Professional Documents
Culture Documents
Exatron, Inc.
2842 Aiello Drive San Jose, California 95111 (408) 629-7600 Tel (800) exa-tron Tel (408) 629-2832 Fax www.exatron.com
Copyright Notice
Copyright 2011 Exatron This document contains proprietary information which is protected by copyright. All rights are reserved. EXATRON MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. The information contained in this document is subject to change without notice.
Table of Contents
List of Figures Chapter 1: Safety, Support and Options
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Exatron Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Lock-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Facilities Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Air Conditioning and Environmental Requirements . . . . . . . . . . . . . . . . . 1-4 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Vacuum/Pneumatic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Uncrating the Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Mounting the Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Customer In-House Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Offshore Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Exatron Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Warranty and Support Contracts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Service Contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Preventive Maintenance Contract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Customer Service Support Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 End-of-Life Handler Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Significance of This Manuals Version Number. . . . . . . . . . . . . . . . . . . . . . 1-21 Typographical Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . 1-22 Terms Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Photo Gallery of Optional Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Optional Accessories and Peripherals Available with Handler . . . . . . . . 1-41
Contents-1
Contents-2
02/2011
02/2011
Contents-3
Chapter 5: Diagnostics
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Keeping Your Original Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Diagnostics Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Using Override Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Input / Output Check Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Input Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Output Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Buttons on All I/O Port Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Ports on Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Selecting a Port to Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Motor Home Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Thermal Head Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Tube Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Taper Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Taper Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Loading an Inspection File to the Camera . . . . . . . . . . . . . . . . . . . . 5-19 Taper Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Taper Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Check Tube Latches Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Setup Parameters Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Test Site Delay Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Rotation / Taper Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Results of Rotation Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Test Interface Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Work Mode Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Tray Delay Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Tape Delay Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Tape and Reel Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Precisor Delay Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Enable Trays Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 Tray Information Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Enable Test Sites Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
-- continued on next page --
Contents-4
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02/2011
Contents-5
Contents-6
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02/2011
Contents-7
Contents-8
02/2011
Index
02/2011
Contents-9
Contents-10
02/2011
List of Figures
Figure 1-1: EMO (Emergency Stop) Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Figure 1-2: Air RegulatorIn ON Position (Left), in OFF Position (Center), in OFF Position with Lock (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Figure 1-3: Lockable Disconnect SwitchIn ON Position (Left), in OFF Position with Lock (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Figure 1-4: Context Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Figure 1-5: Drop-Down Arrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Figure 1-6: Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-7: Input Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-8: Cabinet Model with Detaper, Six Test Sites, Model 201 Taper, and Two Trays. . . Figure 1-9: Cabinet Model with Dual Preheating Trays, Dual Thermal Test Sites, and Two Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-10: Cabinet Model with Detaper, Test Site, Model 201 Taper, and One Tray. . . . . . . Figure 1-11: Cabinet Model with Chiller, Hot and Cold Test Sites, Enclosed Trays, and Laser Figure 1-12: Cabinet Model with Preheating Tray, MEMS Light Source Tester, Enclosed Trays, and Laser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-13: Cabinet Model with Lead Straighteners and Inspection. . . . . . . . . . . . . . . . . . . . . Figure 1-14: Cabinet Model Assembler with Bowl Feeder and Tube Inputs, Inspection, and Taper Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-15: Cabinet Model with Bowl Feeder Input, Preheating Tray, MEMS Magnetic Ambient and Thermal Testing, and Taper Output with In-Tape Inspection . . . . . . . . . . . . . Figure 1-16: Cabinet Model with Four Trays and MEMS Audio Test Box (Left); 16 Test Sockets in Audio Test Box (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-17: Cabinet Model with Bowl Feeder Input, Machine Vision Inspection, MEMS Vibration Testing, and Taper Output (Top); Isolation Plate with 12 Sockets for MEMS Vibration Testing (Bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-18: Benchtop Model with Detaper and Two Trays/Waffle Packs . . . . . . . . . . . . . . . . Figure 1-19: Cabinet Model with Laser and Enclosed Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-20: Hot and Cold Test with Chiller and Air Dryer, Four Trays . . . . . . . . . . . . . . . . . . Figure 1-21: Benchtop Model with Rotary Tester and Trays/Waffle Packs . . . . . . . . . . . . . . . . Figure 1-22: Custom Model with Tube Input and Output, One Test Site . . . . . . . . . . . . . . . . . . Figure 1-23: Cabinet Model with Burn-In Board, Dual Test Sites, and Two Trays . . . . . . . . . . Figure 1-24: Custom Model with Two Input Sources, Two Inspection Cameras, Welder . . . . . Figure 1-25: Port Feeder Track and Tray as Input for Welder . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-26: Fixed and Moving Preheating Trays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-27: Refrigerated/Heating Circulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-28: Air Dryer (Left); Air Filter (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-29: Temperature Controllers for Hot and Cold Testers . . . . . . . . . . . . . . . . . . . . . . . . 1-24 1-24 1-25 1-26 1-26 1-27 1-28 1-29 1-30 1-31
1-32
1-33 1-34 1-35 1-36 1-37 1-38 1-39 1-40 1-41 1-41 1-42 1-42 1-43
02/2011
Figures-1
Figure 1-30: Hot and Cold Test Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43 Figure 2-1: Tray Carriage Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-2: One Type of Rotational Pickup HeadRotation On (Left); Rotation Off (Right) . . Figure 2-3: Another Type of Rotational Pickup HeadRotation On (Left); Rotation Off (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-4: Multiple Nozzles on One Pickup Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-5: Lead Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2-4 2-5 2-5 2-6
Figure 2-6: Two Styles of Tray Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Figure 2-7: Cable Chain to Pickup Head (Left); Z-Chain and Lead Screw Driving Pickup Head (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Figure 2-8: Lead Nutsfor Pickup Head (Left), for Thermal Heads (Right). . . . . . . . . . . . . . . . 2-8 Figure 2-9: Smart BucketsTop View (Left); Front View (Right) . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-10: Anti-Vibration FootTop (Left), Bottom (Right) . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Figure 2-11: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-12: Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-13: 24-Volt DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-14: CPU Power Supply Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-15: ATX Power Supply Switched to 115 Volts (Left) and 230 Volts (Right) Input . . Figure 2-16: Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-17: Location of Jumpers and Connectors for PCM-8152 Motherboard . . . . . . . . . . . . Figure 2-18: PET-C06 I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-19: 5000-M42 Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-20: 8000-D14 I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-21: Serial Adapter (Left); Ethernet Switch (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-22: Y Motor Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-23: Light Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-24: Main Air Regulator Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-25: Automatic Air Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-26: Air Pressure Switch with Digital Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-27: Auxiliary Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-28: Vacuum Generators for Dual Pickup Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-29: Vacuum and Blow-Off Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-30: Dirty Filter (Left) Versus Clean Filter (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-31: Air Valves on Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-32: Pusher and Slider Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-33: Slide Cylinder Retracted, Push Cylinder Down (Left); Slide Cylinder Extended, Push Cylinder Up (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-34: Clamp Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-35: Preheating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10 2-11 2-12 2-12 2-13 2-13 2-14 2-15 2-16 2-16 2-17 2-17 2-18 2-19 2-20 2-20 2-21 2-21 2-22 2-23 2-23 2-24 2-24 2-25 2-26
Figures-2
02/2011
List of Figures
Figure 2-36: Hot and Cold Thermal Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-37: Undersides of Thermal Heads with Purge Enclosures (Hot Head on Left, Cold Head on Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-38: Hot Head Descending to Test Site (Left); Hot Head at Test Site (Right) . . . . . . . Figure 2-39: Cold Head Descending to Test Site (Left); Cold Head at Test Site (Right). . . . . . Figure 2-40: Dual Thermal Head Assembly with Test Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-41: Thermal Head Air Pressure Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-42: Four Trays with 7 x 17 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-43: Multiple Types of Waffle Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-44: Three Waffle Packs on Each Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-45: X Motor Diagram for 4-Tray Handler with 12 Waffle Packs. . . . . . . . . . . . . . . . . Figure 2-46: Y Motor Diagram for 4-Tray Handler with 12 Waffle Packs. . . . . . . . . . . . . . . . . Figure 2-47: Z Motor Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-48: Suction Cup at Z-Get (Pick Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-49: Suction Cup at Z-Put (Put Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-50: Reels on Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-51: Tape Track with Sensors and Pickup Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-52: Pressure Roller Block, Seal Head, and Image Sensor . . . . . . . . . . . . . . . . . . . . . . Figure 2-53: Pressure Roller Block (Left); Pinch Roller on Pressure Roller Block (Right) . . . . Figure 2-54: Taper Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-55: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-26 2-27 2-27 2-28 2-28 2-29 2-30 2-31 2-33 2-34 2-35 2-36 2-36 2-37 2-38 2-39 2-39 2-40 2-41 2-42
Figure 2-56: Gold Alodine Finish on Interior Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Figure 2-57: Ferrite EMI Noise Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Figure 3-1: Wheel Unlocked (Left), Locked (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Figure 3-2: Anti-Vibration Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Figure 3-3: Screws To Be Loosened When Changing Pickup Head. . . . . . . . . . . . . . . . . . . . . . . 3-4 Figure 3-4: Pickup Heads for Two Sizes of Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-5: Pickup Head Firm Against Tray Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-6: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-7: Powering Up a Benchtop System (Left); Powering Up a Cabinet System (Right) . . Figure 3-8: Shutting Down Windows from the Start Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3-5 3-6 3-7 3-8
Figure 3-9: Selecting the Turn Off Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Figure 3-10: Two Styles of Tray Clamps (Left, Center); Spring Clip (Right) . . . . . . . . . . . . . . 3-10 Figure 3-11: Dowel on Holder Fits Dowel Hole on Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Figure 3-12: Tube Held Out Away from Dowel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Figure 3-13: Tube Snapped Into Place on Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Figure 3-14: Tube Dead Nest Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Figure 3-15: Tube Dead Nest Area Resized from 16 to 28-Pin Device . . . . . . . . . . . . . . . . . . . 3-12
02/2011
Figures-3
Figure 3-16: Dead Nest Adjustment Leg in Partially Raised Position . . . . . . . . . . . . . . . . . . . . 3-13 Figure 3-17: Dead Nest Adjustment Leg in Lowered Position . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Figure 3-18: Tape Threading Diagram on Side of Detaper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Figure 3-19: Detaper Supply Reel Tensioner Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-20: Carrier Tape from Supply Reel Threaded Under Both Rollers . . . . . . . . . . . . . . . Figure 3-21: Tape Window LatchClosed (Left), Opened (Right) . . . . . . . . . . . . . . . . . . . . . . Figure 3-22: Tape Window Raised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-23: Winding Cover Tape Onto Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-24: Cover Tape Wound Onto Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-25: Tape Sprockets Fitting Over Gear Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-26: Tape Sprockets Fitting Over Gear Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-27: Detaper Locking Screws on Side Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-28: Detaper Adjustment Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-29: Detaper Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-30: Counting Number of Sprocket Holes Between Pocket CentersBetween Single Pockets (Left), Between Four Pockets (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-31: Model 202 Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-32: Lifting Pressure Roller Arm and Pushing In Keeper Pin . . . . . . . . . . . . . . . . . . . . Figure 3-33: Gap Sensor (Left); Gap Sensor LED Lit (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-34: Locking Hub on Takeup Reel with Alignment Pins. . . . . . . . . . . . . . . . . . . . . . . . Figure 3-35: Center Prongs of Supply Reel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-36: Screws on Side of Tape Track to Be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-37: Tape Track with Part Number and Sample Tape . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-38: Cover Tape Guide Block Assembly Pushed Left . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-39: Guide Block Partly Removed from Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-40: Carrier Tape Under Guide At Bottom Rear of Track . . . . . . . . . . . . . . . . . . . . . . . Figure 3-41: Carrier Tape Under Guide At Top Front of TrackSide View (Left); Top View (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-42: Lifting Pressure Roller Arm and Pushing In Keeper Pin . . . . . . . . . . . . . . . . . . . . Figure 3-43: Tape Under Takeup Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-44: Sealing Tape PlatesOutside (Left), Inside (Right) . . . . . . . . . . . . . . . . . . . . . . . Figure 3-45: Adjustment Collar on Sealing Tape Supply Reel . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-46: Sealing Tape Threaded to Sealing Tape Guide Assembly . . . . . . . . . . . . . . . . . . . Figure 3-47: Model 202 Sealing Tape Threaded to Sealing Tape Guide Assembly (Left); Sealing Tape Threaded Under Guide Block (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-48: Two Widths of Guide BlocksTop View (Left); Bottom View (Right). . . . . . . . 3-15 3-15 3-16 3-16 3-17 3-17 3-18 3-18 3-19 3-20 3-21 3-21 3-23 3-25 3-26 3-27 3-27 3-28 3-29 3-29 3-30 3-31 3-31 3-32 3-32 3-33 3-33 3-34 3-34 3-35
Figure 3-49: Placement in Grooves of Guide Blockof Sealing Tape (Left) and Carrier Tape (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Figure 3-50: Guide Block Partly Removed from Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Figure 3-51: Guide Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Figures-4
02/2011
List of Figures
Figure 3-52: Taper Alignment Knob Above Base Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Figure 3-53: Two Sizes of Heat Seal Blades: 16mm, Top, and 12mm, Bottom . . . . . . . . . . . . . 3-39 Figure 3-54: Top Side of Blades As They Slide into Seal Head (Left); Bottom Side of Blades That Contact Tape (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-55: Replacing Heat Seal Head Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-56: Seal Head with Empty Rails for Blade Insertion (Back View) . . . . . . . . . . . . . . . Figure 3-57: Pressure Seal Blade Inserted Partway into RailTop View (Left), Side View (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-58: Six Lateral Adjustment Screws for Seal Head; Thumbscrew for Small Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-59: Example of Good Tape Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-60: Auxiliary Air Regulator for Seal Head Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-61: Outward-Facing Knob Adjusts Upward Speed; Right Knob Adjusts Downward Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-62: Heater Controller Displaysin Celsius (Left), in Fahrenheit (Right) . . . . . . . . . . Figure 3-63: Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-64: Entering Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-65: Opening a Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-66: Tray Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-67: Example of Row and Column Layout for Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-68: Example of Row and Column Layout for Waffle Pack . . . . . . . . . . . . . . . . . . . . .
3-39 3-40 3-40 3-41 3-42 3-43 3-43 3-44 3-45 3-46 3-50 3-50 3-52 3-53 3-53
Figure 3-69: Changing Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 Figure 4-1: EMO (Emergency Stop) Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Figure 4-2: Auto Run Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Figure 4-3: Opening a Job File for Auto Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Figure 4-4: Starting Input and Output Pockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Figure 4-5: Drop-Off to Inspection Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Figure 4-6: Auto Run Window During Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Figure 4-7: Initializing Taper Before Auto Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Figure 4-8: Auto Run WindowHandler Using Multiple Test Sites . . . . . . . . . . . . . . . . . . . . . 4-11 Figure 5-1: Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Figure 5-2: Entering Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-3: Opening a Job File for Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-4: Buttons on Each Diagnostic Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-5: Examples of Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-6: Push Cylinder Up (Left); Push Cylinder Down (Right) . . . . . . . . . . . . . . . . . . . . . . . Figure 5-7: Slide Cylinder Retracted (Left); Slide Cylinder Extended (Right). . . . . . . . . . . . . . . Figure 5-8: Input / Output Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-9: Buttons Turning All Motors On or Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-10: Corresponding Ports on Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5-3 5-4 5-5 5-6 5-6 5-7 5-8 5-9
02/2011
Figures-5
Figure 5-11: Port Selection Drop-Down ListBoards 1, 2, and 3 . . . . . . . . . . . . . . . . . . . . . . . 5-10 Figure 5-12: Input / Output Check WindowPort for Pickup Nozzle Vacuums. . . . . . . . . . . . Figure 5-13: Input / Output Check WindowPort for Safety Features . . . . . . . . . . . . . . . . . . . Figure 5-14: Input / Output Check WindowPort for Motors Homing and Thermal Heads . . Figure 5-15: Input / Output Check WindowPorts for Signal Lights, Run and Halt Buttons. . Figure 5-16: Input / Output Check WindowPort for Handler with Four Pusher/Sliders. . . . . Figure 5-17: Y Motor Home SensorSignal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-18: Y Motor Home SensorSignal High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-19: X Motor Home Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-20: Z Motor Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-21: Thermal Head Car Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-22: Thermal Cylinder Sensors on Sensor Check Window . . . . . . . . . . . . . . . . . . . . . . Figure 5-23: Thermal Head Up Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-24: Input / Output Check WindowPort for Handler with Tubes. . . . . . . . . . . . . . . . Figure 5-25: Input / Output Check WindowPort for Handler with Taper . . . . . . . . . . . . . . . . Figure 5-26: Example of Inspection Files with Their Slot Numbers. . . . . . . . . . . . . . . . . . . . . . Figure 5-27: Bit Settings for Inspection Files with Binary Numbers 000, 001, and 010 . . . . . . Figure 5-28: Bit Settings for Inspection Files with Binary Numbers 011 and 100 . . . . . . . . . . . Figure 5-29: Taper Control Panel with Sensor Lights and Override Buttons . . . . . . . . . . . . . . . Figure 5-30: Tape Track with Empty/Out-of-Pocket Sensor and Pickup Head . . . . . . . . . . . . . Figure 5-31: Taper Model 202 with Slack Switch and Heat Sensors . . . . . . . . . . . . . . . . . . . . . Figure 5-32: Slack Switch Sensor Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-33: Seal Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-34: Check Tube Latches Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-35: Setup Parameters WindowOne Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-36: Setup Parameters WindowAnother Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-37: Test Site Delay Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-38: Using Normal Top Push Cylinder (Left); Using Z Plunger/Pickup Head (Right) . Figure 5-39: Rotation / Taper Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-40: Test Interface Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-41: Examples of Various Work Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-42: Tray Delay Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-43: Tape Delay Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-44: Tape and Reel Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-45: Precisor Delay Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-46: Enable Trays Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5-11 5-12 5-12 5-13 5-13 5-14 5-14 5-15 5-15 5-16 5-16 5-17 5-18 5-19 5-20 5-20 5-21 5-22 5-23 5-24 5-24 5-25 5-27 5-28 5-29 5-31 5-32 5-34 5-35 5-35 5-36 5-36 5-37 5-38
Figure 5-47: Tray Information Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Figure 5-48: Enable Test Sites Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Figures-6
02/2011
List of Figures
Figure 5-49: Enable Tubes Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Figure 5-50: Simulated Fixed Test Results Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 Figure 5-51: Rub Routine Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 Figure 5-52: Thermal Soak Time Delay Group Box of Setup Parameters Window . . . . . . . . . . Figure 5-53: Sort Interface Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-54: Sorts for Output Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-55: Handler Port Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-56: Motors Setup Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 5-43 5-44 5-45 5-48
Figure 5-57: Fine Tune Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51 Figure 5-58: Examples of Drop-Down List of Selectionswith Four Trays (Left); with Waffle Packs (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53 Figure 5-59: Examples of Drop-Down List of Selectionswith Tube Outputs (Left); with Bowl Feeder, Inspection, and Taper (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53 Figure 5-60: X Distance Calibration Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54 Figure 5-61: Y Distance Calibration Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55 Figure 5-62: Z-Get Distance Calibration Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-63: Z-Put Distance Calibration Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-64: Pitch and Teach Group BoxUsing Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-65: Tray Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-66: Pitch and Teach Group BoxUsing Waffle Packs on Both Trays . . . . . . . . . . . . Figure 5-67: Tray Drawing for Two-Inch Waffle Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-68: Tray Drawing for Four-Inch Waffle Packs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-69: Test Sockets Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-70: Test Sockets Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-71: Rotation Group Box; 360-Degree Rotation Head. . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-72: Z Compress Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-73: ExamplePositive Socket Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-74: ExampleNegative Socket Offset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-75: Fine Tune Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-76: Selections for 4 Trays and 2 Test Sites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-77: Selections for 4 Trays with Waffle Packs and 2 Test Sites . . . . . . . . . . . . . . . . . . Figure 5-78: Selections for Preheating Tray and Multiple Test Sites with Thermal Heads . . . . Figure 5-79: Where to Start Setting Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-80: Test Site Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-81: Y Distance Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-82: Example Z Distances to Test Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-83: Example Z Distances to X Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-84: Suction Cup at Z-Get (Pick Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-85: Suction Cup at Z-Put (Put Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56 5-56 5-57 5-59 5-59 5-60 5-61 5-63 5-63 5-64 5-65 5-65 5-66 5-67 5-70 5-70 5-71 5-73 5-73 5-74 5-75 5-75 5-76 5-76
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Figures-7
Figure 5-86: Z-Put Distance Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77 Figure 5-87: Z-Get Distance Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-88: Tray Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-89: Waffle Pack Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-90: Tray X1, First Pocket Selected (Left); Tray X4, Last Pocket Selected (Right) . . . Figure 5-91: Order of Calibrating Distances for Multiple Trays. . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-92: Order of Calibrating Distances for Multiple Trays with Multiple Waffle Packs . . Figure 5-93: Y Distance Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-94: X Distance Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-95: Four Trays with 7 x 17 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-96: Y Motor Diagram for 4-Tray Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-97: Y Distances to Tray X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-98: X Motor Diagram for 4-Tray Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-99: X Distances for Tray X1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-100: Waffle Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-101: Y Motor Diagram for 4-Tray Handler with 12 Waffle Packs. . . . . . . . . . . . . . . . 5-78 5-79 5-79 5-80 5-81 5-82 5-82 5-83 5-85 5-86 5-87 5-88 5-89 5-90 5-91
Figure 5-102: Y Distances to Tray X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93 Figure 5-103: X Motor Diagram for 4-Tray Handler with 12 Waffle Packs. . . . . . . . . . . . . . . . 5-94 Figure 5-104: X Distances for Tray X4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96 Figure 5-105: Moving Preheating Tray (Left); Thermal Test Site (Right) . . . . . . . . . . . . . . . . . 5-97 Figure 5-106: Y Motor Diagram for 3-Tray Handler with Preheating Tray and Dual Test Sites 5-98 Figure 5-107: X Motor Diagram for 3-Tray Handler with Moving Preheating Tray . . . . . . . . . 5-99 Figure 5-108: Thermal Setup Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100 Figure 5-109: Socket Pressure Group Box (Left); Head Air Pressure (Right) . . . . . . . . . . . . . 5-102 Figure 5-110: Taper Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103 Figure 5-111: Taper Fine Tune Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104 Figure 5-112: Seal Head Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-113: Tape Reel Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-114: Gap Sensor Offset from Pickup Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-115: Leader Pockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-116: Output Tape Slack (Left); Output Tape Taut, Raising Takeup Arm (Right) . . . 5-106 5-107 5-108 5-109 5-110
Figure 5-117: Counting Number of Sprocket Holes Between Pocket Centers . . . . . . . . . . . . . 5-110 Figure 5-118: Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111 Figure 6-1: Terminal Block and Input Connector on Network Card . . . . . . . . . . . . . . . . . . . . . . 6-6 Figure 6-2: Slave Boards Powered Through Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Figure 6-3: Slave Boards Powered Through RS-232 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Figure 6-4: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Network Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Figures-8
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List of Figures
Figure 6-5: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Figure 6-6: Master Network Card with Interface Card on Top . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Figure 6-7: Slave Network Card Powered Through Terminal Block . . . . . . . . . . . . . . . . . . . . . 6-11 Figure 6-8: Slave Network Card Powered Through RS-232 Cable . . . . . . . . . . . . . . . . . . . . . . 6-12 Figure 6-9: New Motor Assembly to Be Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-10: Screwing Motor Drive Board in Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-11: Adding Grommet and Long Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-12: Sliding Network Card into Cover; Adding Long Spacers . . . . . . . . . . . . . . . . . . . Figure 6-13: Sliding Both Covers Together; Adding Rainbow Cable . . . . . . . . . . . . . . . . . . . . Figure 6-14: Initialize Motors Menu Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-15: Initialize Motors Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-16: Serial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-17: Serial Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-18: SMC Air Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-19: Small Black Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-20: Metal Casing Unscrewed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-21: Clear Glass Casing Snapped Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-22: Large Black Inner Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-23: SMC Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-24: Automatic Air Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-25: Auxiliary Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-26: Air Valves with Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-27: OUT Lights Off and Fractional ReadingNo Air Pressure . . . . . . . . . . . . . . . . . Figure 6-28: OUT1 Light GreenNormal Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-29: Control Buttons on Top of Digital Air Pressure Switch. . . . . . . . . . . . . . . . . . . . . Figure 6-30: Display Locked (Left); Unlocked (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-31: Display Locked (Left); Unlocked (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-32: F_1 Alternating with Set Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-33: F_2 Alternating with Set Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-34: P_1 Alternating with Set Value of 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-35: P_2 Alternating with Set Value of 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-36: G.L. Showing Fastest Gain of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-37: S.L. Showing Best Sensitivity of 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-38: Displays of Air Pressure in PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-39: Unit Set to PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-40: Output Mode 1 Normally Open (Left); Output Mode 2 Normally Open (Right). . Figure 6-41: Response Time 2.5 MS (Left); Manual Mode (Right) . . . . . . . . . . . . . . . . . . . . . . Figure 6-42: K15 Vacuum Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 6-14 6-14 6-15 6-15 6-16 6-17 6-18 6-18 6-20 6-20 6-21 6-21 6-22 6-23 6-24 6-25 6-25 6-26 6-27 6-28 6-29 6-30 6-31 6-32 6-33 6-33 6-34 6-34 6-35 6-36 6-36 6-37 6-39
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Figures-9
Figure 6-43: Vacuum AssembliesK15 (Top); K35 Switch for Vacuum Pump (Bottom) . . . . 6-40 Figure 6-44: Extra Holes in K15 Interface Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Figure 6-45: K35 Vacuum SwitchUsed with Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Figure 6-46: Blow-Off Adjustment Screw Locationon Vacuum Generator (Left); on Vacuum Switch (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Figure 6-47: Dirty Filter (Left) Versus Clean Filter (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Figure 6-48: Blow-Off Adjustment Screw at PS Port When Using In-House Air . . . . . . . . . . . 6-44 Figure 6-49: Blow-Off Adjustment Screw at PD Port When Using Vacuum Pump. . . . . . . . . . Figure 6-50: Various Styles of Vacuum Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-51: Vacuum Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-52: Vacuum Assembly with Four Screws Highlighted. . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-53: Vacuum Assembly with One Solenoid Valve Removed . . . . . . . . . . . . . . . . . . . . Figure 6-54: Vacuum Assembly with Both Solenoid Valves Removed . . . . . . . . . . . . . . . . . . . Figure 6-55: Removing Gasket from Vacuum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-56: Vacuum Assembly with Gasket Still Attached. . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-57: Vacuum Assembly with Both Solenoid Valves and Gasket Removed . . . . . . . . . Figure 6-58: Vacuum Generator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-59: Vacuum Generator Optimal Pressurefor Nozzle with Larger Hole . . . . . . . . . . Figure 6-60: Vacuum Generator Optimal Pressurefor Nozzle with Smaller Hole . . . . . . . . . Figure 6-61: Vacuum and Blow-Off Override Buttons on Vacuum Generator . . . . . . . . . . . . . Figure 6-62: P1 Baseline Value Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-63: P1 Set at Least 8-10 Points Higher Than Baseline . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-64: P2 Set to 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-65: Error Code Set to Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-66: Green Indicator Light with High Number Showing Device Attached . . . . . . . . . . Figure 6-67: Computer Sliding Out of Cabinet on Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-68: Four Computer Base Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-69: Sliding Computer Out of Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-70: Front Bolts Securing Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-71: Top Bolts Securing Lid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-72: Benchtop Handler Elevated on Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-73: Marking Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-74: Removing Face Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-75: Omron Sensor Controller Set to L-ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-76: Green and Red Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-77: Conditions of Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-78: Omega Temperature Controller Display Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 6-45 6-46 6-46 6-47 6-47 6-48 6-48 6-49 6-50 6-51 6-52 6-53 6-54 6-54 6-55 6-56 6-57 6-59 6-59 6-60 6-60 6-61 6-62 6-62 6-63 6-64 6-64 6-65 6-66
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List of Figures
Figure 6-80: Current Temperature Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-81: Setpoint 1 Menu Item Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-82: Setpoint 1 Value Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-83: Setpoint 1 Value Increased . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-84: Setpoint 1 Value Saved. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-85: Setpoint 2 Menu Item Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-86: Configuration Menu Item Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-87: Dynamic Socket Pressure Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-88: LAN Setup Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-89: Local Area Connection Status Dialog BoxGeneral Tab. . . . . . . . . . . . . . . . . . . Figure 6-90: Local Area Connection Properties Dialog BoxGeneral Tab . . . . . . . . . . . . . . . Figure 6-91: Internet Protocol (TCP/IP) Properties Dialog BoxGeneral Tab . . . . . . . . . . . . . Figure 6-92: Local Area Connection Properties Dialog BoxAdvanced Tab. . . . . . . . . . . . . . Figure 6-93: Windows Firewall Dialog BoxExceptions Tab . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-94: Selecting Run Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-95: Opening a DOS Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-96: PING Command with Replies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-97: IPCONFIG Command with Reply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-98: E-mail Invitation to WebEx Meeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-99: WebEx Meeting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-100: Exatron Directory with Job Files, 3 Essential System Files, and Existing Program File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-101: Backup Directory with Job Files, Old Program File, and New Zipped File. . . . . Figure 6-102: Exatron Directory with Job Files and New Program File. . . . . . . . . . . . . . . . . . . Figure 6-103: Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-67 6-68 6-68 6-69 6-69 6-70 6-70 6-71 6-73 6-73 6-74 6-75 6-76 6-77 6-78 6-78 6-79 6-79 6-80 6-81 6-82 6-83 6-83 6-84 7-2 7-3 7-3 7-5 8-2
Figure 7-1: Relays12-Volt (Left); 24-Volt (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-2: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-3: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-4: Dimensions Listed From Smallest to Largest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-1: PET-V84-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure A-1: Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Figure A-2: 24-Pin D Connector on Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Figure A-3: TTL 24-Pin Connector with Pin Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Figure A-4: Sort Interface Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Figure A-5: Eight-Bit LED Checker #3000-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Figure A-6: TTL 24-Pin Connector with Pin Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 Figure A-7: Typical RS-232 Interface Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Figure A-8: Getting to HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26
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Figure A-9: Opening the HyperTerminal Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27 Figure A-10: Naming a New Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27 Figure A-11: Selecting the Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-12: Selecting the Port Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-13: Getting to Connection Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-14: Getting to ASCII Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-15: Displaying Typed Commands Onscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28 A-29 A-29 A-30 A-31
Figure A-16: Using Call to Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31 Figure A-17: Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-32 Figure B-1: CMOS Setup Opened to Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Figure B-2: CMOS Setup Changed to Advanced Menu; Advanced BIOS Features Selected . . B-3 Figure B-3: Advanced BIOS Features Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 Figure B-4: Selecting CD-ROM Drive as Boot Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-5: CD-ROM Drive Selected as Boot Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-6: Saving Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-7: Acronis Program Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-8: Acronis Main Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 B-5 B-6 B-6 B-7
Figure B-9: Manage Acronis Secure Zone Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8 Figure B-10: Manage Acronis Secure Zone WizardWelcome . . . . . . . . . . . . . . . . . . . . . . . . B-8 Figure B-11: Creating Secure Zone in Unallocated and Free Space . . . . . . . . . . . . . . . . . . . . . . B-9 Figure B-12: Specifying Size of Secure Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10 Figure B-13: Activating Acronis Startup Recovery Manager . . . . . . . . . . . . . . . . . . . . . . . . . . B-11 Figure B-14: Alternate SelectionDo Not Activate Acronis Startup Recovery Manager. . . . Figure B-15: Confirming Settings Before Creating Secure Zone . . . . . . . . . . . . . . . . . . . . . . . Figure B-16: Secure Zone Successfully Created . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-17: Reviewing Properties of the Created Secure Zone . . . . . . . . . . . . . . . . . . . . . . . Figure B-18: Backup Disk Shipped with Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-19: Selecting the Backup Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-20: Create Backup WizardWelcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-21: Selecting Entire Disk or Partition Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-22: Alternate SelectionIndividual Files and Folders Backup. . . . . . . . . . . . . . . . . Figure B-23: Selecting Partitions to Back Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-24: Explanation of Differences Between Full and Incremental Backups . . . . . . . . . Figure B-25: Restoration Based On Incremental Backups . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-26: Restoration Based On Differential Backups . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-27: Selecting Backup Storage Destination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-28: Selecting a Full Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11 B-12 B-13 B-14 B-15 B-16 B-16 B-17 B-17 B-18 B-19 B-19 B-19 B-20 B-21
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List of Figures
Figure B-30: Selecting a Differential Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-31: Selecting Backup Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-32: Archive SplittingAutomatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-33: Archive SplittingFixed Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-34: Drop-Down List of Fixed Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-35: Adding Optional Archive Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-36: Confirming Settings Before Creating Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-37: Progress Bar Displayed While Backup Is Created. . . . . . . . . . . . . . . . . . . . . . . . Figure B-38: Successful Completion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-39: Archive Files Created. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-40: Acronis Boot Disk Inserted in Drive (Left); Acronis Splash Screen (Right) . . . Figure B-41: Acronis Main Screen with Restore Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-42: Error Messages Due to Inserting Wrong Backup Disk . . . . . . . . . . . . . . . . . . . . Figure B-43: Restore Image WizardWelcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-44: Selecting Archive File for Restoration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-45: Option to Verify Archive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-46: Selecting Partition or Disk to Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-47: Option to Resize Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-48: Resizing Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-49: Deleting Partitions on Destination HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-50: Option to Restore Additional Partition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-51: Confirming Settings Before Restoring Partition . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-52: Prompts to Insert Series of Recovery Disks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-53: Successful Completion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-54: Selecting the Recovery Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-55: Restore Data WizardWelcome. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-56: Selecting Location of Archive File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-57: Selecting Original or New Location for Restoration . . . . . . . . . . . . . . . . . . . . . . Figure B-58: Selecting Restoration Destination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-59: Selecting Archive Files to Be Restored . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-60: Selecting Restoration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-61: Selecting Restoration Options Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-62: Selecting Whether to Overwrite Existing Files . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-63: Confirming Settings Before Restoring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-22 B-22 B-23 B-24 B-24 B-25 B-26 B-27 B-27 B-27 B-28 B-29 B-30 B-30 B-31 B-32 B-33 B-34 B-35 B-36 B-37 B-38 B-39 B-39 B-40 B-41 B-42 B-43 B-44 B-45 B-46 B-47 B-48 B-49
Figure B-64: Progress Bar Displayed While Data Is Restored . . . . . . . . . . . . . . . . . . . . . . . . . B-50 Figure B-65: Successful Completion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-50 Figure B-66: Restored Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-50
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Please read and understand this entire User Manual before installing or using your Exatron handler. A short glossary of terms used in this manual and other keys to understanding is found at the end of this chapter.
