Model 5000 Manual

Gravity-Feed Model 5000 User Manual
Version 3.3 June 8, 2010
Exatron, Inc.
2842 Aiello Drive San Jose, California 95111 (408) 629-7600 Tel (800) exa-tron Tel (408) 629-2832 Fax www.exatron.com
Copyright Notice
Copyright 2010 Exatron This document contains proprietary information which is protected by copyright. All rights are reserved. EXATRON MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. The information contained in this document is subject to change without notice.
Table of Contents
List of Figures Chapter 1: Safety and Support
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Exatron Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Electrical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Laser Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Lock-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Facilities Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Air/Vacuum Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 DUT (Device Under Test) Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Customer In-House Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Offshore Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Exatron Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Warranty and Support Contracts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Service Contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Preventive Maintenance Contract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Customer Service Support Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 End-of-Life Handler Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Significance of This Manuals Version Number. . . . . . . . . . . . . . . . . . . . . . 1-23 Typographical Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . 1-24 Terms Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Chapter 2: System Description

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Overview of Model 5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Key Movements and Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Key Positions for Handler with Quad Test Site. . . . . . . . . . . . . . . . . . . . . 2-7 Model 5000 Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Devices and Packages Accommodated . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Taper Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
-- continued on next page --
06/2010
Copyright Exatron, 2010
Contents-1
Model 5000 Manual
Chapter 2: System Description continued

Mechanical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Tilt Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Safety Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Motors and Drive Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Pickup Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Output Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Changeover Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Electronic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 EMO (Emergency Stop) Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Power Supplies and Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Pickup Head Motor Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Index and Stack Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Test Site Stop Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Photo Display of Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Laser Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 Shuttle Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Output Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 Tray Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 Octoloader/Input Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Test Site/Track Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Laser Mark Site/Track Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Shuttle Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Tube Present Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 Tube Full Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Connectors and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Pneumatic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Air Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Air Blast Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
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06/2010
Chapter 3: Handler Setup and RAM Listing

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Changing Device Sizes or Package Types . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 What the Changeover Kit Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Identification of Ports, Solenoids, and Test Site Sensors . . . . . . . . . . . . . 3-4 Installing the Changeover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Resetting Software Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Aligning the Changeover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Testing Alignment of the Changeover Kit . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Loading Tubes into the Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Securing Output Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Curved Aluminum Output Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Straight Plastic Output Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Output Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Power-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Introduction to the Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Messages from the Laser Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Laser Safety Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Introduction to the Laser Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Edit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Work Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Aligning the Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Setting Temperatures for the Hot Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Understanding the Control Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Changing Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Selecting Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 Selecting Device Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 Selecting Changeover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 Selecting Manual Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 Selecting Stops at Each Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 Selecting Number of Input Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 Setting Pickup Head Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 Selecting Laser Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 Selecting Number of Devices per Output Tube . . . . . . . . . . . . . . . . . . . 3-54 Selecting Number of Devices to Be Tested Simultaneously. . . . . . . . . . 3-54 Selecting Tray or Tube Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 Manual Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Resetting Totals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 Beginning a Production Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 Homing the Octoloader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 Displaying Totals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
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Contents-3
Model 5000 Manual
Chapter 3: Handler Setup and RAM Listing continued

Changing RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 RAM Address Listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 Updating Your EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77 Setting Sorts in RAM Addresses C0 to C7 . . . . . . . . . . . . . . . . . . . . . . . . . 3-77 ExamplePassed Devices to Four Tubes . . . . . . . . . . . . . . . . . . . 3-78 ExamplePassed Devices to Taper . . . . . . . . . . . . . . . . . . . . . . . . 3-78 Setting Bin Displays in RAM Addresses B8 to BF. . . . . . . . . . . . . . . . . . . . 3-79 Decimal-Hex-ASCII Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Chapter 4: Diagnostics and Troubleshooting

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Accessing DIAGNOSTICS Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Diagnostics Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 SENSOR CHECK: Test Site Sensors 0-7 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 SENSOR CHECK: Test Site Sensors 8-Ffor Laser . . . . . . . . . . . . . . . . . 4-13 SENSOR CHECK: Test Site Sensors 8-Ffor Quad Tester . . . . . . . . . . . 4-14 SENSOR CHECK: Shuttle Position Sensors 1-8 . . . . . . . . . . . . . . . . . . . . 4-15 Example of Shuttle Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 SENSOR CHECK: Tube Full Sensors 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Example of Tube Full Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 SENSOR CHECK: Tube Present Sensors 1-8 . . . . . . . . . . . . . . . . . . . . . . 4-20 Example of Tube Present Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 OUTPUT CHECK: Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 OUTPUT CHECK: Solenoid Toggle Check . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 OUTPUT CHECK: Light Pole Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 OUTPUT CHECK: CPU Port Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 INTERFACE CHECK: RS-232 Port Check . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 INTERFACE CHECK: RS-232 Port #2 Checkfor Pickup Heads . . . . . . . 4-28 INTERFACE CHECK: Handler Port Output Check . . . . . . . . . . . . . . . . . . . 4-31 INTERFACE CHECK: Handler Port Input Check . . . . . . . . . . . . . . . . . . . . 4-32 ALL MOTOR CHECK: Shuttle Motor Check . . . . . . . . . . . . . . . . . . . . . . . . 4-33 ALL MOTOR CHECK: Pickup Head Motor Check . . . . . . . . . . . . . . . . . . . 4-34 ALL MOTOR CHECK: Octoloader Motor Check . . . . . . . . . . . . . . . . . . . . . 4-36 OCTO/INDEX CHECK: Shuttle Solenoid Check . . . . . . . . . . . . . . . . . . . . . 4-37 OCTO/INDEX CHECK: Input Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Example of Octoloader Home and Input Sensors . . . . . . . . . . . . . . . . . 4-39 LASER CHECK: Laser Firing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 LASER CHECK: Laser Input Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
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06/2010
Chapter 4: Diagnostics and Troubleshooting continued

LASER CHECK: Laser Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 SERVO TEACH MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Cycling the Handler in Stop Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Cycling the Handler in Loop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Chapter 5: Dictionary of Displayed Messages

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 #### OLDNEW #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 00## DATA ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 - PILOT / . FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 1 LEFT STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 1 RIGHT STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 2 LASER DUT ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 2 LEFT STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 2 RIGHT STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ALIGN MOTORS ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ALL MODES OFF ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ALL MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 ALL MOTORS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 ALL OUTPUTS FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 BAD RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 BAD TEST RESULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 BIN # S# C#### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 BIN 5 S0 FLUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 CHANGE RAM ? NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 CHANGE RAM ? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 CHECK BEAM TUBE? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 CHECK CONTACTS? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 CHECK SUM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 CHECKING LASER ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 CHK OUTPUT DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 CHK SMOKE TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 CHK VAC ADJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 COUNTS RESET 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 CPU ERROR <1-5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 DISPLAY TOTALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 DOUBLE PART ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 DUT IN LASER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 DUT/SHUT LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 EMPTY ALL TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 EMPTY FLUSH TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
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EMPTY/LOAD PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 END LASER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 END TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 EXATRON SUPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 FAIL CHECK ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 FAIL LOAD ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 FAIL PROGRAM ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 FAIL VERIFY ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 FIRE LASER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 FLUSH ALL ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 FLUSH TEST SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 FULL 12345678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 FULL TUBE= #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 HALT!! RESTART ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 HANDLER OUT CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 HANDLER PAUSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 HOME OUTPUT? NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 HOME OUTPUT? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 INDEX EMPTY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 INPUT 12345678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 INSERTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 INTERFACE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 INTO LASER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 INTO SHUT(TLE) JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 INTO STAGE JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 INTO T SITE JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 IS LV PC READY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 IS THE AIR ON ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 ISSUE NEW START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 JOG DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 JOG LEFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 JOG RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 JOG UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 LASER CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 LASER GATE ERR?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 LASER GATE OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 LASER MARK ? / LASER MARK ? NO / YES . . . . . . . . . . . . . . . . . . . . 5-19 LASER OUT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 LASER SIMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 LASER SITE JAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 LIGHT POLE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 LOAD DEFAULT NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 LOAD DEFAULT YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
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LOAD DEVICE ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 LOAD EMPTY TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 LOAD EPROM>RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 LOAD REMOTE RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 LOADER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 LOADING MASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 LOOP MODE ON ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 LV SET UP ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 MANUAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 MARK & CYCLE ON?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 MARK SITE EMPTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 MEMORY ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 MOD SET UP ? NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 MOD SET UP ? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 MODEL 5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 MOTOR <A, B, C, or D> BUSY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 MOTOR <A, B, C, or D> ERROR ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 MOTOR OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 MOVE MOTOR DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 MOVE MOTOR UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 MULTI SORT ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 NO OUTPUT TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 NO RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 NO SORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 NO TUBES OR FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 OCTO MOTOR CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 OCTO/INDEX CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 OCTOLOADER OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 O.K. TO RUN ? # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 OUTPUT CLEAR ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 OUTPUT GO LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 OUTPUT GO RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 OUTPUT TO BIN 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 OUTPUT TUBE JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 PART IN SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 PART IN T SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 PASS PROG/PASS VERIFY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 PASSWORD ABC? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 PICK CHANGE KIT? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 PICK INTERFACE? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 PICK PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 PICK UP = ##### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 PLUNGE = #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
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Contents-7
Model 5000 Manual

PROGRAM DEVICE? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 PROGRAM RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 RAM AUTO RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 READY TO MARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 READY TO RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 RESET TOTALS NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 RESET TOTALS YES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 RS-232 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 RUN 1-2-3-4 PART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 SEN0-7 01234567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 SEN8-F 89ABCDEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 SERVO IS AT ZERO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 SERVO MOVING ? 1 / 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 SET # INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 SET P/V/L MODE? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 SHUT 12345678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 SHUTTLE EMPTY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 SHUTTLE IS LOST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 SHUTTLE OUT JAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 SOAK = #.# SECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 SOAK DELAY ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 SOLENOID CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 SORT INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 SORT MOTOR CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 SORT RESET ERR? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 START 1 TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 START 2 TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 START LASER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 STOP MODE ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 STOP MODE ON ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 STOP ON FAIL ? / STOP ON FAIL NO / YES . . . . . . . . . . . . . . . . . . . . 5-34 STOP ON FAIL YES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 SUM CHECK = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 SUM CHECK ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 T0[1-8] #### ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 T SITE NOT FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 T SITE OUT JAM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 T SITE OUT JAM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 T SITE OVERFILL? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 TEST ABORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 TEST SITE EMPTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Contents-8
06/2010

THANK YOU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 TO EXIT = ##### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 TO SITE = ##### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 TOP OF TUBE JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 TOTALS SET TO 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 TRANSFER ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 TRAY/TUBE OUT ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 TUBE 12345678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 TUBE CLEAR WORKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 TURN ON REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 UART OUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 VERIFY DEVICE ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 VERIFYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 WAITING FOR PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 WAITING FOR R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Z MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Z MOTOR CRASH ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Z MOTOR IS UP / Z MOTOR NOT UP. . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 ZERO COUNT ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Chapter 6: Servicing and Troubleshooting

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Cleaning the Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Checking Motor Serial Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Air Regulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Checking Incoming Air from the House Supply . . . . . . . . . . . . . . . . . . . . 6-3 Checking the Moisture/Dirt Trap in the Air Regulator . . . . . . . . . . . . . . . . 6-3 Checking the Air Regulator Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Adjusting Air Pressure on the Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Adjusting Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Solenoid Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Fiberoptic Photoelectric Sensor Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 6-11
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Model 5000 Manual
Chapter 7: Parts List

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Guide to the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Exatron (Part Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Part Quantity Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 List of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Chapter 8: Prints Chapter 9: Test Interfaces

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 General Interface Options and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Accessing a Handler Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 General Interface RAM Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 INTERFACE TYPE: ADDRESS 00B7 . . . . . . . . . . . . . . . . . . . . . . . . 9-3 TEST SOL DELAY: ADDRESS 0096 . . . . . . . . . . . . . . . . . . . . . . . . 9-3 STOP ON FAIL Y/N: ADDRESS 00A5 . . . . . . . . . . . . . . . . . . . . . . . 9-3 DOUBLE TEST SORT: ADDRESS 00AC . . . . . . . . . . . . . . . . . . . . . 9-3 TESTER SORT SET UP: ADDRESSES 00AF TO 00B6. . . . . . . . . . 9-4 Handler Port Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 TTL Handler Port Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Handler Port Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 EOT (END OF TEST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 START PULSE WIDTH: ADDRESS 0098 . . . . . . . . . . . . . . . . . . . . . 9-9 CHECK SORT RESET: ADDRESS 00A2 . . . . . . . . . . . . . . . . . . . . . 9-9 EXATRON RS-232 Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 RS-232 Port Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 BAUD RATE: ADDRESS 009B . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 DATA FORMAT: ADDRESS 009C . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 EXATRON RS-232 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Handler/Tester Test Cycle Handshake Summary . . . . . . . . . . . . . . . . . 9-12 Explanation of Test Cycle Handshake . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 DOUBLE TEST ASCII OUT: ADDRESS 00A7 . . . . . . . . . . . . . . . . 9-14
Index
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06/2010
List of Figures
Figure 1-1: Pause Button on Control Panel (Left); Emergency Stop Button (Right) . . . . . . . . . . Figure 1-2: Air RegulatorIn ON Position (Left), in OFF Position (Center), in OFF Position with Lock (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-3: Air Line Attached to Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-1: Model 5000 OverviewWith Octoloader Motor and Shuttle Motor Only . . . . . . . Figure 2-2: Model 5000 OverviewWith Pickup Head and Third Motor . . . . . . . . . . . . . . . . . . 1-2 1-4 1-7 2-3 2-4
Figure 2-3: Flow of Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Figure 2-4: Key Device Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Figure 2-5: Key Positions for Handler with Quad Test Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Figure 2-6: Tilt MechanismLeft Side (Left); Right Side (Right) . . . . . . . . . . . . . . . . . . . . . . 2-10 Figure 2-7: Safety Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Figure 2-8: Motor with Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-9: Drive Chain Tension Adjuster for Octoloader (Left), for Shuttle (Right) . . . . . . . . Figure 2-10: Octoloader at Home Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-11: Octoloader Back with Snap-On Pins (Left); Octo Car Block with Holes for Snap-On Pins (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-12: Octoloader Front with Two Tubes Attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-13: Octoloader Gate Depressed by Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-14: Devices Stopped by Octoloader Gate (Left); Devices Released by Octoloader Gate (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-15: Octoloader Gate Pin Blocking Exit (Left); Device Exiting Octoloader Chute (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-16: Octoloader Gate Closed (Left); Octoloader Gate Opened (Right) . . . . . . . . . . . . . Figure 2-17: Pickup Head Motor and Lead Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-18: Device Attached to Plunger on Pickup Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-19: Pickup Head (Left); Device at Pickup Site (Right) . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-20: Pickup Head at Pickup Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-21: Pickup Head at Test Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-22: Pickup Head at Drop-off Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-23: Output Tray with Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-24: Output Gates and Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-25: Releasing Devices From Output Tray to Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-26: Example Changeover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-27: Example Changeover Kit for Hot-Rail Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2-12 2-13 2-14 2-14 2-15 2-16 2-16 2-17 2-18 2-18 2-19 2-19 2-20 2-20 2-21 2-22 2-22 2-23 2-24
Figure 2-28: EMO (Emergency Stop) Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Figure 2-29: Power Wiring Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
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Model 5000 Manual
Figure 2-30: Motor Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Figure 2-31: Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Figure 2-32: Fuses Near Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Figure 2-33: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-34: Cable for Sensors 0-7 Above Test Site; Cable for Sensors 8-F Below Test Site . . Figure 2-35: Override Buttons and Corresponding Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-36: Index/Stack Pin Override Button (Left); Shuttle Pin Override Button (Right) . . . Figure 2-37: Index and Stack Pins at Default Position (Left); at Reverse Position (Right) . . . . Figure 2-38: Cover Foot Retracted and Stack Pin Extended (Left); Cover Foot Extended and Stack Pin Retracted (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-39: Stack Pin Extended to Restrain Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-40: Test Contacts Closed on Device (Left), Opened (Right) . . . . . . . . . . . . . . . . . . . . Figure 2-41: Test Contacts on Custom Quad TesterClosed (Left), Opened (Right) . . . . . . . . Figure 2-42: Air Valve for Test Site Contact Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . Figure 2-43: Test Site Stop Pin Extended (Left), Retracted (Right) . . . . . . . . . . . . . . . . . . . . . . Figure 2-44: Laser Gate Extended (Default, Left), Retracted (Right). . . . . . . . . . . . . . . . . . . . . Figure 2-45: Shuttle Pin Extended to Hold Device (Left), Retracted (Right) . . . . . . . . . . . . . . . Figure 2-46: Shuttle and Override Button in Closed Position (Left), in Open Position (Right) . Figure 2-47: Shuttle at Home Position Between Test Track and Fifth Tube . . . . . . . . . . . . . . . Figure 2-48: Output DisplaysLED On/Off (Left), Digits (Right) . . . . . . . . . . . . . . . . . . . . . . Figure 2-49: PPPP-030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-50: PP-PF030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-51: Tray Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-52: Octoloader at Home Sensor (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-53: Device at Octoloader Gap Sensor (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-54: Device at Top of Track Sensor (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-55: Sensors 0-2 (Left); Sensors 4-7 (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-56: Device at Stack Pin Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-57: Device at Mark Site Sensors 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-58: Shuttle SensorsWithout Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-59: Shuttle SensorsWith Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-60: Tube Present Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-61: Tube Full Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-62: Ports, ClockwiseServo Motor, Sensor Port, Solenoid Port . . . . . . . . . . . . . . . . 2-27 2-28 2-29 2-30 2-31
2-32 2-33 2-33 2-34 2-34 2-35 2-36 2-36 2-37 2-37 2-38 2-39 2-39 2-40 2-41 2-42 2-42 2-43 2-43 2-44 2-45 2-45 2-46 2-46 2-47
Figure 2-63: Solenoid Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Figure 2-64: Hot-Rail Connectors and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Figure 2-65: Air Regulator Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Figure 2-66: Air Blast Switch in OFF Position (Left), in ON Position (Right) . . . . . . . . . . . . . 2-49 Figure 3-1: Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
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Figure 3-2: Three-Piece Hot Rail Assembly (Only for Hot-Rail Handlers) . . . . . . . . . . . . . . . . . Figure 3-3: Test Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-4: Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-5: Output Tube Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-6: Ports and Override Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-7: Ports, ClockwiseServo Motor, Sensor Port, Solenoid Port . . . . . . . . . . . . . . . . . . Figure 3-8: Solenoid Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-9: Snap-On Output Tube Holder Screwed Onto Handler Base . . . . . . . . . . . . . . . . . . . Figure 3-10: Output Tube Holder with Cutouts at Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-11: Screws for Cutouts on Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3 3-3 3-4 3-4 3-5 3-5 3-6 3-8 3-8 3-9
Figure 3-12: Output Tube Holder On Handler BaseIn Unlocked Position (Left); in Locked Position (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Figure 3-13: Back of Shuttle with Snap-On Pins (Left); Insertion Holes on Shuttle Assembly (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Figure 3-14: Shuttle with Black Air Hose Attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Figure 3-15: Inserting Test Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Figure 3-16: Screwing in Bolts at Each End of Test Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Figure 3-17: Two-Pin Molex Connector Plugged In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-18: Pickup Head Cylinder Block Without Plunger (Left); Inserting Plunger into Pickup Head (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-19: Plunger Inserted into Pickup Head (Left); Tightening Pickup Head Screw (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-20: Track Opening in Octoloader Ledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-21: Test Site Screwed Onto Handler Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-22: Sliding in Index Rail, Bottom First (Left); Index Rail in Place (Right) . . . . . . . . . Figure 3-23: Index Rail Pins in Grooves of Rail Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-24: Index Rail Screws to Tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-25: Connection for Index Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-26: Six Screws to Be Tightened on Each Hot Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-27: Clear Cover with Cutout at Bottom of Hot Rail (Left); Snapping Cover Latches Closed (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-28: Air Connected to Handler Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-29: Connectors and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-30: Connectors Plugged Into Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-31: Octoloader Back with Snap-On Pins (Left); Octo Car Block with Holes for Snap-On Pins (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-32: Red Thumb Screws to Be Unscrewed Before Removing Cover . . . . . . . . . . . . . . Figure 3-33: Octoloader Aligned to Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-34: Track Aligned to Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-35: Perimeter Screws for Horizontal Alignment of Output Tube Holder. . . . . . . . . . . Figure 3-36: Perimeter Screws on Output Tube HolderLeft and Right. . . . . . . . . . . . . . . . . . 3-12 3-12 3-13 3-13 3-14 3-14 3-15 3-15 3-16 3-17
3-18 3-18 3-19 3-19 3-20 3-21 3-21 3-22 3-22 3-23
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Figure 3-37: Shuttle Aligned to Output Tube Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-38: Shoulder Screws for Vertical Alignment of Output Tube Holder . . . . . . . . . . . . . Figure 3-39: Device at Stop Pin as Seen Through Changeover Kit . . . . . . . . . . . . . . . . . . . . . . Figure 3-40: Device at Shuttle With Override Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-41: Octoloader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-42: Loading a Tube Perpendicular to Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-43: Securing Tube at Bottom of Input Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-44: Dowel Pin on Holder Fits Dowel Hole on Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-45: Tube Held Out Away from Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-46: Tube Snapped Into Place on Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-47: Tube Top in Place on Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-48: Releasing Devices From Output Tray to Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-49: EMO (Emergency Stop) Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-50: Control Panel Message "READY TO RUN" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-51: EMO (Emergency Stop) Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-52: Laser Supply Unit Powered OFF (Left), ON (Right) . . . . . . . . . . . . . . . . . . . . . . . Figure 3-53: Laser MessagesWAIT FOR START (Left), LASER READY (Right) . . . . . . . Figure 3-54: Smartist Laser Software in Edit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-55: Smartist Laser Software in Work Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-56: Laser ReadyYellow (Left); Laser FiringRed (Right) . . . . . . . . . . . . . . . . . . . Figure 3-57: Octo Stop Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-58: Four Hot Rail Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-59: Heater Controller Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-60: Modifying SetupReference Flowchart for Handler with Pickup Head. . . . . . . . Figure 3-61: Modifying SetupReference Flowchart for Handler with Quad Tester . . . . . . . .
3-23 3-24 3-25 3-26 3-27 3-28 3-28 3-29 3-30 3-30 3-31 3-32 3-33 3-34 3-35 3-37 3-37 3-40 3-41 3-41 3-42 3-43 3-44 3-48 3-49
Figure 3-62: Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Figure 4-1: Eight-Bit LED Checker #3000-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Figure 4-2: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Figure 4-3: Diagnostics Reference Flowchartfor Handler with Pickup Head and Laser . . . . . 4-4 Figure 4-4: Diagnostics Reference Flowchartfor Handler with Quad Tester . . . . . . . . . . . . . . 4-5 Figure 4-5: Shuttle Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-6: LED Pattern for Each Shuttle Position When Shuttle Is Empty. . . . . . . . . . . . . . . . Figure 4-7: Shuttle Position Sensors 4 and 6 Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-8: Shuttle Position Sensors 4-6 Blocked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-9: Tube Full Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-10: Tube Full Sensor Blocked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-11: Tube Present Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-12: Tube Present Sensors Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-13: Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 4-16 4-17 4-17 4-18 4-19 4-20 4-21 4-22
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Figure 4-14: CPU Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Figure 4-15: Pickup Head at Pickup Site (Key 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-16: Pickup Head at Test Site (Key 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-17: Pickup Head at Top of Track (Key 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-18: Shuttle Solenoid Light with Override Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-19: Shuttle in Extended/Closed Position with Device (Left), in Retracted/Open Position (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-20: Octoloader at Home Sensor (Display 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-21: Device at Octoloader Gap Sensor (Display 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-22: Device at Top of Track Sensor (Display 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-23: Octoloader Home and Input Sensors Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-24: Changing Distances on Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 4-34 4-35 4-37 4-37 4-38 4-38 4-38 4-39 4-43 5-1 6-2 6-4 6-4 6-5 6-5 6-6 6-7 6-7 6-8
Figure 5-1: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-1: Serial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-2: SMC Air Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-3: Small Black Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-4: Metal Casing Unscrewed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-5: Clear Glass Casing Snapped Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-6: Large Black Inner Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-7: SMC Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-8: SMC Air Regulator Turned OnAnother Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-9: SMC Air Regulator Turned Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-10: Air Valves with Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Figure 6-11: Sensor Controller Set to L-ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Figure 6-12: Green and Red Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Figure 6-13: Conditions of Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Figure 7-1: Dimensions Listed From Smallest to Largest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Figure 9-1: Eight-Bit LED Checker #3000-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Figure 9-2: Handler Port (Parallel Port) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Figure 9-3: 24-Pin D Connector on Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Figure 9-4: Standard TTLHandler Port Interface Timing Detail for One Tester . . . . . . . . . . . 9-7 Figure 9-5: Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Figure 9-6: Typical RS-232 Interface Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
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Chapter 1: Safety and Support

Chapter Overview
This chapter discusses the following main topics:
Topic Exatron Safety Warnings Lock-Out Procedures Facilities Requirements Installation Overview Standard Warranty Exatron Support Services Warranty and Support Contracts End-of-Life Handler Disposal Significance of This Manuals Version Number Typographical Conventions Used in This Manual Terms Used in This Manual
Page 1-1 1-3 1-4 1-7 1-8 1-10 1-10 1-23 1-23 1-24 1-24
Please read and understand this entire User Manual before installing or using your Exatron handler. A short glossary of terms used in this manual and other keys to understanding is found at the end of this chapter.
Exatron Safety Warnings

Typically, the handler is simply one part of a complete test system. It is the responsibility of the company purchasing the handler to properly train all handler operators in all of the safety practices required for every component of the test system. The following safety procedures must be followed at all times. WARNING! Hi-Pot testers contain high voltage. Do not defeat the interlocks. 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 press the Pause key on the control panel.
Figure 1-1: Pause Button on Control Panel (Left); Emergency Stop Button (Right)
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. 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. 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. WARNING! Never unplug a pressurized air hose while the air regulator is turned on.
Electrical Hazards
High Voltage Testing Applications: It is the policy of Exatron to determine the precise application for every handler we make prior to shipment. In some cases, the handler will be used to test devices at high voltages. If your handler will be used to test devices with voltages in excess of 80-volt DC or 80-volt AC, the handler should be equipped with safety covers. Notify
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Lock-Out Procedures
Laser Hazards
Exatron immediately and place an order for safety covers, if this has not already been done. Added safety covers will be provided at additional cost to the user. If Exatron is notified of high voltage requirements as described above on the written purchase order at the time of order placement, we will equip your handler with safety covers having electrical interlock switches. These switches are intended to be utilized by the operator by connecting them to the customer-supplied tester. When the interlock switch is open, the tester will be shut down with no possibility of high voltage at the handler's contacts. All safety hardware should be verified for proper operation by the customer's own in-house safety officer. In most cases, there are no high voltages used inside the Model 5000 handler electronics with the exception of those using a Hi-Pot tester or the Model 5080 Hot Chamber. High voltage from the facility's electrical line current is present in the Model 5000 power supply. Only qualified service technicians should do any repair work on the power supply. Make sure to use qualified service technicians when attempting to repair any portion of the handler that uses high electrical voltages.
Laser Hazards
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.
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Model 5000 Manual
Figure 1-2: Air RegulatorIn ON Position (Left), in OFF Position (Center), in OFF Position with Lock (Right)
Facilities Requirements
Environmental Requirements
The Model 5000 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. Airborne dust and moisture, if present, will naturally settle on all surfaces of your handler. If allowed to build up, dust can eventually block sensors, clog solenoids, fill up the filters of cooling fans and generally inhibit the smooth movement of devices through the handler. The best defense against this kind of contaminant is to dust the handler off with blasts of compressed air at least every 8 hours. There are no special ventilation requirements. As specified in the table shown below, Exatron handlers are designed to withstand the impact of any physical environment that they may be used in. Periodic maintenance as described in Chapter 6 will ensure that emergency "down time" is kept to a minimum. Handler/Hot Rail Temperature 40 to 115 F, 5 to 45 C Handler with Printer 40 to 105 F, 5 to 40 C 20% to 80%, noncondensing
Relative Humidity 20% to 85%, noncondensing
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Facilities Requirements
Electrical Requirements
Electrical 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. NOTE: 110V AC at 20 amps is preferred when available. All Model 5000 series handler chassis are directly connected through the power supply to earth ground. All guide rails, shuttles, tube holders, hot chamber trays and output trays are connected to earth ground. The handler's power supply ground is directly connected to earth ground. CAUTION: Connect the power cord to earth-grounded power outlets only. Handlers shipped within the United States are factory pre-wired for 110V AC, 60 Hz, unless otherwise specified. Handlers shipped off-shore have built-in electrical supply capability for 100-volt AC to 240-volt AC, 50-Hz to 60-Hz, except in the case of the Model 3010B Hot Rail. The Hot Rail thermocouple card contains either a 50-Hz crystal or 60-Hz crystal, which must be specified by the customer. Handlers shipped to the following destinations are pre-wired for the following voltages unless otherwise specified: Japan - 100 VAC, 50 Hz Continental Europe - 240 VAC, 50 Hz United Kingdom - 220 VAC, 50 Hz Hong Kong - 220 VAC, 50 Hz
Handlers with special features have specific requirements: Ambient handlers require 3 amps at 110-volt AC. Hot-rail handlers require 7 amps at 110-volt AC. Handlers with lasers require 5-10 amps at 110-volt AC. Handlers with hot chambers have the line frequency fixed at either 50 Hz or 60 Hz, as specified by the customer, but not at both frequencies. The power supply is "smart," sensing the voltage in the power line, and matching its power accordingly. Electricity supplied to the handler must be within the recommended operating range. If the line voltage drops too low, the handler may not function properly and may be seriously damaged. Verify that correct operating line voltage is present. If it is not, contact Exatron for assistance.
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Model 5000 Manual
Service calls made to the customer facility to correct problems caused by improper electrical supply are not covered by the Exatron warranty.
Air/Vacuum Requirements
The Model 5000 system requires a supply of pressurized air at a minimum of 80 PSI/3 CFM (+/- 3 PSI), filtered for proper operation. The air supply must be clean (containing no particulate matter greater than 5 microns in size), oil-free, and dry (having a dew point of 36 degrees F to 38 degrees F) to operate correctly. Dirty, oily or wet air will cause the vacuum generator to malfunction and will make your system unreliable. 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 electrical solenoids, causing them to stick or to stop functioning altogether. The best defense against this kind of contaminant 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. A house/shop vacuum is not required. Changeover kit vacuum requirements are supplied by built-in venturi vacuum generators. 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.
Air Connections
Located on the lower right side of the main frame supporting the Model 5000 is an air regulator with a pressure gauge and a filter. Before using the Model 5000, make certain that a compressed air line of 80 PSI is attached to the fitting of this air regulator. The Model 5000 has one 1/4" diameter flexible plastic air line on the outside of the handler's changeover kit.To supply the changeover test site with air, plug this into one of two available compressed air outlets mounted on the right side of the main plate of the Model 5000.
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Installation Overview
DUT (Device Under Test) Materials
Figure 1-3: Air Line Attached to Outlet
DUT (Device Under Test) Materials

Component packages vary as to the materials from which they're made. The composition and size of packages can cause wear on the parts of the handler with which they come into contact. Heavy, rough-surfaced DUTs will cause handler wear faster than lighter, smoother materials. The best defense against the effects of the DUT material on a handler is to ensure that the handler is properly adjusted for the package it is running. The height of the handler door over the DUT should be as close as possible. The test site contacts should close on the DUT with enough pressure to provide good electrical contact, but not press hard enough to force the DUT to the left or the right of the test site rail. If you have any questions regarding handler adjustment issues, please contact the Exatron Customer Service Department.
Installation Overview
Basic installation of your new Exatron handler will consist of the following major steps: Unpacking the handling equipment and assembling its peripheral parts Powering up the handler ("Power-Up Procedure" on page 3-31) and running Diagnostics sequences (Chapter 4)
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Cycling sample tubes of devices Interfacing the handler to your tester/programmer (Chapter 9) The Model 5000 series handler will usually come in a wooden crate which will require some disassembly to remove the handler. Please inspect the system when it is removed from the crate for any obvious damage which may be the result of shipping. Contact Exatron and the shipping company immediately if you see any damage.
Standard Warranty
All Exatron products are under warranty for one year from the date of purchase. Exatron agrees to repair any mechanical or electrical assembly, subassembly, or entire unit which fails during normal use within its first year. The customer agrees to follow the recommended maintenance procedure as defined in this User Manual. Exatron does not warrant test contactors. Handler test contactors are fragile and may be easily ruined by operator abuse. Exatron uses the finest materials available in our contactor designs. Exatron does not warrant the following: Damage caused by improper packaging of equipment returned to Exatron for repair Damage caused by the shipping company Damage caused by natural catastrophes: flood, fire, earthquake, etc. Damage caused by equipment connected to improper power line voltages Damage caused by equipment connected to improper air supply: contaminated with oil, water, dirt, etc. Damage caused by operator abuse or improper practices cautioned against in this manual Damage caused by interface hardware not manufactured by Exatron Damage or malfunction caused by customer modifications Test contactors
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Standard Warranty
Customer In-House Service
Customer In-House Service

