site service as quickly as possible. Our standard warranty does not cover travel expenses. We will waive our technicians time and spare part costs during the warranty period. This does NOT apply to adding newly purchased upgrades. There will be a substantial increase in travel costs for immediate/overnight travel. All of these costs are all passed on to the customer.

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Warranty and Support Contracts

Customer Service Support Guide

Field upgrades lead times must be quoted and confirmed at time of order. All field upgrades are quoted, open ended. We will do all we can to make a field upgrade go as quickly as possible. All costs for any unforeseen delays, for any reason, that requires the Exatron technician to stay extra days or make a return visit will be passed on to the customer as required. One-business-day guaranteed response time: Subject to availability at the time (see below) In-warranty service costs: On-site service within the USA (no Internet access) In the event Exatron is required to provide an on-site service call, where the problem could have been corrected with Internet access prior to the service call, Exatron will bill all costs for the service call at Out of Warranty service rates. Labor performed at no charge within our Standard Exatron Warranty (see above) Labor and travel time will be billed for any work for what is NOT covered by the Standard Exatron Warranty (see above) All actual travel expenses billed to the customer On-site service within the USA (with Internet access) Labor performed at no charge within our Standard Exatron Warranty (see above) Labor and travel time will be billed for any work for what is NOT covered by the Standard Exatron Warranty (see above) All actual travel expenses billed to the customer On-site service outside the USA (no Internet access) All actual travel expenses billed to the customer and $1,875.00 per day, full payment received prior to the service call On-site service outside the USA (with Internet access) All actual travel expenses billed to the customer and $1,200.00 per day, full payment received prior to the service call Field upgrades and out-of-warranty service costs: On-site field upgrade or service within the USA (no Internet access) Labor performed at $200.00 per hour, 1/2 day minimum All actual travel expenses billed to the customer On-site field upgrade or service within the USA (with Internet access) Labor performed at $150.00 per hour, 1/2 day minimum All actual travel expenses billed to the customer On-site field upgrade or service outside the USA (no Internet access) Labor performed at $2,000 per day All actual travel expenses billed to the customer On-site field upgrade or service outside the USA (with Internet access) Labor performed at $1,500.00 per day All actual travel expenses billed to the customer Remote software engineering costs (8am to 5pm Pacific time, Monday-Friday; excludes local holidays: On-site remote software engineering within the USA Labor performed at $150.00 per hour, one hour minimum After hours service, labor performed at $250.00 per hour, one hour minimum On-site remote software engineering outside the USA Labor performed at $200.00 per hour, one hour minimum After hours service, labor performed at $300.00 per hour, one hour minimum

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Chapter 1: Safety, Support and Options

Blanket service purchase order for service/spares: Customers who would like the fastest service at the lowest cost should consider opening a blanket service purchase order. With a standing open P.O. Exatron can respond immediately to customers employees requests for service and/or spare parts. This saves the down time required for Exatron to quote and the customer to generate a PO. Exatron will bill as needed at the time. We recommend a minimum of $5,000.00 per year Contact Exatron for terms. PM contracts: Sold by the day, $1,000 per day, plus travel and living expenses. Please contact Exatron for a copy of our PM Contract. One-business-day turn-around on-site service trips: Available on normal USA business days only Subject to availability at the time, this is not a guarantee Quoted on a "per trip" basis We will bill at the premium rate if Exatron is required to have a service technician on-site within 1 business day. Any unforeseen, no fault of Exatron, travel delays will be still billed at the premium rate. Exatron best effort on making necessary repairs only Flat daily rate, no discount for repairs made in less than 8 hours Service price schedule: One-business-day on-site service trip within the USA (no Internet access) Labor performed at $2,000 per day All actual travel expenses billed to the customer $1,000 premium for guaranteed 1 business day service response time* One-business-day on-site service trip within the USA (with Internet access) Labor performed at $1,500 per day All actual travel expenses billed to the customer $1,000 premium for guaranteed 1 business day service response time* One-business-day on-site service trip outside the USA (no Internet access) Labor performed at $3,000 per day All actual travel expenses billed to the customer Travel time added to 1 Business day guarantee $1,500 premium for guaranteed 1 business day service response time* One-business-day on-site service trip outside the USA (with Internet access) Labor performed at $2,000 per day All actual travel expenses billed to the customer Travel time added to 1 Business day guarantee $1,500 premium for guaranteed 1 business day service response time* * Subject to availability at the time. One-business-day response time starts at time of departure from Exatron; travel time not included. There will be a substantial increase in travel costs for overnight travel. All of these costs are all passed on to the customer. Terms: Terms to be determined at time of service call. Field upgrade terms will be added to our quote. Actual travel expenses include: Air fare as required (All tickets to be purchased thru Exatron's travel agent) Rental car and/or cab fees Lodging Living expenses Field upgrade and all on-site service call shipping costs: In the event a spare part(s) needs to be shipped overnight to a customer's site during a service call or field upgrade. We will ship the package via the customer's account with the shipper. Should Exatron be required to ship via our account, we will then bill the customer for all shipping costs at actual cost plus 50%

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End-of-Life Handler Disposal

Customer Service Support Guide

End-of-Life Handler Disposal


Exatron has no time limit on Exatron product support. We will make every effort to repair any of our products, no matter how old it is. Our never-ending support greatly extends the life of many of our products. Exatron offers trade-in value on any of our products as part of a new Exatron equipment purchase. Exact terms are subject to quote at that time. This applies to any used Exatron product as a trade-in on any new Exatron product. We will service our products even when the product is not purchased directly from Exatron. This makes the resale value of Exatron products high as compared to many of our competitors. The customer can sell the product to a third party, used equipment vendor, or online as, for example, on eBay. Exatron will always offer spare parts, service contacts, and rebuilds of any of our products. Most of the materials used in the construction of our products can be recycled. When it comes time to finally retire an Exatron product, the customer can ship the product back to Exatron, at the customers expense, and we will quote the cost to dismantle and recycle the handler. In many cases, there is no charge for this service other than any third-party disposal fees as required. Whenever possible, reusable components will be offered as a donation to local schools. Please note that in many cases, Exatron builds systems using major third-party pieces of equipment. These include lasers, printers, camera inspection, chillers, fume extractors, and other large OEM (original equipment manufacturer) subsystems. Exatron will attempt to provide the same support as best we can for these subsystems. Exact details cannot be determined until the day comes that end-of-life service is required. The customer is free to contact the OEM directly for its end-of life service policy and then deal directly with that OEM.

Significance of This Manuals Version Number


The version number on the cover page of this manual indicates two levels of revision. The first number is incremented for brand new manuals or complete overhauls, including addition or deletion of chapters. The second number is incremented for small section changes and additions. For example, version 2.0 would refer to a completely redone manual or one that has had chapters moved, added, or deleted. The jump from 2.0 to 2.1 might include new or updated procedures, new screens or photos, or updated sections.

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Typographical Conventions Used in This Manual


Names of menu items, input boxes, and buttons are displayed in bold type, such as: Click the Start Test button. Names of tabs and group boxes are capitalized but not in bold type. Messages displayed on the hardware or software are shown in bold monospaced type, such as: If the tester responds correctly with an "R," you see the message: Pass checking tester. Emphasized words and phrases are displayed in bold and italicized type, such as: Start by calibrating Tray 1.

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Terms Used in This Manual

Customer Service Support Guide

Terms Used in This Manual


Bin Refers to a physical output location, such as a tray, bucket, or tube. Contrast with sort. A positive air pressure in the vacuum lines, used to break any residual vacuum between the pickup head and a device it was suctioning. A pop-up menu that is displayed when you right-click over an area or item. It offers actions appropriate to the item. Blow-off

Context menu

Figure 1-7: Context Menu

Device

A generic term that refers to the chip, package, or other part processed by the Exatron handler. A down-pointing arrow at the right end of an input box. Click the arrow to view and select from the possible options. Some drop-down boxes have a slider bar that you can slide up and down to view even more selections.

Drop-down arrow

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Figure 1-8: Drop-Down Arrow

Group box

A collection of input boxes, buttons, etc., on a window that are grouped together by function and purpose. They are usually surrounded by a thin box and a box title.

Figure 1-9: Group Box

Home position

The location that each motor returns to each time the handler is reset. A box where you can type in text or numbers.

Input box, or box

Figure 1-10: Input Boxes

Job file

Also called settings file. A file generated by the Exatron software that contains job parameters such as number of rows and columns per tray, distances each component must move to key positions, and destinations for each sort category. It may also contain certain references for laser marking or other peripherals, if applicable. Amount of play, or looseness, between a device and its holder. Refers to a logical output location; a type of test result. Contrast with bin.

Slop

Sort

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Photo Gallery of Optional Configurations

Customer Service Support Guide

Venturi

The component of a vacuum generator that sucks air in one hole as air pressure is forced along the pathways, thus causing a vacuum. Left/right axis. The X gantry that moves the pickup heads runs on the X axis. Deep axis. The device trays run on the Y axis. Vertical, up-and-down axis. The pickup nozzles rise and fall on the Z axis.

X axis

Y axis Z axis

Photo Gallery of Optional Configurations

Figure 1-11: Model 8000 with Programmer, Detaper, Lead/Ball Inspection, Laser, and Taper

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Figure 1-12: Model 8000 with Thermal Test Sites on the Left

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Photo Gallery of Optional Configurations

Customer Service Support Guide

Figure 1-13: Model 8000 with Taper on the Right

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Figure 1-14: Model 8000 with Preheating Tray and Laser

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Photo Gallery of Optional Configurations

Optional Accessories and Peripherals Available with Han-

Optional Accessories and Peripherals Available with Handler


As each handler is custom-built for the client companys needs, your handler may have various options. The most common are described in the following sections.

Figure 1-15: Preheating Tray Moving on Track

Figure 1-16: Refrigerated/Heating Circulators

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Figure 1-17: Customer-Ordered Tester Moving on Track

Figure 1-18: Another Customer-Ordered Tester

Testers come from various companies and are integrated to enable two-way communication with the Exatron handler. For details, see Appendix A. The Exatron test site docking ring is designed to accept the docking hardware designed for a specific part after it is fitted with a docking plate.

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Photo Gallery of Optional Configurations

Optional Accessories and Peripherals Available with Han-

Every type of test socket takes a specific Exatron docking plate. There are two major categories of test site sockets. RF/PI socketRequires pickup nozzle to clamp part in socket Independent clamp socketPusher-slider clamping mechanism attached to gantry Every new socket board will need a new docking plate designed for it. New docking plates are available on an ongoing basis; if you do not see a plate for your type of socket board, please contact Exatron for an updated list. If we do not have a plate for your socket board, we can design one for it.

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Figure 1-19: Laser

Models using an integrated laser have the laser head bolted into the handler. A laser is equipped with internal motors and mirrors, allowing the laser beam a range of movement to about 6.5 inches square.

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Photo Gallery of Optional Configurations

Optional Accessories and Peripherals Available with Han-

Figure 1-20: Multiple Pickup Heads; Multiple Inspection Sites

Figure 1-21: Lead/Ball Inspection

BGA (ball grid array) inspection is necessary for devices that have balls rather than pins as their feet or connectors. Each ball or pad must be inspected for regularity of roundness and absence of dents, flaws, or irregularities.

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Figure 1-22: Device with Balls to Be Inspected

See the inspection vendors manual for instructions on calibrating: Camera focusing Diffusion Brightness adjustment for the LEDs The ring light illuminates the device so the camera can get a good image. The round white diffuser focuses light on the device so the camera can see.

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Photo Gallery of Optional Configurations

Optional Accessories and Peripherals Available with Han-

Figure 1-23: Two Designs of Lead/Ball Inspection

A programmer programs devices with a given set of variables.

Figure 1-24: Programmer

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Figure 1-25: Detaper

Devices may be taken from a tape in a detaper for processing.

Figure 1-26: Barcode Reader

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Chapter 2: System Description


Chapter Overview
This chapter discusses features of your handler and concepts of how it works. This chapter deals with the following main topics: Topic System Overview Distinguishing Features Stacker Description Handler Movement Overview Stacker Movement Details Key Positions and Distances X, Y, and Z Axes Home Positions Numbering Order Graphic Display of X, Y, and Z Axes How X and Y Distances Are Measured How Z Distances Are Measured Base Mechanical Systems Electrical Systems Pneumatic Systems Gantry Mechanical Systems Pneumatic Systems Pickup Heads Thermal Test Assembly Tape-and-Reel Assembly CE Marking Standard Practice and Options Page 2-2 2-2 2-3 2-4 2-5 2-12 2-12 2-12 2-12 2-13 2-15 2-17 2-19 2-19 2-24 2-32 2-39 2-39 2-40 2-41 2-42 2-46 2-49

Exatron recommends that you read this part of the manual in the presence of the system to facilitate reference to the actual system. The parts of the system are identified as shown in this chapter. Following chapters show you how to put these concepts into practice and carry out procedures. The Exatron software is discussed primarily in Chapter 4 through Chapter 6.

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Chapter 2: System Description

System Overview
The Model 8000 handler is designed for high-volume, high-speed testing and/or laser marking of uniform devices presented in stackable JEDEC trays. With an intuitive user interface for automation control and advanced graphic design software for creating laser marks, combined with a state-of-the-art tray handling mechanism and safety enclosures, the Model 8000 handler is suitable for the most demanding production environments.

Distinguishing Features
The distinguishing features of the Model 8000 handler are: It uses high-speed, accurate linear motors. It uses stackers for the input and output trays, for 3-dimensional device travel. The Model 8000 has 3, 4, or 5 tray lanes, moving front to back: Regardless of the exact number of tray lanes, they are alike in function and description.

Figure 2-1: Model 8000-3 with 3 Lanes

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System Overview

Stacker Description

Figure 2-2: Model 8000-5 with 5 Lanes

Beyond these features in common, the Model 8000 may have one or several of a number of options.

Input
Devices may be input from trays, a detaper, a wafer, or other input. Tray 1 is on the left and is usually the input tray.

Processing
Devices are carried to a test site, programming site, inspection site, and/or a laser marking site, where they are processed.

Output
Each device is then carried to a destination: Pass or sort tray or tube Tape which is then sealed and wound onto a takeup reel

Stacker Description
Each lane has a stacker at each end. At the input end is a loading (input) stacker where the tray carriage docks to load input trays. At the output end is an unloading (output) stacker where the tray carriage docks to unload output trays.

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Each stacker has two lifter bars, one on each side. Each of the four stacker guideposts has a support pin that hold extra trays while the working tray is being used. These support pins retract while loading or unloading a working tray. Each lifter bar has two lifter pins (front and rear) that extend to hold extra trays while loading or unloading a working tray.

Tray clamps Lifter pins Tray clamps Support pins

Figure 2-3: Position of Pins

Each lane has a tray carriage that shuttles the working tray from the loading stacker to the working area. The working area is under the path of the pickup head on its way to and from the test site(s). From the working area, the tray carriage shuttles the working tray to the unloading stacker, then comes back empty to the loading stacker for another tray. The tray carriage also has a set of four pinstray clampsthat clamp the working tray securely in place on the carriage. Two tray clamp pins are at the front of the carriage, and two tray clamp pins are at the right side of the carriage.

Handler Movement Overview


The X motor moves the pickup head from right to left and back, carrying the devices from input to processing site to output. Some machines rotate each device at one or more points in this journey. Each lane is equipped with stackers that allow trays to be stacked up to 20 deep at both the loading and unloading sites. An operator stacks the loading (front) stacker for the input tray lane with trays filled with devices to be processed.

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System Overview

Stacker Movement Details

The handler separates the waiting trays from the bottom input tray, which it secures on the tray carriage. The carriage moves the working input tray to the middle of the lane, under the path of the pickup head. The pickup head moves each device from the input tray to a processing site (tester, laser, and/or inspection) and then to an output tray. As each input tray is emptied, it is shuttled by the carriage to the unloading stacker at the rear of the handler, and placed in the stack of empty trays. After processing, devices are placed into the output trays in the other lanes. When each tray is filled, it is shuttled by the carriage to the unloading stacker at the rear of the handler, and placed in the stack of filled trays.

Figure 2-4: Pickup Head Over Working Input Tray Separated From Waiting Trays

Stacker Movement Details


The input and output stackers follow precise routines to carefully load and unload each tray. These steps are described here.

Tray Loading Process


Before loading, the support pins are extended to support the suspended trays. 1. The lifter bars lower just below the support heightjust enough so the lifter pins are below the bottom tray of the stack. 2. The lifter pins extend and the lifter bars raise all trays on the stacker above the support pins.

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3. The support pins retract and the lifter bars lower all the suspended trays to the carriage. 4. The lifter pins retract to allow the trays to rest flush on the carriage. (At this point, the lifter pins are below the carriage height.) 5. The lifter bars rise a bit and the tray clamp pins extend to clamp the bottom tray. 6. The lifter pins extend between the lowest tray and the next tray above it. 7. The lifter bars raise the extra trays above the support height. 8. With the lifter pins still extended, the support pins are extended and the lifter bars lower just enough to set the trays on the support pins. 9. The lifter pins are retracted and the lifter rises. Now it is loaded.

Photographic Display of Tray Loading Process

Figure 2-5: Position Before Loading Begins

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System Overview

Stacker Movement Details

Figure 2-6: Lifter Bars Lowered Below Support Height (Step 1)

Figure 2-7: Trays Lifted Above Support Pins (Step 2)

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Figure 2-8: All Trays Lowered to Carriage (Step 3)

Figure 2-9: Lifter Pins Retracted; Clamp Pins Extended (Step 4)

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System Overview

Stacker Movement Details

Figure 2-10: Lifter Pins Extended Above Lowest Tray (Step 5)

Figure 2-11: Lifter Bars Raised to Lift Extra Trays (Step 6)

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Figure 2-12: Support Pins Extended (Step 7)

Figure 2-13: Lifter Pins Retracted (Step 8)

Tray Unloading Process


1. The lifter bars lower just below the support heightjust enough so the support pins are below the bottom tray of the stack. 2. The lifter pins extend. 3. The lifter bars rise above the support pins, lifting the trays off the support pins. 4. The support pins retract. 5. The lifter bars lower to the carriage, with the lifter pins still extended.

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System Overview

Stacker Movement Details

6. The lifter pins retract to allow the lifter to get below the tray to be lifted. 7. The lifter bars lower below the carriage. 8. The lifter pins extend to catch the bottom tray. 9. The lifter bars rise all the way, raising the trays. 10. The support pins extend. 11. The lifter bars lower to set the trays on the support pins. 12. The lifter pins retract. 13. The lifter bars rise. Now the unloading process is complete.

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Key Positions and Distances


X, Y, and Z Axes
The X axis is the plane on which the pickup head moves from right to left; from the trays to the test sites and back to the trays. The Y axis is the plane on which the trays move from input (loading) stackers, under the path of the pickup head, to the output (unloading) stackers. The Z axis is the plane on which the pickup nozzles move up and down, lifting and dropping devices. The loading and unloading stackers also move vertically, on the Z axis. The loading stackers put trays to the carriages, and the unloading stackers lift trays from the carriages.

Home Positions
TraysY home is at the front. Tester with socket gridY home is at the back. Right pickup headX home is at the right end of the X gantry. Left pickup headX home is at the left end of the X gantry. Pickup nozzleZ home is at the top of its travel. StackersZ home is at the top of their travel.

Numbering Order
Pickup head X1 motor is on the right. Test site 1 is at the left end of the handler. Tray Y1 is at the left. Other trays are counted from left to right: Y2, Y3, etc. Pin 1 of each tray is always at the upper left, identified by a 45-degree bevel. Column 1 is at the left, for both trays and testers with socket grids. Row 1 is found at the smallest distance the carriage must travel from its home position. > For trays, Row 1 is closest to the back of the handler. > For test socket grids, Row 1 is closest to the front of the handler.

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Key Positions and Distances

Graphic Display of X, Y, and Z Axes

Graphic Display of X, Y, and Z Axes


The following conceptual diagrams illustrate the movements on the X, Y, and Z axes.

Figure 2-14: X AxisPickup Heads Moving From Trays to Tester

Figure 2-15: Z AxisPickup Nozzle Moving to and from Trays or Tester

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Figure 2-16: Z AxisStackers Moving Trays to and From Carriage

Figure 2-17: Y AxisTrays Moving From Loading to Unloading Stackers

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Key Positions and Distances

How X and Y Distances Are Measured

How X and Y Distances Are Measured


This section and the next provide an overview only. Specific instructions and examples are found in several sections beginning with "Calibrating Positions for Auto Run" on page 4-54. The following example shows how X and Y distances are measured. The handler in this example has 3 tray carriages, each using 3 waffle packs. For this example, we are assuming it has only one pickup nozzle. The 9 waffle packs each need to have two locations calibrated: The corner pocket in the first row and column The corner pocket in the last row and column For each location, X, Y, and Z distances need to be measured, or calibrated. Therefore, this example setup needs the following measurements: 18 X distances (9 first pocket and 9 last pocket) 18 Y distances (9 first pocket and 9 last pocket) 18 Z get distances (9 first pocket and 9 last pocket) 18 Z put distances (9 first pocket and 9 last pocket)

Measuring X Distances
In Figure 2-18, the only movement we are dealing with is that of the X motor, which moves the pickup head. So the distances to be calibrated are the distances the X motor carrying the pickup head must move to be positioned over the centers of specific device pockets.

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Figure 2-18: X Motor Distances Diagram for 3-Tray Handler with 9 Waffle Packs

These distances have been filled in for each waffle pack, for the first row and the last row. NOTE: These measurements are examples only. Your measurements may differ.

Measuring Y Distances
The conceptual diagram in Figure 2-19 shows the Y distances for a hypothetical tray setup, each tray having three waffle packs. The packs are labeled with the tray number and the waffle suffix. Thus, the packs in tray Y1 are labeled Y1_1, Y1_2, and Y1_3. The packs in tray Y2 are labeled Y2_1, Y2_2, and Y2_3. Again in Figure 2-19, the only movement we are dealing with is that of the Y motors and trays. The pickup head stays in the back. Each tray must slide a certain distance toward the back, to get the proper device pocket under the pickup head. So the distances to be calibrated are the distances the Y tray must move to get the centers of specific device pockets under the pickup head. When using waffle packs, the position of the centers of the first and last pockets of each waffle pack must be measured.

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How Z Distances Are Measured

Figure 2-19: Y Motor Distances Diagram for 3-Tray Handler with 9 Waffle Packs

These distances have been filled in for each waffle pack, for the first column and last column. NOTE: These measurements are examples only. Your measurements may differ.

How Z Distances Are Measured


The Z motor is attached to the Y gantry, and drives the vertical movement of the pickup head. Z distances are measured down from Z home, which is at the top of the Z travel. The two important Z distances are Z-get (also referred to as the pick height) and Z-put (also referred to as the put height). These distances may vary slightly from tray to tray, and from trays to test site. The important thing to remember is that Z-put (the put height) for each location is higher than Z-get (the pick height) for that same location. Thus, the Z-put distance from Z home (at the top of Zs vertical travel) is a smaller number than the Z-get distance. This is because closer contact is required for the pickup head to pick up a device than to drop it into the pocket.

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The key to defining a pick height or Z-get distance is to have the suction cup just touching the device, but not flattened on it. The suction cup should be high enough that when you turn on the vacuum, you can see the device lift slightly against the suction cup.

Figure 2-20: Suction Cup at Z-Get (Pick Height)

Notice that the suction cup at Z-get (pick height) is just touching the device, but not flattened on it.

Figure 2-21: Suction Cup at Z-Put (Put Height)

Notice that the suction cup at Z-put (put height) is not quite touching the device.

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Base

Mechanical Systems

Base
Mechanical Systems
Motors
The motors used on the Exatron Model 8000 handler may be of several different types. Digital linear motors for the X-axis movement of the pickup heads Size 23 servo motors for the Z-axis movement of the stackers and the Y-axis movement of the tray carriages Size 17 servo motors for the Z-axis movement of the pickup heads Size 11 servo motors for the theta-axis rotation of pickup nozzles The digital linear motors have 1-micron linear encoders to convert from inches to steps. The servo motors transfer power to the lead screws by a standard flexible motor coupling. These motors are "smart" motors, in that after carrying out a command from the software to move to a certain position, they send back a response to the software that the movement was correctly completed. In this way, the handler is prevented from taking the next action until it is confirmed that the previous action was carried out.

Figure 2-22: Motors

Hub
The Model 8000 uses a hub for the linear motor driver (servo controller). This allows communication with the motor through the ethernet rather than through a serial port. The hub can be used to hook up the handler to an internal network.

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Figure 2-23: Hub

Figure 2-24: Linear Motor Drivers

Lead Screws
The lead screws employed on the Model 8000 are PTFE-baked and employ a Delrin nut for long-term reliability. As each lead screw is used, the teflon gradually wears off the lead screw and embeds itself in the nut to smooth out any irregularities in the nut, thus enhancing long wear. Two different pitches are employed on the Model 8000: the Z-axis screws are 1/2" pitch screws (i.e., the pickup nozzles move one-half inch for every complete rotation of the lead screw). The Y-axis lead screws are 1" pitch lead screws. The 1" pitch screw moves faster (it requires one-half as many steps on the motor to move the same distance as the 1/2" screw.

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Base

Mechanical Systems

A faster movement is preferred on the X axis where the single pickup head must move quickly to improve throughput. A slower motion is preferred on the Y axis where entire trays of devices are being moved (and not held by suction as on the X axis) and thus must not be rudely jostled.

Z motor

Y lead screws

Z lead screw

Figure 2-25: Lead Screws

Tray Carriages
Each tray carriage is mounted on its own lead screw (see above) and is guided and kept square to the system by two linear bearings. Trays are held in precise positioning on the carriage by four tray clamps that are automatically enabled at the beginning of a production run in Auto Run.

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Figure 2-26: Tray Carriage

Tray Configurations
The outline dimensions of Exatrons tray carriages are the JEDEC standard. If a company uses waffle packs, the company-specific waffle packs may be any dimensions that fit the tray carriages. A company may also decide to use two different configurations at the same time. One tray carriage may have waffle packs and another may use a single tray.

Figure 2-27: Waffle Pack with Outline Tray

CAUTION: Be careful when carrying or moving filled trays. Jerking the trays can dislodge devices from their pockets, costing clean-up time.

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Mechanical Systems

Smart Buckets
Some Model 8000s may include new "smart buckets," so called because of the sensors they are equipped with. Features of the smart buckets include: Easy to remove Plexiglass front cover Holes for optional padlocking in place Option in software to clear devices-in-bucket counts or not when the bucket is removed

Figure 2-28: Smart BucketsTop View (Left); Front View (Right)

The solenoid (must be 24-volt, not 12-volt!) in back locks the bucket in place. Two sensors are associated with each smart bucket. The sensor in back sees the bucket (Bucket Present sensor). The fiberoptic sensor inside performs two functions: Counts devices as they fall in. Warns when the bucket is full.

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Anti-Vibration Feet
The feet are equipped with shock-absorbing rubber pads to isolate the handler from external vibrations. Each foot can be individually leveled.

Figure 2-29: Anti-Vibration FootTop (Left), Bottom (Right)

Electrical Systems
Main Disconnect Switch
Your handler is equipped with a main disconnect switch (Figure 2-30). Turning off this switch shuts off AC power to the handler and its computer. Therefore, all computers connected to the handler should be shut down properly before turning off this switch. When the main disconnect switch is turned off, it can be locked so that repairs can be made to any component without danger of accidental startup. Thus, it can be used as a lockout procedure.

Figure 2-30: Main Disconnect SwitchIn OFF Position with Lock (Left),

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Electrical Systems

In OFF Position (Center), in ON Position (Right)

Emergency Stop Button


The EMO (emergency stop) button can be pushed in anytime there is a need to disable the motors and shut off the 24-volt AC. However, it leaves the computer running, so that when Auto Run is continued, the operator is given the choice of restarting where the handler left off with the device count.

Figure 2-31: EMO (Emergency Stop Button)

To release the Emergency Stop button, turn it clockwise until it pops out again.

HALT and RUN Buttons


The HALT and RUN buttons act to pause and restart Auto Run.

Figure 2-32: HALT and RUN Buttons

After pushing in the HALT button, you must push it a second time to release it before you can effectively push the RUN button to restart.

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Power Supplies
The Model 8000 uses two power supplies, both "switching" type. The first supplies 24-volt DC for the servo motors and the solenoids. Input is 100 to 240-volt AC and 50-60 Hz. Output is always DC. It auto-selects the correct input voltage. The second power supply is an ATX-style supply for the PC-104 motherboard. The CPU ATXstyle power supply for the PC-104 allows for manual switching. It supplies multiple voltage whatever is required by standard ATX specifications. Input is 115-volt or 230-volt AC and 50 or 60 Hz, switchable.

Figure 2-33: 24-Volt DC Power Supply

Figure 2-34: CPU Power Supply Installed

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Figure 2-35: ATX Power Supply Switched to 115 Volts (Left) and 230 Volts (Right) Input

The PC-104 motherboard uses all voltages of the ATX power supply. The PET-C06 I/O PCB uses 5 volts from the ATX power supply.

Fuses
The fuses for the Model 8000 system are standard 250-volt AC 5-amp fuses. One or more fuse holders are located on the outside panel of the computer box. These fuses protect the AC circuits. An additional front panel fuse protects the main AC circuit and is located next to the main power breaker on the computer box.

Figure 2-36: Fuses

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PC Boards
PCM-8152 motherboard This is the main computer board for the Model 8000 handler. It uses a PC-104 bus, which allows connection to the PET-C06 board.

Figure 2-37: Location of Jumpers and Connectors for PCM-8152 Motherboard

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Electrical Systems

PET-C06 I/O PC board This PC-104-based board sits over the motherboard and connects to the motherboard via the PC-104 bus. This board routes all the I/O signals for the motors, air solenoids, and sensors. A 40-pin flat cable routes the I/O signals to ports P1 and P2. In turn, port P1 goes to the 5000-M42 circuit board, and port P2 may go to the taper, if so equipped, or to other optional features.

Figure 2-38: PET-C06 I/O Board

5000-M42 board All I/Os come from the PET-C06 board. A 40-pin ribbon cable leads to the 5000-M42 board from the PET-C06 board. The 5000-M42 board (Figure 2-39) splits out inputs (sensors, etc.) and outputs (vacuums, blow-offs, etc.). Wires to all assemblies go through at least one Molex connector in order to facilitate repair and change.

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Figure 2-39: 5000-M42 Circuit Board

8000-D14 I/O PC board (optional) If the handler is equipped with a taper, an 8000-D14 board is added. The 8000-D14 board provides 24V and 5V to the taper solenoids and sensors. The 8000-D14 board is an intermediate I/O board that acts as a buffer, reducing risk of damage to the PET-C06 board. It can also amplify circuits.

Figure 2-40: 8000-D14 I/O Board

Serial Adapter
If your handler has a large number of motors, it may have a serial adapter or network hub to add serial COM ports.

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Figure 2-41: Serial Adapter (Left); Ethernet Switch (Right)

Sensors
Sensors confirm to the Exatron software that various moving parts are at the positions they should be. For example, home sensors tell the software when the pickup assembly, pickup nozzle, and tray carriages are at their home positions.

Pickup assembly home sensor

Figure 2-42: Pickup Assembly Home Sensor

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Light Pole
The light pole on each handler enables an operator to tell at a glance which machines in a room are running and which machines need attention. Color Red Yellow Green Blue Meaning Problem alert Needs operator assistance, such as reloading Handler is operating and busy Laser is operating (if handler is laser-equipped)

Figure 2-43: Light PolesWithout Laser (Left); With Laser (Right)

The background colors of software confirmation and error messages likewise have similar meanings.

Pneumatic Systems
For preventive maintenance procedures for the pneumatic system, see Chapter 7.

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Main Air Regulator


The main air regulator "steps down" the air pressure from the incoming supply for the entire handler. This air regulator is mounted either inside or outside of the lower cabinet. The regulator assembly includes two oil/water particulate traps which should be visually inspected on occasion (see the Preventive Maintenance chapter of this manual). This regulator should be set at factory air pressure of 80 PSI. The system requires a minimum of 80 PSI to operate properlyspecifically, to generate sufficient vacuum through the venturi to pick up devices from the trays. The incoming air line exits the regulator and splits to supply the needs of the entire system.

Adjustment valve

On/off switch in ON position

Figure 2-44: Main Air Regulator Turned On

The main air regulator is attached to a sensor, with a pressure switch with digital display on the outside of the handler (Figure 2-45). This sensor allows you to set a minimum air pressure, so that if the incoming air ever drops below that limit, the handler will stop.

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Figure 2-45: Air Pressure Switch with Digital Display (Left) and Vacuum Wand Attachment (Right)

Auxiliary Air Regulator


Model 8000s that have independent test site clamps include an internal, auxiliary pusher regulator.

Adjustment valve
Figure 2-46: Auxiliary Air Regulator

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Pneumatic Systems

Vacuum Generator with Sensor


The Model 8000 is supplied with a vacuum generator unit for each pickup head, mounted on top of the X-axis pickup heads and behind their motors. When the vacuum is engaged, a hissing noise is heard from its exhaust. It is controlled by an electric valve which is controlled by the handler electronics. In addition to creating a vacuum, the vacuum generator also acts as a regular air valve. It can produce a small positive air pressure, or blow-off, in the vacuum lines. This positive air pressure is used to break any residual vacuum between the pickup head and a device it was suctioning. The vacuum sensor notes when a device is released from the pickup head. It sends a signal to the Exatron software to increment the count of devices placed in various sort categories.

Figure 2-47: Vacuum Generators for Multiple Pickup Heads

A small adjustment screw can be found on the vacuum generator unit which will increase or decrease the blow-off pressure. CAUTION: Be careful when adjusting this screw, as loosening it will have the effect of increasing the blow-off pressure, but if the screw is turned too much it will come out and render the blow-off inoperable. Refer to the vacuum generator manufacturers manual for a drawing of the location of the adjustment screw. The vacuum generator is fitted with an electronic sensor that measures the strength of the vacuum drawn through the air lines. The sensor measures in centimeters of mercury (cmHg) and displays the result on the small LCD screen of the sensor. When the vacuum is engaged, the display should give a reading for the level of vacuum in the system. The sensor puts out a signal when a given level of vacuum is reached, indicating the vacuum has a secure hold on the device being lifted. For instructions on calibrating the vacuum generator, see "Checking and Setting the Vacuum Generator" on page 7-51.

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Finally, note the small white filter on the vacuum generator. If this filter becomes visibly dirty or contaminated, it must be replaced. Please refer to the Replacement Parts section of this manual for more information. A dirty filter means poor handler operation.

Figure 2-48: Dirty Filter (Left) Versus Clean Filter (Right)

Air Valves
Pressurized air for the air cylinders is controlled by a series of 24-volt DC air valves mounted on a manifold block inside the base of the handler. These channel air to the support, lifter, and tray clamp pins.

Figure 2-49: Air Valves

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Support, Lifter, and Tray Clamp Pins


Trays are supported and moved with the aid of three types of pins. A set of 4 support pins is extended from each stacker by default, with or without air pressure, to hold a stack of trays in the stacker. A set of 4 lifter pins is retracted in each stacker by default, and extended only when a stack of trays is being manipulatedeither loading the bottom tray onto the tray carriage, or unloading a tray from the carriage. A set of 4 tray clamp pins is attached to each tray carriage, and extended to secure the tray in place. Two pins are at the front of the carriage, and two are at the right side, pushing the tray toward the upper left corner.

Figure 2-50: Support Pin Retracted (Left) and Extended (Right)

Figure 2-51: Lifter Pin Retracted (Left) and Extended (Right)

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Figure 2-52: Tray Clamp Pin Retracted (Left) and Extended (Right)

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Gantry

Mechanical Systems

Gantry
Mechanical Systems
The X-axis gantry employs a linear motor with a linear motor driver (Figure 2-24), a linear bearing, and a linear motor magnet block to move a pickup head assembly along its length. An infrared through-beam home sensor is mounted to the wall on the motor end of the gantry. The encoder is the gold strip on the linear motor track. The reader head is attached to the side of the pickup assembly and reads the encoder (Figure 2-54).

Figure 2-53: X-Axis Linear Motor Track for Pickup Heads

Figure 2-54: Reader Head over Gold Strip Encoder for Linear Motor

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The pickup head assembly includes a servo motor which turns a short lead screw that drives the pickup head shaft down to the trays and test sites. Wires and air lines are brought to the pickup head by way of a flexible cable chain mounted behind the wall bisecting the long axis of the X gantry. The wires in the cable chain are highflexibility flat cable.

Z lead screw Cable chain

Figure 2-55: Cable Chain to Pickup Head (Left); Lead Screw Driving Pickup Head (Right)

Pneumatic Systems
The pickup head shaft is bored through and the vacuum/blow-off pressure passes through the shaft to the suction cup pick-up. Suction cups are available in various sizes, including 2, 4, 6, 8, and 10 millimeters. The typical size is 6 mm. In general, the preferred size is that which covers the largest possible surface of the device without running off the edge of the part or interfering with any other features of the device. However, there may be situations where a smaller suction cup is preferred, specifically in the case of bare silicon devices (FBGA, (BGA, etc.)

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Pickup Heads

Pneumatic Systems

Pickup Heads
Pickup heads can be custom-built for your companys needs. One option that may be built for the pickup head is rotation on the theta axis. This allows the devices to be turned 90 degrees in either direction before being placed at the test site. Some handlers have infinite rotation. Rotation may be specified at any angle, from 1 degree to 360 degrees.

Figure 2-56: Pickup Heads with Infinite Rotation

When there are multiple pickup nozzles, each may be rotated individually. Pickup heads can be built as two separate entities, moving to complement each other. They may move on the same or separate X gantries. Pickup heads can also be built as multiple nozzles on one X gantry. They move in tandem on the X axis, but individually on the Z axis.

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Figure 2-57: Multiple Z Pickup Heads on One X Gantry

Thermal Test Assembly


Thermal testing may be done by means of ambient, cold, and/or hot heads over test sites. In some cases one or two preheating trays may be included, to get the devices to the desired temperature before being placed in the test sites.

Figure 2-58: Preheating Tray

Handlers customized for thermal testing may have thermal heads on a separate assembly. If a handler is equipped with two testers, it will likely have two thermal head assemblies as well (Figure 2-59).

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Thermal Test Assembly

Pneumatic Systems

Figure 2-59: Left Thermal Head Assembly with Hot, Cold, and Ambient Heads (Left); Right Thermal Head Assembly in Reverse Order (Right)

Thermal heads commonly range from a cold of -55 degrees Celsius (using an appropriate chiller) to a hot of 125 degrees Celsius.

Figure 2-60: Hot and Cold Thermal Ranges

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Figure 2-61: Undersides of Thermal Heads with Purge Enclosures (Hot Head on Left, Cold Head on Right)

A clear retractable tube around the thermal head provides a defrost/purge enclosure for the test site. An air dryer is to be used with cold heads below around 50 degrees Fahrenheit or 10 degrees Celsius to prevent frost on the cold head from damaging the devices or test sockets. This dry or purge air provided by the air dryer slightly pressurizes the test area inside the clear tube and prevents moisture from seeping in to cause frost on any components. The usual order of testing, and the recommended best practice, is to test with ambient or room temperature first, then cold, and hot last; so that the device is placed in the output at a slightly warm temperature that collects no frost.

Figure 2-62: Hot Head Descending to Test Site (Left); Hot Head at Test Site (Right)

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Thermal Test Assembly

Pneumatic Systems

Figure 2-63: Cold Head Descending to Test Site (Left); Cold Head at Test Site (Right)

The thermal heads are driven, not by motors, but by air cylinders. They are pushed all the way to the bottom of their path of travel by positive air pressure. The amount of air pressure to the thermal heads can be adjusted in the Exatron software. Additionally, the thermal head control panel acts like override buttons, enabling you to manually raise and lower the thermal heads and turn on or off the air pressure. By fine-tuning the contact pressure at the test socket, the coplanarity of the device and contact surfaces is improved and the life of the contacts or interposers is extended.

Figure 2-64: Thermal Head Air Pressure Control Panel

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Chapter 2: System Description

Tape-and-Reel Assembly
Some handlers are equipped with a tape-and-reel assembly, or taper. The Model 202 taper uses fixed-width changeover kits that can accommodate devices of certain fixed widths. Alternatively, Model 202 may come with an adjustable-width changeover kit for different sizes or types of devices. A handler equipped with either taper places passed devices into a carrier tape which is then sealed with a sealing tape by either pressure or heat. The supply reel containing the carrier tape is the lower one, sometimes made of cardboard. The takeup reel is directly above it, usually made of plastic. The supply reel containing the sealing tape is toward the front. Supply reel with sealing tape Tape trackcounterclockwise direction Empty/ outof-pocket image sensor Output or takeup reel

Supply reel with carrier tape

Taper alignment screws

Figure 2-65: Reels on Taper

The carrier tape is fed in a counterclockwise direction, forward along the underside of the tape track, then backward along the top of the tape track. On the top surface, the gap sensor detects the hole in the center of the empty pocket, and signals the position to the pickup head. When the empty pocket intersects the path of the pickup head, the pickup head places a passed device into the tape pocket.

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Tape-and-Reel Assembly

Pneumatic Systems

Pickup head nozzle

Gap sensor

Figure 2-66: Tape Track with Sensors and Pickup Head

Behind the path of the pickup head, an image sensor ensures that a device is present and seated correctly in each tape pocket. Then the filled carrier tape is sealed, either with pressure-sensitive sealing tape or heatsealed cover tape. If pressure heads are used to seal, the pressure is continuous; but if heat seal heads are used to seal, the heat seal heads are pressed against the tape only intermittently to prevent burning. A fiberglass inset sits on the tape track just under the heat seal head. It retains heat at the sealing site instead of being dispersed to the rail. This inset is replaceable when worn. Wheels under the PSA seal head blade facilitate the tapes movement and reduce pulling tension from the drive gear.

Figure 2-67: Pressure Roller Block, Seal Head, and Image Sensor

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When a specified number of pockets have been filled, the takeup reel motor is activated long enough to wind the slack tape onto the upper takeup reel. The drive gear drives the tape along, with teeth that protrude upward to fit the holes on the side of the carrier tape. The pinch roller on the pressure roller block presses down on the tape, keeping it meshed with the teeth of the drive gear (Figure 2-68).

Figure 2-68: Pressure Roller Block (Left); Pinch Roller on Pressure Roller Block (Right)

Emergency Stop Button


The EMO (emergency stop) button on the taper plate shuts down everything on the taper only, including the heat seal; whereas the EMO button on the body of the handler stops all motors. Pressing the tapers EMO button causes a taper error message to be displayed on the Auto Run window. The operator then has the option of aborting the job run, or making any necessary adjustments and then selecting the option to continue the run.

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CE Marking Standard Practice and Options

Override Buttons

Override Buttons
The override buttons on the taper plate accomplish the same thing the software can do, but in a more direct way. Either may be used, according to the operators convenience.

Figure 2-69: Taper Override Buttons

Taper Buttons Button Top white Second blue Third yellow Affects Seal head Action When pressed, seal head is lowered onto the tape

Customizable option n/a Takeup reel motor When pressed, takeup reel moves, tightening tape slack

Bottom green Customizable option n/a

CE Marking Standard Practice and Options


Certain options may help your handler meet certain local or federal standards, such as the European CE Marking. The features shown below do not constitute a warranty that a handler equipped with them will meet any particular standards. We self-certify our products as CE Marking-compliant. Some handlers have been CE Marking certified by independent parties. If you need third-party CE Marking certification, this is an extra option.

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Figure 2-70: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right)

All Model 8000s are equipped with a main disconnect switch (Figure 2-70). Turning off this switch shuts off all AC power to the handler and computer(s). Therefore, all computers connected to the handler should be shut down properly before turning off this switch.

Figure 2-71: Gold Alodine Finish on Interior Surfaces

Conductive gold alodine (Figure 2-71) is a microscopic thin film Exatron uses on aluminum sheeting to provide increased corrosion resistance and impose desired electrical resistance characteristics; that is, to help with EMI shielding.

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Override Buttons

Figure 2-72: Ferrite EMI Noise Filter

An EMI filter is available as an extra option when CE Marking certification is desired. The EMI line filter smoothes out noise signals coming in on the power line.

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Chapter 3: Hardware Setup


This chapter discusses the following main topics: Topic Setting Up Your New Handler Changing Device Sizes Installing and Aligning the Laser Loading Trays or Tubes Powering Up the Handler System Powering the Laser System Shutting Down the Handler System Calibrating Stack Height Calibrating Lifter Bar Spacing Aligning Carriage with Stacker Calibrating and Loading a Detaper Setting Up a Taper Page 3-1 3-2 3-5 3-14 3-15 3-18 3-18 3-20 3-23 3-26 3-29 3-38

Setting Up Your New Handler


Your new Model 8000 handler comes complete and set up, including the software and the job file to get you started.

Leveling Feet
To increase handler stability, you must extend and lock the yellow anti-vibration feet to make the handler level. This helps prevent movement in case of earthquake. If desired, use brackets to anchor the feet to the floor after leveling. Each anti-vibration foot is attached with a right-handed thread. Level the handler by screwing each foot down. Use a carpenters level for best results.

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Figure 3-1: Anti-Vibration Foot

If you have a tester from another vendor, you will need to install it at the test site. Follow the instructions from the tester vendor. If Exatron was supplied with sample trays and devices from your company while your handler was being built, the job file that is installed on your handlers computer is factory preset to work with your tray configuration. All you need to do is verify that all the parameters are to your liking. This prodecure is covered in "Verifying the Factory-Installed Job File" on page 4-6. NOTE: Exatron recommends that if you make changes to the job file, you save the changes with a new file name, so that the original job file is preserved with its initial parameters. Instructions on saving a job file are found in "Copying the Job File for Modifications" on page 4-7 and "Saving the Job File" on page 4-73. If at a later time you change your tray configuration or some hardware, you may need to set up a new job file. Instructions for calibrating a new configuration are found in Chapter 4.

Changing Device Sizes


Changing device sizes for processing may require changing some or all of the following components (changeover kits).
Seal Head Blade TAPE-869-C 8mm TAPE-872-D 12mm Cover Tape Guide TAPE-680-D TAPE-680-D

Pickup Head PET-C68-TR-A 4 mm pitch PET-S52-TR-E 4 mm pitch

Tape Track TAPE-925-1-B 8mm-.116 TAPE-924-1-A 12mm-.158

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Changing Device Sizes

Replacing the Pickup Head

Pickup Head PET-S53-TR-C 8 mm pitch PET-S53-TR-C 8 mm pitch PET-S53-TR-C 8 mm pitch

Tape Track TAPE-779-1-G 12mm-.238 TAPE-923-1-A 16mm-.330 TAPE-923-1-A 16mm-.330

Seal Head Blade TAPE-872-D 12mm TAPE-873-B 16mm TAPE-873-B 16mm

Cover Tape Guide TAPE-766-B TAPE-935-B TAPE-935-B

Check or change the following changeover kits. Component


Pickup head Detaper Tape-and-reel assembly

Instructions on Page
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Replacing the Pickup Head


When changing device sizes, you may need to replace the pickup head. To replace the pickup head: 1. Press in the EMO button to turn off the motors. 2. Slide the pickup head to an open place where you can reach it easily. 3. Pull down on the pickup head so it is at the bottom of the Z travel. 4. Note the position of each colored air hose before removing. 5. Remove all air hoses on the pickup head by pressing on each orange fitting latch and pulling out the hose. 6. Using an Allen wrench, loosen but do not remove the two screws in the upper part of the head (Figure 3-2).

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Figure 3-2: Screws To Be Loosened When Changing Pickup Head

7. Pull down on the head and remove it from the shaft. 8. With the air fittings on the left, push the new pickup head up onto the end of the shaft. Make sure it is all the way up on the shaft. 9. Partially tighten the two screws on the side of the pickup head. Shaft hole Part number

Figure 3-3: Pickup Heads for Two Sizes of Device

10. Push the pickup assembly to the right, to where the head is flush against the side of the tray. Make sure both front and back ends of the pickup head are evenly against the tray (Figure 3-4). 11. Tighten the two screws on the pickup head.

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Installing and Aligning the Laser

Rotating the Laser Umbilical

12. Attach the air hoses in the same order to each nozzle.

Figure 3-4: Pickup Head Firm Against Tray Side

Installing and Aligning the Laser


If your handler comes with a Trumpf laser, follow these instructions. The tasks involved in installing and aligning the laser will be explained in detail in the following sections:

Task Rotating the Laser Umbilical Attaching the Laser to the Adapter Plate Adjusting the Laser Height Adjusting the Laser Rotation

Page 3-5 3-9 3-10 3-12

Rotating the Laser Umbilical


The lasers umbilical cord may have been rotated for compact shipping. You may need to rotate it to a position that causes less stress on the umbilical cord before installing the laser.

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Strain relief

Umbilical cord

Screws to remove

Figure 3-5: Strain Relief and Umbilical as Shipped

Remove the outer 4 screws to rotate the strain relief.

Figure 3-6: Removing Outer Screws

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Installing and Aligning the Laser

Rotating the Laser Umbilical

Figure 3-7: Rotating Strain Relief 90 Degrees

Figure 3-8: Strain Relief Mounted at Angle for Operation

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How the Adapter Plate and Deck Work to Align the Laser
The photo in Figure 3-9 shows two metal plates, one on top of the other. The top plate is the adapter plate; the bottom plate is the deck. The lower deck can be moved up and down only. It is fixed rotationally. The adapter plate on top of the deck can rotate.

Adapter plate

Deck

Figure 3-9: Laser Adapter Plate and Deck

The adapter plate has two functions. The laser is mounted on the adapter plate. The adapter plate is rotated in relation to the deck. The deck has two functions. The deck provides a seat for the adapter plate. The deck is used to raise or lower the laser.

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Installing and Aligning the Laser

Attaching the Laser to the Adapter Plate

Attaching the Laser to the Adapter Plate


The adapter plate has four screw holes and alignment pins, one in each corner, as shown by the circles in Figure 3-10.

Adapter plate

Deck
Figure 3-10: Laser Attachment Points

CAUTION: Before mounting the laser: Read the instructions in the laser manufacturers manual for handling the laser before beginning. Do not mount the laser by yourself! Two people are required to assist in mounting the laser. Wipe carefully to clean the bottom of the laser base and the top of the adapter plate. The presence of any debris, burrs, or particles will prevent the laser from seating firmly to the plate. To mount the laser: 1. Put the laser on top of the adapter plate with the hose at the rear of the unit and the black laser box over the front of the unit. 2. Match the screw holes to those on the adapter plate, and fit the laser over the alignment pins. 3. Tighten the laser screws with an Allen wrench.

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Figure 3-11: Tightening Laser Screws

Now you are ready to begin adjusting the laser position.

