Model 1050 Manual

Model 1050 Automated Taper Used with Model 5000 Handler User Manual
Version 3.2 April 1, 2010
Exatron, Inc.
2842 Aiello Drive San Jose, California 95111 (408) 629-7600 Tel (800) exa-tron Tel (408) 629-2832 Fax www.exatron.com
Copyright Notice
Copyright 2010 Exatron This document contains proprietary information which is protected by copyright. All rights are reserved. EXATRON MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. The information contained in this document is subject to change without notice.
Table of Contents
Chapter 1: Safety and Support
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Exatron Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Facilities Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Air Conditioning and Environmental Requirements . . . . . . . . . . . . . . . . . 1-2 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Vacuum/Pneumatic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Uncrating the Handler and Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Customer In-House Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Offshore Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Exatron Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 End-of-Life Taper Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Significance of This Manuals Version Number. . . . . . . . . . . . . . . . . . . . . . . 1-7 Typographical Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . 1-8 Terms Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Chapter 2: System Description

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Key Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 How the Model 1050 Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Identifying Major Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Three Reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Taper Input Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Override Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Index and Stack Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Seal Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Swing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Communication Between Handler and Taper . . . . . . . . . . . . . . . . . . . . . . . 2-19
Chapter 3: Taper Setup and RAM Listing

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Mounting the Takeup Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Mounting the Supply Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
-- continued on next page --
04/2010
Copyright Exatron, 2010
Contents-1
Model 1050 Manual
Chapter 3: Taper Setup and RAM Listing continued

Adjusting the Carrier Tape Track Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Loading the Carrier Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Loading the Sealing Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Adjusting Heat Seal Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Adjusting Lateral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Adjusting Downward Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Adjusting Pressure Seal Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Power-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Setting Temperature for Heat Seal Heads . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Calibrating Device Position in Tape Pocket . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Beginning a Production Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Understanding the Control Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Using the <SET UP> Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Modifying Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Understanding the Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Selecting Type of Tape Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Selecting Number of Devices to Be Put in Tape. . . . . . . . . . . . . . . . . . . 3-31 Setting Tape Pocket Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Selecting Manual Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Resetting the Count of Devices in Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Displaying the Count of Devices in Tape . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Using Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Changing RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Notes About the RAM Address Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Warning About Motor Speeds (00C0-00CF). . . . . . . . . . . . . . . . . . . . . . 3-41 Updating Your EPROM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Separate Settings for Changeover Kits . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Suggested Values for Various Taper Models . . . . . . . . . . . . . . . . . . . . . 3-41 RAM Address Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Hex-Binary Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Decimal-Hex-ASCII Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Chapter 4: Diagnostics
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Accessing DIAGNOSTICS Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Diagnostics Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 SENSOR CHECK: Tape Sensors 0-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 SENSOR CHECK: Pickup Site Sensors 8-F . . . . . . . . . . . . . . . . . . . . . . . . 4-10
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Chapter 4: Diagnostics continued

OUTPUT CHECK: Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 OUTPUT CHECK: Solenoid Toggle Check . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 ALL MOTOR CHECK: Drive Motor Check . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 ALL MOTOR CHECK: Swing Arm Check . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 INTERFACE CHECK: RS-232 Port Check . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 INTERFACE CHECK: Handler Port Output Check . . . . . . . . . . . . . . . . . . . 4-18 Checking Communication Between 5000 Handler and 1050 Taper . . . . . . 4-19 Setting Up HyperTerminal for 1050 Taper . . . . . . . . . . . . . . . . . . . . . . . 4-19 Configuring a Connection Session. . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Testing Communication from PC to Taper. . . . . . . . . . . . . . . . . . . . 4-24 Setting Up HyperTerminal for 5000 Handler. . . . . . . . . . . . . . . . . . . . . . 4-26
Chapter 5: Dictionary of Displayed Messages

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Model 1050 Handler Status and Error Messages . . . . . . . . . . . . . . . . . . . . . 5-3 #### OLDNEW #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 00## DATA ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ADD LEADER DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ADD LEADER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ALIGN MOTORS ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ALL MODES OFF ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 ALL MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 ALL MOTORS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 CHANGE RAM ? NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 CHANGE RAM ? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 CHECK SUM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 CHK VAC ADJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 COUNT SET TO 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 CPU ERROR <1-5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 DRIVE MOTOR CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 EMPTY POCKET ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 EXATRON TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 FIND MOTOR HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 FULL T = ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 GAP STEPS = #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 HANDLER OUT CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 HOME SENSOR ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 HOME SWING HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 INTERFACE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 JOG LEFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 JOG RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
04/2010
Contents-3
Model 1050 Manual
Chapter 5: Dictionary of Displayed Messages continued

LOAD DEFAULT NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 LOAD DEFAULT YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 LOAD EPROM>RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 LOAD REMOTE RAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 LOOP MODE ON ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 MANUAL ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 MEMORY ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 MOD SET UP ? NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 MOD SET UP ? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 MOTOR <A or B> BUSY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 MOTOR <A or B> ERROR ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 MOTOR A OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 MOTOR B OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 MOTOR HOME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 MOVE TAPE LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 MOVE TAPE RIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 NO POCKET? ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 NOT UP TO TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 OFFSET = #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 OFFSET>GAP ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 PASSWORD ABC? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 PAUSED ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 POCKETS = ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 RAM AUTO RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 RESET COUNT NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 RESET COUNT YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 ROTATE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 ROTATE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 RS-232 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 SEN0-7 01234567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 SEN8-F 89ABCDEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 SET GAP ? NO/YES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 SET OFFSET = #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 SOLENOID CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 STOP MODE ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 STOP MODE ON ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 SUM CHECK = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 SUM CHECK ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 TAKE UP MOTOR ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 TAKE UP REEL ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 TAPE GAP LOST ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 TAPE IS FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Contents-4
04/2010
Chapter 5: Dictionary of Displayed Messages continued

TEST TAPE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 THANK YOU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 THERMAL OR PSA ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 TRANSFER ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 TURN ON REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 UART OUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 UPSIDE DOWN ERR ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 ZERO COUNT ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Chapter 6: Servicing and Troubleshooting

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Seal Head Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Pressure-Sensitive Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Heat Seal Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Air Regulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Checking Air Regulator Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Adjusting Air Pressure on the Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Checking the Moisture/Dirt Trap in the Air Regulator . . . . . . . . . . . . . . . . 6-4 Solenoid Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Fiberoptic Photoelectric Sensor Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Chapter 7: Parts List

Guide to the Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Exatron (Part Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Part Quantity Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Lists of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Chapter 8: Prints Index
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List of Figures
Figure 1-1: Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-2: Air Line Attached to Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-1: Key Device Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-2: Reels on Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-3: Tape Track with Swing Armat Pickup Site (Left), at Taper (Right) . . . . . . . . . . . 1-2 1-4 2-2 2-4 2-4
Figure 2-4: Other Features of Taper (Model 201) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Figure 2-5: Index Pin Retracted (Left), Extended (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Figure 2-6: Cover Foot Retracted From Pickup Site and Stack Pin Extended (Left); Cover Foot Extended Over Pickup Site and Stack Pin Retracted (Right) . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Figure 2-7: Phase Motor Driving Swing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Figure 2-8: Tape Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Figure 2-9: Takeup Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-10: Device at Stack Sensor (A, Top); Device at Pickup Site Sensor (B, Bottom) . . . . 2-10 Figure 2-11: Device at Stack Sensor (A, Left); Device at Pickup Site Sensor (B, Right) . . . . . 2-10 Figure 2-12: Taper Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Figure 2-13: Empty Pocket Sensor (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Figure 2-14: Out-of-Pocket Sensor (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-15: Gap Sensor (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-16: Carrier Tape Out Sensor (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-17: Takeup Arm Sensor (3) Closed (Left), Open (Right). . . . . . . . . . . . . . . . . . . . . . . Figure 2-18: Swing Arm Home Sensor (9, Left); Swing Arm at Home (Right) . . . . . . . . . . . . . Figure 2-19: Tape-and-Reel Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-20: Heat Seal Heads with Counterbalance Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-21: Pressure-Sensitive (PSA) Seal Heads with Counterbalance Weight . . . . . . . . . . . Figure 2-22: Swing Arm at Pickup Site (Left), at Tape Drop Site (Right) . . . . . . . . . . . . . . . . . Figure 2-23: Pickup Head Retracted (Left), Extended (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2-12 2-13 2-13 2-14 2-14 2-16 2-16 2-17 2-17
Figure 2-24: Path and Limits of Swing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Figure 2-25: Communication WiringOn 1050 Side (Left), On 5000 Side (Right) . . . . . . . . . 2-19 Figure 2-26: Connection Port for Communication Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Figure 2-27: TAPE-346-E1 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Figure 3-1: Locking Hub on Takeup Reel with Alignment Pins . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Figure 3-2: Supply Reel Tape Unwound from Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-3: Carrier Tape Track at Different Widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-4: Track Width Locking Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-5: Carrier Tape Under Guide At Top Supply End of Track . . . . . . . . . . . . . . . . . . . . . . Figure 3-6: Lifting Pressure Roller Arm and Pushing In Keeper PinTwo Styles . . . . . . . . . . . 3-3 3-3 3-4 3-5 3-6
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Figure 3-7: Takeup Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-8: Tape Drive Gear Adjustment Knob with Blue Locking Knob Unscrewed . . . . . . . . Figure 3-9: Gear Adjustment Narrowed (Left); Widened (Right). . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-10: Sealing Tape PlatesOutside (Left), Inside (Right) . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-11: Sealing Tape Threaded to Sealing Tape Guide Assembly for PSA . . . . . . . . . . . . .
3-6 3-7 3-7 3-8 3-9
Figure 3-12: Sealing Tape Threaded to Sealing Tape Guide Assembly for Heat . . . . . . . . . . . . . 3-9 Figure 3-13: Sealing Tape Threaded Under Guide Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Figure 3-14: Two Widths of Guide BlocksTop View (Left); Bottom View (Right). . . . . . . . 3-10 Figure 3-15: Placement in Grooves of Guide Blockof Sealing Tape (Left) and Carrier Tape (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Figure 3-16: Guide Rod Removed from One Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Figure 3-17: Guide Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-18: Semicircular Seal Head with Adjustment Screw . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-19: Example of Good Tape Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-20: Three-Gram and One-Gram Weights (Left); One-Gram Weight on Heat Seal Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-21: Pair of Pressure Seal Heads with Lateral Adjustment Screws . . . . . . . . . . . . . . . . Figure 3-22: Three-Gram and One-Gram Weights (Left); One-Gram Weight on PSA Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-23: Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-24: Emergency Stop Button on Model 5000 Handler. . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-25: Emergency Stop Buttons for Both Handler and Taper . . . . . . . . . . . . . . . . . . . . . . Figure 3-26: Heater Controller Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-27: SET Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-28: Up Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-29: Digit in Ones Position Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-30: Left Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-31: Digit in Tens Position Selected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-32: Temperature Set Before the SET Button Is Pressed . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-33: Temperature Set After the SET Button Is Pressed . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-34: Down Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-35: Temperature Set to Zero Before the SET Button Is Pressed . . . . . . . . . . . . . . . . . Figure 3-36: Tape Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-37: Swing Arm Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-38: <SET UP> Key Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-39: Gap Versus Offset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-40: Modify Setup Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-41: Manual Mode Flowchart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-13 3-14 3-15 3-15
3-16 3-17 3-18 3-19 3-20 3-21 3-21 3-21 3-22 3-22 3-22 3-23 3-23 3-24 3-25 3-25 3-28 3-29 3-30 3-35
Figure 4-1: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Figure 4-2: Diagnostics Abbreviated Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
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Figure 4-3: Tape Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Figure 4-4: Swing Arm Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Figure 4-5: Getting to HyperTerminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Figure 4-6: Opening the HyperTerminal Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-7: Naming a New Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-8: Selecting the Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-9: Selecting the Port Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-10: Getting to Connection Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 4-20 4-21 4-22 4-22
Figure 4-11: Getting to ASCII Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Figure 4-12: Displaying Typed Commands Onscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Figure 4-13: Using Call to Connect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Figure 4-14: Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Figure 6-1: Brass PSA Rollers (Left); Rubber PSA Rollers (Right) . . . . . . . . . . . . . . . . . . . . . . 6-2 Figure 6-2: Heat Seal Head Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-3: Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-4: Air Regulator with Small Black Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-5: Metal Casing Unscrewed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-6: Clear Glass Casing Snapped Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-7: Large Black Inner Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-8: Solenoid with Plunger on Back Side of Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-9: Sensor Controller Set to L-ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-10: Green and Red Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-11: Conditions of Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-3 6-5 6-5 6-6 6-6 6-7 6-8 6-8 6-9
Figure 7-1: Dimensions Listed From Smallest to Largest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
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Chapter Overview
This chapter discusses the following main topics:
Topic Exatron Safety Warnings Facilities Requirements Installation Overview Standard Warranty Exatron Support Services End-of-Life Taper Disposal Significance of This Manuals Version Number Typographical Conventions Used in This Manual Terms Used in This Manual
Page 1-1 1-2 1-4 1-5 1-6 1-7 1-7 1-8 1-8
Please read and understand this entire manual before installing or using your Exatron taper. A short glossary of terms used in this manual and other keys to understanding is found at the end of this chapter.
Exatron Safety Warnings