WARNING! Keep fingers, hair, and clothing away from any moving parts on the handler. Its motors are very powerful and can cause severe injury.
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WARNING! Always reset all motors before running the machine. Do not run it without homing the motors. WARNING! Never try to stop an action of the handler with your hands or any other device. To stop the handler, press the EMO (emergency stop) button or click Pause on the screen.
WARNING! If your Exatron handler is equipped with safety covers, never operate the handler without them. Never remove the safety covers. Never defeat any electrical interlock switch supplied with the handler. To avoid operator contact with moving parts, the Model 900 is equipped with fixed and moving covers. The fixed covers are screwed in place and should never be removed except for maintenance and then only by qualified maintenance technicians. The movable covers are supplied with interlocks. Exatron specifically disclaims responsibility and/or liability for any injury which occurs as a result of any interlock being defeated and/or bypassed, or for any injury which occurs as a result of any fixed cover being removed during operation. The only hazardous waste associated with any Model 900 handlers is the circulatory fluid used in chillers, for handlers using cold testing. For MSDS, see the suppliers recommendations. WARNING! If your Exatron handler is equipped with a thermal circulator or chiller, dispose of the circulatory fluid in accordance with local or federal regulations. Using compressed air can be hazardous. It is the responsibility of the company purchasing the handler to properly train all handler operators in every aspect of the safety practices associated with the use of compressed air. WARNING! Never operate any Exatron system which requires compressed air without an approved air regulator and shutoff valve, such as that originally supplied with your system.
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Lock-Out Procedures
WARNING! Never unplug a pressurized air hose while the air regulator is turned on. If your handler is equipped with a laser, follow all the federal and state safety regulations for safely operating the laser. Follow the safety warnings in the laser manufacturers manual. WARNING! Only a qualified in-house laser safety officer (LSO) should service the laser, if the handler is equipped with a laser.
Lock-Out Procedures
Lock-out/tag-out procedures should be followed when servicing or repairing the handler. This prevents an operator from turning on the handler when it may be partially disassembled and thus prevents damage or injury. Before servicing or repairing your handler, turn off the air regulator and lock it in the OFF position as shown in Figure 1-2. Then, if you have to leave the handler in an inoperable or unsafe condition, no one can turn it on by mistake. NOTE: Locking devices such as padlocks are provided by you, the customer. WARNING! Turn off the air regulator and lock it in the OFF position before servicing.
Figure 1-2: Air RegulatorIn ON Position (Left), in OFF Position (Center), in OFF Position with Lock (Right)
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The handler has a lockable disconnect switch (Figure 1-3) that shuts off all AC power to the handler and computer(s). When using lockout procedures, turn off and lock this switch also.
Figure 1-3: Lockable Disconnect SwitchIn ON Position (Left), in OFF Position with Lock (Right)
Facilities Requirements
Air Conditioning and Environmental Requirements
The Model 900 handler should be installed in a temperature-controlled, dust-free environment to preclude dust and dirt particles from contaminating its moving parts, especially those parts which come into contact with the devices being tested. The life of your handler is greatly enhanced by keeping it as clean as possible. See Chapter 6 for instructions. Handlers equipped with laser markers must have a smoke extraction/filter system. If no laser is present, there are no special ventilation requirements.
Electrical Requirements
The power supplies for handlers shipped either within the United States or offshore have builtin switching electrical supply capability for 100-volt AC to 240-volt AC, 50 Hz to 60 Hz, at usually 5-10 amps. For more information see "Power Supplies" on page 2-11. However, the handler is wired for either 100-120-volt AC, 50/60 Hz, at 3 amps; or 220-240-volt AC, 50/60 Hz, at 2 amps. You must specify your choice when you order the handler. Tapers, if included, can be wired for either 100-120-volt AC, 60 Hz; or 220-240-volt AC, 50 Hz. You must specify your choice when you order the handler.
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Facilities Requirements
Vacuum/Pneumatic Requirements
If the handler is to be used in an electrically noisy environment or near large electromechanical equipment, Exatron recommends the use of a reliable power conditioner to filter line noise, surges, and spikes which can cause the handler to operate improperly or become damaged. CAUTION: Connect the power cord to earth-grounded power outlets only. Service calls made to the customer facility to correct problems caused by improper electrical supply are not covered by the Exatron warranty.
Vacuum/Pneumatic Requirements
The Model 900 system requires a supply of pressurized air at a minimum of 80 PSI at 2 to 5 CFM (depending on the number of vacuum generators), filtered for proper operation. The air supply must be clean (containing no particulate matter greater than 5 microns in size), oil-free, and dry (having a dew point of 36 degrees F to 38 degrees F) to operate correctly. Dirty, oily or wet air will cause the vacuum generator to malfunction and will make your system unreliable. If the handler is equipped with a taper, add 0.5 CFM of shop air to the CFM required for the handler itself. The external air source should be attached to the air regulator mounted on the handler base. Before turning on the air regulator and using the handler, make certain the compressed air line is attached to the air regulator fitting. Check to make sure the air regulator gauge on the external regulator measures the air pressure at 80 PSI, and adjust if necessary. To maintain these levels of pressurized air quality, replace the air filter (Exatron part #GPA-97075) in the air regulator of your handler after every 6000 hours or 12 months of operation, whichever comes first; or if your air regulator registers a pressure drop of 15 PSI. Moisture of any kind will travel through external and internal air lines. This moisture will coat these air lines and the insides of the handler's cylinders, causing them to stick or to stop functioning altogether. The best defense against this kind of contaminate is to prevent it from occurring in the first place by maintaining the clean air supply described above. If the air lines are allowed to become discolored or the moisture traps become overfilled, damage to the system will occur. The only corrective action to take at that point is to replace all of the air lines and to completely clean all of the solenoids supplied by those air lines. Handler damage due to improper air supply is not covered by the Exatron warranty.
Internet Access
It is strongly recommended that your handler be equipped with Internet access. This is to facilitate remote troubleshooting by Exatron engineers as necessary, and to save you larger onsite costs, the details of which are itemized in the "Customer Service Support Guide" on page 1-15. See Chapter 6 and especially "Remote Handler Control with WebEx" on page 6-80 for how we can help you troubleshoot remotely.
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Exatron strives to maintain low capital acquisition costs and low service costs for our customers. A key part of this strategy is the use of the Internet to provide software updates and perform remote service on our systems. Software support in the field can be extremely expensive to the end user, so high-speed connections are an excellent money-saving tool. We encourage our customers to put our systems on their networks and provide remote access to the system through the Internet. Exatron reserves the right to bill the customer for any on-site warranty work that otherwise could have been accomplished remotely.
Standard Warranty
All Exatron products are under warranty for one year from the date of purchase. Exatron agrees to repair any mechanical or electrical assembly, subassembly, or entire unit that fails during normal use within its first year. The customer agrees to follow the recommended maintenance procedure as defined in this User Manual. Exatron does not warrant test contactors. Handler test contactors are fragile and may be easily ruined by operator abuse. Exatron uses the finest materials available in our contactor designs. Exatron does not warrant the following:
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Standard Warranty
Damage caused by improper packaging of equipment returned to Exatron for repair Damage caused by the shipping company Damage caused by natural catastrophes: flood, fire, earthquake, etc. Damage caused by equipment connected to improper power line voltages Damage caused by equipment connected to improper air supply: contaminated with oil, water, dirt, etc. Damage caused by operator abuse or improper practices cautioned against in this manual Damage caused by interface hardware not manufactured by Exatron Damage or malfunction caused by customer modifications Test contactors
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The model number of the handler The type of device being run by the handler, such as: DIP, SOIC, SOJ, PLCC, LCC, SIP, PGA, PCB, ZIP, etc. The handlers serial number The full shipping address Any special shipping or customs instructions Method of shipment, such as: Federal Express, UPS, DHL, U.S. Mail, or the name of your chosen shipping company In most cases, faxed requests and shipment of replacement parts orders are processed within twenty-four hours of receipt by Exatron.
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Service Contract
Service Contract
www.exatron.com 408-629-7600
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Acts of war Power line problems and damage Air supply problems and damage Ongoing camera & laser application support Any other Exatron products not specifically listed on this contract
Service performed on Exatron-built products only: Service is strictly limited to the Exatron portions of a given system Service work on any OEM subsystem is to be purchased directly from the OEM This includes, and not limited to, bowl feeders, chillers, camera/vision systems, customer supplied equipment, label printers, laser markers, smoke extractors, and any large OEM subsystem used in the overall Exatron system Please note: All laser markers require professional service. Improper service will void the OEM warranty and could result in personal injury and/or serious damage to the laser.
This contract does NOT extend the Exatron product warranty. This contract does NOT provide for any additional service work beyond the limits of this contract.
Service Contract Schedule Exatron will make every effort to have a service engineer at the customers facility with in 1 to 3 business days of the call for service. There are no service response time guaranties. We do offer a 1 business day turn around service on a per occurrence basis. Please contact Exatron for details and quotation. PM Product Movements Preventive maintenance contracts are priced to specific locations. With the exception of movements between buildings on the same campus, any movement of the Exatron product covered by this contract during the period of this contract may result in a change in the price of the preventive maintenance contract, and the contract must be requoted. The value of any unused portion of this contract will be applied towards the new contract price. Exatron reserves the right to refuse service for machines which are moved to parts of the world considered unstable or dangerous. Service Operating Hours Preventive Maintenance service work shall be performed 8:00 AM to 5:00 PM, local time, Monday through Friday, excluding weekends and local public holidays. Availability of Products Any spare parts at site shall be made freely available by Customer to Exatron's engineer to enable remedial work to be carried out. In the event spare parts must be obtained from the factory in San Jose, California, the engineer may return to the customer facility to complete the work. Return to the customer facility will be determined by mutual agreement between Exatron and the customer. Price Call for a quotation. There is a substantial cost increase for customers who do not have and/or allow our service engineer to connect the Exatron Product to the internet allowing for remote diagnostics. Spare Parts 25% discount on all Exatron spare parts, except consumables, during the life of the contract. Spare parts for OEM subsystems should be purchased directly from the OEM vendor. If purchased through Exatron, there is an additional markup and no discounts are available. Terms Call for a quotation.
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Service Contract
All actual travel expenses are NOT included and will be billed at the time: These include as a minimum the following expenses: Air fare as required Rental car and/or cab fees Lodging Per-diem food allowance Equipment and/or spare parts express shipping costs Travel expenses to the customer are waived if within 50 miles of Exatron, San Jose, California. Site Medical Facilities Site medical facilities will be made freely available to Exatron's engineer(s) as needed for emergency medical treatment. Limitation of Liability During the initial warranty period of a system covered by this contract, Exatrons entire liability and customer's exclusive remedy will be repair or replacement of an assembly not meeting Exatron's standard warranty. Following the warranty period, Customer is responsible for any and all costs associated with repairs, replacement parts, etc. In no event will Exatron be liable to the customer for any damages including lost profits, cost saving, or other incidental or consequential damages arising out of the use or inability to use Exatron products referred to herein even if Exatron has been advised of the possibility of such damages, or of any claim by any other party. Customer will indemnify Exatron against any damage to Customers property and against any claims for loss or injury to any person or to the property of any person by reason of the Customers negligence or of any act or omission on the part of the Customers employees, subcontractors, assignees or agents arising out of this contract. Excuse of Performance Neither party shall be liable to the other party for any delay due to causes beyond its reasonable control, including but not limited to faulty instructions, lack of instructions, travel or shipping delays due to weather or other factors outside their control, shipper's error, acts of God, or strikes or other labor disputes. Law The validity, interpretation, and performance of this agreement, and any dispute connected therewith will be governed and construed in accordance with the laws of the State of California. IN WITNESS WHEREOF, the parties have executed this Agreement by their duly authorized representatives as of the date and year stated at the top of this document. Customer TBD EXATRON
_____________________________________________________________________ By ___________________________By _David Ledezma______________ Title __________________________Title _Customer Service Manager____ Customer contact person(s) Phone number(s) Email(s) EXATRON PRODUCTS COVERED UNDER THIS P.M. CONTRACT Serial # Serial #
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www.exatron.com 408-629-7600
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Please note: All laser markers require professional service. Improper service will void the OEM warranty and could result in personal injury and/or serious damage to the laser.
This contract does NOT extend the Exatron product warranty. This contract does NOT provide for any additional service work beyond the limits of this contract.
Preventive Maintenance Visit Schedule There will be two (2) preventive maintenance visits each year. The timing of each visit shall be mutually agreed upon by Exatron and the customer to prevent unnecessary disruption of Customer's plant operation. The dates of the mutually agreed semi-annual visits must be determined at least 30 days prior to its occurrence. One engineer will be dispatched to carry out the preventive maintenance work. PM Product Movements Preventive maintenance contracts are priced to specific locations. With the exception of movements between buildings on the same campus, any movement of the Exatron product covered by this contract during the period of this contract may result in a change in the price of the preventive maintenance contract, and the contract must be requoted. The value of any unused portion of this contract will be applied towards the new contract price. Exatron reserves the right to refuse service for machines that are moved to parts of the world considered unstable or dangerous. Service Operating Hours Preventive Maintenance service work shall be performed 8:00 AM to 5:00 PM, local time, Monday through Friday, excluding weekends and local public holidays. Availability of Products Any spare parts at site shall be made freely available by Customer to Exatron's engineer to enable remedial work to be carried out. In the event spare parts must be obtained from the factory in San Jose, California, the engineer may return to the customer facility to complete the work. Return to the customer facility will be determined by mutual agreement between Exatron and the customer. Price The PM contract is priced by the day. We recommend a minimum of 2 PM visits per year. We recommend a maximum of 4 PM visits per year. Prices DO NOT include any travel costs and/or spare parts if applicable. 2 PM visits per year at $1200 per visit ($2400 Contract Cost) 3 PM visits per year at $1100 per visit ($3300 Contract Cost) 4 PM visits per year at $1000 per visit ($4000 Contract Cost) Spare Parts Spare parts for OEM subsystems could be purchased directly from the OEM vendor and/or Exatron. Exatron manufactured spare parts to be purchased through Exatron only. Terms Call for a quotation. All actual travel expenses are NOT included and will be billed at the time: These include as a minimum the following expenses: Air fare as required Rental car and/or cab fees Lodging Per-diem food allowance Equipment and/or spare parts express shipping costs Travel expenses to the customer waived if within 50 miles of Exatron, San Jose, California. Site Medical Facilities Site medical facilities will be made freely available to Exatron's engineer(s) as needed for emergency medical treatment.
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Limitation of Liability During the initial warranty period of a system covered by this contract, Exatrons entire liability and customer's exclusive remedy will be repair or replacement of an assembly not meeting Exatron's standard warranty. Following the warranty period, Customer is responsible for any and all costs associated with repairs, replacement parts, etc. In no event will Exatron be liable to the customer for any damages including lost profits, cost saving, or other incidental or consequential damages arising out of the use or inability to use Exatron products referred to herein even if Exatron has been advised of the possibility of such damages, or of any claim by any other party. Customer will indemnify Exatron against any damage to Customers property and against any claims for loss or injury to any person or to the property of any person by reason of the Customers negligence or of any act or omission on the part of the Customers employees, subcontractors, assignees or agents arising out of this contract. Excuse of Performance Neither party shall be liable to the other party for any delay due to causes beyond its reasonable control, including but not limited to faulty instructions, lack of instructions, travel or shipping delays due to weather or other factors outside their control, shipper's error, acts of God, or strikes or other labor disputes. Law The validity, interpretation, and performance of this agreement, and any dispute connected therewith will be governed and construed in accordance with the laws of the State of California.
IN WITNESS WHEREOF, the parties have executed this Agreement by their duly authorized representatives as of the date and year stated at the top of this document. Customer TBD EXATRON
_____________________________________________________________________ By ___________________________By _Quang Truong______________ Title __________________________Title _Customer Service Manager____ Customer contact person(s) Phone number(s) Email(s) EXATRON PRODUCTS COVERED UNDER THIS P.M. CONTRACT Serial # Serial #
Original Customer PO# :__________________ Original Ship date#:______________________ PM Contract PO# :__________________ Exatron Invoice# :__________________ NOTE: LASER & LASER PC SERVICE/MAINTENANCE ARE NOT INCLUDED DATES FOR PREVENTIVE MAINTENANCE The Preventive Maintenance procedures will be performed two (2) times semi-annually as scheduled below: (Please fill out and return with signed copy of the contract.) 1: TBD 2007 PM Contract Quote#:______________________
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w w w .exatron.com 408-629-7600
Standard Exatron Warranty: 1 year all Exatron parts other than test contacts and consumables 1 year factory labor. Warranty does not cover travel expenses for on-site service. See note, below, regarding Ethernet access for support All parts listed by OEM and in-house part numbers Typical same day shipment of spare parts PC Anywhere remote update and diagnostic software standard Self-service encouraged with on-line documentation and extensive built-in diagnostics Service contracts available See below Toll free 800-EXA-TRON support service phone line Major OEM subassemblies such as bowl feeders, lasers, vision systems, etc., have pass-through OEM warranties ONLY. No additional Exatron warranty Assume OEM warranties do not include on-site labor usually factory only Any unexpected OEM warranty/service costs passed on to customer at Exatron cost What is NOT covered by the Standard Exatron Warranty: On-site operator or in-house service training after install Consumables and test contacts Shipping damage of any kind Improper or lack of preventative maintenance Operator abuse of any kind Acts of God Acts of war Power line problems and damage Air supply problems and damage Any problems with OEM equipment not covered by OEMs warranty Ongoing camera & laser application support (see below) Ongoing Exatron updates added after shipmen Problems with non-Exatron supplied system components Please note: All of our products are quoted with factory installation. If this option is not ordered, then problems that arise from "self installation" are not considered covered by our standard warranty Exatron comprehensive manuals: Over the years our documentation has improved greatly. We now offer full color comprehensive manuals. These manuals are installed on the handlers hard disk and can be downloaded from our website, anytime. All manuals have fullcolor photos to help get the point across. To keep our costs down, our manuals have grown to cover all possible options and are now considered comprehensive. We then add customized chapters to the comprehensive manual with productspecific electrical schematics, master assembly drawings, and a detailed parts list.
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Self diagnostic support: All Exatron products have substantial built-in self diagnostic software. These diagnostics are well documented in our manuals. Typically every sensor, switch, solenoid, valve, lamp, motor, vacuum can be individually turned on/off and tested quickly. This is a great help with troubleshooting problems. Combine this with remote Internet access and just about all problems can be found quickly and at low cost to everyone. Void warranty stickers: There are no "void warranty" stickers on Exatron products, but there are some on some of our OEM add-ons. We do require that a properly trained service technician perform any service work on Exatron products. Laser self service: Exatron does NOT recommend customer self service for any of our laser products. There are substantial safety issues with lasers and they must be serviced by the OEM laser vendor. In some cases, Exatron can provide basic service work. Laser service work must be quoted on a specific as-needed basis. Any damage, of any kind, to the laser caused by improper service or operator abuse voids any remaining warranty. Factory customer operator and service training: Exatron will train the customers operators and/or service personnel if: The training takes place at Exatron The customer pays all of their own travel / lodging costs Exatron is given at least 30 day notice Exatron will then train on the next best thing we have in-house at that time (best effort) Exatron uses only standard Exatron manuals for training aids Any spare manuals must be purchased by the customer In most cases, we are willing to provide up to two days of training for up to 3 people at no cost during the buy-off of the equipment. Additional factory customer operator service training can be purchased for $600 per day for one person, $200 per additional person all trained at the same time. Typically we would limit our class sizes to 4 people maximum. The number of days required to train depends on the Exatron product(s) and the skill level of the people being trained. On-site training classes: On occasion, Exatron provides our customers with on-site training classes. This can be as simple as a few hours reviewing our standard documentation. Or a more formal class may be required. Exatron will quote on-site training classes based on the customers needs. Spare parts: Most spare parts orders are shipped the same day, if the order is placed before 1pm PST. We do all we can to maintain a good stock of commonly used spare parts. But there will be times were Exatron cannot supply a spare part overnight. The customer must maintain their own stock of spare parts based on their needs. All shipping costs will be charged to the customers account. Please specify shipping method at time of order. Exatron will hold all spare part orders if the customer has any overdue open invoices. Spare test contactors: It is expected that the customer will maintain at least a 60 day inventory of spare test contactors. In many cases, test contactors are custom designed. In many cases, we ship the test contactors as a lot. We do not maintain a stock of spares in these cases. Typical lead time is 3 to 4 weeks; longer is possible for unforeseen reasons. Spare part kits: Exatron offers a well stocked spare parts kit. Call for a quotation. Spare part long-term support: Exatron makes every effort to supply spare parts for the life of the equipment. We manufacture our own machine parts and our ability to find old drawings, for old parts, is excellent. As the handler ages, many of the non-Exatron made parts will no longer be available. In some cases, we may substitute used parts that still have some life in them. If all else fails, we can design in new parts or upgrade around the problem part; this can add substantial extra cost, but will also extend the working life of the handler.
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RoHS Lead Free Compliance: Exatron has been building equipment since 1974. We no longer use lead solder in any of our newly designed products. Some of our "newly built" older designs might in fact use older in-stock parts that are not RoHS compliant. We do have older stocks of spare parts that were originally made with lead solder. Some of these older parts will be used in newly built Exatron products that were originally designed years ago. This applies mostly to older PCBs, both bare boards and assemblies. This may also apply to older test contacts & cable assemblies. In the event the customer needs to have all spare parts, including older in-stock parts, the customer's original order must clearly indicate that RoHS compliance is required. Exatron reserves the right to re-quote as needed. There will be substantial price increases. With many of our older spare parts, we will need to generate new documentation, artworks, and buy a minimum number of parts to remanufacture just one spare part that is now RoHS complaint. All of these costs and a much longer lead time, will be passed on to the customer within the required re-quote. Product upgrades: As the product ages, there will be a time when Exatron will no longer be able to upgrade the product with new options that are constantly being added to our product line. We will do all we can to support the product to work as well as it did when it originally shipped. Spare computer parts: It is simply a fact that as computers get cheaper, they also become less reliable. Exatron does all we can to buy the highest quality and generic computer parts as possible. This is why we build our own PCs. Please note that computer parts typically DO NOT have long term support. In most cases, but not all, we can swap out one PC vendor with another. It is highly recommended that the customer buy a spare PC at time of order (included in some spare parts kits). We maintain a small stock of older computers, subject to prior sale. Recover disks: All Exatron PC based handlers are shipped with software recovery disks. We will store a copy as well at Exatron. This disk(s) will allow the customer to fully recover from a catastrophic computer failure. The disk will recover all of the installed software that was on the handlers hard disk at time of shipment. This disk will not always fully recover if the computer itself has to be changed out to a different type or upgraded version of MS Windows. It is up to the customer to maintain backup files for all job files and Exatron updates after the equipment is shipped from Exatron. Please do not make your only backup files on the Exatron computer. Software updates: Some customers ask for improvements that we add to all future versions. Sometimes we even find "bugs" and fix them. We are always making improvements. Exatron provides these generic software updates on request only. We strongly believe in the idea that "if it isnt broken, dont fix it" when it comes to software adding a change to fix one problem can often lead to more and worse other problems, so we specifically do not make software fixes unless really necessary. Should the customer request be considered by Exatron to be an enhancement, we reserve the right to quote as needed. Spare hard drive: Exatron highly recommends adding a spare hard drive to our computers. This can be ordered at time of order. Adding a disk drive after shipment will require an on-site service call and is not covered by our standard warranty. 8-to 5-phone support: Exatron offers toll free (800-EXA-TRON) phone support, 8am to 5pm Pacific Time, Monday Friday, at no extra cost for the life of the equipment. Most questions are answered on the spot. More complicated issues will take longer. At some point Exatron may require the customer to purchase an on-site service call or return the equipment to Exatron for repair. Internet support: Exatron strives to maintain low capital acquisition costs and low service costs for our customers. A key part of this strategy is the use of the Internet to provide software updates and perform remote service on our systems. Software support in the field can be extremely expensive to the end user, so high-speed connections are an excellent money-saving tool. We strongly encourage our customers to put our systems on their networks and give us access to the system over their networks.
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Internet access software is included with every Exatron PC-based handler. In most cases, handlers can be connected to Exatron over any Internet port as long as the customer initiates the connection. There will be substantially higher service and engineering costs to our customers who cannot provide Internet access to our products. OEM equipment: Many Exatron products are systems built with additional third party OEM products. These products include laser markers, chillers, smoke extraction, vision/camera systems, bowl feeders, label printers, and other big ticket non-Exatron products. In every case, Exatron will require the OEM to pass its standard warranty through to the end user. In every case, Exatron will do all we can to correct any system problems. The specific service policy for the non-Exatron product will be determined at time of order. Most of our OEM products do not include on-site support or return shipping costs without a specific additional order at time of the original system order. In the event an OEM product is supplied by the customer, Exatron will only guarantee the initial integration. This integration must be bought off at Exatron prior to shipment. Exatron will not offer any additional warranty from that point in time. Exatron service work on OEM equipment: Service work is typically limited to repair of Exatron products only. We will make every effort to service our OEM partners equipment to the best of our ability. Should the OEM product require service beyond our limited ability, any and all costs required to bring the OEM equipment back to working order will be passed on to the customer. ONGOING CAMERA AND LASER APPLICATION SUPPORT: Exatron systems that require machine vision (cameras) and/or laser markers include the initial application development only. Depending on how the system is used, ongoing application support may be required. We encourage customers to develop sufficient in-house familiarity with the vision and laser systems to accomplish this themselves. However, in the event that additional application support is needed, Exatron considers this not to be covered by warranty. Applications support is available from Exatron at a price to be determined on a case-by-case basis. Exatron customers are also encouraged to seek applications support directly from the camera and/or laser vendor(s). Third-party service: Exatron has working relationships with qualified third-party service providers in Asia and Europe. Please see our web site for contact information. The customer is free to directly contact any of these service providers. Each has their own pricing structures. Returned to the factory repair turn-around times: Exatrons in-house repairs are billed at $75 per hour, 1 hour minimum. All products sent in to Exatron for repair must have an RMA number. If there is no RMA number, turn-around times can be significantly longer. Work performed 8am-5pm Pacific Time normal business days only Standard service turn-around time (with RMA#) ...typically the next day, best effort Rebuilds & engineering turn-around times...to be determined as needed 1 business day response subject to availability at the time (see below) Field upgrades and service call turn-around times: On-site turn-around time: We will make our best effort to provide on-site service as quickly as possible. Our standard warranty does not cover travel expenses. We will waive our technicians time and spare part costs during the warranty period. This does NOT apply to adding newly purchased upgrades. There will be a substantial increase in travel costs for immediate/overnight travel. All of these costs are all passed on to the customer.
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Field upgrades lead times must be quoted and confirmed at time of order. All field upgrades are quoted, open ended. We will do all we can to make a field upgrade go as quickly as possible. All costs for any unforeseen delays, for any reason, that requires the Exatron technician to stay extra days or make a return visit will be passed on to the customer as required. One-business-day guaranteed response time: Subject to availability at the time (see below) In-warranty service costs: On-site service within the USA (no Internet access) In the event Exatron is required to provide an on-site service call, where the problem could have been corrected with Internet access prior to the service call, Exatron will bill all costs for the service call at Out of Warranty service rates. Labor performed at no charge within our Standard Exatron Warranty (see above) Labor and travel time will be billed for any work for what is NOT covered by the Standard Exatron Warranty (see above) All actual travel expenses billed to the customer On-site service within the USA (with Internet access) Labor performed at no charge within our Standard Exatron Warranty (see above) Labor and travel time will be billed for any work for what is NOT covered by the Standard Exatron Warranty (see above) All actual travel expenses billed to the customer On-site service outside the USA (no Internet access) All actual travel expenses billed to the customer and $1875.00 per day, full payment received prior to the service call On-site service outside the USA (with Internet access) All actual travel expenses billed to the customer and $1200.00 per day, full payment received prior to the service call Field upgrades and out-of-warranty service costs: On-site field upgrade or service within the USA (no Internet access) Labor performed at $200.00 per hour, day minimum All actual travel expenses billed to the customer On-site field upgrade or service within the USA (with Internet access) Labor performed at $150.00 per hour, day minimum All actual travel expenses billed to the customer On-site field upgrade or service outside the USA (no Internet access) Labor performed at $2,000 per day All actual travel expenses billed to the customer On-site field upgrade or service outside the USA (with Internet access) Labor performed at $1500.00 per day All actual travel expenses billed to the customer Remote software engineering costs (8am to 5pm Pacific time, Monday-Friday; excludes local holidays: On-site remote software engineering within the USA Labor performed at $150.00 per hour, one hour minimum After hours service, labor performed at $250.00 per hour, one hour minimum On-site remote software engineering outside the USA Labor performed at $200.00 per hour, one hour minimum After hours service, labor performed at $300.00 per hour, one hour minimum
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Blanket service purchase order for service/spares: Customers who would like the fastest service at the lowest cost should consider opening a blanket service purchase order. With a standing open P.O. Exatron can respond immediately to customers employees requests for service and/or spare parts. This saves the down time required for Exatron to quote and the customer to generate a PO. Exatron will bill as needed at the time. We recommend a minimum of $5,000.00 per year Contact Exatron for terms. PM contracts: Sold by the day, $1,000 per day, plus travel and living expenses. Please contact Exatron for a copy of our PM Contract. One-business-day turn-around on-site service trips: Available on normal USA business days only Subject to availability at the time, this is not a guarantee Quoted on a "per trip" basis We will bill at the premium rate if Exatron is required to have a service technician on-site within 1 business day. Any unforeseen, no fault of Exatron, travel delays will be still billed at the premium rate. Exatron best effort on making necessary repairs only Flat daily rate, no discount for repairs made in less than 8 hours Service price schedule: One-business-day on-site service trip within the USA (no Internet access) Labor performed at $2,000 per day All actual travel expenses billed to the customer $1,000 premium for guaranteed 1 business day service response time* One-business-day on-site service trip within the USA (with Internet access) Labor performed at $1,500 per day All actual travel expenses billed to the customer $1,000 premium for guaranteed 1 business day service response time* One-business-day on-site service trip outside the USA (no Internet access) Labor performed at $3,000 per day All actual travel expenses billed to the customer Travel time added to 1 Business day guarantee $1,500 premium for guaranteed 1 business day service response time* One-business-day on-site service trip outside the USA (with Internet access) Labor performed at $2,000 per day All actual travel expenses billed to the customer Travel time added to 1 Business day guarantee $1,500 premium for guaranteed 1 business day service response time* * Subject to availability at the time. One-business-day response time starts at time of departure from Exatron; travel time not included. There will be a substantial increase in travel costs for overnight travel. All of these costs are all passed on to the customer. Terms: Terms to be determined at time of service call. Field upgrade terms will be added to our quote. Actual travel expenses include: Air fare as required (All tickets to be purchased thru Exatron's travel agent) Rental car and/or cab fees Lodging Living expenses Field upgrade and all on-site service call shipping costs: In the event a spare part(s) needs to be shipped overnight to a customer's site during a service call or field upgrade. We will ship the package via the customer's account with the shipper. Should Exatron be required to ship via our account, we will then bill the customer for all shipping costs at actual cost plus 50%
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Context menu
A pop-up menu that is displayed when you right-click over an area or item. It offers actions appropriate to the item.