Adjusting the Laser Height


First you need to adjust the height of the laser. The operating distance for the laser is defined by: Proper scaling of the mark pattern, and... The focus position of the laser beam. This manual explains how you can adjust the laser by proper scaling of the mark pattern. The manual that came with your laser explains how to adjust the focus position of the laser beam. To adjust the laser height by scaling a mark pattern: 1. Tighten the bolts on the two sides of the adjustable laser mount. There are 4 bolts on each side. Be sure to tighten all 8 bolts on both sides.

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Adjusting the Laser Height

Figure 3-12: Bolts for Height Adjustment on Laser Mount

2. Take a blank device for test marking. To make it easier to see and measure the square that will be etched, coat the device with a black marker. 3. Place the prepared device at the laser mark position. Use Exatron's Diagnostics program to move the device to the mark site. (See "DiagnosticsLaser Window (Optional)" on page 6-87.) 4. In the laser marking program, open the marking file that has the correct dimensions that came with your handler and save it with a different name to avoid changing the original file. 5. Manually mark a small square on the device. 6. Measure the resulting square. > If the square etched on the device is smaller than the size you specified, you need to make the square larger. Do this by raising the laser height. > If the square etched on the device is larger than the size you specified, you need to make the square smaller. Do this by lowering the laser height. > If the square etched on the device is exactly the size you specified, you are finished with this procedure. Skip the following steps and go to the next section, "Adjusting the Laser Rotation." 7. Loosen all 8 bolts on both sides of the adjustable laser mount (Figure 3-12).

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Figure 3-13: Laser Head Elevator Crank

8. Turn the laser head elevator crank. > If you need to make the etched square larger, raise the laser height by turning the elevator crank clockwise. > If you need to make the etched square smaller, lower the laser height by turning the elevator crank counterclockwise. > Make small adjustments (less than 1 mm), then recheck scale. 9. Retighten all 8 bolts. > If you made adjustments, redo this entire procedure, including testing a new device, until the scale of the marking is exact. > If the laser power seems weak, refer to the laser manufacturers manual for instructions on adjusting the internal laser focus. > If you did not need to make adjustments, go on to the next procedure. You can now check the rotational alignment of the laser.

Adjusting the Laser Rotation


The rotation adjustment is seen most easily at the corners of the device. To adjust the rotation of the laser: 1. In the laser marking program, open the marking file with the correct dimensions and positions that came with your handler and save it with a different name to avoid changing the original file.

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Adjusting the Laser Rotation

2. Mark your test device at the corners with a black marking pen, as you did the middle of the device in the previous procedure. 3. Mark the device with the laser. 4. Measure the device markings. > If the mark on the lower left corner of the device is too far right, it needs to be moved to the left. It is as if the device needs to be rotated counterclockwise. > If the mark on the lower right corner of the device is too far left, it needs to be moved to the right. It is as if the device needs to be rotated clockwise. > If the mark on each corner of the device is exactly correct, skip to Step 9. 5. Loosen the screws on the two sides of the adapter plate. There are 3 screws on each side. Be sure to loosen all 6 screws on both sides.

Figure 3-14: Rotational Adjustment Screws

6. With your hand, push gently on one side of the laser mounting. > If the corners of the device need to be rotated clockwise, push on the right side of the laser head as you face it. > If the corners of the device need to be rotated counterclockwise, push on the left side of the laser head as you face it. 7. Retighten the screws. 8. Mark a new test device and, starting with Step 2, redo this procedure until the

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rotation of the marking is exact. Refer to the laser manufacturers manual for instructions.

Loading Trays or Tubes


CAUTION: Be careful when carrying or moving filled trays. Jerking the trays can dislodge devices from their pockets, costing clean-up time. CAUTION: Do not exceed the recommended weight or height of the combined trays for your application for any stacker. Ensure that the filled trays are perfectly aligned with one another before placing them on an input stacker. To secure a tube on the tube holder: 1. Hold the tube with the dowel hole at the top end.

Dowels on tube holder

Dowel hole on tube

Figure 3-15: Dowel on Holder Fits Dowel Hole on Tube

2. Slide the tube up the tube track, holding on the bottom end out away from the dowel.

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Adjusting the Laser Rotation

Figure 3-16: Tube Held Out Away from Dowel

3. When the tube reaches the top, push in the bottom end until you hear the dowel snap into the tube hole.

Figure 3-17: Tube Snapped Into Place on Holder

Powering Up the Handler System


Before you power up the system: 1. Make sure the daily maintenance has been performed. (See Chapter 7.) 2. Check that all power cables, connecting cables, monitor, mouse, and keyboard

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are plugged in. 3. Check that the air supply is on and has the correct pressure. 4. Close and latch all covers. 5. Check that the EMO (emergency stop) button is pushed in. To power up the system: 1. Turn the Baco lockable disconnect switch on the handler clockwise to the ON position (Figure 3-18).

Figure 3-18: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right)

2. Turn the black power switch on the computer clockwise to the ON position (Figure 3-19).

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Adjusting the Laser Rotation

Figure 3-19: Front of Computer with Black Power Switch

Figure 3-20: Power Off (Left); Power On (Right)

3. Flip up the system power switch to the ON position (Figure 3-20). 4. Flip up the button cover and press the yellow CPU button. This will power up the computer system. 5. Close the button cover to prevent accidental shutoff. 6. Turn on the monitor if necessary, and at the Windows password prompt, type the username and password. For the factory-set passwords, see "Passwords" on page 4-2. 7. Turn the red EMO (emergency stop) button clockwise to release it. This will

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power up all the system mechanics. NOTE: On systems using an automatic air shut-off valve, it is especially important to turn on the air regulator before releasing the EMO button. If this is not done, an unpleasant but harmless noise may issue until the EMO button is depressed and released again. After the desktop appears on the monitor screen, you can double-click the Exatron program icon, if it does not start automatically.

Powering the Laser System


If your handler is equipped with a laser, follow the laser manufacturers manual for power-up and power-down instructions.

Shutting Down the Handler System


Before you turn the handler off, you must properly shut down the computer. To shut down the handler system: > If a process is running, click the Abort Process button in the Auto Run window. 1. Click the Exit button on the Exatron Auto Run window. 2. Click the Exit button on the Exatron main window. 3. Perform the normal Windows shutdown on the handler computer: Click the Start button in the lower left corner of the screen. Click Turn Off Computer.

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Adjusting the Laser Rotation

Figure 3-21: Shutting Down Windows from the Start Button

4. In the Turn Off Computer dialog box, click Turn Off.

Figure 3-22: Selecting the Turn Off Option

> The yellow CPU button light will go off when Windows has shut down. 5. You can leave the black power switch turned on. 6. Push in the red EMO (emergency stop) button. 7. Turn the Baco lockable disconnect switch on the handler counterclockwise a quarter turn to the OFF position (Figure 3-23).

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Figure 3-23: Lockable Disconnect SwitchIn ON Position (Left), in OFF Position with Lock (Right)

Calibrating Stack Height


Two tasks are closely connected in calibrating the stackers: adjusting the lifter bar spacing (page 3-23) and the stack height. Do both of these at the same time. The stack height is the distance from the stackers home position at the top of its cycle to the stacker position where its extended lifter pins are just above a tray resting on the carriage. Finding the correct stack height is important. If the stack height is wrong, the lifter pins will dig into the sides of a tray during loading or unloading, rather than extending cleanly between trays to separate them. The stack height is correct if the tray can slide freely under the extended lifter pins. NOTE: If some corners seem to slide freely but others dont, the tray carriage may not be level. See "Tray Clamp Pins Fail to Secure Trays" on page 7-83. To change the stack height: 1. Place an empty tray on the carriage. 2. Open the Exatron software, click the Diagnostic button, and click the Fine Tune tab. 3. From the Selections, select the stacker whose height you want to calibrate (Figure 3-24).

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Adjusting the Laser Rotation

Figure 3-24: Input/Output Stacker to Stack Height

4. Make sure the Lift Cylinder checkbox and the Tray Clamp Front checkbox are not checked, so that the lifter pins and tray clamp pins are retracted. 5. Click the Stack Move To button. > The lifter bars lower to the stack height. 6. Check the Lift Cylinder checkbox. > The lifter pins extend.

Figure 3-25: Extending Lifter Pins

7. Raise the cover and gently try to slide the tray back and forth on the carriage. >If the lifter pins are too low for the tray to slide freely under the extended lifter pins, click the [Up] jog arrow button to the left of the Stack Move To button one or more times. Each time you click it, the lifter bars with their pins rise by the increment shown in the Scale box.

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8. Place a finger under each corner of the tray and try to lift it (Figure 3-27). >IIf the lifter pins are too high and the tray can be lifted from the carriage, the pins might jam into a tray above when separating trays. Click the [Down] jog arrow button to the left of the Stack Move To button one or more times. Each time you click it, the lifter bars with their pins lower by the increment shown in the Scale box.

Figure 3-26: Calibrating Stack Height

Figure 3-27: Checking Lifter Pins/Stack Height

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Adjusting the Laser Rotation

Calibrating Lifter Bar Spacing


Two tasks are closely connected in calibrating the stackers: adjusting the lifter bar spacing and the stacker height (page 3-20). Do both of these at the same time. If the lifter bars are too far apart, trays may be allowed to fall during the loading or unloading process. If the lifter bars are too close together, the lifter pins may damage the trays and/or prevent the proper loading or unloading of trays. The lifter pins are correctly positioned if they extend past the outer tray ridge and just to the inner tray ridge, as shown in Figure 3-31. Four lifter pins are at each loading or unloading station, two on each side. Check each lifter pin individually, as one or more may be incorrectly adjusted, whereas the others may be correct. To calibrate the distance for each lifter pin: 1. Place an empty tray on the carriage. 2. Open the Exatron software, click the Diagnostic button, and click the Fine Tune tab. 3. From the Selections, select the stacker whose lifter bars and lifter pins you want to calibrate (Figure 3-28).

Figure 3-28: Input/Output Stacker to Stack Height

4. Make sure the Lift Cylinder checkbox and the Tray Clamp Front checkbox are not checked, so that the lifter pins and tray clamp pins are retracted. 5. Click the Stack Move To button. > The lifter bars lower to the stacker height.

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Figure 3-29: Calibrating Lifter Bar Spacing

6. Check the Lift Cylinder checkbox and the Tray Clamp Front checkbox. > The lifter pins and tray clamp pins extend. With the tray clamp pins extended, the tray is in its Auto Run position. Thus you can more easily see which corner needs calibration, if any.

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Adjusting the Laser Rotation

Figure 3-30: Extending Lifter Pins and Tray Clamp Pins

7. Look at the positions of the lifter pins in relation to a tray on the carriage. > Each pin should extend over the outer ridge of the tray, and extend just to the inner ridge.

Figure 3-31: Lifter Too Far Out (Left); Lifter Correctly Positioned (Right)

8. If any lifter pin is too far out or in, loosen the screw closest to it with an Allen wrench (Figure 3-32). 9. Press gently on the lifter bar to widen or narrow the distance of the lifter pin in relation to the tray. 10. When the distance is correct, retighten the screw.

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Figure 3-32: Lifter Screw Loosened, Lifter Position Adjusted

Aligning Carriage with Stacker


The carriage must be correctly aligned with each stacker for ease of tray transfer to and from the carriage. The following photos show the contrast between a carriage incorrectly positioned and one correctly positioned.

Figure 3-33: Tray Carriage REAR Too Far Forward (Left) Versus Correctly Positioned (Right)

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Adjusting the Laser Rotation

Figure 3-34: Tray Carriage FRONT Too Far Forward (Left) Versus Correctly Positioned (Right)

To align the carriage with a stacker: 1. Place an empty tray on the stacker. 2. Open the Exatron software, click the Diagnostic button, and click the Fine Tune tab. 3. From the Selections, select the stacker whose alignment with the carriage you want to calibrate.

Figure 3-35: Input/Output Stacker Lift to Tray Carriage

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Figure 3-36: Aligning Carriage with Stacker

4. Type the distance from tray carriage home position to the selected stacker. 5. Click Tray Move To to bring the carriage to the selected stacker. 6. Look at the position of the carriage in relation to the stacker, comparing the photos in Figure 3-33 and Figure 3-34 to your setup. >If the selected tray carriage is too far left of its centered position, increase the distance from carriage home by clicking the [Increase Distance] jog button. Each time you click this button, the carriage moves toward the right of the handler by the distance shown in the Scale input box. >If the selected tray carriage is too far right of its centered position, decrease the distance from carriage home by clicking the [Decrease Distance] jog button. Each time you click this button, the tray moves toward the left of the handler by the distance shown in the Scale input box. 7. After doing a visual alignment, fine-tune the alignment by clicking the Load (or UnLoad) button in the Stack Height group box. > If the tray loads smoothly, the alignment is okay. > If the tray has trouble loading, place the tray back on the stacker, click Tray Motor Home, and then do Steps 5 through 7 again.

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Calibrating and Loading a Detaper

Loading the Detaper

Calibrating and Loading a Detaper


If your handler has a Hover-Davis detaper, this short guide will get you started. See the manufacturers documentation for more details.

Figure 3-37: Tape Threading Diagram on Side of Detaper

Loading the Detaper


Follow the directions in the Hover-Davis manual for threading the detaper. Just a few extra guidelines and points to note are included here. To note when threading the detaper: 1. Fit the supply reel onto the shaft, with the supply tape coming clockwise off the top of the reel. 2. Fit the tensioner arm down over the lip of the supply reel (Figure 3-38). This prevents the spool from falling off the shaft as it spins.

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Figure 3-38: Detaper Supply Reel Tensioner Arm

3. Thread the tape forward under both of the rollers (Figure 3-39).

Figure 3-39: Carrier Tape from Supply Reel Threaded Under Both Rollers

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Loading the Detaper

Figure 3-40: Tape Window LatchClosed (Left), Opened (Right)

4. Open the front tape window latch by pulling it up, then out (Figure 3-40). 5. Raise the tape window and pull the tape through (Figure 3-41). 6. Peel the cover tape back over the top of the window.

Figure 3-41: Tape Window Raised

7. Thread the cover tape over the roller behind the tape window and then under the takeup reel, in a clockwise direction. Tape the end to the reel with ESD-safe

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tape (not Scotch tape) and wind it one or two revolutions. CAUTION: Do not use adhesive tape on the carrier tape, as it contains static electricity and can ruin the static-free condition of the carrier tape.

Figure 3-42: Winding Cover Tape Onto Reel

Figure 3-43: Cover Tape Wound Onto Reel

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Loading the Detaper

Figure 3-44: Tape Sprockets Fitting Over Gear Teeth

8. Fit the tape sprockets over the gear teeth (Figure 3-44).

Figure 3-45: Tape Sprockets Fitting Over Gear Teeth

9. Adjust the tape so it is positioned with the ridge between pockets lining up with the grooves at the front of the tape window (Figure 3-45). 10. Fasten down the tape window, and give a little tug on the front of the carrier tape to ensure the sprocket teeth are engaged in the tape. If it is necessary to adjust the tape position, see the next section.

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Aligning the Detaper with the Path of the Pickup Head


If you determine that the only site out of line with the path of the pickup head is the detaper, you can move it forward in tiny adjustments. CAUTION: It is better to start with the detaper just behind the correct path rather than in front of the path. This is because the adjustment screw can push the detaper forward in tiny amounts, but it cannot pull it back. It would have to be pulled back by hand and the process of alignment begun all over again.

To align the detaper forward: 1. Loosen the 6 locking screws on the side plate (Figure 3-46), but do not remove them.

Figure 3-46: Detaper Locking Screws on Side Plate

2. Turn the adjustment screw in the back just 1/4 turn (Figure 3-47).

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Aligning the Detaper with the Path of the Pickup Head

Figure 3-47: Detaper Adjustment Screw

3. Using the Fine Tune window of Exatron Diagnostics, pick a device from the detaper with the pickup head and put it in the test site. 4. Pick the device back up from the test site and move it over the detaper. 5. Visually inspect its position in relation to the tape. > If its position looks good at this height, lower the pickup head to the Z-put position. > If further adjustment is needed, turn the adjustment screw just 1/4 turn at a time until the device fits perfectly in line with the other sites along the path of the pickup head. 6. When you have finished adjusting the detaper position, tighten the 6 locking screws on the side plate.

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Using the Control Panel


On the top of the detaper sits the control panel.

Status light

Forward Feed button

Single Hole Feed button

Reverse Feed button Decrease Pitch Index button Pitch Index Display Increase Pitch Index button
Figure 3-48: Detaper Control Panel

The Pitch Index display number at the bottom of the panel signifies the number of sprocket holes between each pocket center (Figure 3-49, left) or, in the case of multiple simultaneous pickups, between the center of the first pocket to be picked and the center of the last pocket to be picked. Note in Figure 3-49, right, that although each pocket has 2 sprocket holes, the total is only 6, not 8. They are counted from pocket center to pocket center. Thus, 4 pockets at a time will be moved.

Figure 3-49: Counting Number of Sprocket Holes Between Pocket Centers Between Single Pockets (Left), Between Four Pockets (Right)

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Using the Control Panel

To increase this number, press the Increase Pitch Index (+ sign) button below the display once for each increment. To decrease this number, press the Decrease Pitch Index (- sign) button above the display once for each decrement. Above the Pitch Index Display are three directional buttons. The Reverse Feed button is the lowest, surrounded by a down-pointing arrow. The Single Hole Feed button is in the middle, surrounded by a rectangle. The Forward Feed button is the highest, surrounded by an up-pointing arrow. Above the buttons is the status indicator light. To make the detaper ready when the status light is yellow, press the Single Hole Feed button. The status light turns green. To move the tape forward the distance of one pocket, press the Forward Feed button. To move the tape backward the distance of one pocket, press the Reverse Feed button. To move the tape forward the distance of one sprocket hole, press the Forward Feed button while you are holding down the Single Hole Feed button. To move the tape backward the distance of one sprocket hole, press the Reverse Feed button while you are holding down the Single Hole Feed button.

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Setting Up a Taper
Supply reel with sealing tape Taper EMO button Empty/ outof-pocket image sensor Output or takeup reel Tape trackcounterclockwise direction

Supply reel with carrier tape

Taper alignment screws

Figure 3-50: Model 202 Taper

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Setting Up a Taper

Changing Taper Changeover Kit for Different Device Sizes

If your handler has a taper, include the following procedures in your setup. Task
Changing Taper Changeover Kit for Different Device Sizes Mounting a Takeup Reel Mounting a Supply Reel Replacing the Tape Track Loading the Carrier Tape Loading the Sealing Tape Adjusting the Position of the Taper Adjusting Seal Head Setting Temperature for Heat Seal Head

Page
3-39 3-41 3-42 3-43 3-45 3-48 3-52 3-53 3-60

Changing Taper Changeover Kit for Different Device Sizes


The tape-and-reel assembly is one of the components that should be changed before processing a new device size. For the other components, see "Changing Device Sizes" on page 3-2. To change the taper changeover kit: 1. Push in the EMO button on the taper (Figure 3-50) to make sure the heat seal head is turned off. If the seal head was on, wait until it is cold. 2. Lift the pressure roller block out of the way by raising the top screw with your index finger and holding it while you push the keeper pin to the right, into the pressure roller block (Figure 3-51). This holds the pressure roller block in the raised position.

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Figure 3-51: Lifting Pressure Roller Arm and Pushing In Keeper Pin

3. Cut and remove the carrier tape and cover tape and the reels they are on. 4. Mount the new size of carrier tape and cover tape reels as described in "Mounting a Takeup Reel" on page 3-41 and "Mounting a Supply Reel" on page 3-42, but do not thread them yet. 5. Replace the tape track tooling as described in "Replacing the Tape Track" on page 3-43. 6. Replace the seal head blade as described in "Changing Seal Head Blade" on page 3-55. 7. Thread the carrier tape and cover tape as described in "Loading the Carrier Tape" on page 3-45 and "Loading the Sealing Tape" on page 3-48. 8. Turn on the handler computer to provide power to the taper. 9. Push and turn the EMO button on the taper control panel to release it. 10. Adjust the gap sensor by loosening the red thumbscrew (Figure 3-52, left) and sliding the sensor left or right a little until the sensor beam sees through the hole in the bottom of the tape pocket. When it does, the Gap LED on the taper control panel lights up (Figure 3-52, right). When the sensor is positioned, retighten the red thumbscrew.

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Mounting a Takeup Reel

Figure 3-52: Gap Sensor (Left); Gap Sensor LED Lit (Right)

Make any other necessary adjustments to the taper as described in the rest of this chapter.

Mounting a Takeup Reel


To mount an empty takeup reel: 1. Loosen the thumbscrew on the locking hub of the takeup wheel drive shaft located on the extreme left of the taper (Figure 3-53). Remove the hub and place an empty takeup reel onto the drive shaft. 2. With the three hub pins aligned to the three pinholes in the center of the reel (Figure 3-53), slide the locking hub over the reel and back into place. 3. Tighten the thumbscrew to lock the takeup reel in position.

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Figure 3-53: Locking Hub on Takeup Reel with Alignment Pins

Mounting a Supply Reel


Slide the carrier tape supply reel onto the three center prongs of the supply wheel so that the carrier tape unwinds from the bottom of the reel toward the right (Figure 3-50, Figure 3-54).

Figure 3-54: Center Prongs of Supply Reel

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Setting Up a Taper

Replacing the Tape Track

Replacing the Tape Track


To replace the tape track: 1. Turn off the air regulator. 2. Unscrew and remove the two screws on the side of the tape track (Figure 3-55). 3. Remove the air hose (Figure 3-55, right) by pushing up and holding the orange ring and pulling down on the vinyl air hose.

Figure 3-55: Screws on Side of Tape Track to Be Removed

4. Loosen the screw on the cover tape guide block assembly and push it to the left (Figure 3-57). 5. Slide the track out to the side and remove. 6. Slide in the new tape track. > You can confirm the size device the tape track uses in two ways. The sample of the correct tape is attached to the side of the track, and the part number is etched on the fiberglass inset on the top of the track (Figure 3-56).

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Figure 3-56: Tape Track with Part Number and Sample Tape

7. Screw in the two track screws. 8. Insert the air hose into the fitting.

Figure 3-57: Cover Tape Guide Block Assembly Pushed Left

> If you need to change the guide block, slip it off the guide rod and replace the new guide block on the rod (Figure 3-58).

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Loading the Carrier Tape

Figure 3-58: Guide Block Partly Removed from Rod

9. Adjust the guide block to fit directly over the carrier tape and sealing tape. 10. Push the guide block down so that it is flush against the carrier tape. 11. While holding the thin edge down, tighten the adjustment screw on the guide block assembly (Figure 3-70).

Loading the Carrier Tape


To load the carrier tape: 1. Feed the leading end of the carrier tape (the leader) toward the sealing tape guide as shown above, making sure that the rear edge of the tape is under the guide at the rear of the track.

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Figure 3-59: Carrier Tape Under Guide At Bottom Rear of Track

2. Push it toward the front of the underside of the tape track. Until it gets to the front, there are no more guides to thread it through. You can see the tape slack under the track. 3. At the bottom front is another guide. Thread the tape through it. 4. Bring the tape to the top side and thread it through the guides.

Figure 3-60: Carrier Tape Under Guide At Top Front of TrackSide View (Left); Top View (Right)

5. Continue feeding the carrier tape leader under the sealing heads. The sealing heads should be raised above the level of the carrier tape at this point. 6. When the carrier tape leader in the track reaches the pressure roller block, raise the top screw with your index finger and hold it while you push the keeper

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Setting Up a Taper

Loading the Carrier Tape

pin to the right, into the pressure roller block. This holds the pressure roller block in the raised position while you feed the carrier tape along the track underneath.

Figure 3-61: Lifting Pressure Roller Arm and Pushing In Keeper Pin

7. Feed the carrier tape under the projecting takeup arm and over the peel tester knob, if one is installed. Insert the carrier tape leader into the takeup reel according to the manufacturer's specifications. Wind the carrier tape around the take up reel until it is secured in place. The carrier tape should move freely back and forth underneath the takeup arm.

Figure 3-62: Tape Under Takeup Arm

8. Let down the pressure roller block by slowly pulling the keeper pin out to the left until the pinch roller is lowered and just the right pressure on the tape.

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Loading the Sealing Tape


To load the sealing tape: 1. Sandwich a roll of sealing tape between the two sealing tape plates, making sure the roll is snugged around the larger raised circle on the inside (Figure 363).

Figure 3-63: Sealing Tape PlatesOutside (Left), Inside (Right)

2. Suspend the reel on the sealing tape supply reel rod in the center of the taper between the two blue delrin supply reel adjustment collars (Figure 3-64), with the tape coming off the bottom of the reel.

Figure 3-64: Adjustment Collar on Sealing Tape Supply Reel

3. Viewing from above, position the sealing tape supply reel centered over the carrier tape in the carrier tape track. Tighten the adjustment set screw on each

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Setting Up a Taper

Loading the Sealing Tape

supply reel adjustment collar to secure the sealing tape supply reel in this position on the rod. 4. As shown in Figure 3-65, the sealing tape unwinds from the bottom of the reel in a counterclockwise direction toward the sealing tape guide assembly. Feed the sealing tape to the right over both pins of the sealing tape guide assembly and then under the guide block to the left. Notice that the tape rests on the upper, larger projecting pin but never touches the lower, smaller projecting pin.

Figure 3-65: Sealing Tape Threaded to Sealing Tape Guide Assembly

Figure 3-66: Model 202 Sealing Tape Threaded to Sealing Tape Guide Assembly (Left); Sealing Tape Threaded Under Guide Block (Right)

> Guide blocks come in widths from 8 mm to 72 mm (up to 120 mm by special order). There are two sets of grooves on the underside of the guide block.

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The outer set of grooves guides the carrier tape. The inner set of grooves guides the sealing tape.

Figure 3-67: Two Widths of Guide BlocksTop View (Left); Bottom View (Right)

Figure 3-68: Placement in Grooves of Guide Blockof Sealing Tape (Left) and Carrier Tape (Right)

5. Check to make sure the guide block is the right width for the tape you are using. 6. Loosen the side screw on the guide block assembly. > If you need to change the guide block, slip it off the guide rod and replace the new guide block on the rod (Figure 3-69).

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Loading the Sealing Tape

Figure 3-69: Guide Block Partly Removed from Rod

7. Adjust the guide block to fit directly over the carrier tape and sealing tape. > Push the guide block down so that it is flush against the carrier tape. > While holding the thin edge down, tighten the two adjustment screws on the guide block assembly (Figure 3-70). The carrier tape should now be inside the outer set of grooves on the guide block.

Figure 3-70: Guide Block Assembly

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8. Use light pressure or heat to attach the sealing tape to the carrier tape. CAUTION: Do not use adhesive tape on the carrier tape, as it contains static electricity and can ruin the static-free condition of the carrier tape. 9. Feed the sealing tape under the guide block assembly. Advance the tape until approximately five inches of sealing tape extends past the sealing heads. The sealing tape should now be in between the inner set of grooves on the guide block.

Adjusting the Position of the Taper


NOTE: This feature is available only if the Model 202 tape track is parallel to the path of the pickup head. If the tape track is perpendicular to the path of the pickup head, any adjustments can be done in the Exatron software. NOTE: Perform this task after you have calibrated the other positions in the path of the pickup head(s), as described in Chapter 6. The taper is set at the factory to be perfectly in line with the path of the pickup head. However, if at some time you remove the taper or make major adjustments, the procedure for realigning the taper is straightforward. To align the tape track with the path of the pickup head: 1. Loosen the 4 bolts at the base of the taper (Figure 3-71) but dont remove them. 2. Turn the taper alignment knob slightly to change the position of the tape track so it is in line with the path of the pickup head.

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Adjusting Seal Head

Figure 3-71: Taper Alignment Knob Above Base Bolts

3. Using the Exatron Diagnostics software, place a set of devices in the tape with the pickup head. > If necessary, readjust the taper alignment knob and repeat the placement test. 4. When the alignment is perfect, retighten the 4 bolts.

Adjusting Seal Head


Several adjustments may need to be done for a seal head: lateral alignment, downward pressure, and speed of descent and ascent of seal head. Correct lateral alignment assures that the seal heads are on the sealing edges of the tape; correct pressure balances the degree of heat needed to seal without tape damage. Additionally, the sealing blade will need to be changed on occasion.

Understanding Blade Sizes and Orientation


Common tape widths are shown below, with part numbers for the corresponding seal head blade and cover tape guide. Size
8 mm 8 mm 12 mm 12 mm

Type
Heat seal PSA Heat seal PSA

Blade Number
TAPE-869 TAPE-953 TAPE-872 TAPE-952

Cover Tape Guide Number


TAPE-680 TAPE-680 TAPE-766 TAPE-766

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Size
16 mm 16 mm

Type
Heat seal PSA

Blade Number
TAPE-873 TAPE-954

Cover Tape Guide Number


TAPE-723 (cover tape width 0.525) or TAPE-935 (cover tape width 0.545) TAPE-723 (cover tape width 0.525) or TAPE-935 (cover tape width 0.545)

Figure 3-72: Two Sizes of Heat Seal Blades: 16mm, Top, and 12mm, Bottom

Notice in Figure 3-72 that whereas different blade sizes are the same length, the spacing of the runners is what determines the width in millimeters. The runners on the top blade are spaced 16 mm apart, while the runners on the bottom blade are spaced only 12 mm apart. Pressure seal blades

Heat seal blades


Figure 3-73: Top Side of Blades As They Slide into Seal Head (Left); Bottom Side of Blades That Contact Tape (Right)

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Setting Up a Taper

Adjusting Seal Head

Changing Seal Head Blade


You need to change the blade in the bottom of the seal head in two circumstances: You are changing tape width to accommodate a different size of devices. You are changing between heat and pressure sealing tape. To change the seal head blade: 1. To remove the blade, insert a screwdriver as shown in Figure 3-74 and push up on the movable screw and hold it. Pull the blade out to the left as shown.

Figure 3-74: Replacing Heat Seal Head Blade

Figure 3-75: Seal Head with Empty Rails for Blade Insertion (Back View)

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2. To insert a different blade, insert a screwdriver as shown in Figure 3-74 and push up on the movable screw and hold it. Slide the blade in from the left with the smooth side up and the dowel hole toward you (Figure 3-76), then release the screw. 3. Center the blade under the seal head, sliding it back and forth until you can hear it snap and feel it catch.

Figure 3-76: Pressure Seal Blade Inserted Partway into RailTop View (Left), Side View (Right)

Notice that the blade must be inserted with the smooth side up and the hole out toward the operator (Figure 3-76, left). When it is slid into the rails of the seal head, it does not touch the surface of the tape track (Figure 3-76, right).

Adjusting Seal Heads Lateral Position


Use this procedure to align the lateral position of the seal head. This should need to be done very seldom; only when changing tape width by a large amount. To align lateral position of the seal head: 1. Make sure the heater is off and that the seal head is cool. 2. Loosen slightly but do not remove the six screws on the back side of the taper that are connected to the seal head (Figure 3-77). 3. Turn the red thumbscrew for small adjustments to move seal head away from taper base. Push gently with hand to move seal head closer to taper base.

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Adjusting Seal Head

Figure 3-77: Six Lateral Adjustment Screws for Seal Head; Thumbscrew for Small Adjustments

4. Retighten the six screws. 5. Once the head is aligned, turn the heat to the sealing head back on. Set the temperature on the heater to the desired heat. Wait until the display has stabilized. WARNING! Do not touch the heat seal heads directly when the heat is turned on. 6. After the sealing head has warmed up, check the seal on the sealing tape. Manually engage the seal head. Apply pressure to the sealing tape for 3 to 5 seconds. Use the takeup arm to engage the head. This should cause a good seal to the carrier tape. Manually advance the carrier tape and inspect the seal. 7. Run the carrier tape for several pockets with the seal head engaged. NOTE: You may need to practice this adjustment a few times by running the machine briefly at the start of a job and inspecting the seal for quality.

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Figure 3-78: Example of Good Tape Seal

Adjusting Seal Heads Downward Pressure


You may need to adjust the pressure of the seal head. This pressure is controlled by the auxiliary air regulator on the back side of the tape track. To adjust pressure of seal head: Pull out the black adjustment valve just below the seal head. > Turn the valve clockwise to increase the pressure. > Turn the valve counterclockwise to decrease the pressure. 8. Push the black adjustment valve back in to lock it when you have finished the adjustment.

Adjustment valve
Figure 3-79: Auxiliary Air Regulator for Seal Head Pressure

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Setting Up a Taper

Adjusting Seal Head

Adjusting Speed of Seal Head


For lighter weight and smaller devices, the descent and/or ascent of the seal head may need to be slowed, to prevent devices from bouncing out of the tape pockets. See Figure 3-80. To change the upward speed of the seal head, adjust the outward-facing air flow control adjustment knob on the seal head. To change the downward speed of the seal head, adjust the right-facing air flow control adjustment knob (the one closest to the image sensor) on the seal head. To adjust the air flow at the air valve: 1. Turn the lock nut counterclockwise to unlock the adjustment knob. 2. Turn the air flow control adjustment knob: > Turn the knob clockwise to lessen the air flow and slow the speed of the seal head, or... > Turn the knob counterclockwise to increase air flow and quicken the speed of the seal head. 3. When air flow is appropriate, turn the lock nut clockwise to tighten it.

Adjustment knob Lock nut


Figure 3-80: Outward-Facing Knob Adjusts Upward Speed; Right Knob Adjusts Downward Speed

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Setting Temperature for Heat Seal Head


The displayed temperatures are the actual or current temperatures. The temperature displays may be set to show Celsius or Fahrenheit. In Figure 3-81, the top left display is adjusting its temperature, as shown by the small 1 in the upper left corner above the C. In contrast, the temperatures in the other three displays are stable, because there is no number above the C or F. Also, the top left display is hot, whereas the other three displays are room temperature.

Figure 3-81: Heater Controller Displaysin Celsius (Left), in Fahrenheit (Right)

A general guideline may be to use somewhere around 275 to 325 degrees Fahrenheit for a heat seal. A narrow carrier tape takes a lower temperature to prevent burning. If in doubt, it is better to start with a lower temperature and test it, then increase little by little as needed. To set the temperature: On the Taper window of Exatron Diagnostics, set the front and back temperatures to the desired temperature (in Celsius) and then click both Set Temperature buttons. Temperature in Fahrenheit
77 275 300 325 350

Temperature in Celsius
25 135 149 163 177

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Setting Up a Taper

Setting Temperature for Heat Seal Head

See also "Checking Omega Temperature Controller" on page 7-64. However, be aware that the Exatron software settings will override any different settings manually set. To turn off the heat seal head: On the Taper window of Exatron Diagnostics, set the temperature to 25 degrees Celsius and then click the Set Temperature button.

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Chapter 4: Handler Software Setup


Chapter Overview
This chapter discusses the following main topics: Topic Switching Between System Computers Passwords Getting Acquainted with the Main Window Managing Job Files Verifying the Factory-Installed Job File Copying the Job File for Modifications Opening a Job File Checking the Settings Windows Accessed in Setup SettingsWork Mode Window SettingsMotor Window SettingsDelay Window SettingsSetup Trays Window (Optional) SettingsTray Sort Window SettingsThermal Window (Optional) Understanding Tray and Waffle Pack Numbering Setting the Number of Rows and Columns in Trays Fine Tuning Overview Disabling Pickup Heads and/or Test Sites Calibrating Stacker Height Calibrating Lifter Bar Spacing Aligning Carriage with Stacker Calibrating Positions for Auto Run Order of Calibration Example of Calibrating Distances for Two JEDEC Trays Distances Worksheet Setting Tray Distances Setting Test Site Distances Saving the Job File Page 4-2 4-2 4-5 4-6 4-6 4-7 4-9 4-10 4-11 4-12 4-22 4-25 4-30 4-33 4-40 4-42 4-43 4-45 4-45 4-46 4-49 4-52 4-54 4-54 4-55 4-59 4-60 4-68 4-73

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Switching Between System Computers


If your system includes a peripheral that has its own computer (such as a laser or inspection camera), they may all be using one monitor and keyboard. Switch between computers by pressing the <Scroll Lock> key twice, then the Up or Down arrow key one or more times to scroll to the desired computer. If the keyboard has a Function key, use it concurrently with the Scroll Lock key.

Passwords
Windows Password
Both the Windows username and password are factory-set to exatron.

Handler Software Passwords


Three levels of security are built into the Exatron software. The operator level requires no password. The Diagnostics level requires the factory-set password of P1. Whenever the dialog box name is Log On to the Diagnostics (Figure 4-1), use the password P1. This can be changed. See "Changing the Handler Software Password" on page 4-3.

Figure 4-1: Log On to the Diagnostics Dialog Box

The Settings or Administrative level, requires the factory-set password of P2. Whenever the dialog box name is Log On to the Settings (Figure 4-1), use the password P2. This can be changed. See "Changing the Handler Software Password" on page 4-3.

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Passwords

Changing the Handler Software Password

Figure 4-2: Log On to the Settings Dialog Box

Changing the Handler Software Password


To make access to your handler secure, you can change the password initially or periodically. To change the password: 1. On the Exatron main window, click the Pwds button. 2. In the Change Passwords dialog box, type the current password in the Old Password box. 3. Type it again in the Re-type the Old Password box to confirm. 4. Type the new password in the New Password box. 5. Type it again in the Re-type the New Password box to confirm. Click OK.

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Figure 4-3: Changing Password

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Getting Acquainted with the Main Window

Changing the Handler Software Password

Getting Acquainted with the Main Window


The buttons on the main window are described below.

Figure 4-4: Main Window

Buttons on Main Window Button Function Load File Open a dialog box listing available job files. For More Information page 4-9; 4-73

Settings Open a window with tabs to access and save various software settings.

page 4-11

Diagnostics Open a window with tabs to access and save various diagnostic procedures.

page 6-2

Reset All Motors Send all motors to their home positions.

Auto Mode Open a window to do a production job in Auto Run.

page 5-8

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Buttons on Main Window Button Function Operator Open a window with tabs to access various software settings. In Operator Mode, you can change settings for the current Auto Run only, but cannot save them for future use. Passwords Change a password. For More Information page 5-2

page 4-3

Save As Open a dialog box so you can save the job file with a new name.

page 4-73

View Log View the log file from the last-run job.

page 5-22

Exit Close the Exatron software.

Managing Job Files


A job file contains the distances each part of the handler must move to get to various destinations, the number of trays, the delay times, and other settings related to the movement of the devices through the system. The job file is different from a log file; the job file does not record passes and fails or any other results data from a tester or other peripheral.

Verifying the Factory-Installed Job File


Many of the calibrations described in this chapter need to be done only rarely, but it is good to check the job file settings before starting a new job.

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Managing Job Files

Copying the Job File for Modifications

The procedures for verifying the settings of your factory-installed job file and building a new job file are similar. If it becomes necessary to build a new job file, it is better to copy an existing, proven file, and modify it. To verify your file, just check the settings and distances, and make changes wherever needed. This section discusses each part of this procedure: Task Copying the factory-installed job file to modify Opening the modified job file Checking the settings Page 4-7 4-9 4-10

Copying the Job File for Modifications


Exatron recommends that you save the factory-preset job file under a new name before you begin to work with it, to prevent making accidental changes to the original file. To save a job file with a new name: 1. Right-click the Start button at the bottom left corner of your Windows screen. 2. Left-click Explore. Windows Explorer opens.

3. In Explorer, find the Exatron folder directly under the C drive, thus: C:\Exatron. Double-click it to open it.

4. Find the job file. It has the filename extension of .job or .edf (Exatron data file). 5. Right-click on the job file. A context menu opens.

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6. Click Copy on the context menu.

7. Deselect the job file name by clicking somewhere else on the screen. 8. Right-click in the window. A context menu opens. 9. Click Paste on the context menu.

10. Scroll to the bottom of the window and find the copied file. Its name is Copy of ___.job or Copy of ___.edf. 11. Click once on the file to select it.

12. Click inside the filename. The cursor appears, indicating that you can retype the name.

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Managing Job Files

Opening a Job File

13. Type a new name.

14. Press the Enter key on your keyboard. Now the copy has a new name. Make any modifications to this copy. Make sure the file is saved to the Exatron folder.

Opening a Job File


The Exatron software should open upon system startup. If it does not, double-click the The Load Setting File dialog box opens. Exatron icon on the desktop.

Figure 4-5: Opening a Job File

CAUTION: It is strongly recommended that you dont make changes to the factoryset job file. If you need to make changes, first make a backup copy of the original job file, and experiment with the copy. The job file that came with your handler has been preset to fit the configurations you specified. You need to do a verification of all the settings and distances in the job file before you begin a production job in Auto Run. See "Checking the Settings" on page 4-10.

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Checking the Settings


Before starting a new job, you may need to check some of the following settings:

Settings to Check Job count and failure parameters Number of rows and columns in trays or waffle packs Pickup heads rotation options Pickup heads X distance to trays Y distances to tray pockets Z get distance at trays Z put distance at trays Timing delays Destinations for various sort categories Pickup heads X distance to test site Z get distance at test site Z put distance at test site X and Z distances at detaper X and Z distances at taper Sensor adjustments at taper due to pocket size Thermal heads X and Z distances to test site Thermal temperatures and variances X distances to tubes Z get distance at tubes Z put distance at tubes X and Z distances at lead/ball inspection

Page 5-2; 4-12 4-34 4-17; 4-21; 6-107 4-55; 4-61; 6-47 4-57; 4-63; 6-47 4-67; 6-49 4-65; 6-49 4-25 4-33 4-68 4-71; 6-60 4-70; 6-60 6-91 6-94 6-97 6-58 6-72 6-102; 6-104 6-102 6-104 6-80

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Windows Accessed in Setup

Settings Windows

Windows Accessed in Setup


This is a reference section which describes the features of the windows available from the Settings button on the main window. For step-by-step instructions on calibrations, see the rest of this chapter, starting with "Understanding Tray and Waffle Pack Numbering" on page 4-42. You can access each of the Settings windows by clicking on its tab at the top of the screen. NOTE: Your handler software may not display every box or button for various options discussed in this manual. Rest assured that your handler and software have been customized for your companys needs.

Settings Windows
The windows available from the Settings button allow you to set parameters for production runs. The following are the windows available from the Settings button. Your handler has only the ones used in your setup. Window Work Mode Motor Delay Setup Trays Tray Sort Thermal Function Sets type of job to be run: using tester, laser, and/or inspection; sets rotation or not; specifies maximum number of failures Sets or displays speed of various motors Sets delays and timeouts between various actions Enables or disables waffle packs and pickup nozzles; sets tray columns and rows Sorts various test results, or bins, to corresponding trays and other outputs Sets goal temperatures and variances; allows disabling of any thermo head Page 4-12 4-22 4-25 4-30 4-33 4-40

To access the Settings windows: 1. On the main window, click the Settings button. A password box is displayed.

Figure 4-6: Log On to the Settings Dialog Box

2. Enter the correct password. This may be changed at any time with the Pwds button.

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SettingsWork Mode Window


The Work Mode window is the first window that is displayed when you enter Settings from the Main window. It defines basic job parameters such as source and destination of devices, type of processing of devices, maximum device failures, and device rotation.

Figure 4-7: Work Mode Window

Any selections that are unavailable for your handler are grayed out, if they appear at all. The available selections depend on the options your handler is equipped with.

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SettingsWork Mode Window

Settings Windows

Figure 4-8: Work Mode WindowTwo Testers, Two Inspections

In the example in Figure 4-8, the handler is connected to two separate testers. Each tester has a golden unit tray from which to take known good devices. Also, the capability of inspection both before and after testing are included in this example.

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Figure 4-9: Work Mode Window3 Inspections at 2 Locations

In the example in Figure 4-9, the handler has the option for inspection before testing, after testing, and again after laser marking. It also has optional rotation of the pickup nozzles.

Input Operation Group Box

Figure 4-10: Input Operation Group Box

Select the option for the input-output combination you want to use. Only the selections that are not greyed out are available for your handler. Wafer to Tray Devices are taken from an input wafer, processed, and put to an output tray. Devices are taken from an input wafer, processed, and put to a tape.

Wafer to Tape Reel

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SettingsWork Mode Window

Job Information Group Box

Detaper to Tray Detaper to Tape Reel Tray to Tray Tray to Tape Reel

Devices are taken from a tape, processed, and put to a tray. Devices are taken from a tape, processed, and put to a tape. Devices are taken from a tray, processed, and put to a tray. Devices are taken from a tray, processed, and put to a tape.

Job Information Group Box

Figure 4-11: Job Information Group Box

Job Count Consecutive Failure Max Count at Testing

Type the number of devices to be passed in this job. Type the maximum number of back-to-back, or consecutive, device failures the handler can encounter upon testing before stopping. Operator intervention is required before the handler will resume. Type the maximum number of back-to-back, or consecutive, device failures the handler can encounter upon inspection before stopping. Operator intervention is required before the handler will resume. Type the maximum number of back-to-back, or consecutive, empty tray pockets the handler can encounter before stopping. Operator intervention is required before the handler will resume.

Consecutive Failure Max Count at Inspection

Consecutive Failure Max Count at Tray/Empty Pocket Max Count

Run Mode Group Box


Select the mode you want to run. The selection and configuration of various modes differs from handler to handler.

Figure 4-12: Run Mode Group Box

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AutoRun Mode Group Box


Check the boxes for all processes you want to run on the devices. Only the selections that are not greyed out are available for your handler. Enable Inspection Check this box to enable the inspection process. Uncheck this box to disable. Check this box to enable a precisor pocket with vacuum. Uncheck this box to disable. Check this box to enable laser marking. Uncheck this box to disable. Check this box to enable the testing process. Uncheck this box to disable.

Enable Precisor

Enable Laser

Enable Tester

Tester Group Box


If your handler has more than one tester, there may be a group box for each tester.

Figure 4-13: Tester Group Box

Enable Tester [n]

Check this box to enable the designated tester. Uncheck this box to disable the designated tester. Type the correct IP address for the designated tester. Check any boxes to enable the designated golden unit pockets.

IP Address Enable Golden Unit [n]

Tester Operation Group Box

Figure 4-14: Tester Operation Group Box

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SettingsWork Mode Window

Tester Mode Group Box

Real Test

Select this option to run a real test on devices. This is the default setting the system reverts to every time you close the Exatron software.

Simulation

Select this option to simulate the operation of the handler without testing devices. If you select this option, select the desired outputs: pass location, fail locations, or random pass/fail simulation. NOTE: The Simulation setting is not saved with the job file. If you want to run a simulation, you must change to Simulation here every time you run devices in Auto Run.

Tester Mode Group Box

Figure 4-15: Tester Mode Group Box

Serial Port/TTL/GPIB

Select the desired interface between handler and tester. See Appendix A for more information.

Rotation Group Box


If your handler has the option of rotation of the pickup nozzle, you can specify the rotation here. Depending on your options, you may have two locations at which to specify rotation. See "Results of Rotation Combinations" on page 4-21 for illustrations.

Figure 4-16: Rotation Group Box

0 Degree +90 Degree

Select this option to use no rotation. Select this option to rotate each device a quarter-turn clockwise. Select this option to rotate each device a quarter-turn counter-clockwise.

-90 Degree

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180 Degree

Select this option to rotate each device a half-turn.

If your handler has a stepper motor that allows infinite-degree rotation, this group box may include a box allowing you to type in the degrees of rotation you want, instead of a fixed degree.

Inspection Group Box


Your handler may have the option for more than one inspection. If so, you will be able to enable or disable part of the process.

Figure 4-17: Inspection Group Box

Inspection File Name

Type the name of the inspection file you want to use.

Inspection Log File On/Off Check this box if you want the job to produce an inspection log file. 2D/3D Select the desired option. Select 2D for two-dimensional inspection on the X and Y axes. Select 3D for three-dimensional inspection including the Z axis.

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SettingsWork Mode Window

Function Enabling Group Box

> This option is used to inspect the shape, location, and height of balls on BGAs (ball grid arrays). For each separate inspection, you can specify a real or simulated inspection. Real Inspection Select this option to run a real inspection on devices. This is the default setting the system reverts to every time you close the Exatron software. Simulation Select this option to simulate the operation of the handler without inspecting devices. If you select this option, select the desired outputs: pass location, fail locations, or random pass/fail simulation. NOTE: The Simulation setting is not saved with the job file. If you want to run a simulation, you must change to Simulation here every time you run devices in Auto Run.

Function Enabling Group Box

Figure 4-18: Function Enabling Group Box

Enable Precisor

Check this box to include the precisor in the process. Uncheck this box to exclude the precisor from the process. Check this box to include the rub function in the process. Uncheck this box to exclude the rub function from the process. Check this box to display an onscreen confirmation request message when the maximum number of consecutive empty pockets found in an input tray has been reached. Uncheck this box to send the tray to the output stacker when the maximum number of consecutive empty pockets has been reached, without displaying any confirmation message.

Enable Rub

Show Message for Max Empty Pocket at Tray 1

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Turn On Tray Clamp at Last for Stacker

See "Tray Loading Process" on page 2-5 as reference. Check this box to lift up the stack of trays at the input stacker before extending the tray clamp pins to clamp the bottom tray. Thus, step 5 occurs after step 7. Uncheck this box to use the default input stacker process order as described in "Tray Loading Process" on page 2-5.

Enable Move Motor X for RF

Check this box to move the pickup head away from the test sites after putting a device in the test socket. Uncheck this box to leave the pickup head above the test socket after putting a device in the socket. This feature enables you to turn off a motor that might interfere with the RF testing of a device. Check this box to turn off the pickup head motor after it puts a device in the test socket. This disables the normal alternating ping-pong operation if there are two pickup cars. Uncheck this box to leave the pickup head motor on after it puts a device in the test socket. This enables the normal alternating ping-pong operation if there are two pickup cars.

Enable RF

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SettingsWork Mode Window

Results of Rotation Combinations

Results of Rotation Combinations


Following is an example of rotation with dual pickup heads. Rotation is effected at the test site. Rotation Device Position Rotation +90
Input Output Test

Actions 1. Left pickup head picks device from input, then rotates it clockwise. 2. Left pickup head puts device to test site, then unrotates pickup head. 3. Right pickup head rotates clockwise, picks device from test site, then rotates counterclockwise to original position. 4. Right pickup head puts device in output. 1. Left pickup head rotates clockwise, picks device from input, then rotates counterclockwise to original position. 2. Left pickup head puts device to test site. 3. Right pickup head picks device from test site. 4. Right pickup head rotates clockwise, puts device in output, then rotates counterclockwise to original position. 1. Left pickup picks device from input (no rotation). 2. Left pickup head puts device to test site (no rotation). 3. Right pickup head picks device from test site (no rotation). 4. Right pickup head puts device in output (no rotation).

Rotation -90
Input

Test

Output

Rotation 0 Disabled
Input Output Test

Save

If you want to save your changes to the job file you opened when you entered Settings, click Save. If you click Back to Main without saving your changes, they will still apply for the current sessions Auto Run, but the changes wont be preserved after you close the Exatron software.

