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Manual Taper Models 1005 and 1010 User Manual

Version 2.5 January 21, 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
List of Figures Chapter 1: Safety and Support
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Exatron Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Uncrating the Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Mounting the Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Pressurized Air Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 End-of-Life Handler Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Customer In-House Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Offshore Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Exatron Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Significance of the Manuals Version Number. . . . . . . . . . . . . . . . . . . . . . . . 1-6

Chapter 2: Setup
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Identifying the Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 How the Taper Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Mounting the Takeup Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Mounting the Supply Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Adjusting the Carrier Tape Track Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Loading the Carrier Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Loading the Sealing Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Adjusting Heat Seal Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Adjusting Lateral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Adjusting Downward Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Setting Temperature for Heat Seal Heads . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Adjusting Pressure Seal Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Chapter 3: Production Run


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Preparing for a Production Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Testing the Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Setting the Pocket Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Doing a Production Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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Models 1005 & 1010 Manual

Chapter 4: Servicing and Troubleshooting


Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Seal Head Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Pressure-Sensitive Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Heat Seal Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Air Regulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Checking Air Regulator Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Adjusting Air Pressure on the Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Checking the Moisture/Dirt Trap in the Air Regulator . . . . . . . . . . . . . . . . 4-4 Solenoid Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Chapter 5: Parts List


Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Vacuum Generator Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Guide to the Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Exatron (Part Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Part Quantity Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 List of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Chapter 6: Prints

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List of Figures
Figure 1-1: Main Power On (Left), Off (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-1: Model 1010 Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-2: Model 1005 TaperFront Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-3: Locking Hub on Takeup Reel with Alignment Pins. . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-4: Center Prongs of Supply Reel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-5: Carrier Tape Track at Different Widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-6: Track Width Locking Knob (Left); Guide Block with Guide Rod and Screws (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-7: Carrier Tape Under Guide At Top Supply End of Track . . . . . . . . . . . . . . . . . . . . . . Figure 2-8: Lifting Pressure Roller Arm and Pushing In Keeper Pin . . . . . . . . . . . . . . . . . . . . . . Figure 2-9: Takeup Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 2-1 2-2 2-3 2-3 2-4 2-5 2-6 2-6 2-7

Figure 2-10: Drive Gear Adjustment Knob with Blue Locking Knob Unscrewed . . . . . . . . . . . . 2-7 Figure 2-11: Gear Adjustment Narrowed (Left); Widened (Right). . . . . . . . . . . . . . . . . . . . . . . . 2-8 Figure 2-12: Sealing Tape PlatesOutside (Left), Inside (Right) . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-13: Adjustment Collar on Sealing Tape Supply Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-14: Sealing Tape Threaded to Sealing Tape Guide Assemblyfor PSA (Left), for Heat (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Figure 2-15: Sealing Tape Threaded to Sealing Tape Guide Assembly for Heat . . . . . . . . . . . . Figure 2-16: Two Widths of Guide Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-17: Placement in Grooves of Guide Blockof Sealing Tape (Left) and Carrier Tape (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-18: Guide Rod Removed from One Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-19: Guide Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-20: Sealing Tape Threaded Under Guide Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-21: Heat Seal Head with Lateral Adjustment Screw . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-22: Example of Good Tape Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-23: Three-Gram and One-Gram Weights (Left); One-Gram Weight on Heat Seal Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-24: Left Display Set to Fahrenheit; Right Display Set to Celsius . . . . . . . . . . . . . . . . Figure 2-25: Heater Controller Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-26: SET Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-27: Up Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-28: Digit in Ones Position Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-29: Left Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-30: Digit in Tens Position Selected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-31: Temperature Set Before the SET Button Is Pressed . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-32: Temperature Set After the SET Button Is Pressed . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-33: Down Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-34: Temperature Set to Zero Before the SET Button Is Pressed . . . . . . . . . . . . . . . . . 2-10 2-11 2-11 2-12 2-12 2-13 2-14 2-15 2-15 2-16 2-16 2-17 2-17 2-18 2-18 2-18 2-19 2-19 2-20 2-20

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Figure 2-35: Pair of Pressure Seal Heads with Lateral Adjustment Screws . . . . . . . . . . . . . . . . 2-21 Figure 2-36: Three-Gram and One-Gram Weights (Left); One-Gram Weight on PSA Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Figure 3-1: RUN and SEAL Toggle Switches Off; Main Power Off . . . . . . . . . . . . . . . . . . . . . . 3-1 Figure 3-2: RUN and SEAL Toggle Switches Off; Main Power On . . . . . . . . . . . . . . . . . . . . . . 3-2 Figure 3-3: TAPE SPEED Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Figure 3-4: Pocket Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-5: Count Complete Button Lit at End of Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-1: Brass PSA Rollers (Left); Rubber PSA Rollers (Right) . . . . . . . . . . . . . . . . . . . . . . Figure 4-2: Heat Seal Head Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-3: Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-4: Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-5: Small Black Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-6: Metal Casing Unscrewed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-7: Clear Glass Casing Snapped Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-8: Large Black Inner Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-5 4-2 4-2 4-3 4-4 4-5 4-5 4-6 4-6

Figure 4-9: Solenoid with Plunger on Back Side of Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Figure 5-1: Dimensions Listed From Smallest to Largest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

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Chapter 1: Safety and Support


Chapter Overview
This chapter discusses the following main topics:

Topic Exatron Safety Warnings Installation Requirements End-of-Life Handler Disposal Standard Warranty Exatron Support Services Significance of the Manuals Version Number

Page 1-1 1-2 1-3 1-4 1-6 1-6

Please read and understand this entire manual before installing or using your Exatron taper.