Device
A generic term that refers to the chip, package, or other part processed by the Exatron handler. A down-pointing arrow at the right end of an input box. Click the arrow to view and select from the possible options. Some drop-down boxes have a slider bar that you can slide up and down to view even more selections.
Drop-down arrow
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Group box
A collection of input boxes, buttons, etc., on a window that are grouped together by function and purpose. They are usually surrounded by a thin border and a box title.
Home position
The location that each motor returns to each time the handler is reset. A box where you can type in text or numbers.
Slop
Amount of play, or looseness, between a device and its holder. Refers to a logical output location; a type of test result. Contrast with bin. The component of a vacuum generator that sucks air in one hole as air pressure is forced along the pathways, thus causing a vacuum. Left/right axis. For the Model 900 handler, this is viewed as the operator stands at one side of the handler. The device trays move on the X axis. Deep axis. For the Model 900 handler, this is viewed as the operator stands at one side of the handler. The pickup assembly moves along the gantry on the Y axis. Vertical, up-and-down axis. The pickup nozzle lowers and rises on the Z axis.
Sort
Venturi
X axis
Y axis
Z axis
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Figure 1-8: Cabinet Model with Detaper, Six Test Sites, Model 201 Taper, and Two Trays
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Figure 1-9: Cabinet Model with Dual Preheating Trays, Dual Thermal Test Sites, and Two Trays
Figure 1-10: Cabinet Model with Detaper, Test Site, Model 201 Taper, and One Tray
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Figure 1-11: Cabinet Model with Chiller, Hot and Cold Test Sites, Enclosed Trays, and Laser
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Figure 1-12: Cabinet Model with Preheating Tray, MEMS Light Source Tester, Enclosed Trays, and Laser
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Figure 1-14: Cabinet Model Assembler with Bowl Feeder and Tube Inputs, Inspection, and Taper Output
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Figure 1-15: Cabinet Model with Bowl Feeder Input, Preheating Tray, MEMS Magnetic Ambient and Thermal Testing, and Taper Output with In-Tape Inspection
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Figure 1-16: Cabinet Model with Four Trays and MEMS Audio Test Box (Left); 16 Test Sockets in Audio Test Box (Right)
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Figure 1-17: Cabinet Model with Bowl Feeder Input, Machine Vision Inspection, MEMS Vibration Testing, and Taper Output (Top); Isolation Plate with 12 Sockets for MEMS Vibration Testing (Bottom)
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Figure 1-18: Benchtop Model with Detaper and Two Trays/Waffle Packs
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Figure 1-20: Hot and Cold Test with Chiller and Air Dryer, Four Trays
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Figure 1-21: Benchtop Model with Rotary Tester and Trays/Waffle Packs
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Figure 1-22: Custom Model with Tube Input and Output, One Test Site
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Figure 1-23: Cabinet Model with Burn-In Board, Dual Test Sites, and Two Trays
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Figure 1-24: Custom Model with Two Input Sources, Two Inspection Cameras, Welder
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Figure 1-25: Port Feeder Track and Tray as Input for Welder
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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. The Exatron software is discussed primarily in Chapters 4 through 6.
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Use the references in the following table of common options to read about the options on your machine.
Common Options
If You Have This Option... Pickup head rotation Auxiliary pusher and slider See These Sections "Pickup Head Rotation" on page 2-3 "Results of Rotation Combinations" on page 5-33 "Test Site Override Buttons" on page 2-23 "Using Override Buttons" on page 5-4 "Test Site Delay Group Box" on page 5-29 "Test Site Clamp Group Box" on page 5-62 "Multiple Pickup Heads" on page 2-4 "Setting Test Site Distances" on page 5-73 "Thermal Soak Time Delay Group Box" on page 5-42 "Thermal Setup Window (Optional)" on page 5-100 "Tray Configurations" on page 2-30 "How X and Y Distances Are Measured" on page 2-32 "Understanding Tray and Waffle Pack Numbering" on page 5-79 "Pitch and Teach Group Box" on page 5-57 "Example of Calibrating Distances for Waffle Packs" on page 5-90 "Tape-and-Reel Assembly" on page 2-38 "Setting Up a Taper" on page 3-23 "Auto Run Using Tape and Reel" on page 4-9 "Taper Window (Optional)" on page 5-103 "Adjusting Seal Head" on page 3-38 "Setting Temperature for Heat Seal Head" on page 3-45 "Adjusting Seal Head" on page 3-38 "Securing Trays or Tubes" on page 3-9 "Calibrating Procedures for Tube Devices" on page 3-11
Multiple pickup heads Multiple test sites Thermal test sites Waffle packs
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Mechanical Systems
Motors
The Y motor moves the pickup head from right to left and back, carrying the devices from tray to test site to tray. Some handlers rotate the device at one or more points in this journey.
Mechanical Systems
Motors
The motors used on the Exatron Model 900 handler are servo motors. The motors transfer power to the lead screws by a standard flexible motor coupling. These motors are "smart" motors, in that after carrying out a command from the software to move to a certain position, they send back a response to the software that the movement was correctly completed. In this way, the handler is prevented from taking the next action until it is confirmed that the previous action was carried out.
Pickup Heads
Pickup heads can be custom-built for your companys needs.
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Figure 2-2: One Type of Rotational Pickup HeadRotation On (Left); Rotation Off (Right)
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Mechanical Systems
Lead Screws
Figure 2-3: Another Type of Rotational Pickup HeadRotation On (Left); Rotation Off (Right)
In Figure 2-3, dual pickup heads are in operation. The left nozzle is rotated; the right nozzle is not. Pickup heads can be built as multiple nozzles on one Z pickup head, moving in tandem to and from test sites.
Lead Screws
The lead screws employed on the Model 900 are PTFE-baked and employ a Delrin nut for long-term reliability. As each lead screw is used, the teflon gradually wears off the lead screw and embeds itself in the nut to smooth out any irregularities in the nut, thus enhancing long wear.
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Different pitches may be employed on the Model 900. For example, one-half-inch pitch screws signify that the carriages move one-half inch for every complete rotation of the lead screw; one-inch pitch screws signify that the carriages move one inch for every complete rotation of the lead screw. The 1" pitch screw moves faster: it requires one-half as many steps on the motor to move the same distance as the 1/2" screw. Therefore, the 1" pitch screw is used where a faster movement is preferred; a 1/2" pitch lead screw is used where a slower motion is preferred, as where entire trays of devices are being moved (and not held by suction as on the Y axis) and thus must not be rudely jostled.
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Mechanical Systems
Tray Carriages
Tray Carriages
Each tray carriage is mounted on its own lead screw (see above) and is guided and kept square to the system by two linear bearings. The tray is held on the carriage by a colored tray clamp: anodized red for failed parts and green for good parts, other colors for other sort categories. There is also a spring clip in the right rear of the carriage for added tray stability.
Gantry
The Y-axis gantry employs a servo-motor-driven lead screw to move a pickup head assembly along its length. The pickup head is guided by two linear bearings along which the pickup head rides. An infrared through-beam home sensor is mounted to the wall on the motor end of the gantry. The pickup head assembly includes a servo motor driving a chain which turns a short lead screw which in turn drives the pickup head shaft down to the trays and test sites. Wires and air lines are brought to the pickup head by way of a flexible cable chain mounted under the Z-motor, behind the wall bisecting the long axis of the Y gantry. The wires in the cable chain are high-flexibility flat cable.
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Z-chain
Figure 2-7: Cable Chain to Pickup Head (Left); Z-Chain and Lead Screw Driving Pickup Head (Right)
Some handlers have thermal heads as well as one or more pickup heads. Where multiple gantry lead screws exist, the lead screw that a certain head runs on can be identified by the lead nut.
Figure 2-8: Lead Nutsfor Pickup Head (Left), for Thermal Heads (Right)
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Mechanical Systems
Smart Buckets
Smart Buckets
Some Model 900s may include new "smart buckets," so called because of the sensors they are equipped with. Features of the smart buckets include: Easy to remove Plexiglass front cover Holes for optional padlocking in place Option in software to clear devices-in-bucket counts or not when the bucket is removed
The solenoid (must be 24-volt, not 12-volt!) in back locks the bucket in place. Two sensors are associated with each smart bucket. The sensor in back sees the bucket (Bucket Present sensor). The fiberoptic sensor inside performs two functions: Counts devices as they fall in. Warns when the bucket is full.
Anti-Vibration Feet
The anti-vibration feet are equipped with shock-absorbing rubber pads to isolate the handler from external vibrations. Each foot can be individually leveled.
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Electrical Systems
Main Disconnect Switch
Your handler is equipped with a main disconnect switch (Figure 2-11). Turning off this switch shuts off AC power to the handler and its computer. Therefore, all computers connected to the handler should be shut down properly before turning off this switch. When the main disconnect switch is turned off, it can be locked so that repairs can be made to any component without danger of accidental startup. Thus, it can be used as a lockout procedure.
Figure 2-11: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right)
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Electrical Systems
Power Supplies
The Model 900 uses two power supplies, both "switching" type. The first supplies 24-volt DC for the servo motors and the solenoids. Input is 100 to 240-volt AC and 50-60 Hz. Output is always DC. It auto-selects the correct input voltage. The second power supply is an ATX-style supply for the PC-104 motherboard. The CPU ATXstyle power supply for the PC-104 allows for manual switching. It supplies multiple voltage whatever is required by standard ATX specifications. Input is 115 or 230-volt AC and 50 or 60 Hz, switchable.
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Electrical Systems
Fuses
Figure 2-15: ATX Power Supply Switched to 115 Volts (Left) and 230 Volts (Right) Input
The PC-104 motherboard uses all voltages of the ATX power supply. The PET-C06 I/O PCB uses 5 volts from the ATX power supply. If your handler stands on its own frame, the power supplies are in the CPU box. If your handler is a benchtop model, the power supplies are on the bottom of the machine.
Fuses
The fuses for the handler are standard fuses.
When the handler is plugged into a power source, the bottom AC fuse lights up. When the black power switch is turned on, the middle +5-volt DC fuse lights too. When the yellow CPU reset button is turned on, the top +24-volt DC fuse lights in addition to the other two.
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PC Boards
PCM-8152 Motherboard
This is the main computer board for the Model 900 handler. It uses a PC-104 bus, which allows connection to the PET-C06 board.
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Electrical Systems
PC Boards
5000-M42 Board
All I/Os come from the PET-C06 board. A 40-pin ribbon cable leads to the 5000-M42 board from the PET-C06 board. The 5000-M42 board (Figure 2-19) splits out inputs (sensors, etc.) and outputs (vacuums, blow-offs, etc.). Wires to all assemblies go through at least one Molex connector in order to facilitate repair and change.
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Serial Adapter
If your handler has a large number of motors, it may have a serial adapter or network hub to add serial COM ports.
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Electrical Systems
Sensors
Sensors
Sensors confirm to the Exatron software that various moving parts are at the positions they should be. For example, home sensors tell the software when the pickup assembly, pickup nozzle, and tray carriages are at their home positions.
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Light Pole
The light pole on each machine enables an operator to tell at a glance which machines in a room are running and which machines need attention. Color Red Yellow Green Meaning Problem alert Needs operator assistance, such as reloading Machine is operating and busy
The background colors of the Exatron software confirmation and error messages likewise have similar meanings.
Pneumatic Systems
Pickup Head Shaft
The pickup head shaft is bored through and the vacuum/blow-off pressure passes through the shaft to the suction cup pick-up. Suction cups are available in various sizes, including 2, 4, 6, 8, and 10 millimeters. The typical size is 6 mm. In general, the preferred size is that which covers the largest possible surface of the device without running off the edge of the part or interfering with any other features of the device. However, there may be situations where a smaller suction cup is preferred, specifically in the case of bare silicon devices (FBGA, BGA, etc.).
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Pneumatic Systems
On some models, an optional automatic air shut-off valve is part of the air regulator (Figure 225). This shut-off valve automatically cuts off air to the handler and to the vacuum generators when the power is shut off or any EMO button is pushed.
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On some models, the main air regulator is attached to a sensor, with a pressure switch with digital display on the outside of the handler (Figure 2-26). This switch allows you to set a minimum air pressure, so that if the incoming air ever drops below that limit, the handler will stop.
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Pneumatic Systems
Adjustment valve
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The vacuum and blow-off features of the vacuum generator can be manually actuated by way of override buttons mounted on the side wall of the handler base near the vacuum assembly.
A small adjustment screw can be found on the vacuum generator unit which will increase or decrease the blow-off pressure. CAUTION: Be careful when adjusting this screw, as loosening it will have the effect of increasing the blow-off pressure, but if the screw is turned too much it will come out and render the blow-off inoperable. Refer to the vacuum generator manufacturers manual for a drawing of the location of the adjustment screw. The vacuum generator is fitted with an electronic sensor that measures the strength of the vacuum drawn through the air lines. The sensor measures in centimeters of mercury (cmHg) and displays the result on the small LCD screen of the sensor. When the vacuum is engaged, the display should give a reading for the level of vacuum in the system. The sensor puts out a signal when a given level of vacuum is reached, indicating the vacuum has a secure hold on the device being lifted. For instructions on calibrating the vacuum generator, see "Checking and Setting the Vacuum Generator" on page 6-50. Finally, note the small white filter on the vacuum generator. If this filter becomes visibly dirty or contaminated, it must be replaced. See "Vacuum Generator Air Filter" on page 7-2 for the part number. CAUTION: A dirty filter causes poor handler operation. Replace your filter!
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Pneumatic Systems
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Affects Pusher, test site 1 Pusher, test site 2 Slider, test site 1 Slider, test site 2
Action When pressed, pusher at test site 1 is lowered When pressed, pusher at test site 2 is lowered When pressed, slider at test site 1 is extended over test site When pressed, slider at test site 2 is extended over test site
Figure 2-33: Slide Cylinder Retracted, Push Cylinder Down (Left); Slide Cylinder Extended, Push Cylinder Up (Right)
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Test Sites
Docking Ring
Test Sites
Docking Ring
The Exatron test site docking ring is designed to accept the docking hardware designed for a specific part after it is fitted with a docking plate. The docking plate has tabs along two sides, which mate with tabs in the docking ring.
Sockets
Every type of test socket takes a specific Exatron docking plate. There are two major categories of test site sockets. RF/PI SocketRequires Z axis to clamp part in socket Clamp SocketClamping mechanism attached to Y gantry
Docking Plates
Every new socket board will need a new docking plate designed for it. New docking plates are available on an ongoing basis; if you do not see a plate for your type of socket board, please contact Exatron for an updated list. If we do not have a plate for your socket board, we can design one for it.
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Handlers customized for thermal testing may have thermal heads on a separate assembly. If a handler is equipped with two testers, it will likely have two thermal head assemblies as well. Thermal heads commonly range from a cold of -55 degrees Celsius (using an appropriate chiller) to a hot of 125 degrees Celsius.
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Test Sites
Figure 2-37: Undersides of Thermal Heads with Purge Enclosures (Hot Head on Left, Cold Head on Right)
A clear retractable tube around the thermal head provides a defrost/purge enclosure for the test site. An air dryer is to be used with cold heads below around 50 degrees Fahrenheit or 10 degrees Celsius to prevent frost on the cold head from damaging the devices or test sockets. This dry or purge air provided by the air dryer slightly pressurizes the test area inside the clear tube and prevents moisture from seeping in to cause frost on any components. The usual order of testing, and the recommended best practice, is to test with ambient or room temperature first, then cold, and hot last; so that the device is placed in the output at a slightly warm temperature that collects no frost.
Figure 2-38: Hot Head Descending to Test Site (Left); Hot Head at Test Site (Right)
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Figure 2-39: Cold Head Descending to Test Site (Left); Cold Head at Test Site (Right)
The thermal heads are driven, not by motors, but by air cylinders. They are pushed all the way to the bottom of their path of travel by positive air pressure. The amount of air pressure to the thermal heads can be adjusted in the Exatron software. (See "Air Pressure Group Box" on page 5-67.) Additionally, the thermal head control panel acts like override buttons, enabling you to manually raise and lower the thermal heads and turn on or off the air pressure (Figure 2-41). By fine-tuning the contact pressure at the test socket, the coplanarity of the device and contact surfaces is improved and the life of the contacts or interposers is extended.
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Test Sites
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Tray Configurations
The outline dimensions of Exatrons tray carriages are the JEDEC standard. If a company uses waffle packs, the company-specific waffle packs may be any dimensions that fit the tray carriages.
In the example in Figure 2-42, each tray has 7 columns and 17 rows. A company may also decide to use two different configurations at the same time. One tray carriage may have waffle packs and another may use a single tray. Or each tray may use a different configuration of waffle packs (Figure 2-43).
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A colored tray clamp is used to secure each tray in place. Pull the tray clamp toward the front of the handler and carefully slide in the tray. When the tray is all the way to the back, push the tray clamp back to secure the tray. CAUTION: Be careful when carrying or moving filled trays. Jerking the trays can dislodge devices from their pockets, costing clean-up time.
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Y1 home is at the right end of the Y gantry. If there is a second pickup car or a thermal car, the Y2 home is usually at the left end of the gantry. Z home is at the top of the pickup head. Test site 1 is at the left end of the handler. Tray X1 is at the left. Other trays are counted from left to right: X2, X3, etc. Pin 1 of each tray is always at the upper left, identified by a 45-degree bevel. Pin 1 of each device placed in a tape pocket is usually placed toward the tape sprocket holes.
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Measuring X Distances
The conceptual diagram in Figure 2-45 shows the X distances for a hypothetical tray setup. It follows the example shown in Figure 2-44, each tray having three waffle packs. The packs are labeled with the tray number and the waffle suffix. Thus, the packs in tray X1 are labeled X1_1, X1_2, and X1_3. The packs in tray X2 are labeled X2_1, X2_2, and X2_3. Again in Figure 2-45, the only movement we are dealing with is that of the X motors and trays. The pickup head stays in the back. Each tray must slide a certain distance toward the back, to get the proper device pocket under the pickup head. So the distances to be calibrated are the distances the X tray must move to get the centers of specific device pockets under the pickup head. When using waffle packs, the position of the centers of the first and last pockets of each waffle pack must be measured.
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Figure 2-45: X Motor Diagram for 4-Tray Handler with 12 Waffle Packs
These distances have been filled in for each waffle pack, for the first column and last column. NOTE: These measurements are examples only. Your measurements may differ.
Measuring Y Distances
In Figure 2-46, the only movement we are dealing with is that of the Y motor, which moves the pickup head. So the distances to be calibrated are the distances the Y motor carrying the pickup head must move to be positioned over the centers of specific device pockets.
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Figure 2-46: Y Motor Diagram for 4-Tray Handler with 12 Waffle Packs
These distances have been filled in for each waffle pack, for the first row and the last row. NOTE: These measurements are examples only. Your measurements may differ.
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The important thing to remember is that Z-put (the put height) for each location is higher than Z-get (the pick height) for that same location. Thus, the Z-put distance from Z home (at the top of Zs vertical travel) is a smaller number than the Z-get distance. This is because closer contact is required for the pickup head to pick up a device than to drop it into the pocket. The key to defining a pick height or Z-get distance is to have the suction cup just touching the device, but not flattened on it. The suction cup should be high enough that when you turn on the vacuum, you can see the device lift slightly against the suction cup.
Notice that the suction cup at Z-get (pick height) is just touching the device, but not flattened on it.
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Notice that the suction cup at Z-put (put height) is not quite touching the device.
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Tape-and-Reel Assembly
Some handlers are equipped with a tape-and-reel assembly, or taper. The Model 202 taper uses fixed-width changeover kits that can accommodate devices of certain fixed widths. Alternatively, Model 202 may come with an adjustable-width changeover kit for different sizes or types of devices. A handler equipped with either taper places passed devices into a carrier tape which is then sealed with a sealing tape by either pressure or heat. The supply reel containing the carrier tape is the lower one, sometimes made of cardboard. The takeup reel is directly above it, usually made of plastic. The supply reel containing the sealing tape is toward the front. Supply reel with sealing tape Tape trackcounterclockwise direction Empty/ outof-pocket image sensor Output or takeup reel
The carrier tape is fed in a counterclockwise direction, forward along the underside of the tape track, then backward along the top of the tape track. On the top surface, the gap sensor detects the hole in the center of the empty pocket, and signals the position to the pickup head. When the empty pocket intersects the path of the pickup head, the pickup head places a passed device into the tape pocket.
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Tape-and-Reel Assembly
Gap sensor
Behind the path of the pickup head, an image sensor ensures that a device is present and seated correctly in each tape pocket. Then the filled carrier tape is sealed, either with pressure-sensitive sealing tape or heatsealed cover tape. If pressure heads are used to seal, the pressure is continuous; but if heat seal heads are used to seal, the heat seal heads are pressed against the tape only intermittently to prevent burning. A fiberglass inset sits on the tape track just under the heat seal head. It retains heat at the sealing site instead of being dispersed to the rail. This inset is replaceable when worn. Wheels under the PSA seal head blade facilitate the tapes movement and reduce pulling tension from the drive gear.
Figure 2-52: Pressure Roller Block, Seal Head, and Image Sensor
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When a specified number of pockets have been filled, the takeup reel motor is activated long enough to wind the slack tape onto the upper takeup reel. The drive gear drives the tape along, with teeth that protrude upward to fit the holes on the side of the carrier tape. The pinch roller on the pressure roller block presses down on the tape, keeping it meshed with the teeth of the drive gear (Figure 2-53).
Figure 2-53: Pressure Roller Block (Left); Pinch Roller on Pressure Roller Block (Right)
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Override Buttons
Override Buttons
The override buttons on the taper plate accomplish the same thing the software can do, but in a more direct way. Either may be used, according to the operators convenience.
Taper Buttons Button Top white Second blue Third yellow Affects Seal head Action When pressed, seal head is lowered onto the tape (Figure 2-52)
Customizable option n/a Takeup reel motor When pressed, takeup reel moves, tightening tape slack
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Figure 2-55: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right)
All Model 900s built on their own frame (not benchtop models) are equipped with a main disconnect switch (Figure 2-55). Turning off this switch shuts off all AC power to the handler and computer(s). Therefore, all computers connected to the handler should be shut down properly before turning off this switch.
Conductive gold alodine (Figure 2-56) is a microscopic thin film Exatron uses on aluminum sheeting to provide increased corrosion resistance and impose desired electrical resistance characteristics; that is, to help with EMI shielding.
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Override Buttons
An EMI filter is available as an extra option when CE Marking certification is desired. The EMI line filter smoothes out noise signals coming in on the power line.
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Benchtop Models
If you have a benchtop model, be sure to mount it securely to a stable surface to ensure reliability and functionality.
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When you get the handler to the exact position you want it, lock the wheels down by pressing down on the lever of each wheel to prevent movement. Then you can engage the leveling feet.
Each anti-vibration foot (Figure 3-2) is attached with a right-handed thread. Level the handler by screwing each foot down. Use a carpenters level for best results.
If you have a tester from another vendor, you will need to install it at the test site. Follow the instructions from the tester vendor.
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If Exatron was supplied with sample trays and devices from your company while your handler was being built, the job file that is installed on your handlers computer is factory preset to work with your tray configuration. All you need to do is verify that all the parameters are to your liking. This prodecure is covered in "Verifying the Factory-Installed Job File" on page 3-47. NOTE: Exatron recommends that if you make changes to the job file, you save the changes with a new file name, so that the original job file is preserved with its initial parameters. Instructions on saving a job file are found in "Copying the Job File for Modifications" on page 3-48. If at a later time you change your tray configuration or some hardware, you may need to set up a new job file. Instructions for calibrating a new configuration are found under the section "Fine Tune Window" on page 5-51.
Pickup Head PET-C68-TR-A 4 mm pitch PET-S52-TR-E 4 mm pitch PET-S53-TR-C 8 mm pitch PET-S53-TR-C 8 mm pitch PET-S53-TR-C 8 mm pitch
Tape Track TAPE-925-1-B 8mm-.116 TAPE-924-1-A 12mm-.158 TAPE-779-1-G 12mm-.238 TAPE-923-1-A 16mm-.330 TAPE-923-1-A 16mm-.330
Instructions on Page
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7. Pull down on the head and remove it from the shaft. 8. With the air fittings on the left, push the new pickup head up onto the end of the shaft. Make sure it is all the way up on the shaft. 9. Partially tighten the two screws on the side of the pickup head.
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Shaft hole
Part number
10. Push the pickup assembly to the right, to where the head is flush against the side of the tray. Make sure both front and back ends of the pickup head are evenly against the tray (Figure 3-5). 11. Tighten the two screws on the pickup head. 12. Attach the air hoses in the same order to each nozzle.
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Figure 3-6: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right)
2. If your handler has a black power switch on the computer, turn it clockwise to the ON position. > Benchtop systems have the computer inside the handler, so the yellow CPU reset switch (power button) is on the front of the handler, under the tray carriages (Figure 3-7, left).
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> Systems attached to a cabinet have a separate computer, which is located directly behind the front door of the cabinet (Figure 3-7, right).
Figure 3-7: Powering Up a Benchtop System (Left); Powering Up a Cabinet System (Right)
3. Press the yellow CPU reset switch button. This will power up the computer system. 4. Turn on the monitor if necessary, and at the Windows password prompt, type the username and password. Both username and password are factory-set to exatron. 5. Turn the red EMO (emergency stop) button clockwise to release it. This will power up all the system mechanics. NOTE: On systems using an automatic air shut-off valve, it is especially important to turn on the air regulator before releasing the EMO button. If this is not done, an unpleasant but harmless noise may issue until the EMO button is depressed and released again.
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> The yellow CPU button light will go off when Windows has shut down. 5. You can leave the black power switch turned on. 6. Push in the red EMO (emergency stop) button. 7. If the handler is equipped with a Baco lockable disconnect switch, turn it counterclockwise a quarter turn to the OFF position.
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Figure 3-10: Two Styles of Tray Clamps (Left, Center); Spring Clip (Right)
To secure a tube on the tube holder: 1. Hold the tube with the dowel hole at the top end.
2. Slide the tube up the tube track, holding on the bottom end out away from the dowel.
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3. When the tube reaches the top, push in the bottom end until you hear the dowel snap into the tube hole.
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Two adjustments can be made to accomodate the size of the devices in the tube dead nest area. One is the length of the dead nest, and the other is the height of the dead nest.
Figure 3-15: Tube Dead Nest Area Resized from 16 to 28-Pin Device
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This dimension is important because if the dead nest is too short to accomodate the device, the device will be up-ended, and the pickup head cannot get a grip on the device. If the dead nest is too long, the pickup head may get the device near one end, and it will not be placed into the test site properly.
To raise or lower the adjustment leg, loosen the four screws and push the leg up or down to the correct position. Then tighten the screws.
This dimension is important because if the dead nest is too high, the device will not slide out of the tube smoothly. If the dead nest is too low, devices will be vibrated out and stacked on top of one another before the pickup head comes along.
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3. Thread the tape forward under both of the rollers (Figure 3-20).
Figure 3-20: Carrier Tape from Supply Reel Threaded Under Both Rollers
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4. Open the front tape window latch by pulling it up, then out (Figure 3-21). 5. Raise the tape window and pull the tape through (Figure 3-22). 6. Peel the cover tape back over the top of the window (Figure 3-22).
7. Thread the cover tape over the roller behind the tape window and then under the takeup reel, in a clockwise direction. Tape the end to the reel with ESD-safe
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tape (not Scotch tape) and wind it one or two revolutions. CAUTION: Do not use adhesive tape on the carrier tape, as it contains static electricity and can ruin the static-free condition of the carrier tape.
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8. Fit the tape sprockets over the gear teeth (Figure 3-25).
9. Adjust the tape so it is positioned with the ridge between pockets lining up with the grooves at the front of the tape window (Figure 3-26). 10. Fasten down the tape window, and give a little tug on the front of the carrier tape to ensure the sprocket teeth are engaged in the tape. If it is necessary to adjust the tape position, see the next section.
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To align the detaper forward: 1. Loosen the 6 locking screws on the side plate (Figure 3-27), but do not remove them.
2. Turn the adjustment screw in the back just 1/4 turn (Figure 3-28).
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3. Using the Fine Tune window of Exatron Diagnostics, pick a device from the detaper with the pickup head and put it in the test site. 4. Pick the device back up from the test site and move it over the detaper. 5. Visually inspect its position in relation to the tape. > If its position looks good at this height, lower the pickup head to the Z-put position. > If further adjustment is needed, turn the adjustment screw just 1/4 turn at a time until the device fits perfectly in line with the other sites along the path of the pickup head. 6. When you have finished adjusting the detaper position, tighten the 6 locking screws on the side plate.
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Status light
Reverse Feed button Decrease Pitch Index button Pitch Index Display Increase Pitch Index button
Figure 3-29: Detaper Control Panel
The Pitch Index display number at the bottom of the panel signifies the number of sprocket holes between each pocket center (Figure 3-30, left) or, in the case of multiple simultaneous pickups, between the center of the first pocket to be picked and the center of the last pocket to be picked. Note in Figure 3-30, right, that although each pocket has 2 sprocket holes, the total is only 6, not 8. They are counted from pocket center to pocket center. Thus, 4 pockets at a time will be moved.
Figure 3-30: Counting Number of Sprocket Holes Between Pocket Centers Between Single Pockets (Left), Between Four Pockets (Right)
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To increase this number, press the Increase Pitch Index (+ sign) button below the display once for each increment. To decrease this number, press the Decrease Pitch Index (- sign) button above the display once for each decrement. Above the Pitch Index Display are three directional buttons. The Reverse Feed button is the lowest, surrounded by a down-pointing arrow. The Single Hole Feed button is in the middle, surrounded by a rectangle. The Forward Feed button is the highest, surrounded by an up-pointing arrow. Above the buttons is the status indicator light. To make the detaper ready when the status light is yellow, press the Single Hole Feed button. The status light turns green. To move the tape forward the distance of one pocket, press the Forward Feed button. To move the tape backward the distance of one pocket, press the Reverse Feed button. To move the tape forward the distance of one sprocket hole, press the Forward Feed button while you are holding down the Single Hole Feed button. To move the tape backward the distance of one sprocket hole, press the Reverse Feed button while you are holding down the Single Hole Feed button.