Back to Main

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SettingsMotor Window
The Motor window allows the speed of each motor to be set.

Figure 4-19: Motor Window

CAUTION: Changing motor settings may cause damage to the handler and devices. The settings displayed come from the file you opened at the beginning of the Settings session. If you opened the file containing the factory presets, you will likely not need to change the factory settings unless a piece of hardware or a tray configuration is changed. If you make changes, save them under a new file name. The stacker motors act to load and unload the trays from the carriages. They move on the Z axis. NOTE: The Y1 Load, Y3 Unload, etc. labels refer to stacker motor locations, not to the stackers axis of movement. The Y motors move the tray carriages on the Y axis from the front to the back of the handler. The X motors move the pickup heads on the X axis from the trays to the test sites and back.

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SettingsMotor Window

General Motion Group Box

The Z motors move the pickup heads on the Z axis up and down to the trays and test sites. Select a Motor from the List This drop-down list allows you to select one of the following motors (depending on your handler configuration).

Stacker motors

Y motors X motors Z motors

Figure 4-20: Motor Drop-Down List

Resolution: Step Counts per Revolution

The number displayed is a calculation of the settings of the specific motor and lead screw used on this handler. This is for Exatron support diagnostics only. The number displayed is the allowed position variance. This is for Exatron support diagnostics only.

Position Error Limit: Step Count

General Motion Group Box


The values in this group box apply to the various motors as they move through production in Auto Run. These settings can be changed only by the administrator. For details, see the motor manufacturers manual. Speed AC DC The selected motors speed is displayed. The selected motors acceleration is displayed. The selected motors deceleration is displayed.

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Home Sequence Group Box


The values in this group box apply only to the pickup heads linear motor during its homing routine. These are usually slower speeds than those used for normal production. These settings can be changed only by the administrator. For details, see the motor manufacturers manual. Home Speed Home AC The pickup heads linear motor homing speed is displayed. The pickup heads linear motor homing acceleration is displayed. The pickup heads linear motor homing deceleration is displayed.

Home DC

PID Group Box


The values in this group box apply only to the pickup heads linear motor. They are for the PID loop. They are designed to prevent oscillation or the motors losing its position after it stops. Gains must be high enough for the motor to hold its position when stopping. These values are to be calibrated only by an Exatron service person. KP KI KD Proportional. Integral. Derivative.

Save

If you want to save your changes to the job file you opened when you entered Settings, click Save. If you click Back to Main without saving your changes, they will still apply for the current sessions Auto Run, but the changes wont be preserved after you close the Exatron software.

Back to Main

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SettingsDelay Window

PID Group Box

SettingsDelay Window
The Delay window sets delays and maximum timeouts between various actions.

Figure 4-21: Delay Windowwith Thermal Test Option

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Figure 4-22: Delay Windowwith Laser and Inspection Options

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SettingsDelay Window

PID Group Box

Figure 4-23: Delay Windowwith Multiple Input Options

Type each time delay in milliseconds. Delay Between Each Stacker Step This delay applies only to the steps taken by the stackers in loading or unloading a tray. After taking each step in the process, the handler waits the number of milliseconds shown before taking the next step. See "Stacker Movement Details" on page 2-5 for details. After issuing the command to turn on the vacuum, the handler waits the number of milliseconds shown before giving the next command (to check the vacuum sensor to see if a device is attached to the pickup head). You may have to change this setting for different devices due to size, weight, test time, etc. Delay After Vacuum Off After issuing the command to turn off the vacuum, the handler waits the number of milliseconds shown before giving the next command (to turn on the air blower). You may have to change this setting for different devices due to size, weight, test time, etc.

Delay After Vacuum On

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Delay After Air Blow On

After the vacuum is turned off with the pickup head at the tray or test socket, this is the number of milliseconds the air blower stays on to blow a device off the pickup head. After the air blow is turned off with the pickup head at the tray or test socket, this is the number of milliseconds the air blower stays off before the Z nozzle is raised. After issuing the command to move the pickup head to the Z put position at the socket, the handler waits the number of milliseconds shown before turning the vacuum off. After issuing the command to move the pickup head to the Zput position at the tray, the handler waits the number of milliseconds shown before giving the next command (to turn the vacuum off). After the vacuum is turned off with the pickup head at the taper, this is the number of milliseconds the air blower stays on to blow a device off the pickup head. After the air blow is turned off with the pickup head at the taper, this is the number of milliseconds the air blower stays off before the Z nozzle is raised. After issuing the command to lower the thermal head, the handler waits the number of milliseconds shown before giving the next command. After issuing the command to raise the thermal head, the handler waits the number of milliseconds shown before giving the next command. After issuing the command to lower the cold head, the handler waits the number of milliseconds shown in this box plus the Delay After Pressure Down box before giving the command to start the test. After issuing the command to lower the hot head, the handler waits the number of milliseconds shown in this box plus the Delay After Pressure Down box before giving the command to start the test. Type the number of milliseconds that the handler will wait after it tries to read a response from the thermal head before calling a timeout. Type the number of seconds after the device is placed in the test socket and before the test begins.

Delay After Air Blow Off

Delay of Socket Z Put

Delay of Tray Z Put

Delay After Air Blow On (Taper)

Delay After Air Blow Off (Taper)

Delay After Pressure Down

Delay After Pressure Up

Tester [n] Cold Thermo Soak Time

Tester [n] Hot Thermo Soak Time

Thermo Timeout

Start Test

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SettingsDelay Window

PID Group Box

Tester Timeout

Type the number of seconds that the handler will wait after it tries to read the response from the tester. If the part times out, it is sorted to the fail tray and the handler waits for operator intervention. After issuing a rotation command, the handler waits the number of milliseconds shown before issuing the command for the next action, allowing time for the rotation to occur. Type the number of milliseconds that the handler will wait after it tries to read the response from the laser. If the part times out, it is sorted to the fail tray and the handler waits for operator intervention. Type the number of milliseconds that the handler will wait after it tries to read the response from the inspection. If the part times out, it is sorted to the fail tray and the handler waits for operator intervention. Type the number of milliseconds that the handler will wait after it places the device at the inspection site before inspection begins. This allows all movement to stop and the device to stabilize before inspection. After the Z1 pickup nozzle gets a device from the input tube, rises, and moves left, this is the delay while the input tube vibrates to move the next device into the pickup path and before the Z2 pickup nozzle lowers to get a device from the input tube. After the Z1 pickup nozzle gets a device from the detaper, rises, and moves left, this is the delay while the detaper moves the next device into the pickup path and before the Z2 pickup nozzle lowers to get a device from the detaper. This delay is for the seal head found on a tape-and-reel assembly. Type the number of milliseconds that the handler will wait after the seal head goes down before the motor advances the tape.

Delay After Rotation

Laser Timeout

Inspection Timeout

Start Inspection

Delay for Input Tube

Delay for Detaper

Seal Head Down

Save

If you want to save your changes to the job file you opened when you entered Settings, click Save. If you click Back to Main without saving your changes, they will still apply for the current sessions Auto Run, but the changes wont be preserved after you close the Exatron software.

Back to Main

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SettingsSetup Trays Window (Optional)


If you use waffle packs, you will find the Setup Trays window. This window allows you to select the waffle packs you want to use, and disable others you dont want to use, both for input and for output. It also allows you to disable selected Z pickup nozzles, and to set the number of rows and columns in each waffle pack.

Figure 4-24: Setup Trays Window

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SettingsSetup Trays Window (Optional)

Enable/Disable Input and Output Trays Group Boxes

Enable/Disable Input and Output Trays Group Boxes

Figure 4-25: Enable/Disable Output Trays Group Box

Any waffle packs that your handler is not set up with are completely grayed out. The ones that are not grayed out are your possible selections. To enable a waffle pack, click to place a checkmark in its box. To disable a waffle pack, click again to remove the checkmark.

Tray Setting Group Box


This group box allows you to specify the number of rows and columns in each tray or waffle pack, and apply that configuration to all the others. NOTE: These settings may be available on the Tray Sort window instead.

Figure 4-26: Tray Setting Group Box

[Select tray]

Click the drop-down arrow and select the tray or waffle pack you want to configure.

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Number of Rows Number of Columns

Type the number of rows each tray or waffle pack contains. Type the number of columns each tray or waffle pack contains. Click this button to apply the settings to all the other trays or waffle packs. NOTE: If most have the same configuration, but only one is different, you can use the Copy button to apply settings globally, and then select the one that is different and change the settings for just that one.

Copy from Tray 1_1

Both for trays and for waffle packs, columns are counted from left to right. Rows are counted from the back of the tray to the front.

Tray Y1_3 Column 1

Tray Y1_3 Column 6

Tray Y1_3 Row 2 Tray Y1_3 Row 5

Figure 4-27: Example of Row and Column Layout for Waffle Pack

Head Mode Group Box

Figure 4-28: Head Mode Group Box

For each pickup nozzle, check to enable the nozzle, or uncheck to disable it from action.

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SettingsTray Sort Window

Head Mode Group Box

SettingsTray Sort Window


The Tray Sort window directs the disposition or placement of devices in various conditions; it determines which sort goes to which bin.

Figure 4-29: Tray Sort Window

In this matrix you match physical output locations to tester sort results. Here you specify which sort categories are sent to which destinations. Sort Sorts are logical categories determined from the tester or inspection. For each sort, place a checkmark in the output destination where you want that sort to be placed. Designated sort categories of devices are placed in the checked trays. NOTE: All like sites are numbered from left to right.

Tray [n]

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Double Test Mode Group Box


The options here go into effect when a device fails the test.

Figure 4-30: Double Test Mode Group Box

Send S Only

Select this option to cause the handler to send another "S" test command. The device is left clamped in the socket between the first and second test. Select this option to retract the pusher-slider mechanism after the failed test and reclamp the device before the second test. Select this option to retract the pusher-slider mechanism after the failed test and cause the pickup head to remove and reinsert the device into the test socket and reclamp it before the second test.

Retract Pusher and Reclamp

Take Part Out and Reinsert Part

Tray Setting Group Box

Figure 4-31: Tray Setting Group Box

Tray List

Click the drop-down arrow and select the tray you want to configure. Type the number of rows each tray contains. Type the number of columns each tray contains.

Number of Rows Number of Columns

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SettingsTray Sort Window

Stop-On-Fail Group Box

Figure 4-32: Example of Row and Column Layout for Tray

Columns are counted from left to right. Rows are counted from the back of the tray to the front.

Stop-On-Fail Group Box

Figure 4-33: Stop-On-Fail Group Box

Stop-On-Fail

If one or more sorts are checked here, when a device is tested and has that sort, the handler will stop and display a confirmation request message. If no sorts are checked, the handler will not stop after the test sort. The settings in this group box work in conjunction with the Enable Stop-on-Fail checkbox on the Auto Run window. If that box is not checked, the settings here have no impact on the handler functioning.

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Example Setups

Figure 4-34: Sort Configuration for Three Trays

For example, in Figure 4-34, Tray 1 is set to receive devices assigned to sort category 1 only. Tray 2 is set to receive devices assigned to sort categories 2 through 8. Tray 3 has been disabled.

Figure 4-35: Sort Configuration for Two Trays and Taper

In the example in Figure 4-35, Tray 1 is set to receive devices assigned to sort categories 2 through 8. As the entire row for Tray 3 is greyed out, this handler has no Tray 3. Rather, this handler is equipped with a taper, which is set to receive devices assigned to sort category 1 only. Each tray has 10 rows and 4 columns.

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SettingsTray Sort Window

Example Setups

Figure 4-36: Sort Configuration for Output Tubes

Whenever a tube is filled, if no further tube is designated for that Sort category, the handler will pause and a message will be displayed, telling which tube is full and requesting a replacement tube. The yellow light on the light pole will turn on to alert the operator.

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Figure 4-37: Sort Configuration for Multiple Inspections

The example in Figure 4-37 has four extra sort categories because this handler has two separate testersone for the left side of the handler and one for the right sideand two types of inspection for each tester. Sort 9 is for pre-test inspection failures before going to tester 0, and sort 10 is for post-test inspection failures coming from the same tester. Sort 11 is for pre-test inspection failures before going to tester 1, and sort 12 is for post-test inspection failures coming from the same tester.

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SettingsTray Sort Window

Example Setups

If your handler uses waffle packs, you will see many more options on this window.

Figure 4-38: Sort Configuration for Waffle Packs

In the example in Figure 4-38, passed devices (sort 1) are sent to the taper, and sorts 2 through 8 are sent to the third waffle pack in tray 2. Devices that passed the last inspection, after laser marking, are sent to the taper. Devices that failed an inspection are sent to the fifth waffle pack in tray 2. See "Understanding Tray and Waffle Pack Numbering" on page 4-42. If your handler has a double-test option, you can check any sort category to be tested a second time before it is sent to an output bin. Save If you want to save your changes to the job file you opened when you entered Settings, click Save. If you click Back to Main without saving your changes, they will still apply for the current sessions Auto Run, but the

Back to Main

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changes wont be preserved after you close the Exatron software.

SettingsThermal Window (Optional)


If your test process involves thermal testing, your handler has a Thermal window. It has various group boxes depending on the number of thermal test heads.

Figure 4-39: Thermal Window

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SettingsThermal Window (Optional)

Hot Thermal Group Box

The example in Figure 4-39 uses not just one but two separate thermal test head assemblies, one for the left side of the handler and one for the right side. After a device is deposited at a test socket, either the hot or cold thermal head is used on the device; and then the other thermal head is used. However, with this window, you can disable one or the other or both, and test using just heat or just cold. You can also use one for thermal testing, and the other for pressure only.

Hot Thermal Group Box


The Hot Thermal group box controls the hot tester. Enable/Disable/Clamp Thermal Head Temperature Select the desired option. To run a simulation only, select Clamp. Type the desired hot Celsius temperature in the Temperature input box. Type the allowed variance for the hot tester in the Guard Band boxes. Upper refers to the number of degrees above the desired temperature that is allowed. Lower refers to the number of degrees below the desired temperature that is allowed.

Guard Band

Cold Thermal Group Box


The Cold Thermal group box controls the cold tester. Enable/Disable/Clamp Thermal Head Temperature Select the desired option. To run a simulation only, select Clamp. The current cold Celsius temperature is displayed in the Temperature box. Type the allowed variance for the cold tester in the Guard Band boxes. Upper refers to the number of degrees above the desired temperature that is allowed. Lower refers to the number of degrees below the desired temperature that is allowed. Set Cold Temperature Type a number that is several degrees colder than the desired Celsius temperature in the Set Cold Temperature input box.

Guard Band

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Defrost Thermal Omega Group Box


The defrost feature ensures that no ice builds up on the cold test head. Desired Temperature Guard Band Type the desired defrost temperature in Celsius. Type the allowed variance for the defrost temperature in the Guard Band boxes. + refers to the number of degrees above the desired temperature that is allowed. - refers to the number of degrees below the desired temperature that is allowed. For example, if the compared defrost temperature is 70 with the + guard band set at 7 and the - guard band set at 5, then a range of 65 to 77 is acceptable, and the signal is sent to test the device. Enable Ambient Check this box to enable the ambient test head. Uncheck this box to disable the ambient test head.

Understanding Tray and Waffle Pack Numbering


Single test sites and JEDEC trays are numbered from left to right.

Test Site 1

Test Site 2

Tray Y1

Tray Y2

Tray Y3

Figure 4-40: Test Site and Tray Numbering

When waffle packs are used, they are numbered back to front, and left to right.

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Setting the Number of Rows and Columns in Trays

Defrost Thermal Omega Group Box

Y1_1

X2_1

Y1_2

Y2_2

Y1_3

Y2_3

Figure 4-41: Waffle Pack Numbering

Setting the Number of Rows and Columns in Trays


If desired, you can set a different configuration for each tray. To set the number of rows and columns in a tray or waffle pack: 1. From the main window, click the Settings button. 2. Click the Tray Sort tab. 3. Select the tray or waffle pack whose rows and columns you want to define. 4. Type the number of rows and columns in the tray or waffle pack, remembering that rows run on the X axis, and columns run on the Y axis.

Figure 4-42: Tray Information

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Figure 4-43: Example of Row and Column Layout for Tray

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Fine Tuning Overview

Defrost Thermal Omega Group Box

Fine Tuning Overview


The following procedure is to be used only as a quick reference. Before performing this procedure for the first time, please read the sections under "Calibrating Positions for Auto Run" on page 4-54. To fine-tune any position: 1. Enter Diagnostics and select the tab for the type of entity whose positions you want to calibrate (tray, taper, etc.). 2. Select the specific entity from the drop-down list (tray 1, Z2, tube 1, etc.). 3. Type the approximate distance of the position from the motors zero position. 4. Type the scale or increment by which you want to jog the motor. 5. Click the Move To button to move the motor to the position selected. 6. Click either of the jog arrow buttons (left or right; up or down) to jog the motor away from the position shown, by the scale or increment shown.

Disabling Pickup Heads and/or Test Sites


If your handler has options to disable some of its pickup heads and/or test sites, you can make these selections from the Edit menu of the Main window. To disable some hardware features: 1. Open the Main window of the Exatron program. 2. Click the Edit menu at the top left of the window. 3. Click Setup Head Mode and Tester Site.

Figure 4-44: Edit Menu Selections

4. In the ZHead Mode group box, click to select the number of pickup heads you

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want to use. NOTE: If you use only 2 pickup heads, they must be the left 2 heads, Z1 and Z2. 5. In the Tester Mode group box, click to select the number of testers you want to use. Tester 1 is on the left. NOTE: If you use all 4 pickup heads, you must also use both testers. 6. Click OK.

Figure 4-45: Z Head and Tester Mode Setup

Calibrating Stacker Height


Two tasks are closely connected in calibrating the stackers: adjusting the lifter bar spacing (page 4-49) and the stacker height. Do both of these at the same time. The stacker height is the distance from the stackers home position at the top of its cycle to the stacker position where its extended lifter pins are just above a tray resting on the carriage. Finding the correct stacker height is important. If the stacker height is wrong, the lifter pins will dig into the sides of a tray during loading or unloading, rather than extending cleanly between trays to separate them.

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Calibrating Stacker Height

Defrost Thermal Omega Group Box

The stacker height is correct if the tray can slide freely under the extended lifter pins. NOTE: If some corners seem to slide freely but others dont, the tray carriage may not be level. See "Tray Clamp Pins Fail to Secure Trays" on page 7-83. To change the stacker height: 1. Place an empty tray on the carriage. 2. Open the Exatron software, click the Diagnostics button, and click the Stacker tab. 3. From the Stacker List, select the stacker whose height you want to calibrate. 4. Make sure the Lift On/Off checkbox and the Tray Clamp On/Off checkbox are not checked, so that the lifter pins and tray clamp pins are retracted. 5. Click the Stack Move To button. > The lifter bars lower to the stacker height. 6. Check the Lift On/Off checkbox. > The lifter pins extend.

Figure 4-46: Extending Lifter Pins

7. Raise the cover and gently try to slide the tray back and forth on the carriage. >If the lifter pins are too low for the tray to slide freely under the extended lifter pins, click the [Up] jog arrow button to the right of the Stacker Height button one or more times. Each time you click it, the lifter bars with their pins rise by the increment shown in the Increment/Decrement box. 8. Place a finger under each corner of the tray and try to lift it. >IIf the lifter pins are too high and the tray can be lifted from the carriage, the pins might jam into a tray above when separating trays. Click the [Down] jog arrow button to the right of the Stacker Height button one or more times. Each time you click it, the lifter bars with their pins lower by the increment shown in the Increment/Decrement box.

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Figure 4-47: Calibrating Stacker Height

Figure 4-48: Checking Lifter Pins/Stacker Height

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Calibrating Lifter Bar Spacing

Defrost Thermal Omega Group Box

Calibrating Lifter Bar Spacing


Two tasks are closely connected in calibrating the stackers: adjusting the lifter bar spacing and the stacker height (page 4-46). Do both of these at the same time. If the lifter bars are too far apart, trays may be allowed to fall during the loading or unloading process. If the lifter bars are too close together, the lifter pins may damage the trays and/or prevent the proper loading or unloading of trays. The lifter pins are correctly positioned if they extend past the outer tray ridge and just to the inner tray ridge, as shown in Figure 4-51. Four lifter pins are at each loading or unloading stacker, two on each side. Check each lifter pin individually, as one or more may be incorrectly adjusted, whereas the others may be correct. To calibrate the distance for each lifter pin: 1. Place an empty tray on the carriage. 2. Open the Exatron software, click the Diagnostics button, and click the Stacker tab. 3. From the Stacker List, select the stacker whose lifter bars you want to calibrate. 4. Make sure the Lift On/Off checkbox and the Tray Clamp On/Off checkbox are not checked, so that the lifter pins and tray clamp pins are retracted. 5. Click the Stacker Height button. > The lifter bars lower to the stacker height.

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Figure 4-49: Calibrating Lifter Bar Spacing

6. Check the Lift On/Off checkbox and the Tray Clamp On/Off checkbox. > The lifter pins and tray clamp pins extend. With the tray clamp pins extended, the tray is in its Auto Run position. Thus you can more easily see which corner needs calibration, if any.

Figure 4-50: Extending Lifter Pins and Tray Clamp Pins

7. Look at the positions of the lifter pins in relation to a tray on the carriage. > Each pin should extend over the outer ridge of the tray, and extend just to the inner ridge.

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Calibrating Lifter Bar Spacing

Defrost Thermal Omega Group Box

Figure 4-51: Lifter Too Far Out (Left); Lifter Correctly Positioned (Right)

8. If any lifter pin is too far out or too far in, loosen the screw closest to it with an Allen wrench. 9. Press gently on the lifter bar to widen or narrow the distance of the lifter pin in relation to the tray. 10. When the distance is correct, retighten the screw.

Figure 4-52: Lifter Screw Loosened, Lifter Position Adjusted

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Aligning Carriage with Stacker


The carriage must be correctly aligned with the stacker, on the Y axis, for ease of tray transfer to and from the carriage. The following photos show the contrast between a carriage incorrectly positioned and one correctly positioned.

Figure 4-53: Tray Carriage REAR Too Far Forward (Left) Versus Correctly Positioned (Right)

Figure 4-54: Tray Carriage FRONT Too Far Forward (Left) Versus Correctly Positioned (Right)

To align the carriage with the stacker: 1. Place an empty tray on the stacker.

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Aligning Carriage with Stacker

Defrost Thermal Omega Group Box

2. Open the Exatron software, click the Diagnostics button, and click the Stacker tab. 3. From the Stacker List, select the stacker whose carriage you want to calibrate.

Figure 4-55: Aligning Carriage with Stacker

4. Type the distance from tray carriage home position to the selected stacker. 5. Click Align Position to bring the carriage to the selected stacker. 6. Look at the position of the carriage in relation to the stacker, comparing the photos in Figure 4-53 and Figure 4-54 to your setup. >If the selected tray carriage is too far forward of its centered position, increase the distance from Y home by clicking the [Increase Distance] jog button. Each time you click this button, the carriage moves toward the back of the handler by the distance shown in the Increment/Decrement input box. >If the selected tray carriage is too far behind its centered position, decrease the distance from Y home by clicking the [Decrease Distance] jog button. Each time you click this button, the tray moves toward the front of the handler by the distance shown in the Increment/Decrement input box. 7. After doing a visual alignment, fine-tune the alignment by clicking the Load Y[n] button. > If the tray loads smoothly, the alignment is okay. > If the tray has trouble loading, place the tray back on the stacker and do Steps 5 through 7 again.

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Calibrating Positions for Auto Run


Whenever you set up a job with new tray configurations or device sizes, you may need to set, or calibrate, critical locations and distances between various motor positions and device destinations, whether tray, tube, or tape. Y motors, moving the trays in and out of the pickup area X motor(s), moving the pickup head from the trays to the test site(s) and back Z motor(s), lowering and raising the pickup nozzles from the surface of the trays and test site(s) The goal of the fine tuning is to adjust the motor positions such that the handler can pick up the devices, place them onto the test site, and unload the devices with precision. Fine tuning includes positioning the devices correctly at the sensors for proper detection.

Order of Calibration
Calibrate the distances in the same order that devices are moved during a production run. Start by calibrating the input tray or other input location, then the test site(s), inspection site, or laser marking site, and lastly calibrate the output trays or other destinations.

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Calibrating Positions for Auto Run

Example of Calibrating Distances for Two JEDEC Trays

Example of Calibrating Distances for Two JEDEC Trays


The following example uses a handler configuration with 4 pickup nozzles and only 2 trays.

Defining X Distances for JEDEC Trays


When each tray of a 2-lane handler is used as a single unit, 16 X distances are needed, 8 for each tray. For each pickup nozzle on the pickup head, the distance must be calibrated to the first row and column, and to the last row and column, of each tray.

Figure 4-56: X Motor Distances Diagram for 2-Tray Handler

If each tray is divided into multiple waffle packs, the distances to the first and last pockets of each waffle pack must be calibrated. In Figure 4-56, the only movement we are dealing with is that of the X motor, which moves the pickup head. So the distance we must calibrate is the distance the X motor carrying the pickup head must move. Notice that the pickup head has to move only 15.88 inches to get its leftmost nozzle, Z1, to the first pocket of tray 1. But the pickup head has to move farther, 22.20 inches, to get its rightmost nozzle, Z4, to the same row and column.

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These distances have been filled in for each tray, for the first column and last column. These are shown as follows. A blank table is provided for your use in "Distances Worksheet" on page 4-59.
Tray and Pocket Distance X Motor Must Travel to Get Pickup Nozzle [n] Over Center of Pocket Z1 Y1, first column Y1, last column Y2, first column Y2, last column 15.88" 12.94 6.86 3.98 Z2 17.98 15.08 9.00 6.10 Z3 20.08 17.96 11.08 8.20 Z4 22.20 19.28 13.16 10.28

NOTE: These distances are examples only. Your measurements may differ. So the Z1 pickup nozzle must move 3.98" to get from its home position to the last column of tray Y2. It moves less than 3" farther to get to the first column of tray Y2. Then it moves another 6" to get to the last column of tray Y1, and a final 3" to get to the first column of tray Y1.

Figure 4-57: X Distances for Tray 1 and Head Z1

Figure 4-57 shows how these Y distances for tray 1 are displayed on the Tray window.

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Example of Calibrating Distances for Two JEDEC Trays

Defining Y Distances for JEDEC Trays


When each tray of a 2-tray handler is used as a single unit, eight Y distances are needed, two for each tray. The conceptual diagram in Figure 4-58 shows the Y distances for a hypothetical tray setup.

Figure 4-58: Y Motor Distances Diagram for 2-Tray Handler

In Figure 4-58, the only movement we are dealing with is that of the Y motors and trays. The pickup head stays in the back. Each tray must slide a certain distance toward the back, to get the proper device pocket under the pickup head. So the distance we must calibrate is the distance the Y tray must move. These measurements are about the same for each tray, because each tray must travel about the same distance to get to the pickup head area, the X gantry. When the trays move about 7 inches toward the back, the first column is under the pickup head. When the trays move about 17.4 inches, the last column is under the pickup head. Notice that the farther the Y tray must move, the larger the distance.

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These distances have been filled in for each tray, for the first row and last row, as follows.
Tray and Pocket Y1, first row Y1, last row Y2, first row Y2, last row Distance Y Motor Must Travel to Get Center of Pocket Under Pickup Head 7.17" 17.39 7.19 17.38

NOTE: These distances are examples only. Your measurements may differ.

Figure 4-59: Y Distances for Tray 1 and Any Pickup Head

Figure 4-59 shows how these Y distances for tray 1 are displayed on the Tray window.

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Distances Worksheet

Distances Worksheet
Following is a blank table for you to use as a worksheet. You can write in the appropriate distances here for your handler.

X, Y, and Z Distances from Home Positions to Key SitesBlank Table


Site Tray 1, first pocket Tray 1, last pocket Tray 2, first pocket Tray 2, last pocket Tray 3, first pocket Tray 3, last pocket Tray 4, first pocket Tray 4, last pocket Detaper Bowl feeder Inspection site Precisor tray Transfer tray Test site 1 Test site 2 Bucket 1 Bucket 2 Bucket 3 Taper X Distance Y Distance Z-Get Distance Z-Put Distance

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Setting Tray Distances


CAUTION: Before setting tray distances, check that the correct number of columns and rows for each tray have been specified. See "SettingsTray Sort Window" on page 4-33. NOTE: Do the X, Y, and Z calibrations for each pocket before moving on to the next location. When setting the tray distances, first attach a device by hand to the pickup nozzle and turn on the vacuum by checking the Z Vacuum On/Off checkbox on the Tray window. During the calibrations, let the pickup head carry the device back and forth. It is easier to see whether the pickup head is positioned correctly over a tray pocket if it is holding a device. The distances to be set for each tray are:
Setting Procedure X Distance Y Distance Z Put Distance Z Get Distance Page 4-61 4-63 4-65 4-67

Two locations on each tray must be calibrated, in terms of distances each motor must travel: Pocket in first row and column Pocket in last row and column Furthermore, if a handler is set up to use waffle packs, then each of these distances and locations must be calibrated for each waffle pack.

Calibration Order for Tray Pockets


Calibrate tray pockets in the order shown.

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Figure 4-60: Order of Calibrating Distances for Multiple Trays

Calibrate the first pocket of the first waffle pack of the input tray, followed by the last pocket of that waffle pack. Then, if all the waffle packs on that tray are for input devices, calibrate them as well. Do all the input waffle packs before calibrating the test site(s).

Setting the Pickup Heads X Distance to a Tray Pocket


Before starting, make sure a device is attached to the pickup head. The X distance is the distance the pickup heads X motor must move from the X motor home position to get the pickup nozzle over the center of the drop-off point for the selected tray row. Begin with the first pocket of the input tray (usually tray 1).

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Figure 4-61: First Pocket Group BoxSetting X Distance

To fine-tune the X distances to a tray: 1. Place a tray with devices in its corner pockets in the appropriate loading stacker. 2. Open the Exatron software and open Diagnostics. 3. Click the Stacker tab. 4. Click the Load Y[n] button. > The tray is loaded and clamped onto the carriage. 5. Click the Tray tab. 6. Using the drop-down arrow, select the appropriate tray (do the input tray first) in the Tray List box. > If you are using waffle packs, select the appropriate waffle pack (do the top left pack first). 7. Select the Z1 pickup head from the Head Z List. 8. Type a measurement estimated to be correct in the input box labeled First Pocket X. 9. Click the button Go to First Pocket (Center). > This moves the pickup head on the X motor to a position over the tray. 10. Look to see whether the pickup head is exactly over the first pocket. >IIf the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Inc/Dec input box.

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Setting Tray Distances

When the X distance to the first pocket is correct, calibrate its Y distance.

Setting the Trays Y Distance for a Tray Pocket


Before starting, make sure a device is attached to the pickup head. The Y distance is the distance the tray carriages Y motor must move from the Y motor home position to get the center of the drop-off point for the selected tray row under the pickup nozzle. Begin with the first pocket of the input tray (usually tray 1).

Figure 4-62: First Pocket Group BoxSetting Y Distance

To fine-tune the Y distances for a tray: 1. Place a tray with devices in its corner pockets in the appropriate loading stacker. 2. Open the Exatron software and open Diagnostics. 3. Click the Stacker tab. 4. Click the Load Y[n] button. > The tray is loaded and clamped onto the carriage. 5. Click the Tray tab. 6. Using the drop-down arrow, select the appropriate tray (do the input tray first) in the Tray List box. > If you are using waffle packs, select the appropriate waffle pack (do the top left pack first). 7. Select the Z1 pickup head from the Head Z List. 8. Type a measurement estimated to be correct in the input box labeled First Pocket Y. 9. Click the button Go to First Pocket (Center).

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> This moves the tray to a position under the path of the Y motor. 10. Look to see whether the pickup head is exactly over the first pocket. >If the selected tray pocket is too far forward of the pickup head and the suction cup is over the rear end of the device, increase the distance from Y home by clicking the [Increase Distance] jog button. Each time you click this button, the tray moves back by the distance shown in the Inc/Dec input box. >If the selected tray pocket is too far behind the pickup head and the suction cup is over the front end of the device, decrease the distance from Y home by clicking the [Decrease Distance] jog button. Each time you click this button, the tray moves forward by the distance shown in the Inc/Dec input box.

Comparing the Z Distances


The two Z distances are: Z-get or pick heightthe distance from the Z home position to the device pickup position Z-putthe distance from the Z home position to the device release position Z-get picks up a device from a tray or test site, so it must be a bit closer to the surface of a device than Z-put, which is required only to drop the device into the pocket.

Figure 4-63: Example Z Distances for Test Site

In Figure 4-63, the Z-get distance is larger than the Z-put distance because its farther from the top, Z home. Furthermore, the Z distances for an X tray may be different than those for a test site. The key to defining a pick height or Z-get distance is to have the suction cup just touching the device, but not flattened on it. The suction cup should be high enough that when you turn on the vacuum, you can see the device lift slightly against the suction cup.

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Figure 4-64: Suction Cup at Z-Get (Pick Height)

Notice that the suction cup at Z-get (pick height) is just touching the device, but not flattened on it.

Figure 4-65: Suction Cup at Z-Put (Put Height)

Notice that the suction cup at Z-put (put height) is not quite touching the device.

Setting the Z-Put Distance to a Tray Pocket


The procedure for defining the Z-put and Z-get distances at a tray is the same as the procedure at a test site. For each location, calibrate Z-put first and then Z-get.

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Figure 4-66: Pick Head ZSetting Z-Put Distance

To fine-tune the Z-put distance to a tray: 1. Place a tray with devices in its corner pockets in the appropriate loading stacker. 2. Open the Exatron software and open Diagnostics. 3. Click the Stacker tab. 4. Click the Load Y[n] button. > The tray is loaded and clamped onto the carriage. 5. Click the Tray tab. 6. Using the drop-down arrow, select the appropriate tray (do the input tray first) in the Tray List box. > If you are using waffle packs, select the appropriate waffle pack (do the top left pack first). 7. Select the Z1 pickup head from the Head Z List. 8. Type a measurement estimated to be correct in the input box below the Z Put button. CAUTION: If in doubt, make this distance smaller than you think necessary, then jog the pickup head down by steps to prevent damage from crashing the pickup nozzle into the socket. NOTE: The Z-put distance should be smaller than the Z-get distance, so that the suction cup is higher with Z-put. 9. Click the Z Put button.

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Setting Tray Distances

>If the suction cup is too close to the device, raise the pickup nozzle by clicking the [Up] jog button. Each time you click this button, the pickup nozzle moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets smaller by the same decrement. >If the suction cup is not close enough to the device, lower the pickup nozzle by clicking the [Down] jog button. Each time you click this button, the pickup nozzle moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets larger by the same increment.

Setting the Z-Get Distance to a Tray Pocket

Figure 4-67: Pick Head ZSetting Z-Get Distance

To fine-tune the Z-get distance to a tray: 1. Place a tray with devices in its corner pockets in the appropriate loading stacker. 2. Open the Exatron software and open Diagnostics. 3. Click the Stacker tab. 4. Click the Load Y[n] button. > The tray is loaded and clamped onto the carriage. 5. Click the Tray tab. 6. Using the drop-down arrow, select the appropriate tray (do the input tray first) in the Tray List box. > If you are using waffle packs, select the appropriate waffle pack (do the top left pack first). 7. Select the Z1 pickup head from the Head Z List. 8. Type a measurement estimated to be correct in the input box below the Z Get

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button. CAUTION: If in doubt, make this distance smaller than you think necessary, then jog the pickup head down by steps to prevent damage from crashing the pickup nozzle into the socket. 9. Click the Z Get button. >If the suction cup is too close to the device, raise the pickup head by clicking the [Up] jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets smaller by the same decrement. >If the suction cup is not close enough to the device, lower the pickup head by clicking the [Down] jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets larger by the same increment. By alternating among the Z Put button, Z Get button, Z Home, jog buttons, and the Z Vacuum checkbox, you can pick and drop the device until you are sure the distances are correct. After you have calibrated the X, Y, and Z positions for the first pocket of an input tray or waffle pack, do the same procedures for its last pocket (using the Last Pocket group box) before making the calibrations for the test site.

Setting Test Site Distances


Setting the Pickup Heads X Distance to a Test Site Socket
The X distance is from the X motor home position to the center of the drop-off point for the test site pocket.

Figure 4-68: Pickup Head X Distance Group BoxWith Socket Grid (Left) and Without (Right)

To fine-tune the pickup heads X distance to a test site: 1. Place a device by hand into the test site closest to tray Y1. 2. Open the Exatron software, click the Diagnostics button, and click the Tester tab.

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Setting Test Site Distances

3. Select the pickup head in the Head Z List box, using the drop-down arrow. 4. Type a measurement estimated to be correct in the Socket X input box. 5. Click the button Head Go to Tester/Socket [n]. > This moves the pickup head on the X motor to a position over the test site. 6. Look to see whether the pickup head is exactly over the test socket. >If the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Inc/Dec input box. Clicking the left jog button increases the distance and makes the number in the Socket X input box larger by the corresponding amount. >If the tester has a socket grid and the specified test socket is too far forward of the pickup head so that the pickup nozzle is over the rear end of the device, increase the distance from Y home by clicking the [Increase Distance] jog button. Each time you click this button, the socket grid moves back by the distance shown in the Inc/Dec input box. >If the tester has a socket grid and the specified test socket is too far behind the pickup head so that the pickup nozzle is over the front end of the device, decrease the distance from Y home by clicking the [Decrease Distance] jog button. Each time you click this button, the socket grid moves forward by the distance shown in the Inc/Dec input box. 7. To retest, click X Home and then Head Go to Tester/Socket [n] again.

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Setting the Z-Put Distance to a Test Site Socket


The procedure for defining the Z-put and Z-get distances at a test site is the same as the procedure at a tray. For each location, calibrate Z-put first and then Z-get.

Figure 4-69: Z-Put Distance Group Box

To fine-tune the Z-put distance to a test site: 1. Type a measurement estimated to be correct in the input box to the right of the Go Down to Put Height button. CAUTION: If in doubt, make this distance smaller than you think necessary, then jog the pickup head down by steps to prevent damage from crashing the pickup nozzle into the socket. NOTE: The Z-put distance should be smaller than the Z-get distance, so that the suction cup is higher with Z-put. 2. Click the button Go Down to Put Height. >If the suction cup is too close to the device, raise the pickup head by clicking the [Up] jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets smaller by the same decrement. >If the suction cup is not close enough to the device, lower the pickup head by clicking the [Down] jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets larger by the same increment. 3. Click the Z Put button to drop the device and raise the pickup head from the socket.

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Setting Test Site Distances

> Alternatively, you can do this in steps by unchecking the Z Vacuum checkbox and then clicking the Z Home button.

Setting the Z-Get Distance to a Test Site Socket

Figure 4-70: Z-Get Distance Group Box

To fine-tune the Z-get distance to a test site: 1. Type a measurement estimated to be correct in the input box to the right of the Go Down to Pick Height button. CAUTION: If in doubt, make this distance smaller than you think necessary, then jog the pickup head down by steps to prevent damage from crashing the pickup nozzle into the socket. 2. Click the button Go Down to Pick Height. >If the suction cup is too close to the device, raise the pickup head by clicking the [Up] jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets smaller by the same decrement. >If the suction cup is not close enough to the device, lower the pickup head by clicking the [Down] jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets larger by the same increment. 3. Click the Z Get button to raise the device from the socket or pocket. > Alternatively, you can do this in steps by checking the Z Vacuum checkbox and then clicking the Z Home button.

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By alternating among the Go Down to Put Height, Go Down to Pick Height, and jog buttons, and the Vacuum On/Off checkbox, you can pick and drop the device until you are sure the distances are correct.

Setting the Thermal Heads X Distance to a Test Site Socket


If your handler has hot/cold test heads, this group box is available. The X distance is from the X motor home position to the center of the drop-off point for the test site pocket.

Figure 4-71: Thermal Heads X Distance Group Box

To fine-tune a thermal heads X distance for a test site: 1. Select the thermal head from the Left Cylinder or Right Cylinder options. 2. Type a measurement estimated to be correct in the input box to the right of the Cylinder Go to Tester button. 3. Click the button Cylinder Go to Tester. > This moves the thermal head on the X motor to a position over the test site. 4. Look to see whether the thermal head is exactly over the test socket. > If the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Inc/Dec input box. 5. To check the position, click Cylinder Down and then Cylinder Up again. If you have more than one test site, work your way to the left in calibrating test sites. For example, if you have four test sites, calibrate number 4 first, then 3, then 2, and finally 1, on the extreme left. After you have calibrated the test site(s), use the instructions from "Setting Tray Distances" on page 4-60 to calibrate the output trays.

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Saving the Job File

Setting Test Site Distances

Saving the Job File


To save changes to the settings under the job file name that is currently open, click the Save button at the lower right of the window. To have any changed settings apply to the current session without saving to the job file, click the Back to Main button at the lower right of the window.

To save changes to the settings under a new or different file name, click the Back to Main button, then on the main window, click the Save As button. The Save As dialog box is displayed, allowing you to save changes to a different file name.

Figure 4-72: Saving to a Different File Name

NOTE: When you save changes to a file using Save As, the new file created is not loaded. The system is still running the original file. If you want to use the new file instead, you must load the new file by clicking the Load button on the Main window. As the job file is being saved, its progress is displayed (Figure 4-73).

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Figure 4-73: Saving File

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Chapter 5: Auto Run


Chapter Overview
This chapter discusses the following main topics: Topic Halt, Run, and EMO Buttons Operator Settings Auto Run Viewing the Log File Examples of Auto Run and Log File Page 5-1 5-2 5-8 5-22 5-23

Halt, Run, and EMO Buttons


The EMO (emergency stop) button can be pushed in anytime there is a need to instantly disable the motors and shut off the 24-volt AC. However, it leaves the computer running, so that when Auto Run is continued, the operator is given the choice of restarting where the handler left off with the device count.

Figure 5-1: EMO (Emergency Stop) Button (Left); HALT Button Depressed (Right)

To release the EMO button, turn it clockwise until it pops out again.

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The HALT and RUN buttons are located near the EMO (emergency stop) button. These hardware buttons work just like the software buttons Pause or HALT and Continue or RUN onscreen. Pressing HALT pauses the handler, while it keeps count of the devices. NOTE: After depressing the HALT button, you must press HALT a second time to release it and permit RUN to be pressed. Pressing RUN resumes the Auto Run where it left off.

Operator Settings
The handler operator can adjust settings for an impending job by clicking the Operator button on the main window. No password is required.

The Operator Setting window opens with the Work Mode tab displayed. Here you can specify settings for the job you want to run next. NOTE: These settings are valid for the current run only. They will not be saved when you close the Exatron software.

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Operator Settings

Figure 5-2: Work Mode Window in Operator Settings

Input Operation Group Box


Select the option for the input-output combination you want to use. Only the selections that are not greyed out are available for your handler.

Job Information Group Box


Job Count Consecutive Failure Max Count at Testing Type the number of devices to be passed in this job. Type the number of back-to-back, or consecutive, device failures the handler can encounter upon testing before stopping. Operator intervention is required before the handler will resume.

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Consecutive Failure Max Count at Tray

Type the number of back-to-back, or consecutive, empty tray pockets the handler can encounter before stopping. Operator intervention is required before the handler will resume. Type the number of back-to-back, or consecutive, device failures the handler can encounter upon inspection before stopping. Operator intervention is required before the handler will resume.

Consecutive Failure Max Count at Inspection

Run Mode Group Box


Select the mode you want to run.

AutoRun Mode Group Box


Check the boxes for all processes you want to run on the devices. Only the selections that are not greyed out are available for your handler.

Tester Group Box


If your handler has more than one tester, there may be a group box for each tester.

Figure 5-3: Tester Group Box

Enable Tester [n]

Check this box to enable the designated tester. Uncheck this box to disable the designated tester. Type the correct IP address for the designated tester. Check any boxes to enable the designated golden unit pockets. Select the Thermo option to use hot/cold testing for the designated tester. Select the Ambient option to use only clamp testing at room temperature for the designated tester.

IP Address Enable Golden Unit [n]

Thermo/Ambient

Tester Operation Group Box


Real Test When preparing to do an Auto Run, the option is always real test. This option is not available in Auto Run.

Simulation

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Operator Settings

Tester Mode Group Box

Figure 5-4: Tester Mode Group Box

Serial Port/TTL

Select the desired interface between handler and tester. See Appendix A for more information.

Rotation Group Box


If your handler has the option of rotation of the pickup nozzle, you can specify the rotation here. Depending on your options, you may have two locations at which to specify rotation.

Figure 5-5: Rotation Group Box

0 Degree +90 Degree

Select this option to use no rotation. Select this option to rotate each device a quarter-turn clockwise. Select this option to rotate each device a quarter-turn counter-clockwise. Select this option to rotate each device a half-turn.

-90 Degree

180 Degree

Inspection Group Box

Figure 5-6: Inspection Group Box

Inspection File Name

Type the desired file name.

Inspection Log File On/Off Check this box if you want the job to produce an inspection log file.

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2D/3D

Select the desired option. Select 2D for two-dimensional inspection on the X and Y axes. Select 3D for three-dimensional inspection including the Z axis. > This option is used to inspect the shape, location, and height of balls on BGAs (ball grid arrays).

Real Test

Select this option to run a real inspection on devices. This is the default setting the system reverts to every time you close the Exatron software.

Simulation

Select this option to simulate the operation of the handler without inspecting devices. If you select this option, select the desired outputs: pass location, fail locations, or random pass/fail simulation.

Function Enabling Group Box

Figure 5-7: Function Enabling Group Box

Enable Precisor

Check this box to include the precisor in the process. Uncheck this box to exclude the precisor from the process. Check this box to include the rub function in the process. Uncheck this box to exclude the rub function from the process. Check this box to display an onscreen confirmation request message when the maximum number of consecutive empty pockets found in an input tray has been reached. Uncheck this box to send the tray to the output stacker when the maximum number of consecutive empty pockets has been reached, without displaying any confirmation message.

Enable Rub

Show Message for Max Empty Pocket at Tray 1

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Operator Settings

Turn On Tray Clamp at Last for Stacker

See "Tray Loading Process" on page 2-5 as reference. Check this box to lift up the stack of trays at the input stacker before extending the tray clamp pins to clamp the bottom tray. Thus, step 5 occurs after step 7. Uncheck this box to use the default input stacker process order as described in "Tray Loading Process" on page 2-5.

Enable Move Motor X for RF

Check this box to move the pickup head away from the test sites after putting a device in the test socket. Uncheck this box to leave the pickup head above the test socket after putting a device in the socket. This feature enables you to turn off a motor that might interfere with the RF testing of a device. Check this box to turn off the pickup head motor after it puts a device in the test socket. This disables the normal alternating ping-pong operation if there are two pickup cars. Uncheck this box to leave the pickup head motor on after it puts a device in the test socket. This enables the normal alternating ping-pong operation if there are two pickup cars.

Enable RF

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Auto Run
On the main window, click the Auto Mode button. A Lot Information dialog box is displayed. Type your user name and the lot ID of the serial numbers you want to run. The lot ID can contain any combination of letters and/or numbers. Click OK.

Figure 5-8: Lot Information Dialog Box

The Auto Run window opens.

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Auto Run

Figure 5-9: Auto Run Window During Run

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Figure 5-10: Auto Run Window Initial AppearanceHandler Using Inspection and Output Tubes

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Auto Run

Window Features Description

Figure 5-11: Auto Run WindowHandler Using Thermal Heads

Window Features Description


Run/Resume Click the Run button to begin a production run in Auto Run. Click this button to resume a run after pausing with the Halt button. Halt Click the Halt button to pause the job or production run. The handler keeps count of the devices already processed. After clicking Halt and providing whatever service is necessary, you can click the Resume button again to restart the production run where it left off.

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End of Lot

After clicking the Halt button, you can click the End of Lot button to end the production run, finalize the count, and create the log file. Click the Back button to return to the main window.

Back

Statistics Group Box


The categories of information displayed here will vary depending on the features customized on your handler. Pass, Fail/ Sort [n], Other, For each of these sort categories, two statistics are continually updated: and Total NumberThe total number of devices thus far assigned to the category, and Yield(%)The percent of the total number of devices processed that have been assigned to this category. Tester The type of test (simulation or a real test) and interface used are displayed. Whether the current run is a real inspection before testing, a simulation, or disabled is displayed. Whether the current run is a real inspection after testing, a simulation, or disabled is displayed. Whether the thermal head is enabled or disabled, or is in clamp mode is displayed. Clamp mode means the thermo motor is actively moving, but the thermal head is inactive. This is for contact pressure only. Input Mode If your handler is equipped with more than one input type, the selected input is displayed; for example, tray, bowl feeder, detaper, tubes, etc. The statistics are displayed for devices put in the taper. The statistics are displayed for devices failed from an electrical test. The statistics are displayed for devices failed from a visual test. Whether the current run is a simulation (pilot) or a real laser marking is displayed.

Inspection Before Test

Inspection After Test

Left/Right Thermo/Ambient

Taper Tray [n] E Fail

Tray [n] V Fail

Laser

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Auto Run

Window Features Description

Rotation

The plus or minus degree of rotation applied, if any, is displayed. The input-to-output mode in use is displayed.

Operation

Auto Run Status Group Box


Initially this display area is blank. As the Auto Run progresses, each action is displayed here. You can scroll up to see previous messages. You can also check the log file later. The log file will be stored in the Log folder which is inside the Exatron folder. The log file is named for the date and time of the Auto Run that created it. Enable Status List Check this box to display progress messages. Uncheck this box to forego the display of progress messages, which might save a miniscule amount of time.

Time and Count Group Box


Some features here are set in the Settings windows. See page 4-19 and page 4-35. Enable Precisor If this box is checked, the precisor is included in the process. If this box is unchecked, the precisor is excluded from the process. If this box is checked, the rub function is included in the process. If this box is unchecked, the rub function is excluded from the process. If this box is checked, an onscreen confirmation request message is displayed when the maximum number of consecutive empty pockets found in an input tray has been reached. If this box is unchecked, the tray is sent to the output stacker when the maximum number of consecutive empty pockets has been reached, without displaying any confirmation message. If this box is checked, the pickup head is moved away from the test sites after putting a device in the test socket. If this box is unchecked, the pickup head is left above the test socket after putting a device in the socket. If this box is checked, the pickup head motor is turned off after it puts a device in the test socket. This disables the normal alternating ping-pong operation if there are two pickup cars. If this box is unchecked, the pickup head motor is left on after it puts a device in the test socket. This enables the normal alternating ping-pong operation if there are two pickup cars.