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

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

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

The following three sample contracts show details of what is covered. They may be changed without notice.
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Service Contract
Service Contract
2842 Aiello Drive, San Jose, CA 95111
www.exatron.com 408-629-7600
SERVICE CONTRACT Rev H

for Customer TBD Street Address City, State, Zip
Please see our Customer Service Support document for detailed warranty details This contract shall commence on Starting Date for a period of twelve (12) months and shall be renewed only upon receipt of new purchase order for a new 12 month period. Exatron shall provide service by way of prompt, reliable technical consultation and service coordination with respect to Customers Exatron built products located at their TBD facility, full address. Please see section Product Movements, below, for more information regarding the location of the Exatron products covered by this contract.. This Service Contract" includes: Perform Preventive Maintenance procedures as defined in the Exatron Manual. Clean, align and inspect handler for worn and/or damaged parts. Examine handler for signs of wear and notify the Customer. A list of required replacement parts will be supplied to the customer during each visit. Purchased parts may be installed during the next visit. 1 year factory labor Installation of any update and diagnostic software as might be available Best effort response time, 1 to 3 business days typical Typical same day shipment of spare parts Toll free 800-EXA-TRON support service phone line What is NOT covered by this Service Contract: All actual travel costs, see below The cost of all spare parts The cost of consumables and test contacts Any OEM equipment warranty/service costs (non-Exatron products) Operator and/or service training of customer personnel Shipping damage of any kind Acts of God
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Acts of war Power line problems and damage Air supply problems and damage Ongoing camera & laser application support Any other Exatron products not specifically listed on this contract
Service performed on Exatron-built products only: Service is strictly limited to the Exatron portions of a given system Service work on any OEM subsystem is to be purchased directly from the OEM This includes, and not limited to, bowl feeders, chillers, camera/vision systems, customer supplied equipment, label printers, laser markers, smoke extractors, and any large OEM subsystem used in the overall Exatron system Please note: All laser markers require professional service. Improper service will void the OEM warranty and could result in personal injury and/or serious damage to the laser.
This contract does NOT extend the Exatron product warranty. This contract does NOT provide for any additional service work beyond the limits of this contract.
Service Contract Schedule Exatron will make every effort to have a service engineer at the customers facility with in 1 to 3 business days of the call for service. There are no service response time guaranties. We do offer a 1 business day turn around service on a per occurrence basis. Please contact Exatron for details and quotation. PM Product Movements Preventive maintenance contracts are priced to specific locations. With the exception of movements between buildings on the same campus, any movement of the Exatron product covered by this contract during the period of this contract may result in a change in the price of the preventive maintenance contract, and the contract must be requoted. The value of any unused portion of this contract will be applied towards the new contract price. Exatron reserves the right to refuse service for machines which are moved to parts of the world considered unstable or dangerous. Service Operating Hours Preventive Maintenance service work shall be performed 8:00 AM to 5:00 PM, local time, Monday through Friday, excluding weekends and local public holidays. Availability of Products Any spare parts at site shall be made freely available by Customer to Exatron's engineer to enable remedial work to be carried out. In the event spare parts must be obtained from the factory in San Jose, California, the engineer may return to the customer facility to complete the work. Return to the customer facility will be determined by mutual agreement between Exatron and the customer. Price Call for a quotation. There is a substantial cost increase for customers who do not have and/or allow our service engineer to connect the Exatron Product to the internet allowing for remote diagnostics. Spare Parts 25% discount on all Exatron spare parts, except consumables, during the life of the contract. Spare parts for OEM subsystems should be purchased directly from the OEM vendor. If purchased through Exatron, there is an additional markup and no discounts are available. Terms Call for a quotation.
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Service Contract
All actual travel expenses are NOT included and will be billed at the time: These include as a minimum the following expenses: Air fare as required Rental car and/or cab fees Lodging Per-diem food allowance Equipment and/or spare parts express shipping costs Travel expenses to the customer are waived if within 50 miles of Exatron, San Jose, California. Site Medical Facilities Site medical facilities will be made freely available to Exatron's engineer(s) as needed for emergency medical treatment. Limitation of Liability During the initial warranty period of a system covered by this contract, Exatrons entire liability and customer's exclusive remedy will be repair or replacement of an assembly not meeting Exatron's standard warranty. Following the warranty period, Customer is responsible for any and all costs associated with repairs, replacement parts, etc. In no event will Exatron be liable to the customer for any damages including lost profits, cost saving, or other incidental or consequential damages arising out of the use or inability to use Exatron products referred to herein even if Exatron has been advised of the possibility of such damages, or of any claim by any other party. Customer will indemnify Exatron against any damage to Customers property and against any claims for loss or injury to any person or to the property of any person by reason of the Customers negligence or of any act or omission on the part of the Customers employees, subcontractors, assignees or agents arising out of this contract. Excuse of Performance Neither party shall be liable to the other party for any delay due to causes beyond its reasonable control, including but not limited to faulty instructions, lack of instructions, travel or shipping delays due to weather or other factors outside their control, shipper's error, acts of God, or strikes or other labor disputes. Law The validity, interpretation, and performance of this agreement, and any dispute connected therewith will be governed and construed in accordance with the laws of the State of California. IN WITNESS WHEREOF, the parties have executed this Agreement by their duly authorized representatives as of the date and year stated at the top of this document. Customer TBD EXATRON
_____________________________________________________________________ By ___________________________By _David Ledezma______________ Title __________________________Title _Customer Service Manager____ Customer contact person(s) Phone number(s) Email(s) EXATRON PRODUCTS COVERED UNDER THIS P.M. CONTRACT Serial # Serial #
Handler Model Exatron PC
Original Customer PO# :__________________ Original Ship date#:______________________
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Preventive Maintenance Contract
2842 Aiello Drive, San Jose, CA 95111
www.exatron.com 408-629-7600
PREVENTIVE MAINTENANCE CONTRACT Rev J

for Customer TBD Street Address City, State, Zip
Please see our Customer Service Support document for detailed warranty details This contract shall commence on Starting Date for a period of twelve (12) months and shall be renewed only upon receipt of new purchase order for a new 12 month period. Exatron shall provide service by way of prompt, reliable technical consultation and service coordination with respect to Customers Exatron built products located at their TBD facility, full address. Please see section Product Movements, below, for more information regarding the location of the Exatron products covered by this contract. This "Preventive Maintenance Contract" includes: Perform Preventive Maintenance procedures as defined in the Exatron Manual. Clean, align and inspect handler for worn and/or damaged parts. Examine handler for signs of wear and notify the Customer. A list of required replacement parts will be supplied to the customer during each visit. Purchased parts may be installed during the next visit. Installation of any update and diagnostic software as might be available Scheduled PM visits only, as listed below. Typical same day shipment of spare parts Toll free 800-EXA-TRON support service phone line What is NOT covered by this "Preventive Maintenance Contract": All actual travel costs, see below The cost of all spare parts The cost of consumables and test contacts Un-scheduled service calls Any OEM equipment warranty/service costs (non-Exatron products) Operator and/or service training of customer personnel Shipping damage of any kind Acts of God Acts of war Power line problems and damage Air supply problems and damage Ongoing camera & laser application support Any other Exatron products not specifically listed on this contract Service performed on Exatron-built products only: Service is strictly limited to the Exatron portions of a given system Service work on any OEM subsystem is to be purchased directly from the OEM This includes, and not limited to, bowl feeders, chillers, camera/vision systems, customer supplied equipment, label printers, laser markers, smoke extractors, and any large OEM subsystem used in the overall Exatron system
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Preventive Maintenance Contract
Please note: All laser markers require professional service. Improper service will void the OEM warranty and could result in personal injury and/or serious damage to the laser.
This contract does NOT extend the Exatron product warranty. This contract does NOT provide for any additional service work beyond the limits of this contract.
Preventive Maintenance Visit Schedule There will be two (2) preventive maintenance visits each year. The timing of each visit shall be mutually agreed upon by Exatron and the customer to prevent unnecessary disruption of Customer's plant operation. The dates of the mutually agreed semi-annual visits must be determined at least 30 days prior to its occurrence. One engineer will be dispatched to carry out the preventive maintenance work. PM Product Movements Preventive maintenance contracts are priced to specific locations. With the exception of movements between buildings on the same campus, any movement of the Exatron product covered by this contract during the period of this contract may result in a change in the price of the preventive maintenance contract, and the contract must be requoted. The value of any unused portion of this contract will be applied towards the new contract price. Exatron reserves the right to refuse service for machines that are moved to parts of the world considered unstable or dangerous. Service Operating Hours Preventive Maintenance service work shall be performed 8:00 AM to 5:00 PM, local time, Monday through Friday, excluding weekends and local public holidays. Availability of Products Any spare parts at site shall be made freely available by Customer to Exatron's engineer to enable remedial work to be carried out. In the event spare parts must be obtained from the factory in San Jose, California, the engineer may return to the customer facility to complete the work. Return to the customer facility will be determined by mutual agreement between Exatron and the customer. Price The PM contract is priced by the day. We recommend a minimum of 2 PM visits per year. We recommend a maximum of 4 PM visits per year. Prices DO NOT include any travel costs and/or spare parts if applicable. 2 PM visits per year at $1200 per visit ($2400 Contract Cost) 3 PM visits per year at $1100 per visit ($3300 Contract Cost) 4 PM visits per year at $1000 per visit ($4000 Contract Cost) Spare Parts Spare parts for OEM subsystems could be purchased directly from the OEM vendor and/or Exatron. Exatron manufactured spare parts to be purchased through Exatron only. Terms Call for a quotation. All actual travel expenses are NOT included and will be billed at the time: These include as a minimum the following expenses: Air fare as required Rental car and/or cab fees Lodging Per-diem food allowance Equipment and/or spare parts express shipping costs Travel expenses to the customer waived if within 50 miles of Exatron, San Jose, California. Site Medical Facilities Site medical facilities will be made freely available to Exatron's engineer(s) as needed for emergency medical treatment.
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Limitation of Liability During the initial warranty period of a system covered by this contract, Exatrons entire liability and customer's exclusive remedy will be repair or replacement of an assembly not meeting Exatron's standard warranty. Following the warranty period, Customer is responsible for any and all costs associated with repairs, replacement parts, etc. In no event will Exatron be liable to the customer for any damages including lost profits, cost saving, or other incidental or consequential damages arising out of the use or inability to use Exatron products referred to herein even if Exatron has been advised of the possibility of such damages, or of any claim by any other party. Customer will indemnify Exatron against any damage to Customers property and against any claims for loss or injury to any person or to the property of any person by reason of the Customers negligence or of any act or omission on the part of the Customers employees, subcontractors, assignees or agents arising out of this contract. Excuse of Performance Neither party shall be liable to the other party for any delay due to causes beyond its reasonable control, including but not limited to faulty instructions, lack of instructions, travel or shipping delays due to weather or other factors outside their control, shipper's error, acts of God, or strikes or other labor disputes. Law The validity, interpretation, and performance of this agreement, and any dispute connected therewith will be governed and construed in accordance with the laws of the State of California.
IN WITNESS WHEREOF, the parties have executed this Agreement by their duly authorized representatives as of the date and year stated at the top of this document. Customer TBD EXATRON
_____________________________________________________________________ By ___________________________By _Quang Truong______________ Title __________________________Title _Customer Service Manager____ Customer contact person(s) Phone number(s) Email(s) EXATRON PRODUCTS COVERED UNDER THIS P.M. CONTRACT Serial # Serial #
Handler Model Exatron PC
Original Customer PO# :__________________ Original Ship date#:______________________ PM Contract PO# :__________________ Exatron Invoice# :__________________ NOTE: LASER & LASER PC SERVICE/MAINTENANCE ARE NOT INCLUDED DATES FOR PREVENTIVE MAINTENANCE The Preventive Maintenance procedures will be performed two (2) times semi-annually as scheduled below: (Please fill out and return with signed copy of the contract.) 1: TBD 2007 PM Contract Quote#:______________________
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Customer Service Support Guide
2842 Aiello D rive, San Jo se, C A 95111
w w w .exatron.com 408-629-7600
C ustom er S ervice & S upport Rev K

Manager Factory service hours Phone numbers Fax number E-mail Quang Truong (or Eric Hagquist) 8:00AM-5:00PM M-F Pacific Time 408-629-7600 or 1-800-EXATRON 408-629-2832 [email protected] or [email protected]
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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Model 5000 Manual
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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End-of-Life Handler Disposal
End-of-Life Handler Disposal

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

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

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

Bin Refers to a physical output location, such as a tray, bucket, or tube. Contrast with sort. A positive air pressure in the vacuum lines, used to break any residual vacuum between the pickup head and a device it was suctioning. A generic term that refers to the chip, package, or other part processed by the Exatron handler. The location that each motor returns to each time the handler is reset. 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 total of the parameter values for all the RAM addresses displayed in hex. The component of a vacuum generator that sucks air in one hole as air pressure is forced along the pathways, thus causing a vacuum. Blow-off
Device
Home position
Slop
Sort
Sum check
Venturi
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Chapter Overview
This chapter discusses concepts of how your handler works. Following chapters show you how to put these concepts into practice and carry out procedures. This chapter deals with the following main topics:
Topic Overview of Model 5000 Key Movements and Positions Model 5000 Optional Features Mechanical Features Electronic Features Pneumatic Features
Page 2-1 2-5 2-8 2-9 2-24 2-48
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.
Overview of Model 5000

The Model 5000 handler is a tube-to-tube, gravity-feed, eight-sort handler designed for a wide variety of package typesboth surface-mount and through-hole technologiesusing SnapOn Changeover Kits to convert from one device size to another. It integrates customer-specified programming and/or test sites. Blank/untested devices are loaded in tubes at the top of the handler, then sent (indexed) one at a time (or up to 4 at a time for custom options) to a test contact mechanism. Among the standard choices, you can select special SMD (Surface Mount Device) test sites which plunge the Device Under Test (DUT) up to 1.5 inches past the back of the handler to a load board. Programming and testing take place here, using any of several types of programmers and testers. The devices are sorted by "pass" or "fail" categories after each test. After testing, failed devices are sorted into reject tubes (usually bin 5). Devices that pass the test stage are sorted to the output tubes or to a taper. The Model 5000 handler operation is constantly monitored by its standard-bus CPU. Once a device enters the handler, it is tracked by sensors as it passes through every step until it is positively placed in the correct output tube. If a device jam should occur, an appropriate error message will be displayed on the handler controller's control panel. Most jams can be cleared by pressing the <RUN> or <Clear> keys on the front panel.
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The handler can be operated in either of two modes: Run or Manual. Manual mode allows for handler diagnostics sequences to be run, handler setup changes to be entered, and mechanical adjustments to be made at the operator's convenience before, during, and after automatic handler operation. Run mode continuously cycles devices through the handler. The handler stops when empty but restarts automatically when more devices are loaded. Each output tube may be filled to any preset amount, with individual counters keeping track of quantities in each output. When an output tube is filled, the handler automatically begins to fill any other unfilled tube assigned to the sort signal received from the tester. When all output tubes are filled, the handler stops and a message is displayed, such as: "ALL OUTPUTS FULL." The tube counter is automatically reset by removing the full tube and re-inserting an empty tube. The handler will not cycle devices to outputs that are full or have no tubes. Additionally, a running count is maintained for all outputs, up to a total of 999,999 devices. Sorting is accomplished by use of a stepper motor and shuttle. Sensors keep track of the shuttle's position at all times. In the event of a sorting problem, a message is displayed on the handler's control panel, and the device is not binned until the problem is corrected. The Model 5000 handler, like all Exatron handlers, is guaranteed to properly bin every device even during "power down" conditions. The Model 5000 handler can have numerous options: It can use a tester, a programmer, and/or a laser marker, integrating customerspecified programming and/or test sites. It can use 8 input tubes or a bowl feeder. It can use 8 output tubes with 8 sort categories, or it can use 5 output tubes plus a tape-and-reel system. Both can be used together, or the output tubes can be used without the taper. It can be designed for a wide variety of package typesboth surface-mount and through-hole technologiesusing Snap-On Changeover Kits to convert from one device size to another.
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Octoloader (input)
Test site (processing)
Output tubes (output)
Figure 2-1: Model 5000 OverviewWith Octoloader Motor and Shuttle Motor Only
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Octoloader (input)
Test site (processing) Pickup head motor Pickup head
Output tubes (output)
Figure 2-2: Model 5000 OverviewWith Pickup Head and Third Motor
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Key Movements and Positions
Key Movements and Positions
Figure 2-3: Flow of Movement
Two or three motors drive the movement of devices. One motor drives the horizontal movement of the octoloader; the second motor drives the horizontal movement of the shuttle. If the handler is equipped with a pickup head that moves each device through the test site, a third motor controls the pickup head. In Figure 2-3, the red arrows show the movement driven by the motors; the blue arrows show the gravity-induced movement of the devices. If the handler is equipped with a third motor driving a pickup head, the pickup head moves the device through the test area. Figure 2-4 shows all the positions where a device might rest or be deposited during its course through the Model 5000 handlerand Model 1050 taper, if so equipped. If there is no taper, the handler is equipped with 8 output tubes instead of 5. Everything below the dotted red line belongs to the 1050 taper and is discussed in the Model 1050 User Manual.
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Top of octoloader gate
Top of index pin Input track Top of stack pin

Pickup head
Pickup site w/ cover foot
Test site
Pickup head dropoff site Output track Laser bottom gate Laser mark site
Shuttle Taper input track Top of index pin Top of stack pin Pickup site w/ cover foot
Swing arm
Tape
Figure 2-4: Key Device Positions
Note that there are two index pins and two stack pinsone set for the handler, and one set for the taper. However, this should not cause confusion, because the set for the handler is discussed in this manual, the Model 5000 User Manual; whereas the set for the taper is discussed in the Model 1050 User Manual.
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Key Positions for Handler with Quad Test Site
Key Positions for Handler with Quad Test Site

In addition to the positions shown in the previous sections, a handler with a quad tester (for simultaneous movement and testing of four devices) has a few extra positions. Devices from the octoloader are held up from the gravity-feed track by the index pin, which is extended into the main track by default. The index pin is on a see-saw with the stack pin, so that when the index pin is retracted to allow a set of four devices into the main track, the stack pin is extended to hold them up from entering the quad test site. When the index pin is again extended, the stack pin retracts and drops the four devices into the test site, where they are held by the test site stop pin.
Figure 2-5: Key Positions for Handler with Quad Test Site
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The test site clamps close on each side, and the testing occurs. After the test results are sent to the handler, the test site stop pin retracts and the four devices are dropped to the stage or holding site, where they are stopped by the stage stop pin. When the shuttle is in position to receive them, the stage stop pin retracts and the devices are dropped into the shuttle, where they are then distributed to their respective sort outputs.
Model 5000 Optional Features

Many options are available for the Model 5000 handler, most of which may be added at the customer site. Available options are described in detail at the time of equipment price quote and include: One-track hot rail Upgrade to automatic print-and-apply labeler High frequency particle-interconnect contact sets Extruded aluminum output tubes Output tube guard "Live bug" or "dead bug" operation (available in most cases) Bowl-feed input Output tape and reel Opto-isolation interface (noise protection for handler if tester is not already equipped with this safety feature) Status light pole Extended warranties Service contracts Other options are available if requested.
Devices and Packages Accommodated

Model 5000 handlers may be configured for all of the following packages, besides numerous other custom packages. DIP, dual in-line packages: "Live bug" or "dead bug" 0.300", 0.400", 0.600", 0.900" body width 8 to 48 pins, standard range 4 to 64 pins, optional range 0.070" or 0.100" lead pitch
SOIC, small outline integrated circuits: "Live bug" or "dead bug" 0.150", 0.170", 0.210", 0.300", 0.330", 0.350", 0.450" body width SOJ, "J" lead shape: 0.170", 0.210", 0.300", 0.330", 0.350", 0.450" body width
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Mechanical Features
Taper Option
0.100", 0.079", 0.050", 0.039", 0.025", 0.020" lead pitch PLCC, plastic leaded chip carriers: 18, 20, 24, 28, 32, 44, 52, 68, 84 pins, "live bug" only LCC, leadless chip carriers: 18, 20, 24, 28, 32, 44, 52, 68, 84 pads, "live bug" only SIP; SIL, single in-line packages: D-Pak, D2-Pak, D3-Pak, TO-218, TO-220, TO-247, TO-3P, TO-3PBL, DO-214, SOT-23 Custom hybrid SIPs, others TSSOP Small printed circuit boards ZIP, staggered lead form single in-line package SIMM, single in-line memory modules Other memory modules
Numerous custom packages
Taper Option
If the handler is equipped with a taper, it can have only 5 output tubes instead of 8. Rather, it is equipped with a taper input track below the shuttle and to the right of the 5 output tubes, as shown in Figure 2-4. The taper input track has pins that correspond to the ones on the handlers input track. Both sets of pins control the movement of devices. The taper input track is discussed in more detail in the Model 1050 User Manual. NOTE: You cannot use both the output tubes and the tape-and-reel assembly at the same time. You must use either one or the other for any run.
Mechanical Features
Tilt Mechanism
All gravity-feed handlers include an adjustable tilt mechanism. The tilt angle is critical for ceramic DIPs and LCCs since too much drop angle may cause chipping of the packages. Making the slide angle more horizontal than vertical increases drag and slows the devices movement, thus minimizing chipping from impact.
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The handler cycle timing is sensor-controlled, so the cycle speed will be automatically slowed to match that of the devices. The maximum slide angle for PLCC devices is 45 degrees from vertical. NOTE: Ceramic device damage may be minimized by use of bumpers which attach directly to each device. Some types of these bumpers will run through a standard Exatron handler. In some cases, custom rails may be required.
Figure 2-6: Tilt MechanismLeft Side (Left); Right Side (Right)
The tilt mechanism in Figure 2-6 can be tilted to three angles (35-, 45-, and 55-degree angle), by unbolting the top bolt only on each side and moving it to one of the three holes. The angle shown in Figure 2-6 is 45 degrees.
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Mechanical Features
Safety Cover
Safety Cover
The Model 5000 comes with a clear safety cover equipped with interlocks. If the cover is opened while the handler is processing devices, all operation instantly stops.
Figure 2-7: Safety Cover
Motors and Drive Chains

The motors driving the octoloader and shuttle are DC stepper motors. Stepper motors have no homing routine. However, Exatron has added sensors that tell the software when the component is at its "home" position according to the Exatron software (Figure 2-9). Each motor drives movement by means of a chain, whose tension can be adjusted by loosening and moving the red tensioner slightly.
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Figure 2-8: Motor with Drive Chain
Figure 2-9: Drive Chain Tension Adjuster for Octoloader (Left), for Shuttle (Right)
If the handler is equipped with a pickup head that moves each device through the test site, a third motor, a servo motor, controls the pickup head. The servo motor has a homing routine and absolute positions.
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Mechanical Features
Octoloader
Octoloader
Exatron's octoloader is an ambient automatic eight-tube loader. The standard Model 5000 comes equipped with this octoloader which is a moving metal plate holding up to eight tubes of devices, controlled by the handler's CPU by means of a stepper motor. The plate automatically moves both left and right, positioning each tube of devices over the handler input track. When the input track is emptied, the octoloader automatically searches for tubes with devices. The octoloader has a sensor mounted at its junction with the input track. The octoloader can "see" a device jam and stop its own movement to prevent breaking the jammed device. The octoloader also has an automatic "wiggle" jam-clearing operation which it will implement immediately in an effort to remove the jam without operator assistance. Model 5000 octoloaders use a snap-on plate which is specifically fitted with tube holders for a given device application. It can be snapped on and unsnapped to clear device jams. When the octoloader is at its home position, it is pressing the sensor on the red octoloader stop.
Figure 2-10: Octoloader at Home Position
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Figure 2-11: Octoloader Back with Snap-On Pins (Left); Octo Car Block with Holes for Snap-On Pins (Right)
Figure 2-12: Octoloader Front with Two Tubes Attached
Each of the 8 octoloader chutes has a gate that restrains the devices. As the octoloader moves each tube over the track, the roller depresses the gate for that chute, thus opening it and allowing one device to fall through. Each tube is emptied of devices before the octoloader moves the next tube over the track.
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Mechanical Features
Octoloader
Each gate acts as a pivot. When not depressed, its pin extends, blocking the fall of devices from the input tube. When a gate is depressed, its pin retracts, allowing devices through.
Figure 2-13: Octoloader Gate Depressed by Roller
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Figure 2-14: Devices Stopped by Octoloader Gate (Left); Devices Released by Octoloader Gate (Right)
Figure 2-15: Octoloader Gate Pin Blocking Exit (Left); Device Exiting Octoloader Chute (Right)
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Mechanical Features
Octoloader
Figure 2-16: Octoloader Gate Closed (Left); Octoloader Gate Opened (Right)
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Pickup Head
The pickup head moves on a lead screw driven by its own motor. The pickup heads home position is at its zero position at the top of its path, above the pickup site.
Figure 2-17: Pickup Head Motor and Lead Screw
The pickup head is equipped with a plunger, which uses an air vacuum to pick up devices and transport them from the pickup site, to the test site, and finally to the dropoff site.
Figure 2-18: Device Attached to Plunger on Pickup Head
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Mechanical Features
Pickup Head
The pickup head moves devices from the pickup site (Figure 2-20), through the test site (Figure 2-21), and down to the drop-off site at the top of the output track (Figure 2-22).
Figure 2-19: Pickup Head (Left); Device at Pickup Site (Right)
Figure 2-20: Pickup Head at Pickup Site
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Figure 2-21: Pickup Head at Test Site
Figure 2-22: Pickup Head at Drop-off Site
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Mechanical Features
Output Tray
Output Tray
Adding an output tray for tested and sorted devices allows you to put the devices into tubes later, and helps reduce device jams.
Figure 2-23: Output Tray with Counter Display
After devices have been sorted, a tube is fastened in place at the bottom of each tray row. Then each output gate is opened by pressing the corresponding button, releasing the devices from the tray row to the tube.
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Figure 2-24: Output Gates and Buttons
Figure 2-25: Releasing Devices From Output Tray to Tubes
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Mechanical Features
Changeover Kits
Changeover Kits
Your handler can be configured to accept more than one changeover kit. If the handler is to process more than one size or type of device package, a different changeover kit may need to be installed for a different device. See "Changing Device Sizes or Package Types" on page 3-1 for instructions. NOTE: When switching device types, you need to specify the new type in the software as well as by changing the changeover kit. See "Changing Settings" on page 3-46. Common components of a changeover kit include: Octoloader Test-site changeover kit, including index track, pickup assembly if so equipped, and connected electronics Shuttle Output tube holder Output tubes Output tube holder
Track
Shuttle
Test-site c/o kit
Octoloader
Figure 2-26: Example Changeover Kit
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Pickup nozzle Shuttle
Octoloader
Output tube holder
3-piece hot rail
Test-site c/o kit

Figure 2-27: Example Changeover Kit for Hot-Rail Handler
Electronic Features
EMO (Emergency Stop) Button
The EMO (emergency stop) button, located on the power supply, can be pushed in anytime there is a need to disable the motors and shut off the 24-volt AC.
Figure 2-28: EMO (Emergency Stop) Button
To release the EMO button, turn it clockwise until it pops out again.
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Electronic Features
Power Supplies and Wiring
Power Supplies and Wiring

The Model 5000 uses two power supplies. The 24-volt DC power supply runs the solenoids; the 5-volt DC power supply runs the control panel.
Figure 2-29: Power Wiring Connection
Pickup Head Motor Driver
Figure 2-30: Motor Driver
The pickup head is driven by a servo motor and has a motor driver as shown in Figure 2-30. When power is supplied to the handler, the green GND light should be on. This means it has power. Only the 24-volt and ground connections are used by Exatron; A and B are not used.
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Fuses
The fuse displays are located to the left of the EMO button.
Figure 2-31: Fuses
Color Red Orange White
Position Upper left Upper right Lower left 5-volt power 24-volt power
Purpose
AC power; stays on when handler turned off but still plugged in
Each power supply has its own fuse, located inside the housing to which the control panel is attached.
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Electronic Features
Control Panel
Power supply
Motor driver Fuses

Figure 2-32: Fuses Near Power Supply
Control Panel
The control panel provides two-way communication between the operator and the handler. The operator can enter commands to run, perform diagnostics, or change settings using the keys on the control panel. (See "Understanding the Control Panel Keys" on page 3-45 for a list of key commands.) In return, the message display area on the control panel confirms the actions that are taking place or issues alert messages.
Figure 2-33: Control Panel
Sensors
For a custom handler with a quad tester, the cable for sensors 0 through 7 is the top cable that is attached just above the test site. The cable for sensors 8 through F is the bottom cable that is attached just below the test site (Figure 2-34).
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Figure 2-34: Cable for Sensors 0-7 Above Test Site; Cable for Sensors 8-F Below Test Site
Solenoids
The Model 5000 is equipped with solenoids that work together in moving each device through the test site. Four of these solenoids (which may be color-coded) correspond with one of the override buttons on the left side of the track. The override buttons are useful for wiggling loose a jammed device. While holding down the yellow index button to restrain other devices, you can toggle the other three buttons.
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Electronic Features
Solenoids
Figure 2-35: Override Buttons and Corresponding Solenoids
Solenoid Button 1 2 3 4 5 6 7 8 Yellow White
Location
Affects
Action
Button panel Pickup vacuum When pressed, pickup head vacuum is turned on Button panel Pickup blow-off When pressed, pickup head blow-off is turned on When pressed, index air is turned on, preventing flash, or devices sticking together When pressed, pickup head is lowered When pressed, index pin is extended When pressed, stack pin is retracted and cover foot is extended When pressed, top gate is extended/raised, blocking passage of a device to the laser mark site When pressed, bottom gate is extended/raised, blocking passage of a device from the laser mark site When pressed, shuttle pin is retracted
Orange Button panel Index air assist Black Green Gray Red Red Blue Button panel Pickup head Button panel Index pin Button panel Stack & cover foot Button panel Top gate Button panel Bottom gate Right end of shuttle path, under LED cover Shuttle pin
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On a custom handler with quad tester, the override buttons may be as follows: Button Red Top 2nd 3rd Location Under octoloader ledge Button panel Button panel Button panel Affects Index pin & stack pin Action When pressed, index pin is extended but stack pin is retracted
Test site stop Opens/retracts stop pin below test site Track air blast Stage stop When pressed, air blast is turned on to push devices, in 3 places: above index pin, below stack, & below test site stop Opens/retracts stop pin below stage or holding site
Bottom Button panel Red
Test site con- Closes test site contacts tacts When pressed, shuttle pin is retracted, allowing devices to fall
Right end of shuttle Shuttle pin path, under LED cover
Figure 2-36: Index/Stack Pin Override Button (Left); Shuttle Pin Override Button (Right)
Index and Stack Pins

During a production run, the stack pin is by default extended, restraining the line of devices waiting to fall to the test site. When the handler is ready to move another device, the index pin is extended between the lowest device in line and the device just above it. Then the stack pin is retracted, allowing the lowest device to fall. On a custom handler with quad tester, the index and stack pins are simultaneously controlled by the same solenoid. In the default position, the index pin is retracted but the stack pin is extended into the track (Figure 2-37, left). When the solenoid is activated, this is reversed: the index pin is extended into the track but the stack pin is retracted (Figure 2-37, right).
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Electronic Features
Solenoids
Index pin
Stack pin
Figure 2-37: Index and Stack Pins at Default Position (Left); at Reverse Position (Right)
On other models, the stack pin and cover foot (Figure 2-38) are activated simultaneously to prevent the device from jumping the stop block. Thus, when the stack pin retracts to release a device, the cover foot is extended to hold the device at the pickup site momentarily until any bouncing action stops.
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Figure 2-38: Cover Foot Retracted and Stack Pin Extended (Left); Cover Foot Extended and Stack Pin Retracted (Right)
Test Site Stop Pin

By default the test site stop pin is extended to stop the device at the test site. At the test site, the sensor notes the presence of the device and causes the test contacts to close so testing can occur. After the tester sends a sort result, the test contacts are opened and the test site stop pin is retracted, allowing the device to fall to the shuttle, which takes it to the appropriate ouput tube. The test site stop pin is again extended just before the stack pin is retracted, allowing another device into the test site.
Photo Display of Pins

The next few photos show the underside of the changeover kit that normally faces the test site.
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Electronic Features
Solenoids
Figure 2-39: Stack Pin Extended to Restrain Device
Figure 2-40: Test Contacts Closed on Device (Left), Opened (Right)
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Figure 2-41: Test Contacts on Custom Quad TesterClosed (Left), Opened (Right)
In some cases, an additional air valve may be necessary to allow adjustment of the amount of pressure with which the test site contacts are closed, as in Figure 2-42.
Figure 2-42: Air Valve for Test Site Contact Pressure Adjustment
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Electronic Features
Solenoids
Figure 2-43: Test Site Stop Pin Extended (Left), Retracted (Right)
Laser Gate
For handlers equipped with a laser marker, the laser gate is by default extended to keep the device in place while it is being laser marked. After each device is marked, the laser gate retracts momentarily, allowing the device to drop to the output tube.
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Figure 2-44: Laser Gate Extended (Default, Left), Retracted (Right)
Shuttle Pin
The fifth solenoid controls the shuttle pin. The shuttle pin, extended by default, catches each device after the stop pin retracts and releases it. Then the shuttle carries the device to the appropriate output tube and its pin retracts to release the device.
Figure 2-45: Shuttle Pin Extended to Hold Device (Left), Retracted (Right)
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Electronic Features
Solenoids
Figure 2-46: Shuttle and Override Button in Closed Position (Left), in Open Position (Right)
The shuttles home position is directly in line with the test track and the fifth output tube. The shuttles movement from tube to tube is controlled, not by its solenoid, but by its stepper motor.
Figure 2-47: Shuttle at Home Position Between Test Track and Fifth Tube
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Output Displays
The most common type of output display is LED on/off only. Alternatively, a digital display is available by request, showing at each output a "P" for Pass, an "F" for Fail, or a digit representing a sort category.
Figure 2-48: Output DisplaysLED On/Off (Left), Digits (Right)
LED Display
The output tube cover is equipped with LEDs that give several indicators. In Run mode, the LED for the next or current output tube in use is lit. (In Figure 2-48, output tube 4 is being filled.) This enables you to avoid swapping out a full tube when the handler is trying to use it. In Run mode, LEDs flash for any outputs that have full tubes or no tubes. In Diagnostics mode, the sensor check results are reflected in the LEDs.
Digital Display
An unblinking display on the tube cover shows which bins are receiving which sorts. With this, you can control how the devices get sorted. The factory default is as follows. The first 4 bins are for passed devices routed to tubes. Bin 5 is always fail because its the most direct from the exit track and easiest to dump to. Bins 6 and 8 are unused on a handler with this hardware configuration.
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Electronic Features
Output Displays
Bin 7 is for passed devices routed to the tape-and-reel assembly. NOTE: You cannot use both the output tubes and the tape-and-reel assembly at the same time. You must use either one or the other for any run. So the factory-default order is PPPPF030. Output tube switches
Figure 2-49: PPPP-030
Output tube with dash
Figure 2-50: PP-PF030
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In each case, a dash signifies a tubes presence. If 5 tubes are present, the display reads: - - - - - 0 3 0 . As a tube is inserted, it presses down on the output tube switch and causes the sensor underneath to register as a dash.
Display P F 3 0
Meaning Pass In use Fail
Use Tube Both Tube Taper
Not used
Tray Counter Display

If a tray output is used, it may have a counter display for each output.
Figure 2-51: Tray Counter Display
Sensors
Each sensor is placed to detect the presence or absence of a device or machine part, thus providing feedback to the handler for the flow of devices.
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Electronic Features
Sensors
Octoloader/Input Sensors
Sensor Octoloader at home Purpose Detects when the octoloader is at its home position
Device at octoloader gap Detects a device that has passed the input gate and is waiting at the octoloader ledge. Octoloader will not move laterally if a device is here. Device at top of track Detects a device at the top of the track. Octoloader will not move laterally if a device is here.
Figure 2-52: Octoloader at Home Sensor (8)
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Figure 2-53: Device at Octoloader Gap Sensor (7)
The Device at Octoloader Gap sensor (number 7 on the control panel display) is above the ledge, and above the Device at Top of Track sensor (number 6 on the control panel display).
Figure 2-54: Device at Top of Track Sensor (6)
For more information, see "OCTO/INDEX CHECK: Input Sensor Check" on page 4-38.
Test Site/Track Sensors

These sensors track the movement of devices along the track to and at the test site.
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Electronic Features
Sensors
Figure 2-55: Sensors 0-2 (Left); Sensors 4-7 (Right)
For more information, see "SENSOR CHECK: Test Site Sensors 0-7" on page 4-12.
Laser Mark Site/Track Sensors

These sensors track the movement of devices along the track to and at the laser mark site (if any).
Figure 2-56: Device at Stack Pin Sensor
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The Device at Stack Pin sensor (number 0 on the control panel display) sees when a device is resting on the stack pin.
Figure 2-57: Device at Mark Site Sensors 1-3
The Device at Mark Site sensors (numbers 1-3 on the control panel display) see when one or more devices is at the mark site. In the case of long devices, 2 or 3 sensors may be activated for just one device. In the case of short devices, 2 or 3 sensors activated may indicate there are two devices at the mark site.
Shuttle Position Sensors

Eight sensors detect the position of the shuttle along the top of the output tubes. One sensor is located directly above each output tube.
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Electronic Features
Sensors
Figure 2-58: Shuttle SensorsWithout Device
When the shuttle does not contain a device, only the two sensors on either side are blocked, but the one in the middle, where the device would be, is open (Figure 2-58).
Figure 2-59: Shuttle SensorsWith Device
When the shuttle does contain a device, all three sensors are blocked (Figure 2-59). For more information, see "SENSOR CHECK: Shuttle Position Sensors 1-8" on page 4-15.
Tube Present Sensors

Each of these eight sensors detects the presence of an output tube. When a tube is inserted, the tube switch is depressed, activating its sensor.
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Figure 2-60: Tube Present Sensors
For more information, see "SENSOR CHECK: Tube Present Sensors 1-8" on page 4-20.
Tube Full Sensors

Each of these eight sensors detect when an output tube is full, and direct the shuttle to a different output tube, or else cause a message to be displayed to replace the tube.
Figure 2-61: Tube Full Sensors
For more information, see "SENSOR CHECK: Tube Full Sensors 1-8" on page 4-18.
Connectors and Ports

The ports are located around the override buttons.
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Electronic Features
Connectors and Ports
Servo motor port
Sensor port
Solenoid port
Figure 2-62: Ports, ClockwiseServo Motor, Sensor Port, Solenoid Port
If a pickup head transports devices to the test site, the test head motor port is located under the override buttons (Figure 2-63).
Test head Z motor port (optional)
Figure 2-63: Solenoid Override Buttons
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For handlers having a hot rail, the hot-rail connectors are plugged in on the top side of the control panel.
Figure 2-64: Hot-Rail Connectors and Ports
Connector Large black-&-white Red White Blue Yellow
Purpose Connects octoloader motor Heats upper hot rail Heats lower hot rail Heats index rail Heats test site
Pneumatic Features
Air Regulator
This air regulator is mounted on the rear right corner of the base. The regulator assembly includes two oil/water particulate traps which should be visually inspected on occasion (see "Checking the Moisture/Dirt Trap in the Air Regulator" on page 6-3). This regulator should be set at factory air pressure of 80 PSI. The system requires a minimum of 80 PSI to operate properlyspecifically, to generate sufficient vacuum through the venturi to pick up devices. The incoming air line exits the regulator and splits to supply the needs of the entire system.
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Pneumatic Features
Air Blast Switch
Adjustment valve
On/off switch in ON position
Figure 2-65: Air Regulator Turned On
Air Blast Switch