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 the taper, press the MAIN POWER button on the left side of the control box.

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Chapter 1: Safety and Support

Figure 1-1: Main Power On (Left), Off (Right)

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.

Installation Requirements
Uncrating the Taper
The Model 1010 will usually come in a wooden crate which will require some disassembly to remove the taper. 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 should you see any damage.

Mounting the Taper


This machine should be installed in a 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.

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. CAUTION: Connect the power cord to earth-grounded power outlets only.

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End-of-Life Handler Disposal

If the taper is to be used in an electrically noisy environment or near large electromechanical equipment, Exatron recommends the use of a reliable power conditioner to filter line noise, surges, and spikes which can cause the taper to operate improperly or become damaged. Service calls made to the customer facility to correct problems caused by improper electrical supply are not covered by the Exatron warranty.

Pressurized Air Source


The Model 1010 requires a supply of pressurized air at 50 PSI, filtered for proper operation. The air supply must be clean (containing no particulate matter greater than 5 microns in size), oil-free, and dry (having a dew point of 36 degrees F to 38 degrees F) to operate correctly. Dirty, oily or wet air will cause the vacuum generator to malfunction and will make your system unreliable. 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 coalescing air filter (Exatron part #GPA-97-075) in the air regulator of your handler after every 6000 hours or 12 months of operation, whichever comes first; or if your air regulator registers a pressure drop of 15 PSI. Moisture of any kind will travel through external and internal air lines. This moisture will coat these air lines and the insides of the handler's cylinders, causing them to stick or to stop functioning altogether. The best defense against this kind of contaminate is to prevent it from occurring in the first place by maintaining the clean air supply described above. If the air lines are allowed to become discolored or the moisture traps become overfilled, damage to the system will occur. The only corrective action to take at that point is to replace all of the air lines and to completely clean all of the solenoids supplied by those air lines. Handler damage due to improper air supply is not covered by the Exatron warranty.

End-of-Life Handler Disposal


Exatron has no time limit on Exatron product support. We will make every effort to repair any of our products, no matter how old it is. Our never-ending support greatly extends the life of many of our products. Exatron offers "trade-ins" on any of our products as part of a new Exatron equipment purchase. Exact terms are subject to quote at that time. This applies to any used Exatron product as a trade-in on any new Exatron product. We will service our products even when the product is not purchased directly from Exatron. This makes the resale valve 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.

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Chapter 1: Safety and Support

Most of the materials used in the construction of our products can be recycled. When it comes time to finally retire an Exatron product, the customer can ship the product back to Exatron, at the customers expense, and we will quote the cost to dismantle and recycle the handler. In many cases, there is no charge for this service other than any third-party disposal fees as required. Whenever possible, reusable components will be offered as a donation to local schools. Please note that in many cases, Exatron builds systems using major third-party pieces of equipment. These include lasers, printers, camera inspection, chillers, fume extractors, and other large OEM (original equipment manufacturer) subsystems. Exatron will attempt to provide the same support as best we can for these subsystems. Exact details cannot be determined until the day comes that end-of-life service is required. The customer is free to contact the OEM directly for its end-of life service policy and then deal directly with that OEM.

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 the Users Manual. Exatron does not warrant test contactors. Handler test contactors are fragile and may be easily ruined by operator abuse. Exatron uses the finest materials available in our contactor designs. All warranty work must be performed at the Exatron factory or at an authorized Representative Service location. As described below, in-house service by our customers is encouraged. Exatron does not warrant the following: Damage caused by improper packaging of equipment returned to Exatron for repair Damage caused by the freight forwarder Damage caused by acts of God: 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. Operator abuse Interface hardware not manufactured by Exatron Test contactors

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Standard Warranty

Customer In-House Service

Customer In-House Service


Except in the case of laser marking systems, Exatron encourages customer in-house equipment service and tries to make in-house service as easy as possible to perform. There are no "Void Warranty" warning stickers on Exatron tapers. Exatron will even honor the warranty on a unit when an in-house repair attempt leads to further damage to the unit. 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.

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 the part and fax it to Exatron. The model number of the taper 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 freight forwarder In most cases, faxed requests and shipment of replacement parts orders are processed within twenty-four hours of receipt by Exatron.

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Chapter 1: Safety and Support

Exatron Support Services


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

Significance of the Manuals Version Number


The version number on the cover page of this manual indicates three things about the revision version. The first number is for complete overhauls and brand new manuals. The second number is for small section changes and additions. The third number is for small typo changes. For example, version 2.0.1 would refer to a completely redone manual, which had since had a few typographical changes made. The difference between 2.0 and 2.0.1 would be negligible. However, the differences between version 1.0 and 2.0 would be substantial.

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Chapter 2: Setup
Chapter Overview
This chapter discusses the following main topics: Topic Identifying the Parts How the Taper Works 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 Setting Temperature for Heat Seal Heads Adjusting Pressure Seal Heads Page 2-1 2-2 2-2 2-3 2-4 2-6 2-9 2-13 2-16 2-20

Identifying the Parts


Supply reel with carrier tape

Output or takeup reel Supply reel with sealing tape Device insertion area:Tape trackright-to-left direction

Hand/foot pedal

Track width locking knob

Track width adjustment knobs


Figure 2-1: Model 1010 Taper

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Figure 2-2: Model 1005 TaperFront Control Panel

How the Taper Works


The operator manually reels out empty carrier tape from the supply reel on the right end of the taper. The operator places devices in the tape pockets as the tape lies flat on the insertion tape track. When a section of tape has been filled, the operator presses the hand/foot pedal. This does two things: The takeup reel motor is activated, pulling the tape along the track toward the takeup reel. The seal heads are activated, lowering onto the carrier tape and pressing the cover tape against the carrier tape. The seal heads may seal either by pressure or heat, depending on the option(s) ordered. Model 1010 has heat seal heads and meters; Model 1005 does not. When the filled carrier tape has moved left and another section of empty tape is available on the insertion tape track, the operator releases the hand/foot pedal, and the motors stop. The cycle repeats.