Enable Rub

Show Message for Max Empty Pocket at Tray 1

Enable Move Motor X for RF

Enable RF

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Start Time

The start time or ending time of the current run is displayed. This display is in universal time, which adds every hour after noon to the count; for example, 1:10 p.m. is displayed as 13:10, and 4:30 p.m. is displayed as 16:30.

[Current Date] Unit Per Hour

The current date is displayed. The number of devices processed at the current rate is displayed. The total number of devices to be processed in the current run is displayed. You can change this number if necessary. Check this box to cause the handler to stop and display a message whenever a device is sorted according to the setup in the Stop-On-Fail Group Box on page 4-35. Uncheck this box to cause the handler to keep going regardless of any tested sorts.

Job Count

Enable Stop-on-Fail

Thermal Test Group Box

Figure 5-12: Thermal Test Group Box

Current Temperature

The present temperature of each thermal test head is displayed. The set or desired temperature of each thermal test head is displayed. The upper and lower limits of the acceptable temperature of each test head is displayed.

Set Temperature

Guard Band

Optional Features
Release Bucket [n] If your handler has smart buckets, you can click this button to release the latch for the selected bucket to enable removal of the bucket. Click this button to home all motors. Click this button to turn off all motors.

Reset Motor Off

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Auto Run

Window Features Description

Log File [Socket grid display]

Click this button to view the log file. The square at the lower left of Figure 5-13 is a progress display for handlers using a multiple test socket grid. Yellowthe test socket is currently filled. Blackthe row is disabled.

Wafer to Tray 1 Only Group Box


The items in this group box are used only when the mode of wafer to laser mark to tray is in use. In this special mode, no testing is done. Run Wafer to Tray 1 Click this button to begin a production runonly when using the special mode. Click this button to pause a production runonly when using the special mode. Click this button to restart a production runonly when using the special mode. Click this button to stop, or abort, a production runonly when using the special mode. This box displays the number of devices marked and put in Tray 1. Click this button to reset the number displayed in the Tray 1 Count box to zero.

Pause

Continue

Stop

Tray 1 Count

Reset Tray 1 Count

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Figure 5-13: Auto Run WindowHandler Using Tester with Multiple Sockets

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Auto Run

Window Features Description

Figure 5-14: Auto Run Window During RunHandler Using Inspection and Output Tubes

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Figure 5-15: Auto Run Window During RunHandler Using Thermal Testing and Multiple Inspection

Process Instructions
CAUTION: Be careful when carrying or moving filled trays. Jerking the trays can dislodge devices from their pockets, costing clean-up time. To run a job in Auto Run: 1. Place the devices to be processed in the appropriate trays (or other input). Load the trays onto the input stacker of the handler, suspended over the carriage. For a new job, make sure the input carriage itself is empty. 2. Close the handler covers and doors. 3. Verify that the correct job file is loaded by looking at the filename in the title bar in the upper left corner of the Auto Run window.

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Auto Run

Process Descriptions

4. Click the Run button. You will be asked whether you want to continue from the tray pockets where you last stopped, or to begin new trays with the first pockets. > For a new job, click Start Over. The handler will start with the device in the first tray pocket. > For a job you paused or stopped and are resuming, click Continue. The handler will start with the next tray pocket after the last one previously used. NOTE: In both cases, all counts will start at 0, both on the Auto Run window and in the resulting log files.

Figure 5-16: Auto Run Initial Message

Process Descriptions
The handler first checks that all the test sites are empty. If there are any devices in the test sites, they are moved to the flush bin. Next the handler begins testing devices. After testing, each device is placed in the next consecutive pocket, both for pass and fail locations. The order of placement is as follows: columns 1 to last in row 1 are filled, then columns 1 to last in row 2 are filled, etc. As each device is processed, its sort category is added to the count.

Process for Two Pickup Nozzles and One Test Site


For a setup with an input tray and an output tray and one test site, the cycle might be as follows: 1. The X1 pickup head moves to the input tray Y1, and the Z1 pickup nozzle gets a device from tray Y1. 2. The X1 pickup head moves to the test site, and the Z2 pickup nozzle gets a device from the test socket.

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3. The Z1 pickup nozzle puts a device into the test socket. 4. The X1 pickup head moves to the output tray Y2, and the Z2 pickup nozzle puts a device into tray Y2. Then the cycle repeats.

Process for Two Pickup Nozzles and Two Test Sites


This cycle assumes the handler is in Tray-to-Tray mode, and the test sites have independent socket clamps. Here, the left pickup nozzle, or Z1, takes the untested devices from the input to the tester, and Z2 takes the tested devices from the tester to the output. After you click the RUN button, the following cycles occur.

Preliminary:
1. The X pickup heads move to the test sites. 2. Z1 checks for a device at test site 1. 3. Z2 checks for a device at test site 2. 4. If none are found, the X pickup heads move to tray Y1, and Z1 gets a device from tray Y1. Z2 gets a device from tray Y1. > At this point, both nozzles have untested devices. 5. Z1 puts its device into test site 1, and the socket clamp closes. 6. Z2 puts its device into test site 2, and the socket clamp closes. > At this point, both test sites contain devices, and the regular cycle is ready to begin.

Start of cycle:
1. The pickup heads move to tray Y1, and Z1 gets a device from tray Y1. 2. Test site 1 socket opens as the pickup heads move to the tester. 3. Z2 gets the device from test site 1. 4. Z1 puts the device into test site 1. Test socket 1 closes. 5. The pickup heads move to tray Y2, and Z2 puts its device into tray Y2. 6. The pickup heads move to tray Y1, and Z1 gets a device from tray Y1. 7. Test site 2 socket opens as the pickup heads move to the tester.

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Auto Run

Process Descriptions

8. Z2 gets the device from test site 2. 9. Z1 puts the device into test site 2. Test socket 2 closes. 10. The pickup heads move to tray Y2, and Z2 puts its device into tray Y2. Then the cycle repeats.

Process for Tester with Multiple Sockets


This cycle assumes the handler is in Tray-to-Tray mode. After you click the RUN button, the following cycles occur.

Preliminary:
1. The Z pickup heads are checked for devices. 2. If a tray is on any carriage, the carriage is moved back to the unloading area and the tray is unloaded to the stacker. 3. The pickup heads check the left half of the tester, then the right half of the tester for devices. 4. For each tray carriage that is enabled, the stacker deposits the lowest tray on the carriage.

Start of cycle:
1. Pickup heads take 4 devices from tray 1 to left half of tester. 2. Pickup heads take 4 devices from tray 1 to right half of tester. 3. Pickup heads take 4 devices from left half of tester to tray 2. 4. Pickup heads take 4 devices from tray 1 to left half of tester. 5. Pickup heads take 4 devices from right half of tester to tray 2. 6. Pickup heads take 4 devices from tray 1 to right half of tester. 7. Pickup heads take 4 devices from left half of tester to tray 2. Then the cycle repeats, starting from step 4.

Managing Processed Trays


When an input tray has been emptied of devices, the Y carriage takes it to the rear unloading station, and the stacker lifts the tray off the carriage. The carriage comes to the front loading station again, and the front loading stacker lowers and deposits the lowest filled tray onto the carriage, then raises out of the way again.

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When an input stacker has been emptied of trays, a message is displayed to place more filled input trays in the stacker. If this is the end of the job, click End of Lot. If more devices need to be processed, load more devices and click Continue. When an output tray has been filled with devices, the Y carriage takes it to the rear unloading station, and the stacker lifts the tray off the carriage. The carriage comes to the front loading station again, and the front loading stacker lowers and deposits the lowest empty tray onto the carriage, then raises out of the way again. When an output stacker has been filled with trays, a message is displayed to place more empty output trays in the stacker. If this is the end of the job, click End of Lot. If more devices need to be processed, load more devices and click Continue. After you click End of Lot, the pickup head takes all devices from the tester to the output tray.

Ending Auto Run


When you end a production run by clicking HALT and then BACK, the message is displayed: Are you sure you want to go back to Main page? Click OK to end the Auto Run, or click Cancel to stay in the Auto Run window and resume the run.

Figure 5-17: Request for Confirmation to Quit Auto Run

Viewing the Log File


If a Log folder exists inside the Exatron folder on the handlers Exatron CPU, each Auto Run results in a log file, the record of what occurred during the run. The name of each log file consists of the name of the job file that was used in the run, plus the date and time the log file was started. After you finish a production run, you can view the log file. There are two ways to do this. To view a log file from Exatron Main window: 1. Exit the Auto Run window.

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Examples of Auto Run and Log File

Process Descriptions

2. On the Main window, click the View Log button. To view a log file from Windows Explorer: 1. Open Windows Explorer by right-clicking the Start button in the lower left corner of the screen and clicking Explore.

Figure 5-18: Opening Windows Explorer

2. Go to C:\Exatron\Log and double-click on the log file you want.

Examples of Auto Run and Log File


You can halt a job and go back to the Main window to change settings, and then go back into Auto Run to continue a job. Although each time you leave Auto Run by clicking BACK, the log file is closed out, and when you go back into AR, a new log file is created, but it continues the count in the new log file. The contents of the log file varies according to the customization of each handler. Following are two examples. In the first example, the log file contains serial numbers obtained from an inspection, and the location of each. This table is followed by a summary of the various sorts (Figure 5-19).

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Figure 5-19: Log File with Serial Numbers

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Examples of Auto Run and Log File

Process Descriptions

Figure 5-20: Auto Run Initial Appearance

In the second example, notice in Figure 5-20 that the job file opened is named 20x8.edf. Notice also that the value in the [Start Time] box is still N/A, because the run has not been started yet; hence, the start time is unknown. Then the operator clicks the RUN button and the Auto Run begins.

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Figure 5-21: Messages Showing Start of Auto Run

Notice the Auto Run Status message display in Figure 5-21. The first line displays the date (1/10) and the starting time (11:20 a.m. and 36 seconds) of the current run. Then the handler began by checking the test sites for residual devices before beginning to place new ones for testing. As yet, no sorts have been tallied. The first device has just been placed in Tray 2, and in another instant, a 1 will be displayed in the Tray2 row.

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Examples of Auto Run and Log File

Process Descriptions

Pause & resume times noted

Resume time

Figure 5-22: Run Halted After 11 Devices Processed

The operator does a quick HALT, then decides everything is okay, and, still in Auto Run, clicks RESUME. This pause is shown in the Auto Run Status box in Figure 5-22. The pause will also be recorded in the log file. Later, after 11 devices have been processed, the operator decides to make a small adjustment, and clicks the HALT button (Figure 5-22). In Figure 5-22, the resume time of the current run (11:21) is displayed at the bottom of the window rather than the start time. The operator has the option to either resume the run (by clicking RESUME) or go back to the Main window and make other adjustments (by clicking BACK). When the operator clicks the BACK button and confirms his choice by clicking OK, the log file is closed out. The operator makes a few adjustments in Diagnostics before returning to Auto Run.

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Figure 5-23: Log File from First Run

A quick look at the log file produced from this run shows several items: The name of the setting file used (20x8.edf) The starting date and time of the run (01/10, 11:20 a.m.) The pausing and resuming of the run (both at 11:21 a.m.) The time of the halting and exiting of Auto Run (11:22 a.m.) The total number of devices passed (11) and failed (0) If this had been a real test rather than a simulation, the percentage of devices passed and failed would also be displayed. After making adjustments, the operator returns to Auto Run. The operator is given two choices in Figure 5-24: He can load a new tray and click Start Over. In this case the handler will start picking from the first pocket. He can resume the former run by clicking Continue. In this case the handler will continue picking from the next pocket of the current tray. No matter which selection he makes, the run restarts the count from 0, as will the log file.

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Process Descriptions

Figure 5-24: Auto Run Re-entered After Going Back to Main Window

The new or continued run starts at 11:25 a.m. After a second run is completed, the operator looks at the second log file that is produced. Both log files are displayed in Windows Explorer. The name of each log file consists of the name of the job file that was used in the run, plus the date and time the log file was started.

Figure 5-25: List of Log Files

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Figure 5-26: Log File from Second Run

This time the number of devices passed was 10. This number of 10 was not added to the previous run of 11. The run started at 11:25 and ended at 11:27.

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Chapter 6: Diagnostics
Chapter Overview
This is a reference chapter which describes the features of the windows available from the Diags button on the main window. For step-by-step instructions on calibrations, see Chapter 4. NOTE: Your handler software may not display every box or button for various options discussed in this manual. Rest assured that your handler and software have been customized for your companys needs.

Keeping Your Original Job File


The settings displayed come from the file you opened at the beginning of the diagnostic session. If you opened the file containing the factory presets, you will likely not need to change the factory settings unless a piece of hardware or a tray configuration is changed. If you do need to make changes for any reason, it is recommended that you copy the file containing the factory settings first, then use the settings in the copy of the file as a basis for fine-tuning the measurements. Save any changes under a new file name. For information on copying and saving a job file, see "Copying the Job File for Modifications" on page 4-7 and "Saving the Job File" on page 4-73. The distances for each tray configuration need to be fine-tuned only once. If you use trays with various types of waffle packs, set up a separate job file for each tray configuration, and use it each time you use that tray configuration.

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Chapter 6: Diagnostics

Diagnostics Windows
The windows available from the Diags button allow every mechanical and electrical action of the handler to be checked and tested. Usually, best results are obtained when the windows are used in order, from left to right. However, there may be occasions when it is feasible to use the features of just one or two of the windows. The following are the windows available from the Diags button. Your handler has only the ones used in your setup. You can access each of the Diagnostics windows by clicking on its tab at the top of the screen. Window Sensors/Solenoids Check Stacker Z Motors Rotation Motors (Optional) X and Y Motors Golden Unit (Optional) Tray Function Tests signals between hardware and software Tests movements of Y trays and Z stackers Tests vertical (Z-axis) movements of pickup nozzles Tests rotational (theta-axis) movements of pickup nozzles Tests independent movements of Y trays and X pickup heads Sets distances for each pocket of the golden unit Tests interacting movements of X pickup heads and Y trays; sets distances for tray pockets Tester Tests interacting movements of X pickup heads and testers; sets distances to test sockets Thermal (Optional) Sets test temperature ranges for thermal heads Air Pressure (Optional) Sets air pressure and speeds for thermal heads Camera Inspection (Optional) Tests the functioning of the inspection unit; sets distances Laser (Optional) Tests laser; sets laser marking position Detaper (Optional) Tests movement and distance of X pickup head to detaper Tape and Reel (Optional) Defines information about tape; sets distances, reel motor speeds Tube (Optional) Sets distances between various motor positions and tubes Wafer Input (Optional) Sets distances between various pickup heads and the wafer To access the Diagnostics windows: 1. On the main window, click the Diags button. 2. Enter the correct password. See "Passwords" on page 4-2 for the factory-set password. Click OK. Page 6-3 6-29 6-35 6-38 6-39 6-80 6-46 6-56 6-71 6-71 6-80 6-87 6-91 6-94 6-102 6-109

Figure 6-1: Log On to the Diagnostics Dialog Box

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DiagnosticsSensors/Solenoids Check Window

DiagnosticsSensors/Solenoids Check Window


The Sensors/Solenoids Check window (sometimes called the Input/Output Check window) is the first window that is displayed when you enter Diagnostics from the Main window. It allows you to test the functioning of each sensor and solenoid in the system. It tests: The sensor state Whether the software recognizes each sensors change in state Signals between the software and the hardware Correct functioning of every solenoid and light

You can manually actuate each sensor and solenoid, and the corresponding light on this window should toggle. A green sensor light means that the signal indicator is high, or that the sensor is "seeing" an object in its line of sight. A red sensor light means that the signal indicator is low, or that nothing is in front of the sensor. For more information, see "Fiberoptic Photoelectric Sensor Guidelines" on page 7-61. A green solenoid light means that the hardware has been activated. A red solenoid light means that the hardware is inactive. Placing a check mark in each check box should activate the corresponding solenoid or light. See the sensor manufacturers manual for more information on the sensors. This window has a number of pages, accessible by clicking the drop-down arrow to the right of the Port Selection or I/O Card List and clicking one of the selections. The inputs and outputs are grouped by the access port.

Figure 6-2: Example of Drop-Down Selections

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Page X1 X2 Y1 Y2 Y3 Light Taper Tube Laser

Signals Involved Movements of the right pickup head on the X gantry Movements of the left pickup head on the X gantry, if so equipped Movements of the leftmost tray Movements of the tray next to the left Movements of the third tray Actions related to the light pole; and test site clamps, if so equipped Actions related to the taper, if so equipped Actions related to the tubes, if so equipped Actions related to the laser, if so equipped

Page 6-5 6-5 6-7 6-7 6-7 6-12 6-19 6-26 6-28

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DiagnosticsSensors/Solenoids Check Window

Pickup Head X Input/Output

Pickup Head X Input/Output


X1 applies to the right pickup head assembly. X2, if it exists, applies to the left pickup head assembly.

Figure 6-3: Sensors/Solenoids Check WindowX Input/Output

Accessing the same inputs and outputs may be represented a bit differently, as in Figure 6-4.

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Figure 6-4: Input/Output Check WindowX Input/Output

Z blow-off

Z vacuum

Z vacuum sensor
Figure 6-5: Vacuum Generators for Z1, Z2, and Z3

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Trays Y Input/Output

Trays Y Input/Output
The Y I/O pages for the trays and stackers are similar to one another.

Figure 6-6: Sensors/Solenoids Check WindowY Input/Output

Accessing the same inputs and outputs may be represented a bit differently, as in Figure 6-7.

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Figure 6-7: Input/Output Check WindowY Input/Output

Inputs/Sensors
Following is a sample of sensor signals and their meanings. Stacker Position Lowered Raised Lowered Raised Unload Home Sensor Color Red Red Green Red Tray Home Sensor Color Red Green Green Green Load Home Sensor Color Green Red Red Red

Y Tray Position Loading or Input stack Unloading or Output stack

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Trays Y Input/Output

When a stacker is empty, the Stacker Empty sensor is red and the Stacker Full sensor is green. When one tray is on a stacker, both Stacker Empty and Stacker Full sensors are green, because the stacker is neither full nor empty. A few of the sensors are pictured in the following photos.

Figure 6-8: Door Interlock Sensor

Figure 6-9: Input Stacker Empty Sensor

The Input Stacker Empty sensor is located on the left front of each input stacker.

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Figure 6-10: Tray Home Sensor

The Tray Home sensor is located on the floor of each tray lane, at the input stacker.

Figure 6-11: Tray Present Sensor

The Tray Present sensor is located on the right front of each carriage on some handlers, or on the stacker under the Input Stacker Empty sensor on other handlers. It is green when no tray is present.

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Trays Y Input/Output

If the handler has a thermal head, its sensor is shown in Figure 6-12.

Figure 6-12: Thermal Head Car Sensor

Outputs/Solenoids
When an output box is unchecked initially, the solenoid is at its default position. For example, for the selected Y stacker, the support pins are thus: Solenoid Input Stacker Lift Input Stacker Support Output Stacker Lift Output Stacker Support Tray Clamp For What Input stacker Input stacker Output stacker Output stacker Tray carriage Box Unchecked Lifter pins retracted Support pins extended a Lifter pins retracted Support pins extended Box Checked Lifter pins extended Support pins retracted Lifter pins extended Support pins retracted

Tray clamp pins retracted Tray clamp pins extended

a. The support pins are extended by default, with or without air pressure, to support any trays remaining in the stacker when the handler is turned off.

CAUTION: Before checking either the Input Stacker Support or Output Stacker Support solenoid checkboxes, make sure no trays of devices are on the stacker, or they will be dropped when the support pins are retracted.

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Light Input/Output
This page allows you to test each light on the light pole.

Figure 6-13: Sensors/Solenoids Check WindowLight Input/Output

Accessing the same inputs and outputs may be represented a bit differently, as in Figure 6-14.

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Light Input/Output

Figure 6-14: Input/Output Check WindowLight Input/Output

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Chapter 6: Diagnostics

Test Socket Clamps


If the handler has independent test site clamps, you can test their I/Os on one of these pages. Figure 6-6 and Figure 6-13 show two examples of where the pusher/slider I/O controls may be located. The slider makes the horizontal, extending/retracting movement of the test site clamp; the pusher makes the vertical, clamping/unclamping movement (Figure 6-15, Figure 6-16). The air pressure for each pusher and slider can be adjusted at the control panel; see "Test Socket Clamp Air Pressure Controls" on page 6-15.

Figure 6-15: Pusher Up (Left); Pusher Down (Right)

Figure 6-16: Slider Retracted (Left); Slider Extended (Right)

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Test Socket Clamp Air Pressure Controls

Test Socket Clamp Air Pressure Controls


The air pressure of each pusher and slider can be adjusted individually at the controls. The smaller panel (Figure 6-17, left) has an adjustment knob that controls the air pressure for the horizontal slider(s). It also has air flow controls for each pusher and slider. The larger panel (Figure 6-17, right) has an adjustment knob that controls the air pressure for the vertical pusher(s). It also has switches that allow you to test the movement of each pusher and slider. Slider control knob

Pusher control knob

Figure 6-17: Test Site Clamps Air Pressure Controls

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Thermal Heads Input/Output


If your handler is equipped with thermal heads, the Thermo page is available.

Figure 6-18: Sensors/Solenoids Check WindowThermal Heads Input/Output

The example in Figure 6-18 uses two separate thermal head assemblies, T1 and T2, with 3 thermal heads on each assembly: a hot head, a cold head, and an ambient or room temperature head.

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DiagnosticsSensors/Solenoids Check Window

Thermal Heads Input/Output

Figure 6-19: Cylinder (Thermal Head) Up Sensors

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Thermal Head Air Pressure Controls

Figure 6-20: Dynamic Socket Pressure Controls

The amount of air pressure applied by the thermal heads at the test socket is set in the Diagnostic software (see "Socket Pressure Group Box" on page 5-102). To manually raise or lower each thermal head, flip the corresponding switch. To turn the air pressure on or off, flip the Air On/Off switch.

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DiagnosticsSensors/Solenoids Check Window

Tape Input/Output

Tape Input/Output
If the handler has a taper attached, those I/Os are displayed.

Figure 6-21: Input / Output Check WindowPage for Handler with Taper

Taper Outputs

Output Seal Head Down Carrier Tape Vacuum Take Up Motor On Trigger Camera Load Inspection Job Inspect Job Bit 0 Lower seal head

Check Box To...

Turn on carrier tape vacuum under the pickup head drop site; helps to seat devices in pocket Turn on takeup reel Trigger an inspection of a tape pocket by the image sensor Load the inspection file specified in the following 3 boxes Switch the binary bit in the 0 position to a high signal to load an inspection file to the camera

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Output Inspect Job Bit 1 Inspect Job Bit 2

Check Box To... Switch the binary bit in the 1 position to a high signal to load an inspection file to the camera Switch the binary bit in the 2 position to a high signal to load an inspection file to the camera

Loading an Inspection File to the Camera


A three-bit high/low signal is sent to the camera (image sensor) to specify the inspection file to load. (Because this 3-bit procedure can encompass only 8 files, any additional inspection files must be manually loaded to the camera.) The binary digit positions are counted from right to left: bit 0, bit 1, and bit 2. A 1 in a bit position sends a high signal; a 0 in a bit position sends a low signal. With three digits, eight combinations are possible, with each one indicating an individual inspection file. The slot for each inspection file is shown on the Setup Parameters window; the drop-down list is shown in Figure 6-22. Bit 2 Position
0 0 0 0 1 1 1 1

Bit 1 Position
0 0 1 1 0 0 1 1

Bit 0 Position
0 1 0 1 0 1 0 1

Combined Binary Number


000 001 010 011 100 101 110 111

Device Type (Write Yours Here)

Inspection Slot Number


0 1 2 3 4 5 6 7

Figure 6-22: Example of Inspection Files with Their Slot Numbers

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Tape Input/Output

Thus, the boxes checked correspond with the binary digit positions. A checked box sends a 1 or high signal; an unchecked box sends a 0 or low signal. Thus, if the Inspect Job Bit 0 box is checked but the other two are not checked, the signal sent is 001, where bits 2 and 1 are zeros and bit 0 is 1.

Binary signal 000

Binary signal 001

Binary signal 010

Figure 6-23: Bit Settings for Inspection Files with Binary Numbers 000, 001, and 010

Binary signal 011

Binary signal 100

Figure 6-24: Bit Settings for Inspection Files with Binary Numbers 011 and 100

After you have set the bits by checking the appropriate Inspect Job Bit boxes, then check the Load Inspection Job box to load the specified inspection file to the camera. Loading an inspection file by these job bits can hold only 8 files. You must manually load additional files to the camera.

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Chapter 6: Diagnostics

Taper Override Buttons


The tapers override buttons are on the taper control panel, on the side of the taper box.

Taper Solenoid Override Buttons


Button White Blue Yellow Green Affects Seal head Output 1 Takeup reel Output 3 Action When pressed, the seal head is lowered Spare button for extra options When pressed, the takeup reel motor is activated, turning the reel Spare button for extra options

Sensor lights

Override buttons

Figure 6-25: Taper Control Panel with Sensor Lights and Override Buttons

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DiagnosticsSensors/Solenoids Check Window

Tape Input/Output

Taper Inputs
Input Empty, Out of Pocket, Tape Inspection Gap Heater Alarm Slack Switch Tape Out Error Box Is Checked When... Pocket under sensor is not empty Gap sensor cannot through pocket hole Present value and set value are same temperature Tape is not taut and takeup arm is down Tape is not out; continuing tape supply

Empty/out-ofpocket sensor

Pickup head nozzles

Figure 6-26: Tape Track with Empty/Out-of-Pocket Sensor and Pickup Head

The image sensor performs the function of an Empty/Out of Pocket sensor. The image sensor is located behind or to the left of the pickup heads drop point for the taper. If a device is missing or not seated correctly in the tape pocket, the Empty/Out of Pocket sensor stops the taper and a message is displayed onscreen. The Gap sensor is located in front of or to the right of the pickup heads drop point for the taper. It finds the home position for the tape and ensures correct offset after homing.

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Chapter 6: Diagnostics

Heater controller display

Slack switch sensor opensignal high

Figure 6-27: Taper Model 202 with Slack Switch and Heat Sensors

The Slack Switch sensor is located on the side of the taper plate (Figure 6-27). When the motor for the takeup reel turns on, the tape is wound onto the takeup reel. The tape becomes taut and raises the tape arm to block the slack switch sensor (Figure 6-28). When the sensor is blocked, it stops the motor on the takeup reel. After a number of tape pockets have been filled and advanced, the tape arm again falls, the sensor is uncovered, and the takeup motor again turns to take up the slack.

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DiagnosticsSensors/Solenoids Check Window

Tape Input/Output

Figure 6-28: Slack Switch Sensor Blocked

The Heater Alarm sensor is located inside the heating unit seal head (Figure 6-29). The heater controller display is located on the side of the tape-and-reel plate (Figure 6-27).

Figure 6-29: Seal Head

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Chapter 6: Diagnostics

Tube Input/Output
If your handler uses tubes, this page is available.

Figure 6-30: Sensors/Solenoids Check WindowTube Input/Output

Click any Cover LED solenoid checkbox to turn on the light with the same number.

Figure 6-31: Cover LEDs On (Left) and Off (Right)

The cover LED lights have 3 functions:

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DiagnosticsSensors/Solenoids Check Window

Tube Input/Output

Each cover LED lights up briefly to show that the handler counted the device when a device passes under its sensor and drops into its tube. When a tube is missing from the tube holder, the cover LED light for that tube flashes on and off. When a tube is full, the cover LED light for that tube turns on and stays on until the tube is replaced by an empty one.

Lead-in #7 sensorjammed Lead-in #3 sensorfull

Tube switch #6 sensor


Figure 6-32: Tube Sensors

The Lead-in sensors each have an upper and lower part, working together. The upper part senses jammed devices; the lower part senses full tubes. The cover must be lowered into a closed position for the lead-in sensors to work. The Tube Switch sensors sense when a tube is removed from the slot, and direct the output to a different tube.

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Chapter 6: Diagnostics

Laser Input/Output
If your handler is equipped with a laser, this page is available.

Figure 6-33: Sensors/Solenoids Check WindowLaser and Light Input/Output

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DiagnosticsStacker Window

Stacker Motor List Group Box

DiagnosticsStacker Window
The Stacker window has two main functions. It allows you to: View or set motor speeds. Calibrate tray loading and unloading on the stackers.

Figure 6-34: Stacker Window

Stacker Motor List Group Box


Stacker List To test a specific stacker motor, click the drop-down arrow by the Stacker List box, and select the motor. The column for that motor is highlighted in dark blue. Most actions you initiate on this window apply to the stacker you select in the Stacker List. Lift On/Off This checkbox activates the lifter pins, which are used while loading or unloading a tray on the stacker.

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Chapter 6: Diagnostics

When checked, the lifter pins are extended, so that when the Align Position button in the Load Sequence group box is clicked, it lifts the tray slightly. When unchecked, the lifter pins are retracted. Support On/Off This checkbox retracts the support pins. The support pins are extended by default to support a stack of trays except when a tray is being loaded or unloaded on the stacker.
NOTE: In contrast to the lift and tray clamp pins, the

support pins are extended when the box is not checked. This is the default position, so the trays are not dropped even when no air pressure is delivered to the handler. When unchecked, the pins are extended, supporting the trays-in-waiting on the stacker. When checked, the pins are retracted, allowing the trays to drop onto the carriage.

Support extended

Lift extended

Figure 6-35: Rear Support Extended but Lift Retracted (Left); Support Retracted but Lift Extended (Right)

Tray # [n] Clamp On/Off

This checkbox activates the tray clamp pins, which secure the working tray in place. When checked, the pins are extended to secure the tray. When unchecked, the pins are retracted.

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DiagnosticsStacker Window

Motor Settings Group Box

Figure 6-36: Rear Tray Clamp Extended (Left); Retracted (Right)

Reset

Click this button to send all the stacker motors to their home positions. If the motors have been turned off, click this button to turn them back on.

Motor Off

Click this button to turn off all the stacker motors.

Motor Settings Group Box


This matrix displays the speeds of the motors as they move through production in Auto Run. For details, see the motor manufacturers manual.

Figure 6-37: Motor Settings Group Box

Speed AC DC

The speed for each stacker motor is displayed. The acceleration for each stacker motor is displayed. The deceleration for each stacker motor is displayed.

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Chapter 6: Diagnostics

Load Sequence Group Box


This group box allows you to calibrate the tray positions while the tray is being loaded or unloaded on the stackers.

Figure 6-38: Load Sequence Group Box

[Distance from tray home to carriage alignment top input box]

Type in the box the distance the tray carriage must move from its home position to where the carriage is aligned directly under the stacker so the trays fall neatly onto the carriage without catching on the ends of the carriage. This button allows you to calibrate the tray on the horizontal axis in relation to the stacker. The function of this button depends on whether a Load or Unload motor is selected. For instructions, see "Aligning Carriage with Stacker" on page 4-52. Stacker Loading Button Function It raises the lifter bars of the input, or loading stacker. If carriage is at the unloading stacker, it then moves the carriage forward to the loading stacker. Unloading If carriage is at the loading stacker, it moves the carriage back to the unloading stacker. It raises the lifter bars of the output, or unloading stacker. You must click this button before you can make fine-tune adjustments with the jog buttons.

Align Position

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DiagnosticsStacker Window

Load Sequence Group Box

[Increase Distance]

If the selected tray carriage is too far forward of its centered position, increase the distance from home by clicking the [Increase Distance] jog button. Each time you click this button, the carriage moves away from its home position by the distance shown in the Inc/Dec input box. The number in the input box gets larger by the same increment. If the selected tray carriage is too far behind its centered position, decrease the distance from home by clicking the [Decrease Distance] jog button. Each time you click this button, the tray moves toward the front of the handler by the distance shown in the Inc/Dec input box. The number in the input box gets smaller by the same decrement.

[Decrease Distance]

[Distance from stacker Type in the box the distance from the Z stacker motor home home to just above tray to where the lifter pins are just above a tray sitting on the carbottom input box] riage. Stacker Height The function of this button depends on whether a Load or Unload motor is selected. For instructions, see "Calibrating Stacker Height" on page 4-46. Stacker Loading Button Function If carriage is at the unloading stacker, it moves the carriage forward to the loading stacker. It lowers the lifter bars of the input, or loading stacker, to the stack height. Unloading If carriage is at the loading stacker, it moves the carriage back to the unloading stacker. It lowers the lifter bars of the output, or unloading stacker, to the stack height. You must click this button before you can make fine-tune adjustments with the jog buttons. [Up] If the stacker lifter bars are too low, raise them by clicking the [Up] jog button. Each time you click this button, the lifter bars move closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the Stacker Height input box gets smaller by the same decrement.

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Chapter 6: Diagnostics

[Down]

If the stacker lifter bars are too high, lower them by clicking the [Down] jog button. Each time you click this button, the lifter bars move away from Z home position by the distance shown in the Inc/Dec input box, and the number in the Stacker Height input box gets larger by the same increment. Type the size of each increment or decrement by which a motor should move when one of the jog buttons is clicked. For example, if the value here is 0.005 and the value in one of the distance boxes is 1.505, then when the Increase Distance or left jog button for that distance box is clicked, the value changes to 1.510. Other examples follow. Current Value 1.365 0.96 Incremented Value 1.370 0.965 Decremented Value 1.360 0.955

Increment/Decrement

Load/Unload Y [n] Abort

Clicking this button loads or unloads a tray on the carriage. Clicking this button stops the loading or unloading process.

Home Sequence Group Box

Figure 6-39: Home Sequence Group Box

Home

Click this button to send only the selected motor to its home position. Click this button to stop the homing of the selected motor. Click this button to turn off only the selected motor.

Abort Motor Off

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DiagnosticsZ Motors Window

Motor List Group Box

Save

If you want to save your changes to the job file you opened when you entered Diagnostics, click this button.

DiagnosticsZ Motors Window


This window displays the timing and speed of the motors that drive the pickup nozzles.

Figure 6-40: Z Motors Window

Motor List Group Box


Motor List To test a specific Z motor, click the drop-down arrow by the Motor List box, and select the motor. The column for that motor is highlighted in dark blue. Most actions you initiate on this window apply to the motor you select in the Motor List.

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Figure 6-41: Z Motor Drop-Down List

Reset

Click this button to send all the pickup nozzle motors to their home positions. If the motors have been turned off, click this button to turn them back on.

Motor Off

Click this button to turn off all the pickup nozzle motors.

Motor Settings Group Box


This matrix displays the speeds of the motors as they move through production in Auto Run. For details, see the motor manufacturers manual.

Figure 6-42: Motor Settings Group Box

Speed AC DC

The speed for each pickup nozzle motor is displayed. The acceleration for each pickup nozzle motor is displayed. The deceleration for each pickup nozzle motor is displayed.

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DiagnosticsZ Motors Window

Home Sequence Group Box

Home Sequence Group Box


Motor Home Click this button to send only the selected motor to its home position. If you have turned the motor off, clicking the Motor Home button turns it back on. Abort Motor Off Click this button to abort the homing of the selected motor. Click this button to turn off only the selected motor.

Test Motor Group Box

Figure 6-43: Test Motor Group Box

A motor test may be set up to test a particular motor. Select one of the motors. Define two different positions as number of inches from the motors home position. These positions cannot exceed the predefined travel limits. Position 1 Type a beginning position from home, in inches, for a test cycle. Click this button to move the motor to Position 1. Type an ending position from home, in inches, for a test cycle. Click this button to move the motor to Position 2. Type the number of times you want the test cycle to repeat. Click this button to begin the test cycle with the specified number of repeats. Click this button to stop the test cycle immediately, before the cycle is finished.

Go Position 2

Go Repeat Start

Abort

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Save

If you want to save your changes to the job file you opened when you entered Diagnostics, click this button.

DiagnosticsRotation Motors Window (Optional)


This window displays the timing and speed of the motors that rotate the pickup nozzles.

Figure 6-44: Rotation Motors Window

Motor List

To view the timings for a rotation motor, click the drop-down arrow by the Motor List box, and select the motor. Any actions you initiate on this window apply to the rotation motor for the Z head you select in the Motor List.

Figure 6-45: Rotation Motor Drop-Down List

Reset

Click this button to initialize, or send home, the selected motor. Check this box to turn on clockwise rotation (on the theta axis). Uncheck this box to turn on counterclockwise rotation. To disable rotation, type 0 in the Angle box. The speed for the selected motor is displayed. For details, see the motor manufacturers manual.

Direction (CW/CCW)

Speed (0 to 5500)

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DiagnosticsX and Y Motors Window

Test Motor Group Box

AC (0 to 20)

The acceleration for the selected motor is displayed. For details, see the motor manufacturers manual. Type the degree of rotation for the selected motor. You can specify any degree; for example: 3, 10, 45, 70, 90, etc. To disable rotation, type 0 in the Angle box.

Angle

Go

Click this button to rotate the Z head to the degree you specified. Click this button to stop the movement of the selected motor.

Stop

DiagnosticsX and Y Motors Window


This window displays the timing and speed of the motors that drive the tray carriages and the pickup heads.

Figure 6-46: X and Y Motors Window

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Motor List Group Box

Figure 6-47: X and Y Motor List Group Box

Motor List

To view the timings for a motor, click the drop-down arrow by the Motor List box, and select the motor. Most actions you initiate on this window apply to the motor you select in the Motor List.

Reset

Click this button to send all the tray carriage and pickup head motors to their home positions. If the motors have been turned off, click this button to turn them back on.

Motor Off

Click this button to turn off all the tray carriage and pickup head motors.

Motor Settings Group Box


This matrix displays the speeds of the motors as they move through production in Auto Run. For details, see the motor manufacturers manual.

Figure 6-48: Motor Settings Group Box

Speed

The speed for each tray carriage or pickup head motor is displayed. The acceleration for each tray carriage or pickup head motor is displayed.

AC

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DiagnosticsX and Y Motors Window

Status Group Box

DC

The deceleration for each tray carriage or pickup head motor is displayed.

The next three values apply only to the X pickup heads linear motor. They are for the PID loop. They are designed to prevent oscillation or the motors losing its position after it stops. Gains must be high enough for the motor to hold its position when stopping. These values are to be calibrated only by an Exatron engineer. KP KI KD Proportional. Integral. Derivative.

Status Group Box


The buttons in the Status group box work only for the X servo motorthe linear motor driving the pickup head. They are to be used only by an Exatron engineer for debugging procedures. Current Position This button displays the current real time position of the linear motor. This button displays the error limit. This button displays the switch status. This button displays the stop code.

Error Switch Status Stop Code

Home Sequence Group Box


Values are displayed in this group box only when the X pickup heads motor is selected. The speeds for the pickup heads linear motor during its homing routine are adjustable. For details, see the motor manufacturers manual.

Figure 6-49: Home Sequence Group Box

Speed AC

The pickup head motors homing speed is displayed. The pickup head motors homing acceleration is displayed.

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Chapter 6: Diagnostics

DC Home

The pickup head motors homing deceleration is displayed. Click this button to send the selected motor to its home position. Click this button to stop the test cycle immediately, before the cycle is finished.

Abort

Test Motor Group Box


This group box allows the operator to perform stability tests on the selected motor.

Figure 6-50: Home Sequence Group Box

Position 1

Type a beginning position from home, in inches, for a test cycle. Click this button to move the motor to Position 1. Type an ending position from home, in inches, for a test cycle. Click this button to move the motor to Position 2. Type the number of times you want the test cycle to repeat. Click this button to begin the test cycle with the specified number of repeats to the two set positions. This box incrementally displays the number of repeats that have finished during the test cycle. Click this button to stop the test cycle immediately, before the cycle is finished. If you want to save your changes to the job file you opened when you entered Diagnostics, click this button.

Go Position 2

Go Repeat Start

[Count]

Abort

Save

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DiagnosticsGolden Unit Window (Optional)

Golden Unit Group Box

DiagnosticsGolden Unit Window (Optional)


If your handler is equipped with a golden unit tray, this window allows you to calibrate all distances and positions related to the golden unit tray.

Figure 6-51: Golden Unit Window

Golden Unit Group Box


The items you select in the top area apply to the entire window. Unit [n] Select the golden unit pocket whose positions you want to fine-tune. Your available selections will depend on the number of trays or waffle packs you have set up. Inc/Dec Type the size of each increment or decrement by which a motor should move when one of the jog buttons is clicked.

Left Pick Head Group Box


This group box allows you to calibrate distances for the left pickup head to the golden unit tray.

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Chapter 6: Diagnostics

Figure 6-52: Left Pick Head Group Box

[X distance to pocket]

Type the distance the pickup head must move from its home position to get the Z nozzle over the specified pocket of the golden unit tray.

Left Pick Head Go To Unit Click this button to move the selected pickup head to a position directly over the selected pocket of the golden unit tray. (X) You must click this button before you can make fine-tune adjustments with the jog buttons. [Left/right] If the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The pickup head moves left or right by the distance shown in the Inc/Dec input box. Clicking the left jog button increases the distance and makes the number in the Unit X input box larger by the same amount. Type the distance from the pickup nozzle home position to the surface of the device in the tray. Click this button to lower the pickup head to the surface of the device in the golden unit tray. You must click this button before you can make fine-tune adjustments with the jog buttons. [Up] If the suction cup is too low, raise the pickup nozzle by clicking the [Up] jog button. Each time you click this button, the pickup nozzle moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets smaller by the same decrement. If the suction cup is too high, lower the pickup nozzle by clicking the [Down] jog button. Each time you

[Z distance to pocket]

Left Head Go Down To Unit (Z)

[Down]

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DiagnosticsGolden Unit Window (Optional)

Right Pick Head Group Box

click this button, the pickup nozzle moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets larger by the same increment. Z Home Z Vacuum Click this button to raise the pickup head to its home position. Check this box to turn on the pickup nozzle vacuum. Uncheck this box to turn off the vacuum.

Left Head Get Device from Click this button to get a device from the golden unit tray Unit (including vacuum action). Left Head Put Device to Socket Click this button to put a device into the test socket (including vacuum and blow-off action).

Right Pick Head Group Box


This group box allows you to calibrate distances for the right pickup head to the golden unit tray. The features work the same as for the left pickup head. See the previous section, "Left Pick Head Group Box" on page 6-43 for details.

Testing Group Box


Left Cylinder Test Right Cylinder Test Click this button to test the left cylinder. Click this button to test the right cylinder.

Testing Status Group Box


[message box] As the testing proceeds, progress and status messages are displayed here. Click this button to test the golden unit.

Test Unit

View Golden Unit Log File Click this button to view the log file. Clear Status Box Click this button to clear messages from the message box.

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Chapter 6: Diagnostics

DiagnosticsTray Window
The Tray window allows you to calibrate all distances and positions related to the trays.

Figure 6-53: Tray Window

Tray and Z Head List Group Box


The items you select in the top area apply to the entire window.

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DiagnosticsTray Window

First Pocket Group Box

Figure 6-54: Tray and Z Head List Group Box

Tray List

Click the drop-down arrow to the right of the Tray List box. From the available selections, click the tray whose positions you want to fine-tune. Your available selections will depend on the number of trays or waffle packs you have set up.

Head Z List

Click the drop-down arrow to the right of the Head Z List box. From the available selections, click the pickup head whose Z put and Z get positions you want to fine-tune. Type the size of each increment or decrement by which a motor should move when one of the jog buttons is clicked. For example, if the value here is 0.005 and the value in one of the distance boxes is 7.505, then when the Increase Distance or left jog button for that distance box is clicked, the value changes to 7.510. Other examples follow. Current Value 10.365 0.96 Incremented Value 10.370 0.965 Decremented Value 10.360 0.955

Inc/Dec

First Pocket Group Box


This group box allows you to calibrate horizontal distances to the first tray pocketrow 1 and column 1 of the specified tray.

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Figure 6-55: First Pocket Group Box

First Pocket X

Type the distance the pickup head must move from its home position to get the specified Z nozzle over the first pocket of the specified tray. Type the distance the tray carriage must move from its home position to get the first pocket of the specified tray under the specified Z nozzle. Click this button to move the selected pickup head and tray to the coordinates specified in the First Pocket X/Y input boxes. You must click this button before you can make fine-tune adjustments with the jog buttons.

First Pocket Y

Go To First Pocket (Center)

[Left/right]

If the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The pickup head moves left or right by the distance shown in the Inc/Dec input box. Clicking the left jog button increases the distance and makes the number in the Socket X input box larger by the same amount. If the specified tray pocket is too far forward of the pickup head so that the pickup nozzle is over the rear end of the device, increase the distance from Y home by clicking the [Increase Distance] jog button. Each time you click this button, the tray carriage moves back by the distance shown in the Inc/Dec input box and the number displayed in the First Pocket Y input box gets larger by the same amount. If the specified tray pocket is too far behind the pickup head so that the pickup nozzle is over the front end of the device, decrease the distance from Y home by clicking the [Decrease Distance] jog button. Each time you click this button, the tray carriage moves for-

[Increase distance]

[Decrease distance]

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DiagnosticsTray Window

Last Pocket Group Box

ward by the distance shown in the Inc/Dec input box and the number displayed in the First Pocket Y input box gets smaller by the same amount.

Last Pocket Group Box


This group box allows you to calibrate horizontal distances to the last tray pocketthe last row and column of the specified tray. The features work exactly the same as for the first pocket. See the previous section, "First Pocket Group Box" on page 6-47 for details.

Pick Head Group Box


This group box allows you to calibrate vertical distances of the specified pickup nozzle to the pockets of the specified tray.

Figure 6-56: Pick Head Group Box

[Z get distance]

Type the distance from the pickup nozzle home position to the surface of the device in the tray. Click this button to move the selected pickup head to the surface of the device in the tray. You must click this button before you can make fine-tune adjustments with the jog buttons.

Z Get

[Up]

If the suction cup is too low, raise the pickup nozzle by clicking the [Up] jog button. Each time you click this button, the pickup nozzle moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets smaller by the same decrement. If the suction cup is too high, lower the pickup nozzle by clicking the [Down] jog button. Each time you click this button, the pickup nozzle moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets larger by the same increment.

[Down]

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Chapter 6: Diagnostics

[Z put distance]

Type the distance from the pickup nozzle home position to a position just above the surface of the device in the tray. Click this button to move the selected pickup head to a position just above the surface of the device in the tray. You must click this button before you can make fine-tune adjustments with the jog buttons.

Z Put

[Up]

If the suction cup is too close to the device, raise the pickup nozzle by clicking the [Up] jog button. Each time you click this button, the pickup nozzle moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets smaller by the same decrement. If the suction cup is not close enough to the device, lower the pickup nozzle by clicking the [Down] jog button. Each time you click this button, the pickup nozzle moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets larger by the same increment.

[Down]

Test Fine Tune Group Box


After you have calibrated the distances, you can test them by using the Test Fine Tune group box. Here you can check the positioning of any row and column of the tray selected from the Tray List box.

Figure 6-57: Test Fine Tune Group Box

Row Column Total Rows Total Columns Get From Selected

Type the tray row whose position you want to test. Type the tray column whose position you want to test. The number of rows in this tray is displayed. The number of columns in this tray is displayed. Click this button to cause the pickup head to get a device from the specified row and column.

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DiagnosticsTray Window

Teach Group Box

Put To Selected

Click this button to cause the pickup head to put a device into the specified row and column. Click this button to cause the pickup head to get a device from the next pocket in order. Click this button to cause the pickup head to put a device into the next pocket in order.

Get From Next

Put To Next

Teach Group Box


The Teach group box allows you to extrapolate the X, Y, and Z distances calibrated at the Z1 pickup head to all the pickup heads. Thus, each pickup head will have the distances calculated for it as it compares to the Z1 pickup head.

Figure 6-58: Teach Group BoxTwo Versions

HeadSpace

Type the distance between the Z1 pickup head and the Z pickup head selected in the Head Z List box at the top of the Tray window. NOTE: Measure the distance for each Z head from the Z1 pickup head. Z1 is the reference point.

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Chapter 6: Diagnostics

Copy X Y Z from Z1 to Other Z for Selected Tray

Click this button to teach, or apply, the X, Y, and Z distances to all the Z pickup heads and trays. NOTE: It is recommended you use this as a general extrapolation before fine-tuning; and afterward recheck and fine-tune each distance. After you click Copy, you will be required to enter a password before the extrapolation occurs. The required password is the same password that opens the Settings button on the Main window.

To better understand the dimensions mentioned in the bottom version of the Teach group box, click the Trays Drawing button first. The dialog box shown in Figure 6-59 is displayed. Notice what each dimension measures. Dimension A is the distance from the first pocket of Tray 1_1 to the first pocket of Tray 1_2. It is the distance on the X axis between waffle packs in the same tray. Dimension B is the distance from the first pocket of Tray 1_1 to the first pocket of Tray 1_3. It is the distance on the Y axis between waffle packs in the same tray. Dimension C is the distance from the first pocket of Tray 1_1 to the first pocket of Tray 2_1. It is the distance on the X axis between corresponding waffle packs in different trays. These distances are what you will enter in the Teach group box. Then when you click the other buttons, the software applies, or extrapolates, the distances to the other waffle packs. CAUTION: Be absolutely sure the distances you enter are accurate. If they are inaccurate, all the calibrations will be skewed, requiring recalibration.

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DiagnosticsTray Window

Teach Group Box

Figure 6-59: Teach Tray Dialog Box

OK

When you have finished studying the dimensions, click OK to close the Teach Tray dialog box.

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Model 8000 Manual

Chapter 6: Diagnostics

Space Between (L/R)Z1 to Type the distance, in inches, from Z1 to the Z head selected (L/R)Z[n] in the Head Z List at the top of the window. For example, when Z1 is selected, this distance should be 0.

Figure 6-60: Distance Between Pickup Nozzles, for LZ4 (Left), and for RZ3 (Right)

In the example in Figure 6-60, the pickup nozzles are two inches apart. The distance from LZ1 to LZ1 is 0"; from LZ1 to LZ2 is 2"; from LZ1 to LZ3 is 4"; and from LZ1 to LZ4 is 6". Dimension A Type the distance on the X axis from the first pocket of Tray 1_1 to the first pocket of Tray 1_2. Type the distance on the Y axis from the first pocket of Tray 1_1 to the first pocket of Tray 1_3. Type the distance on the X axis from the first pocket of Tray 1_1 to the first pocket of Tray 2_1.

Dimension B

Dimension C

Teach X Y Z from RZ1 and Click this button to teach, or apply, the X, Y, and Z distances LZ1 to All Z for Tray 1_1 to all the Z pickup heads. This extrapolates the distances for LZ1 to LZ2, LZ3, and LZ4. It also extrapolates the distances for RZ1 to RZ2, RZ3, and RZ4. After you click the Teach X Y Z button, you will be required to enter a password before the extrapolation occurs. The required password is the same password that opens the Settings button on the Main window. Teach All Y1 Trays from Tray 1_1 Teach Tray 2_1 from Tray 1_1 Click this button to teach, or extrapolate, the X, Y, and Z distances for Tray 1_1 to all the other Y1 waffle packs. Click this button to teach, or extrapolate, the X, Y, and Z distances for Tray 1_1 to Tray 2_1.