If the air blast switch is flipped down to the ON position, every time the shuttle releases, an air blast assists the device to drop into the tube.
Figure 2-66: Air Blast Switch in OFF Position (Left), in ON Position (Right)
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Chapter Overview
This chapter discusses the following main topics:
Topic Changing Device Sizes or Package Types Loading Tubes into the Octoloader Securing Output Tubes Power-Up Procedure Introduction to the Laser Introduction to the Laser Software Aligning the Octoloader Setting Temperatures for the Hot Rail Power-Down Procedure Understanding the Control Panel Keys Changing Settings Manual Mode Resetting Totals Beginning a Production Run Displaying Totals Changing RAM RAM Address Listings Updating Your EPROM Setting Sorts in RAM Addresses C0 to C7 Setting Bin Displays in RAM Addresses B8 to BF Decimal-Hex-ASCII Conversion Table
Page 3-1 3-25 3-28 3-31 3-33 3-38 3-41 3-42 3-44 3-45 3-46 3-55 3-56 3-57 3-58 3-58 3-61 3-76 3-76 3-78 3-79
Changing Device Sizes or Package Types

When you need to run different sizes or types of devices, you may need to change the hardware that handles them. For your convenience in replacing the essential hardware, Exatron provides a changeover kit that is customized to your handler and your device types. (Contact Exatron for details.) The following sections explain what the changeover kit contains, how to replace the changeover kit, and how to align the hardware after its replacement.
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What the Changeover Kit Contains

The changeover kit contains specific components.
Component Octoloader Hot rails (only for hot-rail system) Test site Shuttle Output tube holder Illustration Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5
Figure 3-1: Octoloader
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What the Changeover Kit Contains
Figure 3-2: Three-Piece Hot Rail Assembly (Only for Hot-Rail Handlers)
Figure 3-3: Test Site
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Figure 3-4: Shuttle
Figure 3-5: Output Tube Holder
Identification of Ports, Solenoids, and Test Site Sensors

The assignments in this section are for changeover kit 3000B DIP/5D, as of 3/1/2006.
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Identification of Ports, Solenoids, and Test Site Sensors
Figure 3-6: Ports and Override Buttons
The ports and solenoid override buttons are on the same panel.
Servo motor port Sensor port
Solenoid port
Figure 3-7: Ports, ClockwiseServo Motor, Sensor Port, Solenoid Port
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Test head Z motor port (optional)

Figure 3-8: Solenoid Override Buttons
NOTE: The function of various override buttons may vary for customized handlers.
Functions of Solenoids and Corresponding Override Buttons

Solenoid 1 2 3 4 5 6 7 8 Button Yellow White Orange Black Green Gray Red Blue Affects Pickup vacuum Pickup blow-off Index pin Pickup head Stack pin Index air n/a n/a Action When pressed, pickup head vacuum is turned on When pressed, pickup blow-off is turned on When pressed, index pin is extended When pressed, pickup head is lowered When pressed, stack pin is retracted When pressed, index air assist is turned on, preventing flash, or devices sticking together n/a n/a
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Installing the Changeover Kit
Functions of Track Sensors

Track Sensor 0 1 2 3 4 5 6 7 Pickup vacuum Stack site Pickup site N/A N/A N/A N/A N/A Function

As a general rule: Install a changeover kit from bottom to top. Remove a kit from top to bottom. WARNING: To avoid injury or damage, power off the handler before removing or installing a changeover kit or other parts. The snap-on design makes it easy to install the changeover kit.. To install the changeover kit: 1. Attach the output tube holder to the handler base. Depending on your design, use one of the following means. > If your output tube holder does not have cutouts at both ends, snap it on and tighten the 4 screws (Figure 3-9).
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Figure 3-9: Snap-On Output Tube Holder Screwed Onto Handler Base
> If your output tube holder does have cutouts at both ends, place it on the base and slide it down. The 2 screws do not have to be tightened or loosened (Figure 3-10).
Figure 3-10: Output Tube Holder with Cutouts at Ends
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Figure 3-11: Screws for Cutouts on Base
Figure 3-12: Output Tube Holder On Handler BaseIn Unlocked Position (Left); in Locked Position (Right)
2. Snap the shuttle in place with the snap-on pins (Figure 3-13). 3. Attach the black air hose to the shuttle (Figure 3-14).
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Figure 3-13: Back of Shuttle with Snap-On Pins (Left); Insertion Holes on Shuttle Assembly (Right)
Figure 3-14: Shuttle with Black Air Hose Attached
4. From behind the handler, gently insert the test site. (Figure 3-15 through Figure 3-17 illustrates a custom handler with quad tester).
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Figure 3-15: Inserting Test Site
5. On the back of the handler, screw in the two bolts, one above and one below the test site (Figure 3-16).
Figure 3-16: Screwing in Bolts at Each End of Test Site
6. On the back of the handler, plug in the 2-pin molex connector (Figure 3-17).
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Figure 3-17: Two-Pin Molex Connector Plugged In
7. Lay the test site over the large opening in the handler base, making sure the track lines up with and is inserted in the opening in the octoloaders bottom ledge.
Figure 3-18: Track Opening in Octoloader Ledge
8. Tighten the 4 screws on the back of the handler (Figure 3-19).
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Figure 3-19: Test Site Screwed Onto Handler Base
Several of the following steps are to be done only if your handler uses a hot rail. If not, skip these steps. 9. For hot rails only: Slide the index rail down, bottom first (Figure 3-20). The wiring should be at the top.
Figure 3-20: Sliding in Index Rail, Bottom First (Left); Index Rail in Place (Right)
10. For hot rails only: Press the index rail in so the pins are not quite all the way at the top of the grooves in the hot rail base (Figure 3-21).
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Figure 3-21: Index Rail Pins in Grooves of Rail Base
11. For hot rails only: Screw in and tighten the bottom 2 screws on the index rail (Figure 3-22). CAUTION: Do not overtighten the 2 index rail screws. They screw into a plastic material and you do not want to strip the screw holes.
Figure 3-22: Index Rail Screws to Tighten
12. For hot rails only: Plug the other end of the index hot rail wiring into the third (blue) connector on the top of the control panel (Figure 3-23).
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Figure 3-23: Connection for Index Rail
13. For hot rails only: Attach the middle hot rail and screw in the 3 outer screws on each side of the rail (Figure 3-24). > Note that you do not change the connectors for the top and middle hot rails, since the heating element is inside the base, underneath the rails that you change.
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Figure 3-24: Six Screws to Be Tightened on Each Hot Rail
14. For hot rails only: Attach the top hot rail and screw in the 3 outer screws on each side of the rail. > Note that you do not change the connectors for the top and middle hot rails, since the heating element is inside the base, underneath the rails that you change. 15. For hot rails only: Place the clear cover over the hot rail with the cutout area at the bottom (Figure 3-25, left). 16. For hot rails only: Snap the 6 black cover latches closed (Figure 3-25, right).
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Figure 3-25: Clear Cover with Cutout at Bottom of Hot Rail (Left); Snapping Cover Latches Closed (Right)
17. Plug in the air connector (Figure 3-26) on the right side of the front of the handler base.
Figure 3-26: Air Connected to Handler Base
18. Plug the other 3 connectors into the sensor port, the solenoid port, and the servo motor port (Figure 3-27).
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Figure 3-27: Connectors and Ports
> Note that when you plug the connector into the sensor port (blue, upper right), the latches close on it automatically. (To remove this connector, unlatch it before pulling, by moving the latches away from the connector.)
Figure 3-28: Connectors Plugged Into Ports
19. Snap the octoloader onto the handler base, aligning the snap-on pins with the holes in the octo car block (Figure 3-29).
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Resetting Software Parameters
Figure 3-29: Octoloader Back with Snap-On Pins (Left); Octo Car Block with Holes for Snap-On Pins (Right)
To remove a changeover kit, follow these instructions in reverse order.
Resetting Software Parameters

When changing device sizes or package types, you also need to change some software parameters. See "Changing Settings" on page 3-46 and especially "Selecting Changeover Kit" on page 3-50 for instructions. Note also "MLF Size" on page 3-66.
Aligning the Changeover Kit

The changeover kit must be precisely positioned for the devices to move smoothly from site to site. To correctly align the changeover kit: 1. Line up the octoloader to the center throat of the track work. > To see whether they are aligned, you must unscrew the four red thumb screws on the cover, and lift off the cover. (When you replace the cover, do not overtighten the red thumb screws.) Because the track work is fixed in place, you must move the octoloader. NOTE: It is extremely important that parts from the octoloader fall directly into the throat.
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Figure 3-30: Red Thumb Screws to Be Unscrewed Before Removing Cover
Figure 3-31: Octoloader Aligned to Track
2. Line up the track to the shuttle. > If necessary, jog the shuttle left by pressing the <7> key on the keypad. > If necessary, jog the shuttle right by pressing the <9> key on the keypad.
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Aligning the Changeover Kit
Figure 3-32: Track Aligned to Shuttle
3. Line up the shuttle to the output tube holder at the position of the red tube. > To move the output tube holder, loosen the four screws at the perimeter, and push gently to the left or right. When precisely aligned, retighten screws.
Figure 3-33: Perimeter Screws for Horizontal Alignment of Output Tube Holder
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Figure 3-34: Perimeter Screws on Output Tube HolderLeft and Right
Figure 3-35: Shuttle Aligned to Output Tube Holder
4. Adjust the air gap between the shuttle and the output tube holder.
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Testing Alignment of the Changeover Kit
> To adjust the height of the output tube holder, loosen the two shoulder screws. (When you have finished the adjustment, do not completely tighten these shoulder screws.)
Figure 3-36: Shoulder Screws for Vertical Alignment of Output Tube Holder
5. Test the shuttle position above each output tube, to ensure that no parts are rubbing or striking each other.

Do this procedure after you have aligned the changeover kit as described in the previous section, "Aligning the Changeover Kit" on page 3-19. To set up the handler for a test alignment: 1. Remove all input tubes. 2. Place one empty output tube in bin 5, the tube track in direct line with the test track. 3. Make sure the changeover kit and all other parts are attached to the handler and screwed down at all points. 4. Turn on the handler. When all the introductory messages have cycled, press the <DIAGNOSTICS> key. 5. Press the <4> key to enter ALL MOTOR CHECK. 6. Press the <3> key to enter OCTO MOTOR CHECK. 7. If necessary, press the <1> or <3> key to get a convenient input chute of the
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octoloader in line directly over the test track. 8. Press <ENTER> to go back to ALL MOTOR CHECK. 9. Press the <1> key to enter SORT MOTOR CHECK. 10. Press the <1> or <3> key to get the shuttle directly over output bin 5, the fail tube that is in direct line with the test track. The following test assumes that the alignment is correct and the changeover kit is secured on the handler. If the device catches at any location, redo the alignment for that point and resecure the changeover kit before continuing. To test the alignment: 1. Place one device in the octoloader chute that is directly above the test track. > The device should fall freely past the octoloader ledge and be stopped by the stack pin. You may be barely able to see the device through the hole in the upper part of the changeover kit lid. 2. Press the stack override button. > The device should fall freely to the stop pin. You may be barely able to see the device pins through the hole in the lower part of the changeover kit lid.
Figure 3-37: Device at Stop Pin as Seen Through Changeover Kit
3. Press the stop override button.
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Loading Tubes into the Octoloader
> The device should fall freely into the shuttle.
Figure 3-38: Device at Shuttle With Override Button
4. Press the shuttle release button. > The device should fall freely into output tube 5.

Exatron's eight-tube capacity automatic tube loading mechanism, called the octoloader, will automatically load any device supplied in tubes into your Exatron system. The octoloader assembly snaps onto the system for easy conversion from one device size/type to another.
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Figure 3-39: Octoloader
The octoloader is a moving plate that holds tubes of devices and is controlled by a stepper motor. During production, the plate automatically moves from side to side, positioning each tube above the input track. When the input track becomes empty, the octoloader automatically searches for tubes with devices. A sensor mounted at the junction of the input track allows the octoloader to "see" a device jam, if one occurs. The octoloader then stops moving to prevent damage to the jammed device. In addition, the octoloader has an automatic "wiggle" cycle that will attempt to clear the jam automatically, without operator assistance. (This feature can be turned off at the control panel if necessary.) NOTE: Tubes are installed upside down into the octoloader. To install full tubes into the octoloader: 1. If your model comes with blue anodized tube gates, turn them so that they are in the open or vertical position. 2. Remove the stopper from the top of a full tube of devices. Keeping the open end higher than the closed end, hold the lower half of the tube in one hand and guide the top of the tube to the octoloader with the other hand. 3. Keeping the open end higher than the closed end, press the open end of the tube firmly against the octoloader main plate at the bottom end of the track.
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Figure 3-40: Loading a Tube Perpendicular to Octoloader
4. Keep the open end of the tube pressed against the octoloader to prevent spilling the devices and raise the bottom end of the tube until it is completely upside down. Press the tube into place in the track of the octoloader.
Figure 3-41: Securing Tube at Bottom of Input Track
5. Close the tube gate (if so equipped) over the tube to complete installation. Repeat this process for each additional tube.
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Securing Output Tubes

Output tubes may be either plastic or metal. Both types are simple to secure on the handler.
Curved Aluminum Output Tubes

If your handler is equipped with a tape-and-reel assembly, it also uses a set of five curved aluminum output tubes that are secured with dowel pins. To secure a metal tube on the tube holder: 1. Hold the tube with the dowel hole at the top end.
Dowel pins on tube holder
Dowel hole on tube
Figure 3-42: Dowel Pin on Holder Fits Dowel Hole on Tube
2. Slide the tube up the tube track, holding on the bottom end out away from the dowel.
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Securing Output Tubes
Straight Plastic Output Tubes
Figure 3-43: Tube Held Out Away from Dowel Pin
3. When the tube reaches the top, push in the bottom end until the hole at the top of the output tube is aligned with the sensor hole and you hear the dowel pin snap into the tube hole.
Figure 3-44: Tube Snapped Into Place on Holder
Straight Plastic Output Tubes

If your handler has no tape-and-reel assembly, it may use a set of eight plastic output tubes that are secured by tension only. To secure a plastic tube on the tube holder:
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1. Hold the tube with the open end at the top. 2. Slide the tube all the way up the tube track. 3. When the tube reaches the top, snug it over the little tongue 4. Push the bottom end into the tube holder.
Figure 3-45: Tube Top in Place on Holder
Output Tray
On some handlers, an output tray acts as a holder for tested and sorted devices before they are tubed. 1. At the "EMPTY/LOAD PARTS" prompt, insert a plastic tube and fasten it in place at the bottom of each tray row. 2. Open each output gate by pressing the corresponding button, releasing the devices from the tray row to the tube (Figure 3-46).
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Power-Up Procedure
Output Tray
Figure 3-46: Releasing Devices From Output Tray to Tubes
Power-Up Procedure
Before powering up the system: 1. Connect the handler power cord to the power supply, and plug the power supply only into a 120/100-volt AC 50/60 Hz grounded power outlet. 2. Make sure the air regulator is turned off before connecting the handler to a clean, dry air pressure supply of 80 PSI minimum. Air supply should be free from moisture and oil. After connecting to the air supply, turn on the air regulator. 3. Ensure that the programmer/tester is properly docked to the back of the handler. Verify that the programmer/tester is installed with the correct "Pin 1" orientation. CAUTION: Do not run the handler with the programmer/tester undocked. If you do, the handler will release parts out of the test site onto the floor. 4. Verify that the proper changeover kit is installed on the handler. Check: > > > > > Octoloader input tube holder plate Main test site rail assembly Correct size plunger bar Shuttle assembly (may be insert only) Proper extruded aluminum output tubes or output tube holder with plastic tubes
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5. Move the octoloader plate so that it is flush against the octoloader home switch. 6. Place tubes of devices into the octoloader. You are now ready to power up the handler. If it has a laser attached, follow the instructions on page 3-33. To power up the system: 1. Turn on the power supply by twisting the red EMO (emergency stop) button clockwise on the power supply until it pops out.
> As the handler powers up, it displays the version number with Test Ok, then its model number and current control program with revision date. (Please give this revision date to Exatrons Customer Service Department when calling for assistance or software updates.) At the end it displays "READY TO RUN". An example of the initial display might be: V02.17 Test Ok 5000 QUAD SOIC 3B-YOURS 1-03-10
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Introduction to the Laser
Output Tray
Figure 3-48: Control Panel Message "READY TO RUN"
2. Press the handler's <ENTER> key. The handler should run just one device. 3. Verify that the device is both tested (programmed) and marked, if applicable, correctly. 4. Press the <RUN> key or <ENTER> key on the handler control panel. > The handler will now run the rest of the selected job.

This section applies only to handlers equipped with a laser. The brand illustrated is Laservall, but the principles can be applied to other brands as well. To power up a laser-marker system: 1. Turn the laser interlock key to the Run position (Figure 3-49).
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2. Turn on the handler by twisting the red EMO (emergency stop) button clockwise on the front of the handler (Figure 3-49) until it pops out. > As the handler powers up, it displays the version number with Test Ok, then its model number and current control program with revision date. (Please give this revision date to Exatron's Customer Service Department when calling for assistance or software updates.) At the end it displays "MOD SET UP ? NO." > If the power switch on the back of the laser supply unit has been left on, the laser is turned on at the same time as the handler. If it is not, flip on the power switch for the laser. 3. Turn on the laser computer. It will boot up and open the laser software program. 4. Open the laser mark file you want to use. It is called a project file and has a .prj extension. 5. Put the Smartist program in Work mode. See Figure 3-52 and Figure 3-53. 6. Press the <RUN> key or <ENTER> key on the handler control panel. > The control panel display cycles through each setting briefly, then displays any messages prompting you to change tubes or make other adjustments. > If you see the error message "IS LV PC READY ?" it is because the Smartist laser program is not in Work mode. Toggle it from Edit mode to Work mode and continue.
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Output Tray
> The message "LV SET UP ERROR" is displayed briefly during normal startup. But if it continues to display, it is because the laser supply unit has not been initialized. Restart and continue. 7. Make any prompted adjustments. 8. The display reads "READY TO MARK." 9. Press the <ENTER> key on the handler control panel. > The handler runs the job.
To power up the laser: 1. Turn on the laser computer and launch the Laservall software (see page 3-38) before turning on the laser supply unit. 2. Turn on the power to the laser supply unit (Figure 3-50). > Disable the interlock circuit: Turn on handler power, turn on the laser key control, and close any magnetic circuits. > On the laser supply unit, the display should read WAIT FOR START and the LED indicator should be OFF. 3. Close the shutter: Switch the shutter switch to open (away from red dot). 4. Press the momentary diode start button and hold for 1 second. > On the laser supply unit, the display should read LASER STAND BY and the LED indicator should be ORANGE. 5. Open the shutter: Switch the shutter switch to closed (on red dot). > On the laser supply unit, the display should read LASER READY and the LED indicator should be RED.
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Figure 3-50: Laser Supply Unit Powered OFF (Left), ON (Right)
Messages from the Laser Supply Unit

The front of the laser supply unit gives various status messages, each with an accompanying indicator light.
Figure 3-51: Laser MessagesWAIT FOR START (Left), LASER READY (Right)
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Laser Safety Circuits
Order Displayed on Startup 1 2
Message EMERGENCY ACTIVE WAIT FOR START
Indicator Light Off Off
Meaning Startup message. The handler interface circuit is not yet closed; the laser is not initialized. Power is on; laser is waiting to be initialized. The handler and laser have been powered on, but it is not doing a production run. Either a run has not been started, or the handler is in Pause, Manual, or Diagnostic mode. The laser is ready to mark. Laser is in pilot or simulation mode. It is initialized, waiting for a start mark command from Auto Run or Diagnostics. Shutter is closed. Laser could be fired in "aiming laser" (pilot) mode. This message is also displayed about one minute after the last device has cycled in Run mode. Laser is in yag or marking mode. It is initialized, waiting for a start mark command from Auto Run or Diagnostics. The handler is operating in normal Run mode and the laser is marking at each cycle. The laser key is turned to STOP. The laser is not initialized; hence cannot be fired. A safety circuit has been opened during operation. Reset the laser by turning it off and back on.
LASER STAND BY
Yellow
LASER READY Red
INTERLOCK ACTIVE MAX POWER FAULT
Off Green
Laser Safety Circuits

There are four safety circuits on the laser: Safety Circuit Shutter closed Key interlock off Handler interface Emergency Stop button Laser Supply Unit Message LASER STAND BY INTERLOCK ACTIVE Significance Laser has been initialized; only "aiming laser" is active. Laser diodes cannot be turned on; cannot be initialized.
EMERGENCY ACTIVE External interlock circuit controlled by key and beam tube magnetic switches. None Shuts down handler and laser immediately.
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Introduction to the Laser Software

This section applies only to handlers equipped with a laser. The laser system boots to the Smartist program. The Smartist laser software has two modes: Edit mode, where the laser mark can be designed or modified Work mode, allowing the actual laser marking to take place
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Introduction to the Laser Software
Edit Mode
Edit Mode
In Edit mode, a group of tabs and their properties is visible at the right side (in the Property windowpane), the mark object in the window has sizing handles, and there is an extra toolbar of editing buttons visible at the top (Figure 3-52). The Edit/Work mode toggle button is not depressed. The laser cannot mark when the software is in Edit mode. Edit/Work mode toggle button
Figure 3-52: Smartist Laser Software in Edit Mode
To switch to Work mode, click the green stoplight button at the top. This toggles between the two modes.
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Work Mode
In Work mode, neither the editing toolbar nor the Property windowpane is visible. The Edit/Work mode toggle button is depressed (Figure 3-53). Edit/Work mode toggle button
Figure 3-53: Smartist Laser Software in Work Mode
You can see on this window when the laser is actually firing. The stoplight button on the right turns from yellow to red momentarily when the laser is firing.
Figure 3-54: Laser ReadyYellow (Left); Laser FiringRed (Right)
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Aligning the Octoloader
Work Mode
Aligning the Octoloader

Each day on power-up, you may need to align the octoloader. Vibrations from a long run may have gotten it slightly out of alignment. To align the octoloader: 1. With the handler on, press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <4> key. > Handler displays "ALL MOTOR CHECK". 3. Press the <3> key. > Handler displays "OCTO MOTOR CHK". 4. Press the <1> key to move the octoloader one input tube to the left, or any position such that the octoloader tube 1 is left of the test rail. 5. Loosen the two screws on the octo stop block.
Figure 3-55: Octo Stop Block
6. Press the <3> key to move the octoloader tube 1 approximately over the test rail. 7. Press the <7> or <9> key as needed to jog the octoloader tube 1 directly above the track.
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8. When tube 1 is precisely aligned with the track, gently push the octo stop block flush against the right side of the octoloader, and tighten the lower screw. 9. Press the <1> key to move the octoloader one input tube to the left. 10. Carefully tighten the upper screw on the octo stop block, being sure not to move it. 11. Test your alignment: Press the <8> key to move the octoloader a predefined number of motor steps to the left, then back to the home sensor. It should still be flush with the octo stop block. You can change this number of motor steps by changing RAM address 00D2. See "Changing RAM" on page 3-58.
Setting Temperatures for the Hot Rail

This section applies only to handlers equipped with hot rails. Four hot rail controllers are included on the control panel.
Controller Left Middle Right Upper right Controls Top hot rail Middle hot rail Index hot rail Test site
Figure 3-56: Four Hot Rail Controllers
The red/orange temperature readouts in the lower SV (Set Value) display are the desired temperatures. The green temperature readouts in the upper PV (Present Value) display are the actual or current temperatures.
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Setting Temperatures for the Hot Rail
Work Mode
Present Value temperature
Set Value temperature
Figure 3-57: Heater Controller Display
When the hot rail is heating, the green LED light to the left of the Set Value display is on. When the present temperature is stable, the orange LED light to the left of the Present Value display is on. To set the temperature: This example changes the set temperature from 0 degrees to 250 degrees Farenheit. 1. Press the SET button on the lower left of the temperature control display, as shown in Figure 3-57. > The lower display blinks rapidly, indicating it is ready to be set. 2. Press the Left arrow button to shift the digit that lights up to the tens digit. 3. Press the Up arrow button repeatedly until the 0 changes to 5. 4. Press the Left arrow button to shift the digit that lights up to the hundreds digit. 5. Press the Up arrow button repeatedly until the 0 changes to 2. 6. Press the SET button again. All the set value digits stop blinking and light up in a steady display. 7. Repeat the procedure for each section of the hot rail and the test site.
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To turn off the hot rails: 1. Press the SET button on the lower left of the temperature control display. > The lower display blinks rapidly, indicating it is ready to be set. 2. Press the Down arrow button until the ones value is 0. 3. Press the Left arrow button to shift the digit that lights up to the tens digit. 4. Press the Down arrow button until the tens value is 0. 5. Press the Left arrow button to shift the digit that lights up to the hundreds digit. 6. Press the Down arrow button until the hundreds value is 0. 7. Press the SET button again. All the set value digits stop blinking and light up in a steady display. 8. Repeat the procedure for the other sections of the hot rail and the test site.
Power-Down Procedure
In case of unexpected events, you can push in the EMO (emergency stop) button to turn off the power to the handler at any time. CAUTION: Allow at least 30 seconds before turning the handler's power back on. Avoid rapid OFF/ON cycles. To power down the system: 1. Run the handler until empty of all devices. Finish the current job. 2. Empty all output tubes, or replace with empty tubes. 3. Turn the handler power off by pushing in the EMO button.
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Understanding the Control Panel Keys
Work Mode
Understanding the Control Panel Keys

The handler's control panel keys have the following functions: Key <ENTER> Function Starts operations; enters your selections into the system If you dont make any selections before pressing <ENTER>, the selection that was last in effect will be used. Flushes devices from handler. Removes characters from display when making changes. Puts handler in Ready To Run mode; also starts operations. Puts handler in Manual mode. CHANGE RAM ? YES/NO (Enables you to change RAM settings) RESET TOTALS YES/NO (Enables you to reset device totals to zero) MOD SET UP ? YES/NO (Enables you to modify setup parameters) Pauses handler operation. Displays output bin totals. "All MOTORS OFF" then <ENTER> = "ALIGN MOTORS ?" Moves selected motor (octoloader or shuttle) left 1 tube. Moves selected motor (octoloader or shuttle) right 1 tube. Moves selected motor (octoloader or shuttle) left 2 tubes. Moves selected motor (octoloader or shuttle) right 2 tubes. Jogs selected motor (octoloader or shuttle) left 1 step. Jogs selected motor (octoloader or shuttle) right 1 step. Zeros selection. For long display messages, scrolls to left end of message 1 character at a time. For long display messages, scrolls to right end of message 1 character at a time.
<CLEAR> <DELETE> <RUN> <MANUAL> <SET UP>
<PAUSE> <TOTALS> <0> <1> <3> <4> <6> <7> <9> <-> < >
<DIAGNOSTICS> Puts handler in Diagnostics mode.
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Changing Settings
When you change package type, you will need to change some settings as well. During the handler's powering up message sequence, you can set the handler to go immediately to "DIAGNOSTICS" or "CHANGE RAM". Always select "CHANGE RAM ? YES" when installing new handler update EPROMs into the handler. At the end of the handler's powering up message sequence, the first option given to you is "MOD SET UP ? NO" (modify setup). If you do not wish to make any changes to the handler's setup, press the <ENTER> key. The handler will then scroll through the current settings for any of the following that apply to your handler: Message PICK INTERFACE PICK PACKAGE PICK CHANGE KIT STOP/LOOP MODE STOP ON FAIL YES/NO SET # INPUTS PICKUP HEAD DISTANCE TO TEST SITE Comment Handler port TTL, RS-232, or cycle only Changing device sizes Changing changeover kit for device types For troubleshooting Handler stops after one fail Number of input tubes; or octoloader off For handlers with a pickup head Page 3-49 3-49 3-50 3-50 3-51 3-51 3-52 3-52 3-52 3-52 3-53 3-54 3-54
PICKUP HEAD DISTANCE TO EXIT TO SHUTTLE For handlers with a pickup head PICKUP HEAD DISTANCE TO PICKUP SITE LASER MARKING ON/OFF FULL TUBE TRAY/TUBE OUT RUN 1-2-3-4 PART For handlers with a pickup head For handlers with a laser Number of devices per output tube For handlers with output tray option For handlers with quad tester
If you wish to change any or all of the above settings, press the <SET UP> key when the handler displays "MOD SET UP ? NO." It changes to "MOD SET UP ? YES." Now press the <ENTER> key to make changes.
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Changing Settings
Work Mode
Figure 3-58: Modifying SetupReference Flowchart for Handler with Pickup Head
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Figure 3-59: Modifying SetupReference Flowchart for Handler with Quad Tester
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Changing Settings
Selecting Interface
For a handler with a quad tester, it is important to pick the "HANDLER PORT" interface, and the "QUAD SOIC 5000" package. Otherwise, you may see options like the ones shown in Figure 3-58, for a pickup head. If you get lost in the selections, just keep pressing <ENTER> until you get to the end of the cycle, then press <SET UP> again to restart the cycle.
Selecting Interface
The handler displays "PICK INTERFACE?" Select one of the following keypad choices: <1> keySets the handler to use "HANDLER PORT." (See "TTL Handler Port Interface" on page 9-5.) NOTE: If your handler uses a quad tester, select the "HANDLER PORT" option! <2> keySets the handler to use "EXATRON RS-232." (See "EXATRON RS232 Interface" on page 9-9.) <3> keyStarts "CYCLE ONLY NO T" (no test). <CLEAR> keyRedisplays the message "PICK INTERFACE?" and gives you a chance to change your selection. <ENTER> keyConfirms your selection and continues on to the next option.
Selecting Device Package

The handler displays "PICK PACKAGE." Select one of the following keypad choices: <1> = "8-PIN NB-SOIC." <2> = "16-PIN WB-SOIC." <3> = "16-PIN NB-SOIC." <4> = "QUAD SOIC 5000." NOTE: If your handler uses a quad tester, select the "QUAD SOIC 5000" option! <CLEAR> keyRedisplays the message "PICK PACKAGE" and gives you a chance to change your selection. <ENTER> keyEnters your selection into the handler and continues on to the next option.
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Selecting Changeover Kit

The handler displays "PICK CHANGE KIT." Select one of the following keypad choices: <1> = "RUN DIP CO KIT." <2> = "RUN TYPE 5B." <3> = "RUN TYPE 5C." <CLEAR> keyRedisplays the message "PICK CHANGE KIT" and gives you a chance to change your selection. <ENTER> keyEnters your selection into the handler and continues on to the next option.
Selecting Manual Cycling

The handler displays "STOP MODE ON/OFF." Stop and loop modes are for testing and troubleshooting of the handler. Select one of the following keypad choices: <1> = "STOP MODE ON ?" The handler will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. For operational information, see "Cycling the Handler in Stop Mode" on page 4-43. <2> = "LOOP MODE ON ?" The handler will stop after a complete cycle for one device. Each cycle ends with the pickup head above the test site, and the previous device dropped from the shuttle to an output. For operational information, see "Cycling the Handler in Loop Mode" on page 4-44. <3> = "ALL MODES OFF ?" The handler will cycle multiple devices in a normal run. This is the default. <CLEAR> keyRedisplays the message "STOP MODE ON/OFF" and gives you a chance to change your selection. <ENTER> keyEnters your selection into the handler and continues on to the next option.
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Changing Settings
Selecting Stops at Each Failure
Selecting Stops at Each Failure

The handler displays "STOP ON FAIL ?" The handler will either stop on fail or continue operation, as desired by the operator. If "STOP ON FAIL YS" is chosen, the handler will stop operation at every DUT test failure that the handler receives. The handler provides the operator with many helpful troubleshooting options while the DUT is in the contacts and "STOP ON FAIL" is displayed by the handler. Select one of the following keypad choices: <1> = "STOP ON FAIL YES." Stop on fail is now ON. <2> = "STOP ON FAIL NO." Stop on fail is now OFF. <CLEAR> keyRedisplays the message "STOP ON FAIL ?" and gives you a chance to change your selection. <ENTER> keyEnters your selection into the handler and continues on to the next option.
Selecting Number of Input Tubes

The handler displays "SET # INPUTS". This is the number of input tubes the handler will look for. Select one of the following keypad choices: <1> or <8> = "8 TUBE INPUT." This is for narrow to medium devices. The octoloader will stop at all 8 input tube locations. <2> or <4> = "4 TUBE INPUT." This is for very wide devices, and must be used with the appropriate changeover kit. The octoloader will stop at only 4 input tube locations rather than 8. <3> or <0> = "OCTOLOADER OFF." This allows for manual device input. <CLEAR> keyRedisplays the message "SET # INPUTS" and gives you a chance to change your selection. <ENTER> keyEnters your selection into the handler and continues on to the next option.
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Setting Pickup Head Distances

For each of the next 3 settings, follow the directions in this section. The handler displays "TO SITE = 04520." This is the number of steps the pickup motor will move to get the pickup head from its home position to a position directly over the test site. The handler displays "TO SITE = #####." This is the number of motor steps needed to get the pickup head from its home position at the top of its path to a position directly over the test site. The handler displays "TO EXIT = #####." This is the number of motor steps needed to get the pickup head from its home position at the top of its path to the exit to the shuttle. The handler displays "PICK UP = #####." This is the number of motor steps needed to get the pickup head from its home position at the top of its path to the device pickup site. Use the keypad to make your selection. The handler accepts changes to each digit from lowest to highest, in order; that is, Ones, Tens, Hundreds, Thousands, etc. Thus, the first number key you press changes the ones value; the second number key you press changes the tens value, and so forth. This is sometimes referred to as Polish notation. For example, if the correct number of motor steps is 08125, you change the number this way: Press the <5> key, then the <2> key, then the <1> key, then the <8> key, then the <0> key. <-> The minus key sets the count to 0000. <CLEAR> keyRedisplays the message and gives you a chance to change your selection. This also reloads the handler's EPROM default values. <ENTER> keyEnters your selection into the handler and continues on to the next option.
Selecting Laser Marking

The handler displays "LASER MARK ?" This is the number of steps the pickup motor will move to get the pickup head from its home position to a position directly over the pickup site. Select one of the following keypad choices: <1> = "LASER MARK ? YES." Each passed device will be laser marked. <2> = "LASER MARK ? NO." No laser marking will occur.
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Changing Settings
Selecting Number of Devices per Output Tube
<CLEAR> keyRedisplays the message "LASER MARK ?" and gives you a chance to change your selection. <ENTER> keyEnters your selection into the handler and continues on to the next option.
Selecting Number of Devices per Output Tube

The handler displays "FULL TUBE = ####". This is the number of devices the handler will place into each of the handler's output tubes. CAUTION: Be careful not to set the count for more parts than will fit into each output tube. Use the keypad to make your selection. The handler accepts changes to each digit from lowest to highest, in order; that is, Ones, Tens, Hundreds, Thousands, etc. Thus, the first number key you press changes the ones value; the second number key you press changes the tens value, and so forth. This is sometimes referred to as Polish notation. For example, if you want to place only 25 devices in a tube that could hold 47, you change the number this way: Press the <5> key, then the <2> key, then the <0> key twice. <-> The minus key sets the count to 0000. <CLEAR> keyResets to the beginning of the handler's "FULL TUBE = ####" Loop. This will also reload the handler's EPROM default values. <ENTER> keyEnters your selection into the handler. The handler displays "READY TO RUN". NOTE: Whenever the handler is running, you can press the <3> key. This will stop the handler and allow you to "Change RAM ? Y/N" or "MOD SET UP ? Y/N" NOTE: Whenever the handler is running, you can press the <SET UP> key. This stops the handler and offers you the options to "CHANGE RAM ?", then "RESET TOTALS", then "MOD(ify) SET UP ?"
Selecting Number of Devices to Be Tested Simultaneously

A handler using a quad tester displays "RUN 1-2-3-4 PART". Select one of the following keypad choices: <1> keySets the handler to "RUN ONE PART" at a time in the test site.
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<2> keySets the handler to "RUN TWO PARTS" at a time in the test site. <3> keySets the handler to "RUN THREE PARTS" at a time in the test site. <4> keySets the handler to "RUN FOUR PARTS" at a time in the test site. <CLEAR> keyRedisplays the message "RUN 1-2-3-4 PART" and gives you a chance to change your selection. <ENTER> keyConfirms your selection and continues on to the next option.
Selecting Tray or Tube Output

A handler that has the option of an output tray displays "TRAY/TUBE OUT". The tray is an addition that holds a number of sorted devices and allows for putting into tubes later. See "Output Tray" on page 2-21. Select one of the following keypad choices: <1> keySets the handler to "USE TUBE OUTPUT". <2> keySets the handler to "USE TRAY OUTPUT". <CLEAR> keyRedisplays the message "RUN 1-2-3-4 PART" and gives you a chance to change your selection. <ENTER> keyConfirms your selection and continues on to the next option.
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Manual Mode
Selecting Tray or Tube Output
Manual Mode
You can enter Manual mode at any time by pressing the <MANUAL> key. After you do, the handler displays "MANUAL MODE". Then you can press any numeric key to go straight to the desired setting. Control Panel Key <1> <2> <4> <5> <6> <8> <0> Message PICK PACKAGE ? FULL TUBE= #### PICK INTERFACE ? STOP MODE ON/OFF SET # INPUTS STOP ON FAIL ? ALL MOTORS OFF Page 3-49 3-53 3-49 3-50 3-51 3-51
Figure 3-60: Manual Mode
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Resetting Totals
The handler keeps a running count of total devices sent to each output bin. These counts are preserved in the battery-backed-up RAM, even when the handler is turned off. Therefore, you have to reset the counts to zero at the control panel. To keep an accurate count of devices processed, you may want to reset the totals at the beginning of each day or of each production run. To reset the totals: 1. Press the <SET UP> key. > The message "CHANGE RAM? NO" is displayed. 2. Press the <ENTER> key. > The message "RESET TOTALS NO" is displayed. 3. Press the <SET UP> key. > The message "RESET TOTALS YES" is displayed. 4. Press the <ENTER> key. > The message "TOTALS SET TO 0" is displayed briefly, then the handler goes back to the routine it was in before you pressed <SET UP>. > If any output tubes remain in place, the reminder to "EMPTY ALL TUBES" is displayed, and all LEDs having a tube attached are flashing. Remove tubes.
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Beginning a Production Run
Homing the Octoloader
Beginning a Production Run

Before you begin a production run, make sure the octoloader is at the Exatron-designated home position.