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Setting Up a Taper
Setting Up a Taper
Supply reel with sealing tape Tape trackcounterclockwise direction Empty/ outof-pocket image sensor Output or takeup reel
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If your handler has a taper, include the following procedures in your setup. Task
Changing Taper Changeover Kit for Different Device Sizes Mounting a Takeup Reel Mounting a Supply Reel Replacing the Tape Track Loading the Carrier Tape Loading the Sealing Tape Adjusting the Position of the Taper Adjusting Seal Head Setting Temperature for Heat Seal Head
Page
3-24 3-26 3-27 3-28 3-30 3-33 3-37 3-38 3-45
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Setting Up a Taper
Figure 3-32: Lifting Pressure Roller Arm and Pushing In Keeper Pin
3. Cut and remove the carrier tape and cover tape and the reels they are on. 4. Mount the new size of carrier tape and cover tape reels as described in "Mounting a Takeup Reel" on page 3-26 and "Mounting a Supply Reel" on page 3-27, but do not thread them yet. 5. Replace the tape track tooling as described in "Replacing the Tape Track" on page 3-28. 6. Replace the seal head blade as described in "Changing Seal Head Blade" on page 3-40. 7. Thread the carrier tape and cover tape as described in "Loading the Carrier Tape" on page 3-30 and "Loading the Sealing Tape" on page 3-33. 8. Turn on the handler computer to provide power to the taper. 9. Push and turn the EMO button on the taper control panel to release it. 10. Adjust the gap sensor by loosening the red thumbscrew (Figure 3-33, left) and sliding the sensor left or right a little until the sensor beam sees through the hole in the bottom of the tape pocket. When it does, the Gap LED on the taper control panel lights up (Figure 3-33, right). When the sensor is positioned, retighten the red thumbscrew.
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Figure 3-33: Gap Sensor (Left); Gap Sensor LED Lit (Right)
Make any other necessary adjustments to the taper as described in the rest of this chapter.
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Setting Up a Taper
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4. Loosen the screw on the cover tape guide block assembly and push it to the left (Figure 3-38). 5. Slide the track out to the side and remove. 6. Slide in the new tape track. > You can confirm the size device the tape track uses in two ways. The sample of the correct tape is attached to the side of the track, and the part number is etched on the fiberglass inset on the top of the track (Figure 3-37).
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Setting Up a Taper
Figure 3-37: Tape Track with Part Number and Sample Tape
7. Screw in the two track screws. 8. Insert the air hose into the fitting.
> If you need to change the guide block, slip it off the guide rod and replace the new guide block on the rod (Figure 3-39).
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9. Adjust the guide block to fit directly over the carrier tape and sealing tape. 10. Push the guide block down so that it is flush against the carrier tape. 11. While holding the thin edge down, tighten the adjustment screw on the guide block assembly (Figure 3-51).
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Setting Up a Taper
2. Push it toward the front of the underside of the tape track. Until it gets to the front, there are no more guides to thread it through. You can see the tape slack under the track. 3. At the bottom front is another guide. Thread the tape through it. 4. Bring the tape to the top side and thread it through the guides.
Figure 3-41: Carrier Tape Under Guide At Top Front of TrackSide View (Left); Top View (Right)
5. Continue feeding the carrier tape leader under the sealing heads. The sealing heads should be raised above the level of the carrier tape at this point. 6. When the carrier tape leader in the track reaches the pressure roller block, raise the top screw with your index finger and hold it while you push the keeper pin to the right, into the pressure roller block. This holds the pressure roller
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block in the raised position while you feed the carrier tape along the track underneath.
Figure 3-42: Lifting Pressure Roller Arm and Pushing In Keeper Pin
7. 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.
8. Let down the pressure roller block by slowly pulling the keeper pin out to the left until the pinch roller is lowered and just the right pressure on the tape.
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Setting Up a Taper
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 3-45), with the tape coming off the bottom of the reel.
3. Viewing from above, position the sealing tape supply reel centered over the carrier tape in the carrier tape track. Tighten the adjustment set screw on each
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supply reel adjustment collar to secure the sealing tape supply reel in this position on the rod. 4. As shown in Figure 3-46, the sealing tape unwinds from the bottom of the reel in a counterclockwise direction toward the sealing tape guide assembly. Feed the sealing tape to the right over both pins of the sealing tape guide assembly and then under the guide block to the left. Notice that the tape rests on the upper, larger projecting pin but never touches the lower, smaller projecting pin.
Figure 3-47: Model 202 Sealing Tape Threaded to Sealing Tape Guide Assembly (Left); Sealing Tape Threaded Under Guide Block (Right)
> Guide blocks come in widths from 8 mm to 72 mm (up to 120 mm by special order). There are two sets of grooves on the underside of the guide block.
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Setting Up a Taper
The outer set of grooves guides the carrier tape. The inner set of grooves guides the sealing tape.
Figure 3-48: Two Widths of Guide BlocksTop View (Left); Bottom View (Right)
Figure 3-49: Placement in Grooves of Guide Blockof Sealing Tape (Left) and Carrier Tape (Right)
5. Check to make sure the guide block is the right width for the tape you are using. 6. Loosen the side screw on the guide block assembly. > If you need to change the guide block, slip it off the guide rod and replace the new guide block on the rod (Figure 3-50).
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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 screw on the guide block assembly (Figure 3-51). The carrier tape should now be inside the outer set of grooves on the guide block.
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Setting Up a Taper
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.
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3. Using the Exatron Diagnostics software, place a set of devices in the tape with the pickup head. > If necessary, readjust the taper alignment knob and repeat the placement test. 4. When the alignment is perfect, retighten the 4 bolts.
Type
Heat seal PSA Heat seal PSA
Blade Number
TAPE-869 TAPE-953 TAPE-872 TAPE-952
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Setting Up a Taper
Size
16 mm 16 mm
Type
Heat seal PSA
Blade Number
TAPE-873 TAPE-954
Figure 3-53: Two Sizes of Heat Seal Blades: 16mm, Top, and 12mm, Bottom
Notice in Figure 3-53 that whereas different blade sizes are the same length, the spacing of the runners is what determines the width in millimeters. The runners on the top blade are spaced 16 mm apart, while the runners on the bottom blade are spaced only 12 mm apart. Pressure seal blades
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Figure 3-56: Seal Head with Empty Rails for Blade Insertion (Back View)
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Setting Up a Taper
2. To insert a different blade, insert a screwdriver as shown in Figure 3-55 and push up on the movable screw and hold it. Slide the blade in from the left with the smooth side up and the dowel hole toward you (Figure 3-57), then release the screw. 3. Center the blade under the seal head, sliding it back and forth until you can hear it snap and feel it catch.
Figure 3-57: Pressure Seal Blade Inserted Partway into RailTop View (Left), Side View (Right)
Notice that the blade must be inserted with the smooth side up and the hole out toward the operator (Figure 3-57, left). When it is slid into the rails of the seal head, it does not touch the surface of the tape track (Figure 3-57, right).
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Figure 3-58: Six Lateral Adjustment Screws for Seal Head; Thumbscrew for Small Adjustments
4. Retighten the six screws. 5. Once the head is aligned, turn the heat to the sealing head back on. Set the temperature on the heater to the desired heat. Wait until the display has stabilized. WARNING! Do not touch the heat seal heads directly when the heat is turned on. 6. After the sealing head has warmed up, check the seal on the sealing tape. Manually engage the seal head. Apply pressure to the sealing tape for 3 to 5 seconds. Use the takeup arm to engage the head. This should cause a good seal to the carrier tape. Manually advance the carrier tape and inspect the seal. 7. Run the carrier tape for several pockets with the seal head engaged. NOTE: You may need to practice this adjustment a few times by running the machine briefly at the start of a job and inspecting the seal for quality.
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Setting Up a Taper
Adjustment valve
Figure 3-60: Auxiliary Air Regulator for Seal Head Pressure
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Setting Up a Taper
A general guideline may be to use somewhere around 275 to 325 degrees Fahrenheit for a heat seal. A narrow carrier tape takes a lower temperature to prevent burning. If in doubt, it is better to start with a lower temperature and test it, then increase little by little as needed. To set the temperature: On the Taper window of Exatron Diagnostics, set the temperature to the desired temperature (in Celsius) and then click the Set Temperature button. Temperature in Fahrenheit
77 275 300 325 350
Temperature in Celsius
25 135 149 163 177
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See also "Checking Omega Temperature Controller" on page 6-66. However, be aware that the Exatron software settings will override any different settings manually set. To turn off the heat seal head: On the Taper window of Exatron Diagnostics, set the temperature to 25 degrees Celsius and then click the Set Temperature button.
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. Buttons on Main Window Button Function Diagnostic Open a window with tabs to access various software settings and diagnostic procedures. For More Information Chapter 5
page 4-2
page 3-54
3-47
3. In Explorer, find the Exatron folder directly under the C drive, thus: C:\Exatron. Double-click it to open it.
4. Find the job file. It has the filename extension of .job or .edf (Exatron data file). 5. Right-click on the job file. A context menu opens. 6. Click Copy on the context menu.
7. Deselect the job file name by clicking somewhere else on the screen. 8. Right-click on the screen. A context menu opens.
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10. Scroll to the bottom of the screen and find the copied file. Its name is Copy of ___.job or Copy of ___.edf. 11. Click once on the file to select it.
12. Click inside the filename. The cursor appears, indicating that you can retype the name.
14. Press the Enter key on your keyboard. Now the copy has a new name. Make any modifications to this copy. Make sure the file is saved to the Exatron folder.
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2. Enter the correct password. The factory-set password is P1. This may be changed at any time with the Change Password button. 3. Inside the dialog box, open the file containing the factory presets.
CAUTION: It is strongly recommended that you dont make changes to the factoryset job file. If you need to make changes, first make a backup copy of the original job file, and experiment with the copy.
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The job file that came with your handler has been preset to fit the configurations you specified. You need to do a verification of all the settings and distances in the job file before you begin a production job in Auto Run. See the next section.
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Settings to Check Destinations for various sort categories Set temperatures for thermal testing 5-44 5-100
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Both for trays and for waffle packs, rows are counted from the back of the tray to the front. Columns are counted from left to right.
X1_3 Column 1
X1_3 Column 6
Figure 3-68: Example of Row and Column Layout for Waffle Pack
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NOTE: Before beginning a production run, be sure the input devices are secured, as discussed in "Securing Trays or Tubes" on page 3-9.
To release the EMO button, turn it clockwise until it pops out again. Some handlers have HALT and RUN buttons near the EMO button. These hardware buttons work just like the Exatron software buttons Pause or HALT and Continue or RUN in the Auto Run window.
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Pressing HALT pauses the handler, while it keeps count of the devices. NOTE: After depressing the HALT button, you must press HALT a second time to release it and permit RUN to be pressed. Pressing RUN resumes the Auto Run where it left off.
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Log File
Work Mode
Count
Messages
Pause
Continue
Enable/Disable Socket On This button is displayed for handlers having more than one The Fly test site. If one site becomes dysfunctional, you do not have
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to stop the job and leave Auto Run. You can click this button to continue the job using only the functional test site. If you need to disable a socket during the production run, click Pause, then click the Enable/Disable Socket On The Fly button. Then click Continue to proceed without exiting the Auto Run window.
Clear X[n]
If you stop the handler in the middle of a job, one or more trays may still be in the work area. To home them, or move them out of the way to the front, click the button that controls each tray: Clear X1, Clear X2, etc. Click this button to begin the processing of devices in Auto Run. First, the Load Job dialog box is displayed (Figure 4-3). Open the file that corresponds with the type of device you want to run. Next, a dialog box is displayed (Figure 4-4) that lets you specify the first tray pockets to pick from (input) and put to (output). To start at the beginning of each tray, click the Reset Input/Output Trays buttons. Or you can type a different row and column to start with for the input and/or output, if you had stopped in the middle of a run.
Auto Run
End of Lot
Click this button to stop the handler from searching for more devices before the number of empty pockets specified has been reached. Any devices that remain at the test site(s) are tested, then the pickup head takes these last tested devices to their sorted destination. Then all motors are sent home. The Stop button completely stops the motors. However, the part count for the current run is kept. You will have the option to continue the counts where you last stopped when you restart the run. Click Exit to return to the main window.
Stop
Exit
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4. In the Load Job dialog box, select the correct job file to load. 5. In the Start Picking Up dialog box, specify the tray row and column to start with. > You will be asked whether you want to continue the counts where you last stopped, or to reset all counts. Reset All Counts Click this button to reset the total counts to zero. If the handler has a taper, the number of pockets specified (on the Setup Parameters window, Figure 4-5) between the pickup head drop-off and the image sensors inspection will not be inspected for devices present. Click this button to start where you stopped before. If the handler has a taper, the number of pockets specified (on the Setup Parameters window, Figure 4-5) between the pickup head drop-off and the image sensors inspection will be inspected for devices present.
Continue
The handler first checks that all the test sites are empty. If there are any devices in the test sites, they are moved to the flush bin. Next the handler begins testing devices. After testing, each device is placed in the next consecutive pocket, both for pass and fail locations. The order of placement is as follows: rows 1 to last in column 1 are filled, then rows 1 to last in column 2 are filled, etc. As each device is processed, its sort category is added to the count. When an input tray or tube is empty, a message is displayed to replace the input tray or tube. If this is the end of the job, click End of Lot. If more devices need to be tested, load more devices and click Continue. When an output tray or tube is full, a message is displayed to replace the output tray or tube. If this is the end of the job, click End of Lot. If more devices need to be tested, load more devices and click Continue. If you click Pause, you must first click Continue before you can click End of Lot to interrupt and go back to Diagnostics. Clicking End of Lot clears any parts out of the system that are in progress. Now you can click Exit to close Auto Run. Then you can re-enter Diagnostics if desired.
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In Figure 4-6, a running account of the actions is shown in the Messages display.
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Would you like to initialize Click Yes or No. Tape and Reel? Clicking Yes has the same effect as clicking the Initial Taper button on the Taper window in Diagnostics. It homes the tape, or moves it to the Gap sensor and then to where the next empty pocket is under the path of the pickup head. Click No if you want to restart a job that is already in the correct position. The tape is not advanced before Auto Run begins. Advance Leader Counts This is the the number of empty tape pockets to be advanced at the start of Auto Run, or when the Advance Leader button is clicked on the Auto Run window. The default number comes from the Leader Count box in the Taper window of Diagnostics. You can type a different number of leader pockets for the current run, but the changed value is not saved. The next time Auto Run is opened, the default value will be shown again. This is the number of empty tape pockets to be advanced at the end of Auto Run, or when the Advance Trailer button is
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clicked on the Auto Run window. The default number comes from the Trailer Count box in the Taper window of Diagnostics. You can type a different number of trailer pockets for the current run, but the changed value is not saved. The next time Auto Run is opened, the default value will be shown again. Current Tape Counts The number of devices already placed in the tape is displayed incrementally. You can change this number if necessary. For example, if the number of devices previously processed in this job was 3, but the tape has advanced two empty pockets, you can manually place two passed devices in the empty pockets behind the pickup head. Then you can change the number 3 to 5, and the count will be correct again. Total Tape Counts The total number of devices to be placed in the reel of tape is displayed here. You can change this number if necessary. Type the total number of devices to be run in a job. This number may be equal to or greater than the number in the Tape Total Count box. If this number is greater, when the tape is filled with its quota, a message is displayed in Auto Run. If the option to Continue is selected, the extra devices in the job run will be placed in a tray rather than in the tape. Click this button to start the Auto Run. Click this button to close this box and return to the Auto Run window.
OK Cancel
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If your handler uses multiple test sites, you may see an added section showing the percentage of devices tested at each socket that were passed.
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Chapter 5: Diagnostics
Chapter Overview
This chapter describes diagnostic tasks for the Model 900, accessed by clicking the Diagnostic button on the main window.
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Chapter 5: Diagnostics
Diagnostics Windows
The windows available from the Diagnostic button allow every mechanical and electrical action of the handler to be checked and tested. Usually, best results are obtained when the windows are used in order, from left to right. However, there may be occasions when it is feasible to use the features of just one or two of the windows. The following are the windows available from the Diagnostic button. Your handler has only the ones used in your setup. You can access each of the Diagnostics windows by clicking on its tab at the top of the screen. Window Input / Output Check Function Page
Tests signals between hardware and software (This window was formerly 5-7 split into Sensor Check and Solenoid Check) Check Tube Latches Gives temporary display of output tube sensor actions 5-25 Setup Parameters Sets timing of various actions 5-26 Sort Interface Directs the disposition or placement of devices in various conditions; 5-43 determines which sort goes to which bin Motors Setup Sets or displays the speed of the various motors; tests motor movements 5-47 Fine Tune Sets distances between various motor positions and tray pockets 5-51 Thermal Setup (Optional) Sets hot/cold temperatures 5-100 Taper (Optional) Sets information about tape; sets reel motor speeds 5-103
NOTE: Your handler software may not display every box or button for various options discussed in this manual. Rest assured that your handler and its software have been customized for your companys needs.
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Diagnostics Windows
To access the Diagnostics windows: 1. On the main window, click the Diagnostic button. 2. Enter the correct password. The factory-set password is P1 (Figure 5-2).
> The Load Job dialog box is displayed (Figure 5-3). 3. Open the file you need to check or modify.
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Chapter 5: Diagnostics
At the bottom right of each tabbed window in Diagnostics are two functioning buttons.
OK
Clicking this button exits Diagnostics and displays the Save As dialog box, where you are given a chance to save your changes under a new file name. Clicking this button exits Diagnostics and returns to the main window without saving any changes.
Cancel
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Diagnostics Windows
Following are some examples of test site clamps, each consisting of a slider (horizontal, forward-backward motion) and a pusher (vertical, up-and-down motion).
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Chapter 5: Diagnostics
Figure 5-7: Slide Cylinder Retracted (Left); Slide Cylinder Extended (Right)
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Chapter 5: Diagnostics
Click this button to turn off all the motors. Click this button to turn on all the motors.
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Chapter 5: Diagnostics
Port Selection
Click the dropdown arrow to the right of the box, and click the port page you want to access. For each input, a checkmark toggles on or off when the input is activated. For each output, click to place a checkmark and toggle on or off the output.
Input
Output
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Figure 5-12: Input / Output Check WindowPort for Pickup Nozzle Vacuums
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Chapter 5: Diagnostics
Figure 5-14: Input / Output Check WindowPort for Motors Homing and Thermal Heads
Figure 5-15: Input / Output Check WindowPorts for Signal Lights, Run and Halt Buttons
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Figure 5-16: Input / Output Check WindowPort for Handler with Four Pusher/Sliders
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Chapter 5: Diagnostics
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Chapter 5: Diagnostics
The extra sensors here apply to the thermal head cylinders. Left Thermal 1 Up This sensor detects when the left thermal cylinder on the left thermal head assembly (Y2) is up, at its home position. This sensor detects when the right thermal cylinder on the left thermal head assembly (Y2) is up, at its home position. This sensor detects when the left thermal cylinder on the right thermal head assembly (Y3) is up, at its home position. This sensor detects when the right thermal cylinder on the right thermal head assembly (Y3) is up, at its home position.
Left Thermal 2 Up
Right Thermal 1 Up
Right Thermal 2 Up
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Figure 5-24: Input / Output Check WindowPort for Handler with Tubes
Lead In [1-8]
These are output tube counter sensors. Each time a device passes the sensor and drops into one of the 8 output tubes, the count for that tube is incremented, and a checkmark flashes briefly. To view a record of which tubes had devices pass these sensors, see "Check Tube Latches Window" on page 5-25.
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Chapter 5: Diagnostics
These are output tube present sensors. When a tube is present, the corresponding box is checkmarked. When you check any of these boxes, the corresponding LED on the output tube holder lights up.
Figure 5-25: Input / Output Check WindowPort for Handler with Taper
Taper Outputs
Output Seal Head Down Carrier Tape Vacuum Take Up Motor On Trigger Camera Lower seal head
Turn on carrier tape vacuum under the pickup head drop site; helps to seat devices in pocket Turn on takeup reel Trigger an inspection of a tape pocket by the image sensor
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Output Load Inspection Job Inspect Job Bit 0 Inspect Job Bit 1 Inspect Job Bit 2
Check Box To... Load the inspection file specified in the following 3 boxes Switch the binary bit in the 0 position to a high signal to load an inspection file to the camera Switch the binary bit in the 1 position to a high signal to load an inspection file to the camera Switch the binary bit in the 2 position to a high signal to load an inspection file to the camera
Bit 1 Position
0 0 1 1 0 0 1 1
Bit 0 Position
0 1 0 1 0 1 0 1
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Chapter 5: Diagnostics
Thus, the boxes checked correspond with the binary digit positions. A checked box sends a 1 or high signal; an unchecked box sends a 0 or low signal. Thus, if the Inspect Job Bit 0 box is checked but the other two are not checked, the signal sent is 001, where bits 2 and 1 are zeros and bit 0 is 1.
Figure 5-27: Bit Settings for Inspection Files with Binary Numbers 000, 001, and 010
Figure 5-28: Bit Settings for Inspection Files with Binary Numbers 011 and 100
After you have set the bits by checking the appropriate Inspect Job Bit boxes, then check the Load Inspection Job box to load the specified inspection file to the camera. Loading an inspection file by these job bits can hold only 8 files. You must manually load additional files to the camera.
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Sensor lights
Override buttons
Figure 5-29: Taper Control Panel with Sensor Lights and Override Buttons
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Chapter 5: Diagnostics
Taper Inputs
Input Empty, Out of Pocket, Tape Inspection Gap Heater Alarm Slack Switch Tape Out Error Box Is Checked When... Pocket under sensor is not empty Gap sensor cannot see through pocket hole Present value and set value are same temperature Tape is not taut and takeup arm is down Tape is not out; continuing tape supply
Empty/out-ofpocket sensor
Figure 5-30: Tape Track with Empty/Out-of-Pocket Sensor and Pickup Head
The image sensor performs the function of an Empty/Out of Pocket sensor. The image sensor is located behind or to the left of the pickup heads drop point for the taper. If a device is missing or not seated correctly in the tape pocket, the Empty/Out of Pocket sensor stops the taper and a message is displayed onscreen. The Gap sensor is located in front of or to the right of the pickup heads drop point for the taper. It finds the home position for the tape and ensures correct offset after homing.
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Figure 5-31: Taper Model 202 with Slack Switch and Heat Sensors
The Slack Switch sensor is located on the side of the taper plate (Figure 5-31). When the motor for the takeup reel turns on, the tape is wound onto the takeup reel. The tape becomes taut and raises the tape arm to block the slack switch sensor (Figure 5-32). When the sensor is blocked, it stops the motor on the takeup reel. After a number of tape pockets have been filled and advanced, the tape arm again falls, the sensor is uncovered, and the takeup motor again turns to take up the slack.
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Chapter 5: Diagnostics
The Heater Alarm sensor is located inside the heating unit seal head (Figure 5-33). The heater controller display is located on the side of the tape-and-reel plate (Figure 5-31).
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Lead In [1-8]
These are output tube counter sensors. Each time a device passes the sensor and drops into one of the 8 output tubes, the count for that tube is incremented, and a checkmark is placed in the corresponding checkbox until the Clear Lead In Latches button is clicked. These are output tube present sensors. Each time a tube is withcrawn from the output tube holder, a checkmark is placed in the corresponding checkbox until the Clear Tube Switch Latches button is clicked. Click this button to clear the checkmarks from all the Lead In checkboxes. Click this button to clear the checkmarks from all the Tube Switch checkboxes.
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Chapter 5: Diagnostics
Handlers Using
Test sites Pickup head rotation/taper Test sites Custom Trays Taper Taper Precisor Trays Trays Multiple test sites Tubes "Smart" buckets Multiple test sites Custom Thermal heads/preheat sites
Page
5-29 5-32 5-33 5-34 5-35 5-36 5-36 5-37 5-38 5-39 5-39 5-40 5-40 5-41 5-41 5-42
NOTE: The settings displayed come from the file you opened at the beginning of the diagnostic session. If you opened the file containing the factory presets, you will likely not need to change the factory settings unless a piece of hardware or a tray configuration is changed. If you make changes, save them under a new file name.
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Chapter 5: Diagnostics
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The following parameters apply to events occurring at the test site. Vacuum On After issuing the command to turn on the vacuum, the handler waits the number of milliseconds shown before giving the next command (to check the vacuum sensor to see if a device is attached to the pickup head). You may have to change this setting for different devices due to size, weight, test time, etc. Vacuum Off After issuing the command to turn off the vacuum, the handler waits the number of milliseconds shown before giving the next command (to turn on the air blower). You may have to change this setting for different devices due to size, weight, test time, etc. Air Blow On After the vacuum is turned off, this is the number of milliseconds the air blower stays on to blow a device off the pickup head.
Z Put (Before Vacuum Off) After issuing the command to move the pickup head to the Zput position, the handler waits the number of milliseconds shown before giving the next command (to turn the vacuum off). Socket Open/Close After actuating the socket, the handler waits the number of milliseconds shown.
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Chapter 5: Diagnostics
Push Cylinder Up
After issuing the command to retract the push cylinder up from the test site, the handler waits the number of milliseconds shown before giving the next command. After issuing the command to extend the push cylinder down to the test site, the handler waits the number of milliseconds shown before giving the next command (to begin the test). After issuing the command to extend the slide cylinder out over the test site, the handler waits the number of milliseconds shown before giving the next command (to extend the pusher down to the test site). This option is available only for handlers that use a slider/pusher cylinder for depositing devices in the test socket.
After issuing the command to retract the slide cylinder in from the test site, the handler waits the number of milliseconds shown before giving the next command (to check the home sensor to see if the slider is at its home position). This option is available only for handlers that use a slider/pusher cylinder for depositing devices in the test socket.
If your handler is equipped with auxiliary push/slide cylinders or a Y2 head used as a plunger, this option is available. Check this box if you want to use the Z plunger/pickup head as the top pusher. Unheck this box if you want to use the normal top pusher.
When you use the normal top pusher, the Z pickup head drops the device into the test socket, then raises and waits for the slider/pusher cylinder to move in and clamp the device into place during the test. After the slider/pusher cylinder retracts, the Z pickup head again lowers and picks up the device to move it to its destination. > If you are using more than one test site, you
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When you use the Z plunger/pickup head as the top pusher, the Z pickup head never lifts off the device, but is used to clamp the device in place while its in the test site. > Using the Z plunger/pickup head as the top pusher is faster than using the normal top pusher if you have only one test site. Also, you can use it if you enable only one test site.
Figure 5-38: Using Normal Top Push Cylinder (Left); Using Z Plunger/Pickup Head (Right)
Check this box to activate the specified pickup nozzle to be part of the normal pick-and-place routine. Uncheck this box to deactivate the specified pickup nozzle. Check this box to get devices from the golden unit at tray 2 for testing. Uncheck this box to get devices from the precisor/golden unit tray by the test site for testing.
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Type the number of milliseconds given the rotation to finish before any other action occurs on the handler. Type the number of degrees each device is to be rotated clockwise from the input to the test site. See "Results of Rotation Combinations" on page 5-33 for examples. Type the number of degrees each device is to be rotated clockwise from the input to the tape. See "Results of Rotation Combinations" on page 5-33 for examples. Type the number of degrees each device is to be rotated clockwise from the input to the output tray. Type the number of tape pockets to fill with devices and seal in a job. Type the total number of devices to be run in a job. This number may be equal to or greater than the number in the Tape Total Count box. If this number is greater, when the tape is filled with its quota, a message is displayed in Auto Run. If the option to Continue is selected, the extra devices in the job run will be placed in a tray rather than in the tape. Type the allowable number of consecutive empty tray pockets before a message to add a tray of devices is displayed in the Auto Run window. Type the number of milliseconds after the seal head goes down to the tape before the tape is moved.
Rotation Delay (msec) Test Site Rotation (Degree) Taper Output Rotation (Degree)
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Type the number of milliseconds after the heat seal head rises from the tape before it can be lowered again. This box is used only for handlers designed such that the time between deposits into the tape is so short that there is danger of melting the tape from almost constant thermal tape sealing.
Actions The pickup nozzle gets a device and rotates it clockwise 90 degrees from the input before placing it at the test site. Because the tape rotation is the same degree, the device is then placed in the tape at the same angle. Rotation occurs only once during this process.
Test
Output
The pickup nozzle carries an unrotated device to the test site and tests it. Then it rotates it clockwise 90 degrees from the input before placing it into the tape pocket. Rotation occurs only once during this process.
Test
The pickup nozzle gets a device and rotates it clockwise 90 degrees from the input before placing it at the test site. After testing, it then rotates the device counterclockwise before placing it into the tape pocket. Thus, the devices rotation at the tape in relation to its original position at the input is 0. Rotation occurs twice during this process.
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If your handler uses Transistor-Transistor Logic (TTL, 0 to 5 volt) to communicate with the test site, select this option. See your tester manual for details. All devices will be placed in the destination for passed devices. No actual testing of devices will occur. All devices will be placed in the destination(s) for failed devices. No actual testing of devices will occur. Devices will be randomly placed in the destinations for passed and failed devices. No actual testing of devices will occur. If your handler uses one of the RS-232 languages to communicate with the test site, select this option. See your tester manual for details. See also "Exatron RS-232 Commands" on page A-10. If your handler uses the GPIB interface to communicate with the test site, select this option. Rather than using a random simulation, you can specify the exact results for each test socket. Use this option along with the values you type in the Simulated Fixed Test Results group box, described in "Simulated Fixed Test Results Group Box" on page 5-41.
RS-232
GPIB
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Vacuum On/Off
After issuing a vacuum command, the handler waits the number of milliseconds shown before checking the vacuum sensor to see if a device is attached to the pickup head. You may have to change this setting for different devices due to size, weight, test time, etc.
Air Blow On
After the vacuum is turned off, this is the number of milliseconds the air blower stays on to blow a device off the pickup head.
Z Put (Before Vacuum Off) After the pickup head moves to the Z-put position, the handler waits the number of milliseconds shown before turning the vacuum off.
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Vacuum Off
After issuing the command to turn off the vacuum at the taper, the handler waits the number of milliseconds shown before raising the pickup nozzle. You may have to change this setting for different devices due to size, weight, test time, etc.
Air Blow On
After the vacuum is turned off, this is the number of milliseconds the air blower stays on to blow a device off the pickup head.
Z Put (Before Vacuum Off) After the pickup head moves to the Z-put position, the handler waits the number of milliseconds shown before turning the vacuum off.
Check this box to turn on the vacuum at the tape pockets under the pickup head. Uncheck this box to turn off the vacuum.
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Number of Pockets Before Type the number of tape pockets to advance between the Start Checking for back pocket under the pickup head and the first pocket under Devices in Tape Pockets the image sensors vision. This prevents the image sensor from checking empty pockets before the filled tape reaches the image sensor. Tape Total Count Type the number of tape pockets to fill with devices and seal in a job. Type the total number of devices to be run in a job. This number may be equal to or greater than the number in the Tape Total Count box. If this number is greater, when the tape is filled with its quota, a message is displayed in Auto Run. If the option to Continue is selected, the extra devices in the job run will be placed in a tray rather than in the tape.
Vacuum On
After issuing the command to turn on the vacuum, the handler waits the number of milliseconds shown before giving the next command (to check the vacuum sensor to see if a device is attached to the pickup head). You may have to change this setting for different devices due to size, weight, test time, etc.
Vacuum Off
After issuing the command to turn off the vacuum, the handler waits the number of milliseconds shown before giving the next command (to turn on the air blower). You may have to change this setting for different devices due to size, weight, test time, etc.
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Air Blow On
After the vacuum is turned off, this is the number of milliseconds the air blower stays on to blow a device off the pickup head.
Z Put (Before Vacuum Off) After issuing the command to move the pickup head to the Zput position, the handler waits the number of milliseconds shown before giving the next command (to turn the vacuum off). Y1 Precisor Offset This is the distance the pickup nozzle moves to the left before dropping the device at the precisor. Check this box to cause an air blast in each precisor tray pocket to snug the device against the upper right corner. Check this box to lower the pickup nozzle from the Z-put to the Z-get position, and then to the Z-compress position before turning off the nozzles vacuum. Uncheck this box to allow the device to fall free from the Z-put position.
