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Model 1020 Tube-Input Taper User Manual

Version 3.0 October 5, 2010

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 2010 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
Chapter 1: Safety and Support
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Exatron Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Facilities Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Vacuum/Pneumatic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Uncrating the Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Customer In-House Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Offshore Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Exatron Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 End-of-Life Taper Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Significance of This Manuals Version Number. . . . . . . . . . . . . . . . . . . . . . . 1-7 Typographical Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . 1-8 Terms Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Chapter 2: System Description


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Key Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 How the Model 1020 Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Identifying Major Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Three Reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Taper Input Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Motors and Drive Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Index and Stack Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Seal Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Swing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Chapter 3: Taper Setup and RAM Listing


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Mounting the Takeup Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Mounting the Supply Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Adjusting the Carrier Tape Track Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
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Chapter 3: Taper Setup and RAM Listing continued


Loading the Carrier Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Loading the Sealing Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Adjusting Heat Seal Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Adjusting Lateral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Adjusting Downward Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Adjusting Pressure Seal Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Loading Tubes into the Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Power-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Aligning the Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Setting Temperature for Heat Seal Heads . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Calibrating Device Position in Tape Pocket . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Inspection at Beginning of Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Beginning a Production Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Homing the Octoloader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Understanding the Control Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Using the <SET UP> Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Modifying Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Understanding the Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Selecting Type of Tape Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Selecting Number of Devices to Be Put in Tape. . . . . . . . . . . . . . . . . . . 3-34 Setting Tape Pocket Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Selecting Manual Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Resetting the Count of Devices in Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Displaying the Count of Devices in Tape . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Using Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Changing RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 Notes About the RAM Address Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Warning About Motor Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Updating Your EPROM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Separate Settings for Changeover Kits . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Suggested Values for Various Taper Models . . . . . . . . . . . . . . . . . . . . . 3-46 RAM Address Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Hex-Binary Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 Decimal-Hex-ASCII Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

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Chapter 4: Diagnostics
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Accessing DIAGNOSTICS Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Diagnostics Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 SENSOR CHECK: Tape Sensors 0-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 SENSOR CHECK: Input and Pickup Sensors 8-F . . . . . . . . . . . . . . . . . . . 4-12 SENSOR CHECK: Image Sensors 0-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 OUTPUT CHECK: Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 OUTPUT CHECK: Solenoid Toggle Check . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 ALL MOTOR CHECK: Drive Motor Check . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 ALL MOTOR CHECK: Swing Arm Check . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 ALL MOTOR CHECK: Octoloader Motor Check . . . . . . . . . . . . . . . . . . . . . 4-20

Chapter 5: Dictionary of Displayed Messages


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Model 1050 Handler Status and Error Messages . . . . . . . . . . . . . . . . . . . . . 5-4 00## DATA ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 1 LEFT STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 1 RIGHT STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 2 LEFT STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 2 RIGHT STEPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 4 TUBE INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 8 TUBE INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ADD LEADER DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ADD LEADER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ALIGN OCTOLOADER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ALL MODES OFF ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ALL MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 ALL MOTORS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 CHANGE RAM ? NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 CHANGE RAM ? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 COUNT SET TO 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 CPU ERROR [1-6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 DRIVE MOTOR CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 EMPTY/LOAD PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 EMPTY POCKET ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 EXATRON TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 FIND MOTOR HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 FULL T = ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 GAP STEPS = #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 HANDLER OUT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
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HOME SENSOR ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 HOME SWING HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 INDEX/STACK JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 IN-SEN 01234567. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 INSPECT YES/NO ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 INSPECTION FAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 INSPECTION OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 INSPECTION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 INSPECTION PASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 INTERFACE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 ISSUE NEW START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 JOG LEFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 JOG OCTOLOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 JOG RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 LOAD DEFAULT NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 LOAD DEFAULT YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 LOAD EPROM>RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 LOADER JAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 LOOP MODE ON ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 MANUAL ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 MOD SET UP ? NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 MOD SET UP ? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 MOTOR [A, B, or C] BUSY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 MOTOR <A, B, or C> ERROR ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 MOTOR A OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 MOTOR B OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 MOTOR C OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 MOTOR HOME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 MOVE TAPE LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 MOVE TAPE RIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 NEW JOBEMPTY OK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 NEW TAPE SET UP? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 NO POCKET? ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 NOT UP TO TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 OCTO MOTOR CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 OCTOLOADER OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 OFFSET = #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 OFFSET>GAP ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 OK TO RUN ? 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 OUT OF POCKET ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 OUTPUT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 PASSWORD ABC? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 PAUSED ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
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PART AT PICK UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 PART DROPPED ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 PICK UP AT HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 PICK UP DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 PICK UP NOT HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 PLACE PART ERR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 POCKETS = ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 RAM AUTO RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 READY TO RUN ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 RESET COUNT NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 RESET COUNT YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 RETURN ERROR ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 ROTATE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 ROTATE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 RS-232 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 RUN 4 X 4 MLF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 RUN 5 X 5 MLF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 RUN DEFAULT 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 RUN SSOIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 RUN UNTIL 1 PASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 SEN0-7 01234567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 SEN8-F 89ABCDEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 SET # INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 SET GAP ? NO/YES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 SET OFFSET = #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 SOL TOGGLE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 SOLENOID CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 SORT = 12345678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 STOP MODE ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 STOP MODE ON ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 SWING HEAD CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 SWING HOME = ### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 SWING STEP = ### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 TAKE UP MOTOR CK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 TAKE UP REEL ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 TAPE GAP LOST ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 TAPE IS FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 TAPE OUT ERROR ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 TAPE STACK EMPTY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 TEST TAPE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 THANK YOU #. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 THERMAL OR PSA ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
-- continued on next page --

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Chapter 5: Dictionary of Displayed Messages continued


UART OUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 USE PSA TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 USE THERMAL TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 VAC NOT ADJUSTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 ZERO COUNT ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Chapter 6: Servicing and Troubleshooting


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Seal Head Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Pressure-Sensitive Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Heat Seal Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Air Regulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Checking Incoming Air from the House Supply . . . . . . . . . . . . . . . . . . . . 6-3 Checking Air Regulator Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Adjusting Air Pressure on the Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Adjusting Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Checking the Moisture/Dirt Trap in the Air Regulator . . . . . . . . . . . . . . . . 6-6 Solenoid Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Fiberoptic Photoelectric Sensor Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Chapter 7: Parts List


Guide to the Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Exatron (Part Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Part Quantity Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Lists of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Chapter 8: Prints
List of Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 How to View the Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Index

Contents-6

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List of Figures
Figure 1-1: Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-2: Air Line Attached to Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-1: Key Device Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-2: Reels on Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-3: Tape Track with Swing Armat Pickup Site (Left), at Taper (Right) . . . . . . . . . . . 1-2 1-4 2-2 2-3 2-4

Figure 2-4: Other Features of Taper (Model 201) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Figure 2-5: Index Pin Retracted (Left), Extended (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Figure 2-6: Cover Foot Retracted From Pickup Site and Stack Pin Extended (Left); Cover Foot Extended Over Pickup Site and Stack Pin Retracted (Right) . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Figure 2-7: Motor with Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Figure 2-8: Drive Chain Tension Adjuster for Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Figure 2-9: Tape Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Figure 2-10: Takeup Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Figure 2-11: Octoloader at Home Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-12: Octoloader Back with Snap-On Pins (Left); Octo Car Block with Holes for Snap-On Pins (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Figure 2-13: Octoloader Front with Two Tubes Attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Figure 2-14: Octoloader Gate Depressed by Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-15: Devices Stopped by Octoloader Gate (Left); Devices Released by Octoloader Gate (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-16: Octoloader Gate Pin Blocking Exit (Left); Device Exiting Octoloader Chute (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-17: Octoloader Gate Closed (Left); Octoloader Gate Opened (Right) . . . . . . . . . . . . . Figure 2-18: Device at Stack Sensor (A, Top); Device at Pickup Site Sensor (B, Bottom) . . . . Figure 2-19: Device at Stack Sensor (A, Left); Device at Pickup Site Sensor (B, Right) . . . . . Figure 2-20: Taper Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-21: Empty Pocket Sensor (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-22: Out-of-Pocket Sensor (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-23: Gap Sensor (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-24: Carrier Tape Out Sensor (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-25: Takeup Arm Sensor (3) Closed (Left), Open (Right). . . . . . . . . . . . . . . . . . . . . . . Figure 2-26: Swing Arm Home Sensor (9, Left); Swing Arm at Home (Right) . . . . . . . . . . . . . Figure 2-27: Heat Seal Heads with Counterbalance Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-28: Pressure-Sensitive (PSA) Seal Heads with Counterbalance Weight . . . . . . . . . . . 2-11 2-12 2-12 2-13 2-14 2-14 2-15 2-15 2-16 2-16 2-17 2-17 2-18 2-19 2-19

Figure 2-29: Swing Arm at Pickup Site (Left), at Tape Drop Site (Right) . . . . . . . . . . . . . . . . . 2-20 Figure 2-30: Pickup Head Retracted (Left), Extended (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Figure 2-31: Path and Limits of Swing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Figure 3-1: Locking Hub on Takeup Reel with Alignment Pins . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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Model 1020 Manual

Figure 3-2: Supply Reel Tape Unwound from Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Figure 3-3: Carrier Tape Track at Different Widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-4: Track Width Locking Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-5: Carrier Tape Under Guide At Top Supply End of Track . . . . . . . . . . . . . . . . . . . . . . Figure 3-6: Lifting Pressure Roller Arm and Pushing In Keeper PinTwo Styles . . . . . . . . . . . Figure 3-7: Takeup Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-8: Tape Drive Gear Adjustment Knob with Blue Locking Knob Unscrewed . . . . . . . . Figure 3-9: Gear Adjustment Narrowed (Left); Widened (Right). . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-10: Sealing Tape PlatesOutside (Left), Inside (Right) . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-11: Sealing Tape Threaded to Sealing Tape Guide Assembly for PSA . . . . . . . . . . . . . Figure 3-12: Sealing Tape Threaded to Sealing Tape Guide Assembly for Heat . . . . . . . . . . . . . Figure 3-13: Sealing Tape Threaded Under Guide Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-14: Two Widths of Guide BlocksTop View (Left); Bottom View (Right). . . . . . . . Figure 3-15: Placement in Grooves of Guide Blockof Sealing Tape (Left) and Carrier Tape (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-16: Guide Rod Removed from One Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-17: Guide Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-18: Semicircular Seal Head with Adjustment Screw . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-19: Example of Good Tape Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-20: Three-Gram and One-Gram Weights (Left); One-Gram Weight on Heat Seal Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-21: Pair of Pressure Seal Heads with Lateral Adjustment Screws . . . . . . . . . . . . . . . . Figure 3-22: Three-Gram and One-Gram Weights (Left); One-Gram Weight on PSA Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-23: Octoloader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-24: Loading a Tube Perpendicular to Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-25: Securing Tube at Bottom of Input Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-26: Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-27: Octo Stop Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-28: Heater Controller Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-29: SET Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-30: Up Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-31: Digit in Ones Position Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-32: Left Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-33: Digit in Tens Position Selected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-34: Temperature Set Before the SET Button Is Pressed . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-35: Temperature Set After the SET Button Is Pressed . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-36: Down Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-37: Temperature Set to Zero Before the SET Button Is Pressed . . . . . . . . . . . . . . . . . 3-3 3-4 3-5 3-6 3-6 3-7 3-7 3-8 3-9 3-9

3-10 3-10 3-11 3-11 3-12 3-13 3-14 3-15 3-15 3-16 3-17 3-18 3-18 3-19 3-21 3-22 3-23 3-23 3-23 3-24 3-24 3-24 3-25 3-25 3-26

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Figure 3-38: Tape Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-39: Swing Arm Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-40: Touching the Blue Dashed ROI Border . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-41: ROI Turns Red and Teach Button Is Visible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-42: <SET UP> Key Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-27 3-27 3-28 3-28 3-31

Figure 3-43: Gap Versus Offset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Figure 3-44: Modify Setup Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Figure 3-45: Manual Mode Flowchart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Figure 4-1: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Figure 4-2: Diagnostics Abbreviated Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Figure 4-3: Tape Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Figure 4-4: Swing Arm Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Figure 5-1: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Figure 6-1: Brass PSA Rollers (Left); Rubber PSA Rollers (Right) . . . . . . . . . . . . . . . . . . . . . . 6-2 Figure 6-2: Heat Seal Head Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Figure 6-3: Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-4: Air Valves with Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-5: Air Regulator with Small Black Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-6: Metal Casing Unscrewed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-7: Clear Glass Casing Snapped Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6-5 6-6 6-7 6-7

Figure 6-8: Large Black Inner Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Figure 6-9: Solenoid with Plunger on Back Side of Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Figure 6-10: Sensor Controller Set to L-ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Figure 6-11: Green and Red Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Figure 6-12: Conditions of Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Figure 7-1: Dimensions Listed From Smallest to Largest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-1: 3000-055-C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-2: 3000-223-2-B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-3: 5000-397-2-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-4: 5000-398-2-C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 8-3 8-4 8-5 8-6

Figure 8-5: 5000-A89-C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Figure 8-6: 5000-M08-27-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Figure 8-7: 5000-M15-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Figure 8-8: 5000-M22-A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Figure 8-9: TAPE-190-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Figure 8-10: TAPE-191-3-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-11: TAPE-203-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-12: TAPE-221-A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-13: TAPE-368-1-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 8-13 8-14 8-15

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Figure 8-14: TAPE-368-2-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Figure 8-15: TAPE-368-3-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-16: TAPE-368-4-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-17: TAPE-419-D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-18: TAPE-917-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-19: TAPE-932-A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-20: TAPE-933-10-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-21: TAPE-933-1-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-22: TAPE-933-2-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-23: TAPE-933-3-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-24: TAPE-933-4-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-25: TAPE-933-5-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-26: TAPE-933-6-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-27: TAPE-933-7-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-28: TAPE-933-8-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-29: TAPE-933-9-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 8-18 8-19 8-20 8-21 8-22 8-23 8-24 8-25 8-26 8-27 8-28 8-29 8-30 8-31

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Chapter 1: Safety and Support


Chapter Overview
This chapter discusses the following main topics:

Topic Exatron Safety Warnings Facilities Requirements Installation Overview Standard Warranty Exatron Support Services End-of-Life Taper Disposal Significance of This Manuals Version Number Typographical Conventions Used in This Manual Terms Used in This Manual

Page 1-1 1-2 1-4 1-4 1-6 1-6 1-7 1-8 1-8

Please read and understand this entire manual before installing or using your Exatron taper. 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 taper is simply one part of a complete test system. It is the responsibility of the company purchasing the taper to properly train all taper 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 taper. Its motors are very powerful and can cause severe injury. WARNING! Never try to stop an action of the taper with your hands or any other device. To stop, press the Emergency Stop button on the right side of the control box.

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Using compressed air can be hazardous. It is the responsibility of the company purchasing the taper to properly train all taper 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.

Figure 1-1: Emergency Stop Button

Facilities Requirements
Environmental Requirements
The Model 1020 taper 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 taper is greatly enhanced by keeping it as clean as possible. See Chapter 6 for instructions. There are no special ventilation requirements.

Electrical Requirements
Tapers shipped either within the United States or offshore have built-in switching electrical supply capability for 100-volt AC to 240-volt AC, 50Hz to 60Hz at 3 amps or less. Tapers can be wired for either 100-120-volt AC, 60 Hz; or 220-240-volt AC, 50 Hzthis must be specified at time of order.

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Facilities Requirements

Vacuum/Pneumatic Requirements

If the taper is to be used in an electrically noisy environment or near large electromechanical equipment, Exatron recommends the use of a reliable surge protector to filter line noise, surges, and spikes that can cause the taper to operate improperly or become damaged. CAUTION: Connect the power cord to earth-grounded power outlets only. Electricity supplied to the taper must be within the recommended operating range. If the line voltage drops too low, the taper may not function properly and may be seriously damaged. Verify that correct operating line voltage is present. If it is not, contact Exatron for assistance. 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 taper system requires a supply of pressurized air at 50 PSI, filtered at 3 CFM 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. The external air source should be attached to the air regulator mounted on the taper base. Before turning on the air regulator and using the taper, 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 50 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 taper 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 taper'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. Taper damage due to improper air supply is not covered by the Exatron warranty.

Air Connections
Located on the lower right side of the main frame is an air regulator with a pressure gauge and a filter. Before turning on the air regulator and using the Model 1020 taper, make certain that a compressed air line of 80 PSI is attached to the air regulator fitting.

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Figure 1-2: Air Line Attached to Outlet

Installation Overview
Basic installation of your new Exatron taper will consist of the following major steps: Unpacking the equipment and assembling its peripheral parts Powering up the taper ("Power-Up Procedure" on page 3-19) and running Diagnostics sequences (Chapter 4) Cycling sample tubes of devices

Uncrating the Taper


The taper will usually come in a wooden crate which will require some disassembly to remove. 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.

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 which fails during normal use within its first year. The customer agrees to follow the recommended maintenance procedure as defined in this manual. Exatron does not warrant the following: Damage caused by improper packaging of equipment returned to Exatron for repair

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Standard Warranty

Customer In-House Service

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

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 tapers. 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 taper 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 taper 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 taper

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The type of device being run by the taper, such as: DIP, SOIC, SOJ, PLCC, LCC, SIP, PGA, PCB, ZIP, etc. The tapers 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.

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 taper with all its options The exact wording of any messages that appeared on your taper 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.

End-of-Life Taper 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.

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Significance of This Manuals Version Number

Offshore Warranty Service

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 taper. 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 keys on the control panel are enclosed in angle brackets ( < > ), such as: Press the <DIAGNOSTICS> key and then the <1> key. Messages displayed on the hardware or software are enclosed in straight quotation marks ( " " ), such as: When the handler has been instructed by the operator to send a new start test pulse to the tester/PC, the message: "ISSUE NEW START" is displayed. Emphasized words and phrases are displayed in bold and italicized type, such as: Never use oil or lubricant of any kind on solenoids.

Terms Used in This Manual


Blow-off 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 generic term that refers to the chip, package, or other part processed by the Exatron taper. The gap, or pitch, between the leading edge of adjacent tape pockets. This gap is found automatically by the gap sensor when you press <ENTER> to select "SET GAP ? YES". The additional distance, measured in tape drive motor steps, the tape must advance after the gap sensor has found the leading edge of a tape pocket until the center of a tape pocket is directly under the center of the swing arms pickup head. This is a one-time-only advancement of the tape at the beginning of each run. This distance you must set manually for each tape. The distance, measured in tape drive motor steps, between the leading edge of adjacent tape pockets. The location that each motor returns to each time the taper is reset. The total of the parameter values for all the RAM addresses displayed in hex.

Device

Gap

Gap offset, or Offset

Gap steps

Home position

Sum check

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Chapter 2: System Description


Chapter Overview
This chapter discusses concepts of how your taper works. Following chapters show you how to put these concepts into practice and carry out procedures. This chapter deals with the following main topics:

Topic Key Positions How the Model 1020 Works Identifying Major Parts

Page 2-2 2-2 2-3

This chapter will familiarize you with the various parts of the system hardware, what they do, and how they work. 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.

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Key Positions
Figure 2-1 shows all the positions where a device might rest or be deposited during its course through the Model 1020 taper.

Top of octoloader gate

Taper input track Top of index pin Top of stack pin Pickup site w/ cover foot
Swing arm

Tape
Figure 2-1: Key Device Positions

How the Model 1020 Works


Empty carrier tape is fed on to the tape track from the supply reel, and the tape drive motor advances the tape. The octoloader holds up to 8 tubes of devices. Devices in each tube are stopped by an octoloader gate. The octoloader moves right and left, positioning one tube at a time over the input track. It opens the gate to allow devices to fall down the taper input track. When a tube is emptied of devices, the octoloader moves laterally until another tube with devices is located and placed over the input track. On the input track, the stack pin is by default extended, stopping each device. When a signal is received, the index pin extends to hold the line of waiting devices, the stack pin retracts, and the device drops to the tapers pickup site, where it is held by the cover foot. As each device is dropped to the pickup site, the swing arm rotates up over the pickup site, and the pickup head attached to the swing arm extends, picks it up, and retracts. The swing arm then rotates down and the pickup head again extends to place the device in the carrier tape pocket. The drive motor advances the tape one pocket and the process is repeated.

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Identifying Major Parts

Three Reels

A few inches to the left, a group of sensors ensure that each pocket is filled, and that each device lies flat in the pocket. To the left of these sensors, the sealing heads, either thermal or pressure-sensitive, seal the cover tape onto the edges of the carrier tape. At regular intervals set by the user, the takeup reel motor is activated and the filled tape is wound onto the takeup reel.

Identifying Major Parts


Three Reels
The supply reel (sometimes made of cardboard) containing the carrier tape is at the right end of the taper. The takeup reel (usually made of plastic) is at the left end. The supply reel containing the sealing tape is above the sealing area. Supply reel with sealing tape Output or takeup reel Control panel Swing arm with pickup head Supply reel with carrier tape

Tape track right-to-left direction

Figure 2-2: Reels on Taper

The carrier tape is fed in a right-to-left direction from the supply reel, along the tape track and under the swing arm, past the sealing tape and sealing heads, to the takeup reel. On the top surface, the pitch or gap sensor detects the hole in the center of the empty pocket, and signals the position to the swing arm. When the empty pocket intersects the path of the swing arm, the swing arm places a device into the tape pocket.

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Figure 2-3: Tape Track with Swing Armat Pickup Site (Left), at Taper (Right)

After receiving devices from the swing arm, the filled carrier tape is sealed, either with pressure-sensitive sealing tape or heat-sealed cover tape. If pressure is used to seal, the pressure is continuous; but if heat is used to seal, the heat seal heads are pressed against the tape only intermittently to prevent burning. When a specified number of pockets have been filled, the takeup reel motor is activated long enough to wind the slack tape onto the 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.

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Identifying Major Parts

Taper Input Track

Sensor lights

EMO (emergency stop) button

Heater controller displays Override button lights Heater fuse Pressure seal heads

Empty pocket sensor Takeup arm

Pressure roller block

Track width locking knob


Figure 2-4: Other Features of Taper (Model 201)

Taper Input Track


The taper input track is below the octoloader, at the swing arm. This track has solenoids that control an index pin, a stack pin, and a cover foot. During a production run, the stack pin is by default extended, restraining the waiting line of devices. When the swing arm on the tape-and-reel assembly is ready to move another device, the index pin is extended between the lowest device in line and the device just above it. Then the stack pin is retracted, allowing the lowest device to fall. The stack pin and cover foot are activated simultaneously to prevent the device from jumping the stop block. Thus, when the stack pin retracts to release a device, the cover foot is extended to hold the device at the pickup site momentarily until any bouncing action stops.

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Figure 2-5: Index Pin Retracted (Left), Extended (Right)

Figure 2-6: Cover Foot Retracted From Pickup Site and Stack Pin Extended (Left); Cover Foot Extended Over Pickup Site and Stack Pin Retracted (Right)

Emergency Stop Button


The EMO (emergency stop) button on the taper control box shuts down everything on the taper, including the heat seal. Pressing the tapers EMO button causes a taper error message to be displayed on the control panel. 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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Motors and Drive Chains

Motors and Drive Chains


The motors driving the octoloader, swing arm, and tape drive are DC stepper motors. Stepper motors have no homing routine. However, Exatron has added sensors that tell the software when the component is at its "home" position according to the Exatron software (Figure 2-8). Each motor drives movement by means of a chain, whose tension can be adjusted by loosening and moving the red tensioner slightly.

Figure 2-7: Motor with Drive Chain

Figure 2-8: Drive Chain Tension Adjuster for Octoloader

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The motor driving the tape drive is located directly behind the tape drive gear adjustment knob.

Tape drive motor

Tape drive gear adjustment knob


Figure 2-9: Tape Drive Motor

The motor driving the takeup reel is inside the housing for the control panel (Figure 2-10).

Figure 2-10: Takeup Reel Motor

The sealing heads are driven, not by a motor, but by air solenoids.

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Octoloader

Octoloader
Exatron's octoloader is an ambient automatic eight-tube loader. The standard Model 1020 comes equipped with this octoloader which is a moving metal plate holding up to eight tubes of devices, controlled by the tapers EPROM by means of a stepper motor. The plate automatically moves both left and right, positioning each tube of devices over the handler input track. When the input track is emptied, the octoloader automatically searches for tubes with devices. The octoloader has a sensor mounted at its junction with the input track. The octoloader can "see" a device jam and stop its own movement to prevent breaking the jammed device. The octoloader also has an automatic "wiggle" jam-clearing operation which it will implement immediately in an effort to remove the jam without operator assistance. Model 1020 octoloaders use a snap-on plate which is specifically fitted with tube holders for a given device application. It can be snapped on and unsnapped to clear device jams. When the octoloader is at its home position, it is pressing the sensor on the red octoloader stop.