There is no single command that homes the octoloader. To home the octoloader: 1. Press the <MANUAL> key to enter Manual mode. 2. Press <0> to turn off all motors. The octoloader will now move freely. 3. Slide the octoloader all the way to the left. 4. Press <ENTER>. The message ALIGN MOTORS ? is displayed. 5. Press <ENTER> again to turn the motors back on.
To begin a production run: 1. Load devices into any or all of the octoloader's 8 input slots. 2. Replace all output tubes that may have any devices in them with empty tubes. CAUTION: Make sure all output tubes are empty at the beginning of a run. If you begin a run with devices in an output tube, the count will be off, and the handler may try to overfill the tube, jamming devices. 3. Press the <ENTER> key on the handler. The handler should automatically flush out any devices that may be in the test site, mark site, or shuttle. The handler will then look for devices in the handler's input track. If none is found, the octoloader will turn on and will move 16 times looking for devices. If this does not happen, check for jams and proper handler setup. > If "EMPTY/LOAD PARTS" is displayed by the handler, load more devices into the octoloader and press the handler's <ENTER> key. The handler runs the rest of the selected job. The LED lights up for the current or next output tube it intends to use. As each device is processed, messages are displayed on your control panel. Depending on the options your handler is equipped with, these messages may relate to the laser or tester. Alternatively, the messages may show the current output tube, the sort category, and/or the
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count in the current tube. For example, the message "BIN 3 S1 C0014" indicates that the shuttle has placed a device in output tube 3, having received a sort 1 command, and there are now 14 devices in output tube 1. The counter is for the current output tube full count only. Symbol B S C Meaning Bin, or output tube Sort: 1-8, pass or fail Count of devices in current output tube Examples B1, B8 S1, S8 C0001, C0027
Suppose the first device is a sort 1, passed to bin 1. The display at first reads "BIN 1 S1 C0001". The next device is a sort 2, failed to bin 5. The display now reads "BIN 5 S2 C0001" because this is the first device sent to output tube 5. The third device is again a sort 1, passed to bin 1. The display for it reads "BIN 1 S1 C0002" because this is only the second device sent to output tube 1.
Displaying Totals
Before, during, or after a run, you can display totals of devices sent to each output bin. To display the totals: 1. Press the <TOTALS> key. > If the handler is doing a run, it pauses. The message "DISPLAY TOTALS" is displayed. 2. Press each numeric key to view the totals output to the corresponding bin or tube. > For example, to view the count for tube 3, press <3>. A count something like "T03 0047 000130" may be displayed. This means that for tube 3, 47 devices have been sent to the current tube. A total of 130 devices have been sent to that output bin 3 since the last time the totals were reset; this may include a number of tubes that were replaced in bin 3. 3. Press <ENTER> to quit viewing totals and resume previous action.
Changing RAM
The Model 5000 system allows you to change the RAM of each handler CPU. You can do this in one of three ways: You can change individual address values, or settings. You can reload all the default settings from the EPROM. This will erase any changes that have been made to individual addresses.
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You can reload all the default settings from the EPROM, and then change individual address settings. NOTE: If you consistently use a RAM address setting that is different from the default in the EPROM, write down your changes and fax them to Exatron, and we will send you, free of charge, a new EPROM containing the default settings you use. This will help you avoid unnecessary future changes and confusion over lost changes. The EPROM is seated at the U3 position on the 3000-055 board.
To access the Change RAM mode and change RAM settings: 1. Press the <SET UP> key on the handlers control panel. The message "CHANGE RAM? NO" is displayed. 2. Press the <SET UP> key again. The message "CHANGE RAM? YES" is displayed. 3. Press <ENTER>. > The message "LOAD DEFAULT NO" is displayed. 4. If you want the handler to load the default settings for all the RAM addresses into RAM, press <SET UP> to display "LOAD DEFAULT YES", and then press <ENTER> to load the defaults while the message "LOAD EPROM>RAM" is displayed; or If you want the handler to leave all RAM addresses as they were, press <ENTER> to accept "LOAD DEFAULT NO". In either case, the first RAM address listing is now displayed, allowing you to make changes to individual RAM addresses. 5. Press the <SET UP> key or the <TOTALS> key to scroll through the firmware addresses: > Press the <SET UP> key to display the next address, as from 0090 to 0091. > Press the <TOTALS> key to display the previous address, as from 0091 to 0090 or from 0090 to 00FF. > Press the <RUN> key to toggle the display for the current address between the address and the label. For example, pressing the <RUN> key toggles from "0090 DATA 00" to "MODEL TYPE". 6. When you reach the firmware address desired, press one of the following keys to change the parameter for the currently displayed address.
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> <SPACE> keyIncrements the upper data nibble (the left digit in the setting at the right end of the displayed address) in the current address. For example, if the current setting is "EF", press the <SPACE> key to change the setting to "FF". > <DELETE> keyIncrements the lower data nibble (the right digit in the setting at the right end of the displayed address) in the current address. For example, if the current setting is "04", press the <DELETE> key to change the setting to "05". > <-> minus keySets the parameter for the current address to FF. > <0> zero keySets the parameter for the current address to 00. > <CLEAR> keyLoads the default parameter for the current address from the EPROM into the RAM. 7. To exit the Change RAM mode, press the <ENTER> key. The message "RESET TOTALS NO" is displayed. > If you wish to reset the current output tally for all tubes to zero, press the <SET UP> key. The message "TOTALS SET TO 0" is displayed. > If not, press <ENTER> again. The message "MOD SET UP? NO" is displayed. 8. Press the <ENTER> key again to return to the previous mode. NOTE: Any changes you made take effect immediately. You do not have to power down and up again.
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RAM Address Listings

The following RAM address tables describe each firmware address in numerical order. This information is specific for each gravity-feed handler. Yours may be slightly different. The first one is for a 5D DIP kit; the second one, on page 3-69, is for a handler with a quad tester. The ROM Deflt column shows the factory default value for each address. The Comments column shows the meaning of each selection. The RAM Options column shows the values you can use. The code below the values shows what type of value can be entered. For further reference, see the "Decimal-Hex-ASCII Conversion Table" on page 3-79. Code
A B C H
Type of Value
ASCII Bitmap Choice Hex
5000 DIP/5D 11-23-05

Address 0090 0091 Display Top of EPROM # Motors ROM Deflt 00 05 RAM
Options
Comments Top of EPROM Sets the number of stepper motors inherent in the handler: 01 = Output Shuttle Motor 02 = Plunge to Board (Z Motor) C/O Kits (Type 4, Type 5A only) 04 = Octoloader Motor 08 = Label Apply Motor. 05 = Octoloader Motor/Shuttle Motor (No Z Motor) as in DIP Changeover Kits, Type 5B, 5C, 5D 07 = Octoloader Motor/Z Motor/Shuttle Motor as in Plunge-to-Board Change Kits (Type 4, Type 5A only) Sets the 1000s digit for number of devices in full output full tube. Set the 100s digit for number of devices in full output tube. Set the 10s digit for number of devices in full output tube. Set the 1s digit for number of devices in full output tube. Time delay for test site solenoids to close the test contacts onto the device under test (DUT.) This is a physical settling time for the DUT that eliminates any bouncing motion in the test site. Counts down in HEX in 10 millisecond steps. Time delay before the handler sends a start test command to the tester. Counts down in HEX in 1 millisecond steps. Adjusts the start test pulse width. This is allowed to provide flexibility in interfacing between the handler and tester/programmers. Counts down in HEX in 1 millisecond steps.
C B
0092 0093 0094 0095 0096
Full Tube 1000s 30 Full Tube 100s Full Tube 10s Full Tube 1s Test Sol Delay 30 35 30 10
A A A A 00 to FF H
0097 0098
Start Test Delay Start Pulse Width
05 14
00 to FF H 00 to FF H
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0099 LED/Digit Output Count Mask 00 C FF = Standard LED output cover PCB 00 = Optional 7-segment display output cover PCB NOTE: These settings affect the sensors also. Allows the operator to designate a bin or bins that will ignore the predefined full tube count. This is useful when using bulk/bucket outputs. For example, a bitmap value of 10 = Bin 5 is masked, accepts infinite number of devices; 00 = No masking; 08 = Mask bin 4. system and the PC. If you need to change the value, contact Exatron first.
009A
00
00 to FF B
009B
Baud Rate RS232
0C
See Table in Stores the baud rate of the RS-232 interface between the handler
Interface
Chapter pg 2-13 C
009C
Data Format
03
See Table in Stores the parity/stop/data bits.

Interface
Chapter pg 2-13 C
009D
Wiggle Shuttle
00
00, FF C 00 to FF H
To wiggle the shuttle if a jam is detected during sorting, set this address to 00. If you do not wish to allow the shuttle to wiggle, set this address to FF. A timed delay before the handler aborts the test and turns off all solenoids. Counts down in HEX in 1-second steps. For example: 0A = 10 seconds; 0F = 15 seconds; 10 = 16 seconds. When this address is set to 00, the system will never time out. To thump the shuttle during a device jam by firing the solenoid, set this address to 00. If you do not wish the shuttle to thump, set this address to FF. Turn off shuttle thump when using devices with delicate leads. Adds extra time for device to pass index mechanism. Counts down in 1-millisecond steps. Selects method of input/output to handler from device tubes or device trays. 00 = Tube. FF = Tray. 30 = Operator Choice. Time delay to allow the DUT to settle before turning on the vacuum to pick up the DUT prior to plunging. The delay counts down in HEX in 10-millisecond steps. Used for RS-232 interface. Sets the handler to send the ASCII character H to the tester at the start of each retest cycle, as it does at the start of each first test cycle to establish communication. This may be used for certain device count applications. 00 = H on retest; AA = No H on retest; FF = OK.
009E
Time Out
0A
009F
Shuttle Thump
FF
00, FF C
00A0 00A1 00A2
Index Delay Set Tray/Tube Pickup Delay
20 00 05
H 00 to FF C 00 to FF H 00 to FF C
00A3
Send H on Retest
FF
00A4
D Test ASCII Out
See InterThis is the ASCII letter which the EXATRON RS-232 interface uses as face Chapter an output on a double test.
For further details. A 00A5
S = Normal. D = Handler will issue S on First Test Cycle and D on Double Test Cycle. A D setting prevents a double-tested device from being counted twice. Not used.
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00A6 Check Sort Reset FF 00, FF C Used for TTL (pulse-type) interface. Allows the handler to check whether all sort signals are OFF at the start of the test. To enable this option, set this address to 00. To disable this option, set this address to FF. Set this to FF when using LED checker boxes for simulation purposes. To wiggle the octoloader as it moves from track to track, or during a jam, set this address to 00. If you do not wish the octoloader to wiggle, set this address to FF. 00 = no octoloader. Use for hand-feeding small lots w/o octo action. 04 = 4-tube octoloader input 08 = 8-tube octoloader input AA = large-capacity autoloader such as a bowl feeder Not used. Stop on Fail Y/N 30 30, FF
See Display Dictionary for further details. C
00A7
Wiggle Octoload 00
00, FF C 00 to FF C
00A8
Octo 4/8 Tubes
08
00A9 00AA
Set to FF: No stop on fail. Upon receipt of a fail signal from the tester, the handler will place the device into the pre-assigned fail tube. Set to 30: After the handler receives a fail signal from the tester, the handler will stop with the contacts closed. This will allow the operator to inspect contact alignment or increase/decrease contact pressure and retest as desired. Use for debugging, engineering. See 00B4 for additional settings. Not used. Not used. Not used. Not used.
00AB 00AC 00AD 00AE 00AF 00B0 T Site Out Delay 00 P Up Jog Shut 00 H 00 to FF
Adds time for device to be dropped off at exit site after test is completed. Counts down in 1-millisecond steps. For calibration of mechanical placement of octoloader and shuttle in-house only! Jogs shuttle right and left upon power up if desired, to possibly free a jammed device. 0? = Jog Left. 1? = Jog Right. FOR EXAMPLE: 02 = Jog Left 2 steps; 13 = Jog Right 3 steps. 9 Steps Maximum. For calibration of mechanical placement of octoloader and shuttle in-house only! Jogs octoloader/hot chamber right and left upon power up if desired, to possibly free a jammed device. 0? = Jog Left. 1? = Jog Right. FOR EXAMPLE: 02 = Jog Left 2 steps; 13 = Jog Right 3 steps. 9 Steps Maximum. Sets delay for shuttle motor in 10-millisecond increments. Adds time for device to exit shuttle into the output tubes before shuttle moves again.
00B1
P Up Jog Octo/HC
00
00 to FF
00B2
Shuttle Delay
01
00B3
Package Type
5D
28, 40, 50, 28 = to run DIPs 5A, 5B, 5C, 5D = to run 5D devices 5D C
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00B4 Stop-Fail Sort 00 00 to FF B Tells the handler which sort(s) to stop the system upon Fail from tester, if desired. One sort must be set for Pass; all other sorts may be set for Stop On Fail option. See 00AA for additional settings. 01 = Bin 1; 02 = Bin 2; 04 = Bin 3; 08 = Bin 4; 10 = Bin 5; 20 = Bin 6; 40 = Bin 7; 80 = Bin 8 Tells the handler which test sorts to double test if desired. 00 = Double Test OFF for all sorts. FF = Double Tests ALL devices. FE = Sort 1 is PASS and all other sorts are Double Tested. For laser-equipped handlers only. Tells the handler which test sorts to laser mark. For laser-equipped handlers only. FF = Trumpf, 00 = Laservall. Sets bin 1 output display on optional 7-segment digital output covers. Must be ASCII notation. Possible settings are 1 2 3 4 5 6 7 8 9 P F (capital letters only). Sets bin 2 output display on optional 7-segment digital output covers. Must be ASCII notation. Possible settings are 1 2 3 4 5 6 7 8 9 P F (capital letters only). Sets bin 3 output display on optional 7-segment digital output covers. Must be ASCII notation. Possible settings are 1 2 3 4 5 6 7 8 9 P F (capital letters only). Sets bin 4 output display on optional 7-segment digital output covers. Must be ASCII notation. Possible settings are 1 2 3 4 5 6 7 8 9 P F (capital letters only). Sets bin 5 output display on optional 7-segment digital output covers. Must be ASCII notation. Possible settings are 1 2 3 4 5 6 7 8 9 P F (capital letters only). Sets bin 6 output display on optional 7-segment digital output covers. Must be ASCII notation. Possible settings are 1 2 3 4 5 6 7 8 9 P F (capital letters only). Sets bin 7 output display on optional 7-segment digital output covers. Must be ASCII notation. Possible settings are 1 2 3 4 5 6 7 8 9 P F (capital letters only). Sets bin 8 output display on optional 7-segment digital output covers. Must be ASCII notation. Possible settings are 1 2 3 4 5 6 7 8 9 P F (capital letters only). Input Sort 1 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 2 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 3 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.*
00B5
Double Test Sort 00
00 to FF B
00B6 00B7 00B8
Laser Mark Sort 00 Laser Type Bin 1 Display 00 P
00 to FF B B A
00B9
Bin 2 Display
00BA
Bin 3 Display
00BB
Bin 4 Display
00BC
Bin 5 Display
00BD
Bin 6 Display
00BE
Bin 7 Display
00BF
Bin 8 Display
00C0 00C1 00C2
Sort 1 Bins 1-8 Sort 2 Bins 1-8 Sort 3 Bins 1-8
0F 10 40
00 to FF B 00 to FF B 00 to FF B
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00C3 00C4 00C5 00C6 00C7 00C8 Sort 4 Bins 1-8 Sort 5 Bins 1-8 Sort 6 Bins 1-8 Sort 7 Bins 1-8 Sort 8 Bins 1-8 Tape Out Q 10 10 10 10 10 0A 00 to FF B 00 to FF B 00 to FF B 00 to FF B 00 to FF B 00 to FF H 00 to FF B 25, 26 C Input Sort 4 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 5 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 6 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 7 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 8 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Sets the quantity of good devices to be queued up at the entrance of the tape and reel machine prior to automatically turning on the tape drive motor. FOR MODEL 1050 ONLY. Specifies which output bin from the handler will be used as transition to tape and reel machine. Output bin 7 is standard. ?? = Tape output bin. FF = No tape. Sets default interface to be used by the handler. 25 = EXATRON RS-232 Interface 26 = TTL HANDLER PORT Interface 29 = Cycle only, no test (used for taping devices only) Not used. Laser Mark Delay 0A 00 to FF H 00, FF C Time delay before laser fires. Counts down in 10-millisecond steps. For laser mark systems, the handler will not route devices to the mark site when this feature is turned on; devices will be programmed and/or tested only. 00 = Do not skip mark site. FF = Skip mark site. If your system includes the laser mark option, this must be set to 00 for the laser to operate. Set to FF if your system does not have laser mark capability. Adds time for device to settle in laser site before laser is fired. Counts down in 1-millisecond steps. 00 = Solenoids shut down in 30 seconds when device jammed. FF = Off; solenoids do not shut down. Not used. Not used.
00C9
Tape Output Bin 40
00CA
Interface Type
26
00CB 00CC 00CD
Skip Laser Mark FF
00CE
Laser Site Y/N
FF
00, FF C H H C
00CF 00D0 00D1 00D2
Settling Delay Sol Shut Down
00 00
06
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00D3 MLF Size 01 C After the RAM is blasted in the eprom, or reset to factory defaults, use this setting to select 7x7 mm devices or 9x9 mm devices. 01=7x7 devices, settings in addresses D4 through E2 02=9x9 devices, settings in addresses E3 through F1
If you use the 01 instruction, the handler will use the settings in D4-E2 and ignore the settings in E3-F1. If you use the 02 instruction, the handler will use the settings in E3-F1 and ignore the settings in D4-E2.
00D4
Pickup 10000
When using 7x7 devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 10s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 10s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number.
00D5
Pickup 1000
00D6
Pickup 100
00D7
Pickup 10
00D8
Pickup 1
00D9
T Site 10000
00DA
T Site 1000
00DB
T Site 100
00DC
T Site 10
00DD
T Site 1
00DE
Exit Step 10000
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00DF Exit Step 1000 1 A When using 7x7 devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 10s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 7x7 devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 10s digit of number of steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 10s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number.
00E0
Exit Step 100
00E1
Exit Step 10
00E2
Exit Step 1
00E3
Pickup 10000
00E4
Pickup 1000
00E5
Pickup 100
00E6
Pickup 10
00E7
Pickup 1
00E8
T Site 10000
00E9
T Site 1000
00EA
T Site 100
00EB
T Site 10
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00EC T Site 1 0 A When using 9x9 devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 10s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 9x9 devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Laser Simulator FF C 00 = ON, FF = Normal run.
00ED
Exit Step 10000
00EE
Exit Step 1000
00EF
Exit Step 100
00F0
Exit Step 10
00F1
Exit Step 1
00F2 00F3 00F4 00F5 00F6 00F7 00F8 00F9 00FA 00FB 00FC 00FD 00FE 00FF
* For addresses marked with an asterisk in the above table, refer to Handler Binning Setup procedure earlier in this chapter.
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Address 0090 0091 Display Model Type # Motors ROM Deflt 50 05 RAM
Options
Comments 30 = 3000B. 31 = 3010. 50 = 5000. Sets the number of stepper motors inherent in the handler: 01 = Output Shuttle Motor 04 = Octoloader Motor When using a wide-body kit, sets the 1000s digit for number of devices in a full output full tube. When using a wide-body kit, sets the 100s digit for number of devices in a full output tube. When using a wide-body kit, sets the 10s digit for number of devices in a full output tube. When using a wide-body kit, sets the 1s digit for number of devices in a full output tube. Time delay for test site solenoids to close the test contacts onto the device under test (DUT.) This is a physical settling time for the DUT that eliminates any bouncing motion in the test site. Counts down in HEX in 1 millisecond steps. Time delay before the handler sends a start test command to the tester. Counts down in HEX in 1 millisecond steps. Adjusts the start test pulse width. This is allowed to provide flexibility in interfacing between the handler and tester/programmers. Counts down in HEX in 1 millisecond steps. FF = Standard LED output cover PCB 00 = Optional 7-segment display output cover PCB NOTE: These settings affect the sensors also. Allows the operator to designate a bin or bins that will ignore the predefined full tube count. This is useful when using bulk/bucket outputs. For example, a bitmap value of 10 = Bin 5 is masked, accepts infinite number of devices; 00 = No masking; 08 = Mask bin 4. system and the PC. If you need to change the value, contact Exatron first.
C B
0092 0093 0094 0095 0096
Full Tube 1000s 30 Full Tube 100s Full Tube 10s Full Tube 1s Test Sol Delay 30 35 30 10
A A A A 00 to FF H
0097 0098
Start Test Delay Start Pulse Width LED/Digit Output Count Mask
05 14
00 to FF H 00 to FF H C
0099
00
009A
00
00 to FF B
009B
Baud Rate RS232
0C
See Table in Stores the baud rate of the RS-232 interface between the handler
Interface
Chapter pg 2-13 C
009C
Data Format
03
See Table in Stores the parity/stop/data bits.

Interface
Chapter pg 2-13 C
009D
Wiggle Shuttle
00
00, FF C
To wiggle the shuttle if a jam is detected during sorting, set this address to 00. If you do not wish to allow the shuttle to wiggle, set this address to FF.
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009E Time Out 0A 00 to FF H A timed delay before the handler aborts the test and turns off all solenoids. Counts down in HEX in 1-second steps. For example: 0A = 10 seconds; 0F = 15 seconds; 10 = 16 seconds. When this address is set to 00, the system will never time out. To thump the shuttle during a device jam by firing the solenoid, set this address to 00. If you do not wish the shuttle to thump, set this address to FF. Turn off shuttle thump when using devices with delicate leads. 00 = Places device in shuttle. FF = Drop only. 00, FF C 00, FF C Opto-isolation interface. 00 = On. FF = Off; TTL is used. Used for TTL (pulse-type) interface. Allows the handler to check whether all sort signals are OFF at the start of the test. To enable this option, set this address to 00. To disable this option, set this address to FF. Set this to FF when using LED checker boxes for simulation purposes. To wiggle the octoloader as it moves from track to track, or during a jam, set this address to 00. If you do not wish the octoloader to wiggle, set this address to FF. 00 = no octoloader. Use for hand-feeding small lots w/o octo action. 04 = 4-tube octoloader input 08 = 8-tube octoloader input AA = large-capacity autoloader such as a bowl feeder Set to FF: No stop on fail. Upon receipt of a fail signal from the tester, the handler will place the device into the pre-assigned fail tube. Set to 30: After the handler receives a fail signal from the tester, the handler will stop with the contacts closed. This will allow the operator to inspect contact alignment or increase/decrease contact pressure and retest as desired. Use for debugging, engineering.
009F
Shuttle Thump
FF
00, FF C
00A0 00A1 00A2
5D Exit Drop Opto Input Check Sort Reset
00 FF FF
00A3
Wiggle Octoload 00
00, FF C 00 to FF C
00A4
Octo 4/8 Tubes
08
00A5
Stop on Fail Y/N 30
30, FF
See Display Dictionary for further details. C
00A6
Package Type
41
28, 40, 50, 28 = to run SOIC devices 5A, 5B, 5C, 5D = to run 5D devices 5D C 40 = to run quad 20-pin devices 41 = to run quad 24-pin devices
See InterThis is the ASCII letter which the EXATRON RS-232 interface uses as face Chapter an output on a double test.
00A7
D Test ASCII Out
For further details. A 00A8 P Up Jog Shut 00 00 to FF
S = Normal. D = Handler will issue S on First Test Cycle and D on Double Test Cycle. A D setting prevents a double-tested device from being counted twice. For calibration of mechanical placement of octoloader and shuttle in-house only! Jogs shuttle right and left upon power up if desired, to possibly free a jammed device. 0? = Jog Left. 1? = Jog Right. FOR EXAMPLE: 02 = Jog Left 2 steps; 13 = Jog Right 3 steps. 9 Steps Maximum.
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00A9 P Up Jog Octo/HC 00 00 to FF For calibration of mechanical placement of octoloader and shuttle in-house only! Jogs octoloader/hot chamber right and left upon power up if desired, to possibly free a jammed device. 0? = Jog Left. 1? = Jog Right. FOR EXAMPLE: 02 = Jog Left 2 steps; 13 = Jog Right 3 steps. 9 Steps Maximum. Sets delay for shuttle motor in 10-millisecond increments. Adds time for device to exit shuttle into the output tubes before shuttle moves again. Tells the handler which sort(s) to stop the system upon Fail from tester, if desired. One sort must be set for Pass; all other sorts may be set for Stop On Fail option. See 00AA for additional settings. 01 = Bin 1; 02 = Bin 2; 04 = Bin 3; 08 = Bin 4; 10 = Bin 5; 20 = Bin 6; 40 = Bin 7; 80 = Bin 8 Tells the handler which test sorts to double test if desired. 00 = Double Test OFF for all sorts. FF = Double tests ALL sorts. FE = Double tests all sorts except Sort 1 (Sort 1 must be PASS; all other sorts are Double Tested). 02 = Double tests only Sort 2. Used for RS-232 interface. Sets the handler to send the ASCII character H to the tester at the start of each retest cycle, as it does at the start of each first test cycle to establish communication. This may be used for certain device count applications. 00 = H on retest; AA = No H on retest; FF = OK. 00 = Solenoids shut down in 30 seconds when device jammed. FF = Off; solenoids do not shut down. Input Sort 1 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 2 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 3 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 4 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 5 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 6 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 7 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.* Input Sort 8 to handler output bins. BITMAP. Output cover LEDs will blink output sort locations.*
00AA
Shuttle Delay
01
00AB
Stop-Fail Sort
00
00 to FF B
00AC
Double Test Sort 00
00 to FF B
00AD
Send H on Retest
FF
00 to FF C
00AE 00AF 00B0 00B1 00B2 00B3 00B4 00B5 00B6
Sol Shut Down Sort 1 Bins 1-8 Sort 2 Bins 1-8 Sort 3 Bins 1-8 Sort 4 Bins 1-8 Sort 5 Bins 1-8 Sort 6 Bins 1-8 Sort 7 Bins 1-8 Sort 8 Bins 1-8
00 0F 10 40 10 10 10 10 10
H 00 to FF B 00 to FF B 00 to FF B 00 to FF B 00 to FF B 00 to FF B 00 to FF B 00 to FF B
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00B7 Interface Type 26 25, 26 C Sets default interface to be used by the handler. 25 = EXATRON RS-232 Interface 26 = TTL HANDLER PORT Interface 29 = Cycle only, no test (used for taping devices only) For two test sites: Second start pulse width. For two test sites: Second start delay. For 3010 hot rail only. Set soak time to 1.0 second. For 3010 hot rail only. Set soak time to 0.1 second. Must be 0-9 ASCII. This is the first of 3 digits in the password if turned on at address 00F5. Must be 0-9 ASCII. This is the second of 3 digits in the password. Must be 0-9 ASCII. This is the third of 3 digits in the password. 00 = On. FF = Off. 00 = Interlock check ON. FF = Interlock check OFF. 00 = Off; use if test longer than .5 sec for less noise & less air use. FF = On; use if test shorter than .5 sec for faster cycling. 00, FF C To thump the octoloader during a device jam by firing the solenoid, set this address to 00. If you do not wish the octoloader to thump, set this address to FF. Turn off octoloader thump when using devices with delicate leads. Selects method of input/output to handler from device tubes or device trays. 00 = Tube. FF = Tray. 30 = Operator Choice. If the controller locks up, this turns off all 24V, preventing any solenoids from burning up. FF = off. 00 = on. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. T Site Out Delay 00 H Adds time for device to be dropped off at exit site after test is completed. Counts down in 1-millisecond steps.
00B8 00B9 00BA 00BB 00BC 00BD 00BE 00BF 00C0 00C1 00C2
2nd Start Width 2nd Start Delay Soak Time 1.0 Second Soak Time 0.1 Second Password A Password B Password C Password On/Off Check I-Lock Vac During Test Octo Thump
00 00 30 30 31 32 33 FF 00 00 00
H H A A
See page 4-3. A
A A C C
00C3 00C4 00C5 00C6 00C7 00C8 00C9 00CA 00CB 00CC 00CD
Set Tray/Tube Relay Option
00 FF
00 to FF C 00, FF C
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00CE Pickup Delay 05 00 to FF H H C Time delay to allow the DUT to settle before turning on the vacuum to pick up the DUT prior to plunging. The delay counts down in HEX in 10-millisecond steps. Adds time for device to settle in laser site before laser is fired. Counts down in 1-millisecond steps. After the RAM is blasted in the EPROM, or reset to factory defaults, use this setting to select device size. 01 = 5D kit 1; 8-pin NB-SOIC; settings in addresses D1 through E2 02 = 5D kit 2; spare; settings in addresses E3 through F4
If you use the 01 instruction, the handler will use the settings in D1-E2 and ignore the settings in E3-F4. If you use the 02 instruction, the handler will use the settings in E3-F4 and ignore the settings in D1-E2.
00CF 00D0
Settling Delay MLF Size
00 01
00D1
Pickup 10000
When using 8-pin NB-SOIC devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 10s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 10s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number.
00D2
Pickup 1000
00D3
Pickup 100
00D4
Pickup 10
00D5
Pickup 1
00D6
T Site 10000
00D7
T Site 1000
00D8
T Site 100
00D9
T Site 10
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00DA T Site 1 0 A When using 8-pin NB-SOIC devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 10s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 100s digit of number of devices in a full output tube. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 10s digit of number of devices in a full output tube. Set as ASCII number. When using 8-pin NB-SOIC devices, this sets the 1s digit of number of devices in a full output tube. Set as ASCII number. When using other devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 10s digit of number of steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the pickup site. 5000 steps = 1 inch. Set as ASCII number.
00DB
Exit Step 10000
00DC
Exit Step 1000
00DD
Exit Step 100
00DE
Exit Step 10
00DF
Exit Step 1
00E0 00E1 00E2 00E3
Full 100 Kit Full 10 Kit Full 1 Kit Pickup 10000
0 9 6 0
A A A A
00E4
Pickup 1000
00E5
Pickup 100
00E6
Pickup 10
00E7
Pickup 1
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00E8 T Site 10000 0 A When using other devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 10s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the test site. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 10,000s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 1000s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 100s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 10s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 1s digit of number of motor steps traveled by the pickup head from pickup head home to the drop-off site at the top of the output track. 5000 steps = 1 inch. Set as ASCII number. When using other devices, this sets the 100s digit of number of devices in a full output tube. Set as ASCII number. When using other devices, this sets the 10s digit of number of devices in a full output tube. Set as ASCII number. When using other devices, this sets the 1s digit of number of devices in a full output tube. Set as ASCII number. Not used.
00E9
T Site 1000
00EA
T Site 100
00EB
T Site 10
00EC
T Site 1
00ED
Exit Step 10000
00EE
Exit Step 1000
00EF
Exit Step 100
00F0
Exit Step 10
00F1
Exit Step 1
00F2 00F3 00F4 00F5
Full 100 Kit Full 10 Kit Full 1 Kit
0 9 6
A A A
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00F6 00F7 00F8 00F9 00FA 00FB 00FC 00FD 00FE 00FF Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Not used.
Updating Your EPROM

Write down all changes you make in your RAM address listing. Permanent selections should be programmed into the EPROM. You can then fax your updated RAM listing to Exatron, and we will program a new EPROM for you, free. The benefit of having your customized changes in the EPROM is that when it is necessary to blast the RAM back to the factory default, you will not lose your changes.
Setting Sorts in RAM Addresses C0 to C7

To set each sort, type the instructions in hexadecimal. We use hex as an easy way of representing binary. It allows us to type an instruction of 2 digits rather than an instruction of 8 digits. The handler decodes the hex instructions into a binary map. The two groups of binary numbers in the binary column in the following table are viewed from the handlers view, or as if you were standing behind the handler, with your chin over the top of the octoloader, looking down at the output tubes. From this standpoint, the numbers represent the following outputs. In binary notation, 1 = TRUE and 0 = FALSE. So only the columns, or outputs, with 1s receive devices.
Comparison of Number Systems Hexadecimal

00 01 02 03
Binary
0000 0000 0000 0001 0000 0010 0000 0011
Result
Devices go to bin 1 only. Devices go to bin 2 only. Devices go to bins 1 and 2.
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Setting Sorts in RAM Addresses C0 to C7
Comparison of Number Systems Hexadecimal

04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 20 30 40
Binary
0000 0100 0000 0101 0000 0110 0000 0111 0000 1000 0000 1001 0000 1010 0000 1011 0000 1100 0000 1101 0000 1110 0000 1111 0001 0000 0010 0000 0011 0000 0100 0000
Result
Devices go to bin 3 only. Devices go to bins 1 and 3. Devices go to bins 2 and 3. Devices go to bins 1 through 3. Devices go to bin 4 only. Devices go to bins 1 and 4. Devices go to bins 2 and 4. Devices go to bins 1, 2, and 4. Devices go to bins 3 and 4. Devices go to bins 1, 3, and 4. Devices go to bins 2 through 4. Devices go to bins 1 through 4. Devices go to bin 5 only. Devices go to bin 6 only (not physically possible). Devices go to bins 5 and 6 (not physically possible). Devices go to bin 7 only.
ExamplePassed Devices to Four Tubes

Lets suppose that you want passed devices categorized as sort 1 to be routed to bins 1 through 4. You would type the instruction of 0F for sort 1, at RAM address C0. The binary code into which the handler would translate this is shown in the bottom row, following. Notice that each bin designated as yes, route here, has a 1 for TRUE.
Bin 8 0 Bin 7 0 Bin 6 0 Bin 5 0 Bin 4 1 Bin 3 1 Bin 2 1 Bin 1 1
ExamplePassed Devices to Taper

Lets next suppose that you want devices categorized as sort 1 to be routed only to the taper, using bin 7. You would type the instruction of 40 for sort 1, at RAM address C0. The binary code into which the handler would translate this is shown in the bottom row, following. Notice that only bin 7, designated as yes, route here, has a 1 for TRUE.
Bin 8 0 Bin 7 1 Bin 6 0 Bin 5 0 Bin 4 0 Bin 3 0 Bin 2 0 Bin 1 0
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Setting Bin Displays in RAM Addresses B8 to BF

If your handler has a digital display for the output bins, this section applies. To display the ASCII alphanumeric characters for each output bin, type the corresponding hex code.
RAM Addresses B8 to BF Hexadecimal

30 31 32 33 34 35 36 37 38 39 50 46
ASCII
0 1 2 3 4 5 6 7 8 9 P F
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Decimal-Hex-ASCII Conversion Table
Decimal-Hex-ASCII Conversion Table