Mounting the Takeup Reel


Ensure the handler is powered off before beginning. To mount an empty takeup reel: 1. Loosen the thumbscrew on the locking hub of the takeup wheel drive shaft located on the extreme left of the taper (Figure 2-3). 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 2-3), slide the locking hub over the reel and back into place. 3. Tighten the thumbscrew to lock the takeup reel in position.

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Mounting the Supply Reel

Figure 2-3: 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 from the top of the reel toward the left (Figure 2-1, Figure 2-4).

Figure 2-4: Center Prongs of Supply Reel

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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 2-6. Track width adjustment knobs

Figure 2-5: Carrier Tape Track at Different Widths

This is accomplished using two of three knobs: either of the track width adjustment knobs, and the track width locking knob. CAUTION: Loosen the track width locking knob and the guide block screws before turning the adjustment knobs to prevent bending and damage to the aluminum parts.

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Adjusting the Carrier Tape Track Width

Figure 2-6: Track Width Locking Knob (Left); Guide Block with Guide Rod and Screws (Right)

To adjust the width of a carrier tape track: 1. Turn the track width locking knob counterclockwise to loosen it (Figure 2-6). 2. Turn both guide block screws counterclockwise to loosen them. 3. Turn either the front or back track width adjustment knob to adjust the track width (Figure 2-5). (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. 4. At this point, leave the tape track a little wider than necessary and do the following procedure, "Loading the Carrier Tape." 5. 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


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 2-7).

Figure 2-7: 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 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 (Figure 2-8).

Figure 2-8: Lifting Pressure Roller Arm and Pushing In Keeper Pin

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Loading the Carrier Tape

4. Feed the carrier tape under the projecting takeup arm (Figure 2-9). 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 2-9: Takeup Arm

5. Align the carrier tape with the drive gear: Loosen the blue lock nut on the drive gear assembly (Figure 2-10).

Figure 2-10: Drive Gear Adjustment Knob with Blue Locking Knob Unscrewed

6. 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.

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> 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 2-11). 7. Retighten the blue lock nut.

Figure 2-11: Gear Adjustment Narrowed (Left); Widened (Right)

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Loading the Sealing Tape

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 212).

Figure 2-12: Sealing Tape PlatesOutside (Left), Inside (Right)

2. Place one of the two blue delrin supply reel adjustment collars (Figure 2-13) on the empty sealing tape supply reel rod in the center of the taper. 3. Position the sealing tape supply reel on the rod so that the sealing tape unwinds from the bottom of the reel in a counterclockwise direction toward the sealing tape guide assembly (Figure 2-12). 4. Place the other blue delrin supply reel adjustment collar on the sealing tape supply reel rod, so the two collars are on each side of the supply reel.

Figure 2-13: Adjustment Collar on Sealing Tape Supply Reel


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5. 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. > 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 2-14, left). Notice that the tape rests on the upper, larger projecting pin but never touches the lower, smaller projecting pin.

Figure 2-14: Sealing Tape Threaded to Sealing Tape Guide Assemblyfor PSA (Left), for Heat (Right)

> 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 2-14, right; Figure 2-15).

Figure 2-15: Sealing Tape Threaded to Sealing Tape Guide Assembly for Heat

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Loading the Sealing Tape

> Guide blocks come in widths from 8 mm to 72 mm (120 mm by special order). There are two grooves on the underside of the guide block. The outer, wider groove guides the carrier tape. The inner, narrower groove guides the sealing tape.

Figure 2-16: Two Widths of Guide Blocks

Figure 2-17: Placement in Grooves of Guide Blockof Sealing Tape (Left) and Carrier Tape (Right)

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 2-18). Then replace the rod in the bracket.

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Figure 2-18: 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. > While holding the thin edge down, tighten the adjustment screws on the guide block assembly (Figure 2-19). The carrier tape should now be inside the outer set of grooves on the guide block (Figure 2-20).

Guide block adjustment screws


Figure 2-19: Guide Block Assembly

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Adjusting Heat Seal Heads

Adjusting Lateral Position

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 (Figure 2-20). Toggling the RUN switch, 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.

Figure 2-20: Sealing Tape Threaded Under Guide Block

Adjusting Heat Seal Heads


The information in this section does not apply to Model 1005 tapers, as they do not have 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 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 readouts for each heater controller display. The top line is the present value

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(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 2-16 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 place 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 2-21: Heat Seal Head with Lateral Adjustment Screw

7. Once both heads are aligned, turn the heat to the sealing heads back on. Set the bottom line (the Set Value) on both heaters to 300 degrees Fahrenheit. Wait until the top line (the Present Value) reads 300. 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: Toggle the SEAL switch for 3 to 5 seconds to engage both seal heads. Then toggle the RUN switch to advance the carrier tape and inspect the seal.

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Adjusting Heat Seal Heads

Adjusting Downward Pressure

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 2-22: 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 2-23).