Figure 2-11: Octoloader at Home Position

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Figure 2-12: Octoloader Back with Snap-On Pins (Left); Octo Car Block with Holes for Snap-On Pins (Right)

Figure 2-13: Octoloader Front with Two Tubes Attached

Each of the 8 octoloader chutes has a gate that restrains the devices. As the octoloader moves each tube over the track, the roller depresses the gate for that chute, thus opening it and allowing one device to fall through. Each tube is emptied of devices before the octoloader moves the next tube over the track.

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Octoloader

Each gate acts as a pivot. When not depressed, its pin extends, blocking the fall of devices from the input tube. When a gate is depressed, its pin retracts, allowing devices through.

Figure 2-14: Octoloader Gate Depressed by Roller

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Figure 2-15: Devices Stopped by Octoloader Gate (Left); Devices Released by Octoloader Gate (Right)

Figure 2-16: Octoloader Gate Pin Blocking Exit (Left); Device Exiting Octoloader Chute (Right)

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Sensors

Figure 2-17: Octoloader Gate Closed (Left); Octoloader Gate Opened (Right)

Sensors
The sensors for the Model 1020 taper have descriptive names. Sensor ID A B 9 8 6 5 Figure 2-24 Figure 2-21 Sensor Controller yes yes no no no yes If an image sensor (camera) is attached, it replaces this sensor If an image sensor (camera) is attached, it replaces this sensor

Sensor Name Device at Stack Sensor Device at Pickup Site Sensor Swing Arm Home Sensor Pickup Head Vacuum Sensor Carrier Tape Out Sensor Empty Pocket Sensor

Figure Figure 2-18, Figure 2-19 Figure 2-18, Figure 2-19 Figure 2-26

Comment

Out-of-Pocket Sensor

Figure 2-22

yes

Gap Sensor Takeup Arm Sensor

4 3

Figure 2-23 Figure 2-25

yes no

The sensors shown in Figure 2-18 through Figure 2-23 are fiberoptic; they come with sensor controllers. For more information on the controllers, see "Fiberoptic Photoelectric Sensor Guidelines" on page 6-10.

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Figure 2-18: Device at Stack Sensor (A, Top); Device at Pickup Site Sensor (B, Bottom)

Figure 2-19: Device at Stack Sensor (A, Left); Device at Pickup Site Sensor (B, Right)

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Sensors

Figure 2-20: Taper Sensors

In Figure 2-20, the track is shown with no tape to clarify the directions the various sensor beams are aimed. The Empty Pocket sensor, 5, is aimed downward through the hole in any empty pocket. The Out-of-Pocket sensor, 7, is aimed across the top of the tape, looking for any devices sticking up above the surface of the tape. The Gap sensor, 4, is aimed across the tape. It looks for the gap, where the tape is in a position where the ridge between pockets is even with the Gap sensors beam so that it is not blocked by the tape.

Figure 2-21: Empty Pocket Sensor (5)

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Figure 2-22: Out-of-Pocket Sensor (7)

Figure 2-23: Gap Sensor (4)

The following sensors are not fiberoptic, but rather, photo sensors. They do not have sensor controllers.

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Sensors

Figure 2-24: Carrier Tape Out Sensor (6)

Figure 2-25: Takeup Arm Sensor (3) Closed (Left), Open (Right)

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Figure 2-26: Swing Arm Home Sensor (9, Left); Swing Arm at Home (Right)

The true home of the swing arm is at the Swing Arm Home sensor, not necessarily at the pickup site.

Index and Stack Pins


During a production run, the stack pin is by default extended, restraining the line of devices waiting to fall to the pickup site. When the taper is ready to get another device, the index pin is extended between the lowest device in line and the device just above it. Then the stack pin is retracted, allowing the lowest device to fall. The stack pin and cover foot are activated simultaneously to prevent the device from jumping the stop block. Thus, when the stack pin retracts to release a device, the cover foot is extended to hold the device at the pickup site momentarily until any bouncing action stops.

Seal Heads
The seal heads are pneumatic; they do not use sensors.

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Swing Arm

Figure 2-27: Heat Seal Heads with Counterbalance Weight

Figure 2-28: Pressure-Sensitive (PSA) Seal Heads with Counterbalance Weight

Swing Arm
The swing arm rotates from the pickup site at the bottom of the taper output track to the tape pocket underneath its path.

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Figure 2-29: Swing Arm at Pickup Site (Left), at Tape Drop Site (Right)

At the end of the swing arm is attached a pickup head that raises and lowers to place the device in the tape pocket. The pickup head had a suction cup attached, which passes a negative or positive air flow that acts as a vacuum or blow-off. The pickup head is pneumatic, controlled by air pressure.

Figure 2-30: Pickup Head Retracted (Left), Extended (Right)

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Swing Arm

Taper input track

SWING HOME = c. 12 at pickup site Pickup site SWING HOME = 34 maximum

SWING = c. 122 from pickup site Tape output Swing arm positions SWING = 355 maximum
Figure 2-31: Path and Limits of Swing Arm

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Chapter 3: Taper Setup and RAM Listing


Chapter Overview
This chapter discusses the following main topics:

Topic Mounting the Takeup Reel Mounting the Supply Reel Adjusting the Carrier Tape Track Width Loading the Carrier Tape Loading the Sealing Tape Adjusting Heat Seal Heads Adjusting Pressure Seal Heads Loading Tubes into the Octoloader Power-Up Procedure Aligning the Octoloader Setting Temperature for Heat Seal Heads Calibrating Device Position in Tape Pocket Inspection at Beginning of Tape Beginning a Production Run Power-Down Procedure Understanding the Control Panel Keys Using the <SET UP> Key Modifying Setup Resetting the Count of Devices in Tape Displaying the Count of Devices in Tape Using Manual Mode Changing RAM Notes About the RAM Address Listing RAM Address Listing Hex-Binary Conversion Table Decimal-Hex-ASCII Conversion Table

Page 3-2 3-2 3-3 3-5 3-8 3-12 3-15 3-16 3-19 3-20 3-21 3-26 3-27 3-28 3-29 3-30 3-30 3-31 3-35 3-36 3-37 3-44 3-45 3-47 3-52 3-53

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Mounting the 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 end of the tape-and-reel assembly (Figure 3-1). 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 3-1), slide the locking hub over the reel and back into place. 3. Tighten the thumbscrew to lock the takeup reel in position.

Figure 3-1: Locking Hub on Takeup Reel with Alignment Pins

Mounting the Supply Reel


Slide the carrier tape supply reel onto the three center prongs of the supply wheel so that the carrier tape unwinds in a counterclockwise direction from the top of the reel toward the left (Figure 3-2).

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Figure 3-2: Supply Reel Tape Unwound from Top

Adjusting the Carrier Tape Track Width


You may need to change the carrier tape track width when different sized devices are processed. This procedure is best accomplished along with the next procedure, "Loading the Carrier Tape" on page 3-5. Track width adjustment knobs

Figure 3-3: Carrier Tape Track at Different Widths

This is accomplished using two of three knobs: the track width locking knob, and either of the track width adjustment knobs.

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The track width locking knob is located below and between the cover tape reel and the takeup reel. The track width adjustment knobs are located at both ends of the base. CAUTION: Loosen the track width locking knob before turning the adjustment knobs to prevent bending and damage to the aluminum parts.

Figure 3-4: Track Width Locking Knob

To adjust the width of the carrier tape track: 1. Turn the track width locking knob counterclockwise to loosen it. 2. Turn either the front or back track width adjustment knob to adjust the track width. (They are connected by an internal chain, so they work in tandem.) The carrier tape should slide in the track freely but not loosely, and advance easily without binding, but also without too much lateral play in the track. > To make the tape track narrower, turn the knob clockwise. > To make the tape track wider, turn the knob counterclockwise. 3. At this point, leave the tape track a little wider than necessary and do the following procedure, Loading the Carrier Tape. 4. When the carrier tape has been loaded and the adjustment is correct, retighten the locking knob by turning it clockwise.

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Loading the Carrier Tape

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, making sure that the edge of the tape is under the guide at the side of the track.

Figure 3-5: Carrier Tape Under Guide At Top Supply End of Track

2. 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. 3. When the carrier tape leader in the track reaches the pressure roller assembly, raise the pressure roller arm with your index finger. Slide the keeper pin into the pressure roller block assembly to hold it in the raised position while you feed the carrier tape along the track underneath.

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Figure 3-6: Lifting Pressure Roller Arm and Pushing In Keeper PinTwo Styles

4. Feed the carrier tape under the projecting takeup arm. Insert the carrier tape leader into the takeup reel according to the manufacturer's specifications. Wind the carrier tape around the takeup reel until it is secured in place. The carrier tape should move freely back and forth underneath the takeup arm.

Figure 3-7: Takeup Arm

5. Align the carrier tape with the tape drive gear. Loosen the blue lock nut on the drive gear assembly. Then you can turn the red adjustment nut to allow the gear to move laterally. Adjust the gear teeth to fit with the backside track of the carrier tape. Retighten the blue nut. Next turn the gear using the red thumbscrew section of the gear assembly. This should cause the carrier tape to advance freely towards the takeup reel.

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Loading the Carrier Tape

> Turning the red adjustment nut clockwise moves the teeth and tape to the right, widening the tape path. > Turning the red adjustment nut counterclockwise moves the teeth and tape to the left, narrowing the tape path.

Figure 3-8: Tape Drive Gear Adjustment Knob with Blue Locking Knob Unscrewed

Figure 3-9: Gear Adjustment Narrowed (Left); Widened (Right)

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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 310).

Figure 3-10: 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 3-11). 3. Viewing from above, position the sealing tape supply reel centered over the carrier tape in the carrier tape track. Tighten the adjustment setscrew on each supply reel adjustment collar to secure the sealing tape supply reel in this position on the rod. 4. The sealing tape unwinds from the bottom of the reel in a counterclockwise direction toward the sealing tape guide assembly. > For a pressure-sensitive sealing tape, 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 (Figure 3-11). Notice that the tape rests on the upper, larger projecting pin but never touches the lower, smaller projecting pin.

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Loading the Sealing Tape

Figure 3-11: Sealing Tape Threaded to Sealing Tape Guide Assembly for PSA

> For a heat sealing tape, feed the sealing tape to the right under the lower, smaller projecting pin, then over the upper, larger projecting pin of the sealing tape guide assembly and under the guide block to the left (Figure 3-12).

Figure 3-12: Sealing Tape Threaded to Sealing Tape Guide Assembly for Heat

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Figure 3-13: Sealing Tape Threaded Under Guide Block

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

Figure 3-14: Two Widths of Guide BlocksTop View (Left); Bottom View (Right)

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Loading the Sealing Tape

Figure 3-15: 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 two guide block screws. > If you need to change the guide block, slip the guide rod partway out and replace the guide block on the rod (Figure 3-16). Then replace the rod in the bracket.

Figure 3-16: Guide Rod Removed from One Bracket

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.

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> While holding the thin edge down, tighten the two red adjustment screws on the guide block assembly (Figure 3-17). The carrier tape should now be inside the outer set of grooves on the guide block.

Guide block adjustment screws


Figure 3-17: Guide Block Assembly

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 Heat Seal Heads


Two adjustments may need to be done for a pair of heat seal heads: lateral alignment and downward pressure. 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.

Adjusting Lateral Position


If your Model 1010 taper is equipped with heat seal heads, use this procedure to align the lateral position of each head separately. To align lateral position of heat seal heads: 1. Make sure the heaters are off and the thermal heads are cool. There are two

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Adjusting Lateral Position

readouts for each heater controller display. The top line is the present value (PV) and the bottom line is the set value (SV). Set the bottom line to 0 degrees (see "Setting Temperature for Heat Seal Heads" on page 3-21 for instructions), and wait until the sealing head is at ambient room temperature. 2. Remove the seal head closest to you (the front seal head). Use a #10 size hex wrench and remove the seal head adjustment screw. Remove the seal head and lay it aside. 3. Loosen the adjustment screw on the back seal head. Adjust the head laterally so that it is directly over the back edge of the sealing tape. 4. Manually engage the back seal head and confirm that the edge of the seal head is aligned with the back of the sealing tape. Make sure that the track holes on the carrier tape are not blocked by the sealing tape. 5. With the seal head engaged, tighten the adjustment screw. 6. Repeat this process with the front sealing head. Adjustment screw

Figure 3-18: Semicircular Seal Head with Adjustment Screw

7. Once both heads are aligned, turn the heat to the sealing heads on. Note that you must power on the taper in order to do this. (See "Power-Up Procedure" on page 3-19.) Set the bottom line (the Set Value) on both heaters to 350 degrees. (For instructions on changing the Set Value, see "Setting Temperature for Heat Seal Heads" on page 3-21.) Wait until the top line (the Present Value) reads 350. WARNING: Do not touch the heat seal heads directly when the heat is turned on. 8. After the sealing heads have warmed up, check the seal on the sealing tape.

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Manually engage both seal heads. Apply pressure to the sealing tape for 3 to 5 seconds. Use the takeup arm to engage the heads. This should cause a good seal to the carrier tape. Manually advance the carrier tape and inspect the seal. 9. Run the carrier tape for several pockets with the seal heads 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.

Figure 3-19: Example of Good Tape Seal

Adjusting Downward Pressure


To balance the heat temperature with the pressure applied, you may want to adjust the pressure of the heat seal heads. To adjust pressure of heat seal heads: If more pressure is needed to allow a lower heating temperature, add a heavier weight to the counterweight bar (Figure 3-20).

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Adjusting Pressure Seal Heads

Adjusting Downward Pressure

Figure 3-20: Three-Gram and One-Gram Weights (Left); One-Gram Weight on Heat Seal Counterbalance

Adjusting Pressure Seal Heads


Two adjustments may need to be done for a pair of pressure seal heads: the lateral alignment of the rollers, and the weights that cause downward pressure. Correct lateral alignment assures that the seal heads are on the sealing edges of the tape; correct pressure assures a good seal. Lateral adjustment screws

Figure 3-21: Pair of Pressure Seal Heads with Lateral Adjustment Screws

To move either pressure seal head laterally, loosen the adjustment screw and pull or push the head to the correct position. Retighten the screw when the adjustment is correct.

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Figure 3-22: Three-Gram and One-Gram Weights (Left); One-Gram Weight on PSA Counterbalance

If the PSA is not applying enough pressure for a good seal, you can adjust the weight for more pressure. To increase pressure, switch to a heavier weight. To decrease pressure, switch to a lighter weight.

Loading Tubes into the Octoloader


Exatron's eight-tube capacity automatic tube loading mechanism, called the octoloader, will automatically load any device supplied in tubes into your Exatron system. The octoloader assembly snaps onto the system for easy conversion from one device size/type to another.

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Loading Tubes into the Octoloader

Adjusting Downward Pressure

Figure 3-23: Octoloader

The octoloader is a moving plate that holds tubes of devices and is controlled by a stepper motor. During production, the plate automatically moves from side to side, positioning each tube above the input track. When the input track becomes empty, the octoloader automatically searches for tubes with devices. A sensor mounted at the junction of the input track allows the octoloader to "see" a device jam, if one occurs. The octoloader then stops moving to prevent damage to the jammed device. In addition, the octoloader has an automatic "wiggle" cycle that will attempt to clear the jam automatically, without operator assistance. (This feature can be turned off at the control panel if necessary.) NOTE: Tubes are installed upside down into the octoloader. To install full tubes into the octoloader: 1. If your model comes with blue anodized tube gates, turn them so that they are in the open or vertical position. 2. Remove the stopper from the top of a full tube of devices. Keeping the open end higher than the closed end, hold the lower half of the tube in one hand and guide the top of the tube to the octoloader with the other hand. 3. Keeping the open end higher than the closed end, press the open end of the tube firmly against the octoloader main plate at the bottom end of the track.

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Figure 3-24: Loading a Tube Perpendicular to Octoloader

4. Keep the open end of the tube pressed against the octoloader to prevent spilling the devices and raise the bottom end of the tube until it is completely upside down. Press the tube into place in the track of the octoloader.

Figure 3-25: Securing Tube at Bottom of Input Track

5. Close the tube gate (if so equipped) over the tube to complete installation. Repeat this process for each additional tube.

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Power-Up Procedure

Adjusting Downward Pressure

Power-Up Procedure
Before powering up the taper, do the following: 1. Connect the taper power cord to the power supply, and plug the power supply only into a 120/100-volt AC 50/60 Hz grounded power outlet. 2. Make sure the air regulator is turned off before connecting the taper to a clean, dry air pressure supply. Air supply should be free from moisture and oil. After connecting to the air supply, turn on the air regulator. Adjustment valve On/off switch in OFF position On/off switch in ON position

Figure 3-26: Air Regulator Turned Off (Left), On (Right)

3. Move the octoloader plate so that it is flush against the octoloader home switch. 4. Place tubes of devices into the octoloader. You are now ready to power up the Model 1020 taper. NOTE: For thermal tape systems, powering on the Model 1020 also turns on the heaters in the sealing heads. To power up the taper: 1. Turn on the tapers power supply by twisting the red EMO (emergency stop)

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button clockwise on the power supply until it pops out. > As the taper powers up, it displays a list of messages like the following, with its model and current control program with revision date. (Please give this revision date to Exatron's Customer Service Department when calling for assistance or software updates. Exatron offers free firmware updates on request for the life of the equipment.) V02.14 Test Ok EXATRON TAPE TAPE-2 11-16-05 MOD SET UP ? NO FIND MOTOR HOME HOME SWING HEAD MOTOR HOME TAKE UP MOTOR ON READY TO RUN ?

Aligning the Octoloader


Each day on power-up, you may need to align the octoloader. Vibrations from a long run may have gotten it slightly out of alignment. To align the octoloader: 1. With the taper on, press the <DIAGNOSTICS> key. > Taper displays "DIAGNOSTICS". 2. Press the <4> key. > Taper displays "ALL MOTOR CHECK". 3. Press the <3> key. > Taper displays "OCTO MOTOR CHK". 4. Press the <1> key to move the octoloader one input tube to the left, or any position such that the octoloader tube 1 is left of the test rail. 5. Loosen the two screws on the octo stop block.

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Setting Temperature for Heat Seal Heads

Adjusting Downward Pressure

Figure 3-27: Octo Stop Block

6. Press the <3> key to move the octoloader tube 1 approximately over the test rail. 7. Press the <7> or <9> key as needed to jog the octoloader tube 1 directly above the track. 8. When tube 1 is precisely aligned with the track, gently push the octo stop block flush against the right side of the octoloader, and tighten the lower screw. 9. Press the <1> key to move the octoloader one input tube to the left. 10. Carefully tighten the upper screw on the octo stop block, being sure not to move it. 11. Test your alignment: Press the <8> key to move the octoloader a predefined number of motor steps to the left, then back to the home sensor. It should still be flush with the octo stop block. You can change this number of motor steps by changing the RAM address 009E. See "Changing RAM" on page 3-44.

Setting Temperature for Heat Seal Heads


The red/orange temperature readouts in the lower SV (Set Value) display are the desired temperatures. The green temperature readouts in the upper PV (Present Value) display are the actual or current temperatures. The front sealing head is the one nearest you as you stand in front of the taper.

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Present Value temperature

Set Value temperature


Figure 3-28: Heater Controller Display

In Figure 3-28, the back heat seal head has been set to 350 degrees, and the current temperature is 347 degrees. When the seal head is heating, the green LED light to the left of the Set Value display is on. When the present temperature is stable, the orange LED light to the left of the Present Value display is on. A general guideline may be to use somewhere around 275 to 325 degrees Fahrenheit (or 135 to 165 degrees Celsius) for a heat seal. If in doubt, it is better to start with a lower temperature and test the result, then increase little by little as needed. A narrow carrier tape takes a lower temperature to prevent burning. NOTE: It should not take more than 2-3 minutes to heat the seal heads to the Set Value. If it takes longer, the Set Value may be too high. To set the temperature: This example changes the set temperature from 0 degrees to 275 degrees. 1. Press the SET button on the lower left of the temperature control display (Figure 3-29). > The lower display blinks rapidly, indicating it is ready to be set.

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Adjusting Downward Pressure

Figure 3-29: SET Button

2. Press the Up arrow button (Figure 3-30) repeatedly until the 0 changes to 5 (Figure 3-31).

Figure 3-30: Up Arrow Button

Figure 3-31: Digit in Ones Position Selected

3. Press the Left arrow button (Figure 3-32) to shift the digit that lights up to the tens digit.

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Figure 3-32: Left Arrow Button

4. Press the Up arrow button repeatedly until the 0 changes to 7 (Figure 3-33).

Figure 3-33: Digit in Tens Position Selected

5. Press the Left arrow button to shift the digit that lights up to the hundreds digit. 6. Press the Up arrow button repeatedly until the 0 changes to 2 (Figure 3-34).

Figure 3-34: Temperature Set Before the SET Button Is Pressed

7. Press the SET button again. All the set value digits stop blinking and light up in

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Setting Temperature for Heat Seal Heads

Adjusting Downward Pressure

a steady display, and the temperature (PV) increases rapidly.

Figure 3-35: Temperature Set After the SET Button Is Pressed

8. Repeat the procedure for the other seal head. To turn off the heat seal heads: 1. Press the SET button on the lower left of the temperature control display. > The lower display blinks rapidly, indicating it is ready to be set. 2. Press the Down arrow button until the ones value is 0 (Figure 3-36).

Figure 3-36: Down Arrow Button

3. Press the Left arrow button to shift the digit that lights up to the tens digit. 4. Press the Down arrow button until the tens value is 0. 5. Press the Left arrow button to shift the digit that lights up to the hundreds digit. 6. Press the Down arrow button until the hundreds value is 0 (Figure 3-37).

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Chapter 3: Taper Setup and RAM Listing

Figure 3-37: Temperature Set to Zero Before the SET Button Is Pressed

7. Press the SET button again. All the set value digits stop blinking and light up in a steady display. 8. Repeat the procedure for the other seal head.

Calibrating Device Position in Tape Pocket


To calibrate the optimal placement of the devices in the tape pockets: 1. Turn on the taper. (If it was already on, turn it off and back on.) > The swing arm moves to its home position over the pickup site. 2. Drop a device into the track. > The device falls to the pickup site. 3. Press the <SET UP> key on the control panel. 4. Follow the instructions in "Modifying Setup" on page 3-31 and especially "Selecting Manual Cycling" on page 3-35 to set the taper to Stop mode. 5. In Stop mode, press the <ENTER> key repeatedly until the swing arm has dropped a device in the tape pocket. 6. Examine the position of the device in the pocket.

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Inspection at Beginning of Tape

Adjusting Downward Pressure

Figure 3-38: Tape Calibration Needed

> If the swing arm places the device to one end of the pocket or between pockets, the tape position needs to be calibrated. Follow the instructions in "ALL MOTOR CHECK: Drive Motor Check" on page 4-16.

Figure 3-39: Swing Arm Calibration Needed

> If the swing arm places the device to one side of the pocket or the other, the swing arm needs to be calibrated. Follow the instructions in "ALL MOTOR CHECK: Swing Arm Check" on page 4-17.

Inspection at Beginning of Tape


When you run the leader of a new tape, the first pockets will necessarily be empty. If camera inspection is turned on, you will get the message "INSPECTION FAIL." First press the <1> key. The message reads "NEW JOBEMPTY OK". If the failure is because a new tape has been mounted with empty leader pockets, press the <2> key to confirm. The message reads "RUN UNTIL 1 PASS". Empty pockets will be advanced until a good device is inspected. Then the inspection routine will inspect each pocket. For information on using the camera or image sensor, see the camera manufacturers documentation. The only thing that is not evident from that documentation is how to enter the cameras Teach mode. This is accomplished by touching with the stylus the blue dashed line or ROI (Figure 340). After touching, the ROI becomes a solid red line and the Teach button is visible (Figure 341).