Typically, the taper is simply one part of a complete test system. It is the responsibility of the company purchasing the taper to properly train all taper operators in all of the safety practices required for every component of the test system. The following safety procedures must be followed at all times.
WARNING! Keep fingers, hair, and clothing away from any moving parts on the taper. Its motors are very powerful and can cause severe injury. WARNING! Never try to stop an action of the taper with your hands or any other device. To stop, press the Emergency Stop button on the right side of the control box.
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Using compressed air can be hazardous. It is the responsibility of the company purchasing the taper to properly train all taper operators in every aspect of the safety practices associated with the use of compressed air. WARNING! Never operate any Exatron system that requires compressed air without an approved air regulator and shutoff valve, such as that originally supplied with your system. WARNING! Never unplug a pressurized air hose while the air regulator is turned on.
Figure 1-1: Emergency Stop Button
Facilities Requirements
Air Conditioning and Environmental Requirements
The Model 1050 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. There are no special ventilation requirements.
Electrical Requirements
Handlers shipped either within the United States or offshore have built-in switching electrical supply capability for 100-volt AC to 240-volt AC, 50Hz to 60Hz at 3 amps or less. For more information see "Power Supplies" on page 2-12. Tapers, if included, can be wired for either 100-120-volt AC, 60 Hz; or 220-240-volt AC, 50 Hzthis must be specified at time of order.
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Facilities Requirements
Vacuum/Pneumatic Requirements
The power supply is "smart," sensing the voltage in the power line, and matching its power accordingly. 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. CAUTION: Connect the power cord to earth-grounded power outlets only. 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. Service calls made to the customer facility to correct problems caused by improper electrical supply are not covered by the Exatron warranty.
Vacuum/Pneumatic Requirements
The handler system requires a supply of pressurized air at a minimum of 80 PSI at 2 to 5 CFM (depending on the number of vacuum generators), filtered for proper operation. The air supply must be clean (containing no particulate matter greater than 5 microns in size), oil-free, and dry (having a dew point of 36 degrees F to 38 degrees F) to operate correctly. Dirty, oily or wet air will cause the vacuum generator to malfunction and will make your system unreliable. Because 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. To maintain these levels of pressurized air quality, replace the air filter (Exatron part #GPA-97075) in the air regulator of your handler after every 6000 hours or 12 months of operation, whichever comes first; or if your air regulator registers a pressure drop of 15 PSI. Moisture of any kind will travel through external and internal air lines. This moisture will coat these air lines and the insides of the handler's cylinders, causing them to stick or to stop functioning altogether. The best defense against this kind of contaminate is to prevent it from occurring in the first place by maintaining the clean air supply described above. If the air lines are allowed to become discolored or the moisture traps become overfilled, damage to the system will occur. The only corrective action to take at that point is to replace all of the air lines and to completely clean all of the solenoids supplied by those air lines. Handler damage due to improper air supply is not covered by the Exatron warranty.
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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 turning on the air regulator and using the Model 5000 handler and 1050 taper, make certain that a compressed air line of 80 PSI is attached to the air regulator fitting. The Model 1050 taper takes its air supply from a 1/4" diameter flexible plastic air line plugged into a compressed air outlet mounted on the right side of the Model 5000 handler's main plate.
Figure 1-2: Air Line Attached to Outlet
Installation Overview
Basic installation of your new Exatron handler and taper will consist of the following major steps: Unpacking the handling equipment and assembling its peripheral parts Powering up the handler and taper ("Power-Up Procedure" on page 3-16) and running Diagnostics sequences (Chapter 4) Cycling sample tubes of devices Interfacing the handler to your tester/programmer (Chapter 3)
Uncrating the Handler and Taper

The handler and taper will usually come in a wooden crate which will require some disassembly to remove. Please inspect the system when it is removed from the crate for any obvious damage which may be the result of shipping. Contact Exatron and the shipping company immediately if you see any damage.
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Standard Warranty
Customer In-House Service
Standard Warranty
All Exatron products are under warranty for one year from the date of purchase. Exatron agrees to repair any mechanical or electrical assembly, subassembly, or entire unit which fails during normal use within its first year. The customer agrees to follow the recommended maintenance procedure as defined in this manual. Exatron does not warrant 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
Customer In-House Service

Except in the case of laser marking systems, Exatron encourages customer in-house equipment service and tries to make in-house service as easy as possible to perform. There are no "Void Warranty" warning stickers on Exatron handlers. By using the built-in diagnostic software and diagnostic tools, it is usually possible for the operator to isolate a problem quickly and effect a repair. The customer is responsible for all cost of in-bound shipping expenses. Standard out-bound shipping expenses will be paid by Exatron. In such cases where the customer requests specific out-bound shipping methods be used, the customer is responsible for all shipping costs and any additional related charges.
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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 taper The type of device being run by the handler, such as: DIP, SOIC, SOJ, PLCC, LCC, SIP, PGA, PCB, ZIP, etc. The tapers serial number The full shipping address Any special shipping or customs instructions Method of shipment, such as: Federal Express, UPS, DHL, U.S. Mail, or the name of your chosen shipping company In most cases, faxed requests and shipment of replacement parts orders are processed within twenty-four hours of receipt by Exatron.
Exatron Support Services

For factory technical support, you can contact us in several ways. Call 1-800-EXA-TRON or 1-408-629-7600, between 8:00 A.M. and 5:00 P.M. Pacific time, Monday through Friday. E-mail us anytime at [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.)
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End-of-Life Taper Disposal
Offshore Warranty Service
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.
End-of-Life Taper Disposal

Exatron has no time limit on Exatron product support. We will make every effort to repair any of our products, no matter how old it is. Our never-ending support greatly extends the life of many of our products. Exatron offers trade-in value on any of our products as part of a new Exatron equipment purchase. Exact terms are subject to quote at that time. This applies to any used Exatron product as a trade-in on any new Exatron product. 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.
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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.
Typographical Conventions Used in This Manual

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

Blow-off A positive air pressure in the vacuum lines, used to break any residual vacuum between the pickup head and a device it was suctioning. A generic term that refers to the chip, package, or other part processed by the Exatron handler. The gap, or pitch, between the leading edge of adjacent tape pockets. This gap is found automatically by the gap sensor when you press <ENTER> to select "SET GAP ? YES". The additional distance, measured in tape drive motor steps, the tape must advance after the gap sensor has found the leading edge of a tape pocket until the center of a tape pocket is directly under the center of the swing arms pickup head. This is a one-time-only advancement of the tape at the beginning of each run. This distance you must set manually for each tape. The distance, measured in tape drive motor steps, between the leading edge of adjacent tape pockets. The location that each motor returns to each time the handler is reset. The total of the parameter values for all the RAM addresses displayed in hex.
Device
Gap
Gap offset, or Offset
Gap steps
Home position
Sum check
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Chapter 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 Key Positions How the Model 1050 Works Identifying Major Parts Communication Between Handler and Taper
Page 2-2 2-3 2-3 2-19
This chapter will familiarize you with the various parts of the system hardware, what they do, and how they work. Exatron recommends that you read this part of the manual in the presence of the system to facilitate reference to the actual system. The parts of the system are identified as shown in this chapter.
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Key Positions
Figure 2-1 shows all the positions where a device might rest or be deposited during its course through the Model 5000 handler and Model 1050 taper. Everything above the dotted red line belongs to the 5000 handler and is discussed in the Model 5000 User Manual.
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 2-1: Key Device Positions
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How the Model 1050 Works
Three Reels
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 the Model 5000 User Manual; whereas the set for the taper is discussed in this manual, the Model 1050 User Manual.
How the Model 1050 Works