Figure 2-23: Three-Gram and One-Gram Weights (Left); One-Gram Weight on Heat Seal Counterbalance

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Setting Temperature for Heat Seal Heads


The information in this section applies to Model 1010 tapers equipped with heat seal heads.This section does not apply to Model 1005 tapers, as they do not have heat seal heads. The 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 handler. The heaters have been factory-preset to either Fahrenheit or Celsius, depending on your needs. You can confirm the setting by the display when the taper is first turned on and the heater display is powering up. For example, Figure 2-24 shows the left initial display set to Fahrenheit and the right initial display set to Celsius. (Such a dual setting is not recommended; it is just shown for illustration purposes only.)

Figure 2-24: Left Display Set to Fahrenheit; Right Display Set to Celsius

Present Value temperature

Set Value temperature


Figure 2-25: Heater Controller Display

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Setting Temperature for Heat Seal Heads

Adjusting Downward Pressure

In Figure 2-25, the back heat seal head has been set to 350 degrees Fahrenheit, and the current temperature is 347 degrees Fahrenheit. 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. 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 2-26). > The lower display blinks rapidly, indicating it is ready to be set.

Figure 2-26: SET Button

2. Press the Up arrow button (Figure 2-27) repeatedly until the 0 changes to 5 (Figure 2-28).

Figure 2-27: Up Arrow Button

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Figure 2-28: Digit in Ones Position Selected

3. Press the Left arrow button (Figure 2-29) to shift the digit that lights up to the tens digit.

Figure 2-29: Left Arrow Button

4. Press the Up arrow button repeatedly until the 0 changes to 7 (Figure 2-30).

Figure 2-30: Digit in Tens Position Selected

5. Press the Left arrow button to shift the digit that lights up to the hundreds digit.

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Setting Temperature for Heat Seal Heads

Adjusting Downward Pressure

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

Figure 2-31: 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 a steady display, and the temperature (PV) increases rapidly.

Figure 2-32: 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 2-33).

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Figure 2-33: 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 2-34).

Figure 2-34: 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.

Adjusting Pressure Seal Heads


Two adjustments may need to be done for a pair of pressure seal heads: the lateral position 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.

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Adjusting Pressure Seal Heads

Adjusting Downward Pressure

Lateral adjustment screws

Figure 2-35: 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.

Figure 2-36: 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.

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Chapter 3: Production Run


Chapter Overview
This chapter discusses the following main topics: Topic Preparing for a Production Run Testing the Seal Setting the Pocket Counter Doing a Production Run Page 3-1 3-3 3-3 3-5

Preparing for a Production Run


To prepare for a production run: 1. Verify that the RUN and SEAL toggle switches on the left side of the control box are in the OFF position.

Figure 3-1: RUN and SEAL Toggle Switches Off; Main Power Off

2. Verify that a supply of clean, dry, 50-PSI compressed air is connected to the air regulator on the back of the handler.

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3. Press to turn on the MAIN POWER button on the side panel. > For heat adhesive tape, this also turns on the heaters.

Figure 3-2: RUN and SEAL Toggle Switches Off; Main Power On

4. On the front of the control box, turn the TAPE SPEED dial to 1 for the initial setup.

Figure 3-3: TAPE SPEED Dial

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Testing the Seal

Testing the Seal


To test the seal: 1. If you have a taper using thermal adhesive tape, wait a few minutes while the thermal sealing heads heat up to the set temperature. (The initial recommended setting is 275-325 degrees Fahrenheit, or 135-165 degrees Celsius.) Watch the two temperature control displays on the front of the control box to verify temperatures. See "Setting Temperature for Heat Seal Heads" on page 2-16. > Heating the heads to the desired temperature should not take more than 2 or 3 minutes. If heating takes longer, the set temperature may be too high. 2. For both pressure-sensitive adhesive (PSA) and thermal handlers, toggle the SEAL switch to ON and toggle the RUN switch to ON (or depress the hand/foot pedal) to advance the carrier tape in the track. > The carrier tape and sealing tape are sealed and pulled through the sealing assembly until you release the pedal. 3. Run enough tape through the sealing assembly to seal several empty pockets. Inspect the location and quality of the seal. Adjust tape speed and temperature.

Setting the Pocket Counter


When the seal is satisfactory, set the pocket counter located on the front of the control box.

Figure 3-4: Pocket Counter

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The upper digits in orange display the present valuethe number of pockets that have been counted. You can reset the present value count to zero by pressing the RST (reset) button at the lower left. The lower digits in green display the set valuethe number of pockets you want to count. When you power up the handler, the set value is at the same value it was when last used. You can set the count for any quantity of sealed pockets up to 999,999 by pressing the small Up button below the corresponding digit. To set a digit to a lower number, press the button repeatedly till it cycles past 0. Button 1 2 3 4 5 6 Ones Tens Hundreds Thousands Ten thousands Hundred thousands Digit Example 1 10 100 1,000 10,000 100,000

> For example, suppose the set value is 100. To change the set value from 100 to 500, press the 3 button four times. > Now suppose you want to change the set value from 500 to 1000. Press the 4 button once so that a 1 is displayed to the left of the 5, thus: 1500. Then press the 3 button five times so that the 5 changes to a 0, thus: 1000. NOTE: If you change the set value so that at any time all digits are 0, the COUNT COMPLETE button lights up; the handler has completed the set value of 0. Press the COUNT COMPLETE button again and the light goes off.