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Chapter 3: Taper Setup and RAM Listing

Figure 3-40: Touching the Blue Dashed ROI Border

Figure 3-41: ROI Turns Red and Teach Button Is Visible

Beginning a Production Run


Before beginning a production run, make sure that the taper is powered up, as described in "Power-Up Procedure" on page 3-19. Then make sure the octoloader is at the Exatron-designated home position.

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Power-Down Procedure

Homing the Octoloader

Homing the Octoloader


There is no single command that homes the octoloader. To home the octoloader: 1. Press the <MANUAL> key to enter Manual mode. 2. Press <0> to turn off all motors. The octoloader will now move freely. 3. Slide the octoloader all the way to the left. 4. Press <ENTER>. The message ALIGN MOTORS ? is displayed. 5. Press <ENTER> again to turn the motors back on.

To begin a production run: 6. Press the <RUN> key on the tapers control panel. > The tapers control panel message changes from "READY TO RUN ?" to "WAITING." When enough devices are stacked in the tapers input track, the taper will begin transferring the devices to the tape automatically. No further action is needed by you.

Power-Down Procedure
In case of unexpected events, you can push in the EMO button to turn off the power to the taper at any time. CAUTION: Allow at least 30 seconds before turning the taper's power back on. Avoid rapid OFF/ON cycles. To power down the system: 1. Run the taper until empty of all devices. Finish the current job. 2. Empty all output tubes, or replace with empty tubes. 3. Turn the taper power off by pushing in the EMO button on the right side of the tapers control panel.

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Chapter 3: Taper Setup and RAM Listing

Understanding the Control Panel Keys


In Ready To Run mode or after you press the <PAUSE> key, the taper's control panel keys have the following functions: Key <ENTER> Function Starts operations; enters your selections into the system If you dont make any selections before pressing <ENTER>, the selection that was last in effect will be used. ADD LEADER UPAdvances tape drive motor and takeup reel motor, with seal heads up in inactive position. ADD LEADER DOWNAdvances tape drive motor and takeup reel motor, with seal heads down in active position. Erases changes just made to current setting. POCKETS = ######Displays number of devices already placed in tape. Puts taper in Manual mode. CHANGE RAM ? YES/NOEnables you to change RAM settings. RESET COUNT NOEnables you to reset the count of devices in tape to zero. MOD SET UP ? YES/NOEnables you to modify setup parameters. Pauses taper operation. Displays total devices placed in tape. Function of numeric keys depends on the mode. See "Using Manual Mode" on page 3-37 or "Diagnostics Quick Reference" on page 4-4. For long display messages, scrolls to left end of message 1 character at a time. For long display messages, scrolls to right end of message 1 character at a time.

<SPACE> <DELETE> <CLEAR> <RUN> <MANUAL> <SET UP>

<PAUSE> <TOTALS> <0>-<9> < >

<DIAGNOSTICS> Puts taper in Diagnostics mode.

If your taper is not running properly at this point, you may wish to enter directly into the Diagnostics mode upon taper power-up. See Chapter 4 for more information.

Using the <SET UP> Key


A number of options are available from the <SET UP> key. You will be stepping through several options, as shown in Figure 3-44. Step-by-step instructions continue on page 3-34. As a reference, you can skip to the desired subtopic:

Topic Changing RAM Resetting the Count of Devices in Tape Modifying Setup

Page 3-44 3-35 3-31

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Modifying Setup

Homing the Octoloader

Figure 3-42: <SET UP> Key Flowchart

Modifying Setup
During the taper's powering up message sequence, you can set the taper to go immediately to "DIAGNOSTICS" or "CHANGE RAM". Always select "CHANGE RAM ? YES" when installing new taper update EPROMs into the taper. At the end of the taper's powering up message sequence, the first option given to you is "MOD SET UP ? NO" (modify setup). If you do not wish to make any changes to the taper's setup, press the <ENTER> key. The taper will then scroll through the current settings for: > THERMAL OR PSA (heat seal tape or pressure-sensitive seal tape) > FULL T = ###### (number of devices to be placed in tape) > SET GAP ? NO (find distance between two adjacent pocket gaps)

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> GAP STEPS = #### (distance between two adjacent pocket gaps) > OFFSET = #### (distance between gap and next pocket center) > ALL MODES OFF ? (STOP mode, LOOP mode, or none) If you wish to change any or all of the above settings, press the <SET UP> key to change the "MOD SET UP ? NO" message to "MOD SET UP ? YES" (modify setup). Now press the <ENTER> key to make changes. You will be stepping through several options, as shown in Figure 3-44. Step-by-step instructions continue on page 3-34. As a reference, you can skip to the desired subtopic:

Topic Selecting Type of Tape Seal Selecting Number of Devices to Be Put in Tape Setting Tape Pocket Gap Selecting Manual Cycling

Page 3-34 3-34 3-34 3-35

Understanding the Gap


A few term definitions are in order before you set the tape pocket gap. The gap is the distance, or pitch, between the leading edge of adjacent tape pockets. This distance is found automatically by the gap sensor when you press <ENTER> to select "SET GAP ? YES". The gap offset, or offset, is the additional distance, measured in tape drive motor steps, the tape must advance after the gap sensor has found the leading edge of a tape pocket until the center of a tape pocket is directly under the center of the swing arms pickup head. This is a one-time-only advancement of the tape at the beginning of each run. This distance you must set manually for each tape. The gap steps is the distance, measured in tape drive motor steps, between the leading edge of adjacent tape pockets. Gap Offset

Figure 3-43: Gap Versus Offset

The gap steps value must always be higher than the offset value.

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Modifying Setup

Understanding the Gap

Figure 3-44: Modify Setup Flowchart

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Selecting Type of Tape Seal


The taper control panel displays "THERMAL OR PSA ?" Select one of the following keypad choices: <1> key = "USE THERMAL TAPE"Use a heat seal. <1> key = "USE PSA TAPE"Use a pressure-sensitive adhesive seal. <CLEAR> = Redisplays the message "THERMAL OR PSA ?" and gives you a chance to change your selection. <ENTER> key = Press to confirm your selection.

Selecting Number of Devices to Be Put in Tape


The taper displays "FULL T = ######" showing a number up to 999,999. This is the number of devices the taper will place into the tape. CAUTION: Be careful not to set the count for more devices than will fit into the reel of tape. Use the keypad to make your selection. The taper accepts changes to each digit from lowest to highest, in order; that is, Ones, Tens, Hundreds, Thousands, etc. Thus, the first number key you press changes the ones value; the second number key you press changes the tens value, and so forth. This is called Polish notation. For example, if you want to put 1852 devices in a tape, you change the number this way: Press the <2> key, then the <5> key, then the <8> key, then the <1> key, then the <0> key twice. <-> The minus key resets the count to 000000. <CLEAR> = key = Redisplays the message "FULL T = ######" and gives you a chance to change your selection. This also reloads the EPROM default values for this setting. <ENTER> key confirms your selection.

Setting Tape Pocket Gap


The taper displays "SET GAP ? NO." The gap is the ridge between adjacent tape pockets. <ENTER> key = Press to display current settings. The display reads "GAP STEPS = ####", then "OFFSET = ####". <SET UP> key = "SET GAP ? YES"This proposes to re-find the gap between the leading edges of two adjacent tape pockets.

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Resetting the Count of Devices in Tape

Selecting Manual Cycling

<ENTER> key = Press to advance the tape and have the taper reset the distance between the gaps at either end of a tape pocket. NOTE: If you get a "NO POCKET? ERROR" message, it means the sensor cannot find the gap. Press down lightly on the tape to let the sensor find the gap. <CLEAR> key = Redisplays the message "SET GAP ? NO" and gives you a chance to change your selection. <ENTER> key confirms your selection. The taper displays "SET OFFSET = ####". Use Polish notation to change the offset if necessary. See "Understanding the Gap" on page 3-32. <ENTER> key confirms your selection.

Selecting Manual Cycling


The taper displays "ALL MODES OFF ?" or "STOP MODE ON/OFF." Stop and loop modes are for testing and troubleshooting of the taper. Select one of the following keypad choices: <1> key = "STOP MODE ON ?" The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. <2> key = "LOOP MODE ON ?" The taper will stop after a complete cycle for one device. <3> key = "ALL MODES OFF ?" The taper will cycle multiple devices in a normal run. This is the default. <CLEAR> key = Redisplays the message "STOP MODE ON/OFF" and gives you a chance to change your selection. <ENTER> key = Enters your selection into the taper. The taper will now display "READY TO RUN ?." NOTE: Any time the taper is running, you can press the <SET UP> key. This stops the taper and offers you the options to "CHANGE RAM ?", then "RESET COUNT", then "MOD(ify) SET UP ?"

Resetting the Count of Devices in Tape


The taper keeps a running count of total devices placed in the tape. These counts are preserved in the battery-backed-up RAM, even when the taper is turned off. Therefore, you have to reset the counts to zero at the control panel.

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To keep an accurate count of devices processed, you may want to reset the totals at the beginning of each day or of each production run. To reset the count: 1. Press the <SET UP> key. > The message "CHANGE RAM? NO" is displayed. 2. Press the <ENTER> key. > The message "RESET COUNT NO" is displayed. 3. Press the <SET UP> key. > The message "RESET COUNT YES" is displayed. 4. Press the <ENTER> key. > The message "COUNT SET TO 0" is displayed briefly, then the taper goes back to the routine it was in before you pressed <SET UP>.

Displaying the Count of Devices in Tape


Before, during, or after a run, you can display the total number of devices placed in the tape since the count was last reset to zero. To display the totals: 1. Press the <TOTALS> key. > If the taper is doing a run, it pauses. The message "POCKETS = ######" is displayed, with up to 6 digits represented by the pound signs. 2. Press <ENTER> to quit viewing the count and resume previous action.

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Using Manual Mode

Selecting Manual Cycling

Using Manual Mode


Manual mode allows you to: Make mechanical adjustments to the taper Check and modify settings related to tape pocket size Check and modify settings related swing arm position Select special troubleshooting modes (stop mode or loop mode) Select seal type (thermal or PSA) Reset total output counts

You can access Manual mode while the taper is processing devices or at any other time. Manual mode steps you through a number of options, as shown in Figure 3-45. Step-by-step instructions begin on page 3-39.

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Figure 3-45: Manual Mode Flowchart

Using Manual Mode

Selecting Manual Cycling

To use Manual mode: 1. Press the <MANUAL> key. If the taper is processing devices, it is paused. > If the password security is turned on, the display reads "PASSWORD ABC ?" Enter a 3-digit password using the numeric keys. The factory-set password is 123, or <1>, <2>, <3>. > The message "MANUAL ######" is displayed, with each pound sign representing a digit of the tape output count. 2. Select one or more of the following keypad choices: <1> key = "NEW TAPE SET UP?"Select the tape setup corresponding to the device type you want to run. <1> key = "RUN 5 X 5 MLF"Use the tape configuration for this device size. <2> key = "RUN 4 X 4 MLF"Use the tape configuration for this device size. <3> key = "RUN SSOIC"Use the tape configuration for this device size. <4> key = "RUN DEFAULT 4"Use another configuration that you have set up. <ENTER> key = Press to confirm your selection. The settings for the setup type selected are displayed. Then the taper returns to the previous mode. <2> key = "FULL T = ######"This is the number of devices that will make up a full reel of tape. It can be any number up to 999,999. You can change this number by using the number keys on the control panel. Work from right to left: Start with the smallest (ones) digit, then the tens digit, and work up to the largest digit. For example, to enter the number 001248, press <8>, <4>, <2>, <1>, <0>, <0>. <ENTER> key = Press to confirm your selection. Next, "RESET COUNT NO" is displayed. <ENTER> key = Press to leave the tape output count as it is and return to the previous mode.

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<SET UP> key = "RESET COUNT YES"This will reset the count of tape pockets filled or passed through the taper to zero. Press <ENTER> to reset the count. The display then reads "COUNT SET TO 0" and returns to the previous mode. <3> key = "THERMAL OR PSA ?"Select the type of seal you want to use. <1> key = "USE THERMAL TAPE"Use a heat seal. <2> key = "USE PSA TAPE"Use a pressure-sensitive adhesive seal. <ENTER> key = Press to confirm your selection and return to the previous mode. <4> key = "SET GAP ? NO" <ENTER> key = Press to display current settings. The display reads "GAP STEPS = ####", then "OFFSET = ####", then "SWING HOME = ##", then "SWING STEP = ###". Each pound sign (#) is replaced by a digit. <SET UP> key = "SET GAP ? YES"This proposes to re-find the gap between tape pockets. <ENTER> key = Press to advance the tape and set the gap. The display reads "JOG LEFT", then "GAP STEPS = ####, then "OFFSET = ####", and stops at "SET OFFSET= ####". NOTE: If you get the message "NO POCKET? ERROR", it means it cant find the gap. Press down lightly on the tape. You can change the offset number by using the number keys on the control panel. Work from right to left: Start with the smallest (ones) digit, then the tens digit, and work up to the largest digit. For example, to enter the number 0725, press <5>, <2>, <7>, <0>. When you finish, press <ENTER> again to redisplay the current settings. <5> key = "FIND MOTOR HOME", "HOME SWING HEAD", then "MOTOR HOME"This automatically resets the swing arm at the pickup position. <6> key = "POCKETS = ######"The drive motor advances by one pocket and activates seal heads; the count of pockets increments by one. However, the swing arm is not activated to get a device from the pickup site. Because it does not attempt to place a device in a pocket, this feature allows the operator to either (1) check the location and quality of the seal, or (2) place devices in the tape manually without running them through the input tubes.

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Using Manual Mode

Selecting Manual Cycling

<7> key = "SWING HEAD CHECK" <1> key = "PART AT PICK UP" or "TAPE STACK EMPTY" or no message One of 3 responses, depending on the situation: If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, and no message is displayed. If a device is already at the pickup site, the message "PART AT PICK UP" is displayed. If no devices are at either the stack or the pickup site, the message "TAPE STACK EMPTY" is displayed. Note that this action is a subset of <5>, below. <2> key Toggles pickup cylinder on/off. <3> key Toggles vacuum on/off. <4> key = "SET GAP ? NO" <ENTER> key = Press to display current settings. The display reads "GAP STEPS = ####", then "OFFSET = ####", then "SWING HOME = ##", then "SWING STEP = ###". Each pound sign (#) is replaced by a digit. <SET UP> key = "SET GAP ? YES"This proposes to re-find the gap between tape pockets. <ENTER> key = Press to advance the tape and set the gap. The display reads "JOG LEFT", then "GAP STEPS = ####, then "OFFSET = ####", and stops at "SET OFFSET= ####". NOTE: If you get the message "NO POCKET? ERROR", it means it cant find the gap. Press down lightly on the tape. You can change the offset number by using the number keys on the control panel. Work from right to left: Start with the smallest (ones) digit, then the tens digit, and work up to the largest digit. For example, to enter the number 0725, press <5>, <2>, <7>, <0>. When you finish, press <ENTER> again to redisplay the current settings. <5> key = "PART AT PICK UP" or "TAPE STACK EMPTY" or no message One of 3 responses, depending on the situation. Note that <1> is a subset of this full cycle:

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If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, the swing arm moves the device to the tape, and the tape advances by one pocket and seals one pocket. No message is displayed. If a device is already at the pickup site, the message "PART AT PICK UP" is displayed. If no devices are at either the stack or the pickup site, the message "TAPE STACK EMPTY" is displayed. <6> key = "POCKETS = ######"The drive motor advances by one pocket and activates seal heads; the count of pockets increments by one. However, the swing arm is not activated to get a device from the pickup site. Because it does not attempt to place a device in a pocket, this feature allows the operator to either (1) check the location and quality of the seal, or (2) place devices in the tape manually without running them through the input tubes. <7> key = "SWING STEP = ###" or "SWING HOME = ###." The result of pressing this key depends on the current position of the swing arm. When the swing arm is over the tape: "SWING STEP = ###." The number gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs up one motor step. When the swing arm is over the pickup site: "SWING HOME = ###." The number gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs up one motor step. This is because the swing arm home sensor is just below the pickup site. <8> key = The result of pressing this key depends on the current position of the swing arm. If swing head is down over tape: "FIND MOTOR HOME", then "HOME SWING HEAD", then "MOTOR HOME"jogs, rotates, and returns swing arm to home position. If swing head is up at home or pickup position: "ROTATE DOWN"head rotates down to tape position. <9> key = "SWING STEP = ###" or "SWING HOME = ###." The result of pressing this key depends on the current position of the swing arm. When the swing arm is over the tape: "SWING STEP = ###." The number gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs down one motor step. When the swing arm is over the pickup site: "SWING HOME = ###." The number gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs down one motor step.

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Using Manual Mode

Selecting Manual Cycling

<8> key = "STOP MODE ON/OFF"Select the mode you want to run. <1> key = "STOP MODE ON ?"The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. <2> key = "LOOP MODE ON ?"The taper will stop after a complete cycle for one device. <3> key = "ALL MODES OFF ?"The taper will cycle multiple devices in a normal run. This is the default. <ENTER> key = Press to confirm your selection and return to the previous mode. <9> key = "TAKE UP MOTOR CK"This turns on the takeup motor until one of 3 things happens: (1) the takeup arm is raised by the tautness of the tape, or (2) you gently lift the takeup arm to turn the motor off, or (3) the time limit in number of seconds is reached. If the motor turns for the full time specified without the takeup arm being raised, the message "TAKE UP REEL ERR" is displayed. At this point you can press either of two keys: <ENTER> key = Press to rotate reel again. <CLEAR> key = Press to return to Manual mode. <0> key = "ALL MOTORS OFF"This turns off the octoloader and swing arm motors, allowing you to move them freely. It does not, however, turn off the takeup and tape drive motors. Press <ENTER> to turn the motors back on. The message "ALIGN OCTOLOADER" is displayed. <DELETE> key = "ADD LEADER DOWN"Runs the takeup and drive motors for the specified number of pockets (stored in RAM addresses) with the sealing heads down, in the active position. This creates a leader of sealed, empty pockets on a new reel, or a place to cut the tape to separate filled tape from unused tape. <CLEAR> key = Press to stop the motors and return to the previous mode. <SPACE> key = "ADD LEADER UP"Runs the takeup and drive motors for the specified number of pockets (stored in RAM addresses) with the sealing heads up, in the inactive position. This creates a leader of unsealed, empty pockets. <CLEAR> key = Press to stop the motors and return to the previous mode.

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<ENTER> key = Press to confirm your selection and return to the previous mode.

Changing RAM
The Model 1020 system allows you to change the RAM of each taper CPU. You can do this in one of three ways: You can change individual address values, or settings. You can reload all the default settings from the EPROM. This will erase any changes that have been made to individual addresses. You can reload all the default settings from the EPROM, and then change individual address settings. NOTE: If you consistently use a RAM address setting that is different from the default in the EPROM, write down your changes and fax them to Exatron, and we will send you, free of charge, a new EPROM containing the default settings you use. This will help you avoid unnecessary future changes and confusion over lost changes. When you press the <SET UP> key, you have several options, as shown in Figure 3-42. To access the Change RAM mode and change RAM settings: 1. Press the <SET UP> key on the tapers control panel. The message "CHANGE RAM? NO" is displayed. 2. Press the <SET UP> key again. The message "CHANGE RAM? YES" is displayed. 3. Press <ENTER>. > The message "LOAD DEFAULT NO" is displayed. 4. If you want the taper to load the default settings for all the RAM addresses into RAM, press <SET UP> to display "LOAD DEFAULT YES", and then press <ENTER> to load the defaults while the message "LOAD EPROM>RAM" is displayed; or If you want the taper to leave all RAM addresses as they were, press <ENTER> to accept "LOAD DEFAULT NO". In either case, the first RAM address listing is now displayed, allowing you to make changes to individual RAM addresses. 5. Press the <SET UP> key or the <TOTALS> key to scroll through the firmware addresses:

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Notes About the RAM Address Listing

Selecting Manual Cycling

> Each time you press the <SET UP> key, the next address is displayed, as from 0090 to 0091. > Each time you press the <TOTALS> key, the previous address is displayed, as from 0091 to 0090 or from 0090 to 00FF. 6. When you reach the firmware address desired, press one of the following keys to change the parameter for the currently displayed address. > <RUN> key = Toggles between a display of the data address and value and a display of the address label. For example, when the data address display is 0094 Data 0C, pressing <RUN> displays the corresponding BAUD RATE RS-232. Pressing <RUN> again returns to 0094 Data 0C. > <SPACE> key = Increments the upper data nibble (the left digit in the setting at the right end of the displayed address) in the current address. For example, if the current setting is "EF", press the <SPACE> key to change the setting to "FF". > <DELETE> key = Increments the lower data nibble (the right digit in the setting at the right end of the displayed address) in the current address. For example, if the current setting is "04", press the <DELETE> key to change the setting to "05". > <-> minus key = Sets the parameter for the current address to FF. > <0> zero key = Sets the parameter for the current address to 00. > <CLEAR> key = Loads the default parameter for the current address from the EPROM into the RAM. 7. To exit the Change RAM mode, press the <ENTER> key. The message "RESET TOTALS NO" is displayed. > If you wish to reset the current output tally for all tubes to zero, press the <SET UP> key. The message "TOTALS SET TO 0" is displayed. > If not, press <ENTER> again to return to the previous mode. NOTE: Any changes you made take effect immediately. You do not have to power down and back up first.

Notes About the RAM Address Listing


A few words of explanation about various listing features follows.

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Warning About Motor Speeds


CAUTION: Only an engineer experienced with motor speeds should adjust any motor speeds. If unwise changes are made, damage to the machine could result. The step rate is the constant cruising speed. The starting rate is the speed on startup, at the beginning of movement. The acceleration slope rate is the length of time it takes the motor to reach cruising speed.

Updating Your EPROM


Write down all changes you make in your RAM address listing. Permanent selections should be programmed into the EPROM. You can then fax your updated RAM listing to Exatron, and we will program a new EPROM for you, free. The benefit of having your customized changes in the EPROM is that when it is necessary to blast the RAM back to the factory default, you will not lose your changes.

Separate Settings for Changeover Kits


Notice that settings for the gap steps, offset, swing home, and swing steps are repeated three times, at 00D9-00E5, 00E6-00F2, and 00F3-00FF. This enables you to save separate settings for three changeover kits without extensive recalibration each time the kit is changed.

Suggested Values for Various Taper Models


A few addresses in the listing should have different default values according to the taper used. These values are repeated in the following table.

Suggested ROM Default Values


Address 0097 009C 009D 009E 00A2 00A4 00A5 Display # Motors Octo 8/4 Tubes Wiggle Octoload P Up Jog Octo Foot Count Pickup Vacuum Delay Place Cycle 1010 Value 01 00 n/a; not checked n/a; not checked 1E (30) n/a; not checked n/a; not checked 1020 Value 07 08 or 04 00 or FF choice n/a; not checked choice choice 1050 Value 03 00 n/a; not checked n/a; not checked n/a; not checked choice choice

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RAM Address Listing

Suggested Values for Various Taper Models

RAM Address Listing


The following sample RAM address table describes each firmware address in numerical order. This information is specific for each Model 1020. It may be slightly different for your taper. For a list of suggested default values that vary according to the taper model, see "Suggested Values for Various Taper Models" on page 3-46. The ROM Deflt column shows the factory-set default value for each address. The Comments column shows the meaning of each selection. The RAM Options column shows the values you can use. The code below the values shows what type of value into which the taper translates the entry. For further reference, see the "Decimal-Hex-ASCII Conversion Table" on page 3-53. Code
A B C H

Type of Value
ASCII Bitmap Choice Hex

RAM Address Listing TAPE1020 10-1-10


Address
0090 0091 0092 0093 0094 0095 0096 0097 0098 0099 009A 009B 009C Temperature Alarm Octo 8/4 Tubes 00 08 C C Seal Down Delay 05 00 to FF H Baud Rate RS232 Data Format 0C 03 C C

Display
Top of EPROM Tape Out Check Thermal or PSA

ROM Deflt
00 00 P

RAM Options
C B Top of EPROM

Comments

00 = Use Tape Out sensor. FF = No tape-out check; sensor 6 ignored. T = Thermal; P = PSA. Not used. Stores the baud rate for the RS-232 interface between the taper system and the PC. Contact Exatron before changing the value. Stores the parity/stop/data bits settings for the RS-232 interface. 07 = 5000; 03 = 802 / 8000 Not used. Not used. Time delay after seal head down and before the tape drive moves. Counts down in hex in 10 millisecond steps. Not used. Not used. Check the default value in replacement from manufacturer; for thermal seal heads only. 00 = Normally open. FF = Normally closed. 00 = 1050, no octoloader. 04 = 4-tube input. 08 = 8-tube input.