Empty carrier tape is fed on to the tape track from the supply reel, and the tape drive motor advances the tape. Each device is dropped by the shuttle down the taper input track. The stack pin is by default extended, stopping each device. When a signal is received, the index pin extends to hold the line of waiting devices, the stack pin retracts, and the device drops to the tapers pickup site, where it is held by the cover foot. As each device is dropped to the pickup site, the swing arm rotates up over the pickup site, and the pickup head attached to the swing arm extends, picks it up, and retracts. The swing arm then rotates down and the pickup head again extends to place the device in the carrier tape pocket. The drive motor advances the tape one pocket and the process is repeated. A few inches to the left, a group of sensors ensure that each pocket is filled, and that each device lies flat in the pocket. To the left of these sensors, the sealing heads, either thermal or pressure-sensitive, seal the cover tape onto the edges of the carrier tape. At regular intervals set by the user, the takeup reel motor is activated and the filled tape is wound onto the takeup reel.
Identifying Major Parts

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

Figure 2-2: Reels on Taper
The carrier tape is fed in a right-to-left direction from the supply reel, along the tape track and under the swing arm, past the sealing tape and sealing heads, to the takeup reel. On the top surface, the pitch or gap sensor detects the hole in the center of the empty pocket, and signals the position to the swing arm. When the empty pocket intersects the path of the swing arm, the swing arm places a device into the tape pocket.
Figure 2-3: Tape Track with Swing Armat Pickup Site (Left), at Taper (Right)
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Taper Input Track
After receiving devices from the swing arm, the filled carrier tape is sealed, either with pressure-sensitive sealing tape or heat-sealed cover tape. If pressure is used to seal, the pressure is continuous; but if heat is used to seal, the heat seal heads are pressed against the tape only intermittently to prevent burning. When a specified number of pockets have been filled, the takeup reel motor is activated long enough to wind the slack tape onto the takeup reel. The drive gear drives the tape along, with teeth that protrude upward to fit the holes on the side of the carrier tape. The pinch roller on the pressure roller block presses down on the tape, keeping it meshed with the teeth of the drive gear. Sensor lights EMO (emergency stop) button
Heater controller displays Override button lights Heater fuse Pressure seal heads
Empty pocket sensor Takeup arm
Pressure roller block
Track width locking knob

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

Although physically attached to the Model 5000 handler, the taper input track is logically part of the taper, because Model 5000s that do not have the taper do not have the taper input track, either. Rather, they are equipped with 8 output tubes instead of 5.
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The taper input track is below the shuttle and to the right of the 5 output tubes. Like the input track on the Model 5000 handler, this track also has solenoids that control an index pin, a stack pin, and a cover foot. During a production run, the stack pin is by default extended, restraining the waiting line of devices. When the swing arm on the tape-and-reel assembly is ready to move another device, the index pin is extended between the lowest device in line and the device just above it. Then the stack pin is retracted, allowing the lowest device to fall. The stack pin and cover foot are activated simultaneously to prevent the device from jumping the stop block. Thus, when the stack pin retracts to release a device, the cover foot is extended to hold the device at the pickup site momentarily until any bouncing action stops.
Figure 2-5: Index Pin Retracted (Left), Extended (Right)
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Emergency Stop Button
Figure 2-6: Cover Foot Retracted From Pickup Site and Stack Pin Extended (Left); Cover Foot Extended Over Pickup Site and Stack Pin Retracted (Right)
Emergency Stop Button

The Emergency Stop button on the taper control box shuts down everything on the taper only, including the heat seal; whereas the Emergency Stop button on the body of the handler stops all motors. Pressing the tapers Emergency Stop button causes a taper error message to be displayed on the control panel. The operator then has the option of aborting the job run, or making any necessary adjustments and then selecting the option to continue the run.
Motors
The motors for the swing arm and tape drive are phase motors. The motor driving the swing arm is inside the cylinder box (Figure 2-7).
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Figure 2-7: Phase Motor Driving Swing Arm
The motor driving the tape drive is located directly behind the tape drive gear adjustment knob.
Tape drive motor
Tape drive gear adjustment knob

Figure 2-8: Tape Drive Motor
The motor driving the takeup reel is inside the housing for the control panel (Figure 2-9).
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Sensors
Figure 2-9: Takeup Reel Motor
The sealing heads are driven, not by a motor, but by air solenoids.
Sensors
The sensors for the Model 1050 taper have descriptive names. Sensor Controller yes yes no no Figure 2-16 Figure 2-13 Figure 2-14 Figure 2-15 Figure 2-17 no yes yes yes no
Sensor Name Device at Stack Sensor Device at Pickup Site Sensor Swing Arm Home Sensor Pickup Head Vacuum Sensor Carrier Tape Out Sensor Empty Pocket Sensor Out-of-Pocket Sensor Gap Sensor Takeup Arm Sensor
Sensor ID A B 9 8 6 5 7 4 3
Figure Figure 2-10, Figure 2-11 Figure 2-10, Figure 2-11 Figure 2-18
The sensors shown in Figure 2-10 through Figure 2-15 are fiberoptic; they come with sensor controllers. For more information on the controllers, see "Fiberoptic Photoelectric Sensor Guidelines" on page 6-8.
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Figure 2-10: Device at Stack Sensor (A, Top); Device at Pickup Site Sensor (B, Bottom)
Figure 2-11: Device at Stack Sensor (A, Left); Device at Pickup Site Sensor (B, Right)
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Sensors
Figure 2-12: Taper Sensors
In Figure 2-12, the track is shown with no tape to clarify the directions the various sensor beams are aimed. The Empty Pocket sensor, 5, is aimed downward through the hole in any empty pocket. The Out-of-Pocket sensor, 7, is aimed across the top of the tape, looking for any devices sticking up above the surface of the tape. The Gap sensor, 4, is aimed across the tape. It looks for the gap, where the tape is in a position where the ridge between pockets is even with the Gap sensors beam so that it is not blocked by the tape.
Figure 2-13: Empty Pocket Sensor (5)
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Figure 2-14: Out-of-Pocket Sensor (7)
Figure 2-15: Gap Sensor (4)
The following sensors are not fiberoptic, but rather, photo sensors. They do not have sensor controllers.
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Sensors
Figure 2-16: Carrier Tape Out Sensor (6)
Figure 2-17: Takeup Arm Sensor (3) Closed (Left), Open (Right)
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Figure 2-18: Swing Arm Home Sensor (9, Left); Swing Arm at Home (Right)
The true home of the swing arm is at the Swing Arm Home sensor, not necessarily at the pickup site.
Override Buttons
The override buttons on the taper plate accomplish the same thing the software can do, but in a more direct way. Either may be used, according to the operators convenience.
Figure 2-19: Tape-and-Reel Override Buttons
NOTE: The action produced by each numbered override button corresponds with the action produced by the key with the same number in DIAGNOSTICS OUTPUT CHECK SOLENOID CHECK. See "OUTPUT CHECK: Solenoid Check" on page 4-11 and "OUTPUT CHECK: Solenoid Toggle Check" on page 4-12.
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Index and Stack Pins
Tape-and-Reel Override Buttons Button 8Blue 7Black 6White 5Gray 4Green Affects Takeup reel motor Pick-and-place head Blow-off Action When pressed, takeup motor is turned on, winding the tape and tightening tape slack When pressed, pickup head extends (Figure 2-23) When pressed, slight positive air pressure is emitted from suction cup on swing arm to break vacuum between device and suction cup
Cover foot and stack pin When pressed, cover foot extends and the stack pin (bottom) retracts (Figure 2-6) Index pin When pressed, the index pin (top) extends Used for custom applications, if requested by customer When pressed, negative air pressure is activated at suction cup on swing arm to form a vacuum between device and suction cup When pressed, seal heads are lowered onto the tape (Figure 2-20, Figure 2-21)
3Orange Customizable button 2Yellow 1Red Vacuum Seal heads
Index and Stack Pins

During a production run, the stack pin is by default extended, restraining the line of devices waiting to fall to the pickup site. When the taper is ready to get another device, the index pin is extended between the lowest device in line and the device just above it. Then the stack pin is retracted, allowing the lowest device to fall. The stack pin and cover foot are activated simultaneously to prevent the device from jumping the stop block. Thus, when the stack pin retracts to release a device, the cover foot is extended to hold the device at the pickup site momentarily until any bouncing action stops.
Seal Heads
The seal heads are pneumatic; they do not use sensors.
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Figure 2-20: Heat Seal Heads with Counterbalance Weight
Figure 2-21: Pressure-Sensitive (PSA) Seal Heads with Counterbalance Weight
Swing Arm
The swing arm rotates from the pickup site at the bottom of the taper output track to the tape pocket underneath its path.
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Swing Arm
Figure 2-22: Swing Arm at Pickup Site (Left), at Tape Drop Site (Right)
At the end of the swing arm is attached a pickup head that raises and lowers to place the device in the tape pocket. The pickup head had a suction cup attached, which passes a negative or positive air flow that acts as a vacuum or blow-off. The pickup head is pneumatic, controlled by air pressure.
Figure 2-23: Pickup Head Retracted (Left), Extended (Right)
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Taper input track
SWING HOME = c. 12 at pickup site Pickup site SWING HOME = 34 maximum
SWING = c. 122 from pickup site Tape output Swing arm positions SWING = 355 maximum
Figure 2-24: Path and Limits of Swing Arm
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Communication Between Handler and Taper
Swing Arm
Communication Between Handler and Taper