Enable Precisor
Check this box to enable, or use, the designated tray or waffle pack as an input. Uncheck this box to disable the designated tray or waffle pack.
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Check this box to enable, or use, the designated tray or waffle pack as an output. Uncheck this box to disable the designated tray or waffle pack.
Select Tray
Click the drop-down arrow and select the tray or waffle pack whose dimensions you want to describe. Type the number of rows in your tray or waffle pack. Rows are counted from the back of the tray to the front. Type the number of columns in your tray or waffle pack. Columns are counted from left to right. After defining the number of rows and columns for the first tray or waffle pack, you can click this button to apply the same number of rows and columns to all trays or to all waffle packs. Only the ones checked in the Enable Input Trays group box will be used.
Number of Rows
Number of Columns
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Check this box to enable TS1 (the left test site). Uncheck this box to disable TS1. Check this box to enable TS2 (the right test site). Uncheck this box to disable TS2.
Enable Tube[n]
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This bypasses the tester for diagnostics. You can set fixed test results here rather than random pass/fail diagnostic results, so you know whether the exact same results are being returned. For each test site, the left input box is for the leftmost LZ1 nozzle, working right until the right input box is for the rightmost LZ6 nozzle. To use the simulated fixed test results feature, in the Test Interface box, select the Simulated Fixed Test Results option. Then type the desired sort in each box.
Type, in inches, the distance you want the tray to move toward the front of the handler while rubbing. This applies only if you enable the rub routine. Type, in inches, the distance you want the Y gantry to move to the left while rubbing. This applies only if you enable the rub routine.
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Type, in inches, the distance you want the Z pickup head to lower while rubbing. This distance should be 0.005 or 0.010 mm more than the Z-get distance. This applies only if you enable the rub routine. Check this box to enable the rub routine. Uncheck this box to disable the rub routine.
Rubbing On/Off
Figure 5-52: Thermal Soak Time Delay Group Box of Setup Parameters Window
This is the number of seconds after the thermal heads lower to touch the devices in test site 0 (the left test site) before the test begins. This is the number of seconds after the thermal heads lower to touch the devices in test site 1 (the right test site) before the test begins. This is the number of seconds after the devices are placed in the back row of the preheating plate before they are moved on to the test site. This is the number of seconds after the devices are placed in the middle row of the preheating plate before they are moved on to the test site. This is the number of milliseconds after the handler software issues the command to lower the thermal head cylinders before the next command is issued, to test the devices.
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This is the number of seconds after the handler requests a temperature reading from the thermal head and the handler waits for a temperature response before it times out. Click this button only if you want to save changes under the current file name. To open a dialog box so you can save changes under a new file name, click the OK button instead.
Save Parameters
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Sorts are logical categories determined from the tester (or inspection, if used). For each destination, type the number of the designated sort category to be placed there. NOTE: All like sites are numbered from left to right.
[Destination]
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Type the number of milliseconds the handler will wait after a device is placed in a test socket and before the device testing begins.
After a device test, a checkmark is displayed in the corresponding sort box according to which sort the tester sent to the handler software. Put a device in the test site, then press the Start Test button. The tester sends the sort result to the software, which places a checkmark in one of the 8 sort boxes according to the correct sort result. To confirm the sort result, compare the display here with the display in your tester software window. When you have finished confirming the result, click the Clear Latch button to clear the checkmarks from the latch displays.
Start Test
Clear Latch
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When the Gap sensor sees through the hole in the center of the tape pocket, the LED light on the taper cabinet turns on, and the software places a checkmark in this checkbox. When the Out-of-Pocket sensor sees a blockage across the top of the tape pocket, the LED light on the taper cabinet turns on, and the software places a checkmark in this checkbox. When the Empty Pocket sensor sees through the hole in the center of the tape pocket, the LED light on the taper cabinet turns on, and the software places a checkmark in this checkbox. When the Bucket Full sensor sees a device drop past it into the specified bucket, the software places a checkmark in this checkbox. When the Tape Out sensor sees no more carrier tape, the software places a checkmark in this checkbox. When you have finished confirming the results, click the Clear Latch button to clear the checkmarks from the latch displays.
Save Parameters
Click this button only if you want to save changes under the current file name. To open a dialog box so you can save changes under a new file name, click the OK button instead.
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This window sets or displays the speed of the various motors and tests motor movements. The settings on this window allow you to move the motors manually. This is a way to test, exercise, and clean the motors. You can select the motor you want to test. CAUTION: Before you move the motor positions, make sure there is no interference that will produce a collision. You can also use this window to turn off one or all motors. When a motor is turned off, the assembly it controls is freely movable by hand. Thus, you can move an assembly out of the way to perform inspections or repairs. To turn the selected motor back on, click the Motor On button; or to turn all motors back on, click All Motors On. When you first access the Motors Setup window after each computer startup, the motors reset. You see the message: Resetting Motors, please wait... When all the motors have moved to their home positions, this window becomes available.
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The motor acceleration, or RPM2, is displayed. This setting can be changed only by the administrator. The motor speed, or RPM, is displayed. This setting can be changed only by the administrator. The motor deceleration is displayed. This number is a percentage of the acceleration. For example, if the acceleration
Velocity
Deceleration (% of Acceleration)
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is 2000 RPMs and the deceleration is 100 percent of that, then the deceleration is also 2000 RPMs. If the deceleration is 50 percent of that, then the deceleration is 1000 RPMs. This setting can be changed only by the administrator. CAUTION: Changing motor settings may cause damage to the handler and devices. Position (inches) Type a distance from home position, in inches, that you want the specified motor to move to when you click the Motor Move To button. Click this button to move the selected motor to the position shown. Click this button to move the selected motor to its home position. Click this button to turn off the selected motor, enabling the corresponding component to move freely. Thus you can adjust its position manually. Click this button to turn on the selected motor and give it control of the corresponding component.
Home Motor
Motor Off
Motor On
Position 2
Start Test
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Abort
Click this button to stop the test cycle immediately, before the cycle is finished. Click this button to turn all motors off. Click this button to turn all motors on. Click this button to instruct the motors to find their home positions. If any motor speeds have been changed, you can click this button to restore the factory-set default speeds. A handler that has an input tube insert on tray X1 may have this button. Click to shake the input tubes back and forth once to drop devices to the dead nest.
Save Parameters
Click this button only if you want to save changes under the current file name. To open a dialog box so you can save changes under a new file name, click the OK button instead.
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The function of each feature of this window is described first. Afterward, a sample procedure for calibrating various distances is described, starting in "Setting Distances to Various Positions" on page 5-68.
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To refer to a specific area of this window, find the group box in the following list. Group Box or Area
Selections Group Box X Distance Calibration Group Box Y Distance Calibration Group Box Z-Get Distance Calibration Group Box Z-Put Distance Calibration Group Box Pitch and Teach Group Box Z Vacuums Group Box Test Site Clamp Group Box Rotation Group Box Z Compress Group Box Socket Offsets Group Box Air Pressure Group Box Other Buttons
Page
5-53 5-54 5-55 5-56 5-56 5-57 5-62 5-62 5-64 5-64 5-65 5-67 5-67
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Figure 5-58: Examples of Drop-Down List of Selectionswith Four Trays (Left); with Waffle Packs (Right)
Figure 5-59: Examples of Drop-Down List of Selections with Tube Outputs (Left); with Bowl Feeder, Inspection, and Taper (Right)
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In the input box, type the distance from the selected trays X home to the selected position (first pocket or last pocket under path of pickup head). Click this button to move the specified tray to the specified destination. You must click this button before you can make fine-tune adjustments with the jog buttons.
Move X[n] To
[Increase distance]
If the selected tray pocket is too far forward of the pickup head and the suction cup is over the back side of the device, increase the distance from X home by clicking the [Increase Distance] jog button. Each time you click this button, the tray moves back by the distance shown in the Scale (inches) input box. If the selected tray pocket is too far behind the pickup head and the suction cup is over the front side of the device, decrease the distance from Z home by clicking the [Decrease Distance] jog button. Each time you click this button, the tray moves forward by the distance shown in the Scale (inches) input box. Click this button to move the specified pickup head to its home position.
[Decrease distance]
X[n] Home
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Scale
Type the scale, or size, of each increment or decrement by which a motor should move when one of the jog buttons is clicked. For example, if the value here is 0.005 and the value in one of the distance boxes is 17.505, then when the Increase Distance or left jog button for that distance box is clicked, the value changes to 17.510. Other examples follow. Current Value 10.365 0.96 Incremented Value 10.370 0.965 Decremented Value 10.360 0.955
In the input box, type the distance from the selected pickup heads Y home to the selected position. Click this button to move the specified pickup head to the specified destination. You must click this button before you can make fine-tune adjustments with the jog buttons.
[Left/right]
If the alignment is off in the Y direction, make any small adjustments by clicking the left or right jog buttons. The pickup head moves left or right by the distance shown in the Scale input box, and the number shown in the Distance input box changes accordingly. Click this button to move the specified pickup head to its home position. Type the scale, or size, of each increment or decrement by which a motor should move when one of the jog buttons is clicked.
Y[n] Home
Scale
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Z Get Distance
In the input box, type the distance from the selected pickup heads home to the selected position. Click this button to move the pickup nozzle down to the Z-get position shown in the Z Get Distance input box. You must click this button before you can make fine-tune adjustments with the jog buttons.
Move ZGet To
[Up]
If the suction cup is too close to the device, raise the pickup head by clicking the Up jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Scale input box, and the number in the Z Get Distance input box gets smaller by the same scale. If the suction cup is not close enough to the device, lower the pickup head by clicking the Down jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Scale input box, and the number in the Z Get Distance input box gets larger by the same scale. Click this button to raise the pickup head to its Z home position. Type the scale, or size, of each increment or decrement by which a motor should move when one of the jog buttons is clicked.
[Down]
Z Home
Scale
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Z Put Distance
In the input box, type the distance from the selected pickup heads home to the selected position. Click this button to move the pickup nozzle down to the Z-put position shown in the Z Put Distance input box. You must click this button before you can make fine-tune adjustments with the jog buttons.
Move ZPut To
[Up]
If the suction cup is too close to the device, raise the pickup head by clicking the Up jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Scale input box, and the number in the Z Put Distance input box gets smaller by the same scale. If the suction cup is not close enough to the device, lower the pickup head by clicking the Down jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Scale input box, and the number in the Z Put Distance input box gets larger by the same scale. Click this button to raise the pickup head to its Z home position. Type the scale, or size, of each increment or decrement by which a motor should move when one of the jog buttons is clicked.
[Down]
Z Home
Scale
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Compare the available features in Figure 5-64 and Figure 5-66. NOTE: Before teaching tray distances, check that the correct number of columns and rows for each tray have been specified. See "Tray Information Group Box" on page 5-39. Y Distance Between Tubes Y Distance Between Z1 and Z2 Type the distance between the leading edge of one tube and that of the one next to it. Type the distance from the center of the Z1 nozzle to the center of the Z2 nozzle.
X Distance Between Trays Type the distance, on the X axis, between the leading edge of one tray and that of the one next to it. Y Distance Between Trays Type the distance, on the Y axis, between the leading edge of one tray and that of the one next to it. Display Tray Drawing To determine which dimension is X and which is Y, click this button.
First do all the measurements for the first tray or unit, then use this box, and it extrapolates the measurements for the other trays or units. It is recommended that you run the Teach routine first to obtain approximate distances, then fine-tune the distances for each tray individually. Teach Test Site, Precisor, Golden Unit Site Teach All Trays from TrayX1_1 Only Teach Tubes and Trays from TrayX2_1 Click this button to apply the stated distance to each unit in the series. Click this button to apply the distances specified for tray X1_1 to each tray in the series. Click this button to apply the distances specified for tray X2_1 to each tray and tube in the series.
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Figure 5-66: Pitch and Teach Group BoxUsing Waffle Packs on Both Trays
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Distance A (inches)
Type the distance between the left edge of waffle pack 1_1 and the left edge of waffle pack 1_2, both on tray X1. See Figure 5-67. Type the distance between the back edge of waffle pack 1_1 and the back edge of the waffle pack just in front of it, as shown in both Figure 5-67 and Figure 5-68. Type the distance between the left edge of waffle pack 1_1 on tray X1 and the left edge of waffle pack 2_1 on tray X2, as shown in both Figure 5-67 and Figure 5-68. Click this button to display the diagram showing the A, B, and C distances between two-inch waffle packs, shown in Figure 5-67. Click this button to display the diagram showing the B and C distances between four-inch waffle packs, shown in Figure 568.
Distance B (inches)
Distance C (inches)
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Teach All TrayX from Tray Click this button to teach the A, B, and C distances from waffle pack 1_1 to 1_2, 1_3, and 2_1 to the distances to all the X1_1, Using 2x2 Waffle other waffle packs. Trays for Both Tray X1 and X2 This teaches identical distances for both trays. It assumes that both trays are using eight 2" by 2" waffle packs. Teach All TrayX from Tray Click this button to teach the B and C distances from waffle X1_1, Using 4-Inch Waffle pack 1_1 to 1_2 and 2_1 to the distances to all the other waffle packs. Trays for Both Tray X1 and X2 This teaches identical distances for both trays. It assumes that both trays are using three 4" by 4" waffle packs. Teach All Tray X1s from Tray X1_1, Using 4-Inch Waffle Trays Click this button to copy the B distance from waffle pack 1_1 to 1_2 to the distance from 1_2 to 1_3. This teaches distances for only tray X1. It assumes that tray X1 is using three 4" by 4" waffle packs. Thus, you can use a different waffle pack configuration on the other tray.
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Teach All Tray X2s from Tray X2_1, Using 4-Inch Waffle Trays
Click this button to copy the B distance between waffle pack 2_1 and 2_2 to the distance between 2_2 and 2_3. This teaches distances for only tray X2. It assumes that tray X2 is using three 4" by 4" waffle packs. Thus, you can use a different waffle pack configuration on the other tray.
Teach All Tray X1s from Tray X1_1, Using 2-Inch Waffle Trays
Click this button to teach the A and B distances from waffle pack 1_1 to 1_2 and 1_3 to the distances to all the other waffle packs though 1_8. This teaches distances for only tray X1. It assumes that tray X1 is using eight 2" by 2" waffle packs. Thus, you can use a different waffle pack configuration on the other tray.
Teach All Tray X2s from Tray X2_1, Using 2-Inch Waffle Trays
Click this button to teach the A and B distances from waffle pack 2_1 to 2_2 and 2_3 to the distances to all the other waffle packs though 2_8. This teaches distances for only tray X2. It assumes that tray X2 is using eight 2" by 2" waffle packs. Thus, you can use a different waffle pack configuration on the other tray.
RZ[n] Vac On
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Rotation (Degree)
Type the degrees of rotation desired. To rotate the pickup nozzle in a clockwise direction, type a positive number. To rotate the pickup nozzle in a counterclockwise direction, type a negative number (prefixed by a -).
[Repetitions]
Type the number of rotation repetitions desired in testing the motor. Click this button to rotate the pickup nozzle one time by the degrees specified. This button causes the nozzle to rotate but not to return to its home position. Click this button to rotate the pickup nozzle the number of repetitions specified by the degrees specified. Click this button to rotate the pickup nozzle back to its home position after clicking the Rotate button. Click this button to rotate the pickup nozzle back to its default home position.
Rotate
Test Rotate
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Z Compress Distance
Type the distance in inches you want to add to the Z-get distance for the test site. Click this button to lower the pickup head to the position that is the sum of the Z-get distance plus the Z-compress distance.
Move to Z Compress
To use the Z-compress distance: 1. In the Selections box, select Y1 to Test Site. 2. Type identical distances in the Z Get Distance box and the Z Put Distance box. 3. Type a very small distance in the Z Compress Distance box.
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In Figure 5-73, tray X1 is designated as the input tray. Socket 1, the leftmost test site, is recessed toward the back of the handler just five thousandths of an inch. So the pickup head needs to grab the device near its front to place it precisely into the test socket. For this to happen, the X tray also needs to move toward the back of the handler just five thousandths of an inch.
In Figure 5-74, tray X2 is designated as the input tray. Socket 2, the test site on the right (or second from the left, if more test sites exist on the handler), is extended toward the front of the handler one one-hundredth of an inch. So the pickup head needs to grab the device near its back to place it precisely into the test socket. For this to happen, the X tray also needs to move toward the front of the handler one one-hundredth of an inch. X[n] Socket[n] Offset If this tray is designated as the input tray and this test site is offset a bit, type a number in fractions of an inch. If the test site is too far back, causing the device to be placed to the front of the test site, type a positive number. If the test site is too far forward, causing the device to be placed to the back of the test site, type a negative number.
X2
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Type the voltage to apply to the air pressure cylinder. Click this button to apply the voltage to the air cylinder.
Other Buttons
The other buttons available on the Fine Tune window are explained as follows.
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Click this button to move the selected Y pickup head to the position named in Selections. It also moves it to the Z height specified in the Z Get Distance box. Click this button to move the selected Y pickup head to the position named in Selections. It also moves it to the Z height specified in the Z Put Distance box. Click this button to move the X1 tray to its home position. Click this button to move the X[n] tray to its home position. Click this button to move all motors to their home positions. Click this button only if you want to save changes under the current file name. To open a dialog box so you can save changes under a new file name, click the OK button instead.
Home Tray 1 Home Tray [n] Home All Motors Save Parameters
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After all the procedures are explained, the distances are illustrated conceptually in the sections "Example of Calibrating Distances for Four JEDEC Trays" on page 5-85 and "Example of Calibrating Distances for Waffle Packs" on page 5-90.
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Positions to Be Calibrated
Click the drop-down arrow to the right of the Selections box. From the available selections, click the position you want to fine-tune. Your available selections will depend on the number of trays or waffle packs you have set up, as well as the number of test sites you have.
Figure 5-77: Selections for 4 Trays with Waffle Packs and 2 Test Sites
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Positions to Be Calibrated
Figure 5-78: Selections for Preheating Tray and Multiple Test Sites with Thermal Heads
The following table shows example distances, listed in the direction the devices travel. Your distances may vary. 1 You can use the second table as your worksheet to record correct distances calibrated for your handler.
The shaded yellow boxes in the table show that while a value is possible, it would rarely, if ever, be used in diagnostics, and never in Auto Run. The shaded red boxes show where a value would never be used.
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Test Site 1
Test Site 2
Tray X1
Tray X2
Tray X3
Tray X4
If you selected a test site, the top group box under Selections becomes blank. The distances to be set for a test site are:
Setting Procedure Y Distance Z-Get Distance Z-Put Distance Page 5-74 5-78 5-77
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To fine-tune the Y distance to a test site: 1. Place a device by hand into the test site closest to tray X1. 2. Select the test site in the Selections box, using the drop-down arrow. 3. Type a measurement estimated to be correct in the input box labeled Y Distance From Home to Center of Socket [n]. 4. Click the button Move Y To. > This moves the pickup head on the Y motor to a position over the test site. 5. Look to see whether the pickup head is exactly over the test socket. > If the alignment is off in the Y direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Scale (inches) input box. > If the alignment is off in the X direction, see further instructions under "Socket Offsets Group Box" on page 5-65. 6. To retest, click Y Home and then Move Y To again. After calibrating the Y distance, set the Z-get distance (page 5-78) and then the Z-put distance (page 5-77). Then, before calibrating the tray distances, pick up the device again with Z-get.
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In Figure 5-82, the Z-get distance is larger than the Z-put distance because its farther from the top, Z home. Furthermore, the Z distances for an X tray may be different than those for a test site.
NOTE: These measurements are examples only. Your measurements may differ. The key to defining a Z-get distance is to have the suction cup just touching the device, but not flattened on it. The suction cup should be high enough that when you turn on the vacuum, you can see the device lift slightly against the suction cup.
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Notice that the suction cup at Z-get (pick height) is just touching the device, but not flattened on it.
Notice that the suction cup at Z-put (put height) is not quite touching the device.
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To fine-tune the Z-put distance: 1. Type a measurement estimated to be correct in the input box labeled Z Put Distance. CAUTION: If in doubt, make this distance smaller than you think necessary, then jog the pickup head down by steps to prevent damage from crashing the pickup nozzle into the socket. NOTE: The Z-put distance should be smaller than the Z-get distance, so that the suction cup is higher with Z-put. 2. Click the button Move ZPut To. >If the suction cup is too close to the device, raise the pickup head by clicking the Up jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Scale (inches) input box, and the number in the Z Put Distance input box gets smaller by the same scale. >If the suction cup is not close enough to the device, lower the pickup head by clicking the Down jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Scale (inches) input box, and the number in the Z Put Distance input box gets larger by the same scale. 3. Turn the pickup head vacuum off by clicking the Vacuum On/Off checkbox. > The pickup head drops the device into the pocket. 4. Click the Z Home button to raise the pickup head from the socket.
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To fine-tune the Z-get distance: 1. Type a measurement estimated to be correct in the input box labeled Z Get Distance. CAUTION: If in doubt, make this distance smaller than you think necessary, then jog the pickup head down by steps to prevent damage from crashing the pickup nozzle into the socket. 2. Click the button Move ZGet To. >If the suction cup is too close to the device, raise the pickup head by clicking the Up jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Scale (inches) input box, and the number in the Z Get Distance input box gets smaller by the same scale. >If the suction cup is not close enough to the device, lower the pickup head by clicking the Down jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Scale (inches) input box, and the number in the Z Get Distance input box gets larger by the same scale. 3. Turn the pickup head vacuum on by clicking the Vacuum On/Off checkbox. 4. Click the Z Home button to raise the device from the socket or pocket. By alternating among the Move ZGet To, Move ZPut To, and jog buttons, and the Vacuum On/Off checkbox, you can pick and drop the device until you are sure the distances are correct. If you have more than one test site, work your way to the left in defining test sites. For example, if you have four test sites, calibrate number 4 first, then 3, then 2, and then 1, on the extreme left. If any test sites are offset forward or backward, calibrate the trays first, then calibrate the test site offsets. See further instructions under "Socket Offsets Group Box" on page 5-65.
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Test Site 1
Test Site 2
Tray X1
Tray X2
Tray X3
Tray X4
When waffle packs are used, they are numbered back to front, and left to right. X2_1 X1_1 X2_3 X1_2 X2_5 X2_6 X2_4 X2_2
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Figure 5-90: Tray X1, First Pocket Selected (Left); Tray X4, Last Pocket Selected (Right)
Two locations on each tray must be calibrated, in terms of distances each motor must travel: Pocket in first row and column Pocket in last row and column
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Furthermore, if a handler is set up to use waffle packs, then each of these distances and locations must be calibrated for each waffle pack. For more conceptual information, see the sections "Example of Calibrating Distances for Four JEDEC Trays" on page 5-85 and "Example of Calibrating Distances for Waffle Packs" on page 5-90.
Calibrate the first pocket of the first waffle pack of tray X1, followed by the last pocket of that waffle pack. Then work your way forward for that tray. Do all the waffle packs for that tray before moving to tray X2.
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Figure 5-92: Order of Calibrating Distances for Multiple Trays with Multiple Waffle Packs
To fine-tune the Y distances to a tray: 1. Place empty trays onto each tray shelf, ensuring they are fully seated and secured in place by the colored tray clamp. 2. Using the drop-down arrow, select tray X1, first row, first column, in the Selections box.
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> If you are using waffle packs, select tray X1_1, the top left waffle pack. 3. Type a measurement estimated to be correct in the input box labeled Y Distance From Home to Center of First Pocket. 4. Click the button Move Y To. > This moves the pickup head on the Y motor to a position over the tray. 5. Look to see whether the pickup head is exactly over the first pocket. > If the alignment is off in the Y direction, make any small adjustments by clicking the left or right jog buttons. The motor will move left or right by the distance shown in the Scale (inches) input box. 6. To retest, click Y Home and then Move Y To again. When the Y distance to the first pocket is correct, calibrate its X distance.
To fine-tune the X distances for a tray: 1. Place empty trays onto the X1 and X2 tray shelves, ensuring they are fully seated and secured in place by the colored tray clamp. 2. Using the drop-down arrow, select tray X1, first row, first column, in the Selections box. > If you are using waffle packs, select tray X1_1, the top left waffle pack. 3. Type a measurement estimated to be correct in the input box labeled X Distance From Home to Center of First Pocket. 4. Click the button Move X To.
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> This moves the tray to a position under the path of the Y motor. 5. Look to see whether the pickup head is exactly over the first pocket. >If the selected tray pocket is too far forward of the pickup head and the suction cup is over the back side of the device, increase the distance from X home by clicking the [Increase Distance] jog button. Each time you click this button, the tray moves back by the distance shown in the Scale (inches) input box. >If the selected tray pocket is too far behind the pickup head and the suction cup is over the front side of the device, decrease the distance from Z home by clicking the [Decrease Distance] jog button. Each time you click this button, the tray moves forward by the distance shown in the Scale (inches) input box.
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In Figure 5-96, the only movement we are dealing with is that of the Y motor, which moves the pickup head. So the distances to be calibrated are the distances the Y motor carrying the pickup head must move to be positioned over the centers of specific device pockets. These distances have been filled in for each tray, for the first column and last column. Also, the distance to the spare tray is calibrated. These are shown as follows.
Tray and Location X1, first column X1, last column X2, first column X2, last column X3, first column X3, last column X4, first column X4, last column Spare tray Distance Y Motor Must Travel to Get Pickup Head Over Center of Pocket 23.87" 19.65 17.6 13.41 11.354 7.153 5.096 0.903 23.843
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If you analyze these distances, you can see a pattern. Each trays first column appears to be approximately 6.25 inches from the next, and each trays last column appears to be approximately 6.25 inches from the next. The Y motor carrying the pickup head must move less than an inch to get from its home position to the last column of tray X4, then another 4 inches to get to the first column of tray X4. A move of another 2 inches takes the pickup head to the last column of tray X3, then another 4 inches to get to the first column of tray X3.
Figure 5-97 shows how these Y distances to tray X1 are calibrated on the Fine Tune window.
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In Figure 5-98, the only movement we are dealing with is that of the X motors and trays. The pickup head stays in the back. Each tray must slide a certain distance toward the back, to get the proper device pocket under the pickup head. So the distances to be calibrated are the distances the X tray must move to get the centers of specific device pockets under the pickup head. When the tray moves about 3 inches toward the back, the first row is under the Y pickup head. When the tray moves about 14.5 inches, the last row is under the pickup head. These distances have been filled in for each tray, for the first row and last row. Also, the distance to the spare tray is calibrated. These are summed up as follows.
Tray and Location X1, first row X1, last row X2, first row Distance X Motor Must Travel to Get Center of Pocket Under Pickup Head 3.3265" 14.531 3.3295
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Tray and Location X2, last row X3, first row X3, last row X4, first row X4, last row Spare tray
Distance X Motor Must Travel to Get Center of Pocket Under Pickup Head 14.53 3.329 14.54 3.329 14.551 16
NOTE: These measurements are examples only. Your measurements may differ. Notice that the farther the X tray must move, the larger the distance. These measurements are about the same for each tray, because each tray must travel about the same distance to get to the pickup head area, the Y gantry. The X trays must move a little over 3 inches to get the first row positioned under the pickup head, but they must move about 14.5 inches to get the last row under the pickup head.
Figure 5-99 shows how these X distances for tray X1 are calibrated on the Fine Tune window.
02/2011 Copyright Exatron, 2011
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In the example in Figure 5-100, each waffle pack has 5 rows and 6 columns.
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Figure 5-101: Y Motor Diagram for 4-Tray Handler with 12 Waffle Packs
These distances have been filled in for each waffle tray, for the first column and the last column. These are shown as follows.
Tray and Location X1_1, first column X1_1, last column X1_2, first column X1_2, last column X1_3, first column X1_3, last column X2_1, first column X2_1, last column X2_2, first column X2_2, last column X2_3, first column Distance Y Motor Must Travel to Get Pickup Head Over Center of Pocket 22.665" 20.41 22.671 20.39 22.695 20.38 16.424 14.27 16.457 14.19 16.481
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Tray and Location X2_3, last column X3_1, first column X3_1, last column X3_2, first column X3_2, last column X3_3, first column X3_3, last column X4_1, first column X4_1, last column X4_2, first column X4_2, last column X4_3, first column X4_3, last column
Distance Y Motor Must Travel to Get Pickup Head Over Center of Pocket 14.15 10.152 7.993 10.179 7.89 10.183 7.904 3.912 1.663 3.917 1.638 3.917 1.643
NOTE: These measurements are examples only. Your measurements may differ.
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Figure 5-102 shows how these Y distances to tray X4 are calibrated on the Fine Tune window.
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Figure 5-103: X Motor Diagram for 4-Tray Handler with 12 Waffle Packs
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These distances have been filled in for each waffle tray, for the first row and last row. These are shown as follows.
Tray and Location X1_1, first row X1_1, last row X1_2, first row X1_2, last row X1_3, first row X1_3, last row X2_1, first row X2_1, last row X2_2, first row X2_2, last row X2_3, first row X2_3, last row X3_1, first row X3_1, last row X3_2, first row X3_2, last row X3_3, first row X3_3, last row X4_1, first row X4_1, last row X4_2, first row X4_2, last row X4_3, first row X4_3, last row Distance X Motor Must Travel to Get Center of Pocket Under Pickup Head 3.48" 6.1 7.513 10.21 11.54 14.39 3.515 6.16 7.57 10.27 11.7 14.4 3.5 6.2 7.581 10.31 11.685 14.41 3.515 6.208 7.61 10.32 11.7 14.42
NOTE: These measurements are examples only. Your measurements may differ.
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Figure 5-104 shows how these X distances for tray X4 are calibrated on the Fine Tune window.
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Figure 5-105: Moving Preheating Tray (Left); Thermal Test Site (Right)
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Figure 5-106: Y Motor Diagram for 3-Tray Handler with Preheating Tray and Dual Test Sites
In Figure 5-106, the distances and destinations are shown for the Y1 pickup assembly. From its home position at the extreme right (but to the left of the Y3 thermal head assembly), the pickup assembly must move 0.691 inch to get centered over TS1R (the right half of test site 1), so that each of the four Z nozzles fit into the four right sockets. It must move roughly another 3.5 inches, or a total of 4.128 inches from home, to get to the center of TS1L, or the left half of the same test site. The preheating tray is also divided into halves. Therefore, the Y1 pickup assembly must move roughly 10.4 inches from its home position to get to the center of the right half of the preheating tray. Another 2 inches gets it to the left half. NOTE: These measurements are examples only. Your measurements may differ.
Chapter 5: Diagnostics
The distances are shown which the pickup assembly must move to get its four nozzles centered over the first four pockets of each tray. Finally, the largest distances it must travel are to the two halves of the left test site.
Figure 5-107: X Motor Diagram for 3-Tray Handler with Moving Preheating Tray
On the X axis, only the three tray carriages and the preheating tray move. In Figure 5-107, the distances each entity must travel on its X axis are shown. For example, each tray must move the small distance of just over 3 inches to get the first pocket under the path of the pickup assembly. However, each tray must move over 14 inches toward the back to get the last pocket under the path of the pickup assembly. The preheating tray must move just under an inch from its home position at the front, toward the back, to get the back row under the path of the pickup assembly. It must move another inch to get the middle row under the path of the pickup assembly. NOTE: These measurements are examples only. Your measurements may differ.
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Set Temperature
+ Guard Band
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- Guard Band
The allowed variance below the set temperature on the left thermal head is displayed. The actual or current Celsius temperature on the left thermal head is displayed. Click this button to save the desired hot Celsius temperature for the left thermal head, typed in the Set Temperature box. Click this button to display the current Celsius temperature on the left thermal head.