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RAM Address Listing TAPE1020 10-1-10


Address
009D 009E

Display
Wiggle Octoload P Up Jog Octo

ROM Deflt
00 00

RAM Options
00, FF C 00 to FF C

Comments
00 = Wiggles the octoloader if a jam is detected. FF = Octoloader will not wiggle. For calibration of mechanical placement of octoloaderin-house only! Jogs octoloader right and left upon power-up if desired, to possibly free a jammed device. 0? = Jog Left. 1? = Jog Right. FOR EXAMPLE: 02 = Jog Left 2 steps; 13 = Jog Right 3 steps. 9 Steps Maximum. 00 = Use Out of Pocket sensor. FF = No out-of-pocket check; sensor 7 ignored or replaced by image sensor (camera). 00 = Use Empty Pocket sensor. FF = No empty-pocket check; sensor 5 ignored or replaced by image sensor (camera). 00 = Check temperature alarm. For thermal seal heads only. FF = Skip check of temperature alarm. Not used.

009F 00A0 00A1 00A2 00A3 00A4 00A5 00A6 00A7 00A8 00A9 00AA 00AB 00AC 00AD 00AE 00AF 00B0 00B1

Out of Pocket Empty Pocket Check

FF FF

00, FF C 00, FF C 00, FF C

Check Tempera- FF ture Alarm

Inspect Yes/No Pickup Vacuum Delay

00 05

C H

Used only when camera is installed to inspect placement of devices in tape pockets. 00 = On/Yes. FF = Off/No. AA = No option. At pickup site; delay after pickup vacuum turns on and before pickup head lifts device. Default is 10 ms. Not used.

Index Delay Pickup Delay Drop-off Down Delay Drop-off Delay Drop-off Up Delay

05 0A 05 0A 05

H H H H H C
See page 4-2. A

Adds extra time for device to pass index mechanism. 10 ms delay At pickup site; delay after pickup head retracts and before swing arm rotates down. 10 ms steps. At tape; length of time it takes pickup head to extend into tape pocket. 10 ms steps. At tape; delay after vacuum turns off to drop device into tape and before pickup head is retracted. 10 ms steps. At tape; length of time it takes pickup head to retract from tape pocket. 10 ms steps. 00 = On; FF = Off. Must be 0-9 ASCII. This is the first of 3 digits in the password if turned on at address 00AB. Must be 0-9 ASCII. This is the second of 3 digits in the password. Must be 0-9 ASCII. This is the third of 3 digits in the password. Sets the 100,000s digit for number of devices constituting a full tape. Sets the 10,000s digit for number of devices constituting a full tape. Sets the 1,000s digit for number of devices constituting a full tape.

Password On/Off FF Password A Password B Password C Full Tape 100000s 1 2 3 0

A A A A A

Full Tape 10000s 0 Full Tape 1000s 1

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RAM Address Listing

Suggested Values for Various Taper Models

RAM Address Listing TAPE1020 10-1-10


Address
00B2 00B3 00B4 00B5 00B6 00B7 00B8 00B9 00BA 00BB 00BC 00BD 00BE 00BF 00C0 Use Default #? 01

Display
Full Tape 100s Full Tape 10s Full Tape 1s Leader 10 Leader 1 Take Up 10 Take Up 1

ROM Deflt
0 0 0 3 0 2 0

RAM Options
A A A

Comments
Sets the 100s digit for number of devices constituting a full tape. Sets the 10s digit for number of devices constituting a full tape. Sets the 1s digit for number of devices constituting a full tape. Sets the 10s digit for number of pockets in leader tape. Sets the 1s digit for number of pockets in leader tape. Sets the 10s digit for number of pockets to be advanced between takeup reel runs. Sets the 1s digit for number of pockets to be advanced between takeup reel runs. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Switch changeover kit settings by group. The other group settings will be ignored. 01 = 5x5 (00C1-00CD). 02 = 4x4 (00CE-00DA). 03 = SSOIC (00DB-00E7). 04 = spare option (00E8-00F4).

00C1 00C2 00C3 00C4 00C5

Gap Step 1000s Gap Step 100s Gap Step 10s Gap Step 1s Offset 1000s

0 6 0 0 0

A A A A A

Sets the 1,000s digit for first tape drive move. For 5x5 device Sets the 100s digit for first tape drive move. Sets the 10s digit for first tape drive move. Sets the 1s digit for first tape drive move. Sets the 1,000s digit for the distance the tape drive must move between the Gap sensor finding a tape pocket leading edge and the pickup head being aligned with a pocket center. Sets the 100s digit for the offset distance. Sets the 10s digit for the offset distance. Sets the 1s digit for the offset distance. 30, 31, or 32; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. 30-39; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. Sets the 100s digit for the number of motor steps the swing arm rotates down from its pickup position to the tape position.

00C6 00C7 00C8 00C9 00CA 00CB

Offset 100s Offset 10s Offset 1s Swing Home 10 Swing Home 1

0 7 0 0 6

A A A A A A

Swing Step 100s 0

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RAM Address Listing TAPE1020 10-1-10


Address
00CC 00CD 00CE 00CF 00D0 00D1 00D2

Display
Swing Step 10s Swing Step 1s Gap Step 1000s Gap Step 100s Gap Step 10s Gap Step 1s Offset 1000s

ROM Deflt
6 1 1 0 3 7 0

RAM Options
A A A A A A A

Comments
Sets the 10s digit for the swing arms pickup position to tape position. Sets the 1s digit for the swing arms pickup position to tape position. Sets the 1,000s digit for first tape drive move. For 4x4 device Sets the 100s digit for first tape drive move. Sets the 10s digit for first tape drive move. Sets the 1s digit for first tape drive move. Sets the 1,000s digit for the distance the tape drive must move between the Gap sensor finding a tape pocket leading edge and the pickup head being aligned with a pocket center. Sets the 100s digit for the offset distance. Sets the 10s digit for the offset distance. Sets the 1s digit for the offset distance. 30, 31, or 32; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. 30-39; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. Sets the 100s digit for the number of motor steps the swing arm rotates down from its pickup position to the tape position. Sets the 10s digit for the swing arms pickup position to tape position. Sets the 1s digit for the swing arms pickup position to tape position. Sets the 1,000s digit for first tape drive move. For SSOIC device Sets the 100s digit for first tape drive move. Sets the 10s digit for first tape drive move. Sets the 1s digit for first tape drive move. Sets the 1,000s digit for the distance the tape drive must move between the Gap sensor finding a tape pocket leading edge and the pickup head being aligned with a pocket center. Sets the 100s digit for the offset distance. Sets the 10s digit for the offset distance. Sets the 1s digit for the offset distance. 30, 31, or 32; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. 30-39; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. Sets the 1s digit for the swing arms pickup position to tape position.

00D3 00D4 00D5 00D6 00D7 00D8 00D9 00DA 00DB 00DC 00DD 00DE 00DF

Offset 100s Offset 10s Offset 1s Swing Home 10 Swing Home 1

9 6 0 1 2

A A A A A A A A A A A A A

Swing Step 100s 0 Swing Step 10s Swing Step 1s Gap Step 1000s Gap Step 100s Gap Step 10s Gap Step 1s Offset 1000s 6 1 1 0 3 7 0

00E0 00E1 00E2 00E3 00E4 00E5

Offset 100s Offset 10s Offset 1s Swing Home 10 Swing Home 1 Swing Step 1s

9 6 0 1 2 3

A A A A A A

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RAM Address Listing

Suggested Values for Various Taper Models

RAM Address Listing TAPE1020 10-1-10


Address
00E6 00E7 00E8 00E9 00EA 00EB 00EC

Display
Swing Step 10s Swing Step 1s Gap Step 1000s Gap Step 100s Gap Step 10s Gap Step 1s Offset 1000s

ROM Deflt
6 1 1 0 3 7 0

RAM Options
A A A A A A A

Comments
Sets the 10s digit for the swing arms pickup position to tape position. Sets the 1s digit for the swing arms pickup position to tape position. Sets the 1,000s digit for first tape drive move. Sets the 100s digit for first tape drive move. Sets the 10s digit for first tape drive move. Sets the 1s digit for first tape drive move. Sets the 1,000s digit for the distance the tape drive must move between the Gap sensor finding a tape pocket leading edge and the pickup head being aligned with a pocket center. Sets the 100s digit for the offset distance. Sets the 10s digit for the offset distance. Sets the 1s digit for the offset distance. 30, 31, or 32; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. 30-39; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. Sets the 100s digit for the number of motor steps the swing arm rotates down from its pickup position to the tape position. Sets the 10s digit for the swing arms pickup position to tape position. Sets the 1s digit for the swing arms pickup position to tape position. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used.

0ED 00EE 00EF 00F0 00F1 00F2 00F3 00F4 00F5 00F6 00F7 00F8 00F9 00FA 00FB 00FC 00FD 00FE 00FF

Offset 100s Offset 10s Offset 1s Swing Home 10 Swing Home 1

9 6 0 1 2

A A A A A A A A

Swing Step 100s 0 Swing Step 10s Swing Step 1s 6 1

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Hex-Binary Conversion Table


Exatron uses hex as an easy way of representing binary. It allows the user to type an instruction of 2 digits rather than an instruction of 8 digits. The taper decodes the hex instructions into a binary map. In binary notation, 1 = TRUE and 0 = FALSE.

Comparison of Number Systems


Hexadecimal
00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 20 30 40

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 0010 0000 0011 0000 0100 0000

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Decimal-Hex-ASCII Conversion Table

Suggested Values for Various Taper Models

Decimal-Hex-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

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

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

ASCII
" # $ % & ( ) * + , . / 0 1 2 3 4 5 6 7 8 9 : ; < = > ? @ A B C

Space !

66 67

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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

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

ASCII
h i j k l m n o p q r s t u v w x y z { | } ~

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Chapter 4: Diagnostics
Chapter Overview
This chapter describes the operation of the taper's extensive built-in diagnostics. These diagnostics allow every sensor, solenoid, switch, motor, and I/O Port in the taper to be individually tested. Use these checks to troubleshoot any problem the taper may have. This chapter discusses the following main topics:

Topic Accessing DIAGNOSTICS Mode Diagnostics Quick Reference SENSOR CHECK: Tape Sensors 0-7 SENSOR CHECK: Input and Pickup Sensors 8-F SENSOR CHECK: Image Sensors 0-7 OUTPUT CHECK: Solenoid Check OUTPUT CHECK: Solenoid Toggle Check ALL MOTOR CHECK: Drive Motor Check ALL MOTOR CHECK: Swing Arm Check ALL MOTOR CHECK: Octoloader Motor Check

Page
4-2 4-4 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-20

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Chapter 4: Diagnostics

Accessing DIAGNOSTICS Mode


To access Diagnostics mode, press the <DIAGNOSTICS> key on the taper's control panel. If the password security is turned on, the display reads "PASSWORD ABC ?" Enter a 3-digit password using the numeric keys. The factory-set password is 123, or <1> <2> <3>. The display reads: "DIAGNOSTICS." You can access Diagnostics mode whenever the taper powers up, is in Run mode, or is in Manual mode.

Figure 4-1: Control Panel

You can also enter Diagnostics mode during most device jam-clearing cycles, when the output tube cover LEDs are flashing. If using Diagnostics during a jam, the taper will exit its automatic jam clearing cycle and then return to its previous place in the program, upon exiting Diagnostics. In most cases, if the jam is cleared during Diagnostics, the taper will also automatically restart after returning from Diagnostics. An abbreviated flowchart showing the main Diagnostics functions is shown on page 4-3. The "Diagnostics Quick Reference" showing all the functions begins on page 4-4, and detailed explanations of the major ones are in the sections following the quick reference.

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Accessing DIAGNOSTICS Mode

Figure 4-2: Diagnostics Abbreviated Flowchart

NOTE: Depending on the exact configuration of your taper, the functions accessed by one or more keys may be somewhat different.

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Chapter 4: Diagnostics

Diagnostics Quick Reference


The diagnostic selections are in a hierarchy, dropping from a higher level to lower levels. In most cases, pressing the <ENTER> key moves back up one level. In most cases, pressing a numeric key activates the corresponding LED light, as well as performing the action described in this section. <1> key = "SENSOR CHECK", then: <1> key = "SEN0-7 1234567" tape sensors 0-7 0-2 displays = n/a (not applicable) 3 display = takeup arm sensor 4 display = tape pocket gap sensor 5 display = n/a (not applicable) 6 display = carrier tape out switch 7 display = n/a (not applicable) <2> key = "SEN8-F 89ABCDEF" input and swing arm/pickup head sensors 8-F 8 display = pickup head vacuum sensor 9 display = swing arm at home/pickup position sensor A display = device at stack pin sensor B display = device at pickup site sensor C display = n/a (not applicable) D display = device at top of input rail sensor E display = device jammed at octoloader gap sensor F display = octoloader at home position switch <3> key = "IN-SEN 01234567" camera sensor 0-5 displays = n/a (not applicable) 6 display = camera failure sensor 7 display = n/a (not applicable)

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Diagnostics Quick Reference

<4> - <0> keys n/a (not applicable)

<2> key = "OUTPUT CHECK", then:


<1> key = "SOLENOID CHECK" causes continual, intermittent action, then: <1> key activates sealing head cylinder <2> key activates pickup head vacuum <3> key activates optional cylinder valve <4> key activates index solenoid <5> key activates stack cylinder and cover foot cylinder <6> key activates blow-off from pickup head (to break vacuum seal with device) <7> key activates pickup head cylinder on swing arm <8> key activates takeup reel motor <9> key n/a <0> key turns all solenoids OFF <2> key = "SOL TOGGLE CHECK" causes continuous, steady action, then: <Clear> key homes the swing arm <1> key lowers sealing head to tape; press again to raise <2> key turns on pickup head vacuum; press again to turn off <3> key activates optional cylinder valve; press again to turn off <4> key activates index solenoid; press again to turn off CAUTION: Do not leave the index solenoid on for more than a couple of seconds or the solenoid may be damaged. <5> key activates stack cylinder and cover foot cylinder; press again to turn off <6> key turns on blow-off from pickup head; press again to turn off <7> key extends pickup head on swing arm; press again to retract <8> key turns on takeup reel motor; press again to turn off

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Chapter 4: Diagnostics

<9> key n/a <0> key turns all solenoids OFF <3> - <9> keys n/a <3> key = "ALL MOTOR CHECK", then: <1> key = "DRIVE MOTOR CHK" (tape drive motor check), then: <1> key = "MOVE TAPE LEFT"advances carrier tape one tape pocket to the left <2> key = "R235 F30 S235"briefly displays current tape drive motor settings in RAM <3> key = "MOVE TAPE RIGHT"moves carrier tape several motor steps to the right CAUTION: Do not do this diagnostic with a tape present. Tape position will be compromised and/or tape damage may result. <4> key = n/a <5> key = "TEST TAPE MOTOR"advances tape by one pocket <6> key n/a <7> key = "JOG LEFT"moves tape drive motor 1 motor step to the left <8> key n/a <9> key = "JOG RIGHT"moves tape drive motor 1 motor step to the right <0> key = "MOTOR A OFF"turns off tape drive motor <2> key = "SWING HEAD CHECK", then: <1> key = "PART AT PICK UP" or "TAPE STACK EMPTY" or no message One of 3 responses, depending on the situation: If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, and no message is displayed. If a device is already at the pickup site, the message "PART AT PICK UP" is displayed. If no devices are at either the stack or the pickup site, the message "TAPE STACK EMPTY" is displayed.

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Diagnostics Quick Reference

Note that this action is a subset of <5>, below. <2> key Toggles pickup cylinder on/off. <3> key Toggles vacuum on/off. <4> key = "SET GAP ? NO", then: <ENTER> key = Press to display current settings. The display reads "GAP STEPS = ####", then "OFFSET = ####", then "SWING HOME = ##", then "SWING STEP = ###". Each pound sign (#) is replaced by a digit. <SET UP> key = "SET GAP ? YES"This proposes to re-find the gap between tape pockets. <ENTER> key = Press to advance the tape and set the gap. The display reads "JOG LEFT", then "GAP STEPS = ####, then "OFFSET = ####", and stops at "SET OFFSET= ####". NOTE: If you get the message "NO POCKET? ERROR", it means it cant find the gap. Press down lightly on the tape. You can change the offset number by using the number keys on the control panel. Work from right to left: Start with the smallest (ones) digit, then the tens digit, and work up to the largest digit. For example, to enter the number 0725, press <5>, <2>, <7>, <0>. When you finish, press <ENTER> again to redisplay the current settings. <5> key = "PART AT PICK UP" or "TAPE STACK EMPTY" or no message One of 3 responses, depending on the situation. Note that <1> is a subset of this full cycle: If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, the swing arm moves the device to the tape, and the tape advances by one pocket and seals one pocket. No message is displayed. If a device is already at the pickup site, the message "PART AT PICK UP" is displayed. If no devices are at either the stack or the pickup site, the message "TAPE STACK EMPTY" is displayed. <6> key = "POCKETS = ######."tape drive motor advances and activates seal heads; the number of pockets increments by the same number. However, the swing arm is not activated to get a device from the pickup site.

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Chapter 4: Diagnostics

<7> key = "SWING STEP = ###" or "SWING HOME = ###." The result of pressing this key depends on the current position of the swing arm. When the swing arm is over the tape: "SWING STEP = ###." The number gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs up one motor step. When the swing arm is over the pickup site: "SWING HOME = ###." The number gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs up one motor step. This is because the swing arm home sensor is just below the pickup site. <8> key = The result of pressing this key depends on the current position of the swing arm. If swing head is down over tape: "FIND MOTOR HOME", then "HOME SWING HEAD", then "MOTOR HOME"jogs, rotates, and returns swing arm to home position. If swing head is up at home or pickup position: "ROTATE DOWN"head rotates down to tape position. <9> key = "SWING STEP = ###" or "SWING HOME = ###." The result of pressing this key depends on the current position of the swing arm. When the swing arm is over the tape: "SWING STEP = ###." The number gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs down one motor step. When the swing arm is over the pickup site: "SWING HOME = ###." The number gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs down one motor step. <0> key = "MOTOR B OFF"turns off swing arm motor <3> key = "OCTO MOTOR CHK", then: <1> key = "1 LEFT STEP"moves octoloader one tube to the left <2> key = "R200 F10 S200"briefly displays current octoloader motor settings in RAM <3> key = "1 RIGHT STEP"moves octoloader one tube to the right <4> key = "2 LEFT STEPS"moves octoloader two tubes to the left <6> key = "2 RIGHT STEPS"moves octoloader two tubes to the right <7> key = "JOG LEFT"moves octoloader motor 1 motor step to the left

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Diagnostics Quick Reference

<8> key = "SET # INPUTS"accesses number of input tubes setting <1> key = "8 TUBE INPUT"uses all 8 input tubes <2> key = "4 TUBE INPUT"uses 4 input tubes; alternating tracks <3> key = "OCTOLOADER OFF"allows operator to drop devices down input track, bypassing octoloader <9> key = "JOG RIGHT"moves octoloader motor 1 motor step to the right <0> key = "MOTOR C OFF"turns off octoloader motor <4> - <0> keys n/a <4> key = "INTERFACE CHECK", then: <1> key = "RS-232 CHECK", then: <1> - <9> keys send signals "1" - "9" from control panel to tester (these are future option ports) <RUN> key sends signal "A" from control panel to tester <MANUAL> key sends signal "B" from control panel to tester <SET UP> key sends signal "C" from control panel to tester <PAUSE> key sends signal "D" from control panel to tester <TOTALS> key sends signal "E" from control panel to tester <DIAGNOSTICS> key sends signal "F" from control panel to tester <2> key = "HANDLER OUT CHK", then: <1> - <8> keys cause corresponding light ot flash, on LED and on Simulator <9> key activates all ON <0> key activates all OFF <3> key = "SORT = "12345678" <1> key = "ISSUE NEW START" The taper has been instructed to send a new start-test pulse to the tester/PC; then it waits for an end-of-test sort signal from the tester. If none is received, the message "SORT INPUT" is displayed. <4> - <0> keys n/a

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Chapter 4: Diagnostics

<5> key = "TAKE UP MOTOR CK"turns on takeup reel motor. Lift takeup arm to stop motor. <6> key = "INSPECTION PASS" or "INSPECTION FAIL"displays current inspection result. <7> - <0> keys n/a <ENTER> key = Exit DIAGNOSTICS.

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SENSOR CHECK: Tape Sensors 0-7

SENSOR CHECK: Tape Sensors 0-7


This diagnostic tests the sensors related to the tape. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <1> key. > Control panel displays "SENSOR CHECK". 3. Press the <1> key again. > Control panel displays all or part of "SEN0-7 01234567". Specifically, the alphanumeric characters indicate:

Tape Sensors
Control Panel Display
0, 1, 2 3 4 5 6 7

Sensor
N/a, no sensor Takeup Arm Pocket Gap N/a, no sensor Carrier Tape Out N/a, no sensor

Alphanumeric Character Displayed When...

Red Controller Light

Arm raised; signal open Tape not centered at pocket divider; signal blocked

n/a * Off

No tape present; signal open

n/a *

* Sensor is of type photo rather than fiberoptic, and hence has no controller. Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the taper is still in this specific diagnostic check. Press the <ENTER> key to exit this diagnostic check. If you suspect that you have a bad sensor/LED pair, use the EXATRON LED checker #3000052 (small blue plastic box). This diagnostic tool is equipped with a transistor (blue/white wires) and an IR LED (orange/blue wires). Direct the transistor at any of the taper's IR LEDs. The LED on the checker should turn off. Direct the checker's LED at any of the taper's transistors. The corresponding number should turn OFF on the taper's display.

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Chapter 4: Diagnostics

SENSOR CHECK: Input and Pickup Sensors 8-F


This diagnostic tests the sensors related to the octoloader input, the pickup site, and the swing arm. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <1> key. > Control panel displays "SENSOR CHECK". 3. Press the <2> key. > Control panel displays all or part of "SEN8-F 89ABCDEF". Specifically, the alphanumeric characters indicate:

Input and Pickup Sensors


Control Panel Display
8 9 A B C D E F

Sensor
Pickup Head Vacuum Swing Arm Home Device at Stack Device at Pickup Site N/a, no sensor Device at Top of Input Rail Device at Octoloader Gap Octoloader at Home

Alphanumeric Character Displayed When...


No device attached to pickup head; vacuum open or vacuum turned off Swing arm not home; signal open Device at stack pin; signal blocked Device at pickup site; signal blocked

Red Controller Light


n/a n/a * On On

Device at top of input rail; signal blocked Device jammed at octoloader gap; signal blocked Octoloader at home position switch

* Sensor is of type photo rather than fiberoptic, and hence has no controller. Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the taper is still in this specific diagnostic check. Press the <ENTER> key to exit this diagnostic check.

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SENSOR CHECK: Image Sensors 0-7

If you suspect that you have a bad sensor/LED pair, use the EXATRON LED checker #3000052 (small blue plastic box). This diagnostic tool is equipped with a transistor (blue/white wires) and an IR LED (orange/blue wires). Direct the transistor at any of the taper's IR LEDs. The LED on the checker should turn off. Direct the checker's LED at any of the taper's transistors. The corresponding number should turn OFF on the taper's display.

SENSOR CHECK: Image Sensors 0-7


This diagnostic tests the sensors related to the camera (image sensor). To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <1> key. > Control panel displays "SENSOR CHECK". 3. Press the <3> key. > Control panel displays all or part of "IN-SEN 01234567". Specifically, the alphanumeric characters indicate:

(Camera) Image Sensor


Control Panel Display Sensor Alphanumeric Character Displayed When...

0, 1, 2, 3, 4, 5 N/a, no sensor 6 7 Camera Failure N/a, no sensor Camera failed or not turned on

Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the taper is still in this specific diagnostic check. Press the <ENTER> key to exit this diagnostic check.