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Doing a Production Run

Doing a Production Run


To do a production run: 1. Load devices to be sealed into the carrier tape. 2. To seal and advance the tape, either: > Press and hold the hand/foot pedal, or > Toggle the RUN switch to ON. 3. Stop tape advancement when you need to load more devices into tape pockets, then repeat this cycle as desired. > When the set pocket count is reached, the large red COUNT COMPLETE button on the front of the control box lights up, and the handler stops.

Figure 3-5: Count Complete Button Lit at End of Run

4. Press the COUNT COMPLETE button if you want to reset the pocket count value and resume operation.

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Chapter 4: 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 Checking the Moisture/Dirt Trap in the Air Regulator Solenoid Maintenance Recommended Frequency As needed As needed Monthly As needed Weekly As needed Page 4-1 4-3 4-3 4-4 4-4 4-7

Preventive maintenance on the Model 1010 is fairly simple. Following this schedule will help to assure your Model 1010 handler will continue to perform properly. 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.

Pressure-Sensitive Heads
If the PSA rollers on your taper are brass (Figure 4-1, 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 4-1, right), do not use alcohol or other cleaning fluids on them. Just replace them with new ones.

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Figure 4-1: 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 4-2: Heat Seal Head Blade

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Air Regulator Maintenance

Checking Air Regulator Shutoff Valve

Air Regulator Maintenance


Your taper uses compressed air to lower the seal heads. This requires an air regulator. A high quality air regulator with coalescing air filter and shutoff valve is supplied on your handler. CAUTION: NEVER operate any Exatron equipment which 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 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. Adjustment valve On/off switch in OFF position On/off switch in ON position

Figure 4-3: Air Regulator Turned Off (Left), On (Right)

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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.

Checking the Moisture/Dirt Trap in the Air Regulator


Check the moisture/dirt trap on the air regulator and the coalescing filter chamber. Verify that they are clean, empty and dry. There should be no oil and no water in either chamber. If they are dirty, physically disconnect the air regulator from the incoming air pressure supply, then clean or replace the trap and filter as needed. Excessive moisture and/or particulate buildup in the filter trap suggests the air supply to the system is too wet and/or dirty. CAUTION: Excessive moisture in the system can damage the air valves.

Figure 4-4: Air Regulator

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Air Regulator Maintenance

Checking the Moisture/Dirt Trap in the Air Regulator

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 4-5: Small Black Screw Removed

2. Unscrew the metal casing.

Figure 4-6: Metal Casing Unscrewed

3. Snap off the clear glass casing.

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Large black screw


Figure 4-7: Clear Glass Casing Snapped Off

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

Filter

Figure 4-8: 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 4-9: 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 5: Parts List


This chapter contains the following main sections: Topic Obtaining Replacement Parts Guide to the Parts List List of Parts Page 5-1 5-1 5-5

Obtaining Replacement Parts


Spare parts can be obtained from Exatron. It has always been Exatron policy to support all the equipment we have ever manufactured. If the part is still available, or can be made, we will get it for you. In most cases, faxed requests and shipment of replacement parts orders are processed within twenty-four hours of receipt by Exatron. The following sections discuss things to note when ordering replacement parts.

Vacuum Generator Air Filter


The vacuum generator air filter must be replaced when it is visibly dirty or contaminated. The Exatron part number is PNE022-020.

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 shown 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.

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Chapter 5: 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 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 helpful in determining the correct part number and is 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 that you can find in your manual. The print is identified by the part number.

Description
This is the name assigned to the part. In most cases, this description will easily define the part you wish to locate. Please include this description when ordering replacement parts.

Assembly
This column indicates which major system sub-assembly the part belongs to. In most cases, the "Assembly" can be ordered as a complete replacement part.

Size
These are dimensions in inches. The dimesions are listed left to right from smallest to largest: A x B x C. This is the starting size of the part prior to being machined.

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Guide to the Parts List

Finish

C B A
Figure 5-1: 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, 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 surface protects against abrasive wear and corrosion. The dry-lubricated, non-stick surface also reduces friction of moving or sliding parts. NICKEL: Bright nickel plating, silver-chrome in color. NONE: No finish, natural material. PAINT: Painted part, colors may be beige, black or blue. RED: Red anodizing.