Communication signals are sent between the Model 5000 handler and the Model 1050 Taper by means of 4 wires. On the 1050 side they are attached to the 5000-A89 front panel PCB. On the 5000 side they are attached to the 3000-055 PCB. In case of a communication glitch, see the diagnostic instructions in "Checking Communication Between 5000 Handler and 1050 Taper" on page 4-19.
Figure 2-25: Communication WiringOn 1050 Side (Left), On 5000 Side (Right)
Figure 2-26: Connection Port for Communication Wiring
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Figure 2-27: TAPE-346-E1 Wiring Diagram
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Chapter Overview
This chapter discusses the following main topics:
Topic Mounting the Takeup Reel Mounting the Supply Reel Adjusting the Carrier Tape Track Width Loading the Carrier Tape Loading the Sealing Tape Adjusting Heat Seal Heads Adjusting Pressure Seal Heads Power-Up Procedure Setting Temperature for Heat Seal Heads Calibrating Device Position in Tape Pocket Beginning a Production Run Power-Down Procedure Understanding the Control Panel Keys Using the <SET UP> Key Modifying Setup Resetting the Count of Devices in Tape Displaying the Count of Devices in Tape Using Manual Mode Changing RAM Notes About the RAM Address Listing RAM Address Listing Hex-Binary Conversion Table Decimal-Hex-ASCII Conversion Table
Page 3-2 3-2 3-3 3-5 3-8 3-12 3-15 3-16 3-19 3-24 3-25 3-26 3-26 3-27 3-28 3-33 3-33 3-34 3-39 3-40 3-42 3-47 3-48
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Mounting the Takeup Reel

To mount an empty takeup reel: 1. Loosen the thumbscrew on the locking hub of the takeup wheel drive shaft located on the extreme left end of the tape-and-reel assembly (Figure 3-1). Remove the hub and place an empty takeup reel onto the drive shaft. 2. With the three hub pins aligned to the three pinholes in the center of the reel (Figure 3-1), slide the locking hub over the reel and back into place. 3. Tighten the thumbscrew to lock the takeup reel in position.
Figure 3-1: Locking Hub on Takeup Reel with Alignment Pins
Mounting the Supply Reel

Slide the carrier tape supply reel onto the three center prongs of the supply wheel so that the carrier tape unwinds in a counterclockwise direction from the top of the reel toward the left (Figure 3-2).
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Adjusting the Carrier Tape Track Width
Figure 3-2: Supply Reel Tape Unwound from Top
Adjusting the Carrier Tape Track Width

You may need to change the carrier tape track width when different sized devices are processed. This procedure is best accomplished along with the next procedure, "Loading the Carrier Tape" on page 3-5. Track width adjustment knobs
Figure 3-3: Carrier Tape Track at Different Widths
This is accomplished using two of three knobs: the track width locking knob, and either of the track width adjustment knobs.
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The track width locking knob is located below and between the cover tape reel and the takeup reel. The track width adjustment knobs are located at both ends of the base. CAUTION: Loosen the track width locking knob before turning the adjustment knobs to prevent bending and damage to the aluminum parts.
Figure 3-4: Track Width Locking Knob
To adjust the width of the carrier tape track: 1. Turn the track width locking knob counterclockwise to loosen it. 2. Turn either the front or back track width adjustment knob to adjust the track width. (They are connected by an internal chain, so they work in tandem.) The carrier tape should slide in the track freely but not loosely, and advance easily without binding, but also without too much lateral play in the track. > To make the tape track narrower, turn the knob clockwise. > To make the tape track wider, turn the knob counterclockwise. 3. At this point, leave the tape track a little wider than necessary and do the following procedure, Loading the Carrier Tape. 4. When the carrier tape has been loaded and the adjustment is correct, retighten the locking knob by turning it clockwise.
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Loading the Carrier Tape

To load the carrier tape: 1. Feed the leading end of the carrier tape (the leader) toward the sealing tape guide, making sure that the edge of the tape is under the guide at the side of the track.
Figure 3-5: Carrier Tape Under Guide At Top Supply End of Track
2. Continue feeding the carrier tape leader under the sealing heads. The sealing heads should be raised above the level of the carrier tape at this point. 3. When the carrier tape leader in the track reaches the pressure roller assembly, raise the pressure roller arm with your index finger. Slide the keeper pin into the pressure roller block assembly to hold it in the raised position while you feed the carrier tape along the track underneath.
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Figure 3-6: Lifting Pressure Roller Arm and Pushing In Keeper PinTwo Styles
4. Feed the carrier tape under the projecting takeup arm. Insert the carrier tape leader into the takeup reel according to the manufacturer's specifications. Wind the carrier tape around the takeup reel until it is secured in place. The carrier tape should move freely back and forth underneath the takeup arm.
Figure 3-7: Takeup Arm
5. Align the carrier tape with the tape drive gear. Loosen the blue lock nut on the drive gear assembly. Then you can turn the red adjustment nut to allow the gear to move laterally. Adjust the gear teeth to fit with the backside track of the carrier tape. Retighten the blue nut. Next turn the gear using the red thumbscrew section of the gear assembly. This should cause the carrier tape to advance freely towards the takeup reel.
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> Turning the red adjustment nut clockwise moves the teeth and tape to the right, widening the tape path. > Turning the red adjustment nut counterclockwise moves the teeth and tape to the left, narrowing the tape path.
Figure 3-8: Tape Drive Gear Adjustment Knob with Blue Locking Knob Unscrewed
Figure 3-9: Gear Adjustment Narrowed (Left); Widened (Right)
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Loading the Sealing Tape

To load the sealing tape: 1. Sandwich a roll of sealing tape between the two sealing tape plates, making sure the roll is snugged around the larger raised circle on the inside (Figure 310).
Figure 3-10: Sealing Tape PlatesOutside (Left), Inside (Right)
2. Suspend the reel on the sealing tape supply reel rod in the center of the taper between the two blue delrin supply reel adjustment collars (Figure 3-11). 3. Viewing from above, position the sealing tape supply reel centered over the carrier tape in the carrier tape track. Tighten the adjustment setscrew on each supply reel adjustment collar to secure the sealing tape supply reel in this position on the rod. 4. The sealing tape unwinds from the bottom of the reel in a counterclockwise direction toward the sealing tape guide assembly. > For a pressure-sensitive sealing tape, feed the sealing tape to the right over both pins of the sealing tape guide assembly and then under the guide block to the left (Figure 3-11). Notice that the tape rests on the upper, larger projecting pin but never touches the lower, smaller projecting pin.
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Figure 3-11: Sealing Tape Threaded to Sealing Tape Guide Assembly for PSA
> For a heat sealing tape, feed the sealing tape to the right under the lower, smaller projecting pin, then over the upper, larger projecting pin of the sealing tape guide assembly and under the guide block to the left (Figure 3-12).
Figure 3-12: Sealing Tape Threaded to Sealing Tape Guide Assembly for Heat
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Figure 3-13: Sealing Tape Threaded Under Guide Block
> Guide blocks come in widths from 8 mm to 72 mm (up to 120 mm by special order). There are two sets of grooves on the underside of the guide block. The outer set of grooves guides the carrier tape. The inner set of grooves guides the sealing tape.
Figure 3-14: Two Widths of Guide BlocksTop View (Left); Bottom View (Right)
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Figure 3-15: Placement in Grooves of Guide Blockof Sealing Tape (Left) and Carrier Tape (Right)
5. Check to make sure the guide block is the right width for the tape you are using. 6. Loosen the two guide block screws. > If you need to change the guide block, slip the guide rod partway out and replace the guide block on the rod (Figure 3-16). Then replace the rod in the bracket.
Figure 3-16: Guide Rod Removed from One Bracket
7. Adjust the guide block to fit directly over the carrier tape and sealing tape. > Push the guide block down so that it is flush against the carrier tape.
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> While holding the thin edge down, tighten the two red adjustment screws on the guide block assembly (Figure 3-17). The carrier tape should now be inside the outer set of grooves on the guide block.
Guide block adjustment screws

Figure 3-17: Guide Block Assembly
8. Use light pressure or heat to attach the sealing tape to the carrier tape. CAUTION: Do not use adhesive tape on the carrier tape, as it contains static electricity and can ruin the static-free condition of the carrier tape. 9. Feed the sealing tape under the guide block assembly. Advance the tape until approximately five inches of sealing tape extends past the sealing heads. The sealing tape should now be in between the inner set of grooves on the guide block.
Adjusting Heat Seal Heads

Two adjustments may need to be done for a pair of heat seal heads: lateral alignment and downward pressure. Correct lateral alignment assures that the seal heads are on the sealing edges of the tape; correct pressure balances the degree of heat needed to seal without tape damage.
Adjusting Lateral Position