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Chapter 4: Diagnostics

OUTPUT CHECK: Solenoid Check


This diagnostic tests various solenoids. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <2> key. > Control panel displays "OUTPUT CHECK". 3. Press the <1> key. > Control panel displays "SOLENOID CHECK". 4. Press each of the taper terminal's keypad keys 0 through 9. Each key turns on the taper's output cover LEDs and sets the corresponding taper solenoid into a continual, intermittent on/off test cycle. For example, the vacuum is activated in intermittent bursts, or the pickup head moves up and down until you stop the action. Key 1 2 3 4 5 6 7 8 9 0 All OFF Output Cover LED 1 2 3 4 5 6 7 8 Taper Solenoid Action Seal heads lowered to tape Pickup head vacuum on Optional cylinder valve on Index pin extends Stack pin retracts; cover foot extends Positive air pressure emitted from suction cup on pickup head to break vacuum between device and suction cup Pickup head extends on swing arm Takeup reel motor turned on, winding tape and tightening tape slack n/a All solenoids turned off

Pressing the <CLEAR> key will flash the terminal's displayed message to confirm the taper is still in this specific diagnostic check. Press the <ENTER> key to exit this diagnostic check and return to the "DIAGNOSTICS" message.

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OUTPUT CHECK: Solenoid Toggle Check

OUTPUT CHECK: Solenoid Toggle Check


This diagnostic tests various solenoids. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <2> key. > Control panel displays "OUTPUT CHECK". 3. Press the <2> key again. > Control panel displays "SOL TOGGLE CHECK". 4. Press each of the control panel's keypad keys 0 through 9. Each key will turn on/off the taper's output cover LEDs and will set the corresponding taper solenoid into continuous, steady action that can be stopped or toggled by pressing the <0> key. For example, the vacuum is activated in a steady force until you toggle it off, or the pickup head stays down until you toggle it up. Key Clear 1 2 3 4 5 6 7 8 9 0 All OFF All solenoids turned off 1 2 3 4 5 6 7 8 Output Cover LED Taper Solenoid Action Swing arm homed to position over pickup site Seal heads lowered to tape Pickup head vacuum on Optional cylinder valve on Index pin extends * Stack pin retracts; cover foot extends Positive air pressure emitted from suction cup on pickup head to break vacuum between device and suction cup Pickup head extends on swing arm Takeup reel motor turned on, winding tape and tightening tape slack

* CAUTION: Do not leave the index solenoid on for more than a couple of seconds or the solenoid may be damaged. Press the <ENTER> key to exit this diagnostic check and return to the "DIAGNOSTICS" message.
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Chapter 4: Diagnostics

ALL MOTOR CHECK: Drive Motor Check


This diagnostic tests and calibrates the positions of the tape drive motor. If a device placed in the tape pocket is misaligned to the left or right as shown in Figure 4-3, use this diagnostic.

Figure 4-3: Tape Calibration Needed

To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <3> key. > Control panel displays "ALL MOTOR CHECK". 3. Press the <1> key. > Control panel displays "DRIVE MOTOR CHK". <1> key = "MOVE TAPE LEFT." The drive motor moves the tape one pocket to the left. <2> key = "R235 F30 S235." The current motor settings are displayed. <3> key = "MOVE TAPE RIGHT." The drive motor moves the tape one pocket to the right. CAUTION: Do not do this diagnostic with a tape present. Tape position will be compromised and/or tape damage may result. <5> key = "TEST TAPE MOTOR." The drive motor advances the tape two pockets to the left. <7> key = "JOG LEFT." The drive motor moves the tape one motor step to the left. <9> key = "JOG RIGHT." The drive motor moves the tape one motor step to the right. <0> key = "MOTOR A OFF." The drive motor is turned off. Pressing the <CLEAR> key flashes the terminal's displayed message to confirm the taper is still in this specific diagnostic check. Press the <ENTER> key to exit this diagnostic check.

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ALL MOTOR CHECK: Swing Arm Check

ALL MOTOR CHECK: Swing Arm Check


This diagnostic tests and calibrates the positions of the swing arm. If a device placed in the tape pocket is misaligned to the front or back as shown in Figure 4-4, use this diagnostic.

Figure 4-4: Swing Arm Calibration Needed

To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <3> key. > Control panel displays "ALL MOTOR CHECK". 3. Press the <2> key. > Control panel displays "SWING HEAD CHECK". <1> key Indexes device: If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, and no message is displayed. > If a device is already at the pickup site, the message "PART AT PICK UP" is displayed. > If no devices are at either the stack or the pickup site, the message "TAPE STACK EMPTY" is displayed. Note that this action is a subset of <5>, below. <2> key Toggles pickup cylinder on/off. <3> key Toggles vacuum on/off. <4> key = "SET GAP ? NO." If the pickup head is centering devices in each tape pocket, press <ENTER> to move on. But if devices are being placed improperly as shown in Figure 3-38 on page 3-27, press <SET UP> and then <ENTER> to set the gap. You then have the opportunity to visually check the pickup head position and change the offset. See "Understanding the Gap" on page 3-32 and "Setting Tape Pocket Gap" on page 3-34.

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Chapter 4: Diagnostics

<5> key The taper does one full pick-and-place cycle: If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, the swing arm moves the device to the tape, and the tape advances by one pocket and seals one pocket. No message is displayed. > If a device is already at the pickup site, the message "PART AT PICK UP" is displayed. > If no devices are at either the stack or the pickup site, the message "TAPE STACK EMPTY" is displayed. Note that <1> is a subset of this full cycle. <6> key = "POCKETS = ######." The drive motor advances and activates the seal heads; the number of pockets increments by the same number. However, the swing arm is not activated to get a device from the pickup site. <7> key = "SWING STEP = ###" or "SWING HOME = ###." The result of pressing this key depends on the current position of the swing arm. > When the swing arm is over the tape: "SWING STEP = ###." The number gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs up one motor step. 1 > When the swing arm is over the pickup site: "SWING HOME = ##." The number gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs up one motor step. 2 <8> key = The result of pressing this key depends on the current position of the swing arm. > If swing head is down over tape: "FIND MOTOR HOME", then "HOME SWING HEAD", then "MOTOR HOME"The swing arm moves to its home position at the Swing Arm Home sensor, then moves the specified number of motor steps farther up to the pickup site. 3 > If swing head is up at home or pickup position: "ROTATE DOWN"head rotates down to tape position. <9> key = "SWING STEP = ###" or "SWING HOME = ###." The result of pressing this key depends on the current position of the swing arm. > When the swing arm is over the tape: "SWING STEP = ###." The number gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs down one motor step. 4
1 2

3 4

Any change made with the <7> key here at "SWING STEP = " is saved in the RAM addresses for "SWING STEP" and kept until default values are loaded from the EPROM. Any change made with the <7> key here at "SWING HOME = " is saved in the RAM addresses for "SWING HOME" and kept until default values are loaded from the EPROM. This change also affects the number of motor steps the swing arm rotates up past its home sensor when the <8> key is pressed. The number of motor steps that the swing arm moves beyond the sensor is taken from the values in the RAM addresses for "SWING HOME", which are changed by use of the <7> and <9> keys. Any change made with the <9> key here at "SWING STEP = " is saved in the RAM addresses for "SWING STEP" and kept until default values are loaded from the EPROM.

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ALL MOTOR CHECK: Swing Arm Check

> When the swing arm is over the pickup site: "SWING HOME = 0##." The number gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs down one motor step. 1 <0> key = "MOTOR B OFF." The swing arm motor is turned off. Pressing the <CLEAR> key will flash the terminal's displayed message to confirm the taper is still in this specific diagnostic check. Press the <ENTER> key to exit this diagnostic check.

Any change made with the <9> key here at "SWING HOME = " is saved in the RAM addresses for "SWING HOME" and kept until default values are loaded from the EPROM. This change also affects the number of motor steps the swing arm rotates up past its home sensor when the <8> key is pressed.

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Chapter 4: Diagnostics

ALL MOTOR CHECK: Octoloader Motor Check


This diagnostic tests the positions of the octoloader motor. CAUTION: Verify that the octoloader is empty of all devices before using this diagnostic. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Taper displays "DIAGNOSTICS". 2. Press the <4> key. > Taper displays "ALL MOTOR CHECK". 3. Press the <3> key. > Taper displays "OCTO MOTOR CHK". <1> key = "1 LEFT STEP." The octoloader moves one tube to the left. <2> key = "R200 F10 S200." The taper displays the current motor settings in RAM. This display is helpful when trying to increase the motor's speed. <3> key = "1 RIGHT STEP." The octoloader moves one tube to the right. <4> key = "2 LEFT STEPS." The octoloader moves two tubes to the left. <6> key = "2 RIGHT STEPS." The octoloader moves two tubes to the right. <7> key = "JOG LEFT." The octoloader moves one motor step to the left, about .006". <8> key = "SET # INPUTS"accesses number of input tubes setting <1> key = "8 TUBE INPUT"uses all 8 input tubes <2> key = "4 TUBE INPUT"uses 4 input tubes; alternating tracks <3> key = "OCTOLOADER OFF"allows operator to drop devices down input track, bypassing octoloader <9> key = "JOG RIGHT." The octoloader moves one motor step to the right, about .006". <0> key = "MOTOR C OFF." The octoloader motor is turned off. Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the tapertaper is still in this specific diagnostic check. Press the <ENTER> key to exit this diagnostic check.

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Chapter 5: Dictionary of Displayed Messages


Chapter Overview
This reference chapter discusses the following status and error messages displayed on the control panel.

Figure 5-1: Control Panel

Topic 00## DATA ## 1 LEFT STEP 1 RIGHT STEP 2 LEFT STEPS 2 RIGHT STEPS 4 TUBE INPUT 8 TUBE INPUT ADD LEADER DOWN ADD LEADER UP ALIGN OCTOLOADER ALL MODES OFF ? ALL MOTOR CHECK ALL MOTORS OFF CHANGE RAM ? NO

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Chapter 5: Dictionary of Displayed Messages

Topic CHANGE RAM ? YES COUNT SET TO 0 CPU ERROR [1-6] DIAGNOSTICS DRIVE MOTOR CHK EMPTY/LOAD PARTS EMPTY POCKET ? EXATRON TAPE FIND MOTOR HOME FULL T = ###### GAP STEPS = #### HANDLER OUT CHECK HOME SENSOR ERR HOME SWING HEAD INDEX/STACK JAM IN-SEN 01234567 INSPECT YES/NO ? INSPECTION FAIL INSPECTION OFF INSPECTION ON INSPECTION PASS INTERFACE CHECK ISSUE NEW START JOG LEFT JOG OCTOLOADER JOG RIGHT LOAD DEFAULT NO LOAD DEFAULT YES LOAD EPROM>RAM LOADER JAM LOOP MODE ON ? MANUAL ###### MOD SET UP ? NO MOD SET UP ? YES MOTOR [A, B, or C] BUSY ? MOTOR <A, B, or C> ERROR ? MOTOR A OFF MOTOR B OFF MOTOR C OFF

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Chapter Overview

Topic MOTOR HOME MOVE TAPE LEFT MOVE TAPE RIGHT NEW JOBEMPTY OK NEW TAPE SET UP? NO POCKET? ERROR NOT UP TO TEMP OCTO MOTOR CHK OCTOLOADER OFF OFFSET = #### OFFSET>GAP ERROR OK TO RUN ? 6 OUT OF POCKET ? OUTPUT CHECK PASSWORD ABC? PAUSED ###### PART AT PICK UP PART DROPPED ? PICK UP AT HOME PICK UP DOWN PICK UP NOT HOME PLACE PART ERR POCKETS = ###### RAM AUTO RESET READY TO RUN ? RESET COUNT NO RESET COUNT YES RETURN ERROR ? ROTATE DOWN ROTATE UP RS-232 CHECK RUN 4 X 4 MLF RUN 5 X 5 MLF RUN DEFAULT 4 RUN SSOIC RUN UNTIL 1 PASS SEN0-7 01234567 SEN8-F 89ABCDEF SENSOR CHECK

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Topic SET # INPUTS SET GAP ? NO/YES SET OFFSET = #### SOL TOGGLE CHECK SOLENOID CHECK SORT = 12345678 STOP MODE ON/OFF STOP MODE ON ? SWING HEAD CHECK SWING HOME = ### SWING STEP = ### TAKE UP MOTOR CK TAKE UP REEL ERR TAPE GAP LOST ? TAPE IS FULL TAPE OUT ERROR ? TAPE STACK EMPTY ? TEST TAPE MOTOR THANK YOU # THERMAL OR PSA ? UART OUT ERROR USE PSA TAPE USE THERMAL TAPE VAC NOT ADJUSTED ZERO COUNT ERR

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Model 1050 Handler Status and Error Messages


Messages that are displayed on the control panel are alphabetically listed below. Symbols and numbers appear first. Each entry in this section explains why the message is displayed and, when necessary, how to resolve the condition. If further explanation is required, the operator is referred to the appropriate section elsewhere in this manual for details. We are constantly adding messages to the handler's operating code. If a message you need is not listed here, please contact Exatron's Customer Service Department for prompt assistance. For free updates to the firmware, please contact the Exatron Sales Department.

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Model 1050 Handler Status and Error Messages

00## DATA ##

00## DATA ##
This is the Change RAM routine. Current RAM address data will be displayed where each pound sign (#) is shown above. Review the following keys for options allowed: <ENTER> Exits routine; saves parameter into RAM. <SET UP> Each time you press the <SET UP> key, the next address is displayed, as from 0090 to 0091. <TOTALS> Each time you press the <TOTALS> key, the previous address is displayed, as from 0091 to 0090 or from 0090 to 00FF. <SPACE> Increments the upper data nibble (the left digit in the parameter at the right end of the displayed address) in the current address. For example, if the current parameter is "EF", press the <SPACE> key to change the parameter to "FF". <DELETE> Increments the lower data nibble (the right digit in the parameter at the right end of the displayed address) in the current address. For example, if the current parameter is "04", press the <DELETE> key to change the parameter to "05". <-> Sets the parameter for the current address to FF. <0> Sets the parameter for the current address to 00. <CLEAR> key = Loads the default parameter for the current address from the EPROM into the RAM.

1 LEFT STEP
You have pressed <DIAGNOSTICS>, <3>, <3>, <1>. This moves the octoloader one tube to the left.

1 RIGHT STEP
You have pressed <DIAGNOSTICS>, <3>, <3>, <3>. This moves the octoloader one tube to the right.

2 LEFT STEPS
You have pressed <DIAGNOSTICS>, <3>, <3>, <4>. This moves the octoloader two tubes to the left.

2 RIGHT STEPS
You have pressed <DIAGNOSTICS>, <3>, <3>, <6>. This moves the octoloader two tubes to the right.

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4 TUBE INPUT
The octoloader is set to deliver devices from 4 tubes.

8 TUBE INPUT
The octoloader is set to deliver devices from 8 tubes.

ADD LEADER DOWN


This message is displayed when you press the <DELETE> key from RUN mode or WAITING mode. This runs the takeup reel and tape drive motors with the sealing heads engaged to create a tape leader of fifty empty sealed pockets for a new reel. Use this feature when you intend to cut the tape at the leader and separate the full reel from the rest of the tape. Press the <Clear> key to stop the motors and return to the previous mode.

ADD LEADER UP
This message is displayed when you press the <SPACE> key from RUN mode or WAITING mode. This runs the takeup reel and tape drive motors but without the sealing heads engaged to create a tape leader of fifty empty pockets for a new reel. Use this feature when you intend to cut the tape at the leader and separate the full reel from the rest of the tape. Press the <CLEAR> key to stop the motors and return to the previous mode.

ALIGN OCTOLOADER
You have pressed the <0> key to turn off the octoloader motor; then pressed <ENTER> to turn it back on.

ALL MODES OFF ?


You have pressed the <9> key during RUN mode or a waiting mode. Stop and loop modes are for testing and troubleshooting of the taper. Select one of the following keypad choices. <1> = "STOP MODE ON ?" The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. <2> = "LOOP MODE ON ?" The taper will stop after a complete cycle for one device. <3> = "ALL MODES OFF ?" The taper will cycle multiple devices in a normal run. This is the default. <CLEAR> = Resets to the beginning of the taper's "STOP MODE ON/OFF" loop. <ENTER> Confirms your selection.

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Model 1050 Handler Status and Error Messages

ALL MOTOR CHECK

ALL MOTOR CHECK


See "ALL MOTOR CHECK: Drive Motor Check" on page 4-16 and "ALL MOTOR CHECK: Swing Arm Check" on page 4-17.

ALL MOTORS OFF


You have pressed the <0> key. The power to all motors is now OFF. You can realign or move any machine parts driven by the motors manually. Press any control panel key to continue.

CHANGE RAM ? NO
Exits routine without making any changes to the taper's RAM setup parameters. <ENTER> Exits with no changes. <SET UP> Toggles back to CHANGE RAM ? YES.

CHANGE RAM ? YES


Allows the operator to override the taper's setup parameters. <ENTER> Allows changes to the RAM. See "Changing RAM" on page 3-44 for instructions. <SET UP> Toggles back to CHANGE RAM ? NO.

COUNT SET TO 0
You have pressed the <SET UP> key and then selected RESET COUNT YES. The count of devices placed in tape pockets has been reset to zero.

CPU ERROR [1-6]


Any of these errors are critical. The taper's control program has detected a major problem, and has stopped operation. Use the following procedure to resolve this problem: 1. Write down exactly which CPU ERROR message is displayed. 2. Write down, to the best of your knowledge, what message(s) was/were displayed by the taper just before the error. 3. Write down, to the best of your knowledge, what the taper was doing just before the error. 4. Power down the taper and handler. 5. Power the handler and taper back up and answer all of the MOD SET UP ? YES questions. 6. Resume taper operation.

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7. Fax your notes to Exatron as soon as possible. We will answer your fax with an explanation of what occurred, and a free software update to permanently correct the cause of the problem.

DIAGNOSTICS
You have pressed the <DIAGNOSTICS> key. See "Diagnostics Quick Reference" on page 4-4 as well as the sections following it for details.

DRIVE MOTOR CHK


See "ALL MOTOR CHECK: Drive Motor Check" on page 4-16.

EMPTY/LOAD PARTS
You have pressed the <RUN> key, but either no devices are in tubes in the octoloader, or the tape is full.

EMPTY POCKET ?
This error message is displayed when an empty pocket in the carrier tape is detected. This occurs even at startup. When this message is displayed, and if the user visually confirms that no error condition is present, press <Enter>. This overrides the empty pocket message until such time as a device is seen in a pocket. If another empty pocket is then seen, the "EMPTY POCKET" message is displayed again. If a device is placed in the pocket directly underneath the sensor, the message "OK TO RUN? 2" is displayed. Pressing the <Enter> or <RUN> keys will start the system running again.

EXATRON TAPE
Power-up machine identification message; no action required.

FIND MOTOR HOME


This message is part of the routine for automatically resetting the tapers swing arm at its home position at the device pickup location. This routine occurs upon power-up and may also be actuated during various system paused conditions. The complete auto centering sequence consists of: FIND MOTOR HOME HOME SWING HEAD MOTOR HOME

FULL T = ######
Six digits are displayed after the = symbol. This is the number of devices the tape loader will place into a full tape before it stops. The number is adjustable up to 999,999 devices., which would be displayed as 999999.

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Model 1050 Handler Status and Error Messages

GAP STEPS = ####

Use the keypad to make your selection. The tape loader accepts changes to each digit from lowest to highest, in order. First enter Ones, then Tens, then Hundreds, then Thousands. For example, to place 38 devices in each output tube, press <8>, then <3>. <-> The minus key sets the count to 0000. <CLEAR> Resets to the beginning of the handler's FULL T = ###### loop. This will also reload the handler's EPROM default value for this address. <ENTER> Confirms your selection.

GAP STEPS = ####


The number of gap steps is the number of steps the tape drive motor must jog left after the gap sensor finds the gap between tape pockets in order to get the center of the next pocket under the swing arms pickup head.

HANDLER OUT CHECK


You have pressed <DIAGNOSTICS>, <4>, <2>. This is a future option port.

HOME SENSOR ERR


The swing arm motor has attempted to move the swing arm into its home position, that is, fully up and seated at the pickup location, but has not succeeded. This error message may be displayed during power-up of the system or during operation. Inspect the path of the swing arm for any jammed device or other blockage. After removing any blockage, press <Clear> to return to the previous condition. If there is no physical obstacle in the path of the swing arm, you may have a worn sensor. Run the Diagnostics/SENSOR CHECK for the swing arm sensor, described in "SENSOR CHECK: Input and Pickup Sensors 8-F" on page 4-12. Replace the sensor as necessary.

HOME SWING HEAD


This message is part of the routine for automatically resetting the tapers swing arm at its home position at the device pickup location. This routine occurs upon power-up and may also be actuated during various system paused conditions. The complete auto centering sequence consists of: FIND MOTOR HOME HOME SWING HEAD MOTOR HOME

INDEX/STACK JAM
A device is jammed at the index site just above the swing head. <ENTER> fires the index and stack solenoids again to try to dislodge the device.

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<RUN> retries the cycle again to try to dislodge the device. <MANUAL> or <CLEAR> exits Run mode and goes to Manual mode.

IN-SEN 01234567
One or more of the numbers shown above is displayed following IN-SEN. The only significant number is 6, the camera failure sensor. If this number is displayed, there is a problem with the camera. See the camera manufacturers documentation for more information.

INSPECT YES/NO ?
This allows you to turn on or off the camera inspection. <1> = "INSPECTION ON". Press to turn on inspection. <2> = "INSPECTION OFF". Press to turn off inspection. <ENTER> confirms your selection.

INSPECTION FAIL
Inspection is turned on and inspection of a pocket has failed. This may be because a device has failed inspection or because of an empty pocket. It also occurs at the beginning of a new tape, which necessarily has several empty pockets in the leader. <RUN> ignores the error, advances the tape, and continues inspection until the next failure. <ENTER> reinspects the same pocket. <.> = "INSPECT YES/NO ?" accesses the option to toggle the inspection on or off. <1> = "INSPECTION ON" toggles inspection on. <2> = "INSPECTION OFF" toggles inspection off. <ENTER> confirms your selection. <DIAGNOSTICS> exits Run mode and enters Diagnostics mode. <MANUAL> exits Run mode and enters Manual mode.

INSPECTION OFF
Camera inspection of devices in pockets is turned off.

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Model 1050 Handler Status and Error Messages

INSPECTION ON

INSPECTION ON
Camera inspection of devices in pockets is turned on.

INSPECTION PASS
Inspection is turned on and inspection of a pocket has passed. You have pressed <DIAGNOSTICS>, <6>, to view this message.

INTERFACE CHECK
You have pressed <DIAGNOSTICS>, <4>. Keys <1> and <2> check future option ports. Key <3> is not used at this time.

ISSUE NEW START


The handler has sent a new start-test pulse. This is not used at present.

JOG LEFT
The selected motor has moved one motor step left, about .006". If you are in Diagnostics, DRIVE MOTOR CHECK, it is the tape drive motor that has moved. If you are in Diagnostics, OCTO MOTOR CHECK, it is the octoloader motor that has moved.

JOG OCTOLOADER
This message is used only when there is a preset at RAM address 009E: "P Up Jog Octo."

JOG RIGHT
The selected motor has moved one motor step right, about .006". If you are in Diagnostics, DRIVE MOTOR CHECK, it is the tape drive motor that has moved. If you are in Diagnostics, OCTO MOTOR CHECK, it is the octoloader motor that has moved.

LOAD DEFAULT NO
Exits routine without reloading the EPROM default settings into the taper's RAM. <ENTER> exits with no changes. < SET UP> toggles back to LOAD DEFAULT YES.

LOAD DEFAULT YES


Allows the operator to reload the taper's RAM with settings stored in the taper's EPROM. <ENTER> loads defaults from EPROM to RAM. <SET UP> toggles back to LOAD DEFAULT NO.

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LOAD EPROM>RAM
The taper has reloaded its RAM setup data with default settings stored in EPROM. For your reference only.

LOADER JAM
This message is displayed if sensors find a device at the bottom of the octoloader but not at the index or stack.

LOOP MODE ON ?
Loop mode is for testing and troubleshooting of the taper. You can alternate between Stop mode and Loop mode by pressing the <1> and <2> keys, respectively. Select one of the following keypad choices. <1> = "STOP MODE ON ?" The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. <2> = "LOOP MODE ON ?" The taper will stop after a complete cycle for one device. <3> = "ALL MODES OFF ?" The taper will cycle multiple devices in a normal run. This is the default. <CLEAR> = Resets to the beginning of the taper's "STOP MODE ON/OFF" loop. <ENTER> = Executes the next loop cycle.