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DiagnosticsTray Window

I/O Group Box

Teach All Y2 Trays from Tray 2_1

Click this button to teach, or extrapolate, the X, Y, and Z distances for Tray 2_1 to all the other Y2 waffle packs.

I/O Group Box

Figure 6-61: I/O Group Box

Check each box when you want to turn on the corresponding action. Uncheck each box to turn it off. The vacuum and air blow occur at the pickup nozzle. The tray clamp extends to hold the tray securely in place on the carriage when the box is checked.

Home Motors/Motors Go To Zero Position Group Box


Generally speaking, the home position for each motor is the zero position: zero motor steps. X Home / Go to Zero Position Y Home / Go to Zero Position Z Home / Go to Zero Position Click this button to move the specified pickup head to its X home position. Click this button to move the specified tray carriage to its Y home position. Click this button to move the specified pickup nozzle to its Z home position.

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DiagnosticsTester Window
The selections in this window allow you to emulate the entire automatic routine, part by part. When you first access the Tester window after each computer startup, the motors reset. When all the motors have moved to their home positions, this window becomes available.

Figure 6-62: Tester Window

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DiagnosticsTester Window

Tester Fine Tune Group BoxSelection Area

Figure 6-63: Tester WindowAlternate Version

The Tester Fine Tune group box can logically be divided into three functional areas: the selection area, the horizontal tester calibration area, and the vertical tester calibration area.

Tester Fine Tune Group BoxSelection Area

Figure 6-64: Tester Group BoxSelection Area

Select Tester

If your handler has more than one test site, the Select Tester drop-down list is enabled. Select the test site for which you want to calibrate distances. If your test site has multiple rows and columns, the Tester Row # and Tester Column # drop-down lists are enabled. Select the tester row for which you want to calibrate distances.

Tester Row #

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Tester Column #

If your test site has multiple rows and columns, the Tester Row # and Tester Column # drop-down lists are enabled. Select the tester column for which you want to calibrate distances.

Figure 6-65: Configuration for Multiple Testers

Figure 6-66: Configuration for Tester with Socket Grid (Multiple Rows and Sockets)

Inc/Dec

Type the size of each increment or decrement by which a motor should move when one of the jog buttons is clicked. Click the drop-down arrow to the right of the Head Z List box. From the available selections, click the pickup head whose Z put and Z get positions you want to fine-tune. If your handler has a left thermo head, select it here.

Head Z List

Tester Fine Tune Group BoxHorizontal Tester Calibration Area

Figure 6-67: Tester Group BoxHorizontal Tester Calibration Area

[Distance to tester]

Type the distance the selected pickup head must move from its home position to a position directly over the tester. Click this button to move the selected pickup head to a position just above the surface of the device in the test socket, but without engaging the vacuum. You must click this button before you can make fine-tune adjustments with the jog buttons.

Head Go To Tester

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DiagnosticsTester Window

Tester Fine Tune Group BoxHorizontal Tester Calibration

[Left/Right]

If the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Inc/Dec input box.

Figure 6-68: Tester Group BoxHorizontal Tester Calibration Area for Socket Grid

Socket X

Type the distance on the X axis that the selected pickup nozzle must move from the pickup head home position to a position just above the surface of the device in the socket. If the tester has a socket grid, type the distance on the Y axis that the socket grid must move from its home position to get the selected socket under the pickup head. Click this button to move the selected pickup head to a position just above the surface of the device in the test socket, but without engaging the vacuum. You must click this button before you can make fine-tune adjustments with the jog buttons.

Socket Y

Head Z[n] Go To Socket [n]

[Left/Right]

If the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Inc/Dec input box. Clicking the left jog button increases the distance and makes the number in the Socket X input box larger by the same amount. If the tester has a socket grid and the specified test socket is too far forward of the pickup head so that the pickup nozzle is over the rear end of the device, increase the distance from Y home by clicking the [Increase Distance] jog button. Each time you click this button, the socket grid moves back by the distance shown in the Inc/Dec input box and the number displayed in the Socket Y input box gets larger by the same amount.

[Increase Distance]

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[Decrease Distance]

If the tester has a socket grid and the specified test socket is too far behind the pickup head so that the pickup nozzle is over the front end of the device, decrease the distance from Y home by clicking the [Decrease Distance] jog button. Each time you click this button, the socket grid moves forward by the distance shown in the Inc/Dec input box and the number displayed in the Socket Y input box gets smaller by the same amount.

Tester Fine Tune Group BoxVertical Tester Calibration Area

Figure 6-69: Tester Group BoxVertical Tester Calibration Area

[Z-put distance]

Type the distance from the pickup nozzle home position to a position just above the surface of the device in the socket. Click this button to move the selected pickup head to a position just above the surface of the device in the test socket, but without engaging the vacuum. You must click this button before you can make fine-tune adjustments with the jog buttons.

Go Down To Put Height

Z Put

Click this button to cause the selected pickup head to put a device in the test socket. If the suction cup is too close to the device, raise the pickup nozzle by clicking the [Up] jog button to the right of the [Z Put Distance] input box. Each time you click this button, the pickup nozzle moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets smaller by the same decrement.

[Up]

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DiagnosticsTester Window

Tester Fine Tune Group BoxVertical Tester Calibration

[Down]

If the suction cup is not close enough to the device, lower the pickup nozzle by clicking the [Down] jog button to the right of the [Z Put Distance] input box. Each time you click this button, the pickup nozzle moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets larger by the same increment. Type the distance from the pickup nozzle home position to a position just above the surface of the device in the socket. Click this button to move the selected pickup head to a position just above the surface of the device in the test socket, but without engaging the vacuum. You must click this button before you can make fine-tune adjustments with the jog buttons.

[Z get distance]

Go Down To Pick Height

Z Get

Click this button to cause the selected pickup head to put a device in the test socket. If the suction cup is too low, raise the pickup nozzle by clicking the [Up] jog button to the right of the [Z Get Distance] input box. Each time you click this button, the pickup nozzle moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets smaller by the same decrement. If the suction cup is too high, lower the pickup nozzle by clicking the [Down] jog button to the right of the [Z Get Distance] input box. Each time you click this button, the pickup nozzle moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets larger by the same increment. Type the distance in inches you want to add to the Z-get distance for the test site. Click this button to lower the pickup head to the position that is the sum of the Z-get distance plus the Z-compress distance. This compresses the device in the test socket.

[Up]

[Down]

[Compression distance]

Go Down to Compress

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Rotation Group Box

Figure 6-70: Rotation Group Box

Angle

Type the degrees of angle from home position the pickup nozzle should rotate. Note that 360 degrees makes one complete rotation and puts the device back in its original orientation, so the angle you type here should be smaller than 360. Click this button to rotate the pickup nozzle. Click this button to rotate the pickup nozzle back to its home position.

Rotate Rotate Motor to Zero

Tray Group Box


Here you can check the positioning of any row and column of the selected tray.

Figure 6-71: Tray Group Box

Select Tray

Click the drop-down arrow and select the tray whose position you want to test. Type the tray row whose position you want to test.

Selected Row

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DiagnosticsTester Window

Golden Parts and Precisor/Bucket Group Box

Selected Column Total Rows Total Cols Get From Selected

Type the tray column whose position you want to test. The number of rows in this tray is displayed. The number of columns in this tray is displayed. Click this button to cause the pickup head to get a device from the specified row and column. Click this button to cause the pickup head to put a device into the specified row and column. Click this button to cause the pickup head to get a device from the next pocket in order. Click this button to cause the pickup head to put a device into the next pocket in order.

Put To Selected

Get From Next

Put To Next

Golden Parts and Precisor/Bucket Group Box


If a suspiciously large number of devices are failing the testing, you may want to test the tester itself with known good devices. You can place these good devices in the golden unit tray and cause the pickup head to take devices from the golden unit tray and test these devices. This group box allows you to calibrate distances to each pocket of the golden unit tray and/or precisor or buckets, if your handler is so equipped.

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Figure 6-72: Golden Parts and Precisor Group Box

Figure 6-73: Golden Parts and Bucket Group Box

Selection

Click the drop-down arrow and select the golden unit, precisor, or bucket for which you want to set distances. Type the distance the selected pickup head must move from its home position to a position directly over the golden unit pocket, precisor pocket, or bucket. Click this button to move the selected pickup head to a position just above the selected golden unit pocket, precisor pocket, or bucket. You must click this button before you can make fine-tune adjustments with the jog buttons.

[Distance to selected destination]

Head Go To Golden Part/Precisor/Bucket

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DiagnosticsTester Window

Golden Parts and Precisor/Bucket Group Box

[Left/Right]

If the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Inc/Dec input box. Type the distance from the pickup nozzle home position to a position just above the golden unit pocket, precisor pocket, or bucket. Click this button to move the selected pickup head to a position just above the golden unit pocket, precisor pocket, or bucket. Click this button to cause the selected pickup head to put a device in the golden unit pocket, precisor pocket, or bucket. You must click this button before you can make fine-tune adjustments with the jog buttons.

[Z-put distance]

Go Down To Put Height

Z Put

[Up]

If the suction cup is too close to the golden unit or bucket, raise the pickup nozzle by clicking the [Up] jog button to the right of the [Z Put Distance] input box. Each time you click this button, the pickup nozzle moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets smaller by the same decrement. If the suction cup is not close enough to the golden unit or bucket, lower the pickup nozzle by clicking the [Down] jog button to the right of the [Z Put Distance] input box. Each time you click this button, the pickup nozzle moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets larger by the same increment.

[Down]

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Testing Status Group Box


You can check the readiness of the tester here.

Figure 6-74: Testing Status Group BoxThree Versions

Start Test

Click this button to start a real test. The handler sends the "S" signal to the tester to start the test. During the test, the message reads: Testing. After the test is finished, the sort result is displayed. Alternatively, if the tester does not respond within the number of milliseconds specified in the Settings (page 4-25), you see the message: ER_TESTER_TIMEOUT. In this case, see the tester manufacturers manual for instructions.

Abort Connect Network

Click this button to abort the test. Click this button if necessary to reinitialize communication with the tester.

Test Auto Run Group Box


The buttons in this group box are not in strict sequence. For example, there is only one Get option, but three Put options. So use the buttons judiciously to perform each desired action in a logical order. In the example in Figure 6-75, four pickup nozzles move four devices at a time.

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DiagnosticsTester Window

Test Auto Run Group BoxAlternate Version

Figure 6-75: Test Auto Run Group Box

Get 4 Parts from Tray 1 1234

The vacuum is turned on. The pickup nozzles get one device at a time from the first row of tray 1. Because the spacing between nozzles may not be exactly the same as the spacing between tray pockets, the nozzles get a device, then move any distance required for the next nozzle to be positioned over the center of the next pocket.

Put 4 Parts to Socket 1 2 3 The pickup head moves left, and puts one device at a time 4 of Selected Tester Row into each test socket in the left half of the tester. (Each nozzle goes down twice in a row.) Put 4 Parts to Socket 5 6 7 The pickup head moves right, and puts one device at a time 8 of Selected Tester Row into each test socket in the right half of the tester. (Each nozzle goes down twice in a row.) Put 4 Parts to Tray 1 2 3 4 The pickup head moves to the output tray, and puts one device at a time into each pocket. The vacuum is turned off.

Test Auto Run Group BoxAlternate Version


In the example in Figure 6-77, the left pickup head assembly has four pickup heads. Each head has two nozzles and moves two devices in unison. Each pair of tandem nozzles is spaced the width of two tray pockets apart, so that when they get or put devices, it must be in alternating pockets.

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Figure 6-76: Pickup Nozzles Operating on Alternate Tray Pockets

For example, LZ1 may get or put to the pockets marked with a "1." Next, LZ2 may get or put to the pockets marked with a "2." Then LZ3 may get or put to the pockets marked with a "3." Finally, LZ4 may get or put to the pockets marked with a "4."

Figure 6-77: Test Auto Run Group BoxAlternate Version

Left Head Get 2 Parts from The vacuum is turned on. The two tandem pickup nozzles Tray 1 get two devices at once from alternating pockets of the first row of tray 1. Left Head Put 2 Parts to Socket and Get 2 Parts from Socket The pickup head moves left, and puts both devices at once into each test socket in the tester. The devices are tested and immediately the pickup head picks them up again.

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DiagnosticsTester Window

I/O Group Box

Left Head Put 2 Parts to Tray 1

The pickup head moves right, and returns both devices at once into the same two tray pockets from which they came.

Left Head Get 8 Parts from The pickup head assembly gets two devices at a time from Tray 1 alternating pockets. First LZ1 gets, then LZ2, then LZ3, and last LZ4. Left Head Put 8 Parts to Socket The pickup head assembly moves to the output tray, and puts two devices at a time into the two test sockets, where they are tested and immediately picked up again. First LZ1 acts, then LZ2, then LZ3, and last LZ4. The pickup head moves to tray 1, and puts two devices at a time into alternating pockets. First LZ1 puts, then LZ2, then LZ3, and last LZ4. The devices are returned to tray 1 in Diagnostic mode only. In Auto Run, the devices are put into the output tray.

Left Head Put 8 Parts to Tray 1

I/O Group Box

Figure 6-78: I/O Group Box

Check each box when you want to turn on the corresponding action. Uncheck each box to turn it off. The vacuum and air blow occur at the pickup nozzle. The tray clamp extends to hold the tray securely in place on the carriage when the box is checked. All Vacuum Off Click this button to turn off all vacuums.

Motor Home/Motors Go To Zero Position Group Box


X1 Home Click this button to move the X1 pickup head to its home position.

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X2 Home

Click this button to move the X2 pickup head to its home position. Click this button to move the Y tray displayed in the Select Tray box to its home position. Click this button to raise the pickup nozzle displayed in the Head Z List box to its home position at the top of its path.

Y Home

Z Home

Cylinders Group Box


This box calibrates the positions of the thermal heads.

Figure 6-79: Cylinders Group Box

Left Cylinder/Middle Cylinder/Right Cylinder [Distance to test site]

Click to select the thermal head whose X distance you want to calibrate. Type the distance, in inches, the selected thermal head must move on the X axis from its home position to get to a point directly above the test socket. If the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Inc/Dec input box. Click this button to move the selected thermal head on the X axis to a position above the test site. Click this button to raise the specified thermal head from the test site. Click this button to lower the specified thermal head to the test site.

[Left/Right]

Cylinder to Tester

Cylinder Up

Cylinder Down

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DiagnosticsThermal Window (Optional)

Cylinders Group Box

DiagnosticsThermal Window (Optional)


If your handler has thermal testing, the Thermal window is included. The example in Figure 680 has two testers with separate thermal head assemblies, so it has two sets of hot/cold/defrost settings.

Figure 6-80: Thermal WindowTwo Testers

The example in Figure 6-81 has three thermal heads, a hot head, a cold head, and an ambient or room temperature head. Additionally, it has calibration routines for the cold and ambient heads.

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Figure 6-81: Thermal WindowOne Tester

Hot Thermal Omega Group Box


Desired Temperature Current Temperature Type the desired hot testing temperature in Celsius. The current hot testing temperature is displayed in Celsius, only after the Read Hot Temperature button is clicked. Type the allowed variance for the hot tester in Celsius in the Guard Band boxes. + refers to the number of degrees above the desired temperature that is allowed. - refers to the number of degrees below the desired temperature that is allowed.

Guard Band

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DiagnosticsThermal Window (Optional)

Cold Thermal Julabo Group Box

For example, if the compared hot temperature is 70 with the + guard band set at 7 and the - guard band set at 5, then a range of 65 to 77 is acceptable, and the signal is sent to test the device. Set Hot Temperature Read Hot Temperature Click this button to input the temperature you typed. Click this button to refresh the current temperature display.

Cold Thermal Julabo Group Box


Set Cold Temperature Type a number that is several degrees colder than the desired Celsius temperature in the Set Cold Temperature input box. Type the desired cold testing temperature in Celsius here. The current cold testing temperature is displayed in Celsius, only after the Read Cold Temperature button is clicked. Type the allowed variance for the cold tester in the Guard Band boxes. + refers to the number of degrees above the desired temperature that is allowed. - refers to the number of degrees below the desired temperature that is allowed. For example, if the compared cold temperature is -40 with the + guard band set at 5 and the - guard band set at 7, then a range of -35 to -47 is acceptable, and the signal is sent to test the device. Set Cold Temperature Read Cold Temperature Turn On Circulator Turn Off Circulator Click this button to input the temperature you typed. Click this button to refresh the current temperature display. Click this button to turn on the cold temperature circulator. Click this button to turn off the cold temperature circulator.

Desired Temperature Current Temperature

Guard Band

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Ambient Thermal Group Box


Set Temperature Type a number that is several degrees cooler than the desired Celsius temperature in the Set Temperature input box. Type the desired ambient testing temperature in Celsius here. The current ambient testing temperature is displayed in Celsius, only after the Read Cold Temperature button is clicked. Type the allowed variance for the ambient tester in the Guard Band boxes. + refers to the number of degrees above the desired temperature that is allowed. - refers to the number of degrees below the desired temperature that is allowed. For example, if the compared ambient temperature is 25 with the + guard band set at 7 and the - guard band set at 5, then a range of 20 to 32 is acceptable, and the signal is sent to test the device. Set Temperature Read Temperature Turn On Circulator Click this button to input the temperature you typed. Click this button to refresh the current temperature display. Click this button to turn on the ambient temperature circulator. Click this button to turn off the ambient temperature circulator.

Desired Temperature

Current Temperature

Guard Band

Turn Off Circulator

Defrost Thermal Omega Group Box


The defrost feature ensures that no ice builds up on the cold test head. Desired Temperature Current Temperature Type the desired defrost temperature in Celsius. The current defrost temperature is displayed in Celsius, only after the Read Defrost Temperature button is clicked. Type the allowed variance for the defrost temperature in the Guard Band boxes.

Guard Band

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DiagnosticsThermal Window (Optional)

Calibrate Cold Chiller Group Box

+ refers to the number of degrees above the desired temperature that is allowed. - refers to the number of degrees below the desired temperature that is allowed. For example, if the compared defrost temperature is 70 with the + guard band set at 7 and the - guard band set at 5, then a range of 65 to 77 is acceptable, and the signal is sent to test the device. Set Defrost Temperature Click this button to input the temperature you typed.

Read Defrost Temperature Click this button to refresh the current temperature display.

Calibrate Cold Chiller Group Box


The calibration routine consists of the chiller lowering the temperature in a specified range by half-degree increments, then taking readings of the correlation between the temperature at the chiller and the temperature at the thermal head. Each correlation in the range is stored in a correlation table automatically saved as a text file. Some examples are shown in Figure 6-83 on page 6-77. Yours will vary. Delay Type the delay in seconds between the chillers temperature change and the reading taken of the temperature at the head. Type the ending temperature, the coldest temperature, for the calibration range. CAUTION: It is strongly recommended that you include the full range of 0 to -20 degrees in calibrating the cold chiller. If you use less, it may have too little data to accurately set temperatures. Max Temperature Calibrate Cold Chiller Type the beginning temperature for the calibration range. Click this button to begin the calibration. A password box opens, where you need to type the appropriate password in order to begin the calibration (Figure 6-82).

Min Temperature

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Figure 6-82: Password Dialog Box

Calibrate Room Chiller Group Box


Delay Type the delay in seconds between the chillers temperature change and the reading taken of the temperature at the head. Type the minimum temperature for the calibration range. Type the maximum temperature for the calibration range. Click this button to begin the calibration. A password box opens, where you need to type the appropriate password in order to begin the calibration (Figure 6-82).

Min Temperature Max Temperature Calibrate Cold Chiller

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DiagnosticsThermal Window (Optional)

Calibrate Room Chiller Group Box

Figure 6-83: Correlation Table Examplesfor Cold Head (Left & Middle), for Ambient Head (Right)

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Chapter 6: Diagnostics

DiagnosticsAir Pressure Window (Optional)


If your handler has thermal testing, this window may be included. The example in Figure 6-84 has two testers with separate thermal head assemblies, so it has two sets of air pressure and speeds.

Figure 6-84: Air Pressure Window

Select Tester

If your handler has more than one test site, the Select Tester drop-down list is enabled. Select the test site for which you want to set pressure and speeds. Type the size of each increment or decrement by which a voltage should be adjusted when one of the jog buttons is clicked.

Voltage Increment/Decrement

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Calibrate Room Chiller Group Box

Heads Air Pressure Controls

Type a voltage from 0 to 9.5. This is the pressure or force with which a device is held in the test socket by each of the thermal heads. Type a voltage from 0 to 9.5. This is the speed at which each of the 3 test heads descends to the test socket. Type a voltage from 0 to 9.5. This is the speed at which each of the 3 test heads ascends from the test socket. Each of the 3 settings has its own button. Click this button to apply the force by each of the 3 test heads. You must click this button before you can make fine-tune adjustments with the corresponding jog buttons.

Down Speed

Up Speed

Set Air Pressure

[Increase Voltage]

If the air pressure is too low, increase the voltage by clicking the [Increase Voltage] jog button. This makes the number in the corresponding voltage input box larger. If the air pressure is too high, decrease the voltage by clicking the [Decrease Voltage] jog button. This makes the number in the corresponding voltage input box smaller. Click to select the thermal head you want to test.

[Decrease Voltage]

Left Cylinder/Middle Cylinder/Right Cylinder Cylinder to Tester

Click this button to move the selected thermal head on the X axis over to a position above the test site. Click this button to lower the specified thermal head to the test site. Click this button to raise the specified thermal head from the test site.

Cylinder Down

Cylinder Up

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DiagnosticsCamera Inspection Window (Optional)


If your handler is equipped with inspection, this window is available.

Figure 6-85: Inspection Windowfor Stationary Camera

A handler with a stationary camera has only one inspection site per camera, as shown in Figure 6-85. But a handler with a camera attached to the pickup assembly is moving, and can inspect at various tray pockets or other sites, according to the configuration. Figure 6-86 shows the calibration tools for the first and last tray pockets.

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DiagnosticsCamera Inspection Window (Optional)

Inspection Group Box

Figure 6-86: Inspection Windowfor Moving Camera

Inspection Group Box


[Camera] Click the drop-down arrow and select the camera whose distance from the pickup head you want to calibrate.

Figure 6-87: Camera Drop-Down List

Camera 0 is on the left of the stackers, just inside the upper cabinet.

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Camera 1 is on the right of the stackers, just outside the upper cabinet. Head Z List Click the drop-down arrow to the right of the Head Z List box. From the available selections, click the pickup head whose Z-put and Z-get positions you want to fine-tune. Type the size of each increment or decrement by which a motor should move when one of the jog buttons is clicked. Type the distance, on the lateral or X axis, the selected pickup head must move from its home position to get to a position over the inspection site. Click this button to move the selected pickup head to a position over the inspection site. You must click this button before you can make fine-tune adjustments with the jog buttons. [Left/right] If the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The pickup head moves left or right by the distance shown in the Inc/Dec input box, and the distance displayed changes accordingly. Type the distance, on the Z axis, from the pickup nozzles home position at the top of its cycle to its position at the inspection site. Click this button to lower the selected pickup nozzle to the inspection site. You must click this button before you can make fine-tune adjustments with the jog buttons. [Up] If the camera focus is too low, raise the pickup head by clicking the [Up] jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z distance] input box gets smaller by the same decrement. If the camera focus is too high, lower the pickup head by clicking the [Down] jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z distance] input box gets larger by the same increment.

Inc/Dec

[X distance to inspection site]

Go To Inspection

[Z distance]

Go Down To Inspection

[Down]

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DiagnosticsCamera Inspection Window (Optional)

Rotation Group Box

Z Home

Click this button to raise the pickup nozzle to its home position at the top of its path. Click this button to turn off all vacuums. Check this box to turn on the pickup nozzle vacuum. Uncheck this box to turn off the pickup nozzle vacuum.

All Vacuum Off Z Vacuum On/Off

Rotation Group Box


Angle Type the degrees of angle from home position the pickup nozzle should rotate. Note that 360 degrees makes one complete rotation and puts the device back in its original orientation, so the angle you type here should be smaller than 360. Click this button to rotate the pickup nozzle. Click this button to rotate the pickup nozzle back to its home position.

Rotate Rotate Motor to Zero

Tray Group Box


Here you can check the positioning of any row and column of the selected tray.

Figure 6-88: Tray Group Box

Selected Row Selected Column Total Rows Total Cols

Type the tray row whose position you want to test. Type the tray column whose position you want to test. The number of rows in this tray is displayed. The number of columns in this tray is displayed.

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Get From Selected

Click this button to cause the pickup head to get a device from the specified row and column. Click this button to cause the pickup head to put a device into the specified row and column. Click this button to cause the pickup head to get a device from the next pocket in order. Click this button to cause the pickup head to put a device into the next pocket in order.

Put To Selected

Get From Next

Put To Next

Status Group Box


The purpose of the next few items is to test the inspection equipment.

Figure 6-89: Status Group Box with Messages

IP Address Connect New IP Address

The IP address of the camera is displayed here. Click this button to reconnect with the camera. If the connection is successful, the message Pass Connecting to Camera is displayed in the [Inspection Status] box. Click this button to clear the contents of the Status box. Click this button to send a command from the handler to the camera. If the communication is successful, the message Pass Connecting to Camera is displayed in the [Inspection Status] box. Click this button to trigger an inspection of the devices rotation. Click this button to trigger an inspection of a device on the pickup nozzle.

Clear Check Camera Online

Inspect Rotation

Inspect Device

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DiagnosticsCamera Inspection Window (Optional)

First Pocket Group Box

[Inspection Status]

This area displays progress messages for the inspection (Figure 6-89).

First Pocket Group Box


This group box allows you to calibrate camera distances to the first tray pocketrow 1 and column 1 of the specified tray.

Figure 6-90: First Pocket Group Box

Center of First Pocket X

Type the distance the pickup assembly must move from its home position to get the camera over the first pocket of the specified tray. Type the distance the tray carriage must move from its home position to get the first pocket of the specified tray under the camera. Click this button to move the camera and tray to the coordinates specified in the First Pocket X/Y input boxes. You must click this button before you can make fine-tune adjustments with the jog buttons.

Center of First Pocket Y

Go To First Pocket (Center)

[Left/right]

If the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The camera moves left or right by the distance shown in the Inc/Dec input box. Clicking the left jog button increases the distance and makes the number in the Socket X input box larger by the same amount. If the specified tray pocket is too far forward of the camera so that the camera is over the rear end of the device, increase the distance from Y home by clicking the [Increase Distance] jog button. Each time you click this button, the tray carriage moves back by the distance shown in the Inc/Dec input box and the number displayed in the First Pocket Y input box gets larger by the same amount.

[Increase distance]

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[Decrease distance]

If the specified tray pocket is too far behind the camera so that the camera is over the front end of the device, decrease the distance from Y home by clicking the [Decrease Distance] jog button. Each time you click this button, the tray carriage moves forward by the distance shown in the Inc/Dec input box and the number displayed in the First Pocket Y input box gets smaller by the same amount.

Last Pocket Group Box


This group box allows you to calibrate horizontal distances to the last tray pocketthe last row and column of the specified tray. The features work exactly the same as for the first pocket. See the previous section, "First Pocket Group Box" on page 6-85 for details.

Check Fine Tune Group Box


After you have calibrated the distances, you can test them by using the Check Fine Tune group box. Here you can check the positioning of any row and column of the tray selected from the Tray List box.

Figure 6-91: Check Fine Tune Group Box

Row Column Total Rows Total Columns Go to Selected Pocket

Type the tray row whose position you want to test. Type the tray column whose position you want to test. The number of rows in this tray is displayed. The number of columns in this tray is displayed. Click this button to cause the camera to go to a position over the specified row and column. Click this button to cause the camera to go to a position over the next pocket in order.

Go to Next Pocket

Inspect One Tray and Log Click this button to perform inspections for an entire tray of It devices, and log the results. Y1 Home Click this button to move the Y1 tray to its home position.

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DiagnosticsLaser Window (Optional)

Set Variable Group Box

DiagnosticsLaser Window (Optional)


If your handler uses an integrated laser, this window is available.

Figure 6-92: Laser Window

Set Variable Group Box


Variable 1 Type the text you want to use for the first variable. The laser will mark exactly what you type. Type the text you want to use for the second variable. The laser will mark exactly what you type. Type the text you want to use for the third variable. The laser will mark exactly what you type. Type the angle of rotation, in degrees, you want for the laser mark. You can specify any degree of angle: 3, 10, 45, 77, etc. Other examples are: If you want the mark to be placed straight on the device as you are reading it, type 0.

Variable 2

Variable 3

Angle

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If you want the mark to be rotated 90 degrees to the right on the device, type 90. If you want the mark to be rotated 90 degrees to the left on the device, type -90. Reset Laser Click this button to establish communication between the handler and the laser. The handler sends a message to the laser and ascertains whether the laser is ready. Select the laser functioning you want. Pilot is a simulation mode only. It displays where the beam is focused, but does not mark the surface. Use pilot mode when calibrating the laser beam position. The exact mark site is easily identified in this way. Yag is the actual marking mode. When you believe your calibrations are correct and you want to mark a device to be sure, use yag mode.

Pilot/Yag

Mark Position Group Box


This group box allows you to calibrate the laser marking position.

Figure 6-93: Mark Position Group Box

Inc/Dec

Type the size of each increment or decrement by which a motor should move when one of the jog buttons is clicked. Type the distance the tray must move from its home position to get the first tray row to the marking position under the path of the laser beam. Click this button to move the tray the distance specified to the marking position.

[Tray distance to mark position]

Mark Position

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DiagnosticsLaser Window (Optional)

Mark Position Group Box

[Increase distance]

If the first tray row is too far forward of the marking position, increase the distance from Y home by clicking the [Increase Distance] jog button. Each time you click this button, the tray carriage moves back by the distance shown in the Inc/Dec input box and the number displayed in the [Tray distance to mark position] input box gets larger by the same amount. If the first tray row is too far behind the marking position, decrease the distance from Y home by clicking the [Decrease Distance] jog button. Each time you click this button, the tray carriage moves forward by the distance shown in the Inc/Dec input box and the number displayed in the [Tray distance to mark position] input box gets smaller by the same amount. Type the offset, or distance on the X axis, from the path of the laser beam to the first tray column. When the offset is in one direction, the distance will likely be a positive number; in the other direction, the distance will likely be a negative number. > To ascertain which way your laser is set up, use pilot mode to mark a device and note which way the offsets run.

[Decrease distance]

X Offset

Figure 6-94: X Offset from Laser Beam

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Status Group Box


This area displays progress messages.

Mark Testing Group Box


This group box allows you to test the accuracy of the mark position.

Figure 6-95: Mark Testing Group Box

Row Column Perform Mark

Type the row whose marking position you want to check. Type the column whose marking position you want to check. Click this button to move the tray to the marking position and mark a single device. It will mark in pilot or yag mode, whichever you have selected in this window. Click this button to bring the marked tray to the front stacker. NOTE: The tray comes to the front stacker only in this diagnostic mode. When in Auto Run, the tray is unloaded at the output stacker at the back of the handler.

Unload Tray Position

Quit

Click this button to abort the marking process.

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DiagnosticsDetaper Window (Optional)

Fine Tune Group Box

DiagnosticsDetaper Window (Optional)


If your handler uses a detaper, this window is available.

Figure 6-96: Detaper Window

Fine Tune Group Box


[Head Z list] Click the drop-down arrow to the right of this box to display the available pickup nozzles, or Z heads. Click to select the Z head you want to calibrate.

Figure 6-97: Pickup Z Nozzle Motor Drop-Down List

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[Distance from pickup head to detaper]

Type the distance, on the X axis, from the pickup heads home position to its position above the detaper. Following is an example scenario showing how the pickup head must move farther from its home position on the X axis to get the Z4 nozzle over the detaper than it must move to get the Z1 nozzle over the detaper. Pickup Nozzle Z1 Z2 Z3 Z4 Distance to Detaper 23" 25" 27" 29"

Head Go to Detaper

Click this button to move the pickup head from its home position on the X axis to a position over the detaper. You must click this button before you can make fine-tune adjustments with the jog buttons.

[Left/Right]

If the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The motor moves left or right by the distance shown in the Inc/Dec input box, and the distance displayed changes accordingly. Type the distance, on the Z axis, from the pickup nozzles home position at the top of its cycle to its Z get position for a device in the detaper. Click this button to lower the pickup nozzle from its home position to the detaper. You must click this button before you can make fine-tune adjustments with the jog buttons.

[Z Get Distance]

Go to Get Height

[Up]

If the suction cup is too close to the device, raise the pickup head by clicking the [Up] jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets smaller by the same decrement. If the suction cup is not close enough to the device, lower the pickup head by clicking the [Down] jog button. Each time you click this button, the pickup head moves away from Z home position by the distance

[Down]

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DiagnosticsDetaper Window (Optional)

Detaper Group Box

shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets larger by the same increment. Get Device from Detaper Click this button to turn on the vacuum and cause the pickup nozzle to get a device from the detaper. Type the size of each increment or decrement by which a motor should move when one of the jog buttons is clicked. Click this button to raise the pickup head to its Z home position. Check this box to turn the vacuum on. Uncheck this box to turn the vacuum off.

Inc/Dec

Z Home

Vacuum On/Off

Detaper Group Box


Detape One Device Click this button to cause the pickup head to pick a single device from the detaper. Type the minimum pulse width, in milliseconds, necessary to signal the detaper to advance. If the pulse length is too short, the detaper may not catch the signal. If the pulse length is too long, it wastes time. Clear Status Box Click this button to clear the contents of the Detaper Status box. This box displays progress messages from the detaper.

Pulse (ms)

Detaper Status

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DiagnosticsTape and Reel Window (Optional)


If your handler is equipped with a taper, this window is available.

Figure 6-98: Tape and Reel Window

Fine Tune Group Box


The purpose of this group box is to calibrate the X and Z positioning of the pickup nozzles at the tape. The positioning of the tape under the path of the pickup nozzles is accomplished in the Tape Reel group box. Head Z List Click the drop-down arrow to the right of this box to display the available pickup nozzles, or Z heads. Click to select the Z head you want to calibrate.

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DiagnosticsTape and Reel Window (Optional)

Fine Tune Group Box

[Distance from pickup head home to tape]

Type the distance, in inches, the pickup head must move from its home position on the X axis to reach a position over the tape. Click this button to move the pickup head along the X axis to the tape track position shown in the input box to the right. In an example scenario, if the distance required to move nozzle Z1 from the pickup heads home at the right to a position over the tape is 2 inches, then the distance required to move nozzle Z2 may be 4 inches, and to move Z3, 6 inches. You must click this button before you can make fine-tune adjustments with the jog buttons.

Head Go To Tape Reel

[Left/Right]

IIf the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Inc/Dec input box, and the distance displayed will change accordingly. Type the distance, in inches, the Z nozzle must lower to reach the tapethe put height or Z put distance. Click this button to lower the Z nozzle to the tape surface. You must click this button before you can make fine-tune adjustments with the jog buttons.

[Distance from Z nozzle home to tape] Go To Put Height

[Up]

If the suction cup is too close to the device, raise the pickup head by clicking the [Up] jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets smaller by the same decrement. If the suction cup is not close enough to the device, lower the pickup head by clicking the [Down] jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets larger by the same increment. Click this button to cause the pickup head to move to tray 1, turn the vacuum on, and get a device from the first pocket.

[Down]

Get From Tray 1 First Pocket

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Put Device To Tape Reel

Click this button to cause the pickup head to move to the tape, lower the pickup nozzle to the Z put position, and turn the vacuum off. NOTE: Clicking this button does not advance the tape.

Inc/Dec

Type the size of each increment or decrement by which a motor should move when one of the jog buttons is clicked. Check this box to turn the vacuum on. Uncheck this box to turn the vacuum off.

Vacuum On/Off

Motor Home Group Box


The number of buttons in this group box depends on the number of motors your handler is equipped with.

Figure 6-99: Motor Home Group Box

X[n] Home

Click this button to move the pickup head assembly to its X home position. Click this button to move the tray carriage to its Y home position. Click this button to raise the pickup head to its Z home position at the top of its path.

Y[n] Home

Z Home

Motor Group Box


These parameters apply to the taper motor. For details, see the motor manufacturers manual. Speed AC DC The speed for the taper motor is displayed. The acceleration for the taper motor is displayed. The deceleration for the taper motor is displayed.

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DiagnosticsTape and Reel Window (Optional)

Tape Reel Group Box

Steps

Type the number of steps you want to move the taper motor. Note that 50,000 steps complete one revolution. Click this button to turn on the taper motor. Click this button to turn off the taper motor. Click this button to move the taper motor the number of steps displayed in the Steps box to the left.

Enable Motor Motor Off Motor Go

Tape Reel Group Box


Gap Offset (Steps) Type the number of motor steps needed to move the tape from the offset position identified by the gap offset sensor to the center of the pocket. Because of various tape pocket sizes, when the tape is in position so the gap sensor "sees" through the hole in the middle of the empty pocket, the corresponding tape pocket under the pickup head is likely not centered under the pickup head nozzle. Therefore, the tape needs to be advanced the correct number of motor steps, so the pickup head can place the device into the center of the pocket and not on the pocket edge. Notice that in Figure 6-100, when the pocket is centered under the pickup head, the gap sensor is between pockets. This is the gap offset.

Pickup head nozzle

Gap sensor

Figure 6-100: Gap Sensor Offset from Pickup Head

Initial Taper

Click this button to initialize the taper. This advances the tape until the next tape pocket hole is under the front gap sensor.

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From there, it moves the number of motor steps specified in the Gap Offset (Steps) input box to get the next emptypocket hole under the pickup head, and stops. This is the homing process for the taper. After you click Initial Taper, the buttons below it are enabled. Leader Count (# of Pockets) Type the number of pockets needed from the back edge of the tape track to the output reel takeup spool. This is the number of empty pockets passed before the handler begins putting devices in the pockets. Click this button to advance the tape by the number of pockets specified in the Leader Count box.

Advance Leader

Ending point for leader count

Starting point for leader count

Figure 6-101: Leader Pockets

Trailer Count (# of Pockets)

Type the number of empty pockets to be passed after the empty pocket sensor. The tape will continue to be sealed to this number of pockets after the specified number of devices have filled the specified number of pockets for the job. Click this button to advance the tape by the number of pockets specified in the Trailer Count box.

Advance Trailer

Take-up Motor Count (# of Type the number of pockets required for the tape to go from Pockets) a slack position until the slack switch blocks the slack switch sensor and turns on the output reel motor.

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DiagnosticsTape and Reel Window (Optional)

Tape Reel Group Box

Abort

Click this button to stop the action caused by the Advance Leader, Advance Trailer, or Advance Pockets buttons. For example, if the number of leader pockets is set at 50, and you have clicked Advance Leader, and 10 leader pockets have advanced, this button aborts the tape advancement immediately at 10.

Figure 6-102: Output Tape Slack (Left); Output Tape Taut, Raising Takeup Arm (Right)

Number of Holes Between Type the number of holes between the hole in one pocket Pockets and the hole in the pocket next to it. In the example in Figure 6-103, there are three holes between pocket centers.

Figure 6-103: Counting Number of Holes Between Pocket Centers

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Number of Pockets

Type the desired number of test leader pockets to advance (optional). Click this button to advance the tape by the number of pockets specified in the Number of Pockets box (optional).

Advance Pockets

Number of Pockets Before Type the number of pockets to be advanced after the tapeCheck Tape Out Error out error sensor first detects no tape and before the handler stops and gives a tape-out message. Enable/Disable Seal Head Check this box to turn on the seal head and seal the tape after inserting the devices. Uncheck this box to turn off the seal head. Advance Pocket Delay (ms) PSA/Thermo Type the delay, in milliseconds, between the advancement of each pocket after the Advance Pockets button is clicked. Select the desired option to seal with pressure-sensitive (PSA) tape or heat (thermo) tape.

Test Auto Run Group Box

Figure 6-104: Test Auto Run Group Box

The purpose of this group box is to test the Auto Run sequence. By alternating between these two buttons, you can simulate one cycle of the entire Auto Run sequence, including the parameters set in the Tape Reel group box. Get From Tray 1 First Pocket Put Device To Tape Reel Click this button to cause the pickup head to get a device from the first pocket of tray 1. Click this button to cause the pickup head to put a device in the tape. Clicking this button advances the tape just as during Auto Run. Check this box to make the handler remember empty pockets, so the information can be referred to later.

Empty Pocket Latch

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DiagnosticsTape and Reel Window (Optional)

Test Auto Run Group Box

Clear Empty Pocket Latch Click this button to clear the latch memory. Save Parameters Click this button only if you want to save changes under the current file name. To open a dialog box so you can save changes under a new file name, click the OK button instead.

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DiagnosticsTube Window (Optional)


If your handler uses tubes for input and/or output, the software has a Tube window. Calibrate the tube positions on this window.

Figure 6-105: Tube Window

Input Tube Group Box


Tube Index Use the drop-down arrow to select the tube whose position you want to calibrate.

Figure 6-106: Input Tube Drop-Down List

[Head to tube distance]

Type the distance from the pickup head home to the selected input tube in the box.

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DiagnosticsTube Window (Optional)

Input Tube Group Box

Left Head to Tube

Click this button to move the pickup head to the input tube position. You must click this button before you can make fine-tune adjustments with the jog buttons.

[Left/Right]

IIf the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Inc/Dec input box, and the distance displayed will change accordingly. Type the distance, on the Z axis, from the pickup nozzles home position at the top of its cycle to its Z get position for a device. Click this button to lower the pickup nozzle to the Z get position. You must click this button before you can make fine-tune adjustments with the jog buttons.

[Z Get Distance]

Left Head ZGet

[Up]

If the suction cup is too close to the device, raise the pickup head by clicking the [Up] jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets smaller by the same decrement. If the suction cup is not close enough to the device, lower the pickup head by clicking the [Down] jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets larger by the same increment.

[Down]

Left Head Get Device from Click this button to move the left pickup head to the Z get Input Tube position, turn the vacuum on, and raise the head. Copy Tube1 to Others After you have calibrated Tube 1 and typed the distance between each tubefrom the center of one tube to the center of the next tubein the Output Tube Space box, click this button to extrapolate the distances to the other tubes. Then go back and fine-tune each tube in turn for precise distancing.

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Input Tube Space

Type the distance in inches between each input tubefrom the center of one tube to the center of the next tube. After you enter the correct distance from tube to tube, click the Copy Tube 1 to Others button in the Input Tube group box, and the distance is extrapolated for each tube.

Output Tube Group Box


Tube Index Use the drop-down arrow to select the tube whose position you want to calibrate.

Figure 6-107: Output Tube Drop-Down List

[Head to tube distance]

Type the distance from the pickup head home to the selected output tube in the box. Click this button to move the pickup head to the output tube position. You must click this button before you can make fine-tune adjustments with the jog buttons.

Right Head to Tube

[Left/Right]

IIf the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Inc/Dec input box, and the distance displayed will change accordingly. Type the distance, on the Z axis, from the pickup nozzles home position at the top of its cycle to its Z put position for a device. Click this button to lower the pickup nozzle to the Z put position. You must click this button before you can make fine-tune adjustments with the jog buttons.

[Z Put Distance]

Right Head ZPut

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DiagnosticsTube Window (Optional)

Test AutoRun (Apply Rotation) Group Box

[Up]

If the suction cup is too close to the device, raise the pickup head by clicking the [Up] jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets smaller by the same decrement. If the suction cup is not close enough to the device, lower the pickup head by clicking the [Down] jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Put Distance] input box gets larger by the same increment. Click this button to move the right pickup head to the Z put position, turn the vacuum off, and raise the head. After you have calibrated Tube 1 and typed the distance between each tube in the Output Tube Space boxfrom the center of one tube to the center of the next tubeclick this button to extrapolate the distances to the other tubes. Then go back and fine-tune each tube in turn for precise distancing. Type the distance in inches between each output tubefrom the center of one tube to the center of the next tube. After you enter the correct distance from tube to tube, click the Copy Tube 1 to Others button in the Output Tube group box, and the distance is extrapolated for each tube.

[Down]

Right Head Put Device to Output Tube Copy Tube1 to Others

Output Tube Space

# Devices Per Output Tube

Type the number of devices to be placed into each output tube before it is counted as full and a replacement tube is requested.

Test AutoRun (Apply Rotation) Group Box


At the top of this area, the rotation in effect is displayed. For more information about rotation, see "Results of Rotation Combinations" on page 4-21. The buttons in this area take each step of the Auto Run cycle in order, including rotation. Click each one, going down the list, to perform each step of the Auto Run procedure. The last button, Test AutoRun, moves the handler through the complete cycle once. Left Head Get Device from Click this buttom to cause the left pickup head to pick a Input Tube device from the input tube.

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If the rotation is set (from Settings Work Mode) at -90, clockwise rotation occurs before device pickup. If the rotation is set (from Settings Work Mode) at +90, clockwise rotation occurs after device pickup. Left Head Put to Tester Click this buttom to cause the left pickup head to put the device in the test site. If the rotation is set (from Settings Work Mode) at -90, no rotation occurs at this point. If the rotation is set (from Settings Work Mode) at +90, counterclockwise rotation occurs after device putdown. Right Head Get from Tester Click this buttom to cause the right pickup head to pick the device from the test site. If the rotation is set (from Settings Work Mode) at -90, no rotation occurs at this point. If the rotation is set (from Settings Work Mode) at +90, clockwise rotation occurs before device pickup, then counterclockwise rotation occurs after device pickup. Right Head Put Device to Output Tube Click this buttom to cause the right pickup head to put the device in the output tube. If the rotation is set (from Settings Work Mode) at -90, clockwise rotation occurs before device putdown, then counterclockwise rotation occurs after device putdown. If the rotation is set (from Settings Work Mode) at +90, no rotation occurs at this point. These four buttons combined complete one cycle. Test Auto Run Click this button to cause the handler to complete one cycle. It is the same as clicking each of the four above buttons in turn, but all four actions are accomplished without pause in one button click.

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DiagnosticsTube Window (Optional)

Vacuum and Rotation Group Box

Vacuum and Rotation Group Box

Figure 6-108: Vacuum and Rotation Group Box

Z Vacuum

Check this box to turn on the vacuum to pick up a device. Uncheck this box to turn off the vacuum to drop a device. Check this box to turn on the rotation. Uncheck this box to turn off the rotation. Click this button to move the pickup head to its home position at the top of its path.

Z Rotation

Z Home

Increment/Decrement

Type the size of each increment or decrement by which a motor should move when one of the jog buttons is clicked. For example, if the value here is 0.005 and the value in one of the distance boxes is 7.505, then when the Increase Distance or left jog button for that distance box is clicked, the value changes to 7.510. Other examples follow. Current Value 10.365 0.96 Incremented Value 10.370 0.965 Decremented Value 10.360 0.955

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Recovering from Device Jam


If a device gets jammed, you will see an error message like the following. To keep an accurate count of devices processed, you must respond appropriately.

Figure 6-109: Device Jammed Dialog Box

Abort

If you click this button, the handler forgets everything and you must start over. Pick out the jammed device manually and place it into the output tube manually. Then click the Retry button to restart. Pick out the jammed device manually and discard it. Then click the Ignore button to restart.

Retry

Ignore

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DiagnosticsWafer Input Window (Optional)

Fine Tune Group Box

DiagnosticsWafer Input Window (Optional)


If your handler uses a wafer for input, the software has a Wafer Input window. Calibrate the wafer positions on this window.

Figure 6-110: Wafer Input Window

Fine Tune Group Box


Head Z List Click the drop-down arrow to the right of this box to display the available pickup nozzles, or Z heads. Click to select the Z head you want to calibrate. Type the distance from the selected pickup heads home position to its position above the wafer output. Click this button to move the selected pickup head to a position above the wafer output. You must click this button before you can make fine-tune adjustments with the jog buttons.

[X distance to wafer output] Head Go to Wafer

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Chapter 6: Diagnostics

[Left/Right]

IIf the alignment is off in the X direction, make any small adjustments by clicking the left or right jog buttons. The pickup head moves left or right by the distance shown in the Inc/Dec input box, and the distance displayed changes accordingly. Type the distance, in inches, the Z nozzle must lower to reach the wafer outputthe Z get distance. Click this button to lower the Z nozzle to the wafer output surface. You must click this button before you can make fine-tune adjustments with the jog buttons.

[Z Get Distance]

Go To Get Height

[Up]

If the suction cup is too close to the device, raise the pickup head by clicking the [Up] jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets smaller by the same decrement. If the suction cup is not close enough to the device, lower the pickup head by clicking the [Down] jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Inc/Dec input box, and the number in the [Z Get Distance] input box gets larger by the same increment. Click this button to cause the pickup head to get a device from the wafer output. Type the size of each increment or decrement by which a motor should move when one of the jog buttons is clicked. Check this box to turn the vacuum on. Uncheck this box to turn the vacuum off. Click this button to raise the pickup head to its Z home position.

[Down]

Get One Device From Wafer Inc/Dec

Vacuum On/Off

Z Home

Wafer Group Box


Is Part Ready Click this button to ascertain from the wafer machine that the device is on the wafer output at the stop gate position and ready to be picked up. Click this button to clear the status box of all messages. This box displays progress messages pertaining to the wafer.