Current Temperature
+ Guard Band
- Guard Band
Current Temperature
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Figure 5-109: Socket Pressure Group Box (Left); Head Air Pressure (Right)
Type the voltage desired to apply air pressure on the sockets from the thermal heads. A possible ratio might be something like the following; however, it varies from handler to handler. Air Pressure Voltage Input 0.25 0.5 0.75 1 1.25 1.5 1.75 2 Pounds of Air PressureOutput 3 6 10 13 16 19 23 26
Click this button to apply the voltage. Type, in milliseconds, the desired time duration after the cold thermal head clamps on the device in the test socket and before the handler gives the command to start testing. Type, in milliseconds, the desired time duration after the hot thermal head clamps on the device in the test socket and before the handler gives the command to start testing. Click this button only if you want to save changes under the current file name. To open a dialog box so you can save changes under a new file name, click the OK button instead.
Save Parameters
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Select Z Nozzle
Click the drop-down arrow to the right of the box and select the Z nozzle you want to calibrate. The selections vary according to the features of your handler. In the input box to the right of the Head Go To Tape Reel button, type the distance from the Y pickup heads home to the tape track. Click this button to move the Y pickup head to the tape track position shown in the input box to the right. You must click this button before you can make fine-tune adjustments with the jog buttons.
[Left/Right]
If the alignment is off in the Y direction, make any small adjustments by clicking the left or right jog buttons. The pickup head moves left or right by the distance shown in the Scale input box, and the number shown in the Distance input box changes accordingly. Click this button to move the Y pickup head to its home position.
Y[n] Home
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Scale
Type the scale, or size, of each increment or decrement by which a motor should move when one of the jog buttons is clicked. For example, if the value here is 0.005 and the value in one of the distance boxes is 17.505, then when the Increase Distance or left jog button for that distance box is clicked, the value changes to 17.510. Other examples follow. Current Value 10.365 0.96 Incremented Value 10.370 0.965 Decremented Value 10.360 0.955
Y[n] Pick Devices from Tray / Transfer Site / Bowl Feeder Put Device To Tape Reel
Click this button to cause the pickup head to get a device from the designated input.
Click this button to cause the pickup head to put a device in the tape pocket. In the input box to the right of the Go to Put Height button, type the distance from the pickup heads Z home to the Z-put position at the tape track. Click this button to move the pickup nozzle down to the Z-put position shown in the input box to the right. You must click this button before you can make fine-tune adjustments with the jog buttons.
Go to Put Height
[Up]
If the suction cup is too close to the device, raise the pickup head by clicking the Up jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Scale input box, and the number in the Z Put Distance input box gets smaller by the same scale. If the suction cup is not close enough to the device, lower the pickup head by clicking the Down jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Scale input box, and the number in the Z Put Distance input box gets larger by the same scale.
[Down]
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[Z Distance to Z-Get]
In the input box to the right of the Go to Pick Height button, type the distance from the pickup heads Z home to the Z-get position at the tape track. Click this button to move the pickup nozzle down to the Z-get position shown in the input box to the right. You must click this button before you can make fine-tune adjustments with the jog buttons.
Go to Pick Height
[Up]
If the suction cup is too close to the device, raise the pickup head by clicking the Up jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Scale input box, and the number in the Z-Get Distance input box gets smaller by the same scale. If the suction cup is not close enough to the device, lower the pickup head by clicking the Down jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Scale input box, and the number in the Z-Get Distance input box gets larger by the same scale. Click this button to raise the pickup head to its Z home position.
[Down]
Z Home
Type the number of milliseconds after the seal head goes down to the tape before the tape is moved. Type the number of pockets to fill with devices and seal in a job.
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The temperature set here for the heat seal head overrides any manual settings made on the heater controller itself. The input temperature must be in Celsius. Following is a short conversion table that can be used as a rough reference. Temperature in Fahrenheit
77 250 275 300 325 350
Temperature in Celsius
25 121 135 149 163 177
Set Temperature
Type the desired hot temperature in Celsius for the seal head. Click this button to start the heater heating to the set temperature. Click this button to read and display the current temperature on the seal head. After you click the Read Temperature button, the current temperature on the seal head is displayed.
Set Temperature
Read Temperature
Current Temperature
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Type the number of motor steps needed to move the tape from the offset position identified by the gap offset sensor to the center of the pocket. Because of various tape pocket sizes, when the tape is in position so the gap sensor "sees" through the hole in the middle of the empty pocket, the corresponding tape pocket under the pickup head is likely not centered under the pickup head nozzle. Therefore, the tape needs to be advanced the correct number of motor steps, so the pickup head can place the device into the center of the pocket and not on the pocket edge. Notice that in Figure 5-114, when the pocket is centered under the pickup head, the gap sensor is between pockets. This is the gap offset.
Gap sensor
Initial Taper
Click this button to initialize the taper. This advances the tape until the next tape pocket hole is under the front Gap sensor. From there, it moves the number of motor steps specified in the Gap Offset (Steps) input box to get the next emptypocket hole under the pickup head, and stops. This is the homing process for the taper. After you click Initial Taper, the buttons below it are enabled.
Type the number of pockets needed from the back edge of the tape track to the output reel takeup spool. This is the
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number of empty pockets passed before the machine begins putting devices in the pockets. Advance Leader Click this button to advance the tape by the number of pockets specified in the Leader Count box.
Type the number of empty pockets to be passed after the empty pocket sensor. The tape will continue to be sealed to this number of pockets after the specified number of devices have filled the specified number of pockets for the job. Click this button to advance the tape by the number of pockets specified in the Trailer Count box.
Advance Trailer
Take-up Motor Count (# of Type the number of pockets required for the tape to go from Pockets) a slack position until the slack switch blocks the slack switch sensor and turns on the output reel motor (Figure 5-116). Abort Click this button to stop the action caused by the Advance Leader, Advance Trailer, or Advance Pockets buttons. For example, if the number of leader pockets is set at 50, and you have clicked Advance Leader, and ten leader pockets have advanced, this button aborts the tape advancement immediately at ten.
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Figure 5-116: Output Tape Slack (Left); Output Tape Taut, Raising Takeup Arm (Right)
Number of Holes Between Type the number of sprocket holes between the hole in one Pockets pocket and the hole in the pocket next to it. Always count between single pockets, even when dropping from multiple pickup nozzles to the tape. The software adjusts the tape movement according to how many devices were dropped into the tape at one pass. In the example in Figure 5-117, there are three sprocket holes between pocket centers.
Number of Pockets
Type the desired number of test leader pockets to advance (optional). Click this button to advance the tape by the number of pockets specified in the Number of Pockets box (optional).
Advance Pockets
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Number of Pockets Before Type the number of pockets to be advanced after the tapeCheck Tape Out Error out error sensor first detects no tape and before the machine stops and gives a tape-out message. Enable Seal Head Check this box to turn on the seal head and seal the tape after inserting the devices. Uncheck this box to turn off the seal head. Select the desired option to seal with pressure-sensitive tape or thermal (heat) tape.
PSA/Thermo
Tape Vacuum On
Speed AC DC (% of AC)
Type the desired motor speed. Type the acceleration speed. Type the deceleration speed as a percentage of the acceleration speed. For example, if the acceleration speed is 50, and the deceleration speed should be the same as the acceleration, type 100 in the DC box, for 100 percent of the acceleration speed. If the deceleration speed should be half the acceleration speed, type 50 in the DC box.
Steps
Type the number of steps you want to move the motor. Note that 50,000 steps complete one revolution.
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Click this button to turn on the motor. Click this button to turn off the motor. Click this button to move the motor the number of steps displayed in the Steps box to the left.
Other Buttons
Z1 Pick Device from Test Site Z1 Put All Devices to Taper Save Parameters Click this button to cause the pickup head to get device(s) from the test site. Click this button to cause the pickup head to put device(s) in the tape pockets. Click this button only if you want to save changes under the current file name. To open a dialog box so you can save changes under a new file name, click the OK button instead.
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6-1
Task Opening the Computer for Part ReplacementBenchtop Models Fiberoptic Photoelectric Sensor Guidelines Taper Maintenance Checking Omega Temperature Controller Thermal Heads Air Pressure Laser Servicing Networking Internet Access Setting LAN Connections and Required IP Addresses Testing Network Communication with Peripherals Remote Handler Control with WebEx Replacing Exatron Program File with an Upgrade Troubleshooting This chapter also discusses the following problems: Topic Motors Move Very Slowly Tray Carriage Alignment Is Faulty System Does Not Pick Up Devices Reliably System Noise When Y Gantry Moves
Frequency As needed As needed As needed As needed As needed As specified by OEM As needed Always As needed As needed As needed As needed As needed
Page 6-61 6-64 6-65 6-66 6-71 6-71 6-71 6-71 6-72 6-77 6-80 6-82 6-85
Preventive maintenance on the Model 900 is fairly simple. Following this schedule will help to assure your Model 900 handler will continue to perform properly. WARNING! Keep fingers, hair, and clothing away from any moving parts on the handler. Its motors are very powerful and can cause severe injury. WARNING! Always reset all motors before running the machine. Do not run it without homing the motors. WARNING! Never try to stop an action of the handler with your hands or any other device. To stop the handler, press the EMO (emergency stop) button or click Pause on the screen. CAUTION: Do not lubricate any lead screws! Lubricating the screws will void the warranty. CAUTION: Do not use any cleaners or solvents on any bearings or lead screws!
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CAUTION: Always power off the system before doing any maintenance.
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Environmental conditions The two factors that will change from handler to handler are operating hours and environmental conditions. Exatron recommends that the bearing shafts be lubricated every month at a minimum. Exatron strongly recommends the lubrication be done weekly, especially if the handler is in extreme environmental conditions or is operated more than 80 hours per week. Use visual inspection to determine when lubrication will be required in these cases. You should see a thin, clean layer of grease on the stainless steel bearing guide shafts. If grease is not seen, or if they are dirty, the shafts should be cleaned and re-lubed. Manufacturer Kerk Thomson NB THK NSK NSK Thomson Thomson Product Lead screws Bearings Bearing shafts Bearing shafts Bearing shafts self-lubricating Bearing shafts non-self-lubricating Bearing shafts Linear rails NONE NONE Linear Lube (Thomson brand) Linear Lube (Thomson brand) NONE Linear Lube (Thomson brand) M1 (Starrett brand) Linear Lube (Thomson brand) Self-lubing shafts have no lubrication fitting Non-self-lubing shafts have a lubrication fitting M1 is petroleum-based, removes moisture Treatment Comment Black TFE coated screws are never lubed Bearings are Super 4, Super 8, and Super 8 OPN
To lubricate the bearing shafts: 1. Power down the entire system. CAUTION: Do not use water or any cleansers to clean the bearing shafts. This will cause rust damage to the bearings. Also, do not lubricate any of the leadscrews; lubricate only the bearing shafts. 2. Apply an appropriate type of grease to a soft, clean, dry lint-free cloth. Wipe the cloth along the bearing shaft, making sure no grease drops onto the lead screw. Be sure to remove all the old grease and debris. Exatron recommends a Teflon-based grease or M1. Exatron uses Linear Lube grease manufactured by Thomson.
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> The amount of grease used is difficult to specify. The goal is to attain a thin layer of grease along the entire length of the shaft. 3. On a linear motor track, apply a small dab of grease at one point. Then by hand move the Z-axis block along the entire length of the shaft several times. > If no film of grease is seen, apply another small dab of grease and repeat the process. > If there is any clumping of grease along the length of the shaft, remove the excess grease with a dry cloth. Once again move the Z axis block manually several times until a thin film is achieved.
Motor Replacement
When replacing a motor, several tasks may be involved. These are explained in the following sections. For a Cool Muscle motor, you may need to adjust the configuration before installing it; and after installation, you need to program the motor.
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Cool Muscle motors can be used as master or slave motors. You can program a replacement Cool Muscle motor through the Exatron software. See "Programming a Cool Muscle Motor" on page 6-16 for instructions.
Input connector
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Motor Replacement
Notice that in both Figure 6-2 and Figure 6-3, the master board on the left (circled in blue) is powered through its terminal. In Figure 6-2, the slave boards (middle and right, circled in red) are likewise powered through their terminals, as shown by the red wires. In this case, only the sensors are powered through the RS-232 cables. However, in Figure 6-3, the slave boards (middle and right, circled in red) are powered through their RS-232 cables, since no terminal wires are present. In this case, both the slave boards and the sensors are powered through the RS-232 cables.
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A master motor uses a network card equipped with an interface card. The cards together are called a master set. A slave motor uses a network card without an interface card.
Figure 6-4: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Network Card
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Figure 6-5: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations
If you are going to use the controller as a master, leave the JP3, JP4, and JP5 jumpers in the position shown at the right side of Figure 6-5. If you are going to use the controller as a slave, pull off the JP3, JP4, and JP5 jumpers and replace them in the position shown at the left side of Figure 6-5.
Used When...
Power is supplied through terminal block on card. Power is supplied through terminal block on card. Interface card is attached to network card. Interface card is attached to network card. Interface card is attached to network card.
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Slave Network Card Powered Through Terminal Block (See Figure 6-7)
Jumper
JP1 JP2 JP3 JP4 JP5
Used When...
Power is supplied through terminal block on card. Power is supplied through terminal block on card. NO interface card is attached to network card. NO interface card is attached to network card. NO interface card is attached to network card.
Slave Network Card Powered Through RS-232 Cable (See Figure 6-8)
Jumper
JP1 JP2 JP3 JP4 JP5
Used When...
Power is supplied through RS-232 serial cable. Power is supplied through RS-232 serial cable. NO interface card is attached to network card. NO interface card is attached to network card. NO interface card is attached to network card.
Interface Card Piggybacked on Master Network Card (See Figure 6-6, Left)
Jumper
JP1 JP2
Used When...
RS-232 is used rather than RS-485. RS-232 is used rather than RS-485.
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Motor Replacement
JP5 - Pins 2 & 3 connected Interface Card: JP1 - Pins 1 & 2 connected
JP1 open
JP2 open
JP1 open
JP2 open
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Motor Replacement
To replace a servo motor: 1. Place the two nylon washers on the 4/40 x 1/4" screws, and place the screws into the holes of the motor drive board, as shown in Figure 6-10. 2. Place the motor drive board inside the cover with the two screw holes aligned (Figure 6-10).
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3. Wrap the rubber grommet around the wires, and slide the grommet into the grommet holder, as shown in Figure 6-11. 4. Slide the #4 split washers onto the long screws, and slide the four screws through the serial port/network card cover (Figure 6-11). Slide the short (1/4"long) nylon spacers onto the screws.
5. Slide the client network card onto the long screws, with the connectors facing the cover holes, as shown in Figure 6-12. 6. Slide the long (9/16"-long) nylon spacers onto the screws (Figure 6-12).
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Motor Replacement
Figure 6-12: Sliding Network Card into Cover; Adding Long Spacers
7. Slide the motor driver board in its cover onto the long screws so the two covers are piggybacked, as shown in Figure 6-13. 8. Press the short style motor communication rainbow cable into the connectors of both boards (Figure 6-13).
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3. In the Initialize Motors dialog box, click the drop-down arrow to the right of the Select Motor box, and click the motor you want to initialize (Figure 6-15). 4. Click Initialize Motor. 5. Click Exit.
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If your handler has a large number of motors, it may have a serial or network hub to add serial COM ports. Make sure all these connectors are secure, also.
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Follow this procedure for your SMC brand air regulator. 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.
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4. Unscrew the black inner screw that has edges like propeller blades.
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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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Adjustment valve
Figure 6-25: Auxiliary Air Regulator
Lock nut
To adjust the air flow at the air valve: 1. Turn the lock nut counterclockwise to unlock the adjustment knob.
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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.
Figure 6-27: OUT Lights Off and Fractional ReadingNo Air Pressure
During handler operation, the OUT 1 light on the digital air pressure display should be green.
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If the OUT1 light is off when the air pressure is on, as signified by the pressure reading being more than something like .01 or .03, you need to do one of two things: On the handler, increase the air pressure on the main air regulator until it is greater than the P1 setting (page 6-24), or... On the digital air pressure switch, lower the value of P1 until it is lower than the current air pressure. However, never set P1 lower than a minimum of 65!
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Before you can review the settings, you must unlock the settings buttons. To unlock Model ITV: 1. Press and hold down the (left) UNLOCK button (the down arrow) for 3-4 seconds or until the display flashes Loc (Figure 6-30, left). This means the settings are currently locked. 2. Press the (middle) SET button to unlock the settings. > The display briefly flashes unL (Figure 6-30, right). This means the settings are now unlocked.
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To lock Model ITV: 3. Whenever you are ready to exit the programming cycle, press and hold down the (right) LOCK button (the up arrow) for 3 seconds or until the display flashes unL. This means the settings are still unlocked. 4. Press the SET button to lock the settings. > The display briefly flashes Loc. This means the settings are again locked.
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To lock Models ISE40 and ZSE40: 1. Press and hold the SET button 4-5 seconds while the display cycles. The display reads P_1, then PSI, and finally UnL. 2. Press the up-arrow button. The display changes to LoC. 3. Press the SET button to return to normal operations in Measure Mode.
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a. The sensor output mode is determined by the relationship between the P_1 and P_2 values. When the P_1 value is smaller than the P_2 value, this is called comparator mode. The output goes on whenever the outlet pressure is greater than P_1 but less than P_2. See the ITV2000 Easy Programming Guide, page 5, for more details.
To review or change air regulator settings: 1. Unlock the settings, as described in "Unlocking or Locking SMC Model ITV" on page 6-27. > A flashing display of F_1 alternates with the value it is set to (Figure 6-32).
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2. If necessary, press either the up or down arrow button to change the number. > Press and release the up arrow button (the LOCK button) to increase the number by one. (To rapidly increase the numbers, hold down the button.) > Press the down arrow button (the UNLOCK button) to decrease the number by one. (To rapidly decrease the numbers, hold down the button.) CAUTION: Changes in the F_1 or F_2 pressure values take effect as soon as you press the SET button. Be careful to avoid damage or injury. 3. Press the SET button to advance to the next setting. > A flashing display of F_2 alternates with the value it is set to (Figure 6-33).
4. If necessary, press either the up or down arrow button to change the number. 5. Press the SET button to advance to the next setting. > A flashing display of P_1 alternates with the value it is set to (Figure 6-34).
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6. If necessary, press either the up or down arrow button to change the number. 7. Press the SET button to advance to the next setting. > A flashing display of P_2 alternates with the value it is set to (Figure 6-35).
8. If necessary, press either the up or down arrow button to change the number. 9. Press the SET button to advance to the next setting.
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> A steady, non-flashing display of G.L. plus the value is shown (9 is the fastest gain).
10. Press the SET button to advance to the next setting. > A steady, non-flashing display of S.L. plus the value is shown (0 is the best sensitivity).
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> A non-flashing display (Figure 6-38) shows the air pressure in PSI (pounds per square inch). > If you want to cycle through the settings again to confirm they are correct, you can keep pressing the SET button. 12. Whenever you are ready to exit the cycle, relock the settings as described in "Unlocking or Locking SMC Model ITV" on page 6-27.
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3. Press the SET button to advance to the OUT1 setting. 4. Set the output mode for OUT1 to (1 normally open) by pressing one of the arrow buttons one or more times (Figure 6-40, left). 5. Press the SET button to advance to the OUT2 setting. 6. Set the output mode for OUT2 to buttons (Figure 6-40, right). (2 normally open), using the arrow
Figure 6-40: Output Mode 1 Normally Open (Left); Output Mode 2 Normally Open (Right)
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9. Press the SET button to advance to the Auto/Manual mode. 10. Set the mode to (manual), using the arrow buttons (Figure 6-41, right). This mode must be selected before you can set the P1 value as described in the next subsection. 11. Press the SET button a final time to return to normal operations in Measure Mode.
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To set the minimum air pressure: 1. Press the SET button until the display reads . The flashing P_1 display alternates with the value at which P1 is currently set. 2. Press the up or down arrow buttons repeatedly until the P1 value is lower than the current air pressure. CAUTION: Never set the P_1 value below 65! Doing so will cause the handler to continue operating at too low air pressure, causing serious problems to the handler. 3. Press SET again repeatedly to scroll through P_2, P_3, P_4, C_S, and back to normal operations in Measure Mode.
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a. The PV, PS, and PD ports are all common to one another. b. The PV, PS, and PD ports are all common to one another. c. The PS and PD ports are common to each other.
PD port PS port
PV port
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PD (upper hole, Figure 6-42) is the air supply port for the release valve. PS (middle hole, Figure 6-42) is the air supply port for the vacuum valve. PV (lower hole, Figure 6-42) is the vacuum supply port.
Figure 6-43: Vacuum AssembliesK15 (Top); K35 Switch for Vacuum Pump (Bottom)
The black solenoid valves for K35 are longer than those for K15 (Figure 6-43). Also, K35 has two interface plates, whereas K15 has only one.
The locations of the holes in the interface plates (Figure 6-44) serve to redirect the internal air flow. Vacuum switches require the use of a separate vacuum pump.
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Figure 6-46: Blow-Off Adjustment Screw Locationon Vacuum Generator (Left); on Vacuum Switch (Right)
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Vacuum Generators
When the air regulator shows enough pressure but the vacuum at the pickup nozzle is too low, the origin of the problem is somewhere between the air regulator and the vacuum generator. If a problem appears consistently, even at startup, it may be dirt in the air filter. Check for: Dirty air filter in the vacuum generator Loose or pinched air hose Loose air fitting
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Inspect the vacuum generators air filter weekly. The filter should be clean and white. CAUTION: A dirty filter means poor handler operation. Replace your filter!
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PD port
PS port
PV port
Figure 6-49: Blow-Off Adjustment Screw at PD Port When Using Vacuum Pump
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4. Remove the gaskets from both solenoid valves (Figure 6-55). Be careful not to cut or damage the gaskets.
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> Occasionally a gasket may get stuck to the venturi when the solenoid valve is removed (Figure 6-56). Remove the gasket and save it.
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Figure 6-57: Vacuum Assembly with Both Solenoid Valves and Gasket Removed
5. Turn the air supply on and let it blow out the venturi. 6. Use a hand-held air supply to blow out each solenoid valve by hand. 7. Ater all parts are cleaned out, turn the air supply off before reassembling. 8. Press the gaskets back into the solenoid valves. 9. Replace the solenoid valves on the venturi and screw them in.
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When the P1 value is reached, the signal is turned on. From this value and above, the handler considers that a device is attached to the pickup nozzle. When the P2 value is reached, the signal is turned off. For Exatron handlers, the P2 maximum value is set to 101 so that it will never be reached.
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As a general principle, a larger hole in the suction cup of the pickup nozzle will show a lower baseline value (when no device is attached) because the air flow is not obstructed as much as it is with a smaller suction cup hole (Figure 6-59). When the suction cup hole is smaller, the baseline pressure is higher (Figure 6-60).
Figure 6-59: Vacuum Generator Optimal Pressurefor Nozzle with Larger Hole
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Figure 6-60: Vacuum Generator Optimal Pressurefor Nozzle with Smaller Hole
If you replace a vacuum generator with a new one, you need to calibrate its settings. A new vacuum generator has both P1 and P2 set at zero, and EC set at 3. You will need to change these settings. The modes cycle through P1, P2, P3, (P4 is added for a vacuum switch using a vacuum pump system), and EC with repeated pressing of the SET button. Mode
P1 P2 P3 P4 EC Low limit High limit For other sensor For switch using a vacuum pump system Error code
Meaning
Desired Setting
8-10 points higher than vacuum on w/ no device present; minimum 60 101 61 or lowest n/a 0
Result
Device is considered as attached to pickup; green light on No device is considered as attached to pickup; green light off Not used Not used Not used
You can use either the vacuum override buttons on the handler, or the tiny vacuum override button on the vacuum generator itself (Figure 6-62).
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Vacuum button
Blow-off button
To calibrate the vacuum generator: 1. Power on with no air. > A 1 or 0 should be displayed on the LCD screen. 2. Turn on the air and the vacuum, using the software. Do not attach a device yet. 3. Press the vacuum override button with no device attached to the nozzle and note the setting. This is the baseline value (Figure 6-62).
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4. Press the SET button to enter the programming modes. > P1 with the value is displayed. P1 sets the minimum limit at which the sensor detects a device. 5. Press one of the green arrow-shaped buttons to set the number at least 8 to 10 points higher than the baseline value (with no device attached), but no lower than 60 (Figure 6-63). The minimum should be 60. > Press the up-arrow button to increase the number displayed. > Press the down-arrow button to decrease the number displayed. > Factors such as weight of the device or rotation of the pickup nozzle may affect the number that works best for your handler.
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> P2 with the value is displayed. P2 sets the maximum limit beyond which the sensor no longer detects a device. 7. Press the up-arrow button repeatedly to set the P2 number at 101, the maximum limit (Figure 6-64).
8. Press the SET button to advance to the unused P3 setting. 9. Press the down-arrow button repeatedly to set the P2 number at 61 or the minimum limit. 10. Press the SET button to advance to the EC setting. > EC with the value is displayed. 11. Press the down-arrow button repeatedly to set the EC number at 0 (Figure 665). 12. Press the SET button again to return to normal operation mode.
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Now you can check the settings. To check vacuum generator settings: 1. Power on with no air. > A 1 or 0 should be displayed on the LCD screen. The green light on the vacuum generator stays on. 2. Turn on the air and the vacuum, using the software. Do not attach a device yet. 3. Press the vacuum override button with NO device attached to the nozzle and note the setting. > The setting with no device attached should be at least 8 points lower than the P1 setting. 4. Now attach a device to the nozzle and press the vacuum override button. Note this setting number. > The setting with a device attached should be at least 68-75 or higher, or at least 5 points higher than the P1 setting. Lower numbers may indicate some problem with the air line, perhaps the tubes or compressor. 5. Finally, to test your settings, put a device on the nozzle and press the override button. With a device attached, a green indicator light is displayed on the vacuum generator (Figure 6-66). With no device attached, the light goes off (when EC is set to 0; if EC were set to 3, the indicator light would be red when no device is attached).
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Figure 6-66: Green Indicator Light with High Number Showing Device Attached
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Solenoid Maintenance
CAUTION: NEVER use oil or lubricant of any kind on solenoids. Keep the solenoids as clean as possible. If the handler is used with devices which have excessive mold flash, the solenoids will require cleaning regularly. The frequency is dependent upon how much mold flash gets into the solenoids. When cleaning solenoids, take care not to put excessive stress on solenoid wiring. Check all wiring for signs of wear, exposed conditions, or broken connections. Replace as needed with identical type of wire: standard or flex, same gauge, insulation, color, etc. When cleaning solenoids, check the plungers to be sure there are no burrs of any kind on their shafts. Solenoid life is proportional to the handler environment and how often the solenoids are cleaned. We recommend that all solenoids be replaced every two million cycles as part of a good preventive maintenance program. Replace any bent or damaged solenoid return springs with new parts from the Exatron factory. Refer to the hardware specifications in Chapter 7 for the part numbers of all solenoids and springs in your handler.
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Cabinet Models
To replace a computer part on a cabinet-based model: 1. Unscrew and remove the 4 allen screws that bolt the computer to the computer base (Figure 6-68).
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3. Unscrew and remove the 2 bolts at the top front of the computer that secure the lid (Figure 6-70).
4. Unscrew and remove the 6 bolts along the top edges of the computer (3 on each side; Figure 6-71).
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Benchtop Models
5. Lift off the lid. 6. Replace any part that needs to be replaced. 7. Reassemble the computer in reverse order.
Benchtop Models
If any part inside the computer needs to be replaced on a benchtop model, you can take the following steps to avoid turning the handler upside down. NOTE: It is helpful to have two persons doing the work in order to hold the assemblies in place without stressing the connections on the cables. You will need a medium flat-head screwdriver and standard and metric allen key sets for this procedure. It will also be helpful to have a small sturdy box to rest the faceplate on while replacing the hard drive or other part. To replace a computer part on a benchtop model: 1. Power off the handler and set the front of the handler onto blocks elevating the front legs off the work surface (Figure 6-72).
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2. Identify the keyboard and mouse jacks with a label or pen. Although each one is identified on the face plate, you will be separating the face plate from the jacks.
3. Remove keyboard and mouse cables. 4. Unscrew the small screws holding the mouse and keyboard jacks. 5. Remove the screws on the perimeter of the face plate and carefully pull the face plate forward.
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Benchtop Models
NOTE: The bearings at the end of the lead screw will come loose, so be careful not to drop them. The EMO (emergency stop) and power button wires will restrict the face plate from extending farther than five or six inches, so it will be helpful to have a box to rest the face plate on while removing the ribbon cables and replacing the hard drive. 6. Replace computer part and replace ribbon cables. 7. Reassemble the jacks. 8. Reassemble the face plate.
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The green light is the Stable Operation Indicator. When the sensor is operating normally under stable conditions, the green light should be ON. The red light is the Light Reception Indicator. When the sensor is receiving light, the red light should be ON.
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Taper Maintenance
Benchtop Models
For both types of sensor (through-beam and reflective), the red light on means nothing is there; nothing is blocking or reflecting the sensor beam. If the red light is off, something is there, interfering with the sensor beam.
Taper Maintenance
If your handler uses a tape and reel, you need to keep the seal head clean. If you use a heat seal blade, clean the blade with a cotton swab dipped in acetone, isopropyl alcohol, or other suitable (evaporative) cleaning agent. Be sure to do this when the heat seal is cold. If you use a pressure-sensitive seal blade, wipe the pressure roller wheels with a clean dry cloth. The wheel bearings are sealed from the factory and need no maintenance. Clean the sensor optics of dust with a very low blast of air.
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The display at the right is for the pre-heat tray. It is connected at the light blue plug in the back of the box.
Before you begin, the display panel shows the current temperature of the clamp head (Figure 6-80).
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Benchtop Models
Four buttons allow viewing or changing the desired set temperature. Buttons on Temperature Controller Display Panel Button Function Menu Changes the display to configuration mode and advances through menu items. Up Arrow Increases set temperature. Down Arrow Decreases set temperature. Enter Enters a submenu or saves a change made in the current submenu. NOTE: Any set temperature changes made on the control panel will be overridden by the Exatron software settings.
To view or change the set temperature: 1. Press the Menu button. The display reads SP1 (Figure 6-81).
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2. Press the Enter button. The set temperature is displayed, with the rightmost digit flashing (Figure 6-82). You can tell this is different from the current temperature display because instead of a C or F at the left of the display, now a small 1 is visible, signifying that this is displaying the Setpoint 1 value.
> If you do not want to change the set temperature, go to step 3. > If you want to increase the set temperature, press the Up arrow button (Figure 6-83). Holding it down for 3 seconds speeds up the rate of increment. To save your change, press the Enter button. The display reads StRd (stored; Figure 6-84).
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Benchtop Models
> If you want to decrease the set temperature, press the Down arrow button. Holding it down for 3 seconds speeds up the rate of decrement. To save your change, press the Enter button.
3. Press the Menu button. The display reads SP2 (Figure 6-85). The Exatron system does not use the second setpoint.
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4. Press the Menu button. The display reads CNFG (Figure 6-86).
5. Press the Menu button. The display reads RUN briefly before it returns to Run mode, displaying the current temperature again.
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Internet Access
The amount of air pressure applied by the thermal heads at the test socket is set in the Diagnostic software (see "Socket Pressure Group Box" on page 5-102). To manually raise or lower each thermal head, flip the corresponding switch. To turn the air pressure on or off, flip the top switch.
Laser Servicing
If the handler is equipped with a laser, see the manufacturers manual for service instructions. WARNING! Only a qualified in-house laser safety officer (LSO) should service the laser.
Networking
The next few subsections discuss ways of troubleshooting over a network.
Internet Access
It is strongly recommended that your handler be equipped with Internet access, without which Exatron cannot help you troubleshoot the handler remotely.
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Required IP Addresses
IP Address
192.168.12.1 192.168.12.11 through 192.168.12.29 192.168.12.3 192.168.12.4 192.168.12.41 192.168.12.42 192.168.12.5 192.168.12.51 through 192.168.12.59
Component or Peripheral
Exatron PC Handler motors, sensors, PLCs Laser PC Camera/machine vision PC Camera 1 Camera 2 Peregrine tester Other testers
A computer may have more than one LAN (local area connection) setup. In this example, LAN 3 is used. To set the LAN connection: 1. Double-click the icon in the lower left corner of Windows desktop to open a LAN connection setup (Figure 6-88).