If your Model 1010 taper is equipped with heat seal heads, use this procedure to align the lateral position of each head separately. To align lateral position of heat seal heads: 1. Make sure the heaters are off and the thermal heads are cool. There are two
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Adjusting Heat Seal Heads
Adjusting Lateral Position
readouts for each heater controller display. The top line is the present value (PV) and the bottom line is the set value (SV). Set the bottom line to 0 degrees (see "Setting Temperature for Heat Seal Heads" on page 3-19 for instructions), and wait until the sealing head is at ambient room temperature. 2. Remove the seal head closest to you (the front seal head). Use a #10 size hex wrench and remove the seal head adjustment screw. Remove the seal head and lay it aside. 3. Loosen the adjustment screw on the back seal head. Adjust the head laterally so that it is directly over the back edge of the sealing tape. 4. Manually engage the back seal head and confirm that the edge of the seal head is aligned with the back of the sealing tape. Make sure that the track holes on the carrier tape are not blocked by the sealing tape. 5. With the seal head engaged, tighten the adjustment screw. 6. Repeat this process with the front sealing head. Adjustment screw
Figure 3-18: Semicircular Seal Head with Adjustment Screw
7. Once both heads are aligned, turn the heat to the sealing heads on. Note that you must power on the handler and the taper in order to do this. (See "PowerUp Procedure" on page 3-16.) Set the bottom line (the Set Value) on both heaters to 350 degrees. (For instructions on changing the Set Value, see "Setting Temperature for Heat Seal Heads" on page 3-19.) Wait until the top line (the Present Value) reads 350. WARNING: Do not touch the heat seal heads directly when the heat is turned on. 8. After the sealing heads have warmed up, check the seal on the sealing tape.
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Manually engage both seal heads. Apply pressure to the sealing tape for 3 to 5 seconds. Use the takeup arm to engage the heads. This should cause a good seal to the carrier tape. Manually advance the carrier tape and inspect the seal. 9. Run the carrier tape for several pockets with the seal heads engaged. NOTE: You may need to practice this adjustment a few times by running the machine briefly at the start of a job and inspecting the seal for quality.
Figure 3-19: Example of Good Tape Seal
Adjusting Downward Pressure

To balance the heat temperature with the pressure applied, you may want to adjust the pressure of the heat seal heads. To adjust pressure of heat seal heads: If more pressure is needed to allow a lower heating temperature, add a heavier weight to the counterweight bar (Figure 3-20).
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Adjusting Pressure Seal Heads
Figure 3-20: Three-Gram and One-Gram Weights (Left); One-Gram Weight on Heat Seal Counterbalance
Adjusting Pressure Seal Heads

Two adjustments may need to be done for a pair of pressure seal heads: the lateral alignment of the rollers, and the weights that cause downward pressure. Correct lateral alignment assures that the seal heads are on the sealing edges of the tape; correct pressure assures a good seal. Lateral adjustment screws
Figure 3-21: Pair of Pressure Seal Heads with Lateral Adjustment Screws
To move either pressure seal head laterally, loosen the adjustment screw and pull or push the head to the correct position. Retighten the screw when the adjustment is correct.
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Figure 3-22: Three-Gram and One-Gram Weights (Left); One-Gram Weight on PSA Counterbalance
If the PSA is not applying enough pressure for a good seal, you can adjust the weight for more pressure. To increase pressure, switch to a heavier weight. To decrease pressure, switch to a lighter weight.
Power-Up Procedure
You must power up the Model 5000 handler before you can power up the Model 1050 taper. Before powering up the handler, do the following: 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. Air supply should be free from moisture and oil. After connecting to the air supply, turn on the air regulator.
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Power-Up Procedure
Adjustment valve On/off switch in OFF position On/off switch in ON position
Figure 3-23: Air Regulator Turned Off (Left), On (Right)
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 these parts: > > > > > 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
5. Move the octoloader plate so that it is flush against the octoloader home switch. 6. Place tubes of devices into the octoloader.
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7. Place empty output tubes into the output tube holder. 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. You are now ready to power up the Model 5000 handler. To power up the handler: 1. Turn on the handlers power supply by twisting the red Emergency Stop button clockwise on the power supply until it pops out. (Figure 3-24)
Figure 3-24: Emergency Stop Button on Model 5000 Handler
> As the handler powers up, its control panel displays its opening messages. At the end, it displays the message "READY TO RUN." See the Model 5000 User Manual for further power-up information on the handler. You are now ready to power up the Model 1050 taper. NOTE: For thermal tape systems, powering on the Model 1050 also turns on the heaters in the sealing heads. To power up the taper: 1. Turn on the tapers power supply by twisting the red Emergency Stop button clockwise on the power supply until it pops out.
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Setting Temperature for Heat Seal Heads
E-Stop button for Model 1050 taper
E-Stop button for Model 5000 handler
Figure 3-25: Emergency Stop Buttons for Both Handler and Taper
> As the taper powers up, it displays a list of messages like the following, with its model and current control program with revision date. (Please give this revision date to Exatron's Customer Service Department when calling for assistance or software updates. Exatron offers free firmware updates on request for the life of the equipment.) V02.14 Test Ok EXATRON TAPE TAPE-2 11-16-05 MOD SET UP ? NO FIND MOTOR HOME HOME SWING HEAD MOTOR HOME TAKE UP MOTOR ON READY TO RUN ?

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

Figure 3-26: Heater Controller Display
In Figure 3-26, the back heat seal head has been set to 350 degrees, and the current temperature is 347 degrees. When the seal head is heating, the green LED light to the left of the Set Value display is on. When the present temperature is stable, the orange LED light to the left of the Present Value display is on. A general guideline may be to use somewhere around 275 to 325 degrees Fahrenheit (or 135 to 165 degrees Celsius) for a heat seal. If in doubt, it is better to start with a lower temperature and test the result, then increase little by little as needed. A narrow carrier tape takes a lower temperature to prevent burning. NOTE: It should not take more than 2-3 minutes to heat the seal heads to the Set Value. If it takes longer, the Set Value may be too high. To set the temperature: This example changes the set temperature from 0 degrees to 275 degrees. 1. Press the SET button on the lower left of the temperature control display (Figure 3-27). > The lower display blinks rapidly, indicating it is ready to be set.
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Figure 3-27: SET Button
2. Press the Up arrow button (Figure 3-28) repeatedly until the 0 changes to 5 (Figure 3-29).
Figure 3-28: Up Arrow Button
Figure 3-29: Digit in Ones Position Selected
3. Press the Left arrow button (Figure 3-30) to shift the digit that lights up to the tens digit.
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Figure 3-30: Left Arrow Button
4. Press the Up arrow button repeatedly until the 0 changes to 7 (Figure 3-31).
Figure 3-31: Digit in Tens Position Selected
5. Press the Left arrow button to shift the digit that lights up to the hundreds digit. 6. Press the Up arrow button repeatedly until the 0 changes to 2 (Figure 3-32).
Figure 3-32: Temperature Set Before the SET Button Is Pressed
7. Press the SET button again. All the set value digits stop blinking and light up in
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a steady display, and the temperature (PV) increases rapidly.
Figure 3-33: Temperature Set After the SET Button Is Pressed
8. Repeat the procedure for the other seal head. To turn off the heat seal heads: 1. Press the SET button on the lower left of the temperature control display. > The lower display blinks rapidly, indicating it is ready to be set. 2. Press the Down arrow button until the ones value is 0 (Figure 3-34).
Figure 3-34: Down Arrow Button
3. Press the Left arrow button to shift the digit that lights up to the tens digit. 4. Press the Down arrow button until the tens value is 0. 5. Press the Left arrow button to shift the digit that lights up to the hundreds digit. 6. Press the Down arrow button until the hundreds value is 0 (Figure 3-35).
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Figure 3-35: Temperature Set to Zero Before the SET Button Is Pressed
7. Press the SET button again. All the set value digits stop blinking and light up in a steady display. 8. Repeat the procedure for the other seal head.
Calibrating Device Position in Tape Pocket

To calibrate the optimal placement of the devices in the tape pockets: 1. Turn on the handler and taper. (If they were already on, turn the taper off and back on.) > The swing arm moves to its home position over the pickup site. 2. Drop a device into the exit track of the 5000 handler. > The device falls to the pickup site. 3. Press the <SET UP> key on the control panel for the 1050 taper. 4. Follow the instructions in "Modifying Setup" on page 3-28 and especially "Selecting Manual Cycling" on page 3-32 to set the taper to Stop mode. 5. In Stop mode, press the <ENTER> key repeatedly until the swing arm has dropped a device in the tape pocket. 6. Examine the position of the device in the pocket.
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Beginning a Production Run
Figure 3-36: Tape Calibration Needed
> If the swing arm places the device to one end of the pocket or between pockets, the tape position needs to be calibrated. Follow the instructions in "ALL MOTOR CHECK: Drive Motor Check" on page 4-13.
Figure 3-37: Swing Arm Calibration Needed
> If the swing arm places the device to one side of the pocket or the other, the swing arm needs to be calibrated. Follow the instructions in "ALL MOTOR CHECK: Swing Arm Check" on page 4-14.
Beginning a Production Run

Before beginning a production run, make sure that first the handler and then the taper are powered up, as described in "Power-Up Procedure" on page 3-16. To begin a production run: 1. Press the <RUN> key on the handlers control panel. 2. Press the <RUN> key on the tapers control panel. > The tapers control panel message changes from "READY TO RUN ?" to "WAITING." When enough devices are stacked in the tapers input track, the taper will begin transferring the devices to the tape automatically. No further action is needed by you.
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Power-Down Procedure
In case of unexpected events, you can push in the Emergency Stop button to turn off the power to the taper at any time. CAUTION: Allow at least 30 seconds before turning the taper's power back on. Avoid rapid OFF/ON cycles. To power down the system: 1. Run the handler until empty of all devices. Finish the current job. 2. Empty all output tubes, or replace with empty tubes. 3. Turn the taper power off by pushing in the Emergency Stop button on the right side of the tapers control panel. 4. Turn the handler power off by pushing in the Emergency Stop button at the lower left corner of the handler.
Understanding the Control Panel Keys