MANUAL ######
You have pressed the <MANUAL> button. The numbers signified by the # placeholders show the number of tape pockets that have been run past the swing arm. With the taping system in MANUAL mode, several keys on the controller have unique functions. See "Using Manual Mode" on page 3-37 for details.

MOD SET UP ? NO
<SET UP> Modifies the taper's setup. <ENTER> No modifications to the handler's setup are required.

MOD SET UP ? YES


Press the <SET UP> key if no changes to the handler's setup are required. Press the <ENTER> key to make changes to the handler's setup. The handler will now scroll through all of the setup routines listed below. See "Modifying Setup" on page 3-31 for details regarding each setup.

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Model 1050 Handler Status and Error Messages

MOTOR [A, B, or C] BUSY ?

Seal type (thermal or PSA) Number of devices making a full tape Set number of gap steps Set number of offset steps Stop/loop modes off/on

MOTOR [A, B, or C] BUSY ?


The taper is checking to see if the stepper motor is moving as required for each of the following taper components. A = tape drive B = swing arm C = octoloader If this message does not go away within a few seconds, the taper will not operate. To resolve this condition: 1. Turn the taper power OFF then ON and try again. 2. Verify that the motor control cable is plugged in and is not broken. 3. Replace the motor driver module and/or the motor control PCB. 4. Contact Exatron for assistance and replacement parts.

MOTOR <A, B, or C> ERROR ?


The taper is checking to see if the stepper motor is powering up properly as required for each of the following handler components. A = tape drive B = swing arm C = octoloader If this message does not go away within a few seconds, the taper will not operate. To resolve this condition: 1. Turn the taper power OFF then ON and try again. 2. Verify that the motor control cable is plugged in and is not broken. 3. Replace the motor driver module and/or the motor control PCB. 4. Contact Exatron for assistance and replacement parts.

MOTOR A OFF
You have pressed the <0> key while in DIAGNOSTICS DRIVE MOTOR CHK and turned off the tape drive motor.

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MOTOR B OFF
You have pressed the <0> key while in DIAGNOSTICS SWING HEAD CHECK and turned off the swing arm motor. You can now rotate the swing arm freely to clean or replace the suction cup. Press the <CLEAR> key to turn the swing arm motor back on. Then press the <3> key to rotate the swing arm back up.

MOTOR C OFF
You have pressed the <0> key while in DIAGNOSTICS OCTO MOTOR CHK and turned off the octoloader motor.

MOTOR HOME
This message is part of the routine for automatically resetting the tapers swing arm at its home position at the device pickup location. This routine occurs upon power-up and may also be actuated during various system paused conditions. The complete auto centering sequence consists of: FIND MOTOR HOME HOME SWING HEAD MOTOR HOME

MOVE TAPE LEFT


The tape drive motor has moved several steps to the left as part of the Drive Motor Check DIAGNOSTICS routine.

MOVE TAPE RIGHT


The tape drive motor has moved several steps to the right as part of the Drive Motor Check DIAGNOSTICS routine.

NEW JOBEMPTY OK
Inspection of a pocket has failed. You have pressed the <1> key. If the failure is because a new tape has been mounted with empty leader pockets, press the <2> key to confirm. Empty pockets will be advanced until a good device is inspected. Then the inspection routine will inspect each pocket.

NEW TAPE SET UP?


In Manual mode, you have pressed the <1> key. You can now select the tape size to use. <1> = "RUN 5 X 5 MLF" <2> = "RUN 4 X 4 MLF" <3> = "RUN SSOIC"

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Model 1050 Handler Status and Error Messages

NO POCKET? ERROR

<4> = "RUN DEFAULT 4" <ENTER> Confirms your selection.

NO POCKET? ERROR
No carrier tape was found in the tape track.

NOT UP TO TEMP
The temperature of the heaters in the sealing heads is too low. Check the two temperature control displays on the front of the taping system to verify the temperatures. If necessary, change the set temperature as described in "Setting Temperature for Heat Seal Heads" on page 3-21.

OCTO MOTOR CHK


See "ALL MOTOR CHECK: Octoloader Motor Check" on page 4-20.

OCTOLOADER OFF
This message is displayed only if the RAM address for Octo 4/8 Tubes has been set to No Octoloader. In this case, you can either drop one device at a time down the open octoloader track (for troubleshooting purposes), or you can place a tube full of devices at the open octoloader track. In Run mode, it will process all the devices in that tube, but the octoloader will not move to a different input tube.

OFFSET = ####
The gap offset is the distance, measured in tape drive motor steps, between the leading edge of a tape pocket and the center of that pocket. This is a display only. See also "SET OFFSET = ####" on page 5-19.

OFFSET>GAP ERROR
The offset has been set larger than the gap. See "Understanding the Gap" on page 3-32 for details.

OK TO RUN ? 6
An inspection problem has been fixed; the machine is ready to run again.

OUT OF POCKET ?
This error message is displayed when fiberoptic sensors are used to detect whether a device is in the tape pocket and RAM address 009F "Out of Pocket" is turned on. When an image sensor (camera) is used for this function, this control panel message is not displayed.

OUTPUT CHECK
You have pressed <DIAGNOSTICS>, <2>. From here you can test the cylinders and solenoids.

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Press the <1> key to test outputs by using intermittent action. Press the <2> key to test outputs by using steady action. You press each key a second time to toggle the output off again.

PASSWORD ABC?
The password security is turned on. Enter a 3-digit password with the numeric keys. The factory-set password is 123, entered by pressing <1> <2> <3>.

PAUSED ######
You have pressed the <PAUSE> button on the front control panel. The display includes the number of filled tape pockets. The taper will not operate until you select another option from the controller keypad. To restart, press the <RUN> key.

PART AT PICK UP
You have pressed <MANUAL., <7>, <1>. The sensor has detected a device at the pickup site. You can now use the other numeric keys to test the swing arm functions. See "Using Manual Mode" on page 3-37.

PART DROPPED ?
The swing arm (pick and place head) sensor is not detecting a device in place during the rotation cycle. It is possible that the part has been dropped. Inspect the path of the pick and place head for any dropped device or other blockage. After removing any blockage, press <Clear> to resume operation.

PICK UP AT HOME
You have run the Rotation (pick and place motor) Check. From DIAGNOSTICS mode, the operator has pressed the <4> key followed by the <3> key. This rotates the pick and place motor up to the "pick" position (also called "home" position). The rotation motor stops when the sensor sees the pick-up head in the correct position and displays the above status message.

PICK UP DOWN
You have run the Rotation (pick and place motor) Check. From DIAGNOSTICS mode, the operator has pressed the <4> key followed by the <1> key. This rotates the pick and place motor down to the "place" position above the next empty pocket. The rotation motor stops when the sensor sees the pickup head in the correct position and displays the above status message.

PICK UP NOT HOME


This error message indicates that the taping system is in Run mode but the pickup head has not cycled all the way to the "home" position, that is, fully up and seated at the pickup location.

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Model 1050 Handler Status and Error Messages

PLACE PART ERR

Press the <3> key on the front panel controller to activate the Automatic Centering feature. The following sequence of messages will be displayed while the rotation motor moves the pickup head into proper operating alignment: FIND MOTOR HOME JOG ROTATE JOG UP MOTOR HOME Press <ENTER> or <RUN> to start the system running again.

PLACE PART ERR


The device failed to be picked up at the pickup site.

POCKETS = ######
This message is displayed after you have pressed the <TOTALS> key. It shows the total number of devices placed in tape pockets, up to 999,999, since the last time the count was reset to zero. After the count is reset to zero, the display reads: POCKETS = 000000. See "RESET COUNT YES" on page 5-17.

RAM AUTO RESET


The handler has detected errors in its RAM and automatically reloaded its RAM with defaults stored in EPROM. This should occur very rarely or after unexpected power line interruptions. Replace the CPU PCB if this message appears frequently.

READY TO RUN ?
You have pressed the <RUN> key and sensors have found tubes and devices in the right places.

RESET COUNT NO
The current tally of devices placed in the tape remains in memory even when the taper is turned off. Press the <TOTALS> key to see the total, in the format POCKETS = ######. Exits routine without resetting the total count to zero. <ENTER> exits with no changes. <SET UP> toggles back to RESET COUNT YES.

RESET COUNT YES


The current tally of devices placed in the tape remains in memory even when the taper is turned off. Press the <TOTALS> key to see the total, in the format POCKETS = ######.

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Chapter 5: Dictionary of Displayed Messages

<ENTER> resets the total to zero. Display reads: COUNT SET TO 0. <SET UP> toggles back to RESET COUNT NO.

RETURN ERROR ?
When the swing arm was sent to its home position but for some reason it did not go home, this message is displayed.

ROTATE DOWN
The swing arm has moved down one step, about .003".

ROTATE UP
The swing arm has moved up one step, about .003"

RS-232 CHECK
You have pressed <DIAGNOSTICS>, <4>, <1>. This is a future option port.

RUN 4 X 4 MLF
You have pressed <MANUAL>, <1>, <2>. This is the tape setup selection for this size of device. Press <ENTER> to confirm your selection, or another numeric key to change the selection.

RUN 5 X 5 MLF
You have pressed <MANUAL>, <1>, <1>. This is the tape setup selection for this size of device. Press <ENTER> to confirm your selection, or another numeric key to change the selection.

RUN DEFAULT 4
You have pressed <MANUAL>, <1>, <4>. This option allows you to use another configuration that you have set up. Press <ENTER> to confirm your selection, or another numeric key to change the selection.

RUN SSOIC
You have pressed <MANUAL>, <1>, <3>. This is the tape setup selection for this size of device. Press <ENTER> to confirm your selection, or another numeric key to change the selection.

RUN UNTIL 1 PASS


Inspection has failed at the beginning of a new tape because of empty leader pockets. You have pressed the <2> key. Now the empty pockets will be advanced until the camera inspects a good device; then the inspection routine will begin.

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Model 1050 Handler Status and Error Messages

SEN0-7 01234567

SEN0-7 01234567
One or more of the numbers shown above is displayed following SEN0-7. This group of sensors applies to the tape. See "SENSOR CHECK: Tape Sensors 0-7" on page 4-11.

SEN8-F 89ABCDEF
One or more of the numbers/letters shown above is displayed following the phrase SEN8-F. This group of sensors applies to the pickup site. See "SENSOR CHECK: Input and Pickup Sensors 8-F" on page 4-12.

SENSOR CHECK
See the sections "SENSOR CHECK: Tape Sensors 0-7" on page 4-11 and "SENSOR CHECK: Input and Pickup Sensors 8-F" on page 4-12.

SET # INPUTS
You have pressed <DIAGNOSTICS>, <3., <3>, <8>. This message refers to the number of input tubes used, as stored in RAM address 009C: "Octo 8/4 Tubes". <1> key = "8 TUBE INPUT"uses all 8 input tubes. <2> key = "4 TUBE INPUT"uses 4 input tubes; alternating tracks. <3> key = "OCTOLOADER OFF"allows operator to drop devices down input track, bypassing octoloader. <CLEAR> = Resets to the beginning of the taper's "SET # INPUTS" loop. <ENTER> Confirms your selection.

SET GAP ? NO/YES


This proposes to re-find the gap between the leading edges of two adjacent tape pockets. See "Understanding the Gap" on page 3-32 and "Setting Tape Pocket Gap" on page 3-34 for details. <ENTER> key = Press to display current settings. The display reads "GAP STEPS = ####", then "OFFSET = ####". <SET UP> key = "SET GAP ? YES" then press <ENTER> to set the gap.

SET OFFSET = ####


You can type a different offset number if necessary, to get the tape pocket center under the swing arms pickup head. Use Polish notation (right-to-left) to change the number. Then press <ENTER>. The tape advances by the offset you have entered, and SET OFFSET = #### is redisplayed. Again you can look to see if the pocket center is under the pickup head. If not, you can change the number again. Press <ENTER> again to confirm the value.

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Chapter 5: Dictionary of Displayed Messages

SOL TOGGLE CHECK


You have pressed <DIAGNOSTICS>, <2>, <2>. From here you can test various cylinders and solenoids. See "OUTPUT CHECK: Solenoid Toggle Check" on page 4-15.

SOLENOID CHECK
You have pressed <DIAGNOSTICS>, <2>, <1>. From here you can test various cylinders and solenoids. See "OUTPUT CHECK: Solenoid Check" on page 4-14.

SORT = 12345678
This is a future option port.

STOP MODE ON/OFF


You have pressed the <9> key while in RUN mode or a waiting mode. Stop and loop modes are for testing and troubleshooting of the taper. Select one of the following keypad choices. <1> = "STOP MODE ON ?" The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. <2> = "LOOP MODE ON ?" The taper will stop after a complete cycle for one device. <3> = "ALL MODES OFF ?" The taper will cycle multiple devices in a normal run. This is the default. <CLEAR> = Resets to the beginning of the taper's "STOP MODE ON/OFF" loop. <ENTER> Confirms your selection.

STOP MODE ON ?
You are in Stop mode. Stop and loop modes are for testing and troubleshooting of the taper. Select one of the following keypad choices. <1> = "STOP MODE ON ?" The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. Press <ENTER> or <RUN> when you are ready to execute the next action. <2> = "LOOP MODE ON ?" The taper will stop after a complete cycle for one device. <3> = "ALL MODES OFF ?" The taper will cycle multiple devices in a normal run. This is the default.

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Model 1050 Handler Status and Error Messages

SWING HEAD CHECK

<ENTER> = Executes the next Stop mode action.

SWING HEAD CHECK


You have accessed this feature either from pressing <MANUAL>, <7>; or from pressing <DIAGNOSTICS>, <3>, <2>. From here you can test the movements of the swing arm and its pickup head. See page 3-41 or "ALL MOTOR CHECK: Swing Arm Check" on page 4-17.

SWING HOME = ###


You are in SWING HEAD CHECK, accessible from both Diagnostics and Manual mode. The swing arm is over the pickup site, and the number displayed is the number of motor steps from the swing arm home position to the pickup site.

SWING STEP = ###


You are in SWING HEAD CHECK, accessible from both Diagnostics and Manual mode. The swing arm is over the tape, and the number displayed is the number of motor steps from the swing arm home position to the tape.

TAKE UP MOTOR CK
You have activated the takeup motor check feature by pressing the <5> key on the front control panel when the taper was in RUN mode. Pressing the <5> key turns the takeup motor for five seconds or until the takeup arm switch is thrown, while the above status message is displayed. If the motor turns a full five seconds the error message: "TAKE UP REEL ERR" will be displayed. You may: Press <ENTER> to rotate the takeup motor another five seconds. Press <CLEAR> to return to RUN mode or other previous condition.

TAKE UP REEL ERR


You have activated the takeup motor check feature by pressing the <5> key on the front control panel when the taper was either in RUN mode or a paused condition. The takeup motor has turned for five seconds while attempting to advance the carrier tape until the takeup arm switch is thrown, without success. You may: Press <ENTER> to rotate the takeup motor another five seconds. Press <CLEAR> to return to RUN mode or other previous condition.

TAPE GAP LOST ?


This error condition is caused when the carrier tape is in an incorrect position. The gap between tape pockets is not lined up opposite the tape gap sensor. It is possible to move the tape in single-step moves until it is again properly aligned: Press the <7> key to move the tape one step to the left.

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Chapter 5: Dictionary of Displayed Messages

Press the <9> key to move the tape one step to the right. TIP: To quickly move the tape to the left until the gap between tape pockets is aligned directly opposite the sensor, press the <4> key. The taping system will then be ready to resume operation.

TAPE IS FULL
This message advises that the current taping job is complete, that is, the full tape count has been reached. You can press <ENTER> to reset the count to zero and begin operation again. Or, you may create a tape leader of fifty empty sealed pockets by pressing <DELETE> first. This will run the takeup reel and tape drive motors with the sealing heads engaged to create a tape leader of fifty empty sealed pockets for a new reel. Use this feature when you intend to cut the tape at the leader and separate the full reel from the rest of the tape.

TAPE OUT ERROR ?


The sensor has detected no carrier tape in the track. Load a new spool of carrier tape and thread it to the takeup spool. See the first part of Chapter 3.

TAPE STACK EMPTY ?


You have pressed <MANUAL>, <7>, <1>. The sensor has detected no devices either at the pickup site or in the stack. Check whether there are devices in position for the taping pickup head. Check whether the pickup sensor is operating properly. See "SENSOR CHECK: Input and Pickup Sensors 8-F" on page 4-12.

TEST TAPE MOTOR


You have pressed <DIAGNOSTICS>, <3>, <1>, <5> keys. This advances the tape by one pocket.

THANK YOU #
One or more identifier numbers are displayed following the words THANK YOU. The handler is exiting a jam routine correctly. The handler will resume operation at the end of the two-second THANK YOU delay. If your handler is displaying excessive THANK YOU messages, contact Exatron and report the number displayed with the THANK YOU message. This number indicates the source of the former error and what part of the program the handler was in just prior to displaying THANK YOU. 0 = shown after an index jam, "INDEX/STACK JAM," has been cleared 1 = shown after a swing arm homing error, "RETURN ERROR," has been cleared 2 = shown after a loader jam, "LOADER JAM," has been cleared by dropping devices down to the stack pin

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Model 1050 Handler Status and Error Messages

THERMAL OR PSA ?

3 = shown after an optional temperature alarm check has been cleared 4 = shown after a tape gap error, "TAPE GAP LOST," has been cleared and the gap sensor has found the tape gap again 5 = shown after a loader jam, "LOADER JAM," has been cleared by removing devices so that none are at the stack pin 6 = shown after the <PAUSE> key has been pressed and then unpaused

THERMAL OR PSA ?
You have pressed <MANUAL>, <3>. Select the type of seal tape to apply to the carrier tape. Press the <1> key to "USE THERMAL TAPE" or press <2> to "USE PSA TAPE."

UART OUT ERROR


The handler's UART has detected an error. Turn the handler OFF, then ON and try again. If the problem continues, replace the handler's CPU PCB.

USE PSA TAPE


You have pressed <MANUAL>, <3>, <2>. This selection seals a pressure-sensitive adhesive cover tape with pressure only. Press <ENTER> to confirm your selection, or press <1> to change the selection to thermal.

USE THERMAL TAPE


You have pressed <MANUAL>, <3>, <1>. This selection seals a cover tape with heat. Press <ENTER> to confirm your selection, or press <2> to change the selection to PSA.

VAC NOT ADJUSTED


The taper has tried to pick up a device and has failed to detect that the device was already suctioned up by the pickup head's vacuum. To resolve this condition: 1. Press the <PAUSE> key: HANDLER PAUSED. Wiggle the pickup head manually to slightly shift the device. Watch the red LED on the vacuum generator. When the LED lights up, stop wiggling the pickup head. Press any key on the taper's control panel. The taper will automatically resume operation if the device is now detected. 2. Verify that the vacuum line is installed from the vacuum generator to the pickup head. Verify that the pickup head fitting is not leaking. 3. Verify that the pickup head is mechanically adjusted correctly. 4. Pressing the <ENTER> key will skip past this error, but be cautious in selecting this option, because pressing the <ENTER> key will cycle the pickup head down which may destroy the device it is holding.

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Chapter 5: Dictionary of Displayed Messages

5. Pressing the <CLEAR> key will flush all devices from the handler. 6. Use Diagnostics Output Check Solenoid Check <1> key to verify that the vacuum is working properly. See "OUTPUT CHECK: Solenoid Check" on page 4-14.

ZERO COUNT ERR


The operator has set the tape full quantity to 000000. Set the count for more than 0000. See "FULL T = ######" on page 5-8.

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Chapter 6: Servicing and Troubleshooting


Chapter Overview
This chapter discusses the following maintenance tasks and their frequency: Task Seal Head Maintenance Air Regulator Maintenance Checking Air Regulator Shutoff Valve Adjusting Air Pressure on the Regulator Adjusting Air Valves Checking the Moisture/Dirt Trap in the Air Regulator Solenoid Maintenance Fiberoptic Photoelectric Sensor Guidelines Recommended Frequency As needed As needed Monthly As needed As needed Weekly As needed As needed Page 6-1 6-3 6-3 6-4 6-5 6-6 6-9 6-10

Preventive maintenance on the Model 1020 is fairly simple. Following this schedule will help to assure your Model 1020 handler will continue to perform properly. CAUTION: Do not lubricate any lead screws! Lubricating the screws will void the warranty. CAUTION: Do not use any cleaners or solvents on any bearings or lead screws! CAUTION: Always power off the system before disconnecting any cables or doing any maintenance.

Seal Head Maintenance


If one of a pair of thermal seal heads is heating but the other is not, it is likely because it has become slightly unplugged. You may get wildly erratic readings or a display of all zeros (0000). Make sure each seal head is firmly plugged in. The front seal head is color-coded red; the back seal head is color-coded blue. Residue from the carrier tape and sealing tape gradually builds up on the sealing heads, whether you use thermal or PSA (pressure-sensitive) heads. In time, this residue prevents a good tape seal. So when you notice any lowered quality of tape seal, clean the heads.

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Chapter 6: Servicing and Troubleshooting

Pressure-Sensitive Heads
If the PSA rollers on your taper are brass (Figure 6-1, left), you can clean them with alcohol. Apply alcohol to a Q-tip and rub the Q-tip around the PSA rollers until the edges are shiny. However, if the PSA rollers on your taper are rubber (Figure 6-1, right), do not use alcohol or other cleaning fluids on them. Just replace them with new ones.

Figure 6-1: Brass PSA Rollers (Left); Rubber PSA Rollers (Right)

Heat Seal Heads


Disassemble the blades and clean them with very fine (320) sandpaper. First rub the blade edge on the flat sandpaper in the direction of the blade ends. When the edge is shiny, lay the blade flat on the sandpaper and rub it till each side is shiny, as well.

Figure 6-2: Heat Seal Head Blade

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Air Regulator Maintenance

Checking Incoming Air from the House Supply

Air Regulator Maintenance


Your taper uses compressed air to lower the seal heads. This requires an air regulator. A high quality air regulator with air filter and shutoff valve is supplied on your taper. CAUTION: Never operate any Exatron equipment that requires compressed air without an approved air regulator and shutoff valve. The air regulator assembly includes an oil/water particulate trap which should be visually inspected on occasion. This regulator should be set at factory air pressure of 50 PSI.

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 tapers air regulator is not spiking or pulsing. If it is, the house air supply is inadequate.

Checking 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 valve OFF and verify that the air is indeed off. Turn the valve back ON. 2. Check the PSI setting. > Set the air regulator to 50 PSI.

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Adjustment valve On/off switch in OFF position On/off switch in ON position

Figure 6-3: Air Regulator Turned Off (Left), On (Right)

If the air regulator is turned off, turn it on by turning the on/off knob one quarter-turn counterclockwise. You can leave this knob turned on except when you are checking its operation.

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 adjustment valve (the black 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.

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Air Regulator Maintenance

Adjusting Air Valves

Adjusting Air Valves


Pressurized air for the air cylinders at the test sites 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 (Figure 6-4). Air flow control adjustment knob Lock nut

Figure 6-4: 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.

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Chapter 6: Servicing and Troubleshooting

Checking the Moisture/Dirt Trap in the Air Regulator


Check the moisture/dirt trap on the air regulator and the filter chamber. Verify that they are clean, empty and dry. There should be no oil and no water in either 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 suggest the air supply to the system is too wet and/or dirty. CAUTION: Excessive moisture in the system can damage the air valves. Various models of air regulators differ. Here is one 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 6-5: Air Regulator with Small Black Screw Removed

2. Unscrew the metal casing.

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Air Regulator Maintenance

Checking the Moisture/Dirt Trap in the Air Regulator

Figure 6-6: Metal Casing Unscrewed

3. Snap off the clear glass casing.

Large black screw


Figure 6-7: Clear Glass Casing Snapped Off

4. Unscrew the black inner screw that has edges like propeller blades.

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Chapter 6: Servicing and Troubleshooting

Filter

Figure 6-8: 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.

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Solenoid Maintenance

Checking the Moisture/Dirt Trap in the Air Regulator

Solenoid Maintenance
CAUTION: NEVER use oil or lubricant of any kind on solenoids.

Figure 6-9: Solenoid with Plunger on Back Side of Taper

Keep the solenoids as clean as possible. If the taper 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, do not 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 the Parts List for the part numbers of all solenoids and springs in your handler.