Decimal
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Hex
00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 11 12 13 14 15 16 17 18 19 1A 1B 1C 1D 1E 1F 20 21
ASCII
Decimal
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65
Hex
22 23 24 25 26 27 28 29 2A 2B 2C 2D 2E 2F 30 31 32 33 34 35 36 37 38 39 3A 3B 3C 3D 3E 3F 40 41 42 43
ASCII
" # $ % & ( ) * + , . / 0 1 2 3 4 5 6 7 8 9 : ; < = > ? @ A B C
Space !
66 67
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Decimal
68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103
Hex
44 45 46 47 48 49 4A 4B 4C 4D 4E 4F 50 51 52 53 54 55 56 57 58 59 5A 5B 5C 5D 5E 5F 60 61 62 63 64 65 66 67
ASCII
D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] ^ _ a b c d e f g
Decimal
104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139
Hex
68 69 6A 6B 6C 6D 6E 6F 70 71 72 73 74 75 76 77 78 79 7A 7B 7C 7D 7E 7F 80 81 82 83 84 85 86 87 88 89 8A 8B
ASCII
h i j k l m n o p q r s t u v w x y z { | } ~
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Chapter Overview
This chapter describes the operation of the handler's extensive built-in diagnostics. These diagnostics allow every sensor, solenoid, switch, motor, and I/O Port in the handler to be individually tested. Use these checks to troubleshoot any problem the handler may have. This chapter discusses the following main topics: Topic Accessing DIAGNOSTICS Mode Diagnostics Quick Reference SENSOR CHECK: Test Site Sensors 0-7 SENSOR CHECK: Test Site Sensors 8-F for Laser SENSOR CHECK: Test Site Sensors 8-F for Quad Tester SENSOR CHECK: Shuttle Position Sensors 1-8 SENSOR CHECK: Tube Full Sensors 1-8 SENSOR CHECK: Tube Present Sensors 1-8 OUTPUT CHECK: Solenoid Check OUTPUT CHECK: Solenoid Toggle Check OUTPUT CHECK: Light Pole Check OUTPUT CHECK: CPU Port Check INTERFACE CHECK: RS-232 Port Check INTERFACE CHECK: RS-232 Port #2 Check for Pickup Heads INTERFACE CHECK: Handler Port Output Check INTERFACE CHECK: Handler Port Input Check ALL MOTOR CHECK: Shuttle Motor Check ALL MOTOR CHECK: Pickup Head Motor Check ALL MOTOR CHECK: Octoloader Motor Check OCTO/INDEX CHECK: Shuttle Solenoid Check OCTO/INDEX CHECK: Input Sensor Check LASER CHECK: Laser Firing Check LASER CHECK: Laser Input Check LASER CHECK: Laser Output Check SERVO TEACH MODE Cycling the Handler in Stop Mode Cycling the Handler in Loop Mode Page 4-2 4-6 4-12 4-13 4-14 4-15 4-18 4-20 4-22 4-24 4-25 4-26 4-27 4-28 4-31 4-32 4-33 4-34 4-36 4-37 4-38 4-40 4-41 4-42 4-42 4-43 4-44
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Accessing DIAGNOSTICS Mode

Although no tools are required, an Exatron LED checker, part #3000-052, (small blue box, Figure 4-1) will be helpful in troubleshooting broken sensor/LED pairs and for testing the handler control port.
Figure 4-1: Eight-Bit LED Checker #3000-521
To access Diagnostics mode, press the <DIAGNOSTICS> key on the handler's control panel. If the password security is turned on, the display reads "PASSWORD ABC ?" Enter a 3-digit password using the numeric keys. The factory-set password is 123, or <1> <2> <3>. The display reads: "DIAGNOSTICS." You can access Diagnostics mode whenever the handler powers up, is in Run mode, or is in Manual mode.
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You can also access Diagnostics Mode during most device jam-clearing cycles, when the output tube cover LEDs are flashing. If using Diagnostics during a jam, the handler will exit its automatic jam clearing cycle and then return to its previous place in the program, upon exiting Diagnostics. In most cases, if the jam is cleared during Diagnostics, the handler will also automatically restart after returning from Diagnostics. Note that in Figure 4-3 and Figure 4-4 the top line of each action box is the key you press, and the second line is the resulting display on the control panel.
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Model 5000 Manual Chapter 4: Diagnostics and Troubleshooting
Figure 4-3: Diagnostics Reference Flowchartfor Handler with Pickup Head and Laser
NOTE: Depending on the exact configuration of your handler, the functions accessed by one or more keys may be somewhat different.
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Figure 4-4: Diagnostics Reference Flowchartfor Handler with Quad Tester
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Diagnostics Quick Reference

The diagnostic selections are in a hierarchy, dropping from a higher level to lower levels. In most cases, pressing the <ENTER> key moves back up one level. <0> key = "ALL MOTORS OFF" then = "ALIGN MOTORS" <ENTER> key = "ALIGN MOTORS ?" <1> key = "JOG LEFT"jogs octoloader 1 motor step to the left <2> key n/a <3> key = "JOG RIGHT"jogs octoloader 1 motor step to the right <4> - <6> keys n/a <7> key = "JOG LEFT"jogs shuttle 1 motor step to the left <8> key n/a <9> key = "JOG RIGHT"jogs shuttle 1 motor step to the right <0> key = "ALL MOTORS OFF" <1> key = "SENSOR CHECK", then: <1> key = "SEN0-7 1234567" test site sensors 0-7 (track sensors) 0 display = pickup head vacuum 1 display = index sensor 2 display = device at pickup 3 display = Y motor (pickup head) at home position 4-7 display n/a (not applicable) <2> key = "SEN8-F 89ABCDEF" laser sensors (or quad tester sensors) 8-F <3> key = "SHUT 12345678" shuttle sensors 1-8 <4> key = "FULL 12345678" tube full sensors 1-8 <5> key = "TUBE 12345678" tube present sensors 1-8 <6> - <0> keys n/a (not applicable)
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<2> key = "OUTPUT CHECK", then:

<1> key = "SOLENOID CHECK" causes continual, intermittent action, (for handler with pickup head and laser) or <2> key = "SOL TOGGLE CHECK" causes continuous, steady action, (for handler with pickup head and laser) then: <1> key activates pickup head vacuum; LED 1 flashes <2> key activates pickup head blow-off; LED 2 flashes <3> key activates rail air, or air assist, to push device down into shuttle; LED 3 flashes <4> key activates pickup plunge; LED 4 flashes <5> key activates index solenoid; LED 5 flashes <6> key activates stack and cover foot solenoids at pickup site; LED 6 flashes <7> key activates top gate (laser only) <8> key activates bottom gate (laser only) <9> key activates all solenoids ON <0> key activates all solenoids OFF <1> key = "SOLENOID CHECK" causes continual, intermittent action, (for handler with quad tester) or <2> key = "SOL TOGGLE CHECK" causes continuous, steady action, (for handler with quad tester) then: <1> key activates/retracts test site stop pin; LED 1 flashes <2> key deactivates/extends test site stop pin; LED 2 flashes <3> key activates track air blast in 3 places; LED 3 flashes <4> key deactivates track air blast in 3 places; LED 4 flashes <5> key activates/retracts stop pin below stage or holding site; LED 5 flashes <6> key deactivates/extends stop pin below stage or holding site; LED 6 flashes <7> key activates/closes test site contacts; LED 7 flashes
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<8> key deactivates/opens test site contacts; LED 8 flashes <9> key activates all solenoids ON <0> key activates all solenoids OFF <3> key = "LIGHT POLE CHECK", then: <1> key activates green light <2> key activates yellow light <3> key activates red light <4> key activates blue light (if handler is laser-equipped) <5> - <8> keys n/a <9> key turns all lights ON <0> key turns all lights OFF <4> key = "CPU PORT CHECK" <5> key = "PICK OUTPUT ?" (for output tube digital display only) <1-8> keys select output tube for which to change the display, then: "SET DIGIT ?" <1-9> keys display the number in the digital display for that output tube <6> - <9> keys n/a <3> key = "INTERFACE CHECK", then: <1> key = "RS-232 CHECK", then: <1> - <9> keys send signals "1" - "9" from control panel to tester <RUN> key sends signal "A" from control panel to tester <MANUAL> key sends signal "B" from control panel to tester <SET UP> key sends signal "C" from control panel to tester <PAUSE> key sends signal "D" from control panel to tester <TOTALS> key sends signal "E" from control panel to tester
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<DIAGNOSTICS> key sends signal "F" from control panel to tester <2> key = "HANDLER OUT CHK", then: <1> - <8> keys cause corresponding light ot flash, on LED and on Simulator <9> key activates all ON <0> key activates all OFF <3> key = "CHK RS-232 #2 CM" (or "CI") (motor check) (only for <4> key = "ISSUE NEW START" The handler has been instructed to send a new start-test pulse to the tester/PC; then it waits for an end-of-test sort signal from the tester. If none is received, the message "SORT INPUT" is displayed. <5> - <0> keys n/a <4> key = "ALL MOTOR CHECK", then: <1> key = "SORT MOTOR CHECK" (shuttle motor check), then: <1> key = "1 LEFT STEP"moves shuttle 1 output tube to the left <2> key = "R245 F45 S245"current shuttle motor settings in RAM; helpful when trying to increase the motor's speed <3> key = "1 RIGHT STEP"moves shuttle 1 output tube to the right <4> key = "2 LEFT STEPS"moves shuttle 2 output tubes to the left <5> key n/a <6> key = "2 RIGHT STEPS"moves shuttle 2 output tubes to the right <7> key = "JOG LEFT"moves shuttle 1 motor step to the left <8> key n/a <9> key = "JOG RIGHT"moves shuttle 1 motor step to the right <0> key = "MOTOR OFF"turns off shuttle motor <2> key = "SERVO MOTOR CHK" (pickup head check), then: <1> key moves pickup head to pickup site (see Figure 2-4, Figure 2-20) <2> key moves pickup head to test site (see Figure 2-4, Figure 2-21) <3> key moves pickup head to top of output track (see Figure 2-4, Figure 2-22)
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<4> key = "PICK UP = #####"where each # is a number; displays number of motor steps to the pickup site <5> key = "TO SITE = #####"where each # is a number; displays number of motor steps to the test site <6> key = "TO EXIT = #####"where each # is a number; displays number of motor steps to the top of the track, just above air assist After selecting <1>, <2>, or <3>, you can use the next keys to change the number of motor steps to the selected position (see Figure 4-24): <4> key subtracts 10 steps; e.g., changes 15220 to 15210 <5> key subtracts 100 steps; e.g., changes 15220 to 15120 <6> key subtracts 1000 steps; e.g., changes 15220 to 14220 <7> key adds 10 steps; e.g., changes 15220 to 15230 <8> key adds 100 steps; e.g., changes 15220 to 15320 <9> key adds 1000 steps; e.g., changes 15220 to 16220 <Clear> key discards any changes to the number of motor steps <ENTER> key takes you back to the previous level, where you can select another site or perform another action <7> key n/a <8> key moves pickup head to pickup site; if no device present, message "INDEX EMPTY ?" is displayed <9> key toggles air blast on/off <Space> toggles pickup nozzle down/up <Delete> toggles vacuum on/off <0> key = "HALT!! RESTART ?"pickup head motor is turned off and red pole light turns on <ENTER> key = "ZERO Y SERVO", then back to "SERVO MOTOR CHK" <3> key = "OCTO MOTOR CHECK", then: <1> key = "1 LEFT STEP"moves octoloader 1 input tube to the left
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<2> key = "R200 F10 S200"current octoloader motor settings in RAM; helpful when trying to increase the motor's speed <3> key = "1 RIGHT STEP"moves octoloader 1 input tube to the right <4> key = "2 LEFT STEPS"moves octoloader 2 input tubes to the left <5> key n/a <6> key = "2 RIGHT STEPS"moves octoloader 2 input tubes to the right <7> key = "JOG LEFT"moves octoloader 1 motor step to the left <8> key n/a <9> key = "JOG RIGHT"moves octoloader 1 motor step to the right <0> key = "MOTOR OFF"turns off octoloader motor <4> - <0> keys n/a <5> key = "OCTO/INDEX CHK", then: <1> key extends index pin/retracts stop pin <2> key opens shuttle solenoid, and turns on air blast if so equipped <3> key = "INPUT 12345678"input/octoloader sensors 0-5 displays n/a 6 display = device at top of track 7 display = device at octoloader gap 8 display = octoloader at home base on right <6> key = LASER CHECK, then: <1> key = Indexes device into mark site <2> key = Closes top laser gate when ready to laser mark <3> key = Moves device from mark site to output tube <7> key = "SERVO TEACH MODE" (adjustment of pickup head positions), then: <1> key = "PICK UP = #####", pickup head moves to the pickup site <2> key = "TO SITE = #####", pickup head moves to the test site
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<3> key = "TO EXIT = #####", pickup head moves to the top of the track, just above air assist After selecting <1>, <2>, or <3>, you can use the next keys to change the number of motor steps to the selected position (see Figure 4-24): <4> key subtracts 10 steps; e.g., changes 15220 to 15210 <5> key subtracts 100 steps; e.g., changes 15220 to 15120 <6> key subtracts 1000 steps; e.g., changes 15220 to 14220 <7> key adds 10 steps; e.g., changes 15220 to 15230 <8> key adds 100 steps; e.g., changes 15220 to 15320 <9> key adds 1000 steps; e.g., changes 15220 to 16220 <0> key = "HALT!! RESTART ?"the pickup head motor only is turned off and the red pole light turns on <ENTER> key = "ZERO Y SERVO", then back to "SERVO TEACH MODE" <Space> key toggles pickup nozzle down/up <Delete> key toggles pickup vacuum on and off <Clear> key raises pickup nozzle if it is down, moves pickup head to the pickup site <ENTER> after any of these selectionstakes it all the way back up to DIAGNOSTICS <8> - <9> keys n/a <ENTER> key = Exit DIAGNOSTICS.
SENSOR CHECK: Test Site Sensors 0-7

This diagnostic tests the sensors related to the pickup head. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <1> key. > Handler displays "SENSOR CHECK".
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SENSOR CHECK: Test Site Sensors 8-F for Laser
3. Press the <1> key again. > Handler displays all or part of "SEN0-7 01234567". Specifically, the numbers indicate: 0 = pickup head vacuum activated 1 = index sensor activated 2 = device at pickup sensor activated 3 = Y motor (pickup head) home sensor activated 4-7 = n/a (not available) Alternatively, for a custom handler with a quad test site, the first six sensors (012345) are used to determine that four devices and not five are in the test site. Sensors 6 and 7 are not used. Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check. If you suspect that you have a bad sensor/LED pair, use the Exatron LED checker #3000-052. This diagnostic tool is equipped with a transistor (blue/white wires) and an IR LED (orange/blue wires). Direct the transistor at any of the handler's IR LEDs. The LED on the checker should turn off. Direct the checker's LED at any of the handler's transistors. The corresponding number should turn OFF on the handler's display.
SENSOR CHECK: Test Site Sensors 8-F for Laser

This diagnostic tests sensors related to an attached laser. These sensors are active only if the handler is equipped with a laser or quad tester. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <1> key. > Handler displays "SENSOR CHECK". 3. Press the <2> key. > Handler displays all or part of "SEN8-F 89ABCDEF".
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Specifically, the numbers indicate: 8 = Vacuum ON sensors 9 = Z Limit Switch A = not used B = not used C = not used D = Top Laser Gate E = Smoke Tube F = not used Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check. If you suspect that you have a bad sensor/LED pair, use the Exatron LED checker #3000-052. This diagnostic tool is equipped with a transistor (blue/white wires) and an IR LED (orange/blue wires). Direct the transistor at any of the handler's IR LEDs. The LED on the checker should turn off. Direct the checker's LED at any of the handler's transistors. The corresponding number should turn OFF on the handler's display.
SENSOR CHECK: Test Site Sensors 8-F for Quad Tester

This diagnostic tests sensors at a quad test site. These sensors are active only if the handler is equipped with a laser or quad tester. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <1> key. > Handler displays "SENSOR CHECK". 3. Press the <5> key. > Handler displays all or part of "SEN8-F 89ABCDEF". The first six sensors (89ABCD) are used to determine that four devices and not five are in the stage or holding site below the test site and above the shuttle. Sensors E and F are not used.
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SENSOR CHECK: Shuttle Position Sensors 1-8
Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check. If you suspect that you have a bad sensor/LED pair, use the Exatron LED checker #3000-052. This diagnostic tool is equipped with a transistor (blue/white wires) and an IR LED (orange/blue wires). Direct the transistor at any of the handler's IR LEDs. The LED on the checker should turn off. Direct the checker's LED at any of the handler's transistors. The corresponding number should turn OFF on the handler's display.

This diagnostic tests the shuttle position sensors located just above the output tubes.
Figure 4-5: Shuttle Position Sensors
To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <1> key. > Handler displays "SENSOR CHECK". 3. Press the <3> key.
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> Handler displays all or part of "SHUT 12345678". Specifically, the numbers indicate: (1)2 = Shuttle is at Output 1 sensor. 1(2)3 = Shuttle is at Output 2 sensor. 2(3)4 = Shuttle is at Output 3 sensor. 3(4)5 = Shuttle is at Output 4 sensor. 4(5)6 = Shuttle is at Output 5 sensor. 5(6)7 = Shuttle is at Output 6 sensor. 6(7)8 = Shuttle is at Output 7 sensor. 7(8) = Shuttle is at Output 8 sensor. The handler's output cover LEDs indicate the current location of the shuttle. The correct pattern for an empty shuttle at each output bin is as shown in Figure 4-6. Black dots indicate flashing LED. White dots indicate LED turned off. When the shuttle is carrying a device, the center LED is flashing also.
Figure 4-6: LED Pattern for Each Shuttle Position When Shuttle Is Empty
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Example of Shuttle Position Sensors
Example of Shuttle Position Sensors

For example, when the shuttle has no device and is at its home position in line with the test site and output tube 5, the control panel displays the message "SHUT 4 6" and LEDs 4 and 6 are lit. Sensor 5 is not blocked because no device is present.
Sensor 5
Figure 4-7: Shuttle Position Sensors 4 and 6 Blocked
When the shuttle does have a device and is at its home position in line with the test site and output tube 5, the control panel displays the message "SHUT 456" and LEDs 4, 5, and 6 are lit. Sensor 5 is blocked by the device.
Figure 4-8: Shuttle Position Sensors 4-6 Blocked
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SENSOR CHECK: Tube Full Sensors 1-8

This diagnostic tests each sensor that detects when an output tube is full.
Figure 4-9: Tube Full Sensors
To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <1> key. > Handler displays "SENSOR CHECK". 3. Press the <4> key. > Handler displays all or part of "FULL 12345678". Handler displays "FULL " if all output tubes/lead in sensors are clear of devices. If numbers are displayed, they indicate: 1 = Tube 1 Full sensor is activated; tube 1 is full. 2 = Tube 2 Full sensor is activated; tube 2 is full. 3 = Tube 3 Full sensor is activated; tube 3 is full. 4 = Tube 4 Full sensor is activated; tube 4 is full. 5 = Tube 5 Full sensor is activated; tube 5 is full. 6 = Tube 6 Full sensor is activated; tube 6 is full. 7 = Tube 7 Full sensor is activated; tube 7 is full. 8 = Tube 8 Full sensor is activated; tube 8 is full.
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SENSOR CHECK: Tube Full Sensors 1-8
Example of Tube Full Sensors
Example of Tube Full Sensors

For example, when only the third output tube is full, the control panel displays the message "FULL 3" and LED 3 is lit.
Figure 4-10: Tube Full Sensor Blocked
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SENSOR CHECK: Tube Present Sensors 1-8

This diagnostic tests the sensors that detect when an output tube is present, activating the tube switch.
Figure 4-11: Tube Present Sensors
To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <1> key. > Handler displays "SENSOR CHECK". 3. Press the <5> key. > Handler displays all or part of "TUBE 12345678". Handler displays "TUBE displayed, they indicate: " if all output tubes are removed from the handler. If numbers are
1 = Tube 1 is present. 2 = Tube 2 is present. 3 = Tube 3 is present. 4 = Tube 4 is present. 5 = Tube 5 is present. 6 = Tube 6 is present. 7 = Tube 7 is present.
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SENSOR CHECK: Tube Present Sensors 1-8
Example of Tube Present Sensors
8 = Tube 8 is present. NOTE: In Diagnostics mode only, the handler will display "TUBE CLEAR WORKS" for two seconds whenever any of the output tubes is removed. The message may flash when inserting a new tube. This is an indication that the "tube count clearing" pulse is being received by the handler's CPU. If this signal is not present, check pins 2, 4, 6, 8, 11, 13, 15 and 17 on IC U6 on PCB #5000-399. These pins should pulse whenever any tube is removed from the handler. Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check.

For example, when all eight output tubes are present and blocking each sensor, the control panel displays the message "TUBE 12345678" and LEDs 1-8 are lit.
Figure 4-12: Tube Present Sensors Blocked
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OUTPUT CHECK: Solenoid Check

This diagnostic tests various solenoids. The cover foot extends concurrently with the stack pins retraction to stabilize a falling device and prevent it from jumping the stop block. Index solenoid
Photo 6796 Stack solenoid
Cover foot solenoid

Figure 4-13: Solenoids
To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <2> key. > Handler displays "OUTPUT CHECK". 3. Press the <1> key. > Handler displays "SOLENOID CHECK". 4. Press each of the handler control panel's keypad keys 0 through 9.
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OUTPUT CHECK: Solenoid Check
Each key will turn on/off the handler's output cover LEDs and will set the corresponding handler solenoid into a continual, intermittent on/off test cycle. For example, the vacuum is activated in intermittent bursts, or the pickup head moves up and down until you stop the action. Key 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 All ON All OFF Output Cover LED Handler Solenoid Pickup head vacuum Pickup head blow-off Air assist, or rail air Pickup plunge Index solenoid Stack solenoid at pickup site Top gate (laser only) Bottom gate (laser only) All solenoids turned on All solenoids turned off
Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check and return to the "DIAGNOSTICS" message.
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OUTPUT CHECK: Solenoid Toggle Check

This diagnostic tests various solenoids. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <2> key. > Handler displays "OUTPUT CHECK". 3. Press the <2> key again. > Handler displays "SOL TOGGLE CHECK". 4. Press each of the handler control panel's keypad keys 0 through 9. Each key will turn on/off the handler's output cover LEDs and will set the corresponding handler solenoid into continuous, steady action that can be stopped or toggled by pressing the activating key again. For example, the vacuum is activated in a steady force until you toggle it off, or the pickup head stays down until you toggle it up. Key 1 2 3 4 5 6 7 8 9 0 Output Cover LED 1 2 3 4 5 6 7 8 All ON All OFF Handler Solenoid Pickup head vacuum Pickup head blow-off Air assist, or rail air Pickup plunge Index solenoid Stack solenoid at pickup site Top gate (laser only) Bottom gate (laser only) All solenoids turned on All solenoids turned off
Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check and return to the "DIAGNOSTICS" message.
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OUTPUT CHECK: Light Pole Check
OUTPUT CHECK: Light Pole Check

This diagnostic tests each light on the light pole. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <2> key. > Handler displays "OUTPUT CHECK". 3. Press the <3> key. > Handler displays "LIGHT POLE CHECK". 4. Press each of the following handler control panel's keypad keys. <1> key = activates green light <2> key = activates yellow light <3> key = activates red light <4> key = activates blue light if laser-equipped; otherwise n/a <5> - <8> keys = n/a <9> key = turns ON all lights <0> key = turns OFF all lights Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check and return to the "DIAGNOSTICS" message.
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OUTPUT CHECK: CPU Port Check

This diagnostic tests the port that is used for label printers. It requires a special diagnostic tool. Contact Exatron for more information.
Figure 4-14: CPU Port
To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <2> key. > Handler displays "OUTPUT CHECK". 3. Press the <4> key. > Handler displays "CPU PORT CHECK".
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INTERFACE CHECK: RS-232 Port Check
INTERFACE CHECK: RS-232 Port Check

For external Handler RS-232 port, this diagnostic tests port 28, 29, 2A, 2B, 2C, 2D, 2E. For internal Front Panel RS-232 port, this diagnostic tests port F8, F9, FA, FB, FC, FD, FE. Connect a dumb terminal to the Handler's RS-232 port. NOTE: The handler may be set up to use any number of baud rates and stop/parity/bits. The standard factory settings are: RAM address: 009A 0C 9600 BAUD RAM address: 009B 03 1 STOP, 8 BITS, NO PARITY To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <3> key. > Handler displays "INTERFACE CHECK". 3. Press the <1> key. > Handler displays "RS-232 CHECK". 4. Press each of the following handler control panel's keypad keys to send a signal from the handler to the tester.
Control Panel Key 0 1 2 3 4 5 6 7 8
ASCII Character Sent 0 1 2 3 4 5 6 7 8
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Control Panel Key 9 RUN MANUAL SET UP PAUSE TOTALS DIAGNOSTICS
ASCII Character Sent 9 A B C D E F
Press each of the handler control panel's keys (save <ENTER> for last). As you do, the correct ASCII character, 0-F, should appear on the dumb terminal. Send any ASCII character to the handler. The character should appear on the control panel's 16-digit display. Verify that communications to/from the handler's control panel and the PC are clear. NOTE: Characters will be added to the existing display message, which will then scroll as more characters are received. Press the < < > (less-than) key to scroll to the left end of the message, 1 character at a time. Press the < > > (greater-than) key to scroll to the right end of the message, 1 character at a time. Press the <ENTER> key to EXIT this diagnostic check.
INTERFACE CHECK: RS-232 Port #2 Check for Pickup Heads

This diagnostic is used only when the handler is equipped with a pickup head to move the device to and from the test site. This diagnostic tests the electronic port UART #2 that drives the Cool Muscle motor. This port is internal to the handler. CAUTION: Only a trained technician should use this diagnostic! Before performing this check, attach a test jumper, pin 2 to pin 3 (between the brown and black wires), on the Y pickup motor input RS-232 connector. See print 5000-U85-1-D1 for details. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key.
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INTERFACE CHECK: RS-232 Port #2 Check for Pickup Heads
> Handler displays "DIAGNOSTICS". 2. Press the <3> key. > Handler displays "INTERFACE CHECK". 3. Press the <2> key. > Handler displays "CHK RS-232 #2 CM". 4. Press each of the following handler control panel's keypad keys to send a signal from the handler to the tester. Terminal Key 0 1 2 3 4 5 6 7 8 9 RUN MANUAL SET UP PAUSE TOTALS DIAGNOSTICS ASCII Character Sent 0 1 2 3 4 5 6 7 8 9 A B C D E F
Press each of the handler control panel's keys (save <ENTER> for last). As you do, the correct ASCII character, 0-F, should appear on the dumb terminal. Send any ASCII character to the handler. The character should appear on the handler's 16digit controller display. Verify that communications to/from the handler's terminal and the PC are clear. NOTE: Characters will be added to the existing display message, which will then scroll left as more characters are received; for example: "RS-232 #2 C4CEA".
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Press the < < > (less-than) key to scroll to the left end of the message, 1 character at a time. Press the < > > (greater-than) key to scroll to the right end of the message, 1 character at a time. Press the <ENTER> key to EXIT this diagnostic check.
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INTERFACE CHECK: Handler Port Output Check
INTERFACE CHECK: Handler Port Output Check

This diagnostic tests the output signals. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <3> key. > Handler displays "INTERFACE CHECK". 3. Press the <3> key again. > Handler displays "HANDLER OUT CHK". 4. Press each of the handler control panel's keypad keys 1 through 9, then 0 last. Each key will turn on/off the handler's output cover LEDs and will set the corresponding handler interface output low. Normally, all handler outputs are at TTL Logic High (+5). Key 1 2 3 4 5 6 7 8 9 0 Output Cover LED 1 2 3 4 5 6 7 8 All ON All OFF Handler Interface Output Pin (24-Pin "D" Connector) 10 Start test output 22 Testing 9 not usually used 21 not usually used 20 not usually used 19 not usually used 18 not usually used 17 not usually used All outputs low (GND) All outputs high (+5)
Alternatively, you can plug the Exatron LED Checker into the handler's control port. The checker has four LEDs which can be used to check the first four outputs from the handler port. As output 1 flashes, so should the corresponding LED on the checker, etc. Press the <ENTER> key to EXIT this diagnostic check.
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INTERFACE CHECK: Handler Port Input Check

This diagnostic tests the input sort signals. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <3> key. > Handler displays "INTERFACE CHECK". 3. Press the <4> key. > Handler displays "SORT INPUT". Plug the EXATRON LED Checker into the handler's control port. Slide each of the LED checker's eight position DIP switch micro switches. As you do, the corresponding red output cover LED will turn on. These "input" signals should be latched and saved by the handler. Any time you wish to reset the interface latch, turn off all of the DIP switches, and then press the handler controller's <1> key. This also issues a new "Start Test" command to the tester. Output Cover LED 1 2 3 4 5 6 7 8 Handler Interface Input Pin (24-Pin "D" Connector) 1 (Sort 1) 2 (Sort 2) 3 (Sort 3) 4 (Sort 4) 5 (Sort 5) 6 (Sort 6) 7 (Sort 7) 8 (Sort 8) 13 EOT (Special order only) Pressing the <CLEAR> key will flash the control panel's displayed message to confirm that the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check.
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ALL MOTOR CHECK: Shuttle Motor Check
ALL MOTOR CHECK: Shuttle Motor Check

This diagnostic tests the positions of the shuttle motor. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <4> key. > Handler displays "ALL MOTOR CHECK". 3. Press the <1> key. > Handler displays "SORT MOTOR CHK". <1> key = "1 LEFT STEP." The shuttle moves one tube to the left. <3> key = "1 RIGHT STEP." The shuttle moves one tube to the right. <4> key = "2 LEFT STEPS." The shuttle moves two tubes to the left. <6> key = "2 RIGHT STEPS." The shuttle moves two tubes to the right. <7> key = "JOG LEFT." The shuttle moves one motor step to the left, about .006". <9> key = "JOG RIGHT." The shuttle moves one motor step to the right, about .006". <0> key = "MOTOR OFF." The shuttle motor is turned off. Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check.
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ALL MOTOR CHECK: Pickup Head Motor Check

This diagnostic tests the distances the pickup head must move.
Figure 4-15: Pickup Head at Pickup Site (Key 1)
The pickup head first gets a device from the pickup site.
Figure 4-16: Pickup Head at Test Site (Key 2)
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ALL MOTOR CHECK: Pickup Head Motor Check
Figure 4-17: Pickup Head at Top of Track (Key 3)
To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <4> key. > Handler displays "ALL MOTOR CHECK". 3. Press the <2> key. > Handler displays "SERVO MOTOR CHK". Press the <1> key. The pickup head moves up to the pickup site. Press the <2> key. The pickup head moves to the test site. Press the <3> key. The pickup head moves to the top of the track. Press the <4> key: "PICK UP = #####" (each # represents a digit). This displays the number of motor steps required to move the pickup head from its home position to the pickup site. Press the <5> key: "TO SITE = #####" (each # represents a digit). This displays the number of motor steps required to move the pickup head from its home position to the test site. Press the <6> key: "TO EXIT = #####" (each # represents a digit). This displays the number of motor steps required to move the pickup head from its home position to the top of the track. Pressing the <CLEAR> key will flush any devices into the Home bin, output tube 5.
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Press the <ENTER> key to EXIT this diagnostic check. For information on changing any of the motor step distance values, see "SERVO TEACH MODE" on page 4-42.
ALL MOTOR CHECK: Octoloader Motor Check

This diagnostic tests the positions of the octoloader motor. CAUTION: Verify that the octoloader is empty of all devices before using this diagnostic. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <4> key. > Handler displays "ALL MOTOR CHECK". 3. Press the <3> key. > Handler displays "OCTO MOTOR CHK". <1> key = "1 LEFT STEP." The octoloader moves one tube to the left. <2> key = "R200 F10 S200." The handler displays the current motor settings in RAM. This display is helpful when trying to increase the motor's speed. <3> key = "1 RIGHT STEP." The octoloader moves one tube to the right. <4> key = "2 LEFT STEPS." The octoloader moves two tubes to the left. <6> key = "2 RIGHT STEPS." The octoloader moves two tubes to the right. <7> key = "JOG LEFT." The octoloader moves one motor step to the left, about .006". <9> key = "JOG RIGHT." The octoloader moves one motor step to the right, about .006". <0> key = "MOTOR OFF." The octoloader motor is turned off. Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check.
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OCTO/INDEX CHECK: Shuttle Solenoid Check
OCTO/INDEX CHECK: Shuttle Solenoid Check

This diagnostic tests the shuttle solenoid.
Figure 4-18: Shuttle Solenoid Light with Override Button
To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <5> key. > Handler displays "OCTO/INDEX CHECK". 3. Press the <2> key. > The handler activates the shuttle solenoid for 1/4 second. The shuttle pin retracts briefly to release any device it may be holding, and then extends againits default position. If the handler is equipped with an air blast switch, a blast of air assists the device to leave the shuttle. 4. Press the <ENTER> key to EXIT this diagnostic check.
Figure 4-19: Shuttle in Extended/Closed Position with Device (Left), in Retracted/Open Position (Right)
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OCTO/INDEX CHECK: Input Sensor Check

This diagnostic tests the octoloader home sensor and the input sensors.
Figure 4-20: Octoloader at Home Sensor (Display 8)
Figure 4-21: Device at Octoloader Gap Sensor (Display 7)
The Device at Octoloader Gap sensor (number 7 on the control panel display) is above the ledge, and above the Device at Top of Track sensor (number 6 on the control panel display).
Figure 4-22: Device at Top of Track Sensor (Display 6)
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OCTO/INDEX CHECK: Input Sensor Check
Example of Octoloader Home and Input Sensors
To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <5> key. > Handler displays "OCTO/INDEX CHECK". 3. Press the <3> key. > Handler displays all or part of "INPUT 12345678". Specifically, the numbers indicate: 0-5 = n/a (not available); 5 is always displayed 6 = device at top of track sensor activated 7 = device at octoloader gap sensor activated 8 = octoloader at home sensor activated Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check.