In Ready To Run mode or after you press the <PAUSE> key, the taper's control panel keys have the following functions: Key <ENTER> Function Starts operations; enters your selections into the system If you dont make any selections before pressing <ENTER>, the selection that was last in effect will be used. ADD LEADER UPAdvances tape drive motor and takeup reel motor, with seal heads up in inactive position. ADD LEADER DOWNAdvances tape drive motor and takeup reel motor, with seal heads down in active position. Erases changes just made to current setting. POCKETS = ######Displays number of devices already placed in tape. Puts taper in Manual mode. CHANGE RAM ? YES/NOEnables you to change RAM settings. RESET COUNT NOEnables you to reset the count of devices in tape to zero. MOD SET UP ? YES/NOEnables you to modify setup parameters. Pauses taper operation. Displays total devices placed in tape. THERMAL OR PSA ?Press <1> for thermal seal tape; <2> for pressure tape.
<SPACE> <DELETE> <CLEAR> <RUN> <MANUAL> <SET UP>
<PAUSE> <TOTALS> <1>
<DIAGNOSTICS> Puts taper in Diagnostics mode.
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Using the <SET UP> Key
Key <2> <3> <5> <6> <7> <8> <9> <0> <-> <.> < >
Function FULL T = ######Enter number of devices to be put in tape. Homes swing arm. TAKE UP MOTOR ONTakeup reel motor runs briefly; lift takeup arm to stop. POCKETS = ######Advances tape drive motor and takeup reel motor, with seal heads activated. JOG LEFTTape drive advances. SET GAP ? NOPress <SET UP> to change to SET GAP ? YES. STOP MODE ON/OFFPress <1> to turn STOP mode on; <2> to turn LOOP mode on; or <3> to keep all modes off. All MOTORS OFF then <ENTER> = "ALIGN MOTORS ?" Rotates swing arm up one motor step. See "ALL MOTOR CHECK: Swing Arm Check" on page 4-14 for details. Rotates swing arm down one motor step. See "ALL MOTOR CHECK: Swing Arm Check" on page 4-14 for details. 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.
If your taper is not running properly at this point, you may wish to enter directly into the Diagnostics mode upon taper power-up. See Chapter 4 for more information.
Using the <SET UP> Key

A number of options are available from the <SET UP> key. You will be stepping through several options, as shown in Figure 3-40. Step-by-step instructions continue on page 3-31. As a reference, you can skip to the desired subtopic:
Topic Changing RAM Resetting the Count of Devices in Tape Modifying Setup
Page 3-39 3-33 3-28
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Figure 3-38: <SET UP> Key Flowchart
Modifying Setup
During the taper's powering up message sequence, you can set the taper to go immediately to "DIAGNOSTICS" or "CHANGE RAM". Always select "CHANGE RAM ? YES" when installing new taper update EPROMs into the taper. At the end of the taper's powering up message sequence, the first option given to you is "MOD SET UP ? NO" (modify setup). If you do not wish to make any changes to the taper's setup, press the <ENTER> key. The taper will then scroll through the current settings for: > THERMAL OR PSA (heat seal tape or pressure-sensitive seal tape) > FULL T = ###### (number of devices to be placed in tape) > SET GAP ? NO (find distance between two adjacent pocket gaps)
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Modifying Setup
Understanding the Gap
> GAP STEPS = #### (distance between two adjacent pocket gaps) > OFFSET = #### (distance between gap and next pocket center) > ALL MODES OFF ? (STOP mode, LOOP mode, or none) If you wish to change any or all of the above settings, press the <SET UP> key to change the "MOD SET UP ? NO" message to "MOD SET UP ? YES" (modify setup). Now press the <ENTER> key to make changes. You will be stepping through several options, as shown in Figure 3-40. Step-by-step instructions continue on page 3-31. As a reference, you can skip to the desired subtopic:
Topic Selecting Type of Tape Seal Selecting Number of Devices to Be Put in Tape Setting Tape Pocket Gap Selecting Manual Cycling
Page 3-31 3-31 3-31 3-32
Understanding the Gap

A few term definitions are in order before you set the tape pocket gap. The gap is the distance, or pitch, between the leading edge of adjacent tape pockets. This distance is found automatically by the gap sensor when you press <ENTER> to select "SET GAP ? YES". The gap offset, or offset, is the additional distance, measured in tape drive motor steps, the tape must advance after the gap sensor has found the leading edge of a tape pocket until the center of a tape pocket is directly under the center of the swing arms pickup head. This is a one-time-only advancement of the tape at the beginning of each run. This distance you must set manually for each tape. The gap steps is the distance, measured in tape drive motor steps, between the leading edge of adjacent tape pockets. Gap Offset
Figure 3-39: Gap Versus Offset
The gap steps value must always be higher than the offset value.
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Figure 3-40: Modify Setup Flowchart
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Modifying Setup
Selecting Type of Tape Seal
Selecting Type of Tape Seal

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

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

3. The taper displays "SET GAP ? NO." The gap is the ridge between adjacent tape pockets. <ENTER> key = Press to display current settings. The display reads "GAP STEPS = ####", then "OFFSET = ####".
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<SET UP> key = "SET GAP ? YES"This proposes to re-find the gap between the leading edges of two adjacent tape pockets. <ENTER> key = Press to advance the tape and have the taper reset the distance between the gaps at either end of a tape pocket. NOTE: If you get a "NO POCKET? ERROR" message, it means the sensor cannot find the gap. Press down lightly on the tape to let the sensor find the gap. <CLEAR> key = Redisplays the message "SET GAP ? NO" and gives you a chance to change your selection. <ENTER> key confirms your selection. 4. The taper displays "SET OFFSET = ####". Use Polish notation to change the offset if necessary. See "Understanding the Gap" on page 3-29 for more information. <ENTER> key confirms your selection.
Selecting Manual Cycling

5. The taper displays "ALL MODES OFF ?" or "STOP MODE ON/OFF." Stop and loop modes are for testing and troubleshooting of the taper. Select one of the following keypad choices: <1> key = "STOP MODE ON ?" The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. <2> key = "LOOP MODE ON ?" The taper will stop after a complete cycle for one device. <3> key = "ALL MODES OFF ?" The taper will cycle multiple devices in a normal run. This is the default. <CLEAR> key = Redisplays the message "STOP MODE ON/OFF" and gives you a chance to change your selection. <ENTER> key = Enters your selection into the taper. 6. The taper will now display "READY TO RUN ?." NOTE: Any time the taper is running, you can press the <SET UP> key. This stops the taper and offers you the options to "CHANGE RAM ?", then "RESET COUNT", then "MOD(ify) SET UP ?"
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Resetting the Count of Devices in Tape
Resetting the Count of Devices in Tape

The taper keeps a running count of total devices placed in the tape. These counts are preserved in the battery-backed-up RAM, even when the taper is turned off. Therefore, you have to reset the counts to zero at the control panel. To keep an accurate count of devices processed, you may want to reset the totals at the beginning of each day or of each production run. To reset the count: 1. Press the <SET UP> key. > The message "CHANGE RAM? NO" is displayed. 2. Press the <ENTER> key. > The message "RESET COUNT NO" is displayed. 3. Press the <SET UP> key. > The message "RESET COUNT YES" is displayed. 4. Press the <ENTER> key. > The message "COUNT SET TO 0" is displayed briefly, then the taper goes back to the routine it was in before you pressed <SET UP>.
Displaying the Count of Devices in Tape