Clear Status Box [Status box]

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Chapter 7: Servicing and Troubleshooting


Chapter Overview
This chapter is broken into discrete topics which may bear no relation to each other, but which are designed to assist the operator and/or technician to troubleshoot error conditions in the Exatron system. This chapter discusses the following maintenance tasks and their frequency: Task Backing Up the Computer Cleaning the Handler Cleaning or Replacing Suction Cups Lubricating the Bearing Shafts Encoders and Readers Checking Lead Screw/Coupling Tightness Motor Replacement Master and Slave Cool Muscle Motors Setting Up a Cool Muscle Motor Controller Replacing a Cool Muscle Servo Motor Programming a Cool Muscle Motor Checking Motor Serial Cables Air Regulator Maintenance Checking Incoming Air from the House Supply Checking the Moisture/Dirt Trap in the Air Regulator Checking the Air Regulator Shutoff Valve Automatic Air Shut-Off Valve Adjusting Air Pressure on the Regulator Adjusting Auxiliary Air Regulator Adjusting Air Valves Adjusting Air Pressure on a Digital Pressure Switch Unlocking or Locking a Digital Air Pressure Switch Changing Settings on a Digital Air Pressure Switch Vacuum Generator Maintenance Troubleshooting Vacuum Assemblies Checking and Replacing a Vacuum Air Filter Adjusting Pickup Nozzle Blow-Off Cleaning Vacuum Assemblies Checking and Setting the Vacuum Generator Frequency Monthly Daily Weekly Monthly or quarterly Monthly As needed As needed Before installing motor As needed After installing motor Monthly Weekly Weekly Monthly As needed As needed As needed As needed As needed As needed As needed Monthly or quarterly As needed As needed As needed Page 7-3 7-3 7-3 7-3 7-6 7-6 7-7 7-7 7-9 7-14 7-17 7-18 7-20 7-20 7-20 7-23 7-25 7-26 7-26 7-27 7-27 7-29 7-32 7-40 7-43 7-43 7-44 7-47 7-51

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Task Solenoid Maintenance Opening the Computer for Part Replacement Fiberoptic Photoelectric Sensor Guidelines Taper Maintenance Checking Omega Temperature Controller Laser Servicing Networking Internet Access Setting LAN Connections and Required IP Addresses Testing Network Communication with Peripherals Remote Handler Control with WebEx Replacing Exatron Program File with an Upgrade Troubleshooting This chapter also discusses the following problems:

Frequency As needed As needed As needed As needed As needed As specified by OEM As needed Always As needed As needed As needed As needed As needed

Page 7-58 7-58 7-61 7-63 7-64 7-69 7-69 7-69 7-69 7-75 7-78 7-80 7-82

Topic Motors Move Very Slowly Tray Carriage Alignment Is Faulty Tray Clamp Pins Fail to Secure Trays System Does Not Pick Up Devices Reliably System Noise When Y Gantry Moves Software Responds With Error Message When Motor Commanded to Move Suspended Tray Falls Crooked

Page 7-82 7-83 7-83 7-84 7-86 7-86 7-88

Preventive maintenance on the Model 8000 is fairly simple. Following this schedule will help to assure your Model 8000 handler will continue to perform properly. WARNING! Keep fingers, hair, and clothing away from any moving parts on the handler. Its motors are very powerful and can cause severe injury. WARNING! Always reset all motors before running the machine. Do not run it without homing the motors. WARNING! Never try to stop an action of the handler with your hands or any other device. To stop the handler, press the EMO (emergency stop) button or click Pause on the screen. CAUTION: Do not lubricate any lead screws! Lubricating the screws will void the warranty.

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Backing Up the Computer

CAUTION: Do not use any cleaners or solvents on any bearings or lead screws! CAUTION: Always power off the system before doing any maintenance.

Backing Up the Computer


As job files and other data are created or modified, you will need to back up the computer system as a precaution against hard drive failure. Appendix B explains how to back up the entire system. Alternatively, you can back up a few files to a CD or DVD. CAUTION: Back up the computers hard drive monthly or oftener to prevent loss of data.

Cleaning the Handler


Include the following in a daily cleaning routine for longer trouble-free operation: Use a camel-hair brush to remove dust from any optics such as a laser lens. Wipe the lead screw and linear bearing slides with a clean, lint-free cloth. Vacuum any debris and dust from inside the cabinets. Vacuum any debris from the computer chassis.

Cleaning or Replacing Suction Cups


The suction cup on each pickup nozzle of the Model 8000 is subject to fairly serious performance degradation with dirt and oil buildup. This buildup may be due to substances on the devices themselves, such as mold release agent, oils and soaps from anti-static containers, etc. Wipe each suction cup with a cotton swab dipped in isopropyl alcohol or other suitable (evaporative) cleaning agent. This is best performed when the system is switched off to avoid any motor movement during the cleaning process. Depending on volume of use, the suction cups may require replacement. A list of replacement part numbers can be found in Chapter 8.

Lubricating the Bearing Shafts


The bearings on the Y gantry and X axes are lubricated at the factory. However, these bearings need relubrication at regular intervals. The lubrication interval will be different for each handler because this interval is dependent on several factors. These factors are:

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Operation hours Speed Load Temperature Stroke Environmental conditions

The two factors that will change from handler to handler are operating hours and environmental conditions. Exatron recommends that the bearing shafts be lubricated every month at a minimum. Exatron strongly recommends the lubrication be done weekly, especially if the handler is in extreme environmental conditions or is operated more than 80 hours per week. Use visual inspection to determine when lubrication will be required in these cases. You should see a thin, clean layer of grease on the stainless steel bearing guide shafts. If grease is not seen, or if they are dirty, the shafts should be cleaned and re-lubed. Manufacturer Kerk Thomson NB THK NSK NSK Thomson Thomson Product Lead screws Bearings Bearing shafts Bearing shafts Bearing shafts self-lubricating Bearing shafts non-self-lubricating Bearing shafts Linear rails NONE NONE Linear Lube (Thomson brand) Linear Lube (Thomson brand) NONE Linear Lube (Thomson brand) M1 (Starrett brand) Linear Lube (Thomson brand) Self-lubing shafts have no lubrication fitting Non-self-lubing shafts have a lubrication fitting (Figure 7-1) M1 is petroleum-based, removes moisture Treatment Comment Black TFE coated screws are never lubed Bearings are Super 4, Super 8, and Super 8 OPN

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Lubricating the Bearing Shafts

Figure 7-1: Fitting for NSK Non-Self-Lubricating Bearing Shaft

To lubricate the bearing shafts: 1. Power down the entire system. CAUTION: Do not use water or any cleansers to clean the bearing shafts. This will cause rust damage to the bearings. Also, do not lubricate any of the leadscrews; lubricate only the bearing shafts. 2. Apply an appropriate type of grease to a soft, clean, dry lint-free cloth. Wipe the cloth along the bearing shaft, making sure no grease drops onto the lead screw. Be sure to remove all the old grease and debris. Exatron recommends a Teflon-based grease or M1. Exatron uses Linear Lube grease manufactured by Thomson. > The amount of grease used is difficult to specify. The goal is to attain a thin layer of grease along the entire length of the shaft. 3. On a linear motor track, apply a small dab of grease at one point. Then by hand move the Z-axis block along the entire length of the shaft several times. > If no film of grease is seen, apply another small dab of grease and repeat the process. > If there is any clumping of grease along the length of the shaft, remove the excess grease with a dry cloth. Once again move the Z axis block manually several times until a thin film is achieved.

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Encoders and Readers


The Renishaw encoder is the gold strip on the linear motor track. The reader head is attached to the side of the pickup assembly and reads the encoder (Figure 7-2). CAUTION: Do not use any substance to clean the encoder strip! Use only air to blow dust off the strip.

Figure 7-2: Renishaw Reader over Gold Strip Encoder for Linear Motor

Checking Lead Screw/Coupling Tightness


Mechanical alignment of this system relies on the lead screws and motor coupling being tight. To tighten lead screws and motor coupling screws: 1. With the power to the system off, open the two hinged covers and manually push and pull on the lead screws. They should not be loose in their long axis (they will turn, but should not pull in and out at all). 2. Using a #6 (7/64") hex driver (preferably without ball tip), make sure the screws on the motor coupling are tight. The screws are accessible through the slots in the motor mounting bracket. Turn clockwise to tighten. The screws should be tight, but do not over-tighten, as it is possible to break the screws. 3. If the lead screws seem at all loose, it will be necessary to tighten them against the motor coupling. Tighten the lead screws only with the power off! Using a #6 (7/64") hex driver (preferably without ball tip) loosen the screw on the motor coupling, accessible through the slots in the motor mounting bracket. Loosen only the screw nearest the lead screw, not nearest the motor.

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Motor Replacement

Master and Slave Cool Muscle Motors

4. When that screw is loose, push on the lead screw, towards the coupling, to seat the lead screw tightly against the bearing mounted in the system wall. 5. With the lead screw tight against the coupling, tighten the coupling screw again.

Motor Replacement
When replacing a motor, several tasks may be involved. These are explained in the following sections. For a Cool Muscle motor, you may need to adjust the configuration before installing it; and after installation, you need to program the motor. Cool Muscle motors can be used as master or slave motors. You can program a replacement Cool Muscle motor through the Exatron software. See "Programming a Cool Muscle Motor" on page 7-17 for instructions.

Master and Slave Cool Muscle Motors


This section applies to Cool Muscle motors used as master and slaves. Several principles regarding master and slave motors need to be considered. A master motor is always powered through the terminal block on its network card (Figure 7-3, bottom; and Figure 7-4, left). A slave motor can be powered through either of two methods: > Through the terminal block on its network card (Figure 7-4, middle and right), or > Through an RS-232 cable attached to the input connector on its network card (Figure 7-3, top; and Figure 7-5, middle and right).

Input connector

Terminal block + = 24V -- = GND 3 & 4 unused


Figure 7-3: Terminal Block and Input Connector on Network Card

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The following partial diagrams illustrate the differences.

Figure 7-4: Slave Boards Powered Through Terminals

Figure 7-5: Slave Boards Powered Through RS-232 Cables

Notice that in both Figure 7-4 and Figure 7-5, the master board on the left (circled in blue) is powered through its terminal. In Figure 7-4, the slave boards (middle and right, circled in red) are likewise powered through their terminals, as shown by the red wires. In this case, only the sensors are powered through the RS-232 cables. However, in Figure 7-5, the slave boards (middle and right, circled in red) are powered through their RS-232 cables, since no terminal wires are present. In this case, both the slave boards and the sensors are powered through the RS-232 cables.

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Motor Replacement

Setting Up a Cool Muscle Motor Controller

A master motor uses a network card equipped with an interface card. The cards together are called a master set. A slave motor uses a network card without an interface card.

Setting Up a Cool Muscle Motor Controller


If you have ordered a master motor controller (a network card with interface card), it will look like the board at the right side of Figure 7-6. It has a small board (the interface card) piggybacked on top.

Figure 7-6: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Network Card

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Figure 7-7: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations

If you are going to use the controller as a master, leave the JP3, JP4, and JP5 jumpers in the position shown at the right side of Figure 7-7. If you are going to use the controller as a slave, pull off the JP3, JP4, and JP5 jumpers and replace them in the position shown at the left side of Figure 7-7.

Master Network Card with Interface Card (See Figure 7-8)


Jumper
JP1 JP2 JP3 JP4 JP5

Pins Connected (Covered)


2 (open) 2 (open) 2&3 2&3 2&3

Used When...
Power is supplied through terminal block on card. Power is supplied through terminal block on card. Interface card is attached to network card. Interface card is attached to network card. Interface card is attached to network card.

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Setting Up a Cool Muscle Motor Controller

Slave Network Card Powered Through Terminal Block (See Figure 7-9)
Jumper
JP1 JP2 JP3 JP4 JP5

Pins Connected (Covered)


2 (open) 2 (open) 1&2 1&2 1&2

Used When...
Power is supplied through terminal block on card. Power is supplied through terminal block on card. NO interface card is attached to network card. NO interface card is attached to network card. NO interface card is attached to network card.

Slave Network Card Powered Through RS-232 Cable (See Figure 7-10)
Jumper
JP1 JP2 JP3 JP4 JP5

Pins Connected (Covered)


1 & 2 (closed) 1 & 2 (closed) 1&2 1&2 1&2

Used When...
Power is supplied through RS-232 serial cable. Power is supplied through RS-232 serial cable. NO interface card is attached to network card. NO interface card is attached to network card. NO interface card is attached to network card.

Interface Card Piggybacked on Master Network Card (See Figure 7-8, Left)
Jumper
JP1 JP2

Pins Connected (Covered)


1&2 2&3

Used When...
RS-232 is used rather than RS-485. RS-232 is used rather than RS-485.

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JP5 - Pins 2 & 3 connected Interface Card: JP1 - Pins 1 & 2 connected

JP3 - Pins 2 & 3 connected

JP2 - Pins 2 & 3 connected

JP4 - Pins 2 & 3 connected

JP1 open

JP2 open

Figure 7-8: Master Network Card with Interface Card on Top

JP5 - Pins 1 & 2 connected

JP3 - Pins 1 & 2 connected

JP4 - Pins 1 & 2 connected

JP1 open

JP2 open

Figure 7-9: Slave Network Card Powered Through Terminal Block

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Setting Up a Cool Muscle Motor Controller

JP5 - Pins 1 & 2 connected

JP3 - Pins 1 & 2 connected

JP4 - Pins 1 & 2 connected

JP1 JP2 Pins 1 & 2 connected on both


Figure 7-10: Slave Network Card Powered Through RS-232 Cable

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Replacing a Cool Muscle Servo Motor


The instructions in this procedure apply to Cool Muscle motors. To replace a servo motor, use the instructions in this section. The new parts to be assembled and installed are shown in Figure 7-11. # 4 x 1/4" x 1/4" diameter nylon spacers # 4 split washers 4/40 x 2.125" # 4 x 9/16" x 1/4" diameter nylon spacers Motor drive board cover (PET-K66-A) # 4 nylon washers 4/40 x 1/4" Serial port/network card cover (PET-H39-C)

Motor drive board (inside cover) (MOT16-001)

Nema 17 Motor (MOT16-001)

Client network card (MOT16-020)

Short style motor communication cable (MOT16-033)

Figure 7-11: New Motor Assembly to Be Installed

To replace a servo motor: 1. Place the two nylon washers on the 4/40 x 1/4" screws, and place the screws into the holes of the motor drive board, as shown in Figure 7-12. 2. Place the motor drive board inside the cover with the two screw holes aligned (Figure 7-12).

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Replacing a Cool Muscle Servo Motor

Figure 7-12: Screwing Motor Drive Board in Cover

3. Wrap the rubber grommet around the wires, and slide the grommet into the grommet holder, as shown in Figure 7-13. 4. Slide the #4 split washers onto the long screws, and slide the four screws through the serial port/network card cover (Figure 7-13). Slide the short (1/4"long) nylon spacers onto the screws.

Figure 7-13: Adding Grommet and Long Screws

5. Slide the client network card onto the long screws, with the connectors facing the cover holes, as shown in Figure 7-14. 6. Slide the long (9/16"-long) nylon spacers onto the screws (Figure 7-14).

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Figure 7-14: Sliding Network Card into Cover; Adding Long Spacers

7. Slide the motor driver board in its cover onto the long screws so the two covers are piggybacked, as shown in Figure 7-15. 8. Press the short style motor communication rainbow cable into the connectors of both boards (Figure 7-15).

Figure 7-15: Sliding Both Covers Together; Adding Rainbow Cable

9. Attach the assembly to the handler.

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Programming a Cool Muscle Motor

Replacing a Cool Muscle Servo Motor

Programming a Cool Muscle Motor


After you have replaced an old Cool Muscle motor with a new one, you need to program its parameters (sometimes called initializing the motor). The Exatron software streamlines this process for you. To program a new Cool Muscle servo motor: 1. Open the Exatron software. 2. On the Main window, click the Function menu, and click Initialize Motors.

Figure 7-16: Initialize Motors Menu Item

3. In the Initialize Motors dialog box, click the drop-down arrow to the right of the Select Motor box, and click the motor you want to initialize (Figure 7-17). 4. Click Initialize Motor. 5. Click Exit.

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Figure 7-17: Initialize Motors Dialog Box

For more information, see the motor manufacturers manual.

Checking Motor Serial Cables


The motors on the Model 8000 are attached to the system via short serial cables. Check that these cables are plugged in tightly to the CPU box, and the DB-9 connectors are securely screwed to the motors themselves.

Figure 7-18: Serial Cables

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Checking Motor Serial Cables

Replacing a Cool Muscle Servo Motor

If your handler has a large number of motors, it may have a serial hub to add serial COM ports. Make sure all these connectors are secure, also.

Figure 7-19: Serial Hub

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Air Regulator Maintenance


Most Exatron handlers use compressed air, which also requires an air regulator. A high quality air regulator with coalescing air filter and shutoff valve is supplied on your handler. It supplies air at the pressure you specify for the whole handler. Some handlers may also have a digital sensor, which shuts down the handler if the incoming air pressure drops below the limit you set on the digital sensor. See several sections starting with "Adjusting Air Pressure on a Digital Pressure Switch" on page 7-27 for more information. CAUTION: NEVER operate any Exatron equipment which requires compressed air without an approved air regulator and shutoff valve. The external air regulator assembly includes one or two oil/water particulate traps which should be visually inspected on occasion. This regulator should be set at factory air pressure of 80 PSI. The system requires a minimum of 80 PSI to operate properlyspecifically, to generate sufficient vacuum through the venturi to pick up devices from the trays. The incoming air line exits the regulator and splits to supply the vacuum generator and the internal air regulator/test site manifold.

Checking Incoming Air from the House Supply


The first step in ensuring a trouble-free air supply is to ensure the incoming air is adequate. Make sure the incoming air supply is at least 3 CFMs (cubic feet per minute). Make sure the needle on the handlers air regulator is not spiking or pulsing. If it is, the house air supply is inadequate.

Checking the Moisture/Dirt Trap in the Air Regulator


Check the moisture/dirt trap on the air regulator and the coalescing filter chamber. Verify that they are clean, empty and dry. There should be no oil and no water in any chamber. If they are dirty, physically disconnect the incoming air pressure supply from the air regulator and clean the trap and filter as needed. Excessive moisture and/or particulate buildup in the filter traps suggests the air supply to the system is too wet and/or dirty. CAUTION: Excessive moisture in the system can damage the vacuum generator and air valves.

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Checking the Moisture/Dirt Trap in the Air Regulator

Figure 7-20: SMC Air Regulator

If your air regulator is an SMC brand, follow this procedure. To check or replace the air filter: 1. Unscrew the small black screw at the bottom of the filter chamber and remove. If water is present, there is water in the air lines and you have a problem that you must correct.

Figure 7-21: Small Black Screw Removed

2. Unscrew the metal casing.

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Figure 7-22: Metal Casing Unscrewed

3. Snap off the clear glass casing.

Figure 7-23: Clear Glass Casing Snapped Off

4. Unscrew the black inner screw that has edges like propeller blades.

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Air Regulator Maintenance

Checking the Air Regulator Shutoff Valve

Figure 7-24: Large Black Inner Screw Removed

5. Remove the white filter and clean or replace if necessary, and reassemble in reverse order. If you find it necessary to clean the trap and/or filter more often than once a month, you should correct the problem at your in-house air compressor. Check your manufacturers manual for the exact procedure necessary.

Checking the Air Regulator Shutoff Valve


Check the operation of the shutoff valve once a month. To check the operation of the shutoff valve: 1. Turn the Off/On switch off and verify that the air is indeed off. Turn the switch back on. 2. Check the PSI setting. > Some special-case changeover kits may require less than 80 PSI. However, in general, set the air regulator to 80 PSI. If the air regulator is turned off, turn it on by turning the Off/On switch one quarter-turn counterclockwise. You can leave the air regulator turned on except when you are checking its operation.

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Adjustment knob On/off switch in OFF position On/off switch in ON position

Figure 7-25: SMC Air Regulator Turned Off (Left), On (Right)

Adjustment valve On/off switch in ON position

Figure 7-26: SMC Air Regulator Turned OnAnother Type

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Air Regulator Maintenance

Automatic Air Shut-Off Valve

On/off switch in OFF position

Figure 7-27: SMC Air Regulator Turned Off

Automatic Air Shut-Off Valve


On models having an optional automatic air shut-off valve as part of the air regulator (Figure 7-28). This shut-off valve automatically cuts off air to the handler and to the vacuum generators when the power is shut off or any EMO button is pushed. If the air to the handler is turned off or disconnected and then turned back on while the handler is powered up, an unpleasant but harmless noise may issue from the shut-off valve. This may be quickly remedied by depressing and releasing the EMO button.

Figure 7-28: Automatic Air Shut-Off Valve

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Adjusting Air Pressure on the Regulator


You can increase air pressure at the air regulator. To adjust the air pressure: 1. Pull up on the black adjustment knob above the display, and turn it. > Turn it clockwise to increase the pressure. > Turn it counterclockwise to decrease the pressure. 2. Push the knob back down to lock it when you have finished the adjustment. If your handler has an auxiliary or internal (pusher) air regulator, see the next subsection.

Adjusting Auxiliary Air Regulator


The auxiliary or internal air regulator (or auxiliary pusher regulator; Figure 7-29) "steps down" the air pressure for use by the test site air cylinders on those systems using them. The air cylinders found on most test sites require only 30 to 50 PSI to operate properly, and over-driving the cylinders can shorten the life expectancy of both the cylinders and the test sockets. Some sockets require more force than others to operate. The air pressure exerted on the sockets should be adjusted to be just enough for the particular sockets in use. Pull out the black adjustment valve and turn it to step down the pressure here to 30-50 PSI.

Adjustment valve
Figure 7-29: Auxiliary Air Regulator

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Air Regulator Maintenance

Adjusting Air Valves

Adjusting Air Valves


Pressurized air for the air cylinders at the test sites (and thermal heads, if so equipped) is controlled by a series of 24-volt DC air valves mounted on a manifold block. Each air valve is wired through an override button which will turn the valve on while it is pressed. However, the override button will not turn off a valve which has been actuated by the handler itself.

Lock nut

Air flow control adjustment knob


Figure 7-30: Air Valves with Control Adjustment

To adjust the air flow at the air valve: 1. Turn the lock nut counterclockwise to unlock the adjustment knob. 2. Turn the air flow control adjustment knob: > Turn the knob clockwise to lessen the air flow, or... > Turn the knob counterclockwise to increase air flow. 3. When air flow is appropriate, turn the lock nut clockwise to tighten it.

Adjusting Air Pressure on a Digital Pressure Switch


The external air regulator may be attached to a digital pressure switch display on the outside of the handler. The incoming air pressure is sensed, and compared to a low level limit you set. If the incoming air pressure ever drops below the limit set at the digital pressure switch, the handler stops and an error message is displayed. This prevents malfunctioning and damage to devices. When air pressure to the handler is turned off, the reading on the digital air pressure display is something like .01 or .03, and the OUT1 and OUT2 displays are not lit.

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Figure 7-31: OUT Lights Off and Fractional ReadingNo Air Pressure

During handler operation, the OUT 1 light on the digital air pressure display should be green.

Figure 7-32: OUT1 Light GreenNormal Air Pressure

If the OUT1 light is off when the air pressure is on, as signified by the pressure reading being more than something like .01 or .03, you need to do one of two things: On the handler, increase the air pressure on the main air regulator until it is greater than the P1 setting (page 7-26), or... On the digital air pressure switch, lower the value of P1 until it is lower than the current air pressure. However, never set P1 lower than a minimum of 65!

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Air Regulator Maintenance

Unlocking or Locking a Digital Air Pressure Switch

Unlocking or Locking a Digital Air Pressure Switch


The digital air pressure switch is set with the appropriate settings by Exatron, and the settings may be locked. You need to unlock the digital air pressure switch before you can access or change the settings. Afterward, be sure to relock the settings so they cant be accidentally changed.

Unlocking or Locking SMC Model ITV


If, by some chance, the settings become changed, you can change them back to the factory recommendation by using the buttons on top of the digital air pressure switch (for Model ITV, Figure 7-33).

Figure 7-33: Control Buttons on Top of Digital Air Pressure Switch

Before you can review the settings, you must unlock the settings buttons. To unlock Model ITV: 1. Press and hold down the (left) UNLOCK button (the down arrow) for 3-4 seconds or until the display flashes Loc (Figure 7-34, left). This means the settings are currently locked. 2. Press the (middle) SET button to unlock the settings. > The display briefly flashes unL (Figure 7-34, right). This means the settings are now unlocked.

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Figure 7-34: Display Locked (Left); Unlocked (Right)

To lock Model ITV: 3. Whenever you are ready to exit the programming cycle, press and hold down the (right) LOCK button (the up arrow) for 3 seconds or until the display flashes unL. This means the settings are still unlocked. 4. Press the SET button to lock the settings. > The display briefly flashes Loc. This means the settings are again locked.

Unlocking or Locking SMC Models ISE40 and ZSE40


To unlock Models ISE40 and ZSE40: 1. Press and hold the SET button 4-5 seconds. The display reads LoC. 2. Press the down-arrow button. The display changes to UnL. 3. Press the SET button to return to normal operations in Measure Mode.

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Air Regulator Maintenance

Unlocking or Locking a Digital Air Pressure Switch

Figure 7-35: Display Locked (Left); Unlocked (Right)

To lock Models ISE40 and ZSE40: 1. Press and hold the SET button 4-5 seconds while the display cycles. The display reads P_1, then PSI, and finally UnL. 2. Press the up-arrow button. The display changes to LoC. 3. Press the SET button to return to normal operations in Measure Mode.

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Changing Settings on a Digital Air Pressure Switch


If you replace the digital air pressure switch, you need to reset the settings to Exatrons factory settings. Other circumstances may require some small readjustments.

Changing Settings on SMC Model ITV


The following parameters are available on this model: Setting F_1 F_2 P_1 P_2 G.L. S.L. Significance minimum PSI air pressure maximum PSI air pressure monitor/sensor output pressure a monitor/sensor output pressure speed of gain sensitivity

a. The sensor output mode is determined by the relationship between the P_1 and P_2 values. When the P_1 value is smaller than the P_2 value, this is called comparator mode. The output goes on whenever the outlet pressure is greater than P_1 but less than P_2. See the ITV2000 Easy Programming Guide, page 5, for more details.

To review or change air regulator settings: 1. Unlock the settings, as described in "Unlocking or Locking SMC Model ITV" on page 7-29. > A flashing display of F_1 alternates with the value it is set to (Figure 7-36).

Figure 7-36: F_1 Alternating with Set Value

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Changing Settings on a Digital Air Pressure Switch

2. If necessary, press either the up or down arrow button to change the number. > Press and release the up arrow button (the LOCK button) to increase the number by one. (To rapidly increase the numbers, hold down the button.) > Press the down arrow button (the UNLOCK button) to decrease the number by one. (To rapidly decrease the numbers, hold down the button.) CAUTION: Changes in the F_1 or F_2 pressure values take effect as soon as you press the SET button. Be careful to avoid damage or injury. 3. Press the SET button to advance to the next setting. > A flashing display of F_2 alternates with the value it is set to (Figure 7-37).

Figure 7-37: F_2 Alternating with Set Value

4. If necessary, press either the up or down arrow button to change the number. 5. Press the SET button to advance to the next setting. > A flashing display of P_1 alternates with the value it is set to (Figure 7-38).

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Figure 7-38: P_1 Alternating with Set Value of 0

6. If necessary, press either the up or down arrow button to change the number. 7. Press the SET button to advance to the next setting. > A flashing display of P_2 alternates with the value it is set to (Figure 7-39).

Figure 7-39: P_2 Alternating with Set Value of 1

8. If necessary, press either the up or down arrow button to change the number. 9. Press the SET button to advance to the next setting.

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Changing Settings on a Digital Air Pressure Switch

> A steady, non-flashing display of G.L. plus the value is shown (9 is the fastest gain).

Figure 7-40: G.L. Showing Fastest Gain of 9

10. Press the SET button to advance to the next setting. > A steady, non-flashing display of S.L. plus the value is shown (0 is the best sensitivity).

Figure 7-41: S.L. Showing Best Sensitivity of 0

11. Press the SET button.

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Figure 7-42: Displays of Air Pressure in PSI

> A non-flashing display (Figure 7-42) shows the air pressure in PSI (pounds per square inch). > If you want to cycle through the settings again to confirm they are correct, you can keep pressing the SET button. 12. Whenever you are ready to exit the cycle, relock the settings as described in "Unlocking or Locking SMC Model ITV" on page 7-29.

Changing Settings on SMC Models ISE40 and ZSE40


This is the Initial Setting procedure as described in the SMCs documentation. This applies to SMC models ISE40 and ZSE40. To review or change air regulator settings: 1. Press and hold the SET button 2-4 seconds to enter the Initial Set mode. The display reads bAr. 2. Press the up or down arrow buttons on the digital display one or more times, until the display reads (PSI; Figure 7-43).

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Changing Settings on a Digital Air Pressure Switch

Figure 7-43: Unit Set to PSI

3. Press the SET button to advance to the OUT1 setting. 4. Set the output mode for OUT1 to (1 normally open) by pressing one of the arrow buttons one or more times (Figure 7-44, left). 5. Press the SET button to advance to the OUT2 setting. 6. Set the output mode for OUT2 to buttons (Figure 7-44, right). (2 normally open), using the arrow

Figure 7-44: Output Mode 1 Normally Open (Left); Output Mode 2 Normally Open (Right)

7. Press the SET button to advance to the response time setting.

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8. Set the response time to ure 7-45, left).

(2.5 miliseconds), using the arrow buttons (Fig-

9. Press the SET button to advance to the Auto/Manual mode. 10. Set the mode to (manual), using the arrow buttons (Figure 7-45, right). This mode must be selected before you can set the P1 value as described in the next subsection. 11. Press the SET button a final time to return to normal operations in Measure Mode.

Figure 7-45: Response Time 2.5 MS (Left); Manual Mode (Right)

Setting Minimum Air Pressure on SMC Models ISE40 and ZSE40


The P1 value sets the trip point. If at any time the air pressure goes below the value set in P1, the handler will stop. This is the Manual Pressure Setting procedure as described in the SMCs documentation. This applies to SMC models ISE40 and ZSE40. NOTE: The digital pressure switch must have been set in Manual mode before you can enter this Manual Pressure Setting procedure. If necessary, do the previous procedure before you do this one.

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Air Regulator Maintenance

Changing Settings on a Digital Air Pressure Switch

To set the minimum air pressure: 1. Press the SET button until the display reads . The flashing P_1 display alternates with the value at which P1 is currently set. 2. Press the up or down arrow buttons repeatedly until the P1 value is lower than the current air pressure. CAUTION: Never set the P_1 value below 65! Doing so will cause the handler to continue operating at too low air pressure, causing serious problems to the handler. 3. Press SET again repeatedly to scroll through P_2, P_3, P_4, C_S, and back to normal operations in Measure Mode.

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Vacuum Generator Maintenance


Exatron uses one of three types of SMC brand vacuum assemblies on the handlers, depending on the handler setup.
Type Exatron part number SMC part number Port configuration Vacuum supply valve Solenoid valves Interface plates Blow-off screw location Number of air tubes Usage Handler model

K15 Vacuum Generator


PNE022-100 NZX1102-K15LZ-D23CL 1 (PV<-->PS<-->PD) a Normally closed (NC) Short (Figure 7-47, top) 1 (Figure 7-48) PS port (Figure 7-50, left) 1 (Figure 7-46) Has built-in venturi Used by most Model 900s

K35 Vacuum Generator


PNE022-007 NZX1102-K35LZ-D23CL 3 (PV<-->PS<-->PD) b Normally open (NO) Long (Figure 7-47, bottom) 2 stacked (Figure 7-48) PS port (Figure 7-50, left) 1 (Figure 7-46) Has built-in venturi Used by many Model 8000s

K35 Vacuum Switch


PNE022-023 NZX100-K35LZ-D21CL 3 (PV) (PS<-->PD) c Normally open (NO) Long (Figure 7-47, bottom) 2 stacked (Figure 7-48) PD port (Figure 7-50, right) 2 (Figure 7-49) Uses vacuum pump Used for large number of pickup nozzles or complex air pressure needs

a. The PV, PS, and PD ports are all common to one another. b. The PV, PS, and PD ports are all common to one another. c. The PS and PD ports are common to each other.

PD port PS port

PV port

Figure 7-46: K15 Vacuum Generator

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Changing Settings on a Digital Air Pressure Switch

PD (upper hole, Figure 7-46) is the air supply port for the release valve. PS (middle hole, Figure 7-46) is the air supply port for the vacuum valve. PV (lower hole, Figure 7-46) is the vacuum supply port.

Figure 7-47: Vacuum AssembliesK15 (Top); K35 Switch for Vacuum Pump (Bottom)

The black solenoid valves for K35 are longer than those for K15 (Figure 7-47). Also, K35 has two interface plates, whereas K15 has only one.

Figure 7-48: Extra Holes in K15 Interface Plate

The locations of the holes in the interface plates (Figure 7-48) serve to redirect the internal air flow. Vacuum switches require the use of a separate vacuum pump.

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Figure 7-49: K35 Vacuum SwitchUsed with Vacuum Pump

PD portBlow-off adjustment screw location when vacuum pump is used

PS portBlow-off adjustment screw location when in-house air is used

Figure 7-50: Blow-Off Adjustment Screw Locationon Vacuum Generator (Left); on Vacuum Switch (Right)

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Troubleshooting Vacuum Assemblies

Troubleshooting Vacuum Assemblies


Air Regulator
Keep the air regulator set to 80 PSI. If the needle on the air regulator varies more than 10 lbs, there is not enough air flow, although there may be enough air pressure. The reduced air flow will confuse the software and cause improper handling because not enough air is being supplied. If ithe air regulator is set a little higher, it harmlessly bleeds the excess air. However, it should not go much above 80 PSI. If the air regulator drops drastically, perhaps by 40 lbs. or more, not enough air is being supplied, and the source of the problem is somewhere outside the handler. Check your in-house air supply. Are too many machines being supplied by one compressor? Is the compressor dirty or wet? If the problem develops gradually, it may be caused by water in the line. If the problem does not appear at startup but only after the handler has run awhile, again it may be caused by water in the line. If water gets into the vacuum generator or switch, it causes plugging so it loses vacuum and wont pick up devices. This can be due to improper air compressor maintenance.

Vacuum Generators
When the air regulator shows enough pressure but the vacuum at the pickup nozzle is too low, the origin of the problem is somewhere between the air regulator and the vacuum generator. If a problem appears consistently, even at startup, it may be dirt in the air filter. Check for: Dirty air filter in the vacuum generator Loose or pinched air hose Loose air fitting CAUTION: When using a vacuum generator, set the maximum air pressure no higher than 80 PSI at a maximum.

Vacuum Switches Used with Vacuum Pump


When using a vacuum switch with a vacuum pump, the danger is in turning the air pressure too high. The maximum air pressure coming from the vacuum pump must be no higher than 50 PSI. Any greater air pressure may damage components and will void the Exatron warranty. CAUTION: When using a vacuum switch with a vacuum pump, set the maximum air pressure no higher than 50 PSI at a maximum to avoid damage.

Checking and Replacing a Vacuum Air Filter


Whether your handler uses a vacuum generator or a vacuum switch, it has a built-in replaceable air filter (#PNE022-020). The see-through plastic housing for this filter can be removed by hand. Replace the filter when it becomes visibly dirty, gray, or has obvious particulate mat-

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ter buildup. If particle buildup is evident, the air supply lines should be checked for contaminants. Also, the moisture/dirt trap on the incoming air regulator should be checked. See "Checking the Moisture/Dirt Trap in the Air Regulator" on page 7-20 for instructions. Inspect the vacuum generators air filter weekly. The filter should be clean and white. CAUTION: A dirty filter means poor handler operation. Replace your filter!

Figure 7-51: Dirty Filter (Left) Versus Clean Filter (Right)

Adjusting Pickup Nozzle Blow-Off


The procedure in this section allows you to adjust the blow-off strength for each pickup nozzle individually. You can adjust the blow-off for each individual pickup nozzle at the vacuum generators. There is one vacuum generator for each nozzle. You adjust one screw on each vacuum generator or switch, but the screw location differs according to whether: Your handler has a vacuum generator and is attached to an in-house air supply, or Your handler has a vacuum switch and is attached to its own vacuum pump (perhaps because of having many pickup nozzles). See the locations compared in Figure 7-50.

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Vacuum Generator Maintenance

Adjusting Pickup Nozzle Blow-Off

Adjusting Blow-Off for Handler Using In-House Air Supply


If the handler uses an in-house air supply, the vacuum/blow-off is connected to the PV port (the lowest hole, Figure 7-52) and you can adjust the screw in the PS port. Turning it one complete revolution often makes an adequate adjustment. CAUTION: Do not over-adjust the blow-off adjustment screw. If the screw is turned too much, it will come out and make the blow-off inoperable. To increase the blow-off, turn the screw counterclockwise to loosen the screw. To decrease the blow-off, turn the screw clockwise to tighten the screw.

PS portBlow-off adjustment screw when in-house air is used

PV portconnection for air supply or vacuum pump


Figure 7-52: Blow-Off Adjustment Screw at PS Port When Using In-House Air

Adjusting Blow-Off for Handler Using Vacuum Pump Air Supply


Compare the following locations with Figure 7-53. If the handler has its own vacuum pump and chamber(s) as shown in Figure 7-54 and Figure 7-55, the vacuum pump is connected to the PV port (the lowest hole, with the black tube). Therefore, the usual blow-off adjustment screw is removed and the blow-off fitting is attached to the PS port (the yellow tube), where the blow-off adjustment screw would have been. In that case, you must adjust the upper setscrew at the PD port (just above the yellow blow-off tube) instead. Do not turn it more than only one-eighth to one-fourth of a revolution. CAUTION: Do not over-adjust the blow-off adjustment screw. If the screw is turned too much, it will come out and make the blow-off inoperable. When using a vacuum switch with vacuum pump, 1/8" to 1/4" should be the maximum adjustment. To increase the blow-off, turn the screw counterclockwise to loosen the screw. To decrease the blow-off, turn the screw clockwise to tighten the screw.

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PD port

PS port

PV port

Figure 7-53: Blow-Off Adjustment Screw at PD Port When Using Vacuum Pump

Figure 7-54: Various Styles of Vacuum Pumps

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Cleaning Vacuum Assemblies

Figure 7-55: Vacuum Chamber

Cleaning Vacuum Assemblies


This section shows a quick way of cleaning a vacuum assembly. WARNING! Always wear safety glasses before cleaning a vacuum assembly. To clean a vacuum assembly: 1. Turn off the air supply, and turn off the air regulator to release air pressure. 2. Unscrew and remove the two screws from each of the two solenoid valves on each vacuum assembly (Figure 7-56).

Figure 7-56: Vacuum Assembly with Four Screws Highlighted

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3. Remove the two solenoid valves (Figure 7-58).

Figure 7-57: Vacuum Assembly with One Solenoid Valve Removed

Figure 7-58: Vacuum Assembly with Both Solenoid Valves Removed

4. Remove the gaskets from both solenoid valves (Figure 7-59). Be careful not to cut or damage the gaskets.

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Cleaning Vacuum Assemblies

Figure 7-59: Removing Gasket from Vacuum Assembly

Figure 7-60: Vacuum Assembly with Gasket Still Attached

> Occasionally a gasket may get stuck to the venturi when the solenoid valve is removed (Figure 7-60). Remove the gasket and save it.

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Figure 7-61: Vacuum Assembly with Both Solenoid Valves and Gasket Removed

5. Turn the air supply on and let it blow out the venturi. 6. Use a hand-held air supply to blow out each solenoid valve by hand. 7. Ater all parts are cleaned out, turn the air supply off before reassembling. 8. Press the gaskets back into the solenoid valves. 9. Replace the solenoid valves on the venturi and screw them in.

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Checking and Setting the Vacuum Generator

Checking and Setting the Vacuum Generator


The vacuum generator is fitted with an electronic sensor that measures the strength of the vacuum drawn through the air lines. The sensor displays the result on the small LCD screen of the vacuum generator. When the vacuum is engaged, the display should give a reading for the level of vacuum in the system. (The kPa or mPa value is a percentage of the PSI.) The sensor puts out a signal when a given level of vacuum is reached, indicating the vacuum has a secure hold on the device being lifted. To check the vacuum generator adjustment: 1. Turn on the vacuum using the handlers vacuum override button, but do not attach a device to the nozzle or block it. 2. Cover the vacuum hole in the pickup nozzles suction cup with a device. > You will hear a noticeable change in the sound of the vacuum as it intercepts the device, and the green indicator LED should turn on. If the valves in the vacuum generator assembly become plugged with dirt, you may send the assembly back to Exatron Customer Service where it will be repaired, if possible, for a fee. Damage caused by a dirty air supply is not covered by the Exatron warranty. If you are experiencing dirt-clogged vacuum generator valves, check the air regulator. Verify that it is clean and properly installed. See "Air Regulator Maintenance" on page 7-20. Contact the Exatron factory for assistance as needed. The vacuum generator setting is more or less permanent. It should rarely, if ever, need to be recalibrated. The handler has one vacuum generator for each pickup head.

Figure 7-62: Vacuum Generator Controls

When the P1 value is reached, the signal is turned on. From this value and above, the handler considers that a device is attached to the pickup nozzle. When the P2 value is reached, the signal is turned off. For Exatron handlers, the P2 maximum value is set to 101 so that it will never be reached.

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As a general principle, a larger hole in the suction cup of the pickup nozzle will show a lower baseline value (when no device is attached) because the air flow is not obstructed as much as it is with a smaller suction cup hole (Figure 7-63). When the suction cup hole is smaller, the baseline pressure is higher (Figure 7-64).

Figure 7-63: Vacuum Generator Optimal Pressurefor Nozzle with Larger Hole

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Checking and Setting the Vacuum Generator

Figure 7-64: Vacuum Generator Optimal Pressurefor Nozzle with Smaller Hole

If you replace a vacuum generator with a new one, you need to calibrate its settings. A new vacuum generator has both P1 and P2 set at zero, and EC set at 3. You will need to change these settings. The modes cycle through P1, P2, P3, (P4 is added for a vacuum switch using a vacuum pump system), and EC with repeated pressing of the SET button. Mode
P1 P2 P3 P4 EC

Meaning
Low limit High limit For other sensor For switch using a vacuum pump system Error code

Desired Setting
8-10 points higher than vacuum on w/ no device present 101 n/a n/a 0

Result
Device is considered as attached to pickup; green light on No device is considered as attached to pickup; green light off Not used Not used Not used

You can use either the vacuum override buttons on the handler, or the tiny vacuum override button on the vacuum generator itself (Figure 7-66).

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Vacuum button

Blow-off button

Figure 7-65: Vacuum and Blow-Off Override Buttons on Vacuum Generator

To calibrate the vacuum generator: 1. Power on with no air. > A 1 or 0 should be displayed on the LCD screen. 2. Turn on the air and the vacuum, using the software. Do not attach a device yet. 3. Press the vacuum override button with no device attached to the nozzle and note the setting. This is the baseline value (Figure 7-66).

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Checking and Setting the Vacuum Generator

Figure 7-66: P1 Baseline Value Example

4. Press the SET button to enter the programming modes. > P1 with the value is displayed. P1 sets the minimum limit at which the sensor detects a device. 5. Press one of the green arrow-shaped buttons to set the number at least 8 to 10 points higher than the baseline value (with no device attached) (Figure 767). > Press the up-arrow button to increase the number displayed. > Press the down-arrow button to decrease the number displayed. > Factors such as weight of the device or rotation of the pickup nozzle may affect the number that works best for your handler.

Figure 7-67: P1 Set at Least 8-10 Points Higher Than Baseline

6. Press the SET button to advance to the P2 setting.

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> P2 with the value is displayed. P2 sets the maximum limit beyond which the sensor no longer detects a device. 7. Press the up-arrow button repeatedly to set the P2 number at 101, the maximum limit (Figure 7-68).

Figure 7-68: P2 Set to 101

8. Press the SET button to advance to the unused P3 setting. 9. Press the SET button to advance to the EC setting. > EC with the value is displayed. 10. Press the down-arrow button repeatedly to set the EC number at 0 (Figure 769). 11. Press the SET button again to return to normal operation mode.

Figure 7-69: Error Code Set to Zero

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Checking and Setting the Vacuum Generator

Now you can check the settings. To check vacuum generator settings: 1. Power on with no air. > A 1 or 0 should be displayed on the LCD screen. The green light on the vacuum generator stays on. 2. Turn on the air and the vacuum, using the software. Do not attach a device yet. 3. Press the vacuum override button with NO device attached to the nozzle and note the setting. > The setting with no device attached should be at least 8 points lower than the P1 setting. 4. Now attach a device to the nozzle and press the vacuum override button. Note this setting number. > The setting with a device attached should be at least 68-75 or higher, or at least 5 points higher than the P1 setting. Lower numbers may indicate some problem with the air line, perhaps the tubes or compressor. 5. Finally, to test your settings, put a device on the nozzle and press the override button. With a device attached, a green indicator light is displayed on the vacuum generator (Figure 7-70). With no device attached, the light goes off (when EC is set to 0; if EC were set to 3, the indicator light would be red when no device is attached).

Figure 7-70: Green Indicator Light with High Number Showing Device Attached

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Solenoid Maintenance
CAUTION: NEVER use oil or lubricant of any kind on solenoids. Keep the solenoids as clean as possible. If the handler is used with devices that have excessive mold flash, the solenoids will require cleaning regularly. The frequency is dependent upon how much mold flash gets into the solenoids. When cleaning solenoids, take care not to put excessive stress on solenoid wiring. Check all wiring for signs of wear, exposed conditions, or broken connections. Replace as needed with identical type of wire: standard or flex, same gauge, insulation, color, etc. When cleaning solenoids, check the plungers to be sure there are no burrs of any kind on their shafts. Solenoid life is proportional to the handler environment and how often the solenoids are cleaned. We recommend that all solenoids be replaced every two million cycles as part of a good preventive maintenance program. Replace any bent or damaged solenoid return springs with new parts from the Exatron factory. Refer to the hardware specifications in Chapter 8 for the part numbers of all solenoids and springs in your handler.

Opening the Computer for Part Replacement


The computer inside the cabinet slides out on rails, making it easier to change any part of the computer (Figure 7-71).

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Checking and Setting the Vacuum Generator

Figure 7-71: Computer Sliding Out of Cabinet on Rails

To replace a computer part: 1. Unscrew and remove the 4 allen screws that bolt the computer to the computer base (Figure 7-72).

Figure 7-72: Four Computer Base Bolts

2. Pull the computer out by the top rim (Figure 7-73).

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Figure 7-73: Sliding Computer Out of Cabinet

3. Unscrew and remove the 2 bolts at the top front of the computer that secure the lid (Figure 7-74).

Figure 7-74: Front Bolts Securing Lid

4. Unscrew and remove the 6 bolts along the top edges of the computer (3 on each side; Figure 7-75).

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Checking and Setting the Vacuum Generator

Figure 7-75: Top Bolts Securing Lid

5. Lift off the lid. 6. Replace any part that needs to be replaced. 7. Reassemble the computer in reverse order.

Fiberoptic Photoelectric Sensor Guidelines


Each sensor on your handler is connected to a sensor controller, which displays whether the sensor is "seeing" any object. Most fiberoptic sensor controllers are set to L-ON (light on) by Exatron. This causes the output transistor to turn on when light is received by the sensor.

Figure 7-76: Sensor Controller Set to L-ON

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Figure 7-77: Green and Red Indicator Lights

The green light is the Stable Operation Indicator. When the sensor is operating normally under stable conditions, the green light should be ON. The red light is the Light Reception Indicator. When the sensor is receiving light, the red light should be ON.

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Taper Maintenance

Checking and Setting the Vacuum Generator

Figure 7-78: Conditions of Indicator Lights

For both types of sensor (through-beam and reflective), the red light on means nothing is there; nothing is blocking or reflecting the sensor beam. If the red light is off, something is there, interfering with the sensor beam.

Taper Maintenance
If your handler uses a tape and reel, you need to keep the seal head clean. If you use a heat seal head, clean the blade with a cotton swab dipped in acetone, isopropyl alcohol, or other suitable (evaporative) cleaning agent. Be sure to do this when the heat seal is cold. If you use a pressure-sensitive seal blade, wipe the pressure roller wheels with a clean dry cloth. The wheel bearings are sealed from the factory and need no maintenance. Clean the sensor optics of dust with a very low blast of air.

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Checking Omega Temperature Controller


To determine whether the desired temperature that is set in the Exatron software has been read by the Omega temperature controller, you can read it from the temperature controller display panel (Figure 7-79).

Figure 7-79: Omega Temperature Controller Display Panel

The display at the right is for the pre-heat tray. It is connected at the light blue plug in the back of the box.

Figure 7-80: Back of Box with Pre-Heat Plug-in

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Checking and Setting the Vacuum Generator

Figure 7-81: Clamp Head for Test Sockets

Before you begin, the display panel shows the current temperature of the clamp head (Figure 7-82).

Figure 7-82: Current Temperature Displayed

Four buttons allow viewing or changing the desired set temperature. Buttons on Temperature Controller Display Panel Button Function
Next Changes the display to configuration mode and advances through menu items.

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Buttons on Temperature Controller Display Panel Button Function


Up Arrow Increases set temperature. Down Arrow Decreases set temperature. Enter Enters a submenu or saves a change made in the current submenu.

NOTE: Any set temperature changes made on the control panel will be overridden by the Exatron software settings.

To view or change the set temperature: 1. Press the Next button. The display reads SP1 (Figure 7-83).

Figure 7-83: Setpoint 1 Menu Item Displayed

2. Press the Enter button. The set temperature is displayed, with the rightmost digit flashing (Figure 7-84). You can tell this is different from the current temperature display because instead of a C or F at the left of the display, now a small 1 is visible, signifying that this is displaying the Setpoint 1 value.

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Checking Omega Temperature Controller

Checking and Setting the Vacuum Generator

Figure 7-84: Setpoint 1 Value Displayed

> If you do not want to change the set temperature, go to step 3. > If you want to increase the set temperature, press the Up arrow button (Figure 7-85). Holding it down for 3 seconds speeds up the rate of increment. To save your change, press the Enter button. The display reads StRd (Setting Read; Figure 7-86). > If you want to decrease the set temperature, press the Down arrow button. Holding it down for 3 seconds speeds up the rate of decrement. To save your change, press the Enter button.

Figure 7-85: Setpoint 1 Value Increased

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Figure 7-86: Setpoint 1 Value Saved

3. Press the Next button. The display reads SP2 (Figure 7-87). The Exatron system does not use the second setpoint.

Figure 7-87: Setpoint 2 Menu Item Displayed

4. Press the Next button. The display reads CNFG (Figure 7-88).

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Laser Servicing

Internet Access

Figure 7-88: Configuration Menu Item Displayed

5. Press the Next button. The display reads RUN briefly before it returns to run mode, displaying the current temperature again.

Laser Servicing
If the handler is equipped with a laser, see the manufacturers manual for service instructions. WARNING! Only a qualified in-house laser safety officer (LSO) should service the laser.

Networking
The next few subsections discuss ways of troubleshooting over a network.

Internet Access
It is strongly recommended that your handler be equipped with Internet access, without which Exatron cannot help you troubleshoot the handler remotely.

Setting LAN Connections and Required IP Addresses


The handler and its peripherals are on its own private network. To ensure communication between the Exatron software and peripheral devices such as the inspection camera, the IP addresses are static, set to the handlers own private network. Keeping the IP addresses as they come from the factory enables the handler software to communicate with the peripherals. CAUTION: Do not change any IP address associated with the handler or its peripherals unless specifically approved by Exatron. Changing IP addresses can make service billable even when the handler is under warranty.

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Because Exatron has optimized communication on this private network, performance cannot be guaranteed if additional devices are connected or additional non-Exatron software is installed. In order to connect the handler to a LAN for the purpose of remote servicing, Exatron requires the use of a network interface adapter. Exatron can supply a USB-to-Ethernet adapter as an option. Use this adapter to connect to the LAN; do not attach the handlers private network to the LAN. See the following chart for required IP addresses.