For example, when the octoloader is at its home position and devices are blocking each sensor, the control panel displays the message "INPUT 5678" and LEDs 5-8 are lit.
Figure 4-23: Octoloader Home and Input Sensors Blocked
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LASER CHECK: Laser Firing Check

This diagnostic is found only on handlers having a laser marker. It tests the firing of the laser, in either pilot (simulation) or full marking mode. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <6> key. > Handler displays "LASER CHECK". 3. Press the <1> key. > Handler displays "CHECKING LASER ?" while the laser is initialized. Then the display "- PILOT / . FULL" gives you the choice of firing the laser in either pilot or full mode. <-> key fires the laser in pilot (simulation) mode only <.> key fires the laser in full marking mode Press the <ENTER> key to EXIT this diagnostic check.
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LASER CHECK: Laser Input Check
LASER CHECK: Laser Input Check

This diagnostic is found only on handlers having a laser marker. It tests communication from the laser to the handler. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <6> key. > Handler displays "LASER CHECK". 3. Press the <2> key. > Handler displays "L IN 12345678". This troubleshoots the 8 inputs (U3) on the B84 laser interface board. Press the <ENTER> key to EXIT this diagnostic check.
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LASER CHECK: Laser Output Check

This diagnostic is found only on handlers having a laser marker. It tests communication from the handler to the laser. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <7> key. > Handler displays "LASER CHECK". 3. Press the <2> key. > Handler displays "LASER OUT CHECK". This troubleshoots the 8 outputs (U2) on the B84 laser interface board. Press the <ENTER> key to EXIT this diagnostic check.
SERVO TEACH MODE

This diagnostic allows you to view and change three critical distances the pickup head must move from its home position. Use this method when you dont know the motor distances for a device type. These adjustments allow you to make larger adjustments. On the other hand, when you do know the distances for a device type, you can enter the Modify Setup mode and directly enter the exact number of motor steps needed for each position. See "Setting Pickup Head Distances" on page 3-52 for details. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Handler displays "DIAGNOSTICS". 2. Press the <7> key. > Handler displays "SERVO TEACH MODE". Press the <1> key: "PICK UP = #####". The pickup head moves to the pickup site. Press the <2> key: "TO SITE = #####". The pickup head moves to the test site. Press the <3> key: "TO EXIT = #####". The pickup head moves to the top of the track, just above the air assist.
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Cycling the Handler in Stop Mode
After pressing <1>, <2>, or <3>, you can press the following keys in any order to change the number of motor steps to reach the site selected. NOTE: Keys <4>, <5>, and <6> move the pickup head up toward its home position at the top. Keys <7>, <8>, and <9> move the pickup head down toward the output. Pressing <4> subtracts 10 steps; e.g., changes 15220 to 15210. Pressing <5> subtracts 100 steps; e.g., changes 15220 to 15120. Pressing <6> subtracts 1000 steps; e.g., changes 15220 to 14220. Pressing <7> adds 10 steps; e.g., changes 15220 to 15230. Pressing <8> adds 100 steps; e.g., changes 15220 to 15320. Pressing <9> adds 1000 steps; e.g., changes 15220 to 16220.
Figure 4-24: Changing Distances on Keypad
Pressing <ENTER> after any of these selections takes it all the way back up to DIAGNOSTICS.
Cycling the Handler in Stop Mode

Stop and Loop modes are for testing and troubleshooting of the handler. To put the handler in Stop mode, follow the instructions beginning in "Changing Settings" on page 3-46, and specifically in "Selecting Manual Cycling" on page 3-50. When in Stop mode, the handler stops after every confirmable action and waits for your next command, enabling you to identify exactly where a problem is occurring. After each stop, the message "STOP MODE ON ?" flashes. Press <ENTER> or <RUN> when you are ready to execute the next action. Specifically, the handler stops after each of the following steps (events in parentheses occur when necessary but not every time): 1. (At the beginning of the first cycle only, the pickup head moves to its home position.) The pickup head moves to a position over the pickup site.
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2. The pickup head lowers to the pickup site, the vacuum turns on, and the pickup head rises with a device attached. 3. The pickup head moves to a position over the test site. 4. The pickup head lowers to the test site and the device is tested; the index and stack solenoids are activated to drop another device to the pickup site while the cover foot extends briefly to hold the incoming device at the pickup site and then retracts; the shuttle takes a device from the exit site and drops it at the output while a message like "BIN 1 S1 C0024" is briefly displayed; the green pole light turns on briefly. The pickup head rises from the test site. (If necessary, the octoloader moves, looking for another full input tube.) 5. The pickup head moves to a position over the track exit site. 6. The pickup head lowers to the exit site, the vacuum turns off, and the pickup head rises without the device. Then the cycle repeats from step 1.
Cycling the Handler in Loop Mode

Stop and Loop modes are for testing and troubleshooting of the handler. To put the handler in Loop mode, follow the instructions beginning in "Changing Settings" on page 3-46, and specifically in "Selecting Manual Cycling" on page 3-50. When in Loop mode, the handler stops after every complete cycle. After each cycle, the message "LOOP MODE ON ?" flashes. Press <ENTER> or <RUN> when you are ready to execute the next cycle. NOTE: You can alternate between Stop mode and Loop mode by pressing the <1> and <2> keys, respectively. However, when going from Stop mode to Loop mode, it goes through part or all of a cycle until it finishes step 4. The Loop mode always ends with the end of step 4, with the pickup head over the test site.
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Chapter Overview
This reference chapter discusses the following status and error messages that may be displayed on the control panel (Figure 5-1). The list is in alphabetic order, with symbols and numbers listed first. Each entry in this section explains why the message is displayed and, when necessary, how to resolve the condition. If further explanation is required, the operator is referred to the appropriate section elsewhere in this manual for details.
We are constantly adding messages to the handler's operating code. If a message you need is not listed here, please contact Exatron's Customer Service Department for prompt assistance. For free updates to the firmware, please contact the Exatron Sales Department. Not all of these messages may apply to your handler.
Topic #### OLDNEW #### 00## DATA ## - PILOT / . FULL 1 LEFT STEP 1 RIGHT STEP 2 LASER DUT ERR 2 LEFT STEPS
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Topic 2 RIGHT STEPS ALIGN MOTORS ? ALL MODES OFF ? ALL MOTOR CHECK ALL MOTORS OFF ALL OUTPUTS FULL BAD RESPONSE BAD TEST RESULT BIN # S# C#### BIN 5 S0 FLUSH CHANGE RAM ? NO CHANGE RAM ? YES CHECK BEAM TUBE? CHECK CONTACTS? CHECK SUM ERROR CHECKING LASER ? CHK OUTPUT DOOR CHK SMOKE TUBE CHK VAC ADJ COUNTS RESET 0 CPU ERROR <1-5> DIAGNOSTICS DISPLAY TOTALS DOUBLE PART ERR DUT IN LASER DUT/SHUT LOST EMPTY ALL TUBES EMPTY FLUSH TRAY EMPTY/LOAD PARTS END LASER END TEST EXATRON SUPER FAIL CHECK ## FAIL LOAD ## FAIL PROGRAM ## FAIL VERIFY ## FIRE LASER FLUSH ALL ? FLUSH TEST SITE
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Topic FULL 12345678 FULL TUBE= #### HALT!! RESTART ? HANDLER OUT CHK HANDLER PAUSED HOME OUTPUT? NO HOME OUTPUT? YES INDEX EMPTY ? INPUT 12345678 INSERTION ERROR INTERFACE CHECK INTO LASER JAM INTO SHUT(TLE) JAM INTO STAGE JAM INTO T SITE JAM IS LV PC READY ? IS THE AIR ON ? ISSUE NEW START JOG DOWN JOG LEFT JOG RIGHT JOG UP LASER CHECK LASER GATE ERR? LASER GATE OPEN LASER MARK ? / LASER MARK ? NO / YES LASER OUT CHECK LASER SIMULATOR LASER SITE JAM LIGHT POLE CHECK LOAD DEFAULT NO LOAD DEFAULT YES LOAD DEVICE ? LOAD EMPTY TUBE LOAD EPROM>RAM LOAD REMOTE RAM LOADER JAM LOADING MASTER LOOP MODE ON ?
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Topic LV SET UP ERROR MANUAL MODE MARK & CYCLE ON? MARK SITE EMPTY MEMORY ERROR MOD SET UP ? NO MOD SET UP ? YES MODEL 5000 MOTOR <A, B, C, or D> BUSY ? MOTOR <A, B, C, or D> ERROR ? MOTOR OFF MOVE MOTOR DOWN MOVE MOTOR UP MULTI SORT ERR NO OUTPUT TUBES NO RESPONSE NO SORT ERROR NO TUBES OR FULL OCTO MOTOR CHK OCTO/INDEX CHK OCTOLOADER OFF O.K. TO RUN ? # OUTPUT CLEAR ? OUTPUT GO LEFT OUTPUT GO RIGHT OUTPUT TO BIN 8 OUTPUT TUBE JAM PART IN SHUTTLE PART IN T SITE PASS PROG/PASS VERIFY PASSWORD ABC? PICK CHANGE KIT? PICK INTERFACE? PICK PACKAGE PICK UP = ##### PLUNGE = #### PROGRAM DEVICE? PROGRAM RS-232 PROGRAMMING
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Topic RAM AUTO RESET READY TO MARK READY TO RUN RESET TOTALS NO RESET TOTALS YES RS-232 CHECK RUN 1-2-3-4 PART SEN0-7 01234567 SEN8-F 89ABCDEF SENSOR CHECK SERVO IS AT ZERO SERVO MOVING ? 1 / 2 SET # INPUTS SET P/V/L MODE? SHUT 12345678 SHUTTLE EMPTY ? SHUTTLE IS LOST SHUTTLE OUT JAM SOAK = #.# SECS SOAK DELAY ON SOLENOID CHECK SORT INPUT SORT MOTOR CHK SORT RESET ERR? START 1 TEST START 2 TEST START LASER STOP MODE ON/OFF STOP MODE ON ? STOP ON FAIL ? / STOP ON FAIL NO / YES STOP ON FAIL YES SUM CHECK = SUM CHECK ERROR T0[1-8] #### ###### T SITE OUT JAM1 T SITE OUT JAM2 T SITE OVERFILL? TEST ABORTED TEST SITE EMPTY
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Topic THANK YOU TO EXIT = ##### TO SITE = ##### TOP OF TUBE JAM TOTALS SET TO 0 TRANSFER ERROR TRAY/TUBE OUT ? TUBE 12345678 TUBE CLEAR WORKS TURN ON REMOTE UART OUT ERROR VERIFY DEVICE ? VERIFYING WAITING FOR PC WAITING FOR R Z MOTOR CHECK Z MOTOR CRASH ? Z MOTOR IS UP / Z MOTOR NOT UP ZERO COUNT ERR
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#### OLDNEW ####

The handler is using the PROGRAM RS-232 interface. The handler has asked the programmer for a sum check which is displayed following the word NEW, and compared it to the sum check stored in the handler's RAM which is displayed in front of the word OLD. These two sum checks do not match. A sum check is the total of the parameter values for all the RAM addresses displayed in hex, for example: 2EFG. If this is the start of a new job, it is normal for the two sum checks to not match. In this case, if you are sure the new sum check (displayed following the word NEW) is correct, press the <ENTER> key. If the handler is in the middle of a job, and this message appears, check your programmer very thoroughly. Also check whether the handler is making good electrical contact with the programmer. If the above suggestions do not apply, the programmer's RAM may be corrupted. Stop the job. Reload all information and begin again.
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Chapter Overview
00## DATA ##
00## DATA ##
This is the Change RAM routine. Current RAM address data will be displayed where each pound sign (#) is shown above. Review the following keys for options allowed: <ENTER> Exits routine; saves parameter into RAM. <SET UP> Each time you press the <SET UP> key, the next address is displayed, as from 0090 to 0091. <TOTALS> Each time you press the <TOTALS> key, the previous address is displayed, as from 0091 to 0090 or from 0090 to 00FF. <SPACE> Increments the upper data nibble (the left digit in the parameter at the right end of the displayed address) in the current address. For example, if the current parameter is "EF", press the <SPACE> key to change the parameter to "FF". <DELETE> Increments the lower data nibble (the right digit in the parameter at the right end of the displayed address) in the current address. For example, if the current parameter is "04", press the <DELETE> key to change the parameter to "05". <-> Sets the parameter for the current address to FF. <0> Sets the parameter for the current address to 00. <CLEAR> Loads the default parameter for the current address from the EPROM into the RAM. <RUN> Toggles from the display of the address and its set parameter to the significance of the address. For example, a display of the address: 0091 DATA 02 can be toggled to PACKAGE TYPE and then toggled back to the address again.
- PILOT / . FULL
You are in Diagnostics mode under LASER CHECK. This gives you the choice of firing the laser in either pilot or full mode. <-> (minus) key fires laser in pilot (simulation) mode only <.> (period) key fires laser in full marking mode Press the <ENTER> key to return to Diagnostics mode.
1 LEFT STEP
The octoloader or shuttle has moved one tube to the left.
1 RIGHT STEP
The octoloader or shuttle has moved one tube to the right.
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2 LASER DUT ERR

The handler has dropped a marked device into the shuttle. As the device dropped, a second device was detected in the shuttle. This detection is a safety feature to prevent mis-sorts due to mechanical errors or operator mistakes. To resolve this condition: 1. Press the <CLEAR> key to flush the device(s) out of the shuttle. 2. Make sure there is no device jammed at the laser mark site. 3. Make sure devices fall freely out of the laser mark site.
2 LEFT STEPS
The motor under consideration has moved two tubes to the left.
2 RIGHT STEPS
The motor under consideration has moved two tubes to the right.
ALIGN MOTORS ?
The operator can now jog any of the handler's motorized components by one motor step at a time using the keypad keys as described below: <1> Jogs the octoloader left <3> Jogs the octoloader right <7> Jogs the shuttle left <9> Jogs the shuttle right <0> Turns off all motors: "ALL MOTORS OFF"
ALL MODES OFF ?

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

See "ALL MOTOR CHECK: Shuttle Motor Check" on page 4-33 and the sections following it for details.
ALL MOTORS OFF

You have pressed the <0> key. The power to all motors is now OFF. You can realign or move any of the motors manually. Press any handler controller key to continue.
ALL OUTPUTS FULL

The handler is waiting to sort a device but all output tubes are full. Insert an empty tube into any of the handler outputs which have flashing output cover LEDs.
BAD RESPONSE
The handler is in the EXATRON RS-232 INTERFACE mode. Proper communications between the tester and the handler must be established at the start of every test cycle. At this point, the handler is waiting for an "R" Ready, (or an asterisk, "*" for Remote Flush Command) from the tester. However, the tester has sent some response other than an "R" or an "*" and the handler is advising the operator that such response is not correct. See "EXATRON RS-232 Interface" on page 9-9 for details.
BAD TEST RESULT

The handler is in the Exatron RS-232 INTERFACE mode. If the handler receives an incorrect bin sort, the message BAD TEST RESULT is displayed. If so equipped, the handler flashes the HEX equivalent of the result received on the handler's output door LEDs. You can press the <ENTER> key to reissue a Start Test command and the handler will try a second test. You can press the <CLEAR> key to abort the test and restart operation, or send the handler an ASCII "*" or "2A" in HEX. This will automatically flush the DUT and begin a new test cycle. See "EXATRON RS-232 Interface" on page 9-9 for details.
BIN # S# C####
The shuttle is returning after properly placing a device in the output tube whose number is represented above by the pound sign (BIN #). The handler had received a sort command represented above by the pound sign (S#) from the tester/PC. The current device count in that output tube is represented above by four pound signs (C####).
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Actual numbers will be displayed in place of the pound signs on your control panel. For example, the message BIN 3 S1 C0014 indicates that the shuttle is returning after properly placing a device in output tube 3, having received a sort 1 command, and there are now 14 devices in output tube 1. The counter is for the current output tube full count only. Symbol B S C Meaning Bin, or output tube Sort: 1-8, pass or fail Count of devices in current output tube Examples B1, B8 S1, S8 C0001, C0027
The handler also keeps a TOTAL count. To obtain TOTAL counts, press the <MANUAL> key, then press the <TOTALS> key for total counts from output bin keys <1> through <8>. The tube full count rolls over at 9999 devices for output taping machine options.
BIN 5 S0 FLUSH
The handler is flushing one or more devices from the machine. This message is for the PC. It tells the PC not to count the device(s) being flushed.
CHANGE RAM ? NO
Exits routine without making any changes to the handler's RAM setup parameters. <ENTER> Exits with no changes. <SET UP> Toggles back to CHANGE RAM ? YES.
CHANGE RAM ? YES

Allows the operator to override the handler's setup parameters. <ENTER> Allows changes to the RAM. See "Changing RAM" on page 3-58 for instructions. <SET UP> Toggles back to CHANGE RAM ? NO.
CHECK BEAM TUBE?

For laser models: The laser beam tube is not fitted correctly over the laser mark site. Adjust it correctly before proceeding.
CHECK CONTACTS?
This message indicates that the Z plunger has gotten out of step and has moved too far up in the Z motor assembly. At this point, the display may read Z MOTOR CRASH ? only, or it may first read Z MOTOR CRASH ? and then blink CHECK CONTACTS?
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Chapter Overview
CHECK SUM ERROR
If the message CHECK CONTACTS? appears, the handler may have inadvertently dropped the device under test onto the contacts. Immediately check the handler contacts and remove any dropped device. If the message Z MOTOR CRASH ? only is displayed, the device has been picked up but the Z plunger and the device are now too high up. You can press the <CLEAR> key to flush all devices from the handler and start over.
CHECK SUM ERROR

The PC has sent new RAM data to the handler. The handler has calculated the check sum for the file and it does not match the check sum sent by the PC. Press the <ENTER> key to skip past this error. From the PC, stop the job and start over again.
CHECKING LASER ?
For laser models: You are in Diagnostics mode under LASER CHECK. The laser is being initialized. The next message to be displayed is - PILOT / . FULL, which gives you the choice of firing the laser in either pilot or full mode.
CHK OUTPUT DOOR

The output tube cover with LEDs is raised. Close it over the shuttle before operation can resume.
CHK SMOKE TUBE

For laser models: The handler is trying to mark a device, but the smoke tube is not installed, or not fully seated in the alignment block. Install the smoke tube and make sure it is fully seated. Press the <CLEAR> key to flush the handler and abort the laser mark process. Use Diagnostics/Sensor 8-F Check to verify that the smoke tube sensor is working correctly. See "SENSOR CHECK: Test Site Sensors 8-F for Laser" on page 4-13.
CHK VAC ADJ

The handler has tried to pick up a device and has failed to detect that the device was already suctioned up by the plunger's vacuum. To resolve this condition: 1. Press the <PAUSE> key: HANDLER PAUSED. Wiggle the plunger manually to slightly shift the device. Watch the red LED on the vacuum generator. When the LED lights up, stop wiggling the plunger. Press any key on the handler's controller. The handler will automatically resume operation if the device is now detected. 2. Verify that the vacuum line is installed from the vacuum generator to the plunger. Verify that the plunger fitting is not leaking. 3. Verify that the plunger is mechanically adjusted correctly.
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4. Pressing the <ENTER> key will skip past this error, but be cautious in selecting this option, because pressing the <ENTER> key will cycle the plunger down which may destroy the device it is holding. 5. Pressing the <CLEAR> key will flush all devices from the handler. 6. Use Diagnostics Output Check Solenoid Check <1> key to verify that the vacuum is working properly. See "OUTPUT CHECK: Solenoid Check" on page 4-22.
COUNTS RESET 0
This indicates that all output tube counts and all total counts have been reset to 0000. For your reference only.
CPU ERROR <1-5>

Any of these errors (CPU ERROR 1, CPU ERROR 2, CPU ERROR 3, CPU ERROR 4, CPU ERROR 5) are critical. The handler's control program has detected a major problem, and has stopped operation. Use the following procedure to resolve this problem: 1. Write down exactly which CPU ERROR message is displayed. 2. Write down exactly which output cover LEDs are on and whether they are flashing. 3. Write down, to the best of your knowledge, what message(s) was/were displayed by the handler just before the error. 4. Write down, to the best of your knowledge, what the handler was doing just before the error. 5. Power down the handler. 6. Power the handler back up and answer all of the MOD SET UP ? YS questions. 7. Resume handler operation. 8. FAX your notes to Exatron as soon as possible. We will answer your fax with an explanation of what occurred, and a free software update to permanently correct the cause of the problem.
DIAGNOSTICS
You have pressed the <DIAGNOSTICS> key. See "Diagnostics Quick Reference" on page 4-6 as well as the sections following it for details.
DISPLAY TOTALS
You have pressed the <TOTALS> key. You can now display any or all of the output tube total counts: <1> Output tube 1 total
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Chapter Overview
DOUBLE PART ERR
<2> Output tube 2 total <3> Output tube 3 total <4> Output tube 4 total <5> Output tube 5 total <6> Output tube 6 total <7> Output tube 7 total <8> Output tube 8 total <CLEAR> Clears the display <ENTER> Exits this routine
DOUBLE PART ERR

The handler has miscycled and placed two or more devices into the test site. Make sure you are using the correct changeover kit and that it is in good working condition. Press <CLEAR> to flush all miscycled devices into output 5. If that does not solve the problem and one of the devices then jams, pause the handler by pressing the <PAUSE> key. Remove the red thumbscrews on the changeover kit. Lift the changeover kit off the handler, and manually free the jammed device so that it slides down into output 5. Move the remaining device up to block the sensor in the test site. Replace the changeover kit and thumbscrews. Press <ENTER>, then press <CLEAR> to flush the second device into output tube 5.
DUT IN LASER
For laser models: The handler has detected a device in the laser mark site which should not be there. Press the <CLEAR> key to flush the device into output tube 5.
DUT/SHUT LOST
The handler has tried to sort a device, but the shuttle did not arrive at the correct output bin. Press the <0> key to turn off the power to all motors and manually center the shuttle at the output with the flashing LED. Press <ENTER> to restart the handler. You can also press the <CLEAR> key to center the shuttle back at output 5 and flush the handler of all devices.
EMPTY ALL TUBES

The handler has just powered up. It is detecting output tubes that may contain devices. The handler has a battery backed-up RAM which holds the current tube full count.
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Do one of the following actions: Press <ENTER> to continue operation. The handler will use its RAM count data to fill the tubes. Remove all tubes that have devices in them and then press <ENTER> to continue operation. Remove all output tubes and replace them with empty ones. CAUTION: Before pressing <ENTER>, verify that no tubes with devices were installed while the handler was off. If any devices were added at that time, the handler will overfill the tube(s).
EMPTY FLUSH TRAY

For handlers with output trays: After the input, test site, and output have been flushed of devices, this message prompts you to empty the tray row to which the devices have been flushed. Empty the devices in the tray to output tubes and then press <ENTER> to continue operation. The handler will use its RAM count data to fill the tubes.
EMPTY/LOAD PARTS
The handler has run out of devices to test. Reload any of the octoloader's input tubes and/or the output tubes. Then press <RUN> to resume operation.
END LASER
For laser models: The handler has requested an End-Of-Mark command from the PC. <ENTER> aborts the laser-mark process and sorts the device to a fail bin. <CLEAR> aborts the laser mark process and flushes both the device in the mark site and the device in the test site to the flush tube, bin 5.
END TEST
The handler is waiting for a bin signal from the tester. <ENTER> aborts the test cycle: TEST ABORTED, and sorts the device to a fail bin. <CLEAR> aborts the test cycle: TEST ABORTED, and flushes both the device in the test site and the device in the mark site to the flush tube, output bin 5.
EXATRON SUPER
See "PICK INTERFACE?" on page 5-27.
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FAIL CHECK ##
FAIL CHECK ##
Failed illegal bit check cycle. . .
FAIL LOAD ##
Failed to load master device. . .
FAIL PROGRAM ##
Failed programming cycle. . .
FAIL VERIFY ##
Failed verify cycle. . . The handler is using the PROGRAM RS-232 interface. The device has failed a given cycle of the programmer operation and will be sorted to a fail output. When any of the four messages shown above is displayed, it is followed by a two-digit number. The number at the end of the message indicates the error code reported back from the programmer. Please refer to the error code section of the programmer manufacturer's manual for error code details.
FIRE LASER
For laser models: This message is displayed only when the laser is actually firing.
FLUSH ALL ?
This message is displayed only after you have cleared a jam by pressing <Clear>. It gives you the option to empty the handler of devices in case you must turn off the motors and move the octoloader and/or shuttle around for further troubleshooting. <RUN> or <Clear> flushes all devices in all input tubes straight to output tube 5 without testing or processing. <ENTER> continues the processing cycle.
FLUSH TEST SITE

After a jam or other error, this message is displayed as all devices are flushed from the test site to the fail sort output.
FULL 12345678
One or more of the numbers shown above is displayed following the word FULL. See "SENSOR CHECK: Tube Full Sensors 1-8" on page 4-18 for details.
FULL TUBE= ####

Four digits are displayed after the word TUBE= .
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This is the number of devices the handler will place into each of the handler's output tubes. Make certain not to set the count for more devices than will fit into the handler's output tubes. See "Changing Settings" on page 3-46 and especially "Selecting Number of Devices per Output Tube" on page 3-53 for more details. Use the keypad to make your selection. The handler accepts changes to each digit from lowest to highest, in order. First enter Ones, then Tens, then Hundreds, then Thousands. For example, to place 38 devices in each output tube, press <8>, then <3>. <-> The minus key sets the count to 0000. <CLEAR> Resets to the beginning of the handler's FULL TUBE = 0045 loop. This will also reload the handler's EPROM default values. <ENTER> Confirms your selection.
HALT!! RESTART ?
You have turned off power to the pickup head motor only. To turn the motor back on and home it, press the <ENTER> key.
HANDLER OUT CHK

See "INTERFACE CHECK: Handler Port Output Check" on page 4-31 for details.
HANDLER PAUSED
You have pressed the <PAUSE> key. The handler is now in a wait loop. Nothing will occur until you press one or more of the handler controller's keys. While the handler is in Pause mode, you may be able to change certain parameters by pressing the numeric keys. Press the <ENTER> key to return to the "HANDLER PAUSED" message. Press the <RUN> key on the handler controller keypad to exit Pause Mode and return to the previous loop.
HOME OUTPUT? NO
For laser models: This refers to sending the output tube holder to its home position at the extreme left. Press the <SET UP> key to change the message to HOME OUTPUT? YES. Press the <ENTER> key if you do not want the output to move home.
HOME OUTPUT? YES

For laser models: This refers to sending the output tube holder to its home position at the extreme left.
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INDEX EMPTY ?
Press the <SET UP> key to change the message to HOME OUTPUT? NO. Press the <ENTER> key to move the output tube holder home.
INDEX EMPTY ?
No devices were found by the index sensor, or the track is empty. Check for jams at the octoloader and above the track.
INPUT 12345678
One or more of the numbers shown above is displayed following the word INPUT. See "OCTO/INDEX CHECK: Input Sensor Check" on page 4-38 for details.
INSERTION ERROR
The handler has detected a continuity error when trying to insert the device under test into the contacts. To resolve this condition: Inspect your PI contactors and clean the contact pins if necessary. Inspect your device for bent leads.
INTERFACE CHECK
See "INTERFACE CHECK: RS-232 Port Check" on page 4-27 and the sections following it for details.
INTO LASER JAM

For laser models: The handler has tried to cycle a device into the laser site, but the device did not arrive. Check for a jam along the path prior to the laser mark site. If you can clear the jam, the handler will automatically resume operation. You can also press the <CLEAR> key to flush the jammed device into output 5 and start a new cycle.
INTO SHUT(TLE) JAM

A device which has exited the test site has jammed as it arrived at the top of the output shuttle. Open the output door and visually inspect the shuttle area. Verify that the shuttle is fully seated in the handler. Securing the shuttle onto the shuttle car by pressing it down with finger pressure until it snaps into place often resolves this error condition. Close the output door and the handler will resume operation. Alternatively, the shuttle may have become slightly out of alignment with the output track. Do the following, using the photos in the section "Aligning the Changeover Kit" on page 3-19 as a guide. 1. Press the <0> key on the handler controller keypad to turn ALL MOTORS OFF.
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2. Press the <ENTER> key to display ALIGN MOTORS ? 3. Align the shuttle by: > Pressing the <7> key to jog the shuttle one step left, or > Pressing the <9> key to jog the shuttle one step right. 4. When alignment is complete, press the <RUN> key to resume operation.
INTO STAGE JAM

The handler has tried to cycle one to four devices into the stage or holding area below the test site, but a device has jammed. Clear the jammed device by pressing <CLEAR>.
INTO T SITE JAM

The handler has tried to load a device into the test site, but the device has failed to arrive. Manually clear the jammed device and the handler will automatically restart. Alternatively, press the <CLEAR> key to "thump" the test track with the top laser gate. This clears many jams common to this area. You could also press <ENTER> to try the load cycle again. However, this may cause DOUBLE PART ERR messages to appear.
IS LV PC READY ?
For laser models: The laser PC is not turned on, or communication has been lost, or the Smartist laser program is not in Work mode. See "Introduction to the Laser Software" on page 3-38 and the power-up procedure on page 3-31.
IS THE AIR ON ?
The handler is powering up or entering the run cycle. The air is on, yet the pneumatics are not being activated. Verify the following: The air compressor is on and at least 80 PSI. The air compressor is connected to the handler. The handler's air regulator is turned on, and is reading at least 80 PSI. The air line from the handler's changeover kit is plugged into one of the handler's main plate quick-disconnect ports. The changeover kit is properly plugged in and power is being supplied to the air valve. The pneumatic is not mechanically jammed.
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ISSUE NEW START
ISSUE NEW START

The handler has been instructed by the operator to send a new start-test pulse to the tester/PC. See also "SORT INPUT" on page 5-32.
JOG DOWN
The plunger has moved down one motor step, about .003".
JOG LEFT
The shuttle/octoloader has moved one motor step left, about .006".
JOG RIGHT
The shuttle/octoloader has moved one motor step right, about .006".
JOG UP
The plunger has moved up one motor step, about .003".
LASER CHECK
This troubleshoots the inputs and outputs on the laser interface board.
LASER GATE ERR?

The handler is trying to mark a device, but the top laser gate has failed to open. Check whether the top gate is jammed. Press <CLEAR> to flush the handler and abort the laser mark process. Use Diagnostics/Solenoid Check to verify that the top gate opens and closes smoothly. See "OUTPUT CHECK: Solenoid Check" on page 4-22.
LASER GATE OPEN

The handler is trying to mark a device, but the top laser gate has failed to close. Check whether the top gate is jammed. Press <CLEAR> to flush the handler and abort the laser mark cycle. Use Diagnostics/Solenoid Check to verify that the top gate opens and closes smoothly. See "OUTPUT CHECK: Solenoid Check" on page 4-22.
LASER MARK ? / LASER MARK ? NO / YES

This function allows the operator to skip the laser mark site so that devices are not marked. This selection on the handler is to be used as a convenience only because the handler cannot tell the PC to actually turn on a laser mark. The PC has true control of the laser mark, therefore we recommend that you select Laser Mark functions or turn them off from the PC. The
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handler only controls the ability to skip the mark if the mark was turned on by the PC. See "Changing Settings" on page 3-46 and especially "Selecting Laser Marking" on page 3-52 for more details. <1> = LASER MARK ? YS Directs the handler to load (good) devices into the laser mark site and mark them. <2> = LASER MARK ? NO Directs the handler to load (good) devices into the laser mark site, but skip the marking cycle. <ENTER> Confirms your selection. <CLEAR> Resets to the beginning of the handler's LASER MARK ? loop.
LASER OUT CHECK

For laser models: You are in Diagnostics mode under LASER CHECK. This troubleshoots the 8 outputs (U2) on the B84 laser interface board.
LASER SIMULATOR
For laser models: The laser is in pilot (simulation) mode.
LASER SITE JAM

The handler has tried to cycle a device into the laser site, but the device did not arrive. Check for a jam along the path prior to the laser mark site. If you clear the jam, the handler will automatically resume operation. You can press the <CLEAR> key to skip past this error and try again.
LIGHT POLE CHECK

You are in Diagnostics mode. You can check the lights on the light pole. <1> key activates green light <2> key activates yellow light <3> key activates red light <4> key activates blue light <9> key turns ON all lights <0> key turns OFF all lights <ENTER> key returns you to Diagnostics.
LOAD DEFAULT NO
Exits routine without reloading the EPROM default settings into the handler's RAM. <ENTER> exits with no changes. < SET UP> toggles back to LOAD DEFAULT YES.
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LOAD DEFAULT YES
LOAD DEFAULT YES

Allows the operator to reload the handler's RAM with settings stored in the handler's EPROM. <ENTER> loads defaults from EPROM to RAM. <SET UP> toggles back to LOAD DEFAULT NO.
LOAD DEVICE ?
See "SET P/V/L MODE?" on page 5-31.
LOAD EMPTY TUBE

An output tube was removed after the handler selected an output bin, but before the sort shuttle arrived at that tube. Place an empty tube at the output that has the flashing output cover LED.
LOAD EPROM>RAM
The handler has reloaded its RAM set-up data with settings stored in EPROM. For your reference only.
LOAD REMOTE RAM

The PC has sent new handler set-up data to the handler's RAM. Any settings previously made by the operator will be changed. No action is required, although we recommend verifying that the settings are correct after this message turns off.
LOADER JAM
The handler is detecting jammed devices at the output of the octoloader/input to the handler, although no devices are at the index section. You can do one or more of the following: Clear the jammed device(s) manually. When you have done so, the handler will automatically restart. Press the <CLEAR> key to wiggle the octoloader and possibly clear the jammed device(s). Press the <0> key to turn "ALL MOTORS OFF," then realign the octoloader plate to the handler input. Press <ENTER> to turn the motors back on. Use Diagnostics/Octo/Index Check/Input Sensor Check to verify that input sensors 6, 7, 8 are working correctly. See "OCTO/INDEX CHECK: Input Sensor Check" on page 4-38.
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LOADING MASTER
The handler is using the PROGRAM RS-232 interface. The handler is currently loading a master device into the programmer. You can press the <CLEAR> key to abort the test and sort the device to a fail tube.
LOOP MODE ON ?
Loop mode is for testing and troubleshooting of the handler. You can alternate between Stop mode and Loop mode by pressing the <1> and <2> keys, respectively. Select one of the following keypad choices. <1> = "STOP MODE ON ?" The handler will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. For operational information, see "Cycling the Handler in Stop Mode" on page 4-43. <2> = "LOOP MODE ON ?" The handler will stop after a complete cycle for one device. Each cycle ends with the pickup head above the test site, and the previous device dropped from the shuttle to an output. For operational information, see "Cycling the Handler in Loop Mode" on page 4-44. <3> = "ALL MODES OFF ?" The handler will cycle multiple devices in a normal run. This is the default. <CLEAR> = Resets to the beginning of the handler's "STOP MODE ON/OFF" loop. <ENTER> = Executes the next loop cycle.
LV SET UP ERROR
For laser models: This message is displayed briefly during normal startup. But if it continues to display, it is because the laser supply unit has not been initialized. Restart and continue.
MANUAL MODE
You have pressed the <MANUAL> key. You can now do any or all of several things: Change RAM values (page 3-58) Reset output counts (page 3-56) Modify setup ("MOD SET UP ? YES" on page 5-23 and page 3-46) You can resume automatic handler operation by pressing the <RUN> key.
MARK & CYCLE ON?

For laser models: This is one of three running modes. This is the full production mode. It marks devices as it cycles them through the handler.
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MARK SITE EMPTY
MARK SITE EMPTY

The handler control program has been directed to mark a device, but none was present at the mark site. This message indicates that the handler has either gone through an incorrect mechanical cycle, has been recently flushed, or is experiencing mechanical difficulties. The handler should self-clear and continue to operate. If this message repeats from cycle to cycle, you may need service. Contact Exatron Customer Service for assistance.
MEMORY ERROR
The handler's internal memory has failed a self-test. Replace the CPU PCB. Contact Exatron Customer Service for assistance.
MOD SET UP ? NO
Press the <SET UP> key to make changes in the handler's setup. Press the <ENTER> key if no changes to the handler's setup are required.
MOD SET UP ? YES

Press the <SET UP> key if no changes to the handler's setup are required. Press the <ENTER> key to make changes to the handler's setup. The handler will now scroll through all of the setup routines listed below. See "Changing Settings" on page 3-46 for details regarding each setup. Interface type Changeover kit/package type Stop/loop modes for troubleshooting Stopping after one device failure Pickup head distances to 3 critical sites Laser marking on/off Number of devices per output tube
MODEL 5000
Power-up message; no action required.
MOTOR <A, B, C, or D> BUSY ?

The handler is checking to see if the stepper motor is moving as required for each of the following handler components. A = shuttle B = plungertop test site C = octoloader D = plungerbottom test site
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If this message does not go away within a few seconds, the handler will not operate. To resolve this condition: 1. Turn the handler power OFF then ON and try again. 2. Check whether the motor setting address in RAM is correct: > RAM ADDRESS 0091 07 for single test site handlers > RAM ADDRESS 0091 0F for dual test site handlers 3. Verify that the motor control cable is plugged in and is not broken. 4. Replace the motor driver module and/or the motor control PCB. 5. Contact Exatron for assistance and replacement parts.
MOTOR <A, B, C, or D> ERROR ?