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Models 1005 & 1010 Manual

Chapter 5: Parts List

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List of Parts
TAPE MODEL 1010 MANUAL MACHINE THERMAL & PSA 10-20-2008
IN HOUSE PART NUMBER MANUAL DESCRIPTION COMPRESSION SPRING ROUND #8-32 STAND OFF #8 X 1/2" SPACER 1/4" ROUND AL. TAPE MASTER PARTS LIST 5000-877-C 5000-M54-120-A1 5000-M54-240-A1 BEA01-100 BEA03-030 REGULATOR MOUNT INPUT POWER LABEL 100-120 VAC INPUT POWER LABEL 220-240 VAC TEFLON THRUST WASHER 30 GROVE TIMING BELT PULLEY 16 GROVE TIMING BELT PULLEY SPROCKET 1.000 DIA., .25 I.D. SPLIT HUB CLAMPS SS SPLIT HUB CLAMP 10-32 X 1/4" SHOULDER SCREW 10-32 X 1/2" SHOULDER SCREW MINI-E-PITCH CABLE CHAIN 55 GROVE TIMING BELT BALL BEARING BALL BEARING, .187 ID, .500 OD FLANGED BALL BEARING BALL BEARING, PRESS FIT FUSE HOLDER 2 AMP FUSE CARTRIDGE HEATERS, 100 WATT J TYPE THERMACOUPLE SNAP SWITCH 120VAC OPEN AT 170V THERMALCOUPLE CONNECTOR FEMALE J TYPE THERMALCOUPLE CONNECTOR MALE J TYPE CLAMP KNOB COVER TAPE GUIDE .25 ID, .50 OD, .25 L ADJUST SCREW PRESSURE ROLLER PRESSURE ROLLER CRANK TAKE UP MOTOR BALL BEARING BASE SEAL HEAD TAKE UP MOTOR POWER SUPPLY POWER SUPPLY HOT HEAD SEAL HEAD SEAL HEAD ELECTRONICS ELECTRONICS FENWAL BLACK BLACK .250 DIA., 1.18 LONG .25 ID, .50 OD .500 ID, 1.125 OD NONE .125 ID, .375 OD, .16 THK BRONZE NONE NONE 300 PITCH .157 .25 ID. .875 OD, 6-32 TAP POWER SUPPLY TAPE FRAME POWER SUPPLY POWER SUPPLY CRANK TAKE UP MOTOR TAKE UP MOTOR TAPE .375-1.500-3.000 SEE PRINT SEE PRINT .25 ID,.62 OD, .06 THK 1/5 PITCH 1/5 PITCH BERG NONE NONE ALLIED ALLIED NONE NONE BLACK ASSEMBLY PINCH ROLLER .250 DIA., 2.875 L OLANDER OLANDER SIZE FINISH

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List of Parts

BEA03-037 BEA07-002 BEA09-004 BEA09-014 BEA11-018 BEA11-021 BEA12-022 BEA12-155 BEA16-213 BEA16-218 BEA16-222 BEA18-050 FUS1-020 FUS2-002 HOT03-240-100-THIN HOT05-044-J HOT06-183 HOT-07-002-F HOT07-102-M

Finish

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HRD02-500

TAPE MODEL 1010 MANUAL MACHINE THERMAL & PSA 10-20-2008


IN HOUSE PART NUMBER HRD02-505 HRD03-020 HRD03-100 LAB03-007 LAB03-011 LAB03-014 LAB04-020 LAB04-028 MOT10-001 MOT10-003 MOT10-010 MOT10-011 MANUAL DESCRIPTION HAND CRANK KNOB GROMMET BLACK BUMP ON DANGER WATCH YOUR FINGERS DANGER ELECTRICAL HAZARD LABEL CAUTION DO NOT OPERATE WITHOUT GUARDS IN PLACE EXATRON NAME PLATE EARTH GROUND PLATE GEAR MOTOR 90 VDC PERMANENT MAGNET SPEED CONTROL 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 REGULATOR ASSEMBLY SQUARE O-RING AIR VALVE BIMBA CYLINDER, SPRING OUT +24 V DC POWER SUPPLY POWER CORD 3 PRONG 8 FT RELAY 24 VDC RELAY SOCKET TRACK MOUNT MOTOR BRAKE RESISTOR TEMPERATURE CONTROL J TYPE TC WITH ALARM DIGITAL COUNTER FIBER OPTIC AMPLIFIER POWER DIODE TOGGLE SWITCH RUN/SEAL 2 POS MICRO SWITCH SUB MINI SWITCH W/ROLLER ARM P&P MOTOR ELECTRONICS ELECTRONICS DANCER ARM NEWARK ELECTRONICS McMASTER CARR NEWARK DANCER ARM ELECTRONICS ELECTRONICS ELECTRONICS MAIN PLATE MAIN PLATE DRIVE MOTOR DRIVE MOTOR TAKE UP MOTOR TAKE UP MOTOR PEEL TEST TAKE UP MOTOR PIVOT CYLINDER PIVOT CYLINDER PIVOT CYLINDER FRAME PSA PIVOT CYLINDER PIVOT CYLINDER POWER SUPPLY POWER SUPPLY FORESIGHT GRAINGER SEE PART 1/2" X 3/32 24 VDC 100W " 110 VAC ONLY 220 VAC ONLY .250 SHAFT .500 SHAFT NONE NONE NONE NONE NONE SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT PAINT PAINT GRANIGER GRAINGER ASSEMBLY ADJUST SCREW McMASTER CARR NONE SIZE FINISH

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NRET04-53 NRET04-80 PNE002-001 PNE002-005 PNE004-001 PNE015-015-1 PNE015-041 PNE020-350 PNE031-0.5R POW02-050 POW10-025 REL08-001 REL08-002 RES50-00000050 SEM02-301 SEM02-310 SEM03-400 SEM04-200 SWT02-001 SWT13-015