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Chapter 6: Servicing and Troubleshooting

Fiberoptic Photoelectric Sensor Guidelines


Clean dust off the sensor optics with a very low blast of air. 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 6-10: Sensor Controller Set to L-ON

Figure 6-11: 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.

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Fiberoptic Photoelectric Sensor Guidelines

Checking the Moisture/Dirt Trap in the Air Regulator

The red light is the Light Reception Indicator. When the sensor is receiving light, the red light should be ON.

Figure 6-12: 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. For information on fine-tuning the fiberoptic photoelectric sensor and controller, see the vendors manual.

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Chapter 6: Servicing and Troubleshooting

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Chapter 7: Parts List


This chapter contains the following main sections:

Topic Guide to the Parts List Lists of Parts

Page 7-1 7-4

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. Each parts list is specific to each machine, so the parts list is included in the manual that is shipped with each custom Exatron handler.

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 which Exatron has custom manufactured. They include machined parts, sheet metal, printed circuit boards, cables, and standard vendor parts which 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 retrofitted to 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.

10/2010

Copyright Exatron, 2010

7-1

Model 1020 Manual

Chapter 7: Parts List

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.

7-2

Copyright Exatron, 2010

10/2010

Guide to the Parts List

Finish

C B
A

Figure 7-1: 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.

10/2010

Copyright Exatron, 2010

7-3

Lists of Parts
Two parts lists are on the following pages. The first is for the changeover kits; the second is for the base machine.

7-4
Copyright Exatron, 2010 10/2010

Model 1020 Manual

List TAPE 1020 170 SSOIC 4X4 5X5 MLF AXSEM 9-28-2010 TAPE MODEL 1020 BASE MACHINE 8-24-2010

For Changeover kits Base machine

Page 7-4 7-6

TAPE 1020 170 SSOIC 4X4 5X5 MLF AXSEM 9-28-2010


EXATRON 1020 170 1020 4X4 037 SSOIC MLF CO CO KIT KIT 1 2500-101-75-A 2710-060-G 2710-061-B 2710-150-L-D1 2710-150-R-D1 2710-432-B2 2710-B46-A 2710-J32-B 2710-J33-B 2710-J34-A 2710-J57-A 2710-J58-A 5000-717-V 5000-D02-C 1 2 1 2 4 1 1 8 4 4 4 1 1 1 4 4 1 1 1 2 8 4 4 4 8 4 4 4 1 1 1020 5X5 MLF CO KIT 1 1 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

TAPE MASTER PARTS LIST MODIFIED SOLENOID PLUNGER INPUT TUBE HOLDER TUBE CLAMP LEFT CHAMBER STOP RIGHT CHAMBER STOP PIVOT BLOCK .170 TSSOP OCTO TRAY INPUT HOLDER 4X4 LCC CP.230 4X4 LCC OCTO TRAY CLEAR OCTO TRAY GUIDE INPUT HOLDER 5 X 5 LCC CP.268 5 X 5 LCC OCTO TRAY OCTO INPUT BASE PLATE OCTO PLATE ROLLER

TAPE INDEX OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER

TAPE SP-75 .245-1.862-8.250 .250-.500-.937 .500-.632-.984 .500-.632-.984 .468-.694-1.000 .237-2.550-8.000 .245-1.862-8.250 .232-2.550-8.000 .125-1.258-2.550 .245-1.862-8.250 .232-2.550-8.000 NONE NEDOX BLUE HCR HCR BLUE NEDOX NEDOX NEDOX NONE NEDOX .170 TSSOP .316 CPT

Chapter 7: Parts List

NEDOX

.250-8.000-10.750 NICKEL .312-.500-1.127 NICKEL

TAPE 1020 170 SSOIC 4X4 5X5 MLF AXSEM 9-28-2010


EXATRON 1020 170 1020 4X4 037 SSOIC MLF CO CO KIT KIT 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1020 5X5 MLF CO KIT 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 2 1 2 1 2 1 1 1 2 1 1 1 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

10/2010

Lists of Parts

5000-N11-A BEA16-213 HRD03-100 PNE024-001 PNE042-414 SOL1-002 TAPE-540-B TAPE-541-B TAPE-702-E TAPE-703-E TAPE-705-C TAPE-736-B TAPE-929-B TAPE-930-B TAPE-931-B TAPE-932-A TAPE-950-A
Copyright Exatron, 2010

OCTOLOADER TUBE PUSH UP OCTOLOADER BAR BALL BEARING BLACK BUMP ON KNOCK AIR CYLINDER 1/4 BORE, 1/4 STROKE 4 MM VACUUM CUP SIZE 75 SOLENIOD CA OUT GATE OUT CYLINDER MOUNT BALL BEARING DANCER ARM TAPE OUT SWING HEAD 1050 INDEX OUT GATE OUT GATE

.250-1.000-8.000 .125 ID, .375 OD, .16 THK

NEDOX BRONZE NONE

4 MM SEE PART .312-.375-.942 .875-.987-1.765 .300-1.500-9.949 .300-1.500-9.949 .020-.375-9.098 .125-.540-.937 .250-1.899-2.637 .437-.585-7.50 .300-1.500-9.949 SEE PRINT .207-.250-.438 NICKEL NONE NEDOX NICKEL NEDOX NEDOX NONE BLACK NICKEL NONE NEDOX .170 TSSOP 5X5 4X4 SOIC

TAPE OUT BOTTOM RAIL 5 X 5 TAPE OUT MLF TAPE OUT BOTTOM RAIL 4 X 4 TAPE OUT MLF UNDER SOL TAPE OUT TOP GUIDE PICK UP BUMPER MOUNT STACK SOLENOID MOUNT STOP PIN BLOCK TAPE OUT BOTTOM RAIL .170 TSSOP UNDER SOL OUTPUT RAIL INDEX INDEX BOTTOM RAIL

1020 BOTTOM RAIL ASSEMBLY ASSEMBLY DECELERATOR MOUNT BLOCK CO KIT RAIL

Finish

7-5

TAPE MODEL 1020 BASE MACHINE 8-24-2010


EXATRON 1020 TAPING MACHINE 1 2500-048-B1 3000-055-C3 3000-202-B 3000-203-C1 3000-205-L-C 3000-205-R-C 3000-223-2-B2 3000-224-G1 3000-227-B 3000-907-D 3044-344-H 5000-369-B2 5000-370-A2 5000-397-2-A1 5000-398-2-C1 5000-716-D 5000-718-D 5000-720-E1 5000-721-A2 5000-725-BOT-B 5000-725-TOP-B 5000-729-C 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

7-6
Copyright Exatron, 2010 10/2010

Model 1020 Manual

TAPE MASTER PARTS LIST COVER AIR VENT 8085 CPU CARD 3000B BUS BOARD OCTO MOTOR COVER CARD CAGE - LEFT CARD CAGE - RIGHT 3000B I/O PORT PCB OCTO STOP BLOCK OCTO STOP BLOCK OCTO SWITCH COVER PIVOT MOTOR MOUNT RETURN BLOCK QUAD STEPPER DRIVER PCB TEST SITE DRIVER PCB OCTO BEARING SUPPORT OCTO GUIDE BAR OCTO CAR BLOCK OCTO LOADER BEARING INPUT SENSOR MOUNT BLOCK - BOTTOM INPUT SENSOR MOUNT BLOCK - TOP CHAIN GUARD LOWER OCTO SENSOR MOUNT

TAPE MAIN RAIL ELECTRONICS ELECTRONICS OCTOLOADER MAIN RAIL MAIN RAIL ELECTRONICS OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER ELECTRONICS ELECTRONICS OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER OCTOLOADER

TAPE SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT .687-1.500-1.750 .500-1.124-1.333 .562-.673-1.033 .437-.750-1.375 .375-.834-2.360 1.093-1.418-1.628 SEE PRINT SEE PRINT .500-2.538-15.486 .375-2.500-16.280 .505-1.086-4.421 RSR12MX-320 .437-.874-1.185 .250-.874-1.185 SEE PRINT .640-.686-2.604 NEDOX FAB FAB NICKEL NEDOX NEDOX FAB RED NICKEL NICKEL NEDOX BLACK RED FAB FAB NICKEL NICKEL NEDOX NONE NONE NONE NONE NICKEL

Chapter 7: Parts List

5000-735-H1

TAPE MODEL 1020 BASE MACHINE 8-24-2010


EXATRON 1020 TAPING MACHINE 1 1 1 1 1 1 1 1 1 1 OPT 1 4 1 1 1 2 2 2 1 1 1 1 1 1 1 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

10/2010

Lists of Parts

5000-736-F 5000-877-C 5000-957-A 5000-A89-C3 5000-K01-A 5000-M08-27-A1 5000-M15-A 5000-M22-A2 5000-M42-1-A1 5000-M54-120-A1 5000-M54-240-A1 8000-G74-D BEA01-100 BEA03-028 BEA03-030 BEA04-050 BEA07-002 BEA09-004 BEA09-014 BEA11-018 BEA11-020 BEA11-021
Copyright Exatron, 2010

UPPER OCTO SENSOR MOUNT REGULATOR MOUNT EXATRON NAME PLATE FRONT PANEL DRIVER PCB EARTH GROUND PLATE TEST SITE DRIVER CABLE FRONT PANEL CABLE MOTOR DRIVER CABLE CABLE TERMINATION PCB INPUT POWER LABEL 100-120 VAC INPUT POWER LABEL 220-240 VAC VAC ATTACH BLOCK TEFLON THRUST WASHER 10 GROVE TIMING BELT PULLEY 30 GROVE TIMING BELT PULLEY 50 TEETH SPROCKET WHEEL SPROCKET 1.000 DIA., .25 I.D. SPLIT HUB CLAMPS SS SPLIT HUB CLAMP 10-32 X 1/4" SHOULDER SCREW 10-32 X .37 L SHOULDER BOLT 10-32 X 1/2" SHOULDER SCREW

OCTOLOADER FRAME MAIN PLATE ELECTRONICS MAIN PLATE CABLE CABLE CABLE MAIN PLATE POWER SUPPLY POWER SUPPLY SWING HEAD CRANK

.250-.640-2.604 .375-1.500-3.000 SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT .312-.592-1.244 .25 ID,.62 OD, .06 THK

NICKEL BLACK PAINT FAB PAINT NONE NONE NONE FAB

BLACK NONE

TAKE UP MOTOR 1/5 PITCH TAKE UP MOTOR 1/5 PITCH TAPE DRIVE 50 X 4mm NONE/SS BERG COVER TAPE GUIDE ADJUST SCREW PRESSURE ROLLER OCTOLOADER PRESSURE ROLLER #10-32-.37 LONG .25 ID, .50 OD, .25 L NONE

.25 ID. .875 OD, 6-32 TAP NONE ALLIED NONE ALLIED

Finish

7-7

TAPE MODEL 1020 BASE MACHINE 8-24-2010


EXATRON 1020 TAPING MACHINE 1 1 1 2 4 1 2 1 1 2 2 2 2 2 1 2 3 1 1 1 3 2 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

7-8
BEA12-018 BEA12-022 BEA12-155 BEA16-213 BEA16-222 BEA17-070 BEA18-050 FUS1-020 FUS2-002 HOT03-240-100THIN HOT05-044-J HOT06-183 HOT-07-002-F HOT07-102-M HRD02-500 HRD02-505 ICOS-CY545 LAB03-007 LAB03-011 LAB03-014 MOT05-000-P MOT05-001
Copyright Exatron, 2010 10/2010

Model 1020 Manual

MIN-E-PITCH CHAIN MINI-E-PITCH CABLE CHAIN 55 GROVE TIMING BELT BALL BEARING FLANGED BALL BEARING BRONZE SLEEVE BEARING BALL BEARING, PRESS FIT FUSE HOLDER 2 AMP FUSE CARTRIDGE HEATERS, 100 WATT J TYPE THERMACOUPLE SNAP SWITCH 120VAC OPEN AT 170V

OCTOLOADER CRANK 300 PITCH .157

NONE NONE

TAKE UP MOTOR 1/5 PITCH BALL BEARING SEAL HEAD PINCH ROLLER .125 ID, .375 OD, .16 THK BRONZE .25 ID, .50 OD .25 ID, .312 OD, .25 L NONE

TAKE UP MOTOR .500 ID, 1.125 OD POWER SUPPLY POWER SUPPLY SEAL HEAD SEAL HEAD SEAL HEAD FENWAL BLACK BLACK .250 DIA., 1.18 LONG NONE

THERMALCOUPLE CONNECTOR FEMALE J HEATER TYPE THERMALCOUPLE CONNECTOR MALE J TYPE CLAMP KNOB HAND CRANK KNOB MOTOR CONTROL CHIP DANGER WATCH YOUR FINGERS DANGER ELECTRICAL HAZARD LABEL CAUTION DO NOT OPERATE WITHOUT GUARDS IN PLACE 5 PHASE MOTOR DRIVER STEPPER MOTOR 500 STEP ADJUST SCREW ELECTRONICS LABEL LABEL LABEL ELECTRONICS P&P MOTOR SEE PRINT HEATER

Chapter 7: Parts List

SEE PRINT SEE PRINT

TAPE MODEL 1020 BASE MACHINE 8-24-2010


EXATRON 1020 TAPING MACHINE 1 1 OPT 2 1 2 1 1 1 1 1 2 3 1 1 1 2 ? ? ? ? 1 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

10/2010

Lists of Parts

MOT05-010 MOT10-010 MOT10-011 NRET04-53 NRET04-80 PNE002-001 PNE002-005 PNE004-001 PNE013-010 PNE015-015-1 PNE015-025 PNE015-090 PNE020-350 PNE022-100 PNE024-002 PNE025-022 PNE031-0.5R PNE042-412 PNE042-414 PNE042-416 PNE042-418 POW01-070
Copyright Exatron, 2010

STEPPER MOTOR 500 STEP WITH 30 : 1 GEAR 25 RPM SHADED POLE MOTOR, MAG BRAKE, FAN 25 RPM SHADED POLE MOTOR, MAG BRAKE, FAN E-RING E RING RIGHT ANGLE 1/8" TUBE 10-32 FITTING RIGHT ANGLE 1/4' TUBE 1/8 PIPE FITTING "T" 1/8" TUBE 10-32 FITTING MINI REGULATOR M5-.8 THREAD REGULATOR ASSEMBLY O-RING .218 ID, .343 OD, .07 DIA. O-RING SQUARE AIR VALVE VAC GENERATOR 2 NC VALVE QUICK AIR DISCONNECT AIR CYLINDER BIMBA CYLINDER, SPRING OUT 2 MM SUCTION CUP 4 MM VACUUM CUP 6 MM VACUUM CUP 8 MM SUCTION CUP +5 VDC, 13 AMP SWITCHER POWER SUPPLY

DRIVE MOTOR TAKE UP MOTOR 110 VAC ONLY TAKE UP MOTOR 220 VAC ONLY PEEL TEST .250 SHAFT NONE NONE NONE NONE NONE NONE SEE PART NONE 9/16 ID X 1/16 "

TAKE UP MOTOR .500 SHAFT PIVOT CYLINDER PIVOT CYLINDER PIVOT CYLINDER SWING HEAD FRAME SWING HEAD PINCH ROLLER

PIVOT CYLINDER 24 VDC 100W SWING HEAD MAIN PLATE INDEX PIVOT CYLINDER SWING HEAD SWING HEAD SWING HEAD SWING HEAD POWER SUPPLY 2 MM 4 MM 6 MM 8 MM NONE

Finish

SEE PART

7-9

TAPE MODEL 1020 BASE MACHINE 8-24-2010


EXATRON 1020 TAPING MACHINE 1 1 1 1 2 1 3 1 1 1 3 2 1 1 1 2 OPT 1 1 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

7-10
POW01-075 POW10-025 POW17-003 REL01-002??? SEM02-305 SEM02-500
Copyright Exatron, 2010 10/2010

Model 1020 Manual

+24 VDC, 14 AMP SWITCHER POWER SUP- POWER SUPPLY PLY POWER CORD 3 PRONG 8 FT POWER LINE FILTER SOLID STATE RELAY DC IN AC OUT 1/32 DIN TEMPERATURE CONTROLLER W/RS-232 110-240 VAC OEM MICROTERMINAL SENSOR CONNECTOR ASSEMBLY/PLUG THRU BEAM SENSOR ASSEMBLY LED/SENSOR PAIR SENSOR KNOCK AIR CYLINDER 1/4 BORE, 3/8 STROKE FIBER OPTIC AMPLIFIER SCREW IN FIBER OPTIC PROBE SPRING .020 WIRE COMPRESSION SPRING PUSH BUTTON MUSHROOM CAP ASSEMBLY SNAP ON SWITCH ASSEMBLY, 2 RED SWITCHES FOOT SWITCH BACK PLATE FRONT PLATE BASE BASE PINCH ROLLER POWER SUPPLY POWER SUPPLY HEATER ELECTRONICS SWING HEAD SWING HEAD SENSOR P&P MOTOR P&P MOTOR P&P MOTOR POWER SUPPLY POWER SUPPLY

SEE PART GRAINGE R 6 AMP STEVEN ENG. 1/32 DIN RS-232

SEM02-802 SEM02-802 SEM02-803 SEM03-319 SEM03-400 SEM03-415 SPR240-020-1.00 SPR375-.028-1.50 SWT05-100 SWT05-111 SWT20-020 TAPE-102-Y TAPE-103-W

NONE NONE

.25 DIA. 1.00 LONG

NONE

Chapter 7: Parts List

GRAINGE R .500-3.500-30.000 .500-3.500-30.000 PAINT PAINT

TAPE MODEL 1020 BASE MACHINE 8-24-2010


EXATRON 1020 TAPING MACHINE 1 3 1 1 6 4 2 2 1 1 1 1 1 2 2 1 4 1 1 1 1 2 2 2 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

10/2010

Lists of Parts

TAPE-112-B1 TAPE-114-A2 TAPE-115-C TAPE-116-A TAPE-137-A2 TAPE-140-1-C TAPE-140-2-A TAPE-141-F TAPE-142-A TAPE-147-C1 TAPE-149-B TAPE-150-C1 TAPE-150-NP-C1 TAPE-153-B TAPE-156-B TAPE-157-K2 TAPE-158-B2 TAPE-162-F TAPE-163-E TAPE-164-E1 TAPE-165-D TAPE-173-D1 TAPE-180-C
Copyright Exatron, 2010

SUPPLY REEL HUB BRACKET SUPPLY REEL FINGER SUPPLY REEL HUB SUPPLY REEL GUIDE BRACKET GUIDE ROD SMALL PRESSURE WEIGHT LARGE PRESSURE WEIGHT WEIGHT ROD KEEPER PIN END PLATE LOCATOR SUPPLY REEL ROD SPACER CLAMP NUT WITH PIN CLAMP NUT WITH NO PIN RAIL ADJ. BUSHING HEATER ARM STOP PINCH ROLLER TAKE UP & COVER TAPE SPACER BLUE BACK RIGHT RAIL FRONT RIGHT RAIL BACK LEFT RAIL FRONT LEFT RAIL COVER TAPE DISK (LG) M16-2 RAIL ADJUSTMENT SCREW M16X2 RAIL ADJ NUT

SUPPLY REEL SUPPLY REEL SUPPLY REEL SUPPLY REEL BASE SEAL HEAD SEAL HEAD SEAL HEAD PINCH ROLLER BASE SUPPLY REEL BASE BASE ADJUST SCREW HEATER PINCH ROLLER BASE BASE BASE BASE BASE COVER TAPE ADJUST SCREW ADJUST SCREW

.250-4.000 DIA. 2.875-.750 DIA. 1.250-1.500 DIA. .500-.500-2.500 .500 DIA.- 3.630 L .500 -1.000 DIA. 1.00 DIA., 1.25 L 3.375-.250 DIA. 1.250-.230 DIA. .475-1.000-2.000 .780-1.000 DIA. 1.000-1.250 DIA. 1.000-1.250 DIA. 1.125-1.500 DIA. 1.250-.500 DIA. .246-.700 DIA. .437-1.000 DIA. .062-.750-19.255 .062-.750-19.235 .062-.750-9.605 .062-.750-9.585 .375-7.500 DIA. .629 DIA. 6.75L 1.250-1.366-1.500

NICKEL NICKEL NEDOX RED NONE NONE NONE NONE NONE NEDOX BLACK RED RED NONE NONE NICKEL RED NEDOX NEDOX NEDOX NEDOX NICKEL NONE

7-11

Finish

TAPE-181-B

BLUE

TAPE MODEL 1020 BASE MACHINE 8-24-2010


EXATRON 1020 TAPING MACHINE 2 1 1 1 1 2 2 1 1 2 ? 1 2 1 1 1 1 1-MOD 1 1 1 ENG 1 1 1 1 1 1 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

7-12
TAPE-187-A TAPE-188-L-B TAPE-188-R-B TAPE-189-C TAPE-190-B TAPE-191-3-A TAPE-192-B TAPE-195-C1 TAPE-196-C1 TAPE-198-G TAPE-203-B TAPE-218-C TAPE-219-B TAPE-220-D TAPE-221-A TAPE-222-G TAPE-223-K TAPE-224-K1 TAPE-225-B TAPE-256-C TAPE-299-C TAPE-303 TAPE-304-B
10/2010 Copyright Exatron, 2010

Model 1020 Manual

CYLINDER BUMPER LEFT CYLINDER MOUNT RIGHT CYLINDER MOUNT VALVE MOUNT BLOCK CYLINDER ASSEMBLIES SEAL HEAD ASSEMBLY HOT HEAD LABEL LEFT HEAD PLATE RIGHT HEAD PLATE HOT SHOE COVER ADJUST SCREW ASSEMBLY TAKE UP REEL SHAFT TAKE UP MOTOR STAND OFF TAKE UP MOTOR MOUNT PLATE TAKE UP MOTOR ASSEMBLY ELECTRONICS MAIN PLATE ELECTRONICS SIDE PLATE ELECTRONICS BACK COVER 1020 ELECTRONICS SIDE PANEL 1020 INPUT POWER WIRING TAPE OUT SWITCH MOUNT BLOCK 1020 TAPE MACHINE ASSEMBLY 1020 BASE PLATE

PIVOT CYLINDER .650-.750 DIA. PIVOT CYLINDER .750-1.750-2.165 PIVOT CYLINDER .750-1.750-2.165 PIVOT CYLINDER .750-1.224-1.359 PIVOT CYLINDER SEE PRINT ASSEMBLY SEAL HEAD SEAL HEAD SEAL HEAD SEAL HEAD ASSEMBLY SEE PRINT SEE PRINT .250-2.000 DIA. .250-2.000 DIA. .875-2.000 DIA. SEE PRINT

NONE CLEAR CLEAR CLEAR

NONE NONE NONE

TAKE UP MOTOR .500 DIA., 9.000 L TAKE UP MOTOR .374-2.750-2.875 TAKE UP MOTOR .375-2.750-5.968 ASSEMBLY MAIN RAIL MAIN RAIL MAIN RAIL MAIN RAIL POWER SUPPLY MAIN RAIL ASSEMBLY OCTOLOADER BASE SEE PRINT .375-9.880-23.880 .500-5.095-9.732 SEE PRINT .125-5.187-12.232 SEE PRINT 1.000-1.450-1.656 SEE PRINT .250-12.500-36.000

NONE BLACK BLACK

NICKEL NICKEL NONE NICKEL

Chapter 7: Parts List

BLACK 1020 NEDOX 1020

TAPE MODEL 1020 BASE MACHINE 8-24-2010


EXATRON 1020 TAPING MACHINE 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 3 1 1 1 1 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

10/2010

Lists of Parts

TAPE-305-L-F1 TAPE-305-R-F1 TAPE-306-A1 TAPE-307-A TAPE-308-G TAPE-309-C TAPE-310-1-L TAPE-310-2-L TAPE-311-A TAPE-312-H TAPE-328-B TAPE-329-B TAPE-334-F TAPE-335-A TAPE-336-A TAPE-339-A TAPE-353-G TAPE-355-F TAPE-356-C TAPE-360-C
Copyright Exatron, 2010