The handler is checking to see if the stepper motor is powering up properly as required for each of the following handler components. A = shuttle B = plungertop test site C = octoloader D = plungerbottom test site
If this message does not go away within a few seconds, the handler will not operate. To resolve this condition: 1. Turn the handler power OFF then ON and try again. 2. Check whether the motor setting address in RAM is correct: > RAM ADDRESS 0091 07 for single test site handlers > RAM ADDRESS 0091 0F for dual test site handlers 3. Verify that the motor control cable is plugged in and is not broken. 4. Replace the motor driver module and/or the motor control PCB. 5. Contact Exatron for assistance and replacement parts.
MOTOR OFF
The stepper motor being checked is now off.
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MOVE MOTOR DOWN
MOVE MOTOR DOWN

The plunger motor has moved downward.
MOVE MOTOR UP
The plunger motor has moved upward.
MULTI SORT ERR

The handler is at the end of the test cycle. More than one sort command from the tester has been received. The output cover LEDs flash the sorts that were received by the handler. Check whether your tester is working correctly. Check your interface cables for short-circuited connections. Press the <ENTER> key to ISSUE NEW START and to clear the handler's input latch. If you are using an Exatron LED Checker as a simulator, make sure that only one DIP switch is turned on. Be sure that previous tester Sort signals are reset to Off before the end of the handler's next Start pulse.
NO OUTPUT TUBES
The handler is trying to sort a device to an output tube, but no tubes are available. Check the handler's output cover and insert an empty tube at any output(s) with a flashing output cover LED.
NO RESPONSE
The handler is in the Exatron RS-232 INTERFACE mode. Proper communications between the tester and the handler must be established at the start of every test cycle. At this point, the handler is waiting for an "R" Ready, (or an asterisk, "*" for Remote Flush Command) from the tester. However, the tester has not sent a response. NO RESPONSE will alternate with the message, WAITING FOR R, once every second. See "EXATRON RS-232 Interface" on page 9-9 for details.
NO SORT ERROR
The handler is trying to bin a device, but no End Of Test sort has been received. Check the PC's set-up data to verify whether the handler sorts and handler bins are correctly set up. Press the <ENTER> key to skip past this error and try again.
NO TUBES OR FULL
The handler is waiting to sort a device to an output tube, but the tube is full or missing. Check the output cover LEDs and insert an empty tube at any outputs with a flashing output cover LED.
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OCTO MOTOR CHK

See "ALL MOTOR CHECK: Octoloader Motor Check" on page 4-36.
OCTO/INDEX CHK
See "OCTO/INDEX CHECK: Shuttle Solenoid Check" on page 4-37 and "OCTO/INDEX CHECK: Input Sensor Check" on page 4-38.
OCTOLOADER OFF
This message is displayed only if the RAM address for Octo 4/8 Tubes has been set to No Octoloader. In this case, you can either drop one device at a time down the open octoloader track (for troubleshooting purposes), or you can place a tube full of devices at the open octoloader track. In Run mode, it will process all the devices in that tube, but the octoloader will not move to a different input tube.
O.K. TO RUN ? #
A number from 1 to 8 is displayed in place of the pound sign. The handler has just exited a jam-clearing cycle. Press the <RUN> key or the <ENTER> key to continue. The number displayed with O.K. TO RUN ? indicates the location where the stop occurred in the handler's operation.
OUTPUT CLEAR ?
If a device has jammed at the top of the output tube and you cleared it manually, this message may be displayed. If so, press <ENTER> to begin the run again.
OUTPUT GO LEFT
For laser models: The output tube holder is moving 1 output tube to the left.
OUTPUT GO RIGHT
For laser models: The output tube holder is moving 1 output tube to the right.
OUTPUT TO BIN 8
You have directed the output tube holder to move to its home position, and it is moving there. At its home position, tube 8 is at the bottom of the track. and will receive devices. When the output tube holder has finished moving home, the message changes to AT LIMIT SWITCH.
OUTPUT TUBE JAM

The handler has sorted a device to an output tube whose LED is now flashing. The device is jammed at the top of the tube.
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PART IN SHUTTLE
Either clear the jam manually by pressing the shuttle solenoid override button to the right of the output tube holder (Figure 4-18 on page 4-37), or remove the output tube and insert an empty tube.
PART IN SHUTTLE
The handler has detected a device in the shuttle that should not be there. The handler will automatically flush the device to output tube 5.
PART IN T SITE
The handler has detected a device in the test site that should not be there. Press the <CLEAR> key to flush the device into output tube 5.
PASS PROG/PASS VERIFY

The handler is using the PROGRAM RS-232 interface. The device under test has passed the programmer's program/verify cycles. The current sum check will be displayed at the end of the above messages.
PASSWORD ABC?
The password security is turned on. Enter a 3-digit password with the numeric keys. The factory-set password is 123, entered by pressing <1> <2> <3>.
PICK CHANGE KIT?

The handler is asking you to make one of the following selections. See "Changing Settings" on page 3-46 and especially "Selecting Changeover Kit" on page 3-50 for more details. <1> = DIP changeover kit (accepts only DIP package in various lengths). <2> = Type 5B changeover kit (accepts multiple packages, except DIP). <3> = Type 5C changeover kit (accepts multiple packages, except DIP). <CLEAR> Resets to the beginning of the handler's PICK CHANGE KIT? loop. <ENTER> Confirms your selection.
PICK INTERFACE?
The handler is asking you to select one of the following three interface choices. See "Changing Settings" on page 3-46 and especially "Selecting Interface" on page 3-49 for more details. <1> = EXATRON RS-232. See "EXATRON RS-232 Interface" on page 9-9. <2> = HANDLER PORT. See "TTL Handler Port Interface" on page 9-5. <3> = PROGRAM RS-232. Use this interface to connect the handler directly to the programmer according to the following limitations:
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The programmer must be in REMOTE CONTROL. The programmer must be set up manually using the programmer's terminal software. There is no Exatron PC control with this interface. It is not possible to laser mark while using this interface. <5> = CYCLE ONLY NO T(est). Use this interface when checking the handlers device cycling. <CLEAR> Resets to the beginning of the handler's PICK INTERFACE? loop. <ENTER> Confirms your selection.
PICK PACKAGE
The handler is asking you to make one of the following selections. See "Changing Settings" on page 3-46 and especially "Selecting Device Package" on page 3-49 for more details. <1> = "8-PIN NB-SOIC." <2> = "16-PIN WB-SOIC." <3> = "16-PIN NB-SOIC." <4> = "QUAD SOIC 5000." NOTE: If your handler uses a quad tester, select the "QUAD SOIC 5000" option! <CLEAR> Resets to the beginning of the handler's PICK PACKAGE loop. <ENTER> Confirms your selection.
PICK UP = #####
A five-digit number is displayed following PICK UP =. This refers to the number of motor steps required to move the pickup head from its home position to a position directly over the pickup site. See "Changing Settings" on page 3-46 and especially "Setting Pickup Head Distances" on page 3-52 for more details.
PLUNGE = ####
A four-digit number is displayed following PLUNGE =. This refers to the number of motor steps required to move the plunger to place the DUT into the handler's PI contacts. Each step of the motor is approximately .003". 0320 is the factory default setting, although the number of steps is adjustable. Be careful not to drive the DUT too far into the handler's contacts. The device's leads probably will not be bent, but you will cause handler contact/device jams to occur. In addition, the life of the handler's contacts will be decreased if too much plunge is used.
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PROGRAM DEVICE?
Use the keypad to make your selection. The handler accepts changes to each digit from lowest to highest, in order. First enter Ones, then Tens, then Hundreds, then Thousands. <-> The minus key sets the count to 0000. <CLEAR> Resets to the beginning of the handler's PLUNGE = 0320 loop. This will also reload the handler's EPROM default values. <ENTER> Confirms your selection.
PROGRAM DEVICE?
See "SET P/V/L MODE?" on page 5-31.
PROGRAM RS-232
See "PICK INTERFACE?" on page 5-27.
PROGRAMMING
The handler is using the PROGRAM RS-232 interface. The handler is currently programming a device with the programmer. You can press the <CLEAR> key to abort the program/test and sort the device to a fail tube.
RAM AUTO RESET

The handler has detected errors in its RAM and automatically reloaded its RAM with defaults stored in EPROM. This should occur very rarely or after unexpected power line interruptions. Replace the CPU PCB if this message appears frequently.
READY TO MARK
For laser models: The handler is ready to run; press the <ENTER> key to operate.
READY TO RUN
The handler is ready to run; press the <ENTER> key to operate.
RESET TOTALS NO
The current tally of devices sent to each output tube remains in memory even when the handler is turned off. Totals for each tube are displayed as a result of pressing <TOTALS> and then the number key for the corresponding output tube. Exits routine without resetting all tube output total counts to zero. <ENTER> Exits with no changes. <SET UP> Toggles back to RESET TOTALS YES.
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RESET TOTALS YES

<ENTER> The current tally of devices sent to each output tube is reset to zero as the message "TOTALS SET TO 0" is displayed. See "Resetting Totals" on page 3-56 for instructions. <SET UP> Toggles back to RESET TOTALS NO.
RS-232 CHECK
See "INTERFACE CHECK: RS-232 Port Check" on page 4-27.
RUN 1-2-3-4 PART

You have entered the MOD(ify) SET UP routine. Here you can select the number of devices to be tested simultaneously. See "Selecting Tray or Tube Output" on page 3-54.
SEN0-7 01234567
One or more of the numbers shown above is displayed following SEN0-7, indicating the sensors above the test site that are activated. See "SENSOR CHECK: Test Site Sensors 0-7" on page 4-12.
SEN8-F 89ABCDEF
One or more of the numbers/letters shown above is displayed following the phrase SEN8-F, indicating either the laser sensors or the quad test site sensors that are activated. See "SENSOR CHECK: Test Site Sensors 8-F for Laser" on page 4-13 or "SENSOR CHECK: Test Site Sensors 8-F for Quad Tester" on page 4-14.
SENSOR CHECK
See the sections from "SENSOR CHECK: Test Site Sensors 0-7" on page 4-12 through "SENSOR CHECK: Tube Present Sensors 1-8" on page 4-20.
SERVO IS AT ZERO
You have sent a command to home the pickup head. When it reaches home position, this message is displayed. Then the pickup head moves back down to the pickup site, ready to get a device.
SERVO MOVING ? 1 / 2
You have entered another move command while the pickup head motor is moving. 1 = Servo is moving away from home. 2 = Servo is moving toward home.
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SET # INPUTS
SET # INPUTS
You have entered the MOD(ify) SET UP routine. Here you can select either a 4-tube input or an 8-tube input. Alternatively, you can turn the octoloader off and feed in one device at a time for troubleshooting purposes. See "Changing Settings" on page 3-46 and especially "Selecting Number of Input Tubes" on page 3-51 for more details. <4> = 4 TUBE INPUT. <8> = 8 TUBE INPUT. <3> = OCTOLOADER OFF. <CLEAR> Resets to the beginning of the handler's SET # INPUTS loop. <ENTER> Confirms your selection.
SET P/V/L MODE?

The handler is asking you to select a programming operation. This question is only used when the PROGRAM RS-232 interface is selected. Choose one of the following operations: <1> = PROGRAM DEVICE? Sets the handler to bit check and Program the device in the handler. <2> = VERIFY DEVICE ? Sets the handler to Verify the device in the handler. <3> = LOAD DEVICE ? Sets the handler to Load data from the device to the programmer RAM. <CLEAR> Resets to the beginning of the handler's SET P/V/L MODE? <ENTER> Confirms your selection.
SHUT 12345678
One or more of the numbers shown above is displayed following SHUT, indicating the shuttle position sensors that are activated. See "SENSOR CHECK: Shuttle Position Sensors 1-8" on page 4-15.
SHUTTLE EMPTY ?
The handler was expecting a device to be in the shuttle, but none is detected. There has been a miscycle or a flush cycle. Press <CLEAR> to flush devices from the test site through the shuttle.
SHUTTLE IS LOST
The handler has tried to center the shuttle back to the Home bin, output 5, without success. Press the <0> key to turn off the motors. Manually center the shuttle at output 5. Press the <ENTER> key to resume handler operation.
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SHUTTLE OUT JAM

The handler has tried to sort a device. The device is jammed at the output of the shuttle. Verify that the output tube is not overfilled. Manually clear the jam and the handler will automatically restart. Or you can press the <CLEAR> key to wiggle the output shuttle and possibly free the jammed device.
SOAK = #.# SECS

For hot rail models: At the end of the startup routine, this message is displayed to show the length of time each device spends in the hot rail while waiting to be tested. You can change the length of time by using the Polish notation. If you enter an erroneous value, press <Clear>, <5>, <0> to restore the default and start over. The default soak time is 0.5 seconds.
SOAK DELAY ON
For hot rail models: During a production run this message alternates with the output status message. This refers to the time each device spends in the hot rail while waiting to be tested.
SOLENOID CHECK
See "OUTPUT CHECK: Solenoid Check" on page 4-22.
SORT INPUT
After the handler has sent a new start-test pulse to the tester/PC, it waits for an end-of-test sort signal. If none is received, the message SORT INPUT is displayed. See also "ISSUE NEW START" on page 5-19.
SORT MOTOR CHK

See "ALL MOTOR CHECK: Shuttle Motor Check" on page 4-33.
SORT RESET ERR?

The handler has sent a start test pulse out of the Handler Control Port. One or more of the input sorts remained low. All input sorts must return to logic high within 100 msec of the handler issuing a start test pulse. You can turn this check ON or OFF by changing the handler's RAM: 00A6 00 Sort reset check ON 00A6 FF Sort reset check OFF
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START 1 TEST
You can press the <ENTER> key so that the handler will ISSUE NEW START. This may reset the input signals and allow the handler to continue operation. NOTE: Turning off the sort check will allow the handler to be cycled with an Exatron LED Checker, but it may also cause the handler to missort by using previous cycle sort information from testers with poor interface controls. We recommend leaving this check ON.
START 1 TEST
The handler has issued a Start Test command to the PC.
START 2 TEST
The handler has detected a failure on the first test and is attempting to double-test the device. A second Start Test command, possibly more, has been sent to the PC.
START LASER
The handler has sent a Start Laser Mark command to the PC.
STOP MODE ON/OFF

You have entered the MOD(ify) SET UP routine. Stop and loop modes are for testing and troubleshooting of the handler. Select one of the following keypad choices. <1> = "STOP MODE ON ?" The handler will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. For operational information, see "Cycling the Handler in Stop Mode" on page 4-43. <2> = "LOOP MODE ON ?" The handler will stop after a complete cycle for one device. Each cycle ends with the pickup head above the test site, and the previous device dropped from the shuttle to an output. For operational information, see "Cycling the Handler in Loop Mode" on page 4-44. <3> = "ALL MODES OFF ?" The handler will cycle multiple devices in a normal run. This is the default. <CLEAR> = Resets to the beginning of the handler's "STOP MODE ON/OFF" loop. <ENTER> Confirms your selection.
STOP MODE ON ?
You are in Stop mode. Stop and loop modes are for testing and troubleshooting of the handler. Select one of the following keypad choices.
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<1> = "STOP MODE ON ?" The handler will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. Press <ENTER> or <RUN> when you are ready to execute the next action. For operational information, see "Cycling the Handler in Stop Mode" on page 4-43. <2> = "LOOP MODE ON ?" The handler will stop after a complete cycle for one device. Each cycle ends with the pickup head above the test site, and the previous device dropped from the shuttle to an output. For operational information, see "Cycling the Handler in Loop Mode" on page 4-44. <3> = "ALL MODES OFF ?" The handler will cycle multiple devices in a normal run. This is the default. <ENTER> Executes the next Stop mode action.
STOP ON FAIL ? / STOP ON FAIL NO / YES

You have entered the MOD(ify) SET UP routine. The handler is asking if you want it to stop after every device that fails. While this may be useful in troubleshooting, the default is not to stop. See "Changing Settings" on page 3-46 and especially "Selecting Stops at Each Failure" on page 3-51 for more details. <1> = STOP ON FAIL YES. Handler will stop after every fail. <2> = STOP ON FAIL NO. Handler will send every fail to bin 5. <CLEAR> Resets to the beginning of the handler's STOP ON FAIL ? loop. <ENTER> Confirms your selection.
STOP ON FAIL YES

The handler is in the STOP ON FAIL YES mode, that is, stopped with the plunger down and a device in the test site. The handler stopped because it received a "fail" at the end of the test. You can do one of several things: You can press the <ENTER> key to proceed past the stop. You can press the <CLEAR> key to flush the device out of the test site. You can press the <1> key to pick up the device, reseat it and test it again. If the part passes this time, operation will continue. If the part fails, then the handler will again STOP ON FAIL. You can press the <2> key to test the device again, without removing it from the contacts. If the part passes this time, operation will continue. If the part fails, then the handler will again STOP ON FAIL.
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Chapter Overview
STOP ON FAIL YES
You can press the <3> key. The handler display will read: PLUNGE = 0320. This refers to the number of steps the plunger will move when placing the DUT into the handler's PI contacts. Each step of the motor is approximately .003". 0320 is the factory default setting, although the number of steps is adjustable. Be careful not to drive the DUT too far into the handler's contacts. The device's leads probably will not be bent, but you will cause handler contact/device jams to occur. In addition, the life of the handler's contacts will be decreased if too much plunge is used. Use the keypad to make your selection. The handler accepts changes to each digit from lowest to highest, in order. First enter Ones, then Tens, then Hundreds, then Thousands. <-> The minus key sets the count to 0000. <CLEAR> Resets to the beginning of the handler's PLUNGE = 0320 loop. This also reloads the handler's EPROM default values. <ENTER> Confirms your selection. You can press the <4> key. This will cause the handler to move the plunger up one step, about .003". You can press the <6> key. This will cause the handler to move the plunger down one step, about .003". You can press the <7> key. This key only operates when the PROGRAM RS-232 interface has been selected. The handler will display SET P/V/L MODE? Select one of the following operations: <1> = PROGRAM DEVICE? Sets the handler to bit check and program the device in the handler. <2> = VERIFY DEVICE ? Sets the handler to verify the device in the handler. <3> = LOAD DEVICE ? Sets the handler to load data from the device to the programmer RAM. <CLEAR> Resets to the beginning of the handler's "STOP ON FAIL ?" loop. <ENTER> Confirms your selection. You can press the <8> key. The handler will display STOP ON FAIL ? Choose to make the handler either stop on fail or continue operation. If STOP ON FAIL YS is chosen, then the handler will stop operation at every DUT test failure the handler receives. The handler provides many helpful troubleshooting operations while the DUT is in the contacts and STOP ON FAIL is displayed by the handler: <1> = STOP ON FAIL YS. Stop on fail is now ON.
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<2> = STOP ON FAIL NO. Stop on fail is now OFF. <CLEAR> Resets to the beginning of the handler's "STOP ON FAIL ?" loop. <ENTER> Confirms your selection.
SUM CHECK =
Four alphanumeric characters will be displayed following the message shown above. The handler is using the PROGRAM RS-232 interface. The handler has just completed a successful data load of a master device into the programmer's RAM. The handler is displaying the sum check reported back from the programmer.
SUM CHECK ERROR

The handler is using the PROGRAM RS-232 interface. The handler has asked the programmer for the current sum check, and an error was detected. Check the programmer set-up. You can press <ENTER> to skip past this error and try again. Or you can press <CLEAR> to flush the handler of all devices.
T0[1-8] #### ######

You have pressed the <TOTALS> key and then the number key for the bin whose totals you want to view. The first set of digits (01, 02,...07, 08) refers to the output bin number. The second set of 4 digits refers to the output count to that bin since the tube was last changed. The third set of 6 digits refers to the output total to that bin since the count was last reset.
T SITE NOT FULL

Fewer than the required number of devices have dropped into the test site in the case of a handler using a quad tester. The octoloader will keep moving and searching for input devices. Press the <CLEAR> key to flush the handler.
T SITE OUT JAM1

The handler is attempting to move a device out of the test site and into the mark site/shuttle. The device has failed to arrive. You can do any of the following. Inspect the output of the plunger for a jammed device. If you manually clear the jam, the handler will automatically restart. Press the <CLEAR> key to flush the handler. Press the <MANUAL> key to stop the operation and enter Manual Mode.
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Chapter Overview
T SITE OUT JAM2
T SITE OUT JAM2

If the handler is equipped with a second test site, it is attempting to move a device out of the second test site and into the mark site/shuttle. The device has failed to arrive. Follow the instructions in T SITE OUT JAM1.
T SITE OVERFILL?
More than the allowed number of devices have dropped into the test site. In the case of a handler using a quad tester, 5 devices have dropped to the test site. Press the <CLEAR> key to flush the handler. In the case of a quad tester, after pressing <CLEAR>, empty the outputs and the handler will restart.
TEST ABORTED
The handler has been instructed by the operator to abort a test before the end of the test/program cycle. The device in the test head will be sorted to a fail tube.
TEST SITE EMPTY

This may occur in the act of flushing devices or after an input tube has been emptied. While the octoloader is searching for another tube with devices, the handler continues to process devices that have exited the input tube. If no more devices reach the test site before the handler finds another input tube of devices, this message is displayed. Replace tubes and press <ENTER> to continue.
THANK YOU
One or more identifier numbers or characters are displayed following the words THANK YOU. The handler is exiting a jam routine correctly. The handler will resume operation at the end of the two-second THANK YOU delay. If your handler is displaying excessive THANK YOU messages, contact Exatron and report the number displayed with the THANK YOU message. This number indicates what part of the program the handler was in just prior to displaying THANK YOU. Some examples include: ID E F H R U LED output cover closed Output tubes replaced Output tube replaced After "EMPTY/LOAD PARTS" prompt and octoloader jam cleared Output tube replaced Significance
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ID 6
Significance Handler restarted after pause w/ pickup at test
TO EXIT = #####
A five-digit number is displayed following TO EXIT =. This refers to the number of motor steps required to move the pickup head from its home position to a position directly over the tracks exit site. See "Changing Settings" on page 3-46 and especially "Setting Pickup Head Distances" on page 3-52 for more details.
TO SITE = #####
A five-digit number is displayed following TO SITE =. This refers to the number of motor steps required to move the pickup head from its home position to a position directly over the test site. See "Changing Settings" on page 3-46 and especially "Setting Pickup Head Distances" on page 3-52 for more details.
TOP OF TUBE JAM

The handler has detected an overfilled output tube. Check the output cover LEDs. Remove the output tube where the LED is flashing and replace it with an empty tube. If the problem continues, enter Diagnostics Mode and verify that all of the output sensors are working correctly.
TOTALS SET TO 0
This message is displayed after you have reset to zero the current tally of devices sent to each output tube. See "RESET TOTALS YES" on page 5-30.
TRANSFER ERROR
The PC is attempting to send remote RAM data to the handler, but there has been a data transfer error. Turn the handler OFF, then ON and try again.
TRAY/TUBE OUT ?
This message is displayed only if the RAM address for Set Tray/Tube has been set to Operator Choice. <1> = USE TUBE OUTPUT. <2> = USE TRAY OUTPUT. <ENTER> Confirms your selection.
TUBE 12345678
One or more of the numbers shown above is displayed following the word TUBE, indicating the Tube Present sensors that are activated. See "SENSOR CHECK: Tube Present Sensors 1-8" on page 4-20.
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Chapter Overview
TUBE CLEAR WORKS
TUBE CLEAR WORKS

After you remove a tube in Diagnostics/Sensor Check mode, this message is displayed briefly to confirm that the sensor works, before the message "TUBE " is again displayed with the number of that tube missing. See "TUBE 12345678" and "SENSOR CHECK: Tube Present Sensors 1-8" on page 4-20.
TURN ON REMOTE
The handler is using the PROGRAM RS-232 interface. The handler is attempting to communicate with the programmer and cannot obtain a correct answer. Verify all of the following: The programmer is turned on. The RS-232 cable is connected from the handler's RS-232 port directly to the programmer's RS-232 port (labeled "Handler" on Autosites). This interface does not use the PC, except as a terminal to set up the programmer at the start of a job. The programmer is in "Computer Remote Control." The programmer's baud rate is set to 9600. The programmer's port setup is: 1 stop, 8 bits, no parity.
UART OUT ERROR

The handler's UART (a CPU chip) has detected an error. Turn the handler OFF, then ON and try again. If the problem continues, replace the handler's 8085A CPU PCB, Exatron part #3000-055.
VERIFY DEVICE ?
Please refer to SET P/V/L MODE? message earlier in this section.
VERIFYING
The handler is using the PROGRAM RS-232 interface. The handler is currently verifying a device with the programmer. You can press the <CLEAR> key to abort the test process and sort the device to a fail tube.
WAITING FOR PC
The handler is using either the EXATRON SUPER or LASER MARK ONLY interface. A device is in the handler's index section. The handler has sent a "Go" command to the PC but no answer has been received. From the PC, load and run a job. <Please review the Power Up Procedure with Explanation in Chapter 3 of this manual for the correct job start procedure.>
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WAITING FOR R
The handler is in the Exatron RS-232 INTERFACE mode. Proper communications between the tester and the handler must be established at the start of every test cycle. At this point, the handler is waiting for an "R" Ready, (or an asterisk, "*" for Remote Flush Command) from the tester. If an "R" is received, the handler will close the contacts or plunge the device onto the contacts, and no operator action is required. Please refer to Chapter 2, Interface Information, for further details.
Z MOTOR CHECK
See Chapter 4.
Z MOTOR CRASH ?
This message indicates that the Z plunger has gotten out of step and has moved too far up in the Z motor assembly. At this point, the display may read Z MOTOR CRASH ? only, or it may first read Z MOTOR CRASH ? and then blink CHECK CONTACTS? If the message CHECK CONTACTS? appears, the handler may have inadvertently dropped the device under test onto the contacts. Immediately check the handler contacts and remove any dropped device. If the message Z MOTOR CRASH ? only is displayed, the device has been picked up, but the Z plunger and the device are now too high up. You can press the <CLEAR> key to flush all devices from the handler and start over. If necessary, perform the Self Adjust Z procedure described in Chapter 4, Diagnostics.
Z MOTOR IS UP / Z MOTOR NOT UP

If the message Z MOTOR NOT UP is displayed, the Z plunger has not arrived at its upper limit stop switch as required. The operator can use the following options to correct this situation: <ENTER> The handler tries again to locate the upper limit switch. <Diagnostics> The handler enters Diagnostics Mode. Please refer to Chapter 4, ALL MOTOR CHECK: Test Site Plunger Motor Check for further details. <CLEAR> The handler aborts this error loop. <0> The handler turns off the Z motor only. The display reads: MOTOR OFF. To turn the Z motor back on, press the <ENTER> key. <1> or <7> The Z motor jogs up one step. <3> or <9> The Z motor jogs down one step. <4> The Z motor jogs up 80 steps. <6> The Z motor jogs down 80 steps.
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Chapter Overview
ZERO COUNT ERR
When the plunger does arrive at the upper limit stop switch, the displayed message will change to Z MOTOR IS UP. To verify that the stop switch is actually working correctly and not causing Z MOTOR NOT UP messages in error, toggle the stop switch by moving the plunger away from and then back to the stop switch. Exatron recommends the following method: 1. Push the Z plunger down manually or press the <6> key to jog the Z motor down 80 steps. 2. Press the <ENTER> key to automatically locate the Z limit stop switch and restart the handler.
ZERO COUNT ERR

The operator has set the output tube full quantity to 0000. Set the count for more than 0000. See "FULL TUBE= ####" on page 5-15.
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Chapter Overview
This chapter discusses the following maintenance tasks and their frequency: Task Cleaning the Handler Checking Motor Serial Cables Air Regulator Maintenance Checking Incoming Air from the House Supply Checking the Moisture/Dirt Trap in the Air Regulator Checking the Air Regulator Shutoff Valve Adjusting Air Pressure on the Regulator Adjusting Air Valves Solenoid Maintenance Fiberoptic Photoelectric Sensor Guidelines Recommended Frequency Daily As needed As needed Monthly Monthly Monthly As needed As needed As needed As needed Page 6-1 6-2 6-3 6-3 6-3 6-6 6-8 6-9 6-10 6-11
Preventive maintenance on the Model 5000 is fairly simple. Following this schedule will help to assure your Model 5000 handler will continue to perform properly. CAUTION: Do not lubricate any lead screws! Lubricating the screws will void the warranty. CAUTION: Do not use any cleaners or solvents on any bearings or lead screws! CAUTION: Always power off the system before doing any maintenance.
Cleaning the Handler

Include the following in a daily cleaning routine for longer trouble-free operation: Using clean, dry, oil-free compressed air, blast dust and debris from every surface of the handler, from top to bottom, front and back. Verify that the handler is free of all loose devices, pins, screws, and other small objects, especially in the shuttle area.
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Wipe the pickup heads lead screw with a clean, lint-free cloth. Clean metal trackwork with a cotton swab dipped in isopropyl alcohol or other evaporative cleaning agent that leaves no residue. Allow each area to dry before moving components or devices over it.
Checking Motor Serial Cables

The motors on the Model 5000 are attached to the system via short serial cables. Check that these cables are plugged in tightly to the CPU box, and the DB-9 connectors are securely screwed to the motors themselves.
Figure 6-1: Serial Cables
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Air Regulator Maintenance
Checking Incoming Air from the House Supply

Most Exatron handlers use compressed air, which also requires an air regulator. A high quality air regulator with coalescing air filter and shutoff valve is supplied on your handler. It supplies air at the pressure you specify for the whole handler. CAUTION: NEVER operate any Exatron equipment which requires compressed air without an approved air regulator and shutoff valve. The external air regulator assembly includes one or two oil/water particulate traps which should be visually inspected on occasion. This regulator should be set at factory air pressure of 80 PSI. The system requires a minimum of 80 PSI to operate properlyspecifically, to generate sufficient vacuum through the venturi to pick up devices from the trays. The incoming air line exits the regulator and splits to supply the vacuum generator and the internal air regulator/test site manifold.
Checking Incoming Air from the House Supply

The first step in ensuring a trouble-free air supply is to ensure the incoming air is adequate. Make sure the incoming air supply is at least 3 CFMs (cubic feet per minute). Make sure the needle on the handlers air regulator is not spiking or pulsing. If it is, the house air supply is inadequate.
Checking the Moisture/Dirt Trap in the Air Regulator

Check the moisture/dirt trap on the air regulator and the coalescing filter chamber. Verify that they are clean, empty and dry. There should be no oil and no water in any chamber. If they are dirty, physically disconnect the incoming air pressure supply from the air regulator and clean the trap and filter as needed. Excessive moisture and/or particulate buildup in the filter traps suggests the air supply to the system is too wet and/or dirty. CAUTION: Excessive moisture in the system can damage the vacuum generator and air valves.
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Figure 6-2: SMC Air Regulator
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.
Figure 6-3: Small Black Screw Removed
2. Unscrew the metal casing.
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Checking the Moisture/Dirt Trap in the Air Regulator
Figure 6-4: Metal Casing Unscrewed
3. Snap off the clear glass casing.
Figure 6-5: Clear Glass Casing Snapped Off
4. Unscrew the black inner screw that has edges like propeller blades.
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Figure 6-6: Large Black Inner Screw Removed
5. Remove the white filter and clean or replace if necessary, and reassemble in reverse order. If you find it necessary to clean the trap and/or filter more often than once a month, you should correct the problem at your in-house air compressor. Check your manufacturers manual for the exact procedure necessary.
Checking the Air Regulator Shutoff Valve

Check the operation of the shutoff valve once a month. To check the operation of the shutoff valve: 1. Turn the Off/On switch off and verify that the air is indeed off. Turn the switch back on. 2. Check the PSI setting. > Some special-case changeover kits may require less than 80 PSI. However, in general, set the air regulator to 80 PSI. If the air regulator is turned off, turn it on by turning the Off/On switch one quarter-turn counterclockwise. You can leave the air regulator turned on except when you are checking its operation.
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Checking the Air Regulator Shutoff Valve
Adjustment knob On/off switch in OFF position On/off switch in ON position
Figure 6-7: SMC Air Regulator Turned Off (Left), On (Right)
Adjustment valve On/off switch in ON position
Figure 6-8: SMC Air Regulator Turned OnAnother Type
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On/off switch in OFF position
Figure 6-9: SMC Air Regulator Turned Off
Adjusting Air Pressure on the Regulator

You can increase air pressure at the air regulator. To adjust the air pressure: 1. Pull up on the black adjustment knob above the display, and turn it. > Turn it clockwise to increase the pressure. > Turn it counterclockwise to decrease the pressure. 2. Push the knob back down to lock it when you have finished the adjustment.
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Adjusting Air Valves

Pressurized air for the air cylinders at the test sites is controlled by a series of 24-volt DC air valves mounted on a manifold block. Each air valve is wired through an override button which will turn the valve on while it is pressed (Figure 6-10). Air flow control adjustment knob Lock nut
Figure 6-10: Air Valves with Control Adjustment
To adjust the air flow at the air valve: 1. Turn the lock nut counterclockwise to unlock the adjustment knob. 2. Turn the air flow control adjustment knob: > Turn the knob clockwise to lessen the air flow, or... > Turn the knob counterclockwise to increase air flow. 3. When air flow is appropriate, turn the lock nut clockwise to tighten it.
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Solenoid Maintenance
CAUTION: NEVER use oil or lubricant of any kind on solenoids. Keep the solenoids as clean as possible. If the handler is used with devices that have excessive mold flash, the solenoids will require cleaning regularly. The frequency is dependent upon how much mold flash gets into the solenoids. When cleaning solenoids, take care not to put excessive stress on solenoid wiring. Check all wiring for signs of wear, exposed conditions, or broken connections. Replace as needed with identical type of wire: standard or flex, same gauge, insulation, color, etc. When cleaning solenoids, check the plungers to be sure there are no burrs of any kind on their shafts. Solenoid life is proportional to the handler environment and how often the solenoids are cleaned. We recommend that all solenoids be replaced every two million cycles as part of a good preventive maintenance program. Replace any bent or damaged solenoid return springs with new parts from the Exatron factory. Refer to the hardware specifications in the Parts List for the part numbers of all solenoids and springs in your handler.
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Fiberoptic Photoelectric Sensor Guidelines
Fiberoptic Photoelectric Sensor Guidelines

Each sensor on your handler is connected to a sensor controller, which displays whether the sensor is "seeing" any object. Most fiberoptic sensor controllers are set to L-ON (light on) by Exatron. This causes the output transistor to turn on when light is received by the sensor.
Figure 6-11: Sensor Controller Set to L-ON
Figure 6-12: Green and Red Indicator Lights
The green light is the Stable Operation Indicator. When the sensor is operating normally under stable conditions, the green light should be ON. The red light is the Light Reception Indicator. When the sensor is receiving light, the red light should be ON.
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Figure 6-13: Conditions of Indicator Lights
For both types of sensor (through-beam and reflective), the red light on means nothing is there; nothing is blocking or reflecting the sensor beam. If the red light is off, something is there, interfering with the sensor beam. For information on fine-tuning the fiberoptic photoelectric sensor and controller, see the vendors manual.
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Chapter Overview
This chapter contains the following main sections:
Topic
Obtaining Replacement Parts
Page
7-1
Guide to the Parts List List of Parts
7-1 7-4
Obtaining Replacement Parts

Spare parts can be obtained from Exatron. It has always been Exatron policy to support all the equipment we have ever manufactured. If the part is still available, or can be made, we will get it for you. In most cases, faxed requests and shipment of replacement parts orders are processed within twenty-four hours of receipt by Exatron. See "Exatron Support Services" on page 1-10. The following sections discuss things to note when ordering replacement parts.
Guide to the Parts List

This guide shows how to use the parts list to determine the exact part number of any custom part in your machine in order to replace it if necessary. The parts list contains those items which Exatron has custom manufactured. They include machined parts, sheet metal, printed circuit boards, cables, and standard vendor parts which have been modified by Exatron. A limited number of standard vendor parts are also listed here. The title shown at the top of the list indicates the type of parts list. This should match your system's hardware. The parts list may change as Exatron improves each model with each new generation. If you have different generations of the same model, the parts list will vary. Whenever possible, Exatron makes design improvements capable of being used in older versions of the same model. The date on the parts list indicates the date of the last revision of the list, not necessarily the last revision of the system hardware. An explanation of the column categories in the parts list follows.
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Exatron (Part Number)

This column contains the number assigned by Exatron to a specific part; for example, 8000D14 or PET-R44. The part number usually has two sections or number/letter sets. The first set of alphanumeric characters (e.g. 1900, 8000, PET, TAPE) indicates the model number of the system for which the part was originally designed. We use designs of parts from different models to lower inventory costs and to speed the design of custom handlers. The next three alphanumeric characters (e.g. 906, C06, P14) are the numerical count of the part as it was designed. These are the three characters that are stamped or laser marked onto most machined parts. Exatron occasionally uses additional letters or numbers to indicate special features. We use R and L to specify right and left hand parts. AM or HR will indicate parts for Ambient Machines or Hot Rails. We use 62 or 75 to indicate specific sizes of solenoid plungers. There are other special notations which may be used as part of our numbering system and which may change with time. Please contact the Exatron factory for assistance with any questions regarding special letters or numbers attached to part numbers.
Part Quantity Columns