Required IP Addresses
IP Address
192.168.12.1 192.168.12.11 through 192.168.12.29 192.168.12.3 192.168.12.4 192.168.12.41 192.168.12.42 192.168.12.5 192.168.12.51 through 192.168.12.59

Component or Peripheral
Exatron PC Handler motors, sensors, PLCs Laser PC Camera/machine vision PC Camera 1 Camera 2 Peregrine tester Other testers

A computer may have more than one LAN (local area connection) setup. In this example, LAN 3 is used. To set the LAN connection: 1. Double-click the icon in the lower left corner of Windows desktop to open a LAN connection setup (Figure 7-89).

Figure 7-89: LAN Setup Icon

> The Local Area Connection Status dialog box is displayed (Figure 7-90).

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Setting LAN Connections and Required IP Addresses

Figure 7-90: Local Area Connection Status Dialog BoxGeneral Tab

2. Set the parameters on each tab as shown in the following figures.

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Figure 7-91: Local Area Connection Properties Dialog BoxGeneral Tab

3. Under the General tab of the Local Area Connection Status dialog box, click the Properties button (Figure 7-91). > The Local Area Connection Properties dialog box is displayed.

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Figure 7-92: Internet Protocol (TCP/IP) Properties Dialog BoxGeneral Tab

4. Under the General tab of the Local Area Connection Properties dialog box, click the connection Internet Protocol (TCP/IP) (Figure 7-92). 5. Click the Properties button. > The Internet Protocol (TCP/IP) Properties dialog box is displayed.

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Figure 7-93: Local Area Connection Properties Dialog BoxAdvanced Tab

6. Under the Advanced tab of the Local Area Connection Properties dialog box, in the Windows Firewall group box, click the Settings button (Figure 7-93). > The Windows Firewall dialog box is displayed. 7. Under the General tab of the Windows Firewall dialog box, make sure the Dont Allow Exceptions box is not checked.

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Figure 7-94: Windows Firewall Dialog BoxExceptions Tab

8. Under the Exceptions tab of the Windows Firewall dialog box, check all the pcAnywhere... and Remote... boxes (Figure 7-94). 9. Click OK. 10. Click OK repeatedly to close the LAN setup.

Testing Network Communication with Peripherals


If your handler has peripherals such as an inspection camera and/or laser, you can test the TCP/IP connections from the Exatron PC to the laser or camera. To test TCP/IP connections: 1. Close all application programs. 2. Click the Start button at the lower left corner of the screen. Click Run.

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Figure 7-95: Selecting Run Option

3. In the Run dialog box, type cmd.exe and click OK.

Figure 7-96: Opening a DOS Window

4. In the DOS window that opens, at the C:\ prompt, type PING followed by a space and then the IP address of the peripheral with which you want to test communication.

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Testing Network Communication with Peripherals

Figure 7-97: PING Command with Replies

> You should see a series of replies like the ones shown in Figure 7-97. All packets sent should have been received, with none lost. 5. To show the IP address of the host (Exatron) PC, in the DOS window type IPCONFIG /ALL.

Figure 7-98: IPCONFIG Command with Reply

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> You should see information similar to that shown in Figure 7-98. The host (Exatron) IP address in this example is 192.168.10.110.

Remote Handler Control with WebEx


The engineers at Exatron can help you diagnose handler problems with your Internet connection and the WebEx Internet service. When you contact Exatron for troubleshooting, you may receive an e-mail inviting you to a WebEx meeting (Figure 7-99).

Figure 7-99: E-mail Invitation to WebEx Meeting

To join the meeting, just click the link that is displayed in the e-mail message and follow the instructions shown.

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Remote Handler Control with WebEx

Figure 7-100: WebEx Meeting Information

If you have any problems, click on the help link from WebEx at the bottom of the e-mail. Their support is thorough.

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Replacing Exatron Program File with an Upgrade


Upgrades to the Exatron program software may be done in order to add or remove features or functions, or to debug the main system controller software. The Exatron program is a file named [YourCompany]_[Model#]_[suffix]_[date_time]_[version].exe where the date, time, and version of the latest upgrade are included in the filename. It is located on the CPU in the directory C:\Exatron\ . It is important to maintain a backup of all files previously used and tested. If a newly updated file won't perform properly, a copy of the backup may be reinstalled back into the proper working directory. CAUTION: Do not delete the 3 essential system files: WinIO.dll, WinIO.sys, and WinIO.vxd (Figure 7-101).

Figure 7-101: Exatron Directory with Job Files, 3 Essential System Files, and Existing Program File

Following this procedure will insure that a backup is maintained of the original and all subsequent upgrades. CAUTION: Do not delete any previous zip files from the Backup directory. Always maintain an additional up-to-date copy of all the contents in the C:\Exatron\Backup\ directory on external media such as a CD-ROM or a set of floppy disks. Exatron may send zip files by e-mail with modified file extensions so the files don't get stripped or blocked by the firewalls at customer sites. Prior to extracting from these files, rename the zipped file, changing the extension back to *.zip. To install the Exatron software: 1. Close all applications and open Windows Explorer to navigate and edit file directories. 2. Copy the current Exatron program file into the C:\Exatron\Backup directory.

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Remote Handler Control with WebEx

3. Copy the .edf or .job files for the jobs/setting files you are currently running into the same Backup directory. Rename these backup files to include date and time in the file name so you can identify and reuse these files if necessary. 4. In the C:\Exatron\ directory, delete the [YourCompany]_[Model#]_[suffix]_[date_time]_[version].exe file. (A backup is already in the C:\Exatron\Backup\ directory.) 5. Copy the attached .zip file into this same directory (C:\Exatron\Backup).

Figure 7-102: Backup Directory with Job Files, Old Program File, and New Zipped File

6. Double-click on this new *.zip file and extract it into the directory C:\Exatron\ where the previous program file was deleted. It has a newer date/time/version than the previous program file.

Figure 7-103: Exatron Directory with Job Files and New Program File

Typically a shortcut is placed into the C:\Documents and Settings\All Users\Start Menu\Programs\Startup directory so that this program will automatically launch when Windows is started. This shortcut must be replaced with a shortcut pointing to the new program file. 7. Right-click on the filename and select Create Shortcut from the context menu to make a shortcut for the new file.

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8. Click and drag the shortcut (not the original file!) into the directory C:\Documents and Settings\All Users\Start Menu\Programs\Startup. 9. Copy this shortcut to the desktop and delete the old shortcut. 10. Restart appropriate applications, or restart the CPU and the applications will automatically start. The new executable program file is ready to use. When an original .edf or .job file is opened using this new program file, you may see an error message: Unexpected file format. If this happens, it is because the new program file contains new data fields that require values from the job file, so the job file is not properly formatted.

Figure 7-104: Error Message

To reformat the job file: 1. Click OK in the error message dialog box. 2. Click the Diagnostics button and check the various windows for new fields. 3. Enter valid data in any new fields or input boxes. 4. Finally, save these settings before exiting the program. Bacause you have saved the new variable into this .edf or .job file, the next time you open this .edf or .job file, the Unexpected file format error will not appear.

Troubleshooting
The following are problems that have been encountered occasionally, and their solutions.

Motors Move Very Slowly


If the motors seem to be moving too slowly, reboot the computer.

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Tray Carriage Alignment Is Faulty

Tray Carriage Alignment Is Faulty


If the tray calibration is not holding, the tray carriage alignment may be loose. The first thing to do is test to make sure the X and Y leadscrews are tight in the system. With the power off and the covers open, push and pull on the tray carriages and the Y head. These should not move easily, and should only move when the lead screw turns. If the head or carriages can move, even a little, but the lead screw does not turn, then the lead screw is loose, which will cause serious misalignment problems. It is necessary to tighten the lead screws against the motor coupling. Fixing this problem is best left to a test technician or engineer. WARNING! Tighten lead screws only with the power off.

To tighten the lead screws: 1. Power down the entire system. 2. Using a #6 (7/64") hex driver (preferably without ball tip), loosen the screw on the motor coupling, accessible through the slots in the motor mounting bracket. > Loosen only the screw nearest the lead screw, not nearest the motor. 3. When that screw is loose, push on the lead screw, toward the coupling, to seat the lead screw tightly against the bearing mounted in the system wall. 4. With the lead screw tight against the coupling, tighten the coupling screw again. After doing this procedure, recalibrate the trays using the software diagnostics.

Tray Clamp Pins Fail to Secure Trays


If the tray clamp pins on a carriage fail to secure the trays, it may be because the tray does not lie flat on the carriage. To level a carriage: 1. Open the lower cabinet door and find the setscrews that hold the carriage columns in position. 2. Loosen the setscrew for the corner that does not seem to be level. (There are four setscrews for each carriage, one on each corner.)

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Carriage columns

Figure 7-105: Setscrews for Carriage Leveling

3. Adjust the height of the carriage column by the corner in question. 4. Retighten the setscrew.

System Does Not Pick Up Devices Reliably


If the system is not picking devices out of the input tray, there are several possible causes: Pickup height (Z get) is not set correctly in the Exatron Model 8000 software. > If a new type of device, or new brand or model of tray is used, the pickup height previously programmed may be wrong. Ideally, the bottom of the suction cup should be about .050" (1.2 mm) from the top of the device before the rub cycle. If the gap is significantly larger or smaller (.015" or more), then the software setting in the 8000 software should be adjusted accordingly. Vacuum cup is dirty or worn out. > Check the vacuum cup. Visually inspect the suction cup to make sure it is physically intact, i.e., no tears or chunks missing. Then, using a cotton swab dipped in isopropyl alcohol, clean the inside surface of the suction cup bellows. Vacuum adjustment is wrong. > The Model 8000 has a vacuum sensor that tells the system when a vacuum is detected, which means there is a part seated on and being held by the vacuum cup. The vacuum sensor has a small LCD display which shows the strength of the vacuum, as measured in centimeters of mercury (cmHg). The sensor is set at a given measurement, and when the actual vacuum measured in the sensor is higher than that number, it tells the system a part

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System Does Not Pick Up Devices Reliably

is captured. To determine the set point, flip the small switch on the vacuum housing to "SET." Then, with the switch back at "RUN," press the vacuum override button on the side of the handler near the vacuum sensor assembly. This will draw a vacuum and the sensor will show the measurement. Block the pickup head manually with a device to see that setting. The actual measurement should be at least 10 cmHg above the set point. You should see a red light illuminate on the vacuum sensor when a vacuum is measured at or above the set point. Typically, the set point will be around 50 cmHg and the actual measurement with a device present will be around 60 65 cmHg. If your numbers are significantly different than these numbers, you should carefully inspect the rest of the pneumatic system for blockages, breaks, etc., as explained next. Air lines blocked or broken/worn/disassembled. While unlikely, it is possible for the air lines to become broken, blocked, or otherwise rendered non-functional. This can happen due to wear, particulate or liquid contaminants in the air supply lines. > Check all air fittings to assure the air tubing is well seated in the fitting. > Visually inspect all the air lines and the incoming air regulator assembly for wear, discoloration or cracking. Replace any air line that appears compromised. Check for liquid in the reservoirs of the incoming air regulator. If either is full, you must remove the regulator from the system and drain the unit. Disconnect the incoming air supply and tip the unit to allow liquids to drain out. EXATRON STRONGLY RECOMMENDS REPLACING THE REGULATOR UNIT IF THIS PROBLEM HAPPENS MORE THAN ONCE. MOREOVER, THE CUSTOMER SHOULD ATTEMPT TO IMPROVE THE INCOMING AIR SUPPLY TO ASSURE IT IS CLEAN AND DRY. Blow-off is not working properly. In addition to creating the vacuum, the vacuum generator unit also acts as a regular air valve. The 8000 relies on this feature to send a blast of positive air pressure through the vacuum line in order to break the residual vacuum pressure after the vacuum is turned off. Without the blow-off, it is possible for devices to stick to the pickup head due to this residual vacuum. > Test the blow-off function by pressing the blow-off override button on the side wall of the handler base near the vacuum generator unit. A small positive air flow should be felt at the suction cup. If no pressure is felt, the unit may be malfunctioning or set too low. > A small adjustment screw can be found on the vacuum generator unit which will increase or decrease the blow off pressure. Care should be taken when adjusting this screw as loosening it will have the effect of increasing the blow off pressure, but if the screw is turned too much, it will come out and render the blow off inoperable. Refer to the vacuum generator unit manual

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included at the rear of this manual for a drawing of the location of the adjustment screw. Pickup head shaft is loose and out of position. > The pickup head shaft is retained by a clamp at the top of the Y gantry unit. If this clamp is loose, it is possible for the shaft to "migrate" up, thus eventually getting out of position. If this happens, the shaft can be pushed back down and re-tightened, or tightened in the new position and the various job software settings adjusted accordingly. The first course of action is preferable but must be done carefully. In most cases, the migration will be no more than .050" and so only a small adjustment must be made. If the adjustment makes the head too low, it may place unacceptable pressure on the devices in the trays. Thus, make a very small adjustment and test the new setting to see if it picks up devices. Watch carefully for over-travel.

System Noise When Y Gantry Moves


The Y gantry head moves very quickly during normal operation. If a banging or crashing noise is heard when this head moves (and more particularly when it stops at a new location), the problem is likely caused by the Y gantry lead screw being loose. The lead screw is machined down at both ends to allow it to pass through ball bearings. The screw is retained at one end by a ball bearing, and at the other by the motor coupling, after passing through a bearing mounted in the wall of the axis housing. The lead screw should be tight against the motor-end wall of the axis housing (i.e. at the motor end, you should not see any of the machined part of the lead screw on the inside of the wall). WARNING! Tighten lead screws only with the power off. With the power off, manually push and pull the Y lead screw in its axis of travel to see if it is loose; i.e. can the lead screw move away from the motor-end wall? If so, you must tighten it against the wall. First, loosen the motor coupling using a 7/64" (#6) hex head driver (DO NOT USE A BALL HEAD DRIVER). Loosen only the screw nearest the lead screw, not the motor. Access the screw head through the slots in the motor mount block. When the screw is loose, manually push the lead screw as hard as possible against the motor-end wall of the axis housing. WHILE MAINTAINING THIS PRESSURE, tighten the motor coupling screw. Recheck the lead screw to make sure it no longer moves away from the wall.

Software Responds With Error Message When Motor Commanded to Move


It is essential to power up the handler before opening the Exatron software, so the software can communicate with the hardware. If you use a software button to command a motor movement and nothing happens except an error message, the software has lost communication with the hardware. Perhaps the hardware was turned off after the software was started. The Model 8000 uses a hub for the linear motor servo controller. This allows communication with the motor through the ethernet rather than through a serial port. The hub can be used to hook up the handler to an internal network.

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Software Responds With Error Message When Motor Com-

Figure 7-106: Hub Connections

Figure 7-107: Servo Motor Driver Connections

If communication with the motors is lost, check that the plugs on both the hub and the servo motor drivers are securely in place. CAUTION: Do not change any settings on the servo motor drivers. They have been preset at the factory. If difficulties persist, call Exatron. Close the Exatron program and turn the computer and handler off and back on, following the sequences described in the sections "Powering Up the Handler System" on page 3-15 and "Shutting Down the Handler System" on page 3-18.

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Suspended Tray Falls Crooked


If a suspended tray falls at an angle between the stack and the carriage, it may be have one of several causes.

Figure 7-108: Tray Drop Error

One or more trays may have sticky tape residue on them. The delay between each stack step may not be long enough. The base delay should be at least 100 milliseconds. See "SettingsDelay Window" on page 4-25 for details. The stacker height may be incorrect. See "Calibrating Stacker Height" on page 4-46 for details. The lifter bars may be too far apart. See "Calibrating Lifter Bar Spacing" on page 4-49 for details.

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Chapter 8: Parts List


Chapter Overview
This chapter discusses the following main topics: Topic Obtaining Replacement Parts Guide to the Parts List List of Parts Page 8-1 8-4 8-7

Obtaining Replacement Parts


Spare parts can be obtained from Exatron. It has always been Exatron policy to support all the equipment we have ever manufactured. If the part is still available, or can be made, we will get it for you. In most cases, faxed requests and shipment of replacement parts orders are processed within twenty-four hours of receipt by Exatron. The following sections discuss things to note when ordering replacement parts.

Suction Cups
Exatron stocks three sizes of anti-static silicone suction cups for the Model 8000: 4 mm, 6 mm, and 8 mm diameter. The correct size for a given suction cup will depend on the size of the device. Choose a suction cup so that when the vacuum is applied the edge of the cup is at least .020" from any edge of the device (or leads if the device is dead-bug). Keep in mind to use the largest cup that fits this requirement. Exatron part numbers are: 2mm: PNE042-412 (Pisco No. VP2RSE) 4mm: PNE042-414 (Pisco No. VP4RSE) 6mm: PNE042-416 (Pisco No. VP6RSE) 8mm: PNE042-408 (Pisco No. VP8RSE)

The 2 and 4 mm cups fit over one mounting stud, while the 6 and 8 mm cups require a different stud. In most cases, Exatron systems ship with the correct stud for the 6 and 8 mm cups. These studs can be purchased separately, and come with either a 2 mm, 4 mm, or 6 mm cup attached. The part numbers are:

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Stud with 2 mm Cup: PNE042-402 (Pisco No. VPE2RSE) Stud with 4 mm Cup: PNE042-404 (Pisco No. VPE4RSE) Stud with 6 mm Cup: PNE042-406 (Pisco No. VPE6RSE)

Vacuum Generator Filter


The vacuum generator filter must be replaced when it is visibly dirty or contaminated. The Exatron part number is PNE022-020.

Z Chain
This is a 70-link hard plastic chain or belt. The Exatron part number is BEA12-003.

Hose Sizes
Hoses are ESD (electro-static discharged) for handler safety. The size is stamped on the hose: 5/32" or 1/8" or 1/4" or 3/8", to enable you to order the right size.

Relays
The mechanical relay (or contactor) inside the Exatron PC acts as a safety circuit; it cuts power when necessary. When changing out to a new one, make sure you order the right one, either 12 volt or 24 volt (Figure 8-1).

Figure 8-1: Relays12-Volt (Left); 24-Volt (Right)

Motor Controllers
When ordering Cool Muscle motors, be aware that master and slave motors are somewhat different. The master has a secondary circuit board piggybacked on top; the slave does not (Figure 8-2). Exatron recommends that you order a master, because you can use a master as a slave if it becomes desirable; but you cannot use a slave as a master.

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Motor Controllers

Figure 8-2: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Board

Figure 8-3: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations

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Notice that the jumper configurations are different for the master than for the slave. The slave has the black jumpers all the way to the left; the master has them all the way to the right (Figure 8-3). These jumper configurations can be changed just by pulling them off and replacing them on different pins.

Figure 8-4: Linear Motor Controller

Guide to the Parts List


This guide shows how to use the parts list to determine the exact part number of any custom part in your machine in order to replace it if necessary. The parts list contains those items that Exatron has custom manufactured. They include machined parts, sheet metal, printed circuit boards, cables, and standard vendor parts that have been modified by Exatron. A limited number of standard vendor parts are also listed here. The title at the top of the list indicates the type of parts list. This should match your system's hardware. The parts list may change as Exatron improves each model with each new generation. If you have different generations of the same model, the parts list will vary. Whenever possible, Exatron makes design improvements capable of being used in older versions of the same model. The date on the parts list indicates the date of the last revision of the list, not necessarily the last revision of the system hardware. An explanation of the column categories in the parts list follows.

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Exatron (Part Number)

Exatron (Part Number)


The first column contains the number assigned by Exatron to a specific part; for example, 8000-D14 or PET-R44. The part number usually has two sections or number/letter sets. The first set of alphanumeric characters (e.g. 1900, 8000, PET, TAPE) indicates the model number of the system for which the part was originally designed. We use designs of parts from different models to lower inventory costs and to speed the design of custom handlers. The next three alphanumeric characters (e.g. 906, C06, P14) are simply the numerical count of the part as it was designed. These are the three characters that are stamped or laser marked onto most machined parts. Exatron occasionally uses additional letters or numbers to indicate special features. We use R and L to specify right and left hand parts. AM or HR will indicate parts for Ambient Machines or Hot Rails. We use 62 or 75 to indicate specific sizes of solenoid plungers. There are other special notations that may be used as part of our numbering system and that may change with time. Please contact the Exatron factory for assistance with any questions regarding special letters or numbers attached to part numbers.

Part Quantity Columns


The next two or three columns indicate the quantity of the specific part used in the manufacture of this system. This information may be useful in determining the correct part number and was used to build an assembly kit when your system was originally built.

Manual
Each row that has a 1 in this column has a corresponding wiring print in this manual. The print is identified by the part number.

Description
This is the name assigned to the part. In most cases, this description will clearly designate the part you wish to locate. Please include this description when ordering replacement parts.

Assembly
This column indicates which major system sub-assembly the part belongs to. In most cases, the "Assembly" can be ordered as a complete replacement part.

Size
These are dimensions in inches. The dimesions are listed left to right from smallest to largest: A x B x C. This is the starting size of the part prior to being machined.

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C B A
Figure 8-5: Dimensions Listed From Smallest to Largest

Imagine a cube drawn around a part you are trying to identify. The dimensions of this cube can be checked against this size dimension and may be of assistance in determining a required part number. When the parts list indicates another Exatron part number in the size column, then the part was made by modifying an existing Exatron part. The modification is required for this handler only. When ordering replacement parts, be sure to use the part number and not the size. If the size column contains SEE PRINT, then the part is made from sheet metal or a PC board, or is something which is not made from a solid cube of material.

Finish
This column designates the finish used on the part. The following list is in alphabetic order. ALODINE: A non-anodic protective coating, a microscopic thin film commonly prescribed on aluminum to provide increased corrosion resistance and impose desired electrical resistance characteristics. BLACK: Black anodizing. BLUE: Blue anodizing. CLEAR: Clear anodizing, silver in color. HCR: Non-conductive, hard finish, dark green in color. NEDOX: Conductive, hard finish, silver in color, that eliminates static build-up and provides good electrical conductivity. Aluminum parts coated with nedox exhibit the hardness of steel without the weight. The finish protects against abrasive wear and corrosion. The dry-lubricated, non-stick surface also reduces friction of moving or sliding parts. NICKEL: Bright nickel plating, silver-chrome in color. NONE: No finish, natural material. PAINT: Painted part; colors may be beige, black or blue. RED: Red anodizing.

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List of Parts

Finish

List of Parts
A parts list specific to each handler is included with each manual. See the following inserted pages.

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Chapter 9: Prints
A set of prints specific to each handler is included with each manual. See the following inserted pages. Additionally, an optional seismic tie-down kit is available from Exatron (see Figure 9-1 on page 9-2). Call for a quote.

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Figure 9-1: PET-V84-B

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Appendix A: Test Interfaces


Chapter Overview
This chapter discusses the following main topics: Topic Components of Test Interfaces TCP/IP Interface TTL Handler Port Interface Serial Port Commands Exatron RS-232 Commands Exatron Plus RS-232 Commands Serial Commands for Multiple Test Sites with One Serial Port GPIB Test Interface Decimal-Hexadecimal-Binary-ASCII Conversion Table Setting Up HyperTerminal Page A-1 A-3 A-4 A-9 A-10 A-12 A-18 A-21 A-25 A-27

This information applies to both pick-and-place handlers and gravity-feed handlers. NOTE: All the interface types discussed in this chapter are options. No one interface type is included automatically. Whereas every handler has an RS-232 port and an ethernet port (hardware), the software drivers and the interfaces used for your handler will depend on your needs and the features you order.

Components of Test Interfaces


Every test interface has 2 parts: DUT Controllers

DUT InterfaceHardware
DUT (Device Under Test) interface connects the handlers test contacts to the testers test socket. A direct dock interface provides the best performance, although other interface methods are available.

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Control InterfaceMethod of Communication


The control interface allows the handler to send a Start to the tester and subsequently allows the tester to instruct the handler how to process the device under test. The means of access include: Exatrons TTL "Handler Port" An RS-232 serial port The tester sort signals will come into the handler via either the handler port or the RS-232 port. All the interface protocols discussed in this chapter are options. No one protocol is included automatically. Protocols available from Exatron include: TTL RS-232 RS-485 GPIB

Some factors to consider when selecting a protocol include: Serial cable RS-232 interfaces between only 2 entities, but RS-485 allows a daisy chain configuration among multiple entities. These two protocols use slightly different hardware. If a tester uses RS-485, it may not work with Exatrons RS-232. The GPIB language set is quite complex. Its customization for your needs requires a separate quote. The protocol for each handler is custom-designed for the handler and the tester it will use. There are many options that can be selected to customize this interface to your specific application. Each handlers interface is specific to that handler, but it is usually a variation of the RS-232.

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TCP/IP Interface

Control InterfaceMethod of Communication

Serial ports

Handler port
Figure A-1: Ports

In Figure A-1, the Handler Port uses TTL.

Distinguishing Features of Control Interfaces


Control Interface Port type/category of interface Number of pins/wires on connecter Communication type TTL 24 Hi/low signal (+5v/0v) TTL Serial 9 ASCII character string RS-232

TCP/IP Interface
With the TCP/IP protocol interface, the handler acts as the client, and the tester acts as the server. To use this interface, the tester software is opened first. The tester software waits for the Winsock connection over the ethernet from the handler software. After the tester software is running, the Exatron software is opened. The Exatron software connects through Winsock with the tester computer. They use standard serial commands.

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Appendix A: Test Interfaces

TTL Handler Port Interface


This interface is an option on Model 8000 handlers. It is not always installed. There are some other seldom-used options that might not allow this interface to be installed. If this interface is required, it should be installed while the handler is still at Exatron. The TTL Handler Port interface uses simple +5 volt TTL-compatible signals to control the handler. This specialized parallel port interface uses an optional 24-pin "D" connector on the back of the control PC (Figure A-2). It has been designed to be compatible with all Exatron gravityfeed Model 2000, 3000, 5000, and 6000 handlers.

Figure A-2: 24-Pin D Connector on Handler

The TTL Handler Port on a Model 8000 is connected inside the control PC to Port #3 on the 902 I/O PCB, PET-C06. On handlers with PET-C06 Rev A to Rev E, this Port #3 is not protected with opto-isolation. On these older revisions of PET-C06, use cable PET-G70-C which removes the handler +5 VDC from the 24-pin D connector. Connecting the handler's +5 VDC to the tester's +5 VDC is not allowed. Connecting the Tester +5 to the Handler +5 will result in a blown-up PET-C06 PCB, which is not covered by the handler's warranty. Handlers equipped with PET-C06 Rev F or newer I/O PCBs use an opto-isolated Port #3 (Figure A-3). It is highly recommended that when the TTL Handler Port interface is required, older handlers be upgraded. Handlers with opto-islated Port #3 use cable PET-H07-A or newer. The opto-isolated TTL interface will require tester-supplied +5 VDC and tester-supplied ground to be functional. Never connect the handler's +5 VDC or +24 VDC supplies to anything other than the handler.

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TTL Handler Port Interface

Start Test Output

Figure A-3: TTL 24-Pin Connector with Pin Designations

Start Test Output


The handler moves a device into the test site. After allowing time for the device to settle, the handler issues a start-test pulse (Pin 10) to the tester. The start-test pulse width is pre-set to 50 milliseconds. This pulse is normally High (+5) and goes Low for the pulse width. There are optional outputs that may or may not be used in special cases.

Sort Test Result


To complete the test, the tester must send back one of eight sort signals. These signals must be normally High and go Low for at least two milliseconds. The sorts must appear on Pin 1 through Pin 8 on the handler port connector. We recommend that you use Pin 1 for PASS and Pin 2 for FAIL when using the handler in PASS/FAIL applications. The Input Sort is connected to a latch. The latch sets on the falling edge of the sort signal. Make sure that your interface does not allow fast glitches which may become latched, causing the handler to mis-sort.

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Appendix A: Test Interfaces

End of Test
If desired, you can request an "End of Test" be added to your handler software. In this case, the End of Test signal will be connected to Sort 8 on the 24-pin D connector. The End of Test and just one of the other 7 sorts must be low at the same time, for at least 2 milliseconds.

Sort to Bin Selection


The setup window called Sort Interface (Figure A-4) or Tray Sort (Figure A-5) in the Exatron Diagnostics software defines which tester sorts are sent to which handler outputs that your handler is equipped with: trays, tubes, tape, or some other. See "SettingsTray Sort Window" on page 4-33 for more information on mapping each tester sort to a corresponding handler bin.

Figure A-4: Sort Interface Window

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TTL Handler Port Interface

Handler Port Diagnostics

Figure A-5: Tray Sort Window

Handler Port Diagnostics


The Setup Parameters window in the Exatron Diagnostics software allows the user to test the TTL handler port Inputs and outputs.

Handler Port Simulator


An optional 8-bit LED Checker (#3000-521; see Figure A-6) is available from Exatron that will allow the user to test the TTL Handler Port. This "blue box," as it is referred to at Exatron, will allow the user to test the handler I/O and can be used as a simulator. You can operate the handler without the tester connected. It also has LEDs connected to each input/output. This will help troubleshoot any interface problems. You can see the LEDs blink or not when a signal is either sent or received.

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Appendix A: Test Interfaces

Figure A-6: Eight-Bit LED Checker #3000-521

For PET-C06 Rev F I/O PCBs with opto-isolation, it is necessary to use an extension cable with the LED checker that allows the handler's +5 VDC and Ground to be connected.

Figure A-7: TTL 24-Pin Connector with Pin Designations

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Serial Port Commands

Handler Port Simulator

Serial Port Commands


Unless specifically requested, all RS-232 ports are set to: Alphabetic command Baud = 9600 Databits = 8 Stop bit = 1 Parity = N (none)

All commands are standard uppercase ASCII characters. Typically, a NULL modem, female/female, 9 pin RS-232 cable is required for each port. The testers should always include a "\r" carriage return after every command. The handler will send a "\r" after every response. The RS-232 serial ports use only 3 wires to transport ASCII, or serial strings: Send Receive Ground

Figure A-8: Typical RS-232 Interface Cable

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Appendix A: Test Interfaces

Exatron RS-232 Commands


NOTE: These are standard ethernet commands, used over an ethernet cable. The following is a definition of a standard RS-232 control interface from an Exatron handler to one or more testers. Each tester is controlled by its own RS-232 port, thus: 1 tester = 1 port, 2 testers = 2 portsup to 16 ports. This interface can also be used by a single tester with multiple test sites. Using separate RS-232 ports for each test site makes it very easy for the handler to keep track of the status of each test site. For single testers using only one RS-232 port, but with multiple test sites, Exatron has a different RS-232 command set. See "Serial Commands for Multiple Test Sites with One Serial Port" on page A-18.

Beginning the Connection


Once the handler is powered up, all motors homed, and a job is loaded, the operator can start the handler. The handler will send a "H\r" before it picks up the first device to be tested. The tester should respond with a "R\r" if it is completely ready to start testing. Handler sends to the tester: "H\r" (Handler ready to cycle) Tester sends back: "R\r" (Tester is ready to test) > If nothing is received back from the tester, the handler will time out and display an error message. The operator should check that the tester is in fact ready to test and that all cables are properly plugged in. > If the tester sends back an unrecognized answer, the handler will display an error message, and if possible, display what was sent by the tester. Tester sends: "EOL\r" (Command to stop getting device from input; this is optional command) Handler sends: "EOL\r" (Signal that handler finished getting device from input; this is optional command)

Starting the Test


Once the handler receives the "R\r", the handler will pick up a device and place it in the test socket. Once the device is fully clamped in the test socket, the handler will send a "S\r". The tester should start its test.

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Exatron RS-232 Commands

After the Test Is Completed

After the Test Is Completed


Once the tester has completed its test of a device, it needs to send back a Sort Command. The handler will accept up to 8 sorts from the tester. Typically a sort "1\r" is a pass and all other sorts are types of fails. Exactly which sorts mean pass/fail/tape/tube/bucket outputs depend on the options your handler is equipped with. Use the handler's setup software to define the meanings of each sort for your specific application. "1\r" "2\r" "3\r" "4\r" "5\r" "6\r" "7\r" "8\r" = = = = = = = = Sort #1 Sort #2 Sort #3 Sort #4 Sort #5 Sort #6 Sort #7 Sort #8

Once the handler receives the sort command from the tester, the handler picks up the now tested device and sorts it to the predetermined output. This completes a normal test cycle. The handler will move over the next untested device to be picked up and sends a "H\r" to the tester and a new cycle is started. Handler sends: "INPUT_TRAY_EMPTY\r" (Handlers input is empty; it displays message to load more devices)

Cycle Summary
For each cycle, the following exchange occurs. Handler sends: "H\r" (Cycle?) Tester sends: "R\r" (Ready) Tester sends: "EOL\r" (Stop getting device from input) Handler sends: "EOL\r" (Finished getting device from input) Handler sends: "S\r" (Start test) Tester sends: "1\r" (Sort 1) or "2\r" (Sort 2) or "3\r" (Sort 3) or "4\r" (Sort 4) or "5\r" (Sort 5) or "6\r" (Sort 6) or "7\r" (Sort 7) or "8\r" (Sort 8)

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Exatron Plus RS-232 Commands


The Exatron Plus interface is an extension of the standard EXATRON RS-232 interface. The user will be able to select either Exatron or Exatron Plus interface. If you want to implement the Exatron Plus interface, contact Exatron at 800-EXA-TRON. In addition to the command exchange explained under "Exatron RS-232 Commands" on page A-10, the Exatron Plus interface will have the following enhancements:

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Exatron Plus RS-232 Commands


Command Meaning Remote reset Explanation At any point the tester can send a "*\r". When the handler receives an asterisk it will immediately stop its current operations. The handler resets as if the handler has just powered up. Any devices in any of the test sites will be automatically removed and placed in the Dump tray. The handler is equipped with a dump tray on the end of the first X1 tray. The tester can send a "?\r", to the handler to cause the handler to place the tested device in the dump tray. No count is maintained for the dump tray. The operator also needs to keep the dump tray empty to prevent devices from piling up on one another. The dump tray is basically a bucket sort. If at any time a retest is required by the tester, the tester can send back a "0\r". The Handler sends: S\r" (Start test) handler will do one of the following, depending on the type of test socket being used: Tester sends: 0\r" (Retest with mechanical Pick up the device and reseat it socket cycle) Open and close the open top socket, or Cycle the hold-down plunger Handler sends: S\r" (Start test) Tester sends: 0\r" (Retest with mechanical The handler will then send a new "S\r" command to the tester. This cycle can be socket cycle) done over and over as many times as required by the tester. The handler will not Handler sends: S\r" (Start test) sort the tested device until a correct sort command is received. Tester sends: 1\r" (Sort 1) (Sort the nowtested device)
Appendix A: Test Interfaces

Example

Send to dump tray sort

0\r

Remote retest sort

9\r

Return to If the handler receives a "9\r" for a test sort, the handler will return the device to the pickup sort exact pocket it was picked up from. If the pocket to return to already has a device, which is remotely possible in some configurations, the device will be sorted to the dump pocket on the end of tray #1. Pause han- At the start of any cycle, the tester can send a Pause command to the handler. Handler sends: H\r" (Cycle?) When the handler receives a "P\r", the handler will stop cycling and post a message Tester sends: P\r" (Pause handler) dler to the operator. The handler will remain paused until the operator restarts the handler's operation from the handler's control panel. Once the handler is restarted, it will continue with its operations from the point it left off.

P\r

Exatron Plus RS-232 Commands


Command Meaning Z\r Zero all counts Explanation Example

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At the start of any cycle, the tester can send a zero all counts command to the han- Handler sends: H\r" (Cycle?) dler. This command is typically to be used at the start of a new lot of devices. The Tester sends: \r" (Zero counts) handler will send "H\r" to the tester. The tester will send back a "Z\r" to the handler. The handler will stop and display an Are you sure message to the operator. The operator will be given the opportunity to either reset all counts to zero or to continue on with the cycle with counts saved from the previous cycle. The handler will also give the operator an opportunity to reload or replace any trays of devices in the handler.

X\r

Disable socket

This is a way to have the handler "skip" any combination of test sockets, on the fly, Handler sends: "H\r" (Cycle?) when testing with more than one test socket. Tester sends: "X\r" (Skip cycle) The handler will move on to the next cycle for The handler will send a "H\r" at the start of each subsequent cycle. To permanently the next test site. have the handler skip a test site requires changing the handler's set up before starting any test cycles. This command allows the tester to remotely send the handler into an end-of-lot Handler sends: "H\r" (Cycle?) cycle. The handler can also be sent to an end-of-lot cycle from its control panel by Tester sends: "E\r" (End Of Lot, stop cycle) the operator. Handler sends to the tester: "H\r" (Handler ready to cycle). The tester sends back a "E\r" (End Of Lot) The handler will go into its end-of-lot cycle. On single test site handlers, the handler will simply stop testing and display the End Of Lot message to the operator. On handlers with multiple test sites, the handler will stop loading untested devices. It will then either: Automatically remove any devices still being tested and return them to the same place they were picked up from, or Finish any devices still being tested and sort as required. The user can go to the handler's set up to select one of these two options for end-oflot test socket unloading. Once all sockets are emptied the handler will display the End Of Lot message to the operator and stop cycling. If the operator should go to end-of-lot from the handler control, the handler will stop loading untested devices. It will then do one of the two things just described. The user can go to the handler's setup to select one of these two options for end-of-lot test socket unloading. Once all sites are empty, "E\r" will be sent by the handler to every test site. No response is required back from any of the testers.

E\r

End of lot

Cycle Summary

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Exatron Plus RS-232 Commands


Command Meaning G[a][n]\r Explanation Example Handler sends: "H \r" (Cycle?) Tester sends: "GA1\r" (Test Golden Unit from pocket A at test site 1)

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Golden Unit If the handler is set up with a Golden Unit Tray Option, this exchange is used. cycle The handler sends the preliminary handshake: "H\r". The tester sends a response like "GC2\r" specifying the source pocket from which to get the Golden Unit, and the destination test site into which to put it.

(The unit specified may be any Golden Unit from A to G, and may be designated for any The handler picks up a device and places it in the test socket specified by the tester. test site available, thus: GA2, GG1, GF2, etc.) Once the device is fully clamped in the test socket, the handler sends a command to start testing that designates the same test site requested by the tester, like "S2\r". Handler places unit, sends: "S1" (Start testing at test site 1) Once the tester has completed its test, it needs to send back a Sort command, like "1\r" or "7\r". The handler accepts any of 8 sorts from the tester. The handler then Tester finishes test, sends sort result: picks up the device and places it back in the pocket where it was picked up, regard- "1\r" less of the sort received from the tester. This completes a Golden Unit test cycle. Handler retrieves unit into original pocket. The cycle repeats, beginning with the tester sending another source-to-destination command, like "GD1\r". Tester sends another test request: "GB2" The handler can be commanded to pick up any device, from any pocket, from any input tray. This is an option that must be selected prior to cycling the handler. The handler will normally pick untested devices from the first left hand pocket of an input tray and then automatically index to the next pocket or tray until all input pockets are emptied or until the handler reaches a predetermined number of empty pockets in a row. Handler sends: "H \r" (Cycle?) Tester sends string: "T ## _ R # # _ C # #\r" where: T (Tray) # (Tray carriage number, 1 to 5) # (Sub Trayuse 0 for JEDEC trays; use 1 to 8 for 2"/4" waffle packs) The user must select either sequential input pick up or "Pick Up Specific _ (Underscore) Device" prior to cycling the handler. The two choices cannot be intermixed in R (Row) a given setup. Either the handler is in control or the tester is in control. # (Row number, use 0 for rows 1 thru 9) # (Row number, 1 to 9) The handler will go to the specified pocket and attempt to pick up the device. If a _ (Under score) device is found the device will be loaded into the test socket and a test cycle will be C (Column) started. If no device is found, the handler will pause, display an error message, and # (Column number, use 0 for column 1 thru 9) then automatically return to the start of the next cycle. # (Column number, 1 to 9) \r (End of string) At the end of test, the tester can either send the now-tested device back to the pocket it was picked from, or sort it normally. See the above sort commands for details.

T ## _ R # Pick up # _ C # #\r specific device

Appendix A: Test Interfaces

Exatron Plus RS-232 Commands


Command Meaning TRAY <SP> FULL\r Explanation Example

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Output tray At some point the handler output tray(s) will reach its last pocket. The handler will full stop and display a message to the operator. The handler will also be at the start of the next cycle at this point. The handler will send: "TRAY <SP> FULL\r" to the next test socket to be loaded. No answer is required from the tester. This string will be sent only to the next test socket/tester. The operator will be given several choices at this point: The operator can choose to go into an end-of-lot cycle as described above. The operator can reload empty tray(s) as required. Then a new cycle can be started by the operator. A new "H\r" will be sent to the test socket/tester. Output tape Some handlers are equipped with optional output tape-and-reel assemblies. At full some point the taper will reach its preset full count. The handler will stop and display a message to the operator. The handler will also be at the start of the next cycle at this point. The handler will send: "T A P E <SP> F U L L\r" to the next test socket to be loaded. No answer is required from the tester. This string will be sent only to the next test socket/tester. The operator will be given several choices at this point. The operator can choose to go into an end-of-lot cycle as described above. The operator can reload new supplies or a new empty reel as required. Then a new cycle can be started by the operator. A new "H\r" will be sent to the test socket/tester. Output tube Some handlers are equipped with optional output tube holders. At some point the full tube(s) will reach its preset full count. The handler will stop and display a message to the operator. The handler will also be at the start of the next cycle at this point. The handler will send: "T U B E <SP> F U L L\r" to the next test socket to be loaded. No answer is required from the tester. This string will be sent only to the next test socket/tester. The operator will be given several choices at this point. The operator can choose to go into an end-of-lot cycle as described above. The operator can reload new empty tubes as required. Then a new cycle can be started by the operator. A new "H\r" will be sent to the test socket/tester.

TAPE <SP> FULL\r

TUBE <SP> FULL\r

Cycle Summary

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Command Meaning Explanation Example

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S ## _ R # Device out- The handler can be preset to attach the output sort location of each device just after TRAY outputs example: # _ C # #\r put sort the device is placed in its output. This option must be turned on or off in the hanS12_R01_C23\r location dler's setup prior to cycling. S (Sort) # (Tray carriage number, 1 to 5) After the handler drops off a tested device into the tray, it can be preset to send back # (Sub Trayuse 0 for JEDEC trays; use 1 to the following string "S ## _ R # # _ C # #\r". See example for bucket, tape & reel, 8 for 2'/4" waffle packs) and output tube sorting responses. _ (Underscore) R (Row) No response is required back from the tester for any of these messages. The han- # (Row number, use 0 for rows 1 thru 9) dler then moves on to the next cycle. # (Row number, 1 to 9) _ (Underscore) C (Column) # (Column number, use 0 for column 1 thru 9) # (Column number, 1 to 9) \r (End of string) BUCKET outputs example: B1\r B (Bucket) # (Bucket number) \r (End of string) TAPE-AND-REEL outputs example: T256\r T (Tape) # (current pocket count) # # # \r (End of string)

Appendix A: Test Interfaces

OUTPUT TUBE outputs example: O3_15\r O (Output tube) # (Tube number) _ (Under score) # (current pocket count) # # \r (End of string)

Exatron Plus RS-232 Commands

Command Set Summary

Command Set Summary


If at any time the tester sends: " *\r" (remote handler reset) Cycle start: Handler sends: "H\r" (Cycle?) Tester sends: "R\r" (Ready; handler then begins normal cycle) or Tester sends: "P\r" (Pause handler) or Tester sends: "E\r" (End Of Lot, stop cycle) or Tester sends: "X\r" (Skip cycle/test site) or Tester sends: "Z\r" (Zero counts) or Tester sends: "GA1\r" (Test Golden Unit A at test site 1) GB[n]\r" (Test Golden Unit B at designated test site) GC[n]\r" (Test Golden Unit C at designated test site) GD[n]\r" (Test Golden Unit D at designated test site) GE[n]\r" (Test Golden Unit E at designated test site) GF[n]\r" (Test Golden Unit F at designated test site) GG[n]\r" (Test Golden Unit G at designated test site) or Tester sends: "T ## _ R # # _ C # #\r" (Pick up specific device) Test cycle: Handler sends: "S\r" (Start test) Tester sends: "1\r" (Sort 1) "2\r" (Sort 2) "3\r" (Sort 3) "4\r" (Sort 4) "5\r" (Sort 5) "6\r" (Sort 6) "7\r" (Sort 7) "8\r" (Sort 8) "9\r" (Return to pick up) "0\r" (Remote retest) "?\r" (Send to dump tray; no count is maintained for dump tray) At device output drop off/sort: Nothing is sent back to the tester as a standard setup.

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No response is required back from the tester. Other possible handler start of cycle messages: Note: none of these messages require a response back from the tester. "TRAY FULL\r" "TAPE FULL\r" "TUBE FULL\r" "E\r" (End Of Lot)

Serial Commands for Multiple Test Sites with One Serial Port
This interface is an extension of the standard EXATRON RS-232 interface. NOTE: If you want to implement this interface, contact Exatron at 800-EXA-TRON. This interface requires optional test site hardware and software. In addition to the command exchange explained under "Exatron RS-232 Commands" on page A-10, this interface has the following enhancements:

Command Set Summary


Cycle Start: Handler sends: "H\r" (Cycle?) Tester sends: "R\r" (Ready, handler begins normal cycle) Handler sends: "S1\r" (Start test site 1) Handler sends: "E1\r" (Request for end-of-test result from site 1) Tester sends: "1B\r" (Test site 1 busy) > If testers reply is busy, the handler pickup nozzle moves to another test site and sends another "E[n]\r" request; for example, "E2\r". > The handler will later issue a new "E1\r" when the pickup nozzle has moved back to test site #1 and is ready to sort test site #1. If test site #1 is not busy, it sends one of the following signals. Tester sends: "11\r" (Site 1 sort 1) or "12\r" (Site 1 sort 2) or "13\r" (Site 1 sort 3) or "14\r" (Site 1 sort 4) or

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Serial Commands for Multiple Test Sites with One Serial Port

Command Set Summary

"15\r" (Site 1 sort 5) or "16\r" (Site 1 sort 6) or "17\r" (Site 1 sort 7) or "18\r" (Site 1 sort 8) or Tester sends: "10\r" (Retest test site 1) Note that the tester can send a result only from the test site queried by the handler. For example, if the handler request is "E4\r" for test site 4, then the response must be from test site 4. The interchange would be as follows: Handler sends: "S4\r" (Start test site 4) Handler sends: "E4\r" (Request for end-of-test result from site 4) Tester sends: "4B\r" (Test site 4 still busy; handler pickup nozzle then moves to another test site) or Tester sends: "41\r" (Site 4 sort 1) or "42\r" (Site 4 sort 2) or "43\r" (Site 4 sort 3) or "44\r" (Site 4 sort 4) or "45\r" (Site 4 sort 5) or "46\r" (Site 4 sort 6) or "47\r" (Site 4 sort 7) or "48\r" (Site 4 sort 8) or Tester sends: "40\r" (Retest test site 4) As the handler is at various times in a mechanical position to remove devices from any of the test sites, the handlers start test and its request for test results may not be in the order of E1, E2, E3, E4. Rather, the requests may come in any order: E3, E2, E4, E1. The reply from the tester must be concerning the test site specified by the handlers request.

Multiple Sockets in Multiple Sites


An option for testers with multiple sockets in multiple sites is the handlers specifying of which sockets contain devices. This is accomplished by a string of numerics after the starting "S"; for example, "S210\r". The digit on the left signifies the test site; the second digit signifies socket 1. The third digit signifies socket 2, the fourth digit signifies socket 3, etc. A 1 means "true"; there is a device in the socket. A 0 means "false"; there is no device in the socket. Handler sends: "S111\r" (Site 1 holds devices in sockets 1 and 2) or "S110\r" (Site 1 holds a device in socket 1 but not in socket 2) or "S101\r" (Site 1 holds no device in socket 1, but there is a device in socket 2) or "S211\r" (Site 2 holds devices in sockets 1 and 2) or

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"S210\r" (Site 2 holds a device in socket 1 but not in socket 2) or "S201\r" (Site 2 holds no device in socket 1, but there is a device in socket 2)

Request for Tester Results


When the handler is ready to read the test result, it sends a request to the tester for the results, and the tester responds. Handler sends to the tester: "E1\r" (Request for result from test site 1) > If the tester is still busy testing, it sends back: "R1B\r" (Site 1 is still busy) or "R2B\r" (Site 2 is still busy) Tester sends: "R10\r" (Requested sites socket 1 result is sort 1; socket 2 holds no device) or "42\r" (Site 4 sort 2) or "43\r" (Site 4 sort 3) or "44\r" (Site 4 sort 4) or "45\r" (Site 4 sort 5) or "46\r" (Site 4 sort 6) or "47\r" (Site 4 sort 7) or "48\r" (Site 4 sort 8) or

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GPIB Test Interface

If the Tester Controls the Testing

GPIB Test Interface


The GPIB interface is similar to the handler port interface, but it is smarter, with multiple commands. Each socket position is represented in hexadecimal numbering. See "Decimal-Hexadecimal-Binary-ASCII Conversion Table" on page A-25 for details. This interface allows for up to 32 test sockets, with each position represented by "A" or a number in a string of 32 characters separated into 4 groups of 8 bits by commas. Notation \r \n A [ ] Meaning Carriage return Line feed Null value as placeholder Substitute correct value; not literal

The beginning and ending interface commands for both tester-controlled and handler-controlled temperatures are the same. With tester-controlled, the testers setting of test temperature, the testers request for tested temperature, and the handlers supplying of tested temperature are added in the middle. The determination of whether the tester or handler controls the testing may be made on the Work Mode window in Settings (Figure A-9).

Figure A-9: Work Mode Window in Settings

If the Tester Controls the Testing


Once the handler is powered up, all motors homed, and a job is loaded, the operator can start the handler. The following is the exchange for just one device. (The \r dictates a carriage return.) Handler sends to the tester: H\r (Handler ready to cycle)

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Tester sends back the location of the device to be tested: R\r (Regular device; handler should get device from tray) or... A\r (handler should get device from Golden Part A pocket) or... B\r (handler should get device from Golden Part B pocket) or... C\r (handler should get device from Golden Part C pocket) Handler sends: S\r (Handler has gotten device from specified location & requests which thermal head to use at what temperature.) Tester specifies which thermal head and what testing temperature (in Celsius) to use: Set_Temp##_R\r (Room-temperature head; temperature is irrelevant) or... Set_Temp##_C\r (Cold head with temperature) or... Set_Temp##_H\r (Hot head with temperature) Handler sends: Ok\r (Handler has clamped device with specified thermal head and applied specified temperature.) Tester sends Read_Temp?\r (Request for heads temperature.) Handler sends: Temp##.##\r (Handler sends temperature with two decimal places.) At this point, if the thermal heads temperature is outside the range of tolerance, the tester will repeat the request for the heads temperature until it is within the range. Then, if the device passes the test, the tester may ask the handler to test the same device with another thermal head; and the cycle repeats, starting with the testers command Set_Temp##_[C/H/R]. At the end of the testing cycle of one device, or when it has failed a test, the tester gives the sort category: Tester sends: Bin[1-8]. This completes the test cycle for one device.