1020OCTO LOADER SUPPORT PLATE LEFT 1020 OCTO LOADER SUPPORT PLATE RIGHT 1020 BACK COVER SWING HEAD ATTACH BLOCK 1020 SWING HEAD SWING HEAD ATTACH BLOCK ADJUSTABLE PICK UP PLUNGER PLUNGER ADJUST CO KIT TO OCTO PLATE ATTACH 1020 OCTO MAIN PLATE 1020 CONTROL - OCTO - SWING HEAD CABLE 1020 INTERNAL DRIVER CABLE .024" SEAL BLADE HOT HEAD BLOCK RIGHT HOT HEAD BLOCK LEFT WHEEL FELT PAD SWING HEAD PLATE CO KIT RAIL MOUNT BLOCK VALVE BLOCK SWING HEAD BASE COVER

OCTOLOADER BASE OCTOLOADER BASE OCTOLOADER BASE SWING HEAD SWING HEAD SWING HEAD SWING HEAD SWING HEAD OCTOLOADER BASE OCTOLOADER BASE CABLE CABLE SEAL HEAD SEAL HEAD SEAL HEAD COVER TAPE SWING HEAD SWING HEAD SWING HEAD SWING HEAD

.375-10.321-14.817 .375-10.321-14.817 SEE PRINT .687-1.217-2.689 .600-1.813-1.999 .375-.600-1.023 .312 DIA. 1.347 .217 DIA., - .750 L .500-1.500-1.598 .250-14.000-22.000 SEE PRINT SEE PRINT .024-.539-1.500 .718-.875-1.500 .718-.875-1.500 .06-1.00 DIA. .375-6.500-7.470 .375-2.206-2.750 1.125-1.172-3.152 SEE PRINT

PAINT PAINT PAINT NEDOX NEDOX NEDOX NEDOX BLUE RED NEDOX NONE NONE NEDOX NEDOX NEDOX NONE NEDOX NICKEL BLUE PAINT

1020 1020 1020 1020 1020 1020 1020

1020 1020

7-13

Finish

TAPE MODEL 1020 BASE MACHINE 8-24-2010


EXATRON 1020 TAPING MACHINE 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 2 2 1 2 1 1 2 1 1 1 1 1 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

7-14
TAPE-361-C TAPE-368-1-A TAPE-368-2-A TAPE-368-3-A TAPE-368-4-A TAPE-391-C TAPE-392-F TAPE-394-A1 TAPE-395-A TAPE-403-F1 TAPE-404-G TAPE-419-D TAPE-420-A1 TAPE-421-A TAPE-422-B1 TAPE-423-B TAPE-424-A TAPE-426-2-D TAPE-447-D TAPE-451-A TAPE-452-A
10/2010 Copyright Exatron, 2010

Model 1020 Manual

SWING HEAD MAIN COVER 1020 FRONT VIEW 1020 SIDE VIEW TYPE B SWING HEAD 1020 TOP VIEW 1020 BOTTOM COVER 1020/1050 END PLATE 1050 SUPPLY REEL BRACKET SUPPLY REEL OFFSET BLOCK COVER TAPE STOP BLOCK COVER TAPE ADJUST BAR COVER TAPE GUIDE BLOCK TOOLING 1020 POWER SUPPLY BASE 1020 OCTO PLATE CABLE SEAL HEAD ARM SEAL ARM PIVOT POST SEAL HEAD ADJUST 1020 BACK GUIDE RAIL PSA ROLLER BLOCK HEATER PLUG MOUNT BLOCK LEFT HEATER PLUG MOUNT BLOCK RIGHT HEATER MOUNT COVER

SWING HEAD ASSEMBLY ASSEMBLY ASSEMBLY ASSEMBLY OCTO STAND MAIN RAIL SUPPLY REEL SUPPLY REEL COVER TAPE GUIDE COVER TAPE GUIDE COVER TAPE GUIDE POWER SUPPLY CABLE SEAL HEAD SEAL HEAD SEAL HEAD

SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT .500-2.500-10.750 .375-2.000-20.269 .625-1.000-2.000 .500-.899-1.298 .187 DIA, 4.00 L SEE PRINT SEE PRINT SEE PRINT .500-1.880-3.068 1.412 L, .750 DIA. .500-.848-1.500 .093-.750-16.000

PAINT

NONE NEDOX PAINT BLACK NICKEL NONE HCR PAINT NONE NEDOX NONE NONE NEDOX

Chapter 7: Parts List

PSA ROLLER SEAL HEADS SEAL HEADS SEAL HEADS

.500-.500-2.500 .625-1.250-1.620 .625-1.250-1.620 .625-1.250-1.308

NICKEL NEDOX NEDOX NICKEL

TAPE-453-A1

TAPE MODEL 1020 BASE MACHINE 8-24-2010


EXATRON 1020 TAPING MACHINE 1 2 1 2 2 1 1? 1? 1 1? 1? 1? 1? 1? 1 1 1 1 ??? OPT 1 1 1 1 1 1 MANUAL DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

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Lists of Parts

TAPE-478-E TAPE-482-C1 TAPE-526-B TAPE-670-F2 TAPE-671-F TAPE-677-D TAPE-680-C TAPE-694-B TAPE-707-A TAPE-723-D TAPE-725-B TAPE-726-B TAPE-727-1/2-D TAPE-743-A TAPE-748-A TAPE-749-A TAPE-829-B TAPE-830-A1 TAPE-917-B TAPE-921-A TAPE-926-A TAPE-927-A TAPE-928-A
Copyright Exatron, 2010

TOP RAIL SWING HEAD ATTACH BLOCK SPOT GUIDE RAIL COVER TAPE ROLLER SEAL ROLLER RIM SEAL ROLLER RIM PIN TAKE UP SLACK PLATE COVER TAPE GUIDE BLOCK 8 MM TRACK COVER TAPE GUIDE BLOCK 12mm UNDER SOL INDEX SENSOR MOUNT COVER TAPE GUIDE BLOCK 16 MM COVER TAPE GUIDE BLOCK 24 MM COVER TAPE GUIDE BLOCK 32 MM COVER TAPE GUIDE BLOCK 44 MM COVER TAPE GUIDE BLOCK 56mm FRONT FINE GAP & OUT SENSOR MOUNT BACK FINE GAP & OUT SENSOR MOUNT PINCH ROLLER MOUNT PINCH ROLLER SLIDE 1010 iVu CAMERA MOUNT ASSEMBLY iVu CAMERA ATTACH MOTOR SHAFT ADAPTOR 1020 COVER TAPE SPOOL EXTENSION BOTTOM INDEX PIN BLOCK CAMERA OPTION WIRING

SWING HEAD

.375-.600-1.211 .155-.937-1.000 1.000 DIA. 3.000 L

NICKEL NEDOX NONE NONE NONE BLUE HCR HCR NICKEL HCR HCR HCR HCR HCR BLACK BLACK NICKEL NICKEL

LCC

PSA ROLLER PSA ROLLER DANCER TAPE GUIDE 202 TOOLING UNDER SOL TAPE GUIDE TAPE GUIDE TAPE GUIDE TAPE GUIDE TAPE GUIDE RAIL RAIL PINCH ROLLER PINCH ROLLER iVu CAMERA iVu CAMERA DRIVE WHEEL COVER TAPE INDEX WIRING

.140-.625 DIA. .312 DIA. .625 L SEE PRINT .500-.575-1.290 .500-.735-1.290 .625-.625-1.205 .500-.885-1.290 .500-1.200-1.290 .500-1.290-1.512 .500-1.290-1.988 .500-1.290-2.460 .249-.750-.810 .249-.750-.810 .500-1.000-2.376 .437-.437-1.125 SEE PRINT .375-1.457-1.750 .750 DIA. 1.750 L .500-1.500-4.497 .250-.375-.403 SEE PRINT

8mm 12mm

56mm

BLACK NONE NICKEL NICKEL

7-15

Finish

TAPE-933-10-A

TAPE MODEL 1020 BASE MACHINE 8-24-2010


EXATRON 1020 TAPING MACHINE 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1?? OPT OPT 12 MANUAL 1 1 1 1 1 1 1 1 1 DESCRIPTION ASSEMBLY SIZE FINISH WIDTH

7-16
TAPE-933-1-B TAPE-933-2-A TAPE-933-3-A TAPE-933-4-A TAPE-933-5-A TAPE-933-6-A TAPE-933-7-A TAPE-933-8-A
Copyright Exatron, 2010 10/2010

Model 1020 Manual

1020 INPUT POWER WIRING 1020 CARD CAGE & MOTOR DRIVER WIRING SEAL HEAD HEATER WIRING 1020 TAPE I/O PORT PCB TAKE UP MOTOR WIRING 1020 SENSOR/VALVE WIRING TYPE B SWING HEAD WIRING 1020 AIR CIRCUIT 1020 OCTOLOADER WIRING iVu SLIDE BLOCK 1020 MOD iVu CAMERA POST 1020 MOD 1020 CAMERA MOUNT ATTACH BLOCK iVu X SLIDE BLOCK 1020 MOD ELECTRONICS BACK COVER 1020 MOD RING LIGHT MOUNT iVu CAMERA iVu CAMERA CABLE "SPRIAL WRAP

WIRING WIRING WIRING WIRING WIRING WIRING WIRING WIRING WIRING 1020 CAMER MOUNT CAMER MOUNT CAMER MOUNT COVER CAMERA iVu CAMERA iVu CAMERA SEAL HEAD

SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT TAPE-919 .500-.875-6.000 .375-.500-2.251 .500-2.501-3.250 SEE PRINT 1.000-1.155-1.500 BLACK BLACK BLACK BLACK NONE BLACK

TAPE-933-9-A TAPE-937-A TAPE-938-A TAPE-939-A TAPE-940-B TAPE-941-B TAPE-949-A VIS130-070-12 VIS130-071-6 WIR01-325

CARR

Chapter 7: Parts List

Chapter 8: Prints
List of Prints
The following prints are included in this chapter: Part Number
3000-055-C3 3000-223-2-B2 5000-397-2-A1 5000-398-2-C1 5000-A89-C3 5000-M08-27-A1 5000-M15-A 5000-M22-A2 TAPE-190-B TAPE-191-3-A TAPE-203-B TAPE-221-A TAPE-368-1-A TAPE-368-2-C TAPE-368-3-A TAPE-368-4-A TAPE-419-D TAPE-917-B TAPE-932-A TAPE-933-10-A TAPE-933-1-B TAPE-933-2-A TAPE-933-3-A TAPE-933-4-A TAPE-933-5-A 8085 CPU CARD 3000B I/O PORT PCB QUAD STEPPER DRIVER PCB TEST SITE DRIVER PCB FRONT PANEL DRIVER PCB TEST SITE DRIVER CABLE FRONT PANEL CABLE MOTOR DRIVER CABLE CYLINDER ASSEMBLIES SEAL HEAD ASSEMBLY ADJUST SCREW ASSEMBLY TAKE UP MOTOR ASSEMBLY 1020 FRONT VIEW 1020 SIDE VIEW TYPE B SWING HEAD 1020 TOP VIEW COVER TAPE GUIDE BLOCK TOOLING 1010 iVu CAMERA MOUNT ASSEMBLY 1020 BOTTOM RAIL ASSEMBLY CAMERA OPTION WIRING 1020 INPUT POWER WIRING 1020 CARD CAGE & MOTOR DRIVER WIRING SEAL HEAD HEATER WIRING 1020 TAPE I/O PORT PCB TAKE UP MOTOR WIRING

Description

Page
8-3 8-4 8-5 8-6 8-7 8-8 8-9 8-10 8-11 8-12 8-13 8-14 8-15 8-16 8-17 8-18 8-19 8-20 8-21 8-22 8-23 8-24 8-25 8-26 8-27

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8-1

Model 1020 Manual

Chapter 8: Prints

Part Number
TAPE-933-6-A TAPE-933-7-A TAPE-933-8-A TAPE-933-9-A

Description
1020 SENSOR/VALVE WIRING TYPE B SWING HEAD WIRING 1020 AIR CIRCUIT 1020 OCTOLOADER WIRING

Page
8-28 8-29 8-30 8-31

How to View the Prints


If you are viewing this chapter online in a PDF viewer, you can enlarge any print so you can see small details. Click on the PDF viewers magnification tool, which may have an appearance like a magnifying glass.

8-2

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Figure 8-1: 3000-055-C3

Model 1020 Manual

Chapter 8: Prints

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Figure 8-2: 3000-223-2-B2

How to View the Prints

Figure 8-3: 5000-397-2-A1


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8-5

Model 1020 Manual

Chapter 8: Prints

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Figure 8-4: 5000-398-2-C1


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How to View the Prints

Figure 8-5: 5000-A89-C3

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Model 1020 Manual

Chapter 8: Prints

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Figure 8-6: 5000-M08-27-A1

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Figure 8-7: 5000-M15-A

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Model 1020 Manual

Chapter 8: Prints

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Figure 8-8: 5000-M22-A2

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How to View the Prints

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Figure 8-9: TAPE-190-B

Model 1020 Manual

Chapter 8: Prints

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Figure 8-10: TAPE-191-3-A

How to View the Prints

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Figure 8-11: TAPE-203-B

Model 1020 Manual

Chapter 8: Prints

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Figure 8-12: TAPE-221-A

How to View the Prints

Figure 8-13: TAPE-368-1-A

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Model 1020 Manual

Chapter 8: Prints

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Figure 8-14: TAPE-368-2-C


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Figure 8-15: TAPE-368-3-A


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Model 1020 Manual

Chapter 8: Prints

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Figure 8-16: TAPE-368-4-A

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How to View the Prints

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Figure 8-17: TAPE-419-D

Model 1020 Manual

Chapter 8: Prints

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Figure 8-18: TAPE-917-B

How to View the Prints

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Figure 8-19: TAPE-932-A

Model 1020 Manual

Chapter 8: Prints

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Figure 8-20: TAPE-933-10-A


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How to View the Prints

Figure 8-21: TAPE-933-1-B


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Model 1020 Manual

Chapter 8: Prints

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Figure 8-22: TAPE-933-2-A


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Figure 8-23: TAPE-933-3-A


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Model 1020 Manual

Chapter 8: Prints

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Copyright Exatron, 2010

Figure 8-24: TAPE-933-4-A


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Figure 8-25: TAPE-933-5-A

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Model 1020 Manual

Chapter 8: Prints

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Figure 8-26: TAPE-933-6-A


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Figure 8-27: TAPE-933-7-A

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Model 1020 Manual

Chapter 8: Prints

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Figure 8-28: TAPE-933-8-A

How to View the Prints

Figure 8-29: TAPE-933-9-A

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Model 1020 Manual

Chapter 8: Prints

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Index
A
air filter 1-3 air pressure 6-4 fittings 1-3 air regulator 3-19, 6-3, 6-4 air supply 1-3, 6-3 air valve adjustment 6-5 ASCII values 3-47, 3-53 control panel 2-3, 4-2, 5-1 keys 3-30 messages 5-1 to 5-24 counts tape full 3-48, 3-49 totals 3-35, 3-36

D
1-1, 2-6 decimal values 3-47, 3-53 devices changeover kit settings 3-46 totals 3-35, 3-36 Diagnostics mode 4-2, 4-3 displays control panel 3-30, 5-1 to 5-24 heater controller 3-22 drive gear adjustment knob 3-7 drive gear. See tape drive

B
buttons, EMO (emergency stop)

C
calibration carrier tape track width 3-3 device placement in tape pocket 3-26 heat seal heads 3-12 octoloader 3-20 pressure seal heads 3-15 camera sensors 4-13 carrier tape track 3-3 cautions and warnings avoid turning power off and on in rapid cycles 3-29 changing motor speeds can damage machine 3-46 connect power to grounded outlet 1-3 dont do diagnostic "MOVE TAPE RIGHT" with tape present 4-6, 4-16 dont interfere with moving parts 1-1 dont leave on index solenoid 4-5, 4-15 dont lubricate lead screws 6-1 dont lubricate solenoids 6-9 dont touch adhesive tape to carrier tape 3-12 dont touch hot taper seal heads 3-13 dont unplug air hose when air regulator on 1-2 dont use cleaners on bearings or lead screws 6-1 dont use machine without approved air regulator 1-2 keep away from moving parts 1-1 loosen track width locking knob before turning adjustment knobs 3-4 power off system before maintenance 6-1 prevent excess moisture in air regulator and air valves 6-6 Change RAM mode 3-44 changeover kit settings 3-46

E
electrical capability 1-2 Emergency Stop button 1-1 EMO (emergency stop) button 2-6 end-of-life disposal 1-6 EPROM, updating 3-44, 3-46

F
flowcharts <SET UP> key options 3-31 Diagnostics mode 4-3 Manual mode 3-38 Modify Setup mode 3-33

G
gap 3-31, 3-32, 5-21 gap steps 3-32, 5-9 guide block 3-10, 3-12

H
heat seal heads adjusting position 3-12 adjusting pressure 3-14 continued on next column

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Index-1

Model 1020 Manual

heat seal heads continued messages 5-15 setting temperature 3-21 stopping 2-6 heater controller display 2-5, 3-22 heater fuse 2-5 hex values 3-47, 3-53 home positions octoloader 2-9 swing arm 2-18

I
index pin 2-2, 2-6, 2-18 input reel. See supply reel installation 1-4 interface, RS-232 3-47

modes continued Modify Setup 3-31 Run 3-28, 3-29, 4-2 Stop 3-26, 3-35 Modify Setup mode 3-31, 3-33 motors 2-7 messages 5-6, 5-7, 5-13, 5-14 octoloader 2-9, 3-20, 3-29 RAM addresses 3-49, 3-50, 3-51 speeds 3-46 swing arm 4-17 takeup reel 2-3, 2-4, 3-43, 3-49, 5-21 tape drive 2-4, 3-49, 3-50, 3-51, 4-16

O
octoloader 2-9 aligning 3-20 bypassing 5-15 home position 2-9 homing 3-29 loading input tubes 3-16 messages 5-15 movement 4-20 stop block 3-21 tube gates 2-11, 3-17 offset 3-32 output reel. See takeup reel override button lights 2-5

K
keys <-> (minus) 3-45 <0> 3-45 <CLEAR> 3-30, 3-45 <DELETE> 3-30, 3-43, 3-45 <DIAGNOSTICS> 3-30, 4-2 <ENTER> 3-26, 3-30 <MANUAL> 3-30 <PAUSE> 3-30 <RUN> 3-30, 3-45 <SET UP> 3-30, 3-31, 3-35 <SPACE> 3-30, 3-43, 3-45 <TOTALS> 3-30, 3-36 numeric 4-4 to 4-10

P
password 3-39, 4-2 photos, taper parts 2-3 to 2-21 pickup head 2-2 RAM addresses 3-48 pickup site sensors 4-12 pins index 2-2, 2-6, 2-18 octoloader gate 2-11 snap-on 2-10 stack 2-2, 2-6, 2-18 Polish notation 3-34, 3-35, 3-39, 5-19 positions octoloader home 2-9 pickup site 2-2 swing arm home 2-18 tape pocket 2-2 top of index pin 2-2 top of stack pin 2-2 power-down 3-29

L
Loop mode 3-35

M
Manual mode 3-37, 3-38, 3-39, 4-2 manual, users typography significance 1-8 version number significance 1-7 modes Change RAM 3-44 Diagnostics 4-2 Loop 3-35 Manual 3-37, 3-38, 4-2 messages 5-6, 5-12 continued on next column

Index-2

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Index

power-up 3-19 message sequence 3-20, 3-31 pressure roller block 2-4, 2-5 pressure seal heads 2-5, 2-19, 3-15 procedures. See tasks

swing arm 2-2, 2-4, 2-18, 2-19 calibrating position 4-17 home position 2-18 messages 5-8, 5-9, 5-18 path diagram 2-21 pickup head 2-2, 2-20 RAM addresses 3-48, 3-49, 3-50, 3-51

R
RAM addresses changing 3-44, 3-45, 5-5 list 3-47 loading default 3-44, 5-11, 5-12, 5-17 types of values 3-47 reels 2-3, 3-2 RS-232 interface 3-47 Run mode 3-28, 3-29, 4-2

T
takeup arm 3-6 takeup reel 2-3, 3-2 messages 5-21 motor 2-3, 2-4, 3-43, 5-21 RAM addresses 3-49 tape calibrating position 4-16 carrier direction of movement 2-3 loading 3-5 messages 5-8, 5-21, 5-22 sensors 4-11 gap 3-32 offset 3-32 output full count 3-48 output, full count 3-34, 3-48, 3-49 sealing 3-8, 3-11, 3-14, 3-34 sensors 2-13 to 2-17 tape drive calibrating position 4-16 gear 2-4, 3-6 messages 5-6, 5-8, 5-11, 5-14 RAM addresses 3-49, 3-50, 3-51 taper end-of-life disposal 1-6 facilities requirements 1-2 installation 1-4 operation overview 2-2 powering down 3-29 powering up 3-19 requirements electrical 1-2 environmental 1-2 pressurized air 1-3 taper parts see also individual part names air pressure fittings 1-3 air regulator 6-4 carrier tape track 3-3 chains 2-7 control panel 2-3, 3-30, 4-2, 5-1 continued on next column

S
safety 1-1 to 1-4 see also cautions and warnings training responsibilities 1-1 sealing heads 2-3, 2-8, 2-18 adjusting PSA 3-15 adjusting thermal 3-12 messages 5-6, 5-23 RAM addresses 3-47, 3-48 sealing tape 3-8, 3-11, 3-14 selecting 3-31, 3-34 sensors 2-3, 2-13 to 2-18 camera 4-13 Carrier Tape Out 2-13, 2-17 cleaning optics 6-10 Device at Pickup Site 2-13, 2-14 Device at Stack 2-13, 2-14 Empty Pocket 2-5, 2-13, 2-15 fiberoptic controllers 6-10 Gap 2-13, 2-16 lights 2-5 Out-of-Pocket 2-13, 2-16 pickup site 4-12 Swing Arm Home 2-13, 2-18 Takeup Arm 2-13, 2-17 tape 4-11 solenoids maintenance 6-9 testing 4-14, 4-15 stack pin 2-2, 2-6, 2-18 Stop mode 3-26, 3-35 supply reel 3-2 support services 1-5, 1-6

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Index-3

Model 1020 Manual

taper parts continued cover foot 2-6 drive gear adjustment knob 3-7 Emergency Stop button 1-1 EMO (emergency stop) button 2-6 guide block 3-10, 3-12 heater controller display 2-5 heater fuse 2-5 index pin 2-2 motors 2-7 octo stop block 3-21 octoloader 2-9, 3-16, 3-20 octoloader gates 2-11 override button lights 2-5 photos 2-3 to 2-21 pickup site 2-2 pressure roller block 2-4, 2-5 seal heads heat 2-4, 2-19, 3-12, 3-21 pressure 2-19, 3-15 sensor lights 2-5 sensors 2-5, 2-13 to 2-18 stack pin 2-2 swing arm 2-2 pickup head 2-2, 2-20 takeup arm 3-6 takeup reel 2-3 tape drive gear 2-4, 3-6 taper input track 2-2, 2-5 track width adjustment knobs 3-3 track width locking knob 2-5, 3-3 tubes 3-16 tasks adjusting air flow 6-5 adjusting air pressure 6-4 adjusting position of heat seal heads 3-12 adjusting position of PSA heads 3-15 adjusting pressure of heat seal heads 3-14 adjusting PSA pressure 3-16 adjusting tape track width 3-4 aligning octoloader 3-20 calibrating device placement in tape pocket 3-26 changing digits in settings 3-34, 3-35, 3-39, 5-19 changing RAM settings 3-44 checking air filter 6-6 checking air regulator 6-3 checking air regulator moisture/dirt trap 6-6 checking air supply from house generator 6-3 displaying totals 3-36 homing octoloader 3-29 loading carrier tape 3-5 loading sealing tape 3-8 mounting supply reel 3-2 continued on next column

tasks continued mounting takeup reel 3-2 powering down system 3-29 powering up taper 3-19 pre-power-up check 3-19 resetting totals 3-36 securing input tubes on octoloader 3-17 setting temperature for heat seal 3-22 starting production run 3-29 turning off temperature for heat seal 3-25 using Manual mode 3-39 temperatures, setting 3-21 thermal seal heads. See heat seal heads totals displaying 3-36 resetting 3-35 track width adjustment knobs 3-3 track width locking knob 2-5, 3-3, 3-4 tubes, input 2-9, 3-16 typography significance 1-8

W
warnings. See cautions and warnings warranty agreement 1-3, 1-4, 1-5, 6-1

Index-4

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