The next two or three columns indicate the quantity of the specific part used in the manufacture of this system. This information may be useful in determining the correct part number and is used to build an assembly kit when your system was originally built.
Manual
Each row that has a 1 in this column has a corresponding wiring print that you can find in your manual. The print is identified by the part number.
Description
This is the name assigned to the part. In most cases, this description will clearly designate the part you wish to locate. Please include this description when ordering replacement parts.
Assembly
This column indicates which major system sub-assembly the part belongs to. In most cases, the "Assembly" can be ordered as a complete replacement part.
Size
These are dimensions in inches. The dimesions are listed left to right from smallest to largest: A x B x C. This is the starting size of the part prior to being machined.
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Guide to the Parts List
Finish
C B
A
Figure 7-1: Dimensions Listed From Smallest to Largest
Imagine a cube drawn around a part you are trying to identify. The dimensions of this cube can be checked against this size dimension and may be of assistance in determining a required part number. When the parts list indicates another Exatron part number in the size column, then the part was made by modifying an existing Exatron part. The modification is required for this handler only. When ordering replacement parts, be sure to use the part number and not the size. If the size column contains SEE PRINT, then the part is made from sheet metal or a PC board, or is something which is not made from a solid cube of material.
Finish
This column designates the finish used on the part. The following list is in alphabetic order. ALODINE: A non-anodic protective coating, a microscopic thin film commonly prescribed on aluminum to provide increased corrosion resistance and impose desired electrical resistance characteristics. BLACK: Black anodizing. BLUE: Blue anodizing. CLEAR: Clear anodizing, silver in color. HCR: Non-conductive, hard finish, dark green in color. NEDOX: Conductive, hard finish, silver in color, that eliminates static build-up and provides good electrical conductivity. Aluminum parts coated with nedox exhibit the hardness of steel without the weight. The finish protects against abrasive wear and corrosion. The dry-lubricated, non-stick surface also reduces friction of moving or sliding parts. NICKEL: Bright nickel plating, silver-chrome in color. NONE: No finish, natural material. PAINT: Painted part; colors may be beige, black or blue. RED: Red anodizing.
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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.
Figure 8-1
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Chapter 9: Test Interfaces

Overview
This chapter discusses the following main topics: Topic General Interface Options and Setup Accessing a Handler Control Interface General Interface RAM Selections INTERFACE TYPE: ADDRESS 00B7 TEST SOL DELAY: ADDRESS 0096 STOP ON FAIL Y/N: ADDRESS 00A5 DOUBLE TEST SORT: ADDRESS 00AC TESTER SORT SET UP: ADDRESSES 00AF TO 00B6 Handler Port Simulator TTL Handler Port Interface Handler Port Options EOT (END OF TEST) START PULSE WIDTH: ADDRESS 0098 CHECK SORT RESET: ADDRESS 00A2 EXATRON RS-232 Interface RS-232 Port Options BAUD RATE: ADDRESS 009B DATA FORMAT: ADDRESS 009C EXATRON RS-232 Commands Handler/Tester Test Cycle Handshake Summary Explanation of Test Cycle Handshake DOUBLE TEST ASCII OUT: ADDRESS 00A7 Page 9-2 9-2 9-3 9-3 9-3 9-3 9-3 9-3 9-4 9-5 9-8 9-8 9-9 9-9 9-9 9-10 9-11 9-11 9-12 9-12 9-12 9-14
The test site on the Model 5000 handler may be interfaced to virtually any programmer and/or tester available. Some interfaces require custom configuration prior to shipment, but the only requirement for a given programmer or tester itself is that it be capable of issuing and accepting commands to and from the handler or the system controller. There are two basic parts to the handler's interface with your programmer/tester. The first part is the DUT interface. The DUT Interface connects the handler's test contacts to the tester's test socket. There are many ways to accomplish this, depending upon application and type of changeover kit. A direct dock interface which connects the tester directly to the handler con-
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tacts provides the best performance, although other interface methods are available. In most cases, the hardware required for the DUT interface will be built and installed at EXATRON. Therefore, the DUT interface will not be discussed here. The second basic part to every interface is the control interface. The control interface allows the handler to send a Start command to the tester, and subsequently allows the tester to instruct the handler how to process the device under test. The handler is equipped with a variety of ways to accomplish this task using two basic means of access: a parallel port (EXATRON'S "Handler Port") and an RS-232 serial port. The handler has a number of operating features which relate to the handler's tester control interface. Both the Handler Port and RS-232 Port have several distinctive options from which to choose. These various control interfaces available from EXATRON are the subject of the following discussion. They have been organized into three categories: General Interface Options, (common to both Handler Port and RS 232 Port) (page 9-2) Specific Handler Port Interface Options (page 9-5) Specific RS-232 Interface Options (page 9-9)
General Interface Options and Setup

Accessing a Handler Control Interface
When the handler powers up, you will be given the opportunity to "PICK INTERFACE?" If you press the <ENTER> key, the previously selected interface (or default interface, if RAM was cleared) will be used. Or to access this option at another time, press the <MANUAL> key and then press the <4> key. Listed below are the standard interfaces currently supplied with the handler. NOTE: New interfaces are added to the handler from time to time. Contact EXATRON for updates as required. From "PICK INTERFACE?" displayed on the front panel: <1> key sets the handler to use "EXATRON RS-232" <2> key sets the handler to use "HANDLER PORT" <3> key starts "CYCLE ONLY NO T" (no test) <4-0> keys N/A <ENTER> key enters your selection into the handler
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General Interface Options and Setup
General Interface RAM Selections
General Interface RAM Selections

Listed below are addresses in the handler's battery backed-up RAM which may be edited to fine tune the handler for your specific programmer/tester and sorting requirements when using either the Handler Port (parallel) or the RS-232 serial port. These addresses are not part of the standard power-up selections and may be modified only by changing the RAM as described in "Changing RAM" on page 3-58.
INTERFACE TYPE: ADDRESS 00B7

This address allows the user to set the default interface to be used by the handler. The available data settings are: 25 = EXATRON RS-232 26 = HANDLER PORT 39 = CYCLE ONLY
TEST SOL DELAY: ADDRESS 0096

This delay adds "settling" time to the DUT. The delay allows the DUT more time to come to rest in the test site before the contacts close. The delay counts down in 10-millisecond steps.
STOP ON FAIL Y/N: ADDRESS 00A5

The available data settings are: 30 = STOP ON FAIL YES FF = Place failed devices in Fail tube; no stop on fail This option allows the handler to Stop on Fail, or not. The handler can either automatically cycle a failed device into an output tube, or the handler can be set to stop. If set to STOP ON FAIL YES, then the handler will stop on a failure and allow the operator to retest the device again and again, as often as desired. This is very useful when calibrating test fixtures and programs.
DOUBLE TEST SORT: ADDRESS 00AC

This address tells the handler which test sorts to double-test if desired. Each bit represents a tester sort. 00 = turns off double test for all sorts (bitmap: 0000 0000) FF = sets the tester to double test all sorts (bitmap: 1111 1111) FE = double-tests all sorts except Sort 1 (Sort 1 must be Pass) (bitmap: 0111 1111) 02 = double-tests only Sort 2 (bitmap: 0100 0000)
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TESTER SORT SET UP: ADDRESSES 00AF TO 00B6

The handler uses the specifications shown in the following table to assign output bins to tester sorts. If the handler does not receive one of the following test Sorts, the handler will pause and display the message: "BAD TEST RESULT." The handler will output the HEX equivalent of the actual character received by the handler to the LEDs on the handler's output shuttle cover. LED #1 is bit 01, LED #8 is bit 80. Pressing the <CLEAR> key on the handler's front panel will flush the device from the test site and restart operation, or pressing <ENTER> will retry the test. When the handler does receive a proper result in the form of one of the test Sorts, the handler will open the test contacts and flash the output cover LED of the output bin selected. The handler will sort the DUT accordingly and start a new handling cycle. Handler Port Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 n/a RS-232 Input 1 2 3 4 5 6 7 8 0 Sort 1 2 3 4 5 6 7 8 = Output Bins RAM address AF RAM address B0 RAM address B1 RAM address B2 RAM address B3 RAM address B4 RAM address B5 RAM address B6 Remote Retest
Handler Port Simulator

An optional 8-bit LED Checker (#3000-521; see Figure 9-1) is available from Exatron that will allow the user to test the TTL Handler Port. This "blue box," as it is referred to at Exatron, will allow the user to test the handler I/O and can be used as a simulator. You can operate the handler without the tester connected. It also has LEDs connected to each input/output. This will help troubleshoot any interface problems. You can see the LEDs blink or not when a signal is either sent or received.
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TTL Handler Port Interface
Figure 9-1: Eight-Bit LED Checker #3000-521

The TTL Handler Port interface uses simple +5 volt TTL-compatible signals to control the handler. This specialized parallel port interface uses an optional 24-pin "D" connector on the back of the control PC (Figure 9-3). It has been designed to be compatible with all Exatron gravityfeed Model 2000, 3000, and 5000 handlers.
Figure 9-2: Handler Port (Parallel Port)
Figure 9-3: 24-Pin D Connector on Handler
Handlers with opto-islated Port #3 use cable PET-H07-A or newer.
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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.
Handler Port Pin Out

Sort Input 1 Sort Input 2 Sort Input 3 Sort Input 4 Sort Input 5 Sort Input 6 Sort Input 7 Sort Input 8 Output 3 Output 1, Start Test: Pulse Handler Vcc, +5 V DC Handler Ground
a. Special PAL required
Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12
Pin 13 Pin 14 Pin 15 Pin 16 Pin 17 Pin 18 Pin 19 Pin 20 Pin 21 Pin 22 Pin 23 Pin 24
Input 9, End of Test a Not Used Not Used Not Used Output 8 Output 7 Output 6 Output 5 Output 4 Output 2, Start Test: Level Handler Vcc, +5 V DC Handler Ground
CAUTION: Never connect opto isolation port ground to handler ground. CAUTION: Never connect opto isolation port Vcc to handler Vcc. CAUTION: Never connect tester Vcc to handler Vcc. Remember: All signals are TTL/CMOS compatible (+5 volt logic). Opto-isolation is available as an optional feature except on the 2000B Series handlers. To obtain this feature for your Model 3000B or Model 5000 handler, please specify your request at the time of placing your handler order. Additionally, all 3000B and 5000 Series Handlers may be upgraded to opto-isolation in the field. To order this upgrade for an existing handler, contact the Exatron Sales Department. Our toll-free telephone number is 1-800-EXA-TRON.
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The +5 volt output on the handler port (Pins 11, 23) is not to be used by or connected to the tester, unless it is isolated at the tester. Pins 12 and 24 are ground connections.
Figure 9-4: Standard TTLHandler Port Interface Timing Detail for One Tester
The handler first moves a device into the test site. After allowing time for the device to settle, (NOTE: this settling time is programmable; use address 0096) the test head plunger picks up the device and plunges it down toward the contactors. Then the handler issues a start pulse (Pin 10) to the tester. The start pulse width is programmable, (address 0098) but will be preset to 20 milliseconds. This pulse is normally High (+5) and goes Low for the pulse width. There is an additional signal available on Pin 22. This testing signal will go Low for the duration of the test. It will go Low at the start of the start pulse and will not go High again until the handler receives a sort signal.
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To complete the test, the tester must send back one of eight sort signals. These signals must be normally High and go Low for at least two milliseconds. The sorts must appear on Pin 1 through Pin 8 on the handler port connector. Exatron recommends that you use Pin 1 for PASS and Pin 2 for FAIL when using the handler in PASS/FAIL applications. The Input Sort is connected to a PAL device that "latches" the signal. The latch sets the falling edge of the sort signal ON. Make certain that your interface does not allow fast "glitches" which may become latched, causing the handler to mis-sort. If desired, the PAL may be modified to one that requires an "End of Test" edge as well. Further details are provided in the next section, "Handler Port Options". NOTE: EOT requires a special PAL, not typical equipment. Contact Exatron for more information. To abort the test, press the <CLEAR> key on the handler control panel. This will sort the DUT to the Home bin, output tube 5. Once the handler receives a sort pulse, it checks that: 1. The sort has a corresponding output. If not, the message "NO SORT ERROR" is displayed, advising that there are no outputs available. 2. Only one sort has been received. Only one sort signal is allowed. If multiple sorts were received, the message "MULTI SORT ERR" is displayed. The output shuttle cover LEDs will blink the pattern of the actual sorts latched by the handler. Two or more LEDs will blink, indicating the multiple sort error. If the received sort pulse is acceptable, the contacts will open and the device will be sorted to an output tube. Or, in the case of plunge-to-board changeover kits, the test site plunger will pick up the device and rise to its highest point. From there, the device will be sorted to an output tube.
Handler Port Options

EOT (END OF TEST)
The handler port is controlled by two PAL devices. These PALs control the polarity of the handler's input/output signals and whether "EOT" is to be used or not. The EOT input (pin 13) is not active unless the correct PAL is installed on the handler's Front Panel Card #5000-A89. The EOT signal, when used, will cause the handler to ignore all tester sort input signals until the EOT (normally High, active Low) is received by the handler. PAL A89-2 (Sum check 76B0) = No EOT signal required PAL A89-2EOT (Sum check 95B0) = EOT signal required by the handler Correct PALs may always be obtained from EXATRON at no charge.
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EXATRON RS-232 Interface
Handler Port Options
Listed below are addresses in the handler's battery backed-up RAM which may be edited to fine-tune the handler for your specific programmer/tester and sorting requirements. These addresses are not part of the standard power-up selections and may be modified only by changing the RAM, as described in "Changing RAM" on page 3-58.
START PULSE WIDTH: ADDRESS 0098

This delay controls the Start of Test pulse width. The delay counts down in 1-millisecond steps. The standard default is "14." This sets the start test pulse width to 20 milliseconds. On interfaces using a PC to control the handler, a longer start pulse width may be required to guarantee that the PC sees the start test pulse from the handler.
CHECK SORT RESET: ADDRESS 00A2

The available selections are: 00 = On FF = Off The Check Sort Reset feature should always be used on handlers that are employing the Handler Port interface. This check verifies that all Sort signals to the handler are turned off at the end of the Start pulse (all Sorts are at Logic High). Occasions may arise during operation of the Handler Port interface when the handler sends a Start pulse to the tester, but the tester either does not see the Start signal, or the tester fails to clear the previous Sort signal. In the latter case, the previous Tester Sort signal is still active at the end of the Handler's current Start pulse. The handler correctly responds to the previous Sort signal, which means that the current device under test (DUT) will not be tested and will be mis-sorted. It may appear to the operator that the handler is making an error, when in fact the tester has made an error. Therefore, it is a good idea to set this check to ON whenever your application allows for it.

THE EXATRON RS-232 INTERFACE ALLOWS THE HANDLER TO BE INTERFACED TO VIRTUALLY ANY COMPUTER-BASED PIECE OF TEST EQUIPMENT. The user must write a program which communicates with the handler using the commands listed in this section. Typically, a NULL modem, female/female, 9 pin RS-232 cable is required for the computer/tester end. The RS-232 port uses the 25-pin RS-232 connector on the side of the handler. The RS-232 serial ports use only 3 wires to transport ASCII, or serial strings: Send Receive Ground The connector on the handler is a 25-pin RS-232-type "D" connector with female pins. The mating connector on the interface cable must use male pins. The RS-232 side panel port uses the following pins:
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Pin 1 = GROUND Pin 2 = RECEIVE; input to handler Pin 3 = SEND; output from handler Pin 7 = GROUND
All commands are standard uppercase ASCII characters. The testers should always include a "<CR>" carriage return after every command. The handler will send a "<CR>" after every response.
Figure 9-5: Serial Port
Figure 9-6: Typical RS-232 Interface Cable
RS-232 Port Options

The baud rate, stop bits, data bits, and parity may be selected by setting an address (RAM address 009B = baud rate, 009C = data format) in the handler's EPROM. Unless specifically requested, all RS-232 ports are factory-set to: All commands uppercase; ASCII only Baud = 9600 Databits = 8 Stop bit = 1
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RS-232 Port Options
Parity = N (none) CAUTION: If you have a need to change any of these default settings, contact Exatron first. Listed below are addresses in the handler's battery backed-up RAM which can be edited to fine tune the handler for your specific programmer/tester and sorting requirements. These addresses are not part of the standard power-up selections and may be modified only by "Changing The RAM," as described in the Handler Set-Up Chapter of this manual.
BAUD RATE: ADDRESS 009B

This address stores the baud rate setting for the RS-232 port. Address 009B 009B 009B 009B 009B 009B Value 0C 18 30 60 C0 80 Meaning 9600 Baud (default setting) 4800 Baud 2400 Baud 1200 Baud 600 Baud 300 Baud
DATA FORMAT: ADDRESS 009C

This address stores the data format setting for the RS-232 port. Address 009C 009C 009C 009C 009C 009C 009C 009C 009C 009C 009C 009C 009C 009C Value 03 02 2A 3A 1A 0A 06 2E 3E 1E 0E 2B 3B 1B Parity No parity No parity Stick one Stick zero Even parity Odd parity No parity Stick one Stick zero Even parity Odd parity Stick one Stick zero Even parity Data Bits 8 Data 7 Data 7 Data 7 Data 7 Data 7 Data 7 Data 7 Data 7 Data 7 Data 7 Data 8 Data 8 Data 8 Data Stop Bits 1 Stop (default setting) 1 Stop 1 Stop 1 Stop 1 Stop 1 Stop 2 Stop 2 Stop 2 Stop 2 Stop 2 Stop 1 Stop 1 Stop 1 Stop
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Address 009C 009C 009C 009C 009C 009C
Value 0B 07 2F 3F 1F 0F
Parity Odd parity No parity Stick one Stick zero Even parity Odd parity
Data Bits 8 Data 8 Data 8 Data 8 Data 8 Data 8 Data 1 Stop 2 Stop 2 Stop 2 Stop 2 Stop 2 Stop
Stop Bits
EXATRON RS-232 Commands

The following is a definition of a standard RS-232 control interface from an Exatron handler to one tester/one test site. For single testers using only one RS-232 port, but with multiple test sites, Exatron has a different RS-232 command set.
Handler/Tester Test Cycle Handshake Summary

For each cycle, the following exchange occurs. Handler sends: "H <CR>" (Cycle?) Tester sends: "R <CR>" (Ready) Handler sends: "S <CR>" (Start test) Tester sends: "1 <CR>" (Sort 1) or "2 <CR>" (Sort 2) or "3 <CR>" (Sort 3) or "4 <CR>" (Sort 4) or "5 <CR>" (Sort 5) or "6 <CR>" (Sort 6) or "7 <CR>" (Sort 7) or "8 <CR>" (Sort 8) NOTE: REMOTE RETEST ~ You may send a zero, "0 <CR>", to the handler as a test result. This will cause the handler to pick up the device and replunge/retest it. A new "S" will be sent to the tester. You may use the "0" response as many times as you wish. To end a test cycle, send the handler a "1" through "8" as a sort command.
Explanation of Test Cycle Handshake

1. HANDLER SENDS AN "H <CR>".
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Explanation of Test Cycle Handshake
The handler establishes proper communications at the outset of every cycle (except Retest cycles). To do so, an "H" and a carriage return, "<CR>," are sent by the handler to the tester at the start of each test cycle. The handler is seeking an "R <CR>", Ready, from the tester. The display will read: "WAITING FOR R." 2. TESTER SENDS AN "R," READY. 3. HANDLER CLOSES TEST CONTACTS ONTO THE DEVICE UNDER TEST (DUT). If an "R <CR>" is received, the handler will close the contacts or plunge the device onto the contacts. If the handler does not receive a response, the display will briefly read: "NO RESPONSE." "NO RESPONSE" will alternate with: "WAITING FOR R" once per second. Pressing the <ENTER> key on the front panel will cause the handler to send a new "H <CR>". If anything other than an "R <CR>" is received, the handler will pause and display the message: "BAD RESPONSE." The handler will output the hex equivalent of the actual character received by the handler to the LEDs on the handler's output shuttle cover. For example, LED #1 is bit 01; LED #8 is bit 80. Pressing the <ENTER> key on the front panel will cause the handler to send a new "H <CR>" and the handler will try again to receive an "R <CR>". Pressing the <CLEAR> key on the front panel will cause the handler to flush the device from the test site and restart operation. The display will read: "BIN 5 S0 FLUSH." 4. HANDLER SENDS AN "S <CR>," START TEST (FIRST TEST CYCLE). As stated above, once the handler receives an "R <CR>", the test contacts will close onto the DUT. The handler will allow time for the test contacts to close. Then the handler sends an "S <CR>" (Start Test) to the tester. The display will read: "END TEST." If you wish to abort the test at this point, press the <CLEAR> key. This will sort the DUT to the Home bin, output tube 5. NOTE: If the handler receives an incorrect bin sort, the message: "BAD TEST RESULT" will be displayed. The handler display will also flash the hex equivalent of the result received on the handler's output door LEDs. You can press the <ENTER> key to reissue a Start Test command and the handler will try a second test. You can press the <CLEAR> key to abort the test and restart operation, or send the handler an ASCII " * " or "2A" in hex. This will automatically flush the DUT and begin a new test cycle. 5. TESTER SENDS TEST SORT RESULT, "1" THROUGH "8" OR "0" FOR REMOTE RETEST. To complete a test, the handler must receive a test result. Please refer to the table under "TESTER SORT SET UP: ADDRESSES 00AF TO 00B6" on page 9-4. The handler uses the specifications shown in this table to assign output bins to tester sorts.
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You can re-assign any combination of bins to any sort by setting the selection in the handler's RAM. Be very careful not to assign the same bin(s) to both a "PASS" and a "FAIL" sort. Once a Sort/Bin setting has been determined and saved in the handler's RAM, we highly recommend saving the settings in the handler's EPROM as default settings. Contact the EXATRON factory for a free EPROM with changed RAM settings. 6. HANDLER OPENS TEST CONTACTS. 7. DUT CYCLES TO AN OUTPUT TUBE; A NEW CYCLE STARTS. The following address in the handler's battery backed-up RAM may be edited to fine tune the handler for your specific programmer/tester and sorting requirements. This address is not part of the standard power-up selections and may be modified only by "Changing The RAM," as described in the Handler Set-Up Chapter of this manual.
DOUBLE TEST ASCII OUT: ADDRESS 00A7

This address stores the ASCII letter that the EXATRON RS-232 interface will use as an output on a double test. The factory setting is "S" (53 in HEX.) The user may wish to distinguish between a "START 1 TEST" and a "START 2 TEST." The user may set this address to "D" (44 in HEX), in which case the handler will issue an "S" on a First Test Cycle and a "D" on any Double Test Cycles.
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Index
A
air blast switch 2-49, 4-37 air blast, track 2-30 air blow. See blow-off air filter 1-6 air pressure 6-8 fittings 1-6 air regulator 2-48, 6-3, 6-7 adjusting pressure 6-8 locking in OFF position 1-4 replacing 6-4 air supply 1-6, 6-3 air valve adjustment 2-34, 6-9 ASCII values 3-79, 4-28 cautions and warnings continued power off system before changing changeover kit or other parts 3-7 power off system before maintenance 6-1 prevent excess moisture in air regulator and air valves 6-3 run handler only with tester docked 3-31 servicing of laser should be done by LSO 1-3 Change RAM mode 3-58 changeover kit 2-23 aligning 3-19 contents 3-2 installing 3-7 selecting 3-50 testing alignment 3-23 checksum 5-6, 5-36 contracts preventive maintenance 1-14 service 1-11 control panel 2-27 display messages 5-1 to 5-41 keys 3-45 < 3-45, 4-28 < > > (greater-than) 3-45, 4-28 < < > (less-than) 3-45, 4-28 < SET UP> 3-59 <.> (period) 4-40, 5-7 <-> (minus) 3-45, 3-60, 4-40, 5-7, 5-16 <0> 3-45, 3-60 <CLEAR> 3-45, 3-60 <DELETE> 3-45, 3-60 <DIAGNOSTICS> 4-4, 4-5 <ENTER> 3-33, 3-46 <RUN> 3-59 <SET UP> 3-45, 3-46 <SPACE> 3-60 <TOTALS> 3-45, 3-58, 3-59 numeric 4-6 to 4-12 counts totals 3-56, 3-58 tube full 3-46, 3-53, 3-55, 3-61, 3-69
B
bins 1-24, 3-57 see also tubes, output blow-off 1-24 buttons EMO (emergency stop) override 2-28
1-2, 2-24
C
calibration changeover kit 3-19 octoloader 3-41 cautions and warnings avoid rapid power OFF/ON cycles 3-44 connect power to grounded outlet 1-5 dont defeat interlocks 1-1 dont interfere with moving parts 1-1 dont lubricate lead screws 6-1 dont lubricate solenoids 6-10 dont remove safety covers during operation 1-2 dont unplug air hose when air regulator on 1-2 dont use cleaners on bearings or lead screws 6-1 dont use machine without approved air regulator 1-2 empty all output tubes before each run 3-57 end-of-life disposal 1-23 home all motors before starting 1-1 keep away from moving parts 1-1 lock air regulator in OFF position before repairing handler 1-3 continued on next column
D
decimal values 3-79 Device at Mark Site sensor 2-44 Device at Stack Pin sensor 2-44 Device at Top of Track sensor 4-38
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Model 5000 Manual
devices changing sizes or types 3-1 drop angle 2-9 optional 2-8 RAM addresses 3-66, 3-73 selecting package 3-46, 3-49, 3-55, 3-63, 3-70 totals 3-56, 3-58 Diagnostics mode 4-2, 4-4, 4-5 displays control panel 2-27, 5-1 to 5-41 digital 2-38, 2-40, 3-64, 3-78 LED 2-38 tray counter 2-40 double-testing 3-62, 3-64, 3-70, 3-71
E
Edit mode (laser software) 3-34, 3-38 electrical capability 1-5 EMO (emergency stop) button 1-2, 2-24 end-of-life disposal 1-23 EPROM, updating 3-59
F
failures, stopping at 3-51, 3-63, 3-64, 3-70, 3-71, 5-34 flowcharts Diagnostics mode 4-4, 4-5 Modify Setup mode 3-47, 3-48 fuses 2-26
H
handler cleaning 6-1 end-of-life disposal 1-23 installation 1-7 powering down 3-44 powering up 3-31 requirements electrical 1-5 environmental 1-4 pressurized air 1-6 handler options 2-2, 2-8 air valve adjustment 2-34, 6-9 laser see laser output tray 2-21, 3-30, 3-46, 3-54 output tray counter 2-40 messages 5-14 pickup head see pickup head continued on next column
handler options continued quad test sites See quad test handler track air blast 2-30 handler parts see also individual part names, test sites air blast switch 2-49 air pressure fittings 1-6 air regulator 2-48, 6-7 brand names Laservall laser 3-33 SMC air regulators 6-4, 6-7 buttons 2-24, 2-28 chains 2-11 changeover kits 2-23, 3-2, 3-7 connectors 2-48, 3-15 24-pin D 9-5 control panel 2-27, 3-32, 3-45 cover foot 2-32 EMO (emergency stop) button 1-2 fuses 2-26 index pin 2-6 interlocks 1-1, 3-72 laser gate 2-35 laser mark site 2-6 LEDs 2-38, 3-57 motor serial cables 6-2 motors 2-11 octo stop block 3-41 octoloader 2-5, 2-13, 3-19, 3-25, 3-41 octoloader gates 2-15 output tray 2-21, 3-30 output tube cover 2-38 output tube holder 3-8, 3-9 photos 2-9 to 2-49 pickup head 2-6, 2-18 pickup site 2-6 plunger 2-18 ports 2-47, 3-5, 3-18 power supplies 2-25 safety cover 2-11 sensors 2-40 to 2-46 shuttle 2-6, 3-10 solenoids 2-28 stack pin 2-6 track 2-6 tubes 2-5, 3-25, 3-28, 3-29 wiring 6-2 handler port simulator 4-2, 4-13, 4-31, 9-4 heater controller display (hot rail) 3-43 hex values 3-76, 3-79 home positions octoloader 2-13, 2-41 continued on next column
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Index
home positions continued pickup head 2-12, 2-18 shuttle 2-37 hot rail connectors 2-48 controllers 3-42 electrical requirements 1-5 heater controller display 3-43 installing 3-13 messages control panel 5-32 setting temperature 3-42
LED displays 2-38, 3-57 lock-out/tag-out (LOTO) procedures Loop mode 3-50, 4-44, 5-33
1-3
M
Manual mode 2-2, 4-2 manual, user typography significance 1-24 version number significance 1-23 Mark mode 3-52 mark site sensors 2-44 messages, control panel 5-1 to 5-41 modes Change RAM 3-58 Diagnostics 4-2, 4-4, 4-5 Edit (laser software) 3-34, 3-38 Loop 3-50, 4-44, 5-33 Manual 2-2, 4-2 Mark 3-52 Modify Setup 3-46, 3-47, 3-48, 3-49 Run 2-2, 3-35, 3-57, 4-2 Stop 3-50, 4-43, 5-33 Work (laser software) 3-34, 3-38 Modify Setup mode 3-46, 3-47, 3-48, 3-49 motors 2-11 messages 5-8, 5-9, 5-19, 5-23, 5-24 pickup head 2-12 RAM address 3-61, 3-69
I
index pin 2-6, 2-29, 2-30, 3-62 installation 1-7 interfaces opto-isolation 2-8, 3-70 RS-232 3-62, 3-69 selecting 3-46, 3-49, 3-55, 3-65, 3-72 TTL 3-61, 3-63, 3-69, 3-70, 9-5 interlocks 1-1, 3-72
J
jams, clearing 5-17, 5-18 RAM addresses 3-62, 3-63, 3-69, 3-70, 3-72
K
keys. See control panel, keys
O
octoloader 2-13 aligning 3-41 bypassing 5-26 home position 2-13, 2-41 homing 3-57 loading input tubes 3-25 messages 5-26 movement 2-5, 4-36 RAM addresses jog 3-63, 3-71 number of input tubes 3-63, 3-70 thump 3-72 wiggle 3-63, 3-70 snap-on pins 3-19 stop block 3-41 tube gates 2-15, 3-26 Octoloader at Home sensor 4-38 opto-isolation interface 2-8, 3-70 output tray 2-21, 3-30
L
laser checking 5-7 diagnostics 4-40, 4-41, 4-42 Diagnostics flowchart 4-4 electrical requirements 1-5 gate 2-29, 2-35 Mark mode 3-52 messages control panel 3-34, 3-35, 5-10, 5-11, 5-13, 5-14, 5-15, 5-16, 5-18, 5-19, 5-20, 5-22, 5-26, 5-29 laser supply unit 3-36 powering up 3-33, 3-35 RAM address 3-64, 3-65 sensors 2-43, 2-44, 4-13 software 3-34, 3-38 LED checker 4-2, 4-13, 4-31, 9-4
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output tube cover 2-38 output tube holder 3-8, 3-9
preventive maintenance contract
1-14
P
packages. See devices password 3-72, 4-2, 5-27 photos, handler parts 2-9 to 2-49 pickup head 2-18, 2-29 checking positions 4-34 delay 3-62, 3-73 Diagnostics flowchart 4-4 distances to pickup head drop-off site 3-52, 3-66, 3-67, 3-68, 3-74, 3-75, 4-35, 4-42 to pickup site 3-52, 3-66, 3-67, 3-73, 3-74, 4-34, 4-42 to test site 3-52, 3-66, 3-67, 3-73, 3-75, 4-34, 4-42 home position 2-18 messages 5-28, 5-30, 5-38 motor 2-12 motor port 2-47 power-up flowchart 3-47 pins 2-32 dowel, output tube holder 3-28 index 2-6, 2-29, 2-30 octoloader gate 2-15 shuttle 2-29, 2-30, 2-36 snap-on 2-14, 3-10, 3-19 stack 2-6, 2-29, 2-30 test site stop 2-32, 2-35 plunger 2-18 messages 5-10, 5-28 Polish notation 3-52, 3-53, 5-32 ports 2-47, 3-5, 3-18, 4-27, 4-31, 4-32 TTL Handler Port 9-4, 9-5 positions diagram 2-6 home octoloader 2-13, 2-41 pickup head 2-12, 2-18 shuttle 2-37 pickup head drop-off site 2-20, 3-52, 3-66, 3-67, 3-68, 3-74, 3-75, 4-42 pickup site 2-19, 3-52, 3-66, 3-67, 3-73, 3-74, 4-42 test site 2-20, 3-52, 3-66, 3-67, 3-73, 3-75, 4-42 power supplies 2-25 power-down 3-44 power-up 3-31
Q
quad test handler air valve adjustment 2-34, 6-9 diagnostics flowchart 4-5 index and stack pins connected 2-31 key positions 2-7 messages 3-46, 5-15, 5-18, 5-30, 5-36, 5-37 Modify Setup mode flowchart 3-48 number of devices tested at once 3-53 override buttons 2-30 RAM listing 3-61, 3-69 sensors 2-27, 4-13, 4-14 setup options 3-49, 5-28 test contacts 2-34 test site, installing 3-10
R
RAM addresses changing 3-58, 5-7 lists 3-61 loading default 5-21, 5-29 sum check 5-6 RS-232 test interface 3-62, 3-69, 4-27 Run mode 2-2, 3-35, 3-57, 4-2
S
safety and security see also cautions and warnings lock-out/tag-out procedures 1-3 training responsibilities 1-1 sensors 2-40 to 2-46 Device at Mark Site 2-44 Device at Octoloader Gap 2-41, 4-38 Device at Stack Pin 2-44 Device at Top of Track 2-41, 4-38 input 2-41, 4-38 laser 4-13 Octoloader at Home 2-41, 4-38 Shuttle Position 2-44, 4-15, 4-17 test site 2-42, 4-12, 4-14 track 2-43 Tube Full 2-46, 4-18, 4-19 Tube Present 2-45, 4-20, 4-21 service contract 1-11 shuttle 2-29, 2-30, 2-36 air blast 2-49 continued on next column
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Index
shuttle continued home position 2-37 messages 5-13, 5-17, 5-18, 5-27, 5-31, 5-32 movement 2-5, 4-33 opening 4-37 RAM addresses delay 3-63, 3-71 jog 3-63, 3-70 thump 3-62, 3-70 wiggle 3-62, 3-69 snap-on pins 3-10 Shuttle Position sensors 4-17 solenoids maintenance 6-10 RAM addresses 3-62, 3-65, 3-70, 3-71 sorts 1-24 messages 3-57, 5-9, 5-25, 5-32 RAM addresses 3-64, 3-71 setting 3-76 special features. See hot rail, laser stack pin 2-6, 2-29, 2-30 Stop mode 3-50, 4-43, 5-33 stopping for failures 3-51, 3-63, 3-64, 3-70, 3-71, 5-34 support services 1-9, 1-10, 1-17, 1-23
T
taper 2-9, 2-40 facilities requirements 1-6 tasks adjusting air flow 6-9 adjusting air pressure 6-8 aligning changeover kit 3-19 aligning octoloader 3-41 changing RAM settings 3-59 checking air regulator moisture/dirt trap 6-3 checking air regulator shutoff valve 6-6 checking air supply from house generator 6-3 checking motor serial cables 6-2 checking or replacing air filter 6-4 cleaning handler 6-1 displaying totals 3-58 homing octoloader 3-57 hot rail assembly setting temperature for hot rail 3-43 turning off temperature for hot rail 3-44 installing changeover kit 3-7 powering down system 3-44 powering laser 3-35 powering up laser-marker system 3-33 continued on next column
tasks continued powering up system 3-31, 3-32 resetting totals 3-56 securing input tubes on octoloader 3-26 securing metal output tubes on holder 3-28 securing plastic output tubes on holder 3-29 starting production run 3-57 testing alignment of changeover kit 3-23, 3-24 test contacts 3-61, 3-69 test sites calibrating 3-52, 3-63, 3-70, 5-34 messages 5-13, 5-18, 5-27, 5-36 multiple 9-12 quad see quad test handler stop pin 2-32, 2-35 testing interfaces 9-1 messages 5-9 pulse 5-32 RAM addresses 3-61, 3-62, 3-63, 3-64, 3-69, 3-70, 3-71 totals counting 3-58 displaying 3-58, 5-36 resetting 3-56 trays, as input 3-62, 3-72 TTL (Transistor-Transistor Logic) test interface 3-61, 3-63, 3-69, 3-70, 9-5 TTL Handler Port 9-4, 9-5 tubes holders 3-28, 3-29 input 2-13, 3-51 loading 3-25 selecting number 3-63, 3-70 output 2-9 displays 2-38, 2-40, 3-64, 3-78 full count 3-46, 3-53, 3-55, 3-61, 3-69 loading 3-28, 3-29 messages 3-57, 5-9, 5-13, 5-15, 5-25, 5-26, 5-38, 5-39 totals 3-56, 3-58, 3-62, 3-69 Tube Full sensors 4-19 Tube Present sensors 4-21 typography significance 1-24
W
warnings. See cautions and warnings warranty agreement 1-6, 1-8, 1-9, 1-10, 6-1 wiring 6-2 Work mode (laser software) 3-34, 3-38
06/2010
Index-5
Model 5000 Manual
Index-6
06/2010

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Gravity-Feed Model 5000 User Manual

Version 3.3 June 8, 2010

Chapter 2: System Description

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Copyright Exatron, 2010