If the Handler Controls the Testing


Again, the following is the exchange for just one device. (The \r dictates a carriage return.) Handler sends to the tester: H\r (Handler ready to cycle)

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GPIB Test Interface

If the Handler Controls the Testing

Tester sends back the location of the device to be tested: R\r (Regular device; handler should get device from tray) or... A\r (handler should get device from Golden Part A pocket) or... B\r (handler should get device from Golden Part B pocket) or... C\r (handler should get device from Golden Part C pocket) Handler sends: S\r (Handler has gotten device from specified location & decides which thermal head to use at what temperature.) Tester sends: Bin[1-8]. (Tester has tested the device at the specified temperature and sends the sort result.) This completes the test cycle for one device. Exatron uses hexadecimal as an easy way of representing binary. It allows the transmission of an instruction of 2 digits rather than an instruction of 8 digits. The handler decodes the hex instructions into a binary map. Each hex character represents 4 binary digits and 4 sockets. The numbers represent the following outputs. In binary notation, 1 = TRUE and 0 = FALSE. So only the columns, or sockets, with 1s receive devices.

Comparison of Number Systems


Hexadecimal 00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 Binary 0000 0000 0000 0001 0000 0010 0000 0011 0000 0100 0000 0101 0000 0110 0000 0111 0000 1000 0000 1001 0000 1010 0000 1011 0000 1100 0000 1101 0000 1110 0000 1111 0001 0000 Result No device in any socket. Devices in socket 1 only. Devices in socket 2 only. Devices in sockets 1 and 2. Devices in socket 3 only. Devices in sockets 1 and 3. Devices in sockets 2 and 3. Devices in sockets 1 through 3. Devices in socket 4 only. Devices in sockets 1 and 4. Devices in sockets 2 and 4. Devices in sockets 1, 2, and 4. Devices in sockets 3 and 4. Devices in sockets 1, 3, and 4. Devices in sockets 2 through 4. Devices in sockets 1 through 4. Devices in socket 5 only.

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Comparison of Number Systems


Hexadecimal 20 30 40 FF FFF9 Binary 0010 0000 0011 0000 0100 0000 1111 1111 Result Devices in socket 6 only. Devices in sockets 5 and 6. Devices in socket 7 only. Devices in sockets 1 through 8. Devices in sockets 1 through 14.

Lets suppose that devices are in sockets 1-4, 7, and 8; but not in sockets 5 and 6. The hex value sent by the handler is CF. The binary code into which the tester would translate this is shown in the bottom row, following. Notice that each bin designated as yes, put here, has a 1 for TRUE.
Socket 8 1 Socket 7 1

Socket 6
0

Socket 5 0

Socket 4 1

Socket 3 1

Socket 2 1

Socket 1 1

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Decimal-Hexadecimal-Binary-ASCII Conversion Table

If the Handler Controls the Testing

Decimal-Hexadecimal-Binary-ASCII Conversion Table


Decimal
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
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Hex
00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 11 12 13 14 15 16 17 18 19 1A 1B 1C 1D 1E 1F 20 21

Binary
0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 1110 1111 0001 0000 0001 0001 0001 0010 0001 0011 0001 0100 0001 0101 0001 0110 0001 0111 0001 1000 0001 1001 0001 1010 0001 1011 0001 1100 0001 1101 0001 1110 0001 1111 0010 0000 0010 0001

ASCII

Decimal
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65

Hex
22 23 24 25 26 27 28 29 2A 2B 2C 2D 2E 2F 30 31 32 33 34 35 36 37 38 39 3A 3B 3C 3D 3E 3F 40 41 42 43

Binary
0010 0010 0010 0011 0010 0100 0010 0101 0010 0110 0010 0111 0010 1000 0010 1001 0010 1010 0010 1011 0010 1100 0010 1101 0010 1110 0010 1111 0011 0000 0011 0001 0011 0010 0011 0011 0011 0100 0011 0101 0011 0110 0011 0111 0011 1000 0011 1001 0011 1010 0011 1011 0011 1100 0011 1101 0011 1110 0011 1111 0100 0000 0100 0001 0100 0010 0100 0011

ASCII
" # $ % & ( ) * + , . / 0 1 2 3 4 5 6 7 8 9 : ; < = > ? @ A B C

Space !

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Decimal
68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103

Hex
44 45 46 47 48 49 4A 4B 4C 4D 4E 4F 50 51 52 53 54 55 56 57 58 59 5A 5B 5C 5D 5E 5F 60 61 62 63 64 65 66 67

Binary
0100 0100 0100 0101 0100 0110 0100 0111 0100 1000 0100 1001 0100 1010 0100 1011 0100 1100 0100 1101 0100 1110 0100 1111 0101 0000 0101 0001 0101 0010 0101 0011 0101 0100 0101 0101 0101 0110 0101 0111 0101 1000 0101 1001 0101 1010 0101 1011 0101 1100 0101 1101 0101 1110 0101 1111 0110 0000 0110 0001 0110 0010 0110 0011 0110 0100 0110 0101 0110 0110 0110 0111

ASCII
D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] ^ _ a b c d e f g

Decimal
104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139

Hex
68 69 6A 6B 6C 6D 6E 6F 70 71 72 73 74 75 76 77 78 79 7A 7B 7C 7D 7E 7F 80 81 82 83 84 85 86 87 88 89 8A 8B

Binary
0110 1000 0110 1001 0110 1010 0110 1011 0110 1100 0110 1101 0110 1110 0110 1111 0111 0000 0111 0001 0111 0010 0111 0011 0111 0100 0111 0101 0111 0110 0111 0111 0111 1000 0111 1001 0111 1010 0111 1011 0111 1100 0111 1101 0111 1110 0111 1111 1000 0000 1000 0001 1000 0010 1000 0011 1000 0100 1000 0101 1000 0110 1000 0111 1000 1000 1000 1001 1000 1010 1000 1011

ASCII
h i j k l m n o p q r s t u v w x y z { | } ~

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Setting Up HyperTerminal

Configuring a Connection Session

Setting Up HyperTerminal
You can set up HyperTerminal in MS Windows as a way of testing communication between the Exatron handlers CPU and a tester. HyperTerminal emulates the communication protocol used by the tester, and displays the results of checking this communication. NOTE: You cannot use the Exatron program while you are using HyperTerminal. Before you open HyperTerminal, close the Exatron software. Each message is in uppercase ASCII characters, followed by a carriage return. This ensures that all cables are secure and all communication is taking place.

Configuring a Connection Session


To set up a new connection session in HyperTerminal: 1. Click the Windows Start button, and select Programs Accessories Communications HyperTerminal.

Figure A-10: Getting to HyperTerminal

> A brief splash screen is displayed. Wait a second for the window to appear.

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> On some systems, an intermediate window may appear. If so, double-click the HYPERTRM.EXE program icon to open the program. If not, go to the next step.

Figure A-11: Opening the HyperTerminal Program

2. In the Connection Description dialog box, type a name for your new connection, and click an icon to identify it. Click OK.

Figure A-12: Naming a New Connection

3. In the Connect To dialog box, click the drop-down arrow by the Connect Using

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Configuring a Connection Session

box. Select the COM port you want to use. Click OK.

Figure A-13: Selecting the Connection

4. In the Properties dialog box, make the selections as shown in Figure A-14. Click OK.

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Figure A-14: Selecting the Port Settings

If your typed commands are not reflected onscreen, you can change the settings to display them. To display commands typed in HyperTerminal: 1. In the main window, click the Properties button.

Figure A-15: Getting to Connection Properties

2. In the Properties dialog box, under the Settings tab, click the ASCII Setup button.

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Setting Up HyperTerminal

Configuring a Connection Session

Figure A-16: Getting to ASCII Setup

3. In the ASCII Setup dialog box, check the Echo typed characters locally box to display what you type onscreen. 4. Check Send line ends with line feeds and Append line feeds to incoming line ends to continue displaying what was typed previously. (Thus you can scroll up to view the record, or history, of commands.)

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Figure A-17: Displaying Typed Commands Onscreen

5. Click OK. 6. Click OK in the other dialog box. 7. Save your session configurations.

Testing Communication Between Handler and Tester


HyperTerminal displays communication between handler and tester. To test communication between handler and tester: 1. Ensure the tester is turned on and ready. 2. Turn on the handler and get it ready. 3. Open HyperTerminal on the Exatron CPU. 4. Click the Call button to ensure they are connected.

Figure A-18: Using Call to Connect

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Testing Communication Between Handler and Tester

5. Press H (always use capitals) on the handler keyboard. > The tester should send an R that is displayed in HyperTerminal. If so, you know that the serial ports between the two machines are connected correctly. 6. Press S on the handler keyboard. > The tester should send a sort number, such as 0, that is displayed in HyperTerminal. If so, you know that the communication is working correctly. 7. To disconnect, click the Disconnect button.

Figure A-19: Disconnecting

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Appendix B: System Backup and Recovery


Chapter Overview
This chapter is a quick guide to backing up and restoring the contents of the handler computer, using Acronis True Image software. For more information, see the Acronis Users Guide included on the Acronis software disk. This chapter discusses the following main topics: Topic Setting a Computer to Boot from CD-ROM Creating a Secure Zone on the Hard Disk Backing Up a Hard Disk Copying Archive Files to CDs or DVDs Restoring a Disk or Partition Backup from CD-ROM Restoring a Backup Under Windows Page B-1 B-6 B-15 B-28 B-28 B-40

Setting a Computer to Boot from CD-ROM


Your computer may well be already set up to boot from a CD-ROM if a bootable CD is in the drive at bootup. If not, you can set it to boot from CD-ROM this way. To set the computer to boot from the CD-ROM drive: 1. Turn on the computer and watch carefully during the bootup process for your chance to enter Setup. 2. Press the significant key (usually the <Delete> key) during bootup. > The CMOS Setup Utility is displayed (Figure B-1).

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Figure B-1: CMOS Setup Opened to Main Menu

3. Press the right arrow key to select the Advanced menu (Figure B-2).

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Setting a Computer to Boot from CD-ROM

Figure B-2: CMOS Setup Changed to Advanced Menu; Advanced BIOS Features Selected

4. Press the up or down arrow key to select Advanced BIOS Features. 5. Press the Enter key to enter Advanced BIOS Features (Figure B-3).

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Figure B-3: Advanced BIOS Features Screen

6. Press the down arrow key repeatedly until the Second Boot Device line is selected (Figure B-3). 7. Press the Enter key to change its value.

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Setting a Computer to Boot from CD-ROM

Figure B-4: Selecting CD-ROM Drive as Boot Device

8. Press the down arrow key repeatedly until the CDROM line has the square selection mark (Figure B-4). 9. Press the Enter key to confirm this selection.

Figure B-5: CD-ROM Drive Selected as Boot Device

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10. Press the F10 key to save your settings.

Figure B-6: Saving Changes

11. Press the Enter key to save and exit (Figure B-6).

Creating a Secure Zone on the Hard Disk


The Acronis Users Guide says, "The Acronis Secure Zone is a special hidden partition for storing archives on the computer system itself. For archive security purposes, ordinary applications cannot access it....Acronis Secure Zone is necessary for using Acronis Startup Recovery Manager and Acronis Snap Restore features." (page 13) This feature is useful if you have the space on your hard disk for the backup. If not, you can back up to portable storage media instead. In that case, skip to the next section, "Backing Up a Hard Disk" on page B-15. To create the Secure Zone: 1. Make sure there is no floppy in the floppy drive. 2. Open Acronis by double-clicking its icon on the desktop.

Figure B-7: Acronis Program Icon

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Figure B-8: Acronis Main Window

The Acronis main window opens.

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Figure B-9: Manage Acronis Secure Zone Button

3. Click the Manage Acronis Secure Zone button at the upper left (Figure B-9).

Figure B-10: Manage Acronis Secure Zone WizardWelcome

4. Click the Next button (Figure B-10).

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Creating a Secure Zone on the Hard Disk

Figure B-11: Creating Secure Zone in Unallocated and Free Space

5. Click to place a checkmark and select the disk or partition where you want to create the Secure Zone (Figure B-11). 6. Click the Next button.

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Figure B-12: Specifying Size of Secure Zone

7. Specify the size of the Secure Zone, either by clicking on and dragging the slider, or by typing the size in the Partition size box (Figure B-12). NOTE: It is recommended that you use approximately one-third of the drive size, or 33%, for the Secure Zone. 8. Click the Next button.

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Figure B-13: Activating Acronis Startup Recovery Manager

This allows you to press the F11 key during startup to activate the Recovery Manager.

Figure B-14: Alternate SelectionDo Not Activate Acronis Startup Recovery Manager

9. Click to make your selection (Figure B-11). 10. Click the Next button.

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Figure B-15: Confirming Settings Before Creating Secure Zone

11. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-15. 12. Click the Proceed button.

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Creating a Secure Zone on the Hard Disk

Figure B-16: Secure Zone Successfully Created

You can review the parameters of the Secure Zone at any time by clicking the Secure Zone button.

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Figure B-17: Reviewing Properties of the Created Secure Zone

After you have examined the properties, you can click Cancel to exit, or you can make changes as desired.

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Backing Up a Hard Disk

Backing Up a Hard Disk


When you make a backup, you can back up selected files and/or folders, or you can back up an entire hard disk or partition. While it is useful to back up selected files on a periodic basis, it is also recommended that you back up the entire hard disk in case of hard disk failure. Exatron makes a full backup of your handlers hard disk before the handler is shipped to you. In case of emergency, you can use the original backup disks to restore the handler computer to its original factory condition.

Figure B-18: Backup Disk Shipped with Handler

To make the backup: 1. On the main window, click the Backup option (Figure B-19).

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Figure B-19: Selecting the Backup Option

Figure B-20: Create Backup WizardWelcome

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Backing Up a Hard Disk

2. Click the Next button.

Figure B-21: Selecting Entire Disk or Partition Backup

Figure B-22: Alternate SelectionIndividual Files and Folders Backup

Selecting the entire disk or partition is simpler and ensures no files are omitted, but the backup takes more space. Selecting individual files and folders takes less space, but some files may be inadvertently omitted. 3. Click to make your selection (Figure B-11). 4. Click the Next button.

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Figure B-23: Selecting Partitions to Back Up

5. Click to check all the selections you want. 6. Click the Next button.

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Figure B-24: Explanation of Differences Between Full and Incremental Backups

A full backup contains all the data on the partition or hard disk. It is complete. An incremental backup contains only the data changed since the last backup, whether full or incremental. Therefore, if you have done three incremental backups since the full backup, you need all three incremental backups plus the full backup in order to restore the data. Each incremental is based on the incremental before that. Full backup + incremental + incremental + incremental = Restore
Figure B-25: Restoration Based On Incremental Backups

A differential backup contains all the data changed since the last full backup. Therefore, if you have done three differential backups since the last full backup, you need only the latest differential backup plus the full backup in order to restore the data. Each differential is based only on the full backup, and disregards any differential backups created before it. Full backup + differential ... differential ... differential = Restore
Figure B-26: Restoration Based On Differential Backups

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Figure B-27: Selecting Backup Storage Destination

7. Select the location in which to store the backup and click Next (Figure B-27).

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Figure B-28: Selecting a Full Backup

Figure B-29: Selecting an Incremental Backup

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Figure B-30: Selecting a Differential Backup

8. Select the type of backup you wantfull, incremental, or differential. 9. Click Next.

Figure B-31: Selecting Backup Options

You may want to set the options manually. Among these options are password protection, compression level, and specifying the size of the backup files for transference to various portable media (Archive splitting, Figure B-32).

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Figure B-32: Archive SplittingAutomatic

10. Click any of the options in the left box to examine and set the options. Archive splitting can be set to automatic or fixed size. NOTE: It is strongly recommended that you use the Fixed size option and back up to another hard drive first, splitting archive files small enough to fit at least two archive files on each anticipated CD or DVD; then afterward copy the backup files to CDs or DVDs. See "Copying Archive Files to CDs or DVDs" on page B-28. Automatic size is for backing up directly to a series of CDs or DVDs. When each disk is full, you will be prompted for another one. This method is not recommended, as the backup is unreliable. Fixed size is good if you are backing up to a hard drive now, with the intention of copying the backup to a specific set of portable media afterward.

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Figure B-33: Archive SplittingFixed Size

Figure B-34: Drop-Down List of Fixed Sizes

11. It is recommended that you select a size small enough to get at least two of the archive files (the first and last files) on one media. > For example, if you will be copying the files to DVDs, then select the 650 or 700 MB size, to get multiple files on one disk. But if you will be copying the files to CDs, then select the 100 MB size, to get multiple files on one disk. 12. Select the desired options and click Next.

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Backing Up a Hard Disk

Figure B-35: Adding Optional Archive Comments

13. Type any descriptions of the contents of the disk or folders. 14. Click Next.

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Figure B-36: Confirming Settings Before Creating Backup

15. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-36. 16. Click the Proceed button. During the backup, the progress bar shows how the backup is progressing (Figure B-37).

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Figure B-37: Progress Bar Displayed While Backup Is Created

Figure B-38: Successful Completion

Figure B-39: Archive Files Created

After the backup is complete, you can see the archive file(s) on your storage media.

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Copying Archive Files to CDs or DVDs


If you have backed up to a second hard drive using fixed file size and archive splitting as recommended, you should next copy the archive files to CD or DVD. Copy the first and last archive files to the first CD or DVD, so the program will know how many archive files to request. Then copy the other archive files to other CDs or DVDs if necessary, so that all the archive files are included.

Restoring a Disk or Partition Backup from CD-ROM


If you have backed up an entire disk or partition and Windows cannot load, you will need to boot from the bootable Acronis CD-ROM. Do it this way. To restore the backup: 1. Make sure there is no floppy in the floppy drive. 2. Insert the Acronis boot disk in the CD-ROM drive. The Acronis splash screen is displayed, followed by the main window (Figure B-40, Figure B-41).

Figure B-40: Acronis Boot Disk Inserted in Drive (Left); Acronis Splash Screen (Right)

3. Double-click the Restore Image selection (Figure B-41).

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Figure B-41: Acronis Main Screen with Restore Option

4. Remove the Acronis boot disk from the CD-ROM drive, and insert the CD-ROM containing the last file in the backup series of CD-ROM disks. CAUTION: Be sure to insert the last recovery disk first. If you insert any CDROM out of order, or dont start with the last one, you will see an error message (Figure B-42). Insert the correct CD and continue.

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Figure B-42: Error Messages Due to Inserting Wrong Backup Disk

Figure B-43: Restore Image WizardWelcome

The Restore Image Wizard displays the Welcome screen. 5. Click the Next button.

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Figure B-44: Selecting Archive File for Restoration

6. Double-click the CD-ROM drive to display its contents (Figure B-44). 7. Click the Next button.

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Figure B-45: Option to Verify Archive

If you are overwriting the contents of the hard disk with the recovery, you may want to verify the archive before overwriting. 8. Select whether or not to verify before restoring. 9. Click the Next button.

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Restoring a Disk or Partition Backup from CD-ROM

Figure B-46: Selecting Partition or Disk to Restore

10. Check the disk partition you want to restore. 11. Click the Next button.

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Figure B-47: Option to Resize Partitions

You have the option to resize partitions. Doing so may be useful if you are migrating to a larger hard disk, 12. Select whether or not to resize partitions. 13. Click the Next button.

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Figure B-48: Resizing Partitions

14. Click to select the disk location. 15. Slide to resize each partition. 16. Click the Next button.

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Figure B-49: Deleting Partitions on Destination HD

17. Click Yes to delete all the partitions on the destination drive. NOTE: If you click No, the restoration process stops. 18. Click the Next button.

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Restoring a Disk or Partition Backup from CD-ROM

Figure B-50: Option to Restore Additional Partition

You are given the option to restore an additional partition. 19. Make your selection and click Next.

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Figure B-51: Confirming Settings Before Restoring Partition

20. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-51. 21. Click Proceed. As the recovery progresses, you are asked to insert the backup disks in order. 22. Insert each requested disk when prompted (Figure B-52).

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Restoring a Disk or Partition Backup from CD-ROM

Figure B-52: Prompts to Insert Series of Recovery Disks

Figure B-53: Successful Completion

The restoration is completed.

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Restoring a Backup Under Windows


If Windows is running normally, you should use Acronis True Image under Windows, because it provides more functionality. Do it this way. To restore a backup under Windows: 1. Open Acronis by double-clicking its icon on the desktop (Figure B-7). 2. Click the Recovery selection (Figure B-54).

Figure B-54: Selecting the Recovery Option

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Restoring a Backup Under Windows

Figure B-55: Restore Data WizardWelcome

3. Click Next.

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Figure B-56: Selecting Location of Archive File

4. Select the location where your archive file is stored and the name of the archive file. 5. Click Next.

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Restoring a Backup Under Windows

Figure B-57: Selecting Original or New Location for Restoration

Figure B-57 asks for the location where you want the files restored: the same location they were in originally, or a new location. 6. Select original or new location. 7. Click Next.

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Appendix B: System Backup and Recovery

Figure B-58: Selecting Restoration Destination

If you selected a new destination, Figure B-58 asks you to specify the destination of the restoration. 8. Select the destination for the restoration. 9. Click Next.

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Restoring a Backup Under Windows

Figure B-59: Selecting Archive Files to Be Restored

10. Select the archive files to be restored. 11. Click Next.

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Appendix B: System Backup and Recovery

Figure B-60: Selecting Restoration Options

12. Select default or manual options for restoration. 13. Click Next.

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Restoring a Backup Under Windows

Figure B-61: Selecting Restoration Options Manually

If you selected manual options, a list of available options is showed at the left of Figure B-61. 14. Select any options for restoration. 15. Click Next.

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Appendix B: System Backup and Recovery

Figure B-62: Selecting Whether to Overwrite Existing Files

16. Select whether to overwrite existing files. 17. Click Next.

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Restoring a Backup Under Windows

Figure B-63: Confirming Settings Before Restoring Data

18. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-63. 19. Click Proceed.

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Appendix B: System Backup and Recovery

Figure B-64: Progress Bar Displayed While Data Is Restored

Figure B-65: Successful Completion

Figure B-66: Restored Files

After the restoration is complete, you can see the restored files in the selected location.

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Index
A
Administrative level 4-2 air blow. See blow-off air filter 1-7, 2-36, 7-43 air flow 7-27, 7-43 air flow control adjustment knob 3-59, 6-15 air pressure 2-35, 7-26 see also blow-off adjusting 7-27 fittings 1-7, 7-85 recommended range 7-43 setting (tester) 6-78 setting minimum 7-39 setting parameters 7-32, 7-36 test site clamps 6-15 thermal heads 6-18 Air Pressure window 6-78 air regulator 7-20, 7-85 adjusting pressure 7-26 auxiliary 2-34, 7-26 digital pressure switch 2-34, 7-27 SMC Model ITV 7-29, 7-32 SMC Models ISE40 & ZSE40 7-30, 7-36, 7-38 locking in OFF position 1-5 main 2-33, 7-24 replacing 7-21 air supply 1-7, 7-20, 7-43, 7-85 air valves 2-36, 7-27 alignment. See calibration alodine, conductive gold 2-50 archive files, in backup 11-23, 11-24 ASCII values 10-25 Auto Run current settings applied 4-21 description 5-19, 6-105 ending 5-22 example 5-23 pausing 5-1, 5-11 restarting 5-1, 5-11 testing 6-66, 6-100, 6-105, 6-106 tracking device counts 2-35, 5-12 automatic air shut-off valve 3-18, 7-25 auxiliary pusher regulator. See air regulator, auxiliary axes 2-12 theta 2-41, 4-17, 4-21, 6-38, 6-62 continued on next column axes continued X 1-27, 2-12, 2-15, 2-21, 2-39, 2-42 Y 1-27, 2-12, 2-16, 2-21 Z 1-27, 2-12, 2-17, 2-41

B
bearing shafts, lubrication 7-3 bearings 7-3 BGA (ball grid array). See inspection binary values 10-25 bins 1-25, 4-33 blow-off 1-25, 2-35 adjustment screw 2-35, 7-44, 7-85 delay 4-28 operation 2-35, 7-85 buckets 2-23, 6-63 buttons CPU 3-17, 3-19 EMO (emergency stop) 1-2, 2-25, 2-48, 3-17, 3-19, 5-1, 7-2 HALT and RUN 2-25, 5-1 override (taper) 6-22 software Exatron Auto Mode 4-5, 5-8 Back to Main 4-21, 4-73 Diags 4-5, 6-2 Load 4-5, 4-9 main window 4-5 Operator 4-6, 5-2 Pwds 4-3, 4-6 Reset 4-5 Save 4-21, 4-73 Save As 4-73 Settings 4-5, 4-11 View Log 5-23 Windows Start 3-18

C
calibration carriage to stackers 3-26 detaper 6-91 golden unit trays 6-43 laser 6-87 lifter bar spacing 3-23 lifter to tray height (stack height) 3-20 continued on next column

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Index-1

Model 8000 Manual

calibration continued linspection 6-80 order of tasks 4-54 pickup heads 2-15, 2-17 to 2-18, 4-61, 4-64 taper 6-94, 6-97 seal head 3-53 teaching positions 6-51 testers 6-56 testing 6-50, 6-86, 6-105 thermal head 4-41, 4-72, 6-71, 6-75, 6-78 trays 2-16, 4-60, 6-46 tubes 6-102, 6-105 vacuum generator 7-51 wafer input 6-109 waffle packs 2-15, 2-16 worksheet 4-59 X to test site 4-68 X to trays 4-61 Y for trays 4-63 Z-get to test site 4-71 Z-get to trays 4-67 Z-put to test site 4-70 Z-put to trays 4-65 camera. See image sensor carriages aligning with stacker 3-27, 4-52 leveling 7-83 motors, checking 6-39 movement 5-21 cautions and warnings adjusting blow-off screw 2-35 back up hard drive regularly 7-3 changing motor speeds may cause damage 4-22 connect power to grounded outlet 1-6 define tray columns and rows before calibration 4-60 digital air pressure sensor setting minimum 7-39 dispose of chiller fluid according to law 1-4 dont change factory-set job file 4-9, 6-1 dont change IP addresses 7-69 dont change motor settings 7-87 dont interfere with moving parts 1-1 dont jerk filled trays 3-14 dont lubricate lead screws 7-2 dont lubricate solenoids 7-58 dont over-adjust blow-off screw on vacuum generator 7-45 dont over-adjust blow-off screw on vacuum switch 7-45 dont remove safety covers during operation 1-2 dont touch adhesive tape to carrier tape 3-32, 3-52 continued on next column

cautions and warnings continued dont touch hot taper seal heads 3-57 dont unplug air hose when air regulator on 1-4 dont use cleaners on bearings or lead screws 7-3, 7-5 dont use cleaners on encoder strip of linear motor track 7-6 dont use machine without approved air regulator 1-4 home all motors before starting 1-1 insert last recovery disk first 11-29 keep away from lifter undersides during movement 1-3 keep away from moving parts 1-1 keep away from shutters during movement 1-4 laser-mounting 3-9 lock air regulator in OFF position before repairing handler 1-5 lock wheels and level feet 1-8 maintain file backups on external media 7-80 maximum air pressure 50 PSI for vacuum switch using vacuum pump 7-43 maximum air pressure 80 PSI for vacuum generator 7-43 never disassemble air springs 1-4 power off system before maintenance 7-3 prevent excess moisture in air regulator and air valves 7-20 replace dirty vacuum filter 7-44 servicing of laser should be done by LSO 1-5, 7-69 tighten lead screws only with power off 7-83, 7-86 use accurate distances in teaching calibrations 6-52 use full temperature range when calibrating chiller 6-75 CE Marking upgrade options 2-49 changeover kits 3-2 chiller fluid as hazardous waste 1-4 circulator, thermal 6-73, 6-74 columns calibration 4-60 numbering 2-12, 4-32, 4-35 communication between handler software and hardware 6-3, 7-86 motors 2-19 peripherals 10-27 tester 10-1, 10-32 thermal temperature controller 7-64 computer boards 5000-M42 2-29 continued on next column

Index-2

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Index

computer boards continued 8000-D14 2-30 PCM-8152 2-28 PET-C06 2-29 computers backing up hard disk 11-15 opening 7-58 restoring hard disk 11-28, 11-40 shutting down 2-24, 2-50, 3-18 switching between 4-2 conductive gold alodine 2-50 contracts preventive maintenance 1-14 service 1-11 correlation table 6-75, 6-77 counting. See numbering covers 1-2 CPU button 3-17, 3-19 CPU. See computers customization 1-31, 4-11, 6-1

drive gear (taper)

2-48

E
earthquake safety 1-8 electrical capability 1-6 EMO (emergency stop) button 2-25, 7-2 starting 3-17 stopping 1-2, 3-19, 5-1 taper 2-48 end-of-life disposal 1-23 environmental requirements 1-6

F
facilities requirements 1-6 feet, leveling 2-24, 3-1 files archive 11-23, 11-24 backing up 7-3 correlation table 6-75, 6-77 inspection 6-20 job see job files log see log file software upgrades 7-80 system 7-80 fuses 2-27

D
decimal values 10-25 Delay window 4-25 delays 4-25 detaper aligning 3-34 calibrating 6-91 control panel 3-36 loading 3-29 overview 1-38 testing 6-93 using as input 4-15 Detaper window 6-91 devices see also golden units changing sizes 3-2 loading 3-14 types 6-20 Diagnostics level 4-2 Diagnostics windows 6-2 see also under software, windows disconnect switch 1-6, 2-24, 2-25, 2-50, 3-16, 3-19, 3-20 distances. See positions docking ring and plate 1-32 documentation typography significance 1-24 version number significance 1-23

G
gap offset (taper) 6-97 glossary 1-25 Golden Unit window 6-43 golden units 6-43, 6-63 GPIB test interface 10-21

H
HALT button 2-25, 5-1 handler cleaning 7-3 communication see communication between handler and customization 1-31 end-of-life disposal 1-23 installation 1-8, 3-1 movement 2-4 operation overview 2-2 optional features 1-31 powering up 3-15 continued on next column

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Index-3

Model 8000 Manual

handler continued remote control 7-78 requirements environmental 1-6 Internet access 1-7 pressurized air 1-7 shutting down 3-18 troubleshooting 7-82 handler parts see also individual part names, test sites air filter 2-36, 7-44 air pressure fittings 1-7, 7-85 air regulator auxiliary 2-34, 7-26 digital pressure switch 2-34, 7-27, 7-29, 7-32 main 2-33, 7-24 air valves 2-36 automatic air shut-off valve 3-18, 7-25 bearings 7-3 brand names Baco disconnect switch 1-6, 2-25, 2-50, 3-16, 3-19, 3-20 Cool Muscle motors 7-9, 7-17 Hover-Davis detaper 3-29 Kerk lead screws 7-4 NSK bearing shafts 7-4 Omega temperature controller 7-64 Omron fiberoptic sensor controllers 7-61 SMC air regulators 7-21, 7-24 SMC digital air pressure switch 7-27, 7-32 SMC vacuum generators 7-40 SMC vacuum switches 7-40 Thomson bearing shafts 7-4 Thomson bearings 7-4 Thomson linear motor tracks 7-4 Trumpf laser 3-5 buckets 2-23, 6-63 buttons CPU 3-17 HALT and RUN 2-25, 5-1 override (taper) 2-49 chains 2-40, 8-2 computer boards 2-28 connectors 24-pin D 10-4, 10-5 covers 1-2 CPU button 3-17, 3-19 disconnect switch 1-6, 2-25, 2-50, 3-16, 3-20 EMO (emergency stop) button 1-2, 3-17, 3-19, 5-1, 7-2 feet, leveling 2-24, 3-1 fuses 2-27 golden unit tray 6-43, 6-63 continued on next column

handler parts continued HALT and RUN buttons 2-25, 5-1 hub 2-19, 2-30, 7-87 interlocks 1-2, 6-9 laser 3-5 lead screws 2-19, 2-20, 2-40, 7-6, 7-83, 7-86 lifter bars 3-25 lifter pins 2-4, 2-9, 2-10, 2-37 light pole 2-32 line filter 2-51 main disconnect switch 2-24, 2-25, 2-50, 3-16, 3-20 motor controllers 8-2 motors 2-19 coupling 7-83, 7-86 linear 2-39, 7-6 serial cables 7-18 network hub 2-30 photos 1-27 to 2-51 pickup heads 2-41, 2-42 power supplies 2-26 power switch 3-17, 3-19 precisor 6-63 sensors 2-35, 6-9, 7-51 serial adapter 2-30 stacker pins 2-4, 2-8, 2-9, 2-10 stackers 3-20, 3-27 suction cups 2-40, 7-3 support pins 2-4, 2-10, 2-37 temperature controller 7-64 tray carriages 2-21, 3-26, 3-27 tray clamp pins 2-4, 2-8, 2-37 trays 2-22 tubes 3-14 vacuum generators see vacuum generators vacuum pump 7-45, 7-46 vacuum wand attachment 2-34 wiring 2-29, 2-40, 7-18 handler port simulator 10-7 hardware. See handler parts hazardous waste 1-4 heat seal heads (taper) intermittent tape contact 2-47 stopping 2-48 heater controller display (taper) 3-60 hex values 10-25 home positions 2-12 hub 2-19, 2-30 HyperTerminal 10-27

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Index

I
image sensor (taper) 2-47 see also inspection files function 6-23 inspection trigger 6-19 increments 6-43, 6-47 Input/Output Check window 6-3 inspection 2D vs. 3D 4-18 calibration 6-80 enabling or disabling 4-14, 4-16 number of failures 4-15, 5-4 overview 1-35 testing 6-84 time out 4-29 inspection files 6-20 Inspection window 6-80 installation 1-8 interface card 7-9 interfaces GPIB 10-2 RS-232 10-2 RS-485 10-2 TTL 10-2, 10-4 interlocks 1-2, 6-9 IP addresses 7-69, 7-75

J
JEDEC trays 2-22 job files copying 4-7, 6-1 definition 4-6 factory preset 3-2 for various tray configurations 6-1 how named 4-7 opening 4-9 saving 4-73 settings 4-10 verifying 4-6 jobs running 5-1, 10-1, 11-1 setting parameters 4-15, 5-3

laser continued deck 3-8 enabling or disabling 4-16 height adjustment 3-10 input/output 6-28 mounting 3-9 overview 1-34 pilot vs. yag 6-88 rotational adjustment 3-12 testing mark 6-90 time out 4-29 umbilical rotation 3-5 X offset 6-89 Laser window 6-87 lead screws 2-20, 2-21, 2-40, 7-6, 7-83, 7-86 lead/ball inspection. See inspection LED checker 10-7 leveling feet 2-24, 3-1 lifter pins activating 2-9, 6-29 calibrating positions 3-23, 4-49 function 2-37 hazard to fingers 1-3 location 2-4 light pole 2-32, 4-37 line filter 2-51 lock-out/tag-out (LOTO) procedures 1-5 log file 5-13, 5-19 how named 5-29 recording pauses 5-27 sample 5-28 viewing 5-22 lubrication 7-3

M
machine vision. See inspection machine. See handler main disconnect switch 2-24, 2-25, 2-50, 3-16, 3-20 maintenance. See tasks manual, users typography significance 1-24 version number significance 1-23 measurements. See positions messages between handler and tester 10-1 color-coded 2-32 ER_TESTER_TIMEOUT 6-66 in Auto Run 5-13 output full 4-37 progress 6-45, 6-85

L
LAN connections 7-69 laser 7-69 adapter plate 3-8, 3-9 calibration 6-87, 6-88 continued on next column

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Index-5

Model 8000 Manual

Motor window 4-22 motors 2-19 controllers 7-9, 8-2 coupling 2-19, 7-83, 7-86 homing 6-31, 6-36, 6-37, 6-40, 6-56 linear 2-19, 2-39, 4-24, 7-86 cleaning 7-6 testing 6-41 master vs. slave 7-9, 7-10 movement, increments 4-62, 6-43, 6-47 pickup heads checking 6-35, 6-39 rotation 2-41, 6-38, 6-62 positions 4-54, 6-32 programming 7-17 replacing 7-14 serial cables 7-18 speeds 4-22, 4-23, 6-29 stackers, checking 6-29 tray carriages, checking 6-39 turning on and off 6-31, 6-36, 6-40 X 2-4, 2-15, 4-54, 4-55 Y 2-16, 4-54, 4-57, 7-86 Z 2-17, 4-54

N
network cards 7-9 network hub 2-30 networking Internet access 1-7 IP addresses 7-69 LAN connections 7-69 remote handler control 7-78 numbering columns and rows 2-12, 4-32, 4-35 test sites 2-12 trays 2-12, 4-42 waffle packs 2-16, 4-42

O
offset (laser) 6-89 offset, gap (taper) 6-97 Operator level 4-2 Operator Setting window

5-2

P
passwords 3-17, 4-2, 4-3, 6-52, 6-54 PCBs. See computer boards peel tester (taper) 3-47

photos, handler parts 1-27 to 2-51 pick height. See Z-get pickup heads assembly 2-40 blow-off 7-44 disabling 4-32, 4-45 distance between nozzles 6-54 dual assemblies 2-41 dual tandem nozzles 6-67 home position 2-12 looseness 7-86 motors, checking 6-35, 6-39 multiple nozzles setting detaper for 3-36 positions 2-15, 2-17, 7-86 rotation 2-41 motors, setting 6-38, 6-62 results 4-21 specifying 4-17, 5-5 testing 6-107 suction cups 7-3, 7-84 X distance to test site 4-68 X distance to trays 4-61 Z-get to test site 4-71 Z-get to trays 4-67 Z-put to test site 4-70 Z-put to trays 4-65 pin 1, location 2-12 pin designations 10-5 pins. See lifter pins, support pins, tray clamp pins ports 6-3, 10-2, 10-3, 10-27 TTL Handler Port 10-4, 10-7 positions see also under calibration calibrating 2-15 to 2-18, 3-20 to 3-28, 4-54 to 4-72, 6-46 to 6-70 columns and rows 2-12, 4-32, 4-35 pickup heads 2-15, 2-17 teaching 6-51 trays 2-16 waffle packs 2-16 worksheet 4-59 power supplies 2-26 power switch 3-17, 3-19 precisor 6-63 pressure roller block (taper) 2-48 pressure seal head (taper) continuous tape contact 2-47 maintenance 7-63 preventive maintenance contract 1-14 programmer, overview 1-37

Index-6

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Index

push cylinder. See also test sites, clamp sockets 6-14 put height. See Z-put

R
remote handler control 7-78 rotation delay 4-29 results 4-21 specifying 4-17, 5-5 testing 6-105, 6-107 tubes 6-105 Rotation Motors window 6-38 rotation, pickup head 6-38, 6-62 rows calibration 4-60 numbering 2-12, 4-32, 4-35 RS-232 test interface 10-9, 10-10 RUN button 2-25, 5-1

S
safety and security see also cautions and warnings CE Marking upgrade options 2-49 earthquake 1-8 handler covers and interlocks 1-2 hard disk backup 11-15 lock-out/tag-out procedures 1-5 security levels handler 4-2 training responsibilities 1-1 seal head (taper) 2-47, 6-25 adjusting 3-53 adjusting lateral position 3-56 adjusting pressure 3-58 blade sizes 3-2 changing blades 3-55 cleaning 7-63 delay 4-29 enabling or disabling 6-100 setting temperature for heat seal 3-60 seismic safety 1-8 sensors 2-31 bucket 2-23 checking 6-3 cleaning optics 7-63 controller indicator lights 7-63 Door Interlock 6-9 Input Stacker Empty 6-9 lead-in 6-27 continued on next column

sensors continued light-on vs. dark-on 7-61 significance 6-3, 6-8 taper 6-19 to 6-25 Empty/Out-of-Pocket 6-23 Gap 2-47, 6-23, 6-97 Heater Alarm 6-25 Slack Switch 6-24 thermal 6-11 Tray Home 6-10 Tray Present 6-10 tube assembly 6-27 Tube Switch 6-27 vacuum generator 2-35, 7-51, 7-64, 7-84 Sensors/Solenoids Check window 6-3 serial adapter 2-30 service contract 1-11 servo controller 2-19 settings file. See job files Settings windows 4-11 see also under software, Exatron, windows Setup Trays window 4-30 signal tower. See light pole slide cylinder. See also test sites, clamp sockets 6-14 smart buckets 2-23, 6-63 software Acronis True Image 11-1 backup 11-15 emergency recovery 11-28 normal recovery 11-40 Secure Zone 11-6 Exatron customization 4-11, 6-1 messages, color-coded 2-32 setup 4-1 windows Auto Run 5-8 Diagnostics 6-2 Air Pressure 6-78 Detaper 6-91 Golden Unit 6-43 Inspection 6-80 Laser 6-87 Rotation Motors 6-38 Sensors/Solenoids Check 6-3 Stacker 6-29 Tape and Reel 6-94 Tester 6-56 Thermal 6-71 Tray 6-46 Tube 6-102 continued on next column

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Index-7

Model 8000 Manual

software continued Exatron continued windows continued Diagnostics continued Wafer Input 6-109 X and Y Motors 6-39 Z Motors 6-35 Main 4-5 Operator Setting 5-2 Settings 4-11 Delay 4-25 Motor 4-22 Setup Trays 4-30 Thermal 4-40 Tray Sort 4-33 Work Mode 4-12 HyperTerminal 10-27 MS Windows, shutting down 3-18 selections, grayed out 4-12 WebEx 7-78 solenoids 7-58 checking 6-3, 6-26 significance 6-11 sorts 1-26 assigning to trays 4-36 assigning to waffle packs 4-39 Stacker window 6-29 stackers aligning carriage 3-27, 4-52 calibrating positions 3-20, 4-47 delay 4-27 motors, checking 6-29 movement 2-5, 5-21 suction cups 2-40, 7-84 cleaning 7-3 positions, Z-get vs. Z-put 4-64, 4-65 replacing 8-1 support pins activating 6-30 deactivating 2-10 function 2-4, 2-37 hazard to fingers 1-3 location 2-4 support services 1-9, 1-10, 1-17, 1-23

T
takeup arm (taper) 3-47 takeup reel (taper) 2-46, 3-38

tape direction of movement 2-46 gap offset 6-97 initializing/homing 6-97 leader 6-98 threading through assembly 3-48 trailer 6-98 Tape and Reel window 6-94 taper alignment knob 2-46, 3-38 calibration 6-94, 6-97 changing seal head blade 3-55 changing tape track 3-43 drive gear 2-48 EMO (emergency stop) button 2-48 facilities requirements 1-6, 1-7 guide block 3-49, 3-51 heater controller display 3-60 image sensor 6-19, 6-23 Model 202 2-46 motor 6-96 override buttons 2-49, 6-22 overview 2-46 peel tester 3-47 pressure roller block 2-48 seal head delay 4-29 enabling or disabling 6-100 sensors 6-19 to 6-25 Empty/Out-of-Pocket 6-23 Gap 2-47, 6-23, 6-97 Heater Alarm 6-25 Slack Switch 6-24 takeup arm 3-47 takeup reel 2-46, 3-38 tape track 2-46, 3-38, 3-52 tasks adjusting air flow 3-59, 7-27 adjusting air pressure 7-26 adjusting blow-off 7-44 backing up PC hard disk 11-15 calibration carriage to stacker 3-27, 4-52 detaper 6-91 inspection 6-80 laser 6-87 lifter bar spacing 3-23 lifter bars 4-49 number of rows and columns 4-43 order 4-54 positions 4-45 stack height 3-20 continued on next column

Index-8

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Index

tasks continued calibration continued stacker height 4-47 taper 6-94 thermal heads X for test site 4-72 tubes 6-102 vacuum generator 7-54 wafer input 6-109 X to test site 4-68 X to trays 4-62 Y for trays 4-63 Z-get to test site 4-71 Z-get to trays 4-67 Z-put to test site 4-70 Z-put to trays 4-66 carriage leveling 7-83 changing password 4-3 changing pickup head 3-3 checking air filter 7-43 checking air regulator moisture/dirt trap 7-20 checking air regulator shutoff valve 7-23 checking air supply from house generator 7-20 checking motor serial cables 7-18 checking or replacing air filter 7-21 checking vacuum generator adjustment 7-51 cleaning handler 7-3 cleaning suction cups 7-3 cleaning vacuum assembly 7-47 copying job file 4-7 creating backup Secure Zone on hard disk 11-6 disabling handler features 4-45 displaying commands typed in HyperTerminal 10-30, 10-32 entering Diagnostics 6-2 entering Settings 4-11 installing Exatron software 7-80 laser height adjustment 3-10 laser mounting 3-9 laser rotation adjustment 3-12 locking air pressure switch 7-30, 7-31 lubricating bearing shafts 7-5 powering up handler 3-16 programming motor 7-17 reformatting job file 7-82 replacing air filter 2-36 replacing computer part 7-59 replacing motors 7-14 restoring backup under Windows 11-40 restoring backup without Windows 11-28 rotating laser umbilical 3-5 running a job 5-18 securing tubes on holder 3-14 setting air pressure switch 7-32, 7-36, 7-39 continued on next column

tasks continued setting LAN connection 7-70 setting PC to boot from CD 11-1 setting up HyperTerminal 10-27 setting up temperature controller software 7-66 shutting down handler 3-18 starting Exatron software 3-18 taper adjusting seal heads lateral position 3-56 adjusting seal heads pressure 3-58 adjusting seal heads speed 3-59 aligning tape track 3-52 changing changeover kit 3-39 changing seal head blade 3-55 changing tape track 3-43 loading carrier tape 3-45 loading sealing tape 3-48 maintenance 7-63 mounting takeup reel 3-41 setting temperature for heat seal 3-60 turning off temperature for heat seal 3-61 testing network communication with peripherals 7-75 tightening lead screws 7-6, 7-83 unlocking air pressure switch 7-29, 7-30 viewing log file 5-22, 5-23 viewing vacuum generator settings 7-57 TCP/IP interface 10-3 Teach Tray dialog box 6-53 temperature controller 7-64 temperatures, setting (taper) 3-60 temperatures, setting (tester) 6-71 test interfaces. See GPIB test interface, RS-232 test interface, TCP/IP interface, TTL (TransistorTransistor Logic) test interface test sites calibration 4-54, 4-68, 4-70, 4-71, 6-56 checking communication 10-27 checking readiness 6-66 clamp sockets 1-33, 5-20, 6-14 air pressure controls 6-15 movements 6-14 disabling 4-45 docking ring and plate 1-32 instructions from vendor 3-2 multiple 5-15, 5-16, 10-10 numbering 2-12 rotation 4-17, 4-21 socket grid 4-68, 6-58 sockets 1-33 thermal 4-40, 6-71, 6-78, 7-64 Tester window 6-56

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Index-9

Model 8000 Manual

testing see also calibration, Diagnostics windows detaper 6-93 double-test option 4-34, 4-39 enabling or disabling 4-16 inspection 6-84 interfaces 10-1 laser mark 6-90 modes, real vs. simulation 4-16 number of devices passed 4-15 number of failures 4-15, 5-3 thermal heads 4-41, 6-71, 6-78 time out 4-29, 6-66 thermal heads air pressure 6-18 Auto Run display 5-11, 5-14 calibration 4-72, 6-71, 6-78 options 4-41 sensors 6-11 temperature variance allowed 2-43, 4-41, 4-42, 6-72, 6-74 Thermal window 4-40, 6-71 theta axis 2-41, 4-17, 4-21, 6-38, 6-62 tray clamp pins activating 2-8, 6-30, 6-31 function 2-37 hazard to fingers 1-3 location 2-4 Tray Sort window 4-33 Tray window 6-46 trays See also carriages, waffle packs carriages 2-22 configurations, combining 2-22 delays 4-25 empty pockets 4-15, 5-4 home position 2-12 loading 2-5 numbering 2-12, 4-32, 4-35, 4-42 positions, calibrating 2-16, 4-60, 6-46 row and column numbering 4-31, 4-43, 4-60 sorting to bins 4-33, 4-36 unloading 2-10 waffle packs 2-22, 4-60 troubleshooting device jam 6-108 devices not picked up 7-43, 7-84 hard disk wont boot 11-15, 11-28 motors slow 7-82 tray carriage alignment failing 7-83 tray clamp pins failing to secure trays 7-83 Y movement noisy 7-86

TTL (Transistor-Transistor Logic) test interface 10-4 TTL Handler Port 10-4, 10-7 Tube window 6-102 tubes calibration 6-102 holders 3-14 LEDs 6-26 securing 3-14 sensors and solenoids 6-26 typography significance 1-24

V
vacuum delay 4-27 vacuum generators 2-35, 6-6 blow-off adjustment 7-45 blow-off location 7-42 calibrating 7-54 checking 7-51, 7-57 cleaning 7-47 filter 8-2 maximum air pressure 7-43 override buttons 7-54 ports 7-41 sensor 7-84 suggested settings 7-53 troubleshooting 7-43 vacuum pump 7-43, 7-45, 7-46 vacuum switches see also vacuum generators blow-off adjustment 7-45 blow-off location 7-42 how different from vacuum generators maximum air pressure 7-43 vacuum wand attachment 2-34

7-40

W
Wafer Input window 6-109 waffle packs 2-22 calibrating 4-55, 4-60, 4-61 disabling 4-30 numbering 2-16, 4-31, 4-32, 4-42 positions 2-16, 6-52 warnings. See cautions and warnings warranty agreement 1-7, 1-8, 1-9, 1-10, 7-2 WebEx 7-78 Windows, shutting down 3-18 windows. See under software wiring 2-29, 2-40, 7-18 Work Mode window 4-12

Index-10

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Index

X
X and Y Motors window 6-39 X axis 1-27, 2-12, 2-15, 2-21, 2-39, 2-42 conceptual diagram 2-13, 4-55 X calibration 4-54 for test site 4-68 for thermal head 4-72 to trays 4-61 X home position 2-12

Y
Y axis 1-27, 2-12, 2-16, 2-21, 7-86 conceptual diagram 2-13, 4-57 Y calibration 4-54 for trays 4-63 for tubes 6-102, 6-104 Y home position 2-12

Z
Z axis 1-27, 2-12, 2-17, 2-41 conceptual diagram 2-13 Z chain 8-2 Z home position 2-12 Z Motors window 6-35 Z-get 2-17, 4-54, 4-64 calibration for test site 4-71 to tray 4-67 distance from device 2-18, 7-84 Z-put 2-17, 4-54, 4-64 calibration for test site 4-70 to tray 4-65 distance from device 2-18

02/2011

Copyright Exatron, 2011

Index-11

Model 8000 Manual

Index-12

Copyright Exatron, 2011

02/2011