Chapter 5: Parts List

PHX AUTOMATION GRAINGER

TAPE MODEL 1010 MANUAL MACHINE THERMAL & PSA 10-20-2008


IN HOUSE PART NUMBER SWT20-010 SWT20-011 SWT20-012 SWT20-020 TAPE-102-X TAPE-103-W TAPE-104-C1 TAPE-105-G TAPE-106-E1 TAPE-107-A2 TAPE-112-B1 TAPE-114-A2 TAPE-115-C TAPE-116-A TAPE-126-B1 TAPE-127-D TAPE-129-C TAPE-130-C TAPE-134-B TAPE-135-C 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-C TAPE-153-B TAPE-156-B TAPE-157-K1 TAPE-158-B1 MANUAL DESCRIPTION RESET SWITCH LIGHTED PUSH BUTTON SWITCH RED LENS LAMP FOOT SWITCH BACK PLATE FRONT PLATE CONTROL PANEL COVER TAKE UP REEL BRACKET END PLATE STABILIZER SUPPLY REEL HUB BRACKET SUPPLY REEL FINGER SUPPLY REEL HUB SUPPLY REEL GUIDE BRACKET PRESSURE ROLLER ARM PRESSURE ROLLER BLOCK DANCER ARM SWITCH ACTUATOR DANCER ARM PIVOT KNOB (LG) KNOB (SM) GUIDE ROD SMALL PRESSURE WEIGHT LARGE PRESSURE WEIGHT WEIGHT ROD KEEPER PIN END PLATE LOCATOR SUPPLY REEL ROD SPACER CLAMP NUT WITH PIN RAIL ADJ. BUSHING HEATER ARM STOP PINCH ROLLER TAKE UP & COVER TAPE SPACER BLUE BASE BASE CONTROL BOX TAKE UP REEL BASE BASE SUPPLY REEL SUPPLY REEL SUPPLY REEL SUPPLY REEL BASE PINCH ROLLER BASE BASE BASE BASE BASE SEAL HEAD SEAL HEAD SEAL HEAD PINCH ROLLER BASE SUPPLY REEL BASE ADJUST SCREW HEATER PINCH ROLLER BASE .500-3.500-30.000 .500-3.500-30.000 .500-9.250-15.000 .375-9.880-23.880 .500-2.500-10.750 .500-5.120-7.380 .250-4.000 DIA. 2.875-.750 DIA. 1.250-1.500 DIA. .500-.500-2.500 .480-.380-3.750 1.000-1.500-3.310 .235-.500-3.000 .250-.500-1.500 .250-.750 DIA. .750-.500 DIA. .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. 1.125-1.500 DIA. 1.250-.500 DIA. .246-.700 DIA. .437-1.000 DIA. ASSEMBLY POWER SUPPLY POWER SUPPLY POWER SUPPLY SIZE FINISH NEWARK NEWARK NEWARK GRAINGER PAINT PAINT NICKEL PAINT NICKEL PAINT NICKEL NICKEL NEDOX RED NEDOX NEDOX NEDOX NEDOX RED BLUE NONE NONE NONE NONE NONE NEDOX BLACK RED NONE NONE NICKEL

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List of Parts Finish

BLUE

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TAPE MODEL 1010 MANUAL MACHINE THERMAL & PSA 10-20-2008


IN HOUSE PART NUMBER TAPE-162-F TAPE-163-E TAPE-164-E1 TAPE-165-D TAPE-167-J TAPE-168-B TAPE-169-E TAPE-170-J TAPE-172-C1 TAPE-173-D1 TAPE-179-A TAPE-180-C TAPE-181-B TAPE-182-B TAPE-183-B TAPE-187-A TAPE-188-L-B TAPE-188-R-B TAPE-189-C TAPE-190-B TAPE-191-3-A TAPE-192-A TAPE-195-C1 TAPE-196-C1 TAPE-198-G TAPE-202-A TAPE-203-B TAPE-204-3-B1 TAPE-205-110-B3 TAPE-206-C TAPE-207-B 1 1 1 1 MANUAL DESCRIPTION BACK RIGHT RAIL FRONT RIGHT RAIL BACK LEFT RAIL FRONT LEFT RAIL 1010 CONTROL PANEL 1005 CONTROL PANEL PSA ONLY MOTOR COVER CONTROL PANEL BASE PLATE BLUE ESD MAT COVER TAPE DISK (LG) SUPPORT ROLLER BLOCK M16-2 RAIL ADJUSTMENT SCREW M16X2 RAIL ADJ NUT CRANK CRANK HANDLE 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 CABLE CLAMP ADJUST SCREW ASSEMBLY MODEL 1010 SWITCH PCB ASSEMBLY 1010 POWER SUPPLY WIRING 110 VAC POCKET COUNTER WIRING SEALING HEAD HEATER WIRING MOTOR WIRING 120 VAC ASSEMBLY BASE BASE BASE BASE CONTROL BOX CONTROL BOX BASE CONTROL BOX CONTROL BOX COVER TAPE BASE ADJUST SCREW ADJUST SCREW ADJUST SCREW ADJUST SCREW PIVOT CYLINDER PIVOT CYLINDER PIVOT CYLINDER PIVOT CYLINDER PIVOT CYLINDER ASSEMBLY SEAL HEAD SEAL HEAD SEAL HEAD SEAL HEAD BASE ASSEMBLY ASSEMBLY POWER SUPPLY ELECTRONICS ELECTRONICS ELECTRONICS SIZE .062-.750-19.255 .062-.750-19.235 .062-.750-9.605 .062-.750-9.585 SEE PRINT SEE PRINT SEE PRINT .250-9.250-14.480 SEE PRINT .375-7.500 DIA. .500-.531-1.500 .629 DIA. 6.75L 1.250-1.366-1.500 .750-1.000-2.250 .500 DIA., 1.00 LONG .650-.750 DIA. .750-1.750-2.165 .750-1.750-2.165 .750-1.224-1.359 SEE PRINT SEE PRINT SEE PRINT .250-2.000 DIA. .250-2.000 DIA. .875-2.000 DIA. .500-.938-3.115 SEE PRINT NONE NONE NONE BLACK ANODIZE FINISH NEDOX NEDOX NEDOX NEDOX PAINT PAINT PAINT BLACK NONE NICKEL BLACK NONE BLUE BLUE BLUE NONE CLEAR CLEAR CLEAR

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Models 1005 & 1010 Manual Chapter 5: Parts List

SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT

FAB

TAPE-208-120-D

TAPE MODEL 1010 MANUAL MACHINE THERMAL & PSA 10-20-2008


IN HOUSE PART NUMBER TAPE-209-B TAPE-210-D TAPE-211-E TAPE-218-C TAPE-219-B TAPE-220-D TAPE-221-A TAPE-253-A TAPE-254-A TAPE-284-F TAPE-334-F TAPE-335-A TAPE-336-A TAPE-338-E TAPE-339-A TAPE-394-A1 TAPE-395-A TAPE-403-F1 TAPE-404-G TAPE-405-A TAPE-406-C TAPE-407-A TAPE-419-D TAPE-422-B1 TAPE-423-B TAPE-424-A TAPE-426-1-D TAPE-447-D TAPE-451-A TAPE-452-A TAPE-453-A1 TAPE-649-C 1 1 1 1 1 1 1 MANUAL DESCRIPTION CONTROL BOX LAY OUT DRIVE ROLLER ASSEMBLY PRESSURE ROLLER ASSEMBLY TAKE UP REEL SHAFT TAKE UP MOTOR STAND OFF TAKE UP MOTOR MOUNT PLATE TAKE UP MOTOR ASSEMBLY CARRIER TAPE PATH DETAIL TAPE AIR CURCUIT EMPTY POCKET FIBER MOUNT BLOCK .024" SEAL BLADE HOT HEAD BLOCK RIGHT HOT HEAD BLOCK LEFT TAPE DRIVE WHEEL WHEEL FELT PAD 1050 SUPPLY REEL BRACKET SUPPLY REEL OFFSET BLOCK COVER TAPE STOP BLOCK COVER TAPE ADJUST BAR DRIVE WHEEL ADJUST POST DRIVE WHEEL ADJUST HUB ADJUSTABLE DRIVE WHEEL ASSEMBLY COVER TAPE GUIDE BLOCK TOOLING SEAL HEAD ARM SEAL ARM PIVOT POST SEAL HEAD ADJUST 1010/1080 BACK GUIDE RAIL PSA ROLLER BLOCK HEATER PLUG MOUNT BLOCK LEFT HEATER PLUG MOUNT BLOCK RIGHT HEATER MOUNT COVER COVER TAPE GUIDE ASSEMBLY PSA ROLLER SEAL HEADS SEAL HEADS SEAL HEADS ASSEMBLY ASSEMBLY ELECTRONICS DRIVE ROLLER ASSEMBLY TAKE UP MOTOR TAKE UP MOTOR TAKE UP MOTOR ASSEMBLY ASSEMBLY AIR EMPTY POCKET SEAL HEAD SEAL HEAD SEAL HEAD DRIVE WHEEL COVER TAPE SUPPLY REEL SUPPLY REEL SEE PRINT .250-2.250-2.600 .024-.539-1.500 .718-.875-1.500 .718-.875-1.500 .185-2.248 DIA. .06-1.00 DIA. .375-2.000-20.269 .625-1.000-2.000 NEDOX NEDOX NEDOX NEDOX NEDOX NONE PAINT BLACK NICKEL NONE NEDOX BLUE SIZE SEE PRINT SEE PRINT SEE PRINT .500 DIA., 9.000 L .374-2.750-2.875 .375-2.750-5.968 SEE PRINT NONE BLACK BLACK FINISH

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List of Parts

COVER TAPE GUIDE .500-.899-1.298 COVER TAPE GUIDE .187 DIA, 4.00 L DRIVE WHEEL DRIVE WHEEL DRIVE WHEEL .750 DIA. 1.500 L 1.000-1.000-1.500 SEE PRINT

COVER TAPE GUIDE SEE PRINT SEAL HEAD SEAL HEAD SEAL HEAD .500-1.880-3.068 1.412 L, .750 DIA. .500-.848-1.500 .093-.750-15.000 .500-.500-2.500 .625-1.250-1.620 .625-1.250-1.620 .625-1.250-1.308 SEE PRINT

HCR NEDOX NONE NONE NEDOX NICKEL NEDOX NEDOX NICKEL

Finish

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TAPE MODEL 1010 MANUAL MACHINE THERMAL & PSA 10-20-2008


IN HOUSE PART NUMBER TAPE-670-F1 TAPE-671-F TAPE-748-A TAPE-749-A TAPE-750-B1 TAPE-751-C TAPE-782-A TAPE-833-A WIR01-325 1 MANUAL DESCRIPTION SEAL ROLLER RIM SEAL ROLLER RIM PIN FRONT FINE GAP & OUT SENSOR MOUNT BACK FINE GAP & OUT SENSOR MOUNT ADJUSTABLE DRIVE WHEEL ASSEMBLY STEPPER DRIVE WHEEL ATTACH BLOCK BLANK 1010 SIDE PANEL - NO CAMERA 1010 PSA ONLY COVER PLATE SPRIAL WRAP PSA ONLY SEAL HEAD ASSEMBLY PSA ROLLER PSA ROLLER RAIL RAIL DRIVE WHEEL DRIVE WHEEL 1.000-1.000-1.000 .062-2.250-5.500 .062-2.480-4.646 BLUE BLUE PAINT CARR SIZE .140-.625 DIA. .312 DIA. .625 L .249-.750-.810 .249-.750-.810 FINISH NONE NONE BLACK BLACK

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Models 1005 & 1010 Manual Chapter 5: Parts List

Chapter 6: Prints
A set of wiring prints is included in the manual that is shipped with each custom Exatron handler or taper.

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Chapter 6: Prints

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