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

Manual mode allows you to: Make mechanical adjustments to the taper Check and modify settings related to tape pocket size Select special troubleshooting modes (stop mode or loop mode) Select seal type (thermal or PSA) Reset total output counts
You can access Manual mode while the handler is processing devices or at any other time. Manual mode steps you through a number of options, as shown in Figure 3-41. Step-by-step instructions begin on page 3-36.
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Using Manual Mode
Figure 3-41: Manual Mode Flowchart
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To use Manual mode: 1. Press the <MANUAL> key. If the handler is processing devices, it is paused. > If the password security is turned on, the display reads "PASSWORD ABC ?" Enter a 3-digit password using the numeric keys. The factory-set password is 123, or <1>, <2>, <3>. > The message "MANUAL ######" is displayed, with each pound sign representing a digit of the tape output count. 2. Select one or more of the following keypad choices: <1> key = "THERMAL OR PSA ?"Select the type of seal you want to use. <1> key = "USE THERMAL TAPE"Use a heat seal. <2> key = "USE PSA TAPE"Use a pressure-sensitive adhesive seal. <ENTER> key = Press to confirm your selection and return to the previous mode. <2> key = "FULL T = ######"This is the number of devices that will make up a full reel of tape. It can be any number up to 999,999. You can change this number by using the number keys on the control panel. Work from right to left: Start with the smallest (ones) digit, then the tens digit, and work up to the largest digit. For example, to enter the number 001248, press <8>, <4>, <2>, <1>, <0>, <0>. <ENTER> key = Press to confirm your selection. Next, "RESET COUNT NO" is displayed. <ENTER> key = Press to leave the tape output count as it is and return to the previous mode. <SET UP> key = "RESET COUNT YES"This will reset the count of tape pockets filled or passed through the taper to zero. Press <ENTER> to reset the count. The display then reads "COUNT SET TO 0" and returns to the previous mode. <3> key = "FIND MOTOR HOME", "HOME SWING HEAD", then "MOTOR HOME"This automatically resets the swing arm at the pickup position. <4> key = "NEW TAPE SET UP?"Select the tape setup corresponding to the device type you want to run.
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Using Manual Mode
<1> key = "USE SET UP #1"Use setup number 1. <2> key = "USE SET UP #2"Use setup number 2. <3> key = "USE SET UP #3"Use setup number 3. <4> key = "USE SET UP #4"Use setup number 4. <ENTER> key = Press to confirm your selection. The settings for the setup type selected are displayed. Then the taper returns to the previous mode. <5> key = "TAKE UP MOTOR ON"This turns on the takeup motor until one of 3 things happens: (1) the takeup arm is raised by the tautness of the tape, or (2) you gently lift the takeup arm to turn the motor off, or (3) the time limit in number of seconds is reached. If the motor turns for the full time specified without the takeup arm being raised, the message "TAKE UP REEL ERR" is displayed. At this point you can press either of two keys: <ENTER> key = Press to rotate reel again. <CLEAR> key = Press to return to Manual mode. <6> key = "POCKETS = ######"The drive motor advances by one pocket and activates seal heads; the count of pockets increments by one. However, the swing arm is not activated to get a device from the pickup site. Because it does not attempt to place a device in a pocket, this feature allows the operator to either (1) check the location and quality of the seal, or (2) place devices in the tape manually without running them through the handler. <8> key = "SET GAP ? NO" <ENTER> key = Press to display current settings. The display reads "GAP STEPS = ####", then "OFFSET = ####", then "SWING HOME = ##", then "SWING STEP = ###". Each pound sign (#) is replaced by a digit. <SET UP> key = "SET GAP ? YES"This proposes to re-find the gap between tape pockets. <ENTER> key = Press to advance the tape and set the gap. The display reads "JOG LEFT", then "GAP STEPS = ####, then "OFFSET = ####", and stops at "SET OFFSET= ####". NOTE: If you get the message "NO POCKET? ERROR", it means it cant find the gap. Press down lightly on the tape.
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You can change the offset number by using the number keys on the control panel. Work from right to left: Start with the smallest (ones) digit, then the tens digit, and work up to the largest digit. For example, to enter the number 0725, press <5>, <2>, <7>, <0>. When you finish, press <ENTER> again to redisplay the current settings. <9> key = "STOP MODE ON/OFF"Select the mode you want to run. <1> key = "STOP MODE ON ?"The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. <2> key = "LOOP MODE ON ?"The taper will stop after a complete cycle for one device. <3> key = "ALL MODES OFF ?"The taper will cycle multiple devices in a normal run. This is the default. <ENTER> key = Press to confirm your selection and return to the previous mode. <0> key = "ALL MOTORS OFF"This turns off the swing arm motor, allowing you to move it freely. It does not, however, turn off the takeup and tape drive motors. <DELETE> key = "ADD LEADER DOWN"Runs the takeup and drive motors for the specified number of pockets (stored in RAM addresses) with the sealing heads down, in the active position. This creates a leader of sealed, empty pockets on a new reel, or a place to cut the tape to separate filled tape from unused tape. <CLEAR> key = Press to stop the motors and return to the previous mode. <SPACE> key = "ADD LEADER UP"Runs the takeup and drive motors for the specified number of pockets (stored in RAM addresses) with the sealing heads up, in the inactive position. This creates a leader of unsealed, empty pockets. <CLEAR> key = Press to stop the motors and return to the previous mode. <ENTER> key = Press to confirm your selection and return to the previous mode.
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Changing RAM
Changing RAM
The Model 1050 system allows you to change the RAM of each taper CPU. You can do this in one of three ways: You can change individual address values, or settings. You can reload all the default settings from the EPROM. This will erase any changes that have been made to individual addresses. You can reload all the default settings from the EPROM, and then change individual address settings. NOTE: If you consistently use a RAM address setting that is different from the default in the EPROM, write down your changes and fax them to Exatron, and we will send you, free of charge, a new EPROM containing the default settings you use. This will help you avoid unnecessary future changes and confusion over lost changes. When you press the <SET UP> key, you have several options, as shown in Figure 3-38. To access the Change RAM mode and change RAM settings: 1. Press the <SET UP> key on the tapers control panel. The message "CHANGE RAM? NO" is displayed. 2. Press the <SET UP> key again. The message "CHANGE RAM? YES" is displayed. 3. Press <ENTER>. > The message "LOAD DEFAULT NO" is displayed. 4. If you want the taper to load the default settings for all the RAM addresses into RAM, press <SET UP> to display "LOAD DEFAULT YES", and then press <ENTER> to load the defaults while the message "LOAD EPROM>RAM" is displayed; or If you want the taper to leave all RAM addresses as they were, press <ENTER> to accept "LOAD DEFAULT NO". In either case, the first RAM address listing is now displayed, allowing you to make changes to individual RAM addresses. 5. Press the <SET UP> key or the <TOTALS> key to scroll through the firmware addresses: > Each time you press the <SET UP> key, the next address is displayed, as from 0090 to 0091.
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> Each time you press the <TOTALS> key, the previous address is displayed, as from 0091 to 0090 or from 0090 to 00FF. 6. When you reach the firmware address desired, press one of the following keys to change the parameter for the currently displayed address. > <RUN> key = Toggles between a display of the data address and value and a display of the address label. For example, when the data address display is 0094 Data 0C, pressing <RUN> displays the corresponding BAUD RATE RS-232. Pressing <RUN> again returns to 0094 Data 0C. > <SPACE> key = Increments the upper data nibble (the left digit in the setting at the right end of the displayed address) in the current address. For example, if the current setting is "EF", press the <SPACE> key to change the setting to "FF". > <DELETE> key = Increments the lower data nibble (the right digit in the setting at the right end of the displayed address) in the current address. For example, if the current setting is "04", press the <DELETE> key to change the setting to "05". > <-> minus key = Sets the parameter for the current address to FF. > <0> zero key = Sets the parameter for the current address to 00. > <CLEAR> key = Loads the default parameter for the current address from the EPROM into the RAM. 7. To exit the Change RAM mode, press the <ENTER> key. The message "RESET TOTALS NO" is displayed. > If you wish to reset the current output tally for all tubes to zero, press the <SET UP> key. The message "TOTALS SET TO 0" is displayed. > If not, press <ENTER> again to return to the previous mode. NOTE: Any changes you made take effect immediately. You do not have to power down and back up first.
Notes About the RAM Address Listing

A few words of explanation about various listing features follows.
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Notes About the RAM Address Listing
Warning About Motor Speeds (00C0-00CF)
Warning About Motor Speeds (00C0-00CF)

CAUTION: Only an engineer experienced with motor speeds should adjust any motor speeds. If unwise changes are made, damage to the machine could result. The step rate (00C0-00C2 and 00C8-00CA) is the constant cruising speed. The starting rate (00C3-00C4 and 00CB-00CC) is the speed on startup, at the beginning of movement. The acceleration slope rate (00C5-00C7 and 00CD-00CF) is the length of time it takes the motor to reach cruising speed.
Updating Your EPROM

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

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

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

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

The following sample RAM address table describes each firmware address in numerical order. This information is specific for each Model 1050. It may be slightly different for your taper. For a list of suggested default values that vary according to the taper model, see "Suggested Values for Various Taper Models" on page 3-41. The ROM Deflt column shows the factory-set default value for each address. The Comments column shows the meaning of each selection. The RAM Options column shows the values you can use. The code below the values shows what type of value into which the taper translates the entry. For further reference, see the "Decimal-Hex-ASCII Conversion Table" on page 3-48. Code
A B C H
Type of Value
ASCII Bitmap Choice Hex
RAM Address Listing TAPE-2 11-16-05

Addr ess
0090 0091 0092 0093 0094 0095 0096 0097
Display
Top of EPROM Tape Out Check Thermal or PSA
ROM Deflt
00 00 54
RAM Options
C B Top of EPROM
Comments
00 = Use Tape Out sensor. FF = No tape-out check; sensor 6 ignored. 54 = Thermal; 50 = PSA.
Remote Go/5000 FF Baud Rate RS232 Data Format Remote Control # Motors 0C 03 FF 03
C
See page 3-7 C See page 3-7 C
00 = Remote go. AA = Set. FF = Off. Obsolete; used on old tapers. Stores the baud rate for the RS-232 interface between the taper system and the PC. Contact Exatron before changing the value. Stores the parity/stop/data bits settings for the RS-232 interface. 00 = RS-232 control. FF = taper port control. Sets the number of stepper motors inherent in the taper: 01 = Tape drive motor 02 = Swing arm motor 04 = Octoloader motor See "Suggested Values for Various Taper Models" on page 3-41. Time delay after seal head down and before the tape drive moves. Counts down in hex in 10 millisecond steps. Means of seeing device in pickup site. FF = Vacuum sensor (older). 00 = Fiberoptic pickup sensor (newer). Upgrades available.
H
See "MOTOR <A or B> BUSY ?" pg 510
0098 0099
Seal Down Delay 10 Vacuum / Optic Sensor 00
00 to FF H 00, FF C
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RAM Address Listing

Addr ess
009A 009B 009C 009D 009E
Display
Cylinder / Solenoid Index Temperature Alarm Octo 8/4 Tubes Wiggle Octoload P Up Jog Octo
ROM Deflt
00 00 00 00 00
RAM Options
00, FF C C C 00, FF C 00 to FF C
Comments
FF = Cylinder index (older). 00 = Solenoid index (newer). Upgrades available. Check the default value in replacement from manufacturer; for thermal seal heads only. 00 = Normally open. FF = Normally closed. 00 = no octoloader. 04 = 4-tube input. 08 = 8-tube input. 00 = Wiggles the octoloader if a jam is detected. FF = Octoloader will not wiggle. For calibration of mechanical placement of octoloaderin-house only! Jogs octoloader right and left upon power-up if desired, to possibly free a jammed device. 0? = Jog Left. 1? = Jog Right. FOR EXAMPLE: 02 = Jog Left 2 steps; 13 = Jog Right 3 steps. 9 Steps Maximum. 00 = Use Out of Pocket sensor. FF = No out-of-pocket check; sensor 7 ignored. 00 = Use Empty Pocket sensor. FF = No empty-pocket check; sensor 5 ignored. 00 = Check temperature alarm. For thermal seal heads only. FF = Skip check of temperature alarm. Number of leader pockets per foot switch; for 1010 only. Default is 30. Used only when camera is installed to inspect placement of devices in tape pockets. 00 = On/Yes. FF = Off/No. AA = No option. At pickup site; delay after pickup vacuum turns on and before pickup head lifts device. Default is 10 ms. Pickup and place cycle code. FF = Rev A head. 00 = Rev B head, fiberoptic. Adds extra time for device to pass index mechanism. 10 ms delay At pickup site; delay after pickup head retracts and before swing arm rotates down. 10 ms steps. At tape; length of time it takes pickup head to extend into tape pocket. 10 ms steps. At tape; delay after vacuum turns off to drop device and before pickup head is retracted. 10 ms steps. At tape; length of time it takes pickup head to retract from tape pocket. 10 ms steps. 00 = On; FF = Off. Must be 0-9 ASCII. This is the first of 3 digits in the password if turned on at address 00AB. Must be 0-9 ASCII. This is the second of 3 digits in the password.
009F 00A0 00A1 00A2 00A3 00A4 00A5 00A6 00A7 00A8 00A9 00AA 00AB 00AC 00AD
Out of Pocket Empty Pocket Check
00 00
00, FF C 00, FF C 00, FF C H C H 00, FF C H H H H H C