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Networking
> The Local Area Connection Status dialog box is displayed (Figure 6-89).
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3. Under the General tab of the Local Area Connection Status dialog box, click the Properties button (Figure 6-90). > The Local Area Connection Properties dialog box is displayed.
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Networking
4. Under the General tab of the Local Area Connection Properties dialog box, click the connection Internet Protocol (TCP/IP) (Figure 6-91). 5. Click the Properties button. > The Internet Protocol (TCP/IP) Properties dialog box is displayed.
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6. Under the Advanced tab of the Local Area Connection Properties dialog box, in the Windows Firewall group box, click the Settings button (Figure 6-92). > The Windows Firewall dialog box is displayed. 7. Under the General tab of the Windows Firewall dialog box, make sure the Dont Allow Exceptions box is not checked.
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Networking
8. Under the Exceptions tab of the Windows Firewall dialog box, check all the pcAnywhere... and Remote... boxes (Figure 6-93). 9. Click OK. 10. Click OK repeatedly to close the LAN setup.
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4. In the DOS window that opens, at the C:\ prompt, type PING followed by a space and then the IP address of the peripheral with which you want to test communication.
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Networking
> You should see a series of replies like the ones shown in Figure 6-96. All packets sent should have been received, with none lost. 5. To show the IP address of the host (Exatron) PC, in the DOS window type IPCONFIG /ALL.
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> You should see information similar to that shown in Figure 6-97. The host (Exatron) IP address in this example is 192.168.10.110.
To join the meeting, just click the link that is displayed in the e-mail message and follow the instructions shown.
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Networking
If you have any problems, click on the help link from WebEx at the bottom of the e-mail. Their support is thorough.
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Figure 6-100: Exatron Directory with Job Files, 3 Essential System Files, and Existing Program File
Following this procedure will insure that a backup is maintained of the original and all subsequent upgrades. CAUTION: Do not delete any previous zip files from the Backup directory. Always maintain an additional up-to-date copy of all the contents in the C:\Exatron\Backup\ directory on external media such as a CD-ROM or a set of floppy disks. Exatron may send zip files by e-mail with modified file extensions so the files don't get stripped or blocked by the firewalls at client sites. Prior to extracting from these files, rename the zipped file, changing the extension back to *.zip. To install the Exatron software: 1. Close all applications and open Windows Explorer to navigate and edit file directories. 2. Copy the current Exatron program file into the C:\Exatron\Backup directory.
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3. Copy the .edf or .job files for the jobs/setting files you are currently running into the same Backup directory. Rename these backup files to include date and time in the file name so you can identify and reuse these files if necessary. 4. In the C:\Exatron\ directory, delete the [YourCompany]_[Model#]_[suffix]_[date_time]_[version].exe file. (A backup is already in the C:\Exatron\Backup\ directory.) 5. Copy the attached .zip file into this same directory (C:\Exatron\Backup).
Figure 6-101: Backup Directory with Job Files, Old Program File, and New Zipped File
6. Double-click on this new *.zip file and extract it into the directory C:\Exatron\ where the previous program file was deleted. It has a newer date/time/version than the previous program file.
Figure 6-102: Exatron Directory with Job Files and New Program File
Typically a shortcut is placed into the C:\Documents and Settings\All Users\Start Menu\Programs\Startup directory so that this program will automatically launch when Windows is started. This shortcut must be replaced with a shortcut pointing to the new program file. 7. Right-click on the filename and select Create Shortcut from the context menu to make a shortcut for the new file.
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8. Click and drag the shortcut (not the original file!) into the directory C:\Documents and Settings\All Users\Start Menu\Programs\Startup. 9. Copy this shortcut to the desktop and delete the old shortcut. 10. Restart appropriate applications, or restart the CPU and the applications will automatically start. The new executable program file is ready to use. When an original .edf or .job file is opened using this new program file, you may see an error message: Unexpected file format. If this happens, it is because the new program file contains new data fields that require values from the job file, so the job file is not properly formatted.
To reformat the job file: 1. Click OK in the error message dialog box. 2. Click the Diagnostics button and check the various windows for new fields. 3. Enter valid data in any new fields or input boxes. 4. Finally, save these settings before exiting the program. Bacause you have saved the new variable into this .edf or .job file, the next time you open this .edf or .job file, the Unexpected file format error will not appear.
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Troubleshooting
Troubleshooting
The following are problems that have been encountered occasionally, and their solutions.
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the rub cycle. If the gap is significantly larger or smaller (.015" or more), then the software setting in the Exatron software should be adjusted accordingly. Vacuum cup is dirty or worn out. > Check the vacuum cup. Visually inspect the suction cup to make sure it is physically intact, i.e., no tears or chunks missing. Then, using a cotton swab dipped in isopropyl alcohol, clean the inside surface of the suction cup bellows. Vacuum adjustment is wrong. > The Model 900 has a vacuum sensor that tells the system when a vacuum is detected, which means there is a part seated on and being held by the vacuum cup. The vacuum sensor has a small LCD display which shows the strength of the vacuum, as measured in centimeters of mercury (cmHg). The sensor is set at a given measurement, and when the actual vacuum measured in the sensor is higher than that number, it tells the system a part is captured. To determine the set point, flip the small switch on the vacuum housing to "SET." Then, with the switch back at "RUN," press the vacuum override button on the side of the handler near the vacuum sensor assembly. This will draw a vacuum and the sensor will show the measurement. Block the pickup head manually with a device to see that setting. The actual measurement should be at least 10 cmHg above the set point. You should see a red light illuminate on the vacuum sensor when a vacuum is measured at or above the set point. Typically, the set point will be around 50 cmHg and the actual measurement with a device present will be around 60 65 cmHg. If your numbers are significantly different than these numbers, you should carefully inspect the rest of the pneumatic system for blockages, breaks, etc., as explained next. Air lines blocked or broken/worn/disassembled. While unlikely, it is possible for the air lines to become broken, blocked, or otherwise rendered non-functional. This can happen due to wear, particulate or liquid contaminants in the air supply lines. > Check all air fittings to assure the air tubing is well seated in the fitting. > Visually inspect all the air lines and the incoming air regulator assembly for wear, discoloration or cracking. Replace any air line that appears compromised. Check for liquid in the reservoirs of the incoming air regulator. If either is full, you must remove the regulator from the system and drain the unit. Disconnect the incoming air supply and tip the unit to allow liquids to drain out. EXATRON STRONGLY RECOMMENDS REPLACING THE REGULATOR UNIT IF THIS PROBLEM HAPPENS MORE THAN ONCE. MOREOVER, THE CUSTOMER SHOULD ATTEMPT TO IMPROVE THE INCOMING AIR SUPPLY TO ASSURE IT IS CLEAN AND DRY.
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Troubleshooting
Blow-off is not working properly. In addition to creating the vacuum, the vacuum generator unit also acts as a regular air valve. The Model 900 relies on this feature to send a blast of positive air pressure through the vacuum line in order to break the residual vacuum pressure after the vacuum is turned off. Without the blow-off, it is possible for devices to stick to the pickup head due to this residual vacuum. > Test the blow-off function by pressing the blow-off override button on the side wall of the handler base near the vacuum generator unit. A small positive air flow should be felt at the suction cup. If no pressure is felt, the unit may be malfunctioning or set too low. > A small adjustment screw can be found on the vacuum generator unit which will increase or decrease the blow-off pressure. Care should be taken when adjusting this screw, as loosening it will have the effect of increasing the blow-off pressure, but if the screw is turned too much, it will come out and render the blow-off inoperable. See "Adjusting Pickup Nozzle Blow-Off" on page 6-43. Pickup head shaft is loose and out of position. > The pickup head shaft is retained by a clamp at the top of the Y gantry unit. If this clamp is loose, it is possible for the shaft to "migrate" up, thus eventually getting out of position. If this happens, the shaft can be pushed back down and re-tightened, or tightened in the new position and the various job software settings adjusted accordingly. The first course of action is preferable but must be done carefully. In most cases, the migration will be no more than .050" and so only a small adjustment must be made. If the adjustment makes the head too low, it may place unacceptable pressure on the devices in the trays. Thus, make a very small adjustment and test the new setting to see if it picks up devices. Watch carefully for over-travel.
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USE A BALL HEAD DRIVER). Loosen only the screw nearest the lead screw, not the motor. Access the screw head through the slots in the motor mount block. When the screw is loose, manually push the lead screw as hard as possible against the motor-end wall of the axis housing. While maintaining this pressure, tighten the motor coupling screw. Recheck the lead screw to make sure it no longer moves away from the wall.
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Suction Cups
Exatron stocks three sizes of anti-static silicone suction cups for the Model 900: 4 mm, 6 mm, and 8 mm diameter. The correct size for a given suction cup will depend on the size of the device. Choose a suction cup so that when the vacuum is applied the edge of the cup is at least .020" from any edge of the device (or leads if the device is dead-bug). Keep in mind to use the largest cup that fits this requirement. Exatron part numbers are: 2mm: PNE042-412 4mm: PNE042-414 6mm: PNE042-416 8mm: PNE042-418
The 2 and 4 mm cups fit over one mounting stud, while the 6 and 8 mm cups require a different stud. In most cases, Exatron systems ship with the correct stud for the 6 and 8 mm cups. These studs can be purchased separately, and come with either a 2 mm, 4 mm, or 6 mm cup attached. The part numbers are:
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Stud with 2 mm Cup: PNE042-402 Stud with 4 mm Cup: PNE042-404 Stud with 6 mm Cup: PNE042-406
Z Chain
This is a 70-link hard plastic chain or belt. The Exatron part number is BEA12-003.
Hose Sizes
Hoses are ESD (electro-static discharged) for handler safety. The size is stamped on the hose: 5/32" or 1/8" or 1/4" or 3/8", to enable you to order the right size.
Relays
The mechanical relay (or contactor) inside the Exatron PC acts as a safety circuit; it cuts power when necessary. When changing out to a new one, make sure you order the right one, either 12 volt or 24 volt (Figure 7-1).
Motor Controllers
When ordering Cool Muscle motors, be aware that master and slave motors are somewhat different. The master has a secondary circuit board piggybacked on top; the slave does not (Figure 7-2). Exatron recommends that you order a master, because you can use a master as a slave if it becomes desirable; but you cannot use a slave as a master.
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Motor Controllers
Figure 7-2: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Board
Figure 7-3: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations
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Notice that the jumper configurations are different for the master than for the slave. The slave has the black jumpers all the way to the left; the master has them all the way to the right (Figure 7-3). These jumper configurations can be changed just by pulling them off and replacing them on different pins.
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Manual
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.
C B A
Figure 7-4: 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.
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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.
List of Parts
A parts list specific to each handler is included with each manual. See the following inserted pages.
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Chapter 8: Prints
A set of prints specific to each handler is included with each manual. See the following inserted pages. Additionally, an optional seismic tie-down kit is available from Exatron (see Figure 8-1 on page 8-2). Call for a quote.
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Chapter 8: Prints
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This information applies to both pick-and-place handlers and gravity-feed handlers. NOTE: All the interface types discussed in this chapter are options. No one interface type is included automatically. Whereas every handler has an RS-232 port and an ethernet port (hardware), the software drivers and the interfaces used for your handler will depend on your needs and the features you order.
DUT InterfaceHardware
DUT (Device Under Test) interface connects the handlers test contacts to the testers test socket. A direct dock interface provides the best performance, although other interface methods are available.
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Some factors to consider when selecting a protocol include: Serial cable RS-232 interfaces between only 2 entities, but RS-485 allows a daisy chain configuration among multiple entities. These two protocols use slightly different hardware. If a tester uses RS-485, it may not work with Exatrons RS-232. The GPIB language set is quite complex. Its customization for your needs requires a separate quote. The protocol for each handler is custom-designed for the handler and the tester it will use. There are many options that can be selected to customize this interface to your specific application. Each handlers interface is specific to that handler, but it is usually a variation of the RS-232.
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TCP/IP Interface
Handler port
Figure A-1: Ports
TCP/IP Interface
With the TCP/IP protocol interface, the handler acts as the client, and the tester acts as the server. To use this interface, the tester software is opened first. The tester software waits for the Winsock connection over the ethernet from the handler software. After the tester software is running, the Exatron software is opened. The Exatron software connects through Winsock with the tester computer. They use standard serial commands.
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The TTL Handler Port on a Model 900 is connected inside the control PC to Port #3 on the 902 I/O PCB, PET-C06. On handlers with PET-C06 Rev A to Rev E, this Port #3 is not protected with opto-isolation. On these older revisions of PET-C06, use cable PET-G70-C which removes the handler +5 VDC from the 24-pin D connector. Connecting the handler's +5 VDC to the tester's +5 VDC is not allowed. Connecting the Tester +5 to the Handler +5 will result in a blown-up PET-C06 PCB, which is not covered by the handler's warranty. Handlers equipped with PET-C06 Rev F or newer 902 I/O PCBs use an opto-isolated Port #3 (Figure A-3). It is highly recommended that when the TTL Handler Port interface is required, older handlers be upgraded. Handlers with opto-islated Port #3 use cable PET-H07-A or newer. The opto-isolated TTL interface will require tester-supplied +5 VDC and tester-supplied ground to be functional. Never connect the handler's +5 VDC or +24 VDC supplies to anything other than the handler.
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End of Test
If desired, you can request an "End of Test" be added to your handler software. In this case, the End of Test signal will be connected to Sort 8 on the 24-pin D connector. The End of Test and just one of the other 7 sorts must be low at the same time, for at least 2 milliseconds.
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For PET-C06 Rev F I/O PCBs with opto-isolation, it is necessary to use an extension cable with the LED checker that allows the handler's +5 VDC and Ground to be connected.
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All commands are standard uppercase ASCII characters. Typically, a NULL modem, female/female, 9-pin RS-232 cable is required for each port. The testers should always include a "\r" carriage return after every command. The handler will send a "\r" after every response. The RS-232 serial ports use only 3 wires to transport ASCII, or serial strings: Send Receive Ground
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Once the handler receives the sort command from the tester, the handler picks up the now tested device and sorts it to the predetermined output. This completes a normal test cycle. The handler will move over the next untested device to be picked up and sends a "H\r" to the tester and a new cycle is started. Handler sends: "INPUT_TRAY_EMPTY\r" (Handlers input is empty; it displays message to load more devices)
Cycle Summary
For each cycle, the following exchange occurs. Handler sends: "H\r" (Cycle?) Tester sends: "R\r" (Ready) Tester sends: "EOL\r" (Stop getting device from input) Handler sends: "EOL\r" (Finished getting device from input) Handler sends: "S\r" (Start test) Tester sends: "1\r" (Sort 1) or "2\r" (Sort 2) or "3\r" (Sort 3) or "4\r" (Sort 4) or "5\r" (Sort 5) or "6\r" (Sort 6) or "7\r" (Sort 7) or "8\r" (Sort 8)
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*\r ?\r
Copyright Exatron, 2011 02/2011
Example
0\r
9\r
Return to If the handler receives a "9\r" for a test sort, the handler will return the device to the pickup sort exact pocket it was picked up from. If the pocket to return to already has a device, which is remotely possible in some configurations, the device will be sorted to the dump pocket on the end of tray #1. Pause han- At the start of any cycle, the tester can send a Pause command to the handler. Handler sends: H\r" (Cycle?) dler When the handler receives a "P\r", the handler will stop cycling and post a message Tester sends: P\r" (Pause handler) to the operator. The handler will remain paused until the operator restarts the handler's operation from the handler's control panel. Once the handler is restarted, it will continue with its operations from the point it left off.
P\r
At the start of any cycle, the tester can send a zero all counts command to the han- Handler sends: H\r" (Cycle?) dler. This command is typically to be used at the start of a new lot of devices. The Tester sends: \r" (Zero counts) handler will send "H\r" to the tester. The tester will send back a "Z\r" to the handler. The handler will stop and display an Are you sure message to the operator. The operator will be given the opportunity to either reset all counts to zero or to continue on with the cycle with counts saved from the previous cycle. The handler will also give the operator an opportunity to reload or replace any trays of devices in the handler.
X\r
Disable socket
This is a way to have the handler "skip" any combination of test sockets, on the fly, Handler sends: "H\r" (Cycle?) when testing with more than one test socket. Tester sends: "X\r" (Skip cycle) The handler will move on to the next cycle for The handler will send a "H\r" at the start of each subsequent cycle. To permanently the next test site. have the handler skip a test site requires changing the handler's set up before starting any test cycles. This command allows the tester to remotely send the handler into an end-of-lot cycle. The handler can also be sent to an end-of-lot cycle from its control panel by the operator. Handler sends to the tester: "H\r" (Handler ready to cycle). The tester sends back a "E\r" (End Of Lot) The handler will go into its end-of-lot cycle. On single test site handlers, the handler will simply stop testing and display the End Of Lot message to the operator. On handlers with multiple test sites, the handler will stop loading untested devices. It will then either: Automatically remove any devices still being tested and return them to the same place they were picked up from, or Finish any devices still being tested and sort as required. The user can go to the handler's set up to select one of these two options for end-oflot test socket unloading. Once all sockets are emptied the handler will display the End Of Lot message to the operator and stop cycling. If the operator should go to end-of-lot from the handler control, the handler will stop loading untested devices. It will then do one of the two things just described. The user can go to the handler's setup to select one of these two options for end-of-lot test socket unloading. Once all sites are empty, "E\r" will be sent by the handler to every test site. No response is required back from any of the testers. Handler sends: "H\r" (Cycle?) Tester sends: "E\r" (End Of Lot, stop cycle)
E\r
End of lot
Cycle Summary
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Golden Unit If the handler is set up with a Golden Unit Tray Option, this exchange is used. cycle The handler sends the preliminary handshake: "H\r". The tester sends a response like "GC2\r" specifying the source pocket from which to get the Golden Unit, and the destination test site into which to put it.
(The unit specified may be any Golden Unit from A to G, and may be designated for any The handler picks up a device and places it in the test socket specified by the tester. test site available, thus: GA2, GG1, GF2, etc.) Once the device is fully clamped in the test socket, the handler sends a command to start testing that designates the same test site requested by the tester, like "S2\r". Handler places unit, sends: "S1" (Start testing at test site 1) Once the tester has completed its test, it needs to send back a Sort command, like "1\r" or "7\r". The handler accepts any of 8 sorts from the tester. The handler then Tester finishes test, sends sort result: picks up the device and places it back in the pocket where it was picked up, regard- "1\r" less of the sort received from the tester. This completes a Golden Unit test cycle. Handler retrieves unit into original pocket. The cycle repeats, beginning with the tester sending another source-to-destination command, like "GD1\r". Tester sends another test request: "GB2" The handler can be commanded to pick up any device, from any pocket, from any input tray. This is an option that must be selected prior to cycling the handler. The handler will normally pick untested devices from the first left hand pocket of an input tray and then automatically index to the next pocket or tray until all input pockets are emptied or until the handler reaches a predetermined number of empty pockets in a row. Handler sends: "H \r" (Cycle?) Tester sends string: "T ## _ R # # _ C # #\r" where: T (Tray) # (Tray carriage number, 1 to 5) # (Sub Trayuse 0 for JEDEC trays; use 1 to 8 for 2"/4" waffle packs) The user must select either sequential input pick up or "Pick Up Specific _ (Underscore) Device" prior to cycling the handler. The two choices cannot be intermixed in R (Row) a given setup. Either the handler is in control or the tester is in control. # (Row number, use 0 for rows 1 thru 9) # (Row number, 1 to 9) The handler will go to the specified pocket and attempt to pick up the device. If a _ (Under score) device is found the device will be loaded into the test socket and a test cycle will be C (Column) started. If no device is found, the handler will pause, display an error message, and # (Column number, use 0 for column 1 thru 9) then automatically return to the start of the next cycle. # (Column number, 1 to 9) \r (End of string) At the end of test, the tester can either send the now-tested device back to the pocket it was picked from, or sort it normally. See the above sort commands for details.
Output tray At some point the handler output tray(s) will reach its last pocket. The handler will full stop and display a message to the operator. The handler will also be at the start of the next cycle at this point. The handler will send: "TRAY <SP> FULL\r" to the next test socket to be loaded. No answer is required from the tester. This string will be sent only to the next test socket/tester. The operator will be given several choices at this point: The operator can choose to go into an end-of-lot cycle as described above. The operator can reload empty tray(s) as required. Then a new cycle can be started by the operator. A new "H\r" will be sent to the test socket/tester. Output tape Some handlers are equipped with optional output tape-and-reel assemblies. At full some point the taper will reach its preset full count. The handler will stop and display a message to the operator. The handler will also be at the start of the next cycle at this point. The handler will send: "T A P E <SP> F U L L\r" to the next test socket to be loaded. No answer is required from the tester. This string will be sent only to the next test socket/tester. The operator will be given several choices at this point. The operator can choose to go into an end-of-lot cycle as described above. The operator can reload new supplies or a new empty reel as required. Then a new cycle can be started by the operator. A new "H\r" will be sent to the test socket/tester. Output tube Some handlers are equipped with optional output tube holders. At some point the full tube(s) will reach its preset full count. The handler will stop and display a message to the operator. The handler will also be at the start of the next cycle at this point. The handler will send: "T U B E <SP> F U L L\r" to the next test socket to be loaded. No answer is required from the tester. This string will be sent only to the next test socket/tester. The operator will be given several choices at this point. The operator can choose to go into an end-of-lot cycle as described above. The operator can reload new empty tubes as required. Then a new cycle can be started by the operator. A new "H\r" will be sent to the test socket/tester.
Cycle Summary
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S ## _ R # Device out- The handler can be preset to attach the output sort location of each device just after TRAY outputs example: # _ C # #\r put sort the device is placed in its output. This option must be turned on or off in the hanS12_R01_C23\r location dler's setup prior to cycling. S (Sort) # (Tray carriage number, 1 to 5) After the handler drops off a tested device into the tray, it can be preset to send back # (Sub Trayuse 0 for JEDEC trays; use 1 to the following string "S ## _ R # # _ C # #\r". See example for bucket, tape & reel, 8 for 2'/4" waffle packs) and output tube sorting responses. _ (Underscore) R (Row) No response is required back from the tester for any of these messages. The han- # (Row number, use 0 for rows 1 thru 9) dler then moves on to the next cycle. # (Row number, 1 to 9) _ (Underscore) C (Column) # (Column number, use 0 for column 1 thru 9) # (Column number, 1 to 9) \r (End of string) BUCKET outputs example: B1\r B (Bucket) # (Bucket number) \r (End of string) TAPE-AND-REEL outputs example: T256\r T (Tape) # (current pocket count) # # # \r (End of string)
OUTPUT TUBE outputs example: O3_15\r O (Output tube) # (Tube number) _ (Under score) # (current pocket count) # # \r (End of string)
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No response is required back from the tester. Other possible handler start of cycle messages: Note: none of these messages require a response back from the tester. "TRAY FULL\r" "TAPE FULL\r" "TUBE FULL\r" "E\r" (End Of Lot)
Serial Commands for Multiple Test Sites with One Serial Port
This interface is an extension of the standard EXATRON RS-232 interface. NOTE: If you want to implement this interface, contact Exatron at 800-EXA-TRON. This interface requires optional test site hardware and software. In addition to the command exchange explained under "Exatron RS-232 Commands" on page A-10, this interface has the following enhancements:
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Serial Commands for Multiple Test Sites with One Serial Port
"15\r" (Site 1 sort 5) or "16\r" (Site 1 sort 6) or "17\r" (Site 1 sort 7) or "18\r" (Site 1 sort 8) or Tester sends: "10\r" (Retest test site 1) Note that the tester can send a result only from the test site queried by the handler. For example, if the handler request is "E4\r" for test site 4, then the response must be from test site 4. The interchange would be as follows: Handler sends: "S4\r" (Start test site 4) Handler sends: "E4\r" (Request for end-of-test result from site 4) Tester sends: "4B\r" (Test site 4 still busy; handler pickup nozzle then moves to another test site) or Tester sends: "41\r" (Site 4 sort 1) or "42\r" (Site 4 sort 2) or "43\r" (Site 4 sort 3) or "44\r" (Site 4 sort 4) or "45\r" (Site 4 sort 5) or "46\r" (Site 4 sort 6) or "47\r" (Site 4 sort 7) or "48\r" (Site 4 sort 8) or Tester sends: "40\r" (Retest test site 4) As the handler is at various times in a mechanical position to remove devices from any of the test sites, the handlers start test and its request for test results may not be in the order of E1, E2, E3, E4. Rather, the requests may come in any order: E3, E2, E4, E1. The reply from the tester must be concerning the test site specified by the handlers request.
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"S210\r" (Site 2 holds a device in socket 1 but not in socket 2) or "S201\r" (Site 2 holds no device in socket 1, but there is a device in socket 2)
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The beginning and ending interface commands for both tester-controlled and handler-controlled temperatures are the same. With tester-controlled, the testers setting of test temperature, the testers request for tested temperature, and the handlers supplying of tested temperature are added in the middle.
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Set_Temp##_C\r (Cold head with temperature) or... Set_Temp##_H\r (Hot head with temperature) Handler sends: Ok\r (Handler has clamped device with specified thermal head and applied specified temperature.) Tester sends Read_Temp?\r (Request for heads temperature.) Handler sends: Temp##.##\r (Handler sends temperature with two decimal places.) At this point, if the thermal heads temperature is outside the range of tolerance, the tester will repeat the request for the heads temperature until it is within the range. Then, if the device passes the test, the tester may ask the handler to test the same device with another thermal head; and the cycle repeats, starting with the testers command Set_Temp##_[C/H/R]. At the end of the testing cycle of one device, or when it has failed a test, the tester gives the sort category: Tester sends: Bin[1-8]. This completes the test cycle for one device.
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Exatron uses hexadecimal as an easy way of representing binary. It allows the transmission of an instruction of 2 digits rather than an instruction of 8 digits. The handler decodes the hex instructions into a binary map. Each hex character represents 4 binary digits and 4 sockets. The numbers represent the following outputs. In binary notation, 1 = TRUE and 0 = FALSE. So only the columns, or sockets, with 1s receive devices.
Lets suppose that devices are in sockets 1-4, 7, and 8; but not in sockets 5 and 6. The hex value sent by the handler is CF. The binary code into which the tester would translate this is shown in the bottom row, following. Notice that each bin designated as yes, put here, has a 1 for TRUE.
Socket 8 1 Socket 7 1
Socket 6
0
Socket 5 0
Socket 4 1
Socket 3 1
Socket 2 1
Socket 1 1
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Hex
00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 11 12 13 14 15 16 17 18 19 1A 1B 1C 1D 1E 1F 20 21
Binary
0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 1110 1111 0001 0000 0001 0001 0001 0010 0001 0011 0001 0100 0001 0101 0001 0110 0001 0111 0001 1000 0001 1001 0001 1010 0001 1011 0001 1100 0001 1101 0001 1110 0001 1111 0010 0000 0010 0001
ASCII
Decimal
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65
Hex
22 23 24 25 26 27 28 29 2A 2B 2C 2D 2E 2F 30 31 32 33 34 35 36 37 38 39 3A 3B 3C 3D 3E 3F 40 41 42 43
Binary
0010 0010 0010 0011 0010 0100 0010 0101 0010 0110 0010 0111 0010 1000 0010 1001 0010 1010 0010 1011 0010 1100 0010 1101 0010 1110 0010 1111 0011 0000 0011 0001 0011 0010 0011 0011 0011 0100 0011 0101 0011 0110 0011 0111 0011 1000 0011 1001 0011 1010 0011 1011 0011 1100 0011 1101 0011 1110 0011 1111 0100 0000 0100 0001 0100 0010 0100 0011
ASCII
" # $ % & ( ) * + , . / 0 1 2 3 4 5 6 7 8 9 : ; < = > ? @ A B C
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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
Binary
0100 0100 0100 0101 0100 0110 0100 0111 0100 1000 0100 1001 0100 1010 0100 1011 0100 1100 0100 1101 0100 1110 0100 1111 0101 0000 0101 0001 0101 0010 0101 0011 0101 0100 0101 0101 0101 0110 0101 0111 0101 1000 0101 1001 0101 1010 0101 1011 0101 1100 0101 1101 0101 1110 0101 1111 0110 0000 0110 0001 0110 0010 0110 0011 0110 0100 0110 0101 0110 0110 0110 0111
ASCII
D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] ^ _ a b c d e f g
Decimal
104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139
Hex
68 69 6A 6B 6C 6D 6E 6F 70 71 72 73 74 75 76 77 78 79 7A 7B 7C 7D 7E 7F 80 81 82 83 84 85 86 87 88 89 8A 8B
Binary
0110 1000 0110 1001 0110 1010 0110 1011 0110 1100 0110 1101 0110 1110 0110 1111 0111 0000 0111 0001 0111 0010 0111 0011 0111 0100 0111 0101 0111 0110 0111 0111 0111 1000 0111 1001 0111 1010 0111 1011 0111 1100 0111 1101 0111 1110 0111 1111 1000 0000 1000 0001 1000 0010 1000 0011 1000 0100 1000 0101 1000 0110 1000 0111 1000 1000 1000 1001 1000 1010 1000 1011
ASCII
h i j k l m n o p q r s t u v w x y z { | } ~
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A-25
Setting Up HyperTerminal
You can set up HyperTerminal in MS Windows as a way of testing communication between the Exatron handlers CPU and a tester. HyperTerminal emulates the communication protocol used by the tester, and displays the results of checking this communication. HyperTerminal uses a serial interface to communicate with the handler. NOTE: You cannot use the Exatron program while you are using HyperTerminal. Before you open HyperTerminal, close the Exatron software. Each message is in uppercase ASCII characters, followed by a carriage return. This ensures that all cables are secure and all communication is taking place.
> A brief splash screen is displayed. Wait a second for the window to appear.
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Setting Up HyperTerminal
> On some systems, an intermediate window may appear. If so, double-click the HYPERTRM.EXE program icon to open the program. If not, go to the next step.
2. In the Connection Description dialog box, type a name for your new connection, and click an icon to identify it. Click OK.
3. In the Connect To dialog box, click the drop-down arrow by the Connect Using
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A-27
box. Select the COM port you want to use. Click OK.
4. In the Properties dialog box, make the selections as shown in Figure A-12. Click OK.
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Setting Up HyperTerminal
If your typed commands are not reflected onscreen, you can change the settings to display them. To display commands typed in HyperTerminal: 1. In the main window, click the Properties button.
2. In the Properties dialog box, under the Settings tab, click the ASCII Setup button.
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A-29
3. In the ASCII Setup dialog box, check the Echo typed characters locally box to display what you type onscreen. 4. Check Send line ends with line feeds and Append line feeds to incoming line ends to continue displaying what was typed previously. (Thus you can scroll up to view the record, or history, of commands.)
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Setting Up HyperTerminal
5. Click OK. 6. Click OK in the other dialog box. 7. Save your session configurations.
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A-31
5. Press H (always use capitals) on the handler keyboard. > The tester should send an R that is displayed in HyperTerminal. If so, you know that the serial ports between the two machines are connected correctly. 6. Press S on the handler keyboard. > The tester should send a sort number, such as 0, that is displayed in HyperTerminal. If so, you know that the communication is working correctly. 7. To disconnect, click the Disconnect button.
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B-1
3. Press the right arrow key to select the Advanced menu (Figure B-2).
B-2
02/2011
Figure B-2: CMOS Setup Changed to Advanced Menu; Advanced BIOS Features Selected
4. Press the up or down arrow key to select Advanced BIOS Features. 5. Press the Enter key to enter Advanced BIOS Features (Figure B-3).
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B-3
6. Press the down arrow key repeatedly until the Second Boot Device line is selected (Figure B-3). 7. Press the Enter key to change its value.
B-4
02/2011
8. Press the down arrow key repeatedly until the CDROM line has the square selection mark (Figure B-4). 9. Press the Enter key to confirm this selection.
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B-5
11. Press the Enter key to save and exit (Figure B-6).
B-6
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B-7
3. Click the Manage Acronis Secure Zone button at the upper left (Figure B-9).
B-8
02/2011
5. Click to place a checkmark and select the disk or partition where you want to create the Secure Zone (Figure B-11). 6. Click the Next button.
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B-9
7. Specify the size of the Secure Zone, either by clicking on and dragging the slider, or by typing the size in the Partition size box (Figure B-12). NOTE: It is recommended that you use approximately one-third of the drive size, or 33%, for the Secure Zone. 8. Click the Next button.
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02/2011
This allows you to press the F11 key during startup to activate the Recovery Manager.
Figure B-14: Alternate SelectionDo Not Activate Acronis Startup Recovery Manager
9. Click to make your selection (Figure B-11). 10. Click the Next button.
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B-11
11. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-15. 12. Click the Proceed button.
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You can review the parameters of the Secure Zone at any time by clicking the Secure Zone button.
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B-13
After you have examined the properties, you can click Cancel to exit, or you can make changes as desired.
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02/2011
To make the backup: 1. On the main window, click the Backup option (Figure B-19).
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B-15
B-16
02/2011
Selecting the entire disk or partition is simpler and ensures no files are omitted, but the backup takes more space. Selecting individual files and folders takes less space, but some files may be inadvertently omitted. 3. Click to make your selection (Figure B-11). 4. Click the Next button.
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B-17
5. Click to check all the selections you want. 6. Click the Next button.
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02/2011
A full backup contains all the data on the partition or hard disk. It is complete. An incremental backup contains only the data changed since the last backup, whether full or incremental. Therefore, if you have done three incremental backups since the full backup, you need all three incremental backups plus the full backup in order to restore the data. Each incremental is based on the incremental before that. Full backup + incremental + incremental + incremental = Restore
Figure B-25: Restoration Based On Incremental Backups
A differential backup contains all the data changed since the last full backup. Therefore, if you have done three differential backups since the last full backup, you need only the latest differential backup plus the full backup in order to restore the data. Each differential is based only on the full backup, and disregards any differential backups created before it. Full backup + differential ... differential ... differential = Restore
Figure B-26: Restoration Based On Differential Backups
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B-19
7. Select the location in which to store the backup and click Next (Figure B-27).
B-20
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B-21
8. Select the type of backup you wantfull, incremental, or differential. 9. Click Next.
You may want to set the options manually. Among these options are password protection, compression level, and specifying the size of the backup files for transference to various portable media (Archive splitting, Figure B-32).
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02/2011
10. Click any of the options in the left box to examine and set the options. Archive splitting can be set to automatic or fixed size. NOTE: It is strongly recommended that you use the Fixed size option and back up to another hard drive first, splitting archive files small enough to fit at least two archive files on each anticipated CD or DVD; then afterward copy the backup files to CDs or DVDs. See "Copying Archive Files to CDs or DVDs" on page B-28. Automatic size is for backing up directly to a series of CDs or DVDs. When each disk is full, you will be prompted for another one. This method is not recommended, as the backup is unreliable. Fixed size is good if you are backing up to a hard drive now, with the intention of copying the backup to a specific set of portable media afterward.
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B-23
11. It is recommended that you select a size small enough to get at least two of the archive files (the first and last files) on one media. > For example, if you will be copying the files to DVDs, then select the 650 or 700 MB size, to get multiple files on one disk. But if you will be copying the files to CDs, then select the 100 MB size, to get multiple files on one disk. 12. Select the desired options and click Next.
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02/2011
13. Type any descriptions of the contents of the disk or folders. 14. Click Next.
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B-25
15. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-36. 16. Click the Proceed button. During the backup, the progress bar shows how the backup is progressing (Figure B-37).
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02/2011
After the backup is complete, you can see the archive file(s) on your storage media.
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B-27
Figure B-40: Acronis Boot Disk Inserted in Drive (Left); Acronis Splash Screen (Right)
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4. Remove the Acronis boot disk from the CD-ROM drive, and insert the CD-ROM containing the last file in the backup series of CD-ROM disks. CAUTION: Be sure to insert the last recovery disk first. If you insert any CDROM out of order, or dont start with the last one, you will see an error message (Figure B-42). Insert the correct CD and continue.
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B-29
The Restore Image Wizard displays the Welcome screen. 5. Click the Next button.
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02/2011
6. Double-click the CD-ROM drive to display its contents (Figure B-44). 7. Click the Next button.
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B-31
If you are overwriting the contents of the hard disk with the recovery, you may want to verify the archive before overwriting. 8. Select whether or not to verify before restoring. 9. Click the Next button.
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02/2011
10. Check the disk partition you want to restore. 11. Click the Next button.
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B-33
You have the option to resize partitions. Doing so may be useful if you are migrating to a larger hard disk, 12. Select whether or not to resize partitions. 13. Click the Next button.
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02/2011
14. Click to select the disk location. 15. Slide to resize each partition. 16. Click the Next button.
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B-35
17. Click Yes to delete all the partitions on the destination drive. NOTE: If you click No, the restoration process stops. 18. Click the Next button.
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You are given the option to restore an additional partition. 19. Make your selection and click Next.
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B-37
20. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-51. 21. Click Proceed. As the recovery progresses, you are asked to insert the backup disks in order. 22. Insert each requested disk when prompted (Figure B-52).
B-38
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B-39
B-40
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3. Click Next.
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B-41
4. Select the location where your archive file is stored and the name of the archive file. 5. Click Next.
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02/2011
Figure B-57 asks for the location where you want the files restored: the same location they were in originally, or a new location. 6. Select original or new location. 7. Click Next.
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B-43
If you selected a new destination, Figure B-58 asks you to specify the destination of the restoration. 8. Select the destination for the restoration. 9. Click Next.
B-44
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B-45
12. Select default or manual options for restoration. 13. Click Next.
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02/2011
If you selected manual options, a list of available options is showed at the left of Figure B-61. 14. Select any options for restoration. 15. Click Next.
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B-47
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02/2011
18. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-63. 19. Click Proceed.
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B-49
After the restoration is complete, you can see the restored files in the selected location.
B-50
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Index
A
air blow. See blow-off air dryer 1-36 air filter 1-5, 2-22, 6-42 air flow 6-25, 6-42 air flow control adjustment knob 3-44 air pressure 2-21, 6-24 see also blow-off adjusting 6-26 fittings 1-5, 6-86 recommended range 6-42 setting minimum 6-38 setting parameters 6-31, 6-35 thermal heads 2-28, 5-67, 5-102, 6-71 air regulator 6-19, 6-86 adjusting pressure 6-24 auxiliary 2-20, 6-24 digital pressure switch 2-20, 6-26 SMC Model ITV 6-27, 6-31 SMC Models ISE40 & ZSE40 6-29, 6-35, 6-37 locking in OFF position 1-3 main 2-19, 6-23 replacing 6-20 air supply 1-2, 1-5, 6-19, 6-42, 6-86 air valves 2-23, 6-25 alignment. See calibration alodine, conductive gold 2-42 archive files, in backup 10-23, 10-24 ASCII values 9-24 Auto Run log files 4-3 messages 4-3, 4-8 multiple test sites 4-11 pausing 4-1, 4-3 restarting 4-1, 4-3 taper settings 4-9 tracking device counts 2-21, 4-3 automatic air shut-off valve 2-19, 3-7, 6-23 auxiliary pusher regulator. See air regulator, auxiliary axes X 1-24, 2-31, 2-33 Y 1-24, 2-7, 2-31, 2-34 Z 1-24, 2-31, 2-35
B
bearing shafts, lubrication 6-3 bearings 6-3 benchtop handlers 1-6, 2-42, 3-6 binary values 9-24 bins 1-22 blow-off 1-22, 2-18, 2-21 adjustment screw 2-22, 6-43, 6-87 delay 5-29, 5-35, 5-36, 5-38 operation 2-21, 6-87 override buttons 5-4 bowl feeder 1-30, 1-31, 1-33 see also Bowl Feeder Supplement buckets 2-9, 5-71 buttons see also under window names CPU 3-7, 3-9 EMO (emergency stop) 1-2, 2-11, 2-40, 3-7, 3-9, 4-1, 6-2 Exatron software Diagnostic 5-2 Main window 3-46 OK 3-51, 5-43 Save Parameters 3-51, 5-43 HALT and RUN 2-11, 4-1 override blow-off 2-22, 5-4 pusher and slider 2-23, 5-5 taper 5-21 vacuum 2-22, 5-4 Windows Start 3-8
C
calibration buckets 5-71 dead nest for tube devices 3-11 examples trays 5-85 to 5-89 waffle packs 5-90 to 5-96 pickup heads Y positions 2-34 Z positions 2-35 to 2-37 software order of tasks 5-68, 5-73 thermal heads temperature 5-100 X distance for trays 5-83 Y distance to test site 5-74 continued on next column
02/2011
Index-1
calibration continued software continued Y distance to trays 5-82 Z-get distance 5-78 Z-put distance 5-77 taper 5-71 pickup heads 5-104 seal head 3-38 software 5-103 test sites 5-65, 5-71 tray or test site selection 5-70 trays 2-33 tube holders 3-11 vacuum generator 6-50 waffle packs 2-32, 2-33 worksheet 5-72 camera. See image sensor cautions and warnings see also safety and security adjusting blow-off screw 2-22 back up hard drive regularly 6-3 changing motor speeds may cause damage 5-49 connect power to grounded outlet 1-5 define tray columns and rows before calibration 5-80 digital air pressure sensor setting minimum 6-38 dispose of chiller fluid according to law 1-2 dont change factory-set job file 3-50, 5-2 dont change IP addresses 6-72 dont interfere with moving parts 1-1 dont jerk filled trays 3-9, 4-6 dont lubricate lead screws 6-2 dont lubricate solenoids 6-58 dont over-adjust blow-off screw on vacuum generator 6-44 dont over-adjust blow-off screw on vacuum switch 6-44 dont remove safety covers during operation 1-2 dont touch adhesive tape to carrier tape 3-17, 3-37 dont touch hot taper seal heads 3-42 dont unplug air hose when air regulator on 1-3 dont use cleaners on bearings or lead screws 6-2, 6-4 dont use handler without approved air regulator 1-2 home all motors before starting 1-1 insert last recovery disk first 10-29 keep away from moving parts 1-1 lock air regulator in OFF position before repairing handler 1-3 lock wheels and level feet 1-6 continued on next column
cautions and warnings continued maintain file backups on external media 6-82 maximum air pressure 50 PSI from vacuum pump 6-42 mount benchtop handler securely 1-6 power off system before maintenance 6-3 prevent excess moisture in air regulator and air valves 6-19 preview movement to avoid collisions 5-47 replace dirty vacuum filter 2-22, 6-43 servicing of laser should be done by LSO 1-3, 6-71 tighten lead screws only with power off 6-85, 6-87 CE Marking upgrade options 2-41 changeover kits 3-3 Check Tube Latches window 5-25 chiller 1-27, 1-36 fluid as hazardous waste 1-2 software 5-100, 5-101 columns calibration 5-80, 5-81 numbering 2-31, 5-39 communication between handler software and hardware 5-4, 5-7 motors 2-3 peripherals 9-26 tester 5-45, 9-1, 9-31 thermal temperature controller 6-66 computer boards 5000-M42 2-15 8000-D14 2-16 accessing 6-58 PCM-6896 2-14 PET-C06 2-15 computers backing up hard disk 10-15 opening 6-58 restoring hard disk 10-28, 10-40 shutting down 2-10, 2-42, 3-8 switching 3-8 conductive gold alodine 2-42 contracts preventive maintenance 1-12 service 1-9 counting. See numbering covers and doors 1-2 CPU button 3-7, 3-9 CPU. See computers
Index-2
02/2011
Index
D
decimal values 9-24 delays before air blow-off 5-29, 5-35, 5-36, 5-38 before starting test 5-45 before vacuum off 5-29, 5-35, 5-36, 5-38 push cylinder 5-30 rotation 5-32 seal head 5-32, 5-33, 5-106 setting 5-26 slide cylinder 5-30 tape 5-36 test sites 5-29 trays 5-35 vacuum 5-29, 5-35, 5-36, 5-37 detaper 1-25, 1-26, 1-34, 3-14 to 3-22 devices changing sizes 3-3 sorting 5-44 totals 4-3, 4-10, 4-11 types 5-19 Diagnostics windows. See under software, Exatron, windows disconnect switch 1-4, 2-10, 2-42, 3-6, 3-9 distances. See positions documentation typography significance 1-22 version number significance 1-21 doors 1-2 drive gear (taper) 2-40
files archive 10-23, 10-24 backing up 6-3 inspection 5-19 job see job files log 4-3 software upgrades 6-82 system 6-82 Fine Tune window 5-51 fuses 2-13
G
gap offset 4-9, 5-108 GPIB test interface 5-34, 9-21
H
HALT button 2-11, 4-1 handler benchtop 2-42, 3-6 examples 1-34, 1-37 installing 1-6, 3-1 opening computer 6-61 cabinet-based examples 1-26, 1-27, 1-35, 1-39 installing 1-6, 3-1 opening computer 6-58 cleaning 6-3 communication see communication between handler and customization 2-1 end-of-life disposal 1-21 operation overview 2-2 powering up 3-6 remote control 6-80 requirements electrical 1-4 environmental 1-4 Internet access 1-5 pressurized air 1-5 servicing 6-1 shutting down 3-8 troubleshooting 6-85 handler parts see also individual part names, test sites air filter 2-22, 6-43 air pressure fittings 1-5, 6-86 air regulator auxiliary 2-20, 6-24 digital pressure switch 2-20, 6-26, 6-27, 6-31 main 2-19, 6-23 continued on next column
E
earthquake safety 1-6, 3-1 electrical capability 1-4 EMO (emergency stop) button 6-2 starting 3-7 stopping 1-2, 2-11, 3-9, 4-1 taper 2-40 end-of-life disposal 1-21 environmental requirements 1-4
F
facilities requirements 1-4 feet, leveling 2-9, 3-1
02/2011
Index-3
handler parts continued automatic air shut-off valve 2-19, 3-7, 6-23 bearings 6-3 brand names Baco disconnect switch 1-4, 2-10, 2-42, 3-6, 3-9 Cool Muscle motors 6-8, 6-16 Hover-Davis detaper 3-14 Huber chiller 5-101 Julabo chiller 5-101 Kerk lead screws 6-4 NSK bearing shafts 6-4 Omega temperature controller 1-43, 5-100, 6-66 Omron fiberoptic sensor controllers 6-64 SMC air regulators 6-20, 6-23 SMC digital air pressure switch 6-26, 6-31 SMC vacuum generators 6-39 SMC vacuum switches 6-39 Thomson bearing shafts 6-4 Thomson bearings 6-4 Thomson linear motor tracks 6-4 buckets 2-9, 5-71 buttons HALT and RUN 2-11, 4-1 override blow-off 2-22, 5-4 pusher and slider 2-23, 5-5 taper 2-41 vacuum 2-22, 5-4 chains 2-7, 7-2 computer boards 2-14 connectors 24-pin D 9-4, 9-5 covers and doors 1-2 CPU button 3-7, 3-9 disconnect switch 1-4, 2-10, 2-42, 3-6 docking plates 2-25 docking ring 2-25 EMO (emergency stop) button 1-2, 2-11, 3-7, 3-9, 4-1, 6-2 feet, leveling 2-9, 3-1 fuses 2-13 HALT and RUN buttons 2-11, 4-1 hub 2-16, 6-18 interlocks 1-2 lead nut 2-8 lead screws 2-3, 2-5, 2-8, 6-5, 6-85, 6-87 light pole 2-18 line filter 2-43 main disconnect switch 2-10, 2-42, 3-6 manifold 2-23 motor serial cables 6-18 continued on next column
handler parts continued motors 2-3, 5-111, 6-85, 6-87 network hub 2-16, 6-18 optional features 2-1 photos 1-25 to 1-43, 2-3 to 2-43 pickup heads 2-3 ports 5-10 power supplies 2-11 power switch 3-7, 3-9 precisor tray 5-38, 5-71 preheating trays 1-28, 1-31, 1-41 pusher/slider 2-23, 2-24, 5-5, 5-13 sensors 2-22, 6-50 see also sensors serial adapter 2-16, 6-18 solenoids 5-8 suction cups 2-18, 6-3 temperature controller 1-43, 6-66 transfer tray 5-71 tray carriages 2-7, 3-9 tray clamps 3-9, 3-10 tray spring clips 3-10 trays 2-30 tubes 3-10, 3-11 vacuum generators see vacuum generators vacuum pump 6-44, 6-45 wiring 2-7, 2-15 handler port simulator 9-7 hardware. See handler parts hazardous waste 1-2 heat seal heads (taper) blade sizes 3-39 intermittent tape contact 2-39 setting temperature 3-45 heater controller display (taper) 3-45 hex values 9-24 home positions 2-31 hub 2-16, 6-18 HyperTerminal 9-26
I
image sensor (taper) 2-38, 2-39 see also inspection files drop-off to inspection gap 4-7, 5-37 function 5-22 inspection trigger 5-18 Input/Output Check window inspection files 5-19 installation 1-6 5-7
Index-4
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Index
interface card 6-8 interfaces 5-33 GPIB 5-34, 9-2, 9-21 RS-232 5-34, 9-2, 9-9, 9-10 RS-485 9-2 TTL 5-34, 9-2, 9-4 interlocks 1-2 IP addresses 6-72, 6-77
J
JEDEC trays 2-30, 5-73, 5-85 job files copying 3-48, 5-2 definition 3-47 factory preset 3-3 for various tray configurations 5-2 opening 3-49, 4-5 saving 3-51 settings 3-51 verifying 3-47 jobs number of devices in tape 4-10, 5-32, 5-37, 5-106 running 4-1, 9-1, 10-1
L
LAN connections 6-72 laser 1-27, 1-28, 1-35, 6-71 lead nut 2-8 lead screws 2-5, 2-6, 2-7, 2-8, 6-5, 6-85, 6-87 LED checker 9-7 leveling feet 2-9, 3-1 light pole 2-18 line filter 2-43 lock-out/tag-out (LOTO) procedures 1-3 log file 4-3 lubrication 6-3
MEMS testing 1-28, 1-32 messages between handler and tester 9-1 color-coded 2-18 in Auto Run 4-3, 4-8 resetting motors 5-47, 5-51 motor controllers 6-8 motors 2-3 coupling 2-3, 6-85, 6-87 homing 5-49, 5-50, 5-68 master vs. slave 6-8, 6-9 positions 5-68 programming 6-16 replacing 6-13 scale 5-74 speeds 5-48, 5-49 taper 5-111 turning on and off 5-47, 5-49 X 2-33 examples 5-88, 5-94 movement 5-68 X sensor 5-14 Y 2-3, 2-34 examples 5-86, 5-90 movement 5-68 troubleshooting 6-87 Y sensor 5-13 Z 2-35 movement 5-68 Z sensor 5-15 Motors Setup window 5-47
N
network cards 6-8 network hub 2-16 networking Internet access 1-5 IP addresses 6-72 LAN connections 6-72 remote handler control 6-80 numbering columns and rows 5-39 test sites 2-32 trays 2-32, 5-79 waffle packs 2-33, 5-79
M
machine. See handler main disconnect switch 2-10, 2-42, 3-6 maintenance. See preventive maintenance, tasks manifold 2-23 manual, users typography significance 1-22 version number significance 1-21 measurements. See positions
O
offsets gap (taper) 4-9, 5-108 socket 5-65
02/2011
Index-5
P
passwords 3-7, 3-50, 3-54, 5-3 PCBs. See computer boards PCs. See computers peel tester (taper) 3-32 photos, handler parts 1-25 to 1-43, 2-3 to 2-43 pick height. See Z-get pickup heads assembly 2-7 blow-off 6-43 home position 2-32 looseness 6-87 multiple 2-2, 2-4 multiple nozzles setting detaper for 3-21 setting taper for 5-110 positions 2-34, 2-35, 6-87 rotation 2-2, 2-3 delay 5-32 results 5-33 suction cups 5-76, 6-3, 6-86 vs. push cylinder as clamp 5-30 Y distance to taper 5-104 Y distance to test site 5-74 Y distance to trays 5-82 Z-get distances 5-71, 5-78 Z-put distances 5-71, 5-77 pin 1, location 2-32 pin designations 9-5 pockets. See calibration ports 5-10, 9-2, 9-3, 9-26 TTL Handler Port 9-4, 9-7 positions see also under calibration calibrating 2-33 to 2-37, 3-11, 5-51 to 5-96 columns and rows 2-31 pickup heads 2-34, 2-35 trays 2-33 waffle packs 2-33 worksheet 5-72 Z-get vs. Z-put 5-75, 5-76 Z-put 5-38 power supplies 2-11 power switch 3-7, 3-9 precisor tray 5-38, 5-71 preheating trays 1-26, 1-28, 1-31, 1-41 pressure roller block (taper) 2-40 pressure seal head (taper) blade sizes 3-38 continuous tape contact 2-39
preventive maintenance 6-1 preventive maintenance contract 1-12 push cylinder delay 5-30 override buttons 5-5 positions 5-6 testing 5-62 vs. pickup head as clamp 5-30 put height. See Z-put
R
remote handler control 6-80 rotation. See pickup heads, rotation rows calibration 5-80, 5-81 numbering 2-31, 5-39 RS-232 test interface 5-34, 9-9, 9-10 rub routine 5-41 RUN button 2-11, 4-1
S
safety and security see also cautions and warnings CE Marking upgrade options 2-41 earthquake safety 1-6, 3-1 handler covers and interlocks 1-2 hard disk backup 10-15 lock-out/tag-out procedures 1-3 training responsibilities 1-1 scale 5-55, 5-56, 5-57, 5-74, 5-105 seal head (taper) 2-2, 2-39, 5-24 adjusting 3-38 adjusting lateral position 3-41 adjusting pressure 3-43 blade sizes 3-38 changing blades 3-40 cleaning 6-65 delay 5-32, 5-33, 5-106 enabling or disabling 5-111 sealing temperature 5-106 setting temperature for heat seal 3-45 stopping 2-40 seismic safety 1-6, 3-1 Sensor Check window. See Input/Output Check window sensors 2-17 bucket 2-9 checking 5-7 continued on next column
Index-6
02/2011
Index
sensors continued cleaning optics 6-65 controllers 6-64 digital air regulator 2-20 taper 5-17, 5-18, 5-22 to 5-24 Empty/Out-of-Pocket 5-22 Gap 2-39, 4-9, 5-22, 5-108 Heater Alarm 5-24 Slack Switch 5-23 thermal 5-15 vacuum generator 2-22, 6-50, 6-66, 6-86 X motor 5-14 Y motor 5-13 Z motor 5-15 serial adapter 2-16, 6-18 service contract 1-9 settings file. See job files Setup Parameters window 5-26 signal tower. See light pole slide cylinder delay 5-30 override buttons 5-5 positions 5-6 testing 5-62 smart buckets 2-9 sockets 2-25 offset 5-65 pressure 5-102, 6-71 testing 5-62 software Acronis True Image 10-1 backup 10-15 emergency recovery 10-28 normal recovery 10-40 Secure Zone 10-6 Exatron customized 5-2 windows Auto Run 4-2 Diagnostics 5-2 Check Tube Latches 5-25 Fine Tune 5-51 Input/Output Check 5-7 Motors Setup 5-47 Setup Parameters 5-26 Sort Interface 5-43 Taper 5-103 Thermal Setup 5-100 Main 3-46 HyperTerminal 9-26 MS Windows, shutting down 3-8 WebEx 6-80
Solenoid Check window. See Input/Output Check window solenoids 5-7, 5-8, 6-58 Sort Interface window 5-43 Sort Latch 5-45 sorts 1-24 assigning to destinations 5-43 assigning to waffle packs 5-44 order of placement 5-44 suction cups 2-18, 6-86, 7-1 positions Z-get 5-75, 5-76 Z-put 5-76 support services 1-7, 1-8, 1-15, 1-21
T
takeup arm (taper) 3-32 takeup reel (taper) 2-38, 3-23 tape carrier 3-30, 3-35 checking pockets 5-36 delays 5-36 direction of movement 2-38 gap offset 4-9, 5-108 homing 4-9, 5-108 initializing 4-9, 5-108 leader 3-30, 4-9, 5-108, 5-109 passed devices in job 4-10, 5-32, 5-37, 5-106 pin 1 location 2-32 pockets between pickup and image sensor 5-37 rotation 5-33 sealing 3-33, 3-35 threading through assembly 3-33 trailer 4-9, 5-109 taper 2-2 alignment knob 2-38, 3-23 calibrating software 5-71, 5-103 changing seal head blade 3-40 changing tape track 3-28 drive gear 2-40 EMO (emergency stop) button 2-40 facilities requirements 1-4, 1-5 guide block 3-34, 3-35, 3-36 heater controller display 3-45 image sensor 2-38, 2-39, 5-18, 5-22 Model 201 1-25, 1-26, 3-23 Model 202 2-38, 3-23 motor 5-111 override buttons 2-41, 5-21 peel tester 3-32 continued on next column
02/2011
Index-7
taper continued pressure roller block 2-40 seal head heat see seal head (taper) pressure (PSA) see seal head (taper) sensors 5-17, 5-18, 5-22 to 5-24 Empty/Out-of-Pocket 5-22 Gap 2-39, 5-22, 5-108 Heater Alarm 5-24 Slack Switch 5-23 setup parameters 5-32 takeup arm 3-32 takeup reel 2-38, 3-23 tape track 2-38, 3-23, 3-37 Taper window 5-103 tasks adjusting air flow 3-44, 6-25 adjusting air pressure 6-24 adjusting blow-off 6-43 backing up PC hard disk 10-15 calibration number of rows and columns 3-52 order 5-68 positions 3-54 tubes 3-11 vacuum generator 6-53 X distance for trays 5-83 Y distance to test site 5-74 Y distance to trays 5-82 Z-compress distance 5-65 Z-get distance 5-78 Z-put distance 5-77 changing password 3-54 changing pickup head 3-4 checking air filter 6-42 checking air regulator moisture/dirt trap 6-19 checking air regulator shutoff valve 6-22 checking air supply from house generator 6-19 checking motor serial cables 6-18 checking or replacing air filter 6-20 checking vacuum generator adjustment 6-50 cleaning handler 6-3 cleaning suction cups 6-3 cleaning vacuum assembly 6-46 copying job file 3-48 creating backup Secure Zone on hard disk 10-6 displaying commands typed in HyperTerminal 9-29, 9-31 entering Diagnostics 5-3 installing Exatron software 6-82 locking air pressure switch 6-29, 6-30 lubricating bearing shafts 6-4 continued on next column
tasks continued opening computer 6-59, 6-61 opening job file 3-49 powering up system 3-6 programming motor 6-16 reformatting job file 6-84 replacing motors 6-13 restoring backup under Windows 10-40 restoring backup without Windows 10-28 running a job 4-6 securing trays on tray carriages 3-9 securing tubes on holder 3-10 setting air pressure switch 6-31, 6-35, 6-38 setting LAN connection 6-72 setting PC to boot from CD 10-1 setting test temperatures 5-100 setting up HyperTerminal 9-26 setting up temperature controller software 6-67 shutting down system 3-8 starting Auto Run 4-2 taper adjusting seal heads lateral position 3-41 adjusting seal heads pressure 3-43 adjusting seal heads speed 3-44 aligning tape track 3-37 calibrating software 5-103 changing changeover kit 3-24 changing seal head blade 3-40 changing tape track 3-28 loading carrier tape 3-30 loading sealing tape 3-33 maintenance 6-65 mounting takeup reel 3-26 setting temperature for heat seal 3-45 turning off temperature for heat seal 3-46 testing network communication with peripherals 6-77 tightening lead screws 6-5, 6-85 unlocking air pressure switch 6-28, 6-29 viewing vacuum generator settings 6-56 TCP/IP interface 9-3 teaching number of rows and columns 5-39 X and Y positions 5-57 temperature controller 6-66 temperatures, setting (taper) 3-45 temperatures, setting (tester thermal heads) 5-100 test interfaces. See GPIB test interface, RS-232 test interface, TCP/IP interface, TTL (TransistorTransistor Logic) test interface
Index-8
02/2011
Index
test sites calibration 5-71, 5-73, 5-74 checking communication 9-26 delays 5-29, 5-44 disabling 5-39, 5-40 docking plates 2-25 docking ring 2-25 instructions from vendor 3-2 manifold 2-23 multiple 2-2, 4-11, 9-10 numbering 2-32, 5-73 push/slide cylinders 2-23, 2-24, 5-30, 5-62 rotation 5-33 sockets 2-25, 5-65 thermal temperature variances allowed 5-101 thermal heads see thermal heads testing interfaces 5-33, 9-1 magnetic 1-31 MEMS 1-28, 1-31, 1-32, 1-33 modes, real vs. simulation 5-33 thermal 1-26, 1-27, 1-31, 1-36 testing order 2-27 time out 5-44 thermal heads 1-36, 1-43 air pressure 5-102, 6-71 checking communication 6-66 options 2-2, 5-100 sensors 5-15 temperature variances allowed 2-26, 5-100, 5-101 testing order 2-27 thermal seal head (taper). See seal head (taper) Thermal Setup window 5-100 transfer tray 5-71 trays 2-2 see also waffle packs see also under calibration carriages 2-7, 2-30, 3-9 clamps 2-7, 2-31, 3-9, 3-10 configurations, combining 2-30 delays 5-35 dimension drawing 5-59, 5-60, 5-61 disabling 5-38 fill order 4-7 home position 2-31 homing 4-4, 5-68 numbering 2-32, 5-79 pin 1 location 2-32
trays continued positions calibrating 2-33 teaching 5-57 preventing device play 5-41 row and column numbering 3-52, 5-39 securing 3-9 sorted devices 5-44 spring clips 3-10 troubleshooting devices not picked up 6-42, 6-85 hard disk wont boot 10-15, 10-28 motors slow 6-85 tray carriage alignment failing 6-85 Y movement noisy 6-87 TTL (Transistor-Transistor Logic) test interface 5-34, 5-45, 9-4 TTL Handler Port 9-4, 9-7 tubes 1-38, 2-2 dead nest 3-11 dead nest adjustment leg 3-13 holders 3-10 securing 3-10 typography significance 1-22
V
vacuum 2-18 delay 5-29, 5-35, 5-36, 5-37 override buttons 5-4 sensor 6-86 vacuum generators 2-21, 2-22 blow-off adjustment 6-44 blow-off location 6-41 calibrating 6-53 checking 6-50, 6-56 cleaning 6-46 override buttons 6-53 ports 6-40 suggested settings 6-52 troubleshooting 6-42 vacuum pump 6-44, 6-45
vacuum switches see also vacuum generators blow-off adjustment 6-44 blow-off location 6-41 how different from vacuum generators vibrations. See bowl feeder or feet
6-39
02/2011
Index-9
W
waffle packs 2-2, 2-30, 2-31 calibration order 5-81 disabling 5-38 numbering 2-33, 5-79 positions 2-33 teaching dimensions 5-57 warnings. See cautions and warnings warranty agreement 1-5, 1-6, 1-7, 1-8, 6-2 WebEx 6-80 Windows, shutting down 3-8 windows. See under software wiring 2-7, 2-15 work modes 4-3, 5-34
Z-put 2-36, 5-38 calibration 5-77 defined 5-75 distance from device
2-37
X
X see also trays axis 1-24, 2-31, 2-33 conceptual diagrams calibration 5-68, 5-83 home position 2-31 5-88, 5-94, 5-99
Y
Y see also pickup heads, thermal heads axis 1-24, 2-7, 2-31, 2-34, 6-87 conceptual diagrams 5-86, 5-91, 5-98 calibration 5-68 for taper 5-104 for test site 5-74 for trays 5-82 home position 2-32
Z
Z see also pickup heads axis 1-24, 2-31, 2-35 calibration 5-68 chain 2-7, 7-2 home position 2-32 Z-compress 5-38, 5-64 Z-get 2-36, 5-38 calibration 5-78 defined 5-75 distance from device 2-36, 6-85
Index-10
02/2011