See page 4-2. A
Check Tempera- 00 ture Alarm Foot Count Inspect Yes/No Pickup Vacuum Delay Place Cycle Index Delay Pickup Delay Drop-off Down Delay Drop-off Delay Drop-off Up Delay 1E AA 05 00 0A 05 05 05 05
Password On/Off FF Password A Password B 1 2
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Addr ess
00AE 00AF 00B0 00B1 00B2 00B3 00B4 00B5 00B6 00B7 00B8 00B9 00BA 00BB 00BC 00BD 00BE 00BF 00C0 00C1 00C2 00C3 00C4 00C5 00C6 00C7 00C8 00C9 00CA Motor A R1-Motor A R-1Motor A R--1 Motor A F1Motor A F-1 Motor A S1-Motor A S-1Motor A S--1 Motor B R1-Motor B R-1Motor B R--1 2 3 5 3 0 2 3 5 1 6 0 A A A A A A A A A A A
Display
Password C Full Tape 100000s
ROM Deflt
3 0
RAM Options
A A A A A A A
Comments
Must be 0-9 ASCII. This is the third of 3 digits in the password. Sets the 100,000s digit for number of devices constituting a full tape. Sets the 10,000s digit for number of devices constituting a full tape. Sets the 1,000s digit for number of devices constituting a full tape. Sets the 100s digit for number of devices constituting a full tape. Sets the 10s digit for number of devices constituting a full tape. Sets the 1s digit for number of devices constituting a full tape. Sets the 10s digit for number of pockets in leader tape. Sets the 1s digit for number of pockets in leader tape. Sets the 10s digit for number of pockets to be advanced between takeup reel runs. Sets the 1s digit for number of pockets to be advanced between takeup reel runs. Not used. Not used. Not used. Not used. Not used. Not used. Not used. Stores 100s digit of motor A (tape drive) maximum step rate. See "Warning About Motor Speeds (00C0-00CF)" on page 3-41. Stores 10s digit of motor A (tape drive) maximum step rate. Stores 1s digit of motor A (tape drive) maximum step rate. Stores 10s digit of motor A (tape drive) starting rate. Stores 1s digit of motor A (tape drive) starting rate. Stores 100s digit of motor A (tape drive) acceleration slope rate. Stores 10s digit of motor A (tape drive) acceleration slope rate. Stores 1s digit of motor A (tape drive) acceleration slope rate. Stores 100s digit of motor B (swing arm) maximum step rate. Stores 10s digit of motor B (swing arm) maximum step rate. Stores 1s digit of motor B (swing arm) maximum step rate.
Full Tape 10000s 0 Full Tape 1000s Full Tape 100s Full Tape 10s Full Tape 1s Leader 10 Leader 1 Take Up 10 Take Up 1 1 0 0 0 3 0 2 0
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RAM Address Listing

Addr ess
00CB 00CC 00CD 00CE 00CF 00D0 00D1 00D2 00D3 00D4 00D5 00D6 00D7 00D8 00D9 00DA 00DB 00DC 00DD
Display
Motor B F1Motor B F-1 Motor B S1-Motor B S-1Motor B S--1 Motor C R1-Motor C R-1Motor C R--1 Motor C F1Motor C F-1 Motor C S1-Motor C S-1Motor C S--1 Use Default #? Gap Step 1000s Gap Step 100s Gap Step 10s Gap Step 1s Offset 1000s
ROM Deflt
1 0 1 6 0 2 0 0 1 0 2 0 0 01 1 0 3 7 0
RAM Options
A A A A A A A A A A A A A
Comments
Stores 10s digit of motor B (swing arm) starting rate. Stores 1s digit of motor B (swing arm) starting rate. Stores 100s digit of motor B (swing arm) acceleration slope rate. Stores 10s digit of motor B (swing arm) acceleration slope rate. Stores 1s digit of motor B (swing arm) acceleration slope rate. Stores 100s digit of motor C (octoloader) maximum step rate. Stores 10s digit of motor C (octoloader) maximum step rate. Stores 1s digit of motor C (octoloader) maximum step rate. Stores 10s digit of motor C (octoloader) starting rate. Stores 1s digit of motor C (octoloader) starting rate. Stores 100s digit of motor C (octoloader) acceleration slope rate. Stores 10s digit of motor C (octoloader) acceleration slope rate. Stores 1s digit of motor C (octoloader) acceleration slope rate. Switch changeover kit settings by group. 01 = #1 (00D9-00E5). 02 = #2 (00E6-00F2). 03 = #3 (00F3-00FF)
A A A A A
Sets the 1,000s digit for first tape drive move. Sets the 100s digit for first tape drive move. Sets the 10s digit for first tape drive move. Sets the 1s digit for first tape drive move. Sets the 1,000s digit for the distance the tape drive must move between the Gap sensor finding a tape pocket leading edge and the pickup head being aligned with a pocket center. Sets the 100s digit for the offset distance. Sets the 10s digit for the offset distance. Sets the 1s digit for the offset distance. 30, 31, or 32; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. 30-39; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. Sets the 100s digit for the number of motor steps the swing arm rotates down from its pickup position to the tape position. Sets the 10s digit for the swing arms pickup position to tape position. Sets the 1s digit for the swing arms pickup position to tape position. Sets the 1,000s digit for first tape drive move.
00DE 00DF 00E0 00E1 00E2 00E3 00E4 00E5 00E6
Offset 100s Offset 10s Offset 1s Swing Home 10 Swing Home 1
9 6 0 1 2
A A A A A A A A A
Swing Step 100s 1 Swing Step 10s Swing Step 1s Gap Step 1000s 2 3 1
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Addr ess
00E7 00E8 00E9 00EA
Display
Gap Step 100s Gap Step 10s Gap Step 1s Offset 1000s
ROM Deflt
0 4 3 0
RAM Options
A A A A
Comments
Sets the 100s digit for first tape drive move. Sets the 10s digit for first tape drive move. Sets the 1s digit for first tape drive move. Sets the 1,000s digit for the distance the tape drive must move between the Gap sensor finding a tape pocket leading edge and the pickup head being aligned with a pocket center. Sets the 100s digit for the offset distance. Sets the 10s digit for the offset distance. Sets the 1s digit for the offset distance. 30, 31, or 32; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. 30-39; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. Sets the 100s digit for the number of motor steps the swing arm rotates down from its pickup position to the tape position. Sets the 10s digit for the swing arms pickup position to tape position. Sets the 1s digit for the swing arms pickup position to tape position. Sets the 1,000s digit for first tape drive move. Sets the 100s digit for first tape drive move. Sets the 10s digit for first tape drive move. Sets the 1s digit for first tape drive move. Sets the 1,000s digit for the distance the tape drive must move between the Gap sensor finding a tape pocket leading edge and the pickup head being aligned with a pocket center. Sets the 100s digit for the offset distance. Sets the 10s digit for the offset distance. Sets the 1s digit for the offset distance. 30, 31, or 32; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. 30-39; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing. Sets the 100s digit for the number of motor steps the swing arm rotates down from its pickup position to the tape position. Sets the 10s digit for the swing arms pickup position to tape position. Sets the 1s digit for the swing arms pickup position to tape position.
00EB 00EC 0ED 00EE 00EF 00F0 00F1 00F2 00F3 00F4 00F5 00F6 00F7
8 6 0 1 2
A A A A A A A A A A A A A
Swing Step 100s 1 Swing Step 10s Swing Step 1s Gap Step 1000s Gap Step 100s Gap Step 10s Gap Step 1s Offset 1000s 2 5 1 0 0 0 0
00F8 00F9 00FA 00FB 00FC 00FD 00FE 00FF
1 0 0 1 0
A A A A A A A A
Swing Step 100s 1 Swing Step 10s Swing Step 1s 2 5
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Hex-Binary Conversion Table
Hex-Binary Conversion Table

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

Hexadecimal
00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 20 30 40
Binary
0000 0000 0000 0001 0000 0010 0000 0011 0000 0100 0000 0101 0000 0110 0000 0111 0000 1000 0000 1001 0000 1010 0000 1011 0000 1100 0000 1101 0000 1110 0000 1111 0001 0000 0010 0000 0011 0000 0100 0000
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Model 1050 Manual
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-Hex-ASCII Conversion Table
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 taper may have. This chapter discusses the following main topics:
Topic Accessing DIAGNOSTICS Mode Diagnostics Quick Reference SENSOR CHECK: Tape Sensors 0-7 SENSOR CHECK: Pickup Site Sensors 8-F OUTPUT CHECK: Solenoid Check OUTPUT CHECK: Solenoid Toggle Check ALL MOTOR CHECK: Drive Motor Check ALL MOTOR CHECK: Swing Arm Check INTERFACE CHECK: RS-232 Port Check INTERFACE CHECK: Handler Port Output Check Checking Communication Between 5000 Handler and 1050 Taper
Page
4-2 4-4 4-9 4-10 4-11 4-12 4-13 4-14 4-16 4-18 4-19
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Model 1050 Manual
Accessing DIAGNOSTICS Mode

Although no tools are required, an EXATRON LED checker, part #3000-052, (small blue plastic box) will be helpful in troubleshooting broken sensor/LED pairs and for testing the handler control port. To access Diagnostics mode, press the <DIAGNOSTICS> key on the taper's control panel. If the password security is turned on, the display reads "PASSWORD ABC ?" Enter a 3-digit password using the numeric keys. The factory-set password is 123, or <1> <2> <3>. The display reads: "DIAGNOSTICS." You can access Diagnostics mode whenever the handler powers up, is in Run mode, or is in Manual mode.
Figure 4-1: Control Panel
You can also enter Diagnostics mode during most device jam-clearing cycles, when the output tube cover LEDs are flashing. If using Diagnostics during a jam, the 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. An abbreviated flowchart showing the main Diagnostics functions is shown on page 4-3. The "Diagnostics Quick Reference" showing all the functions begins on page 4-4, and detailed explanations of the major ones are in the sections following the quick reference.
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04/2010 Copyright Exatron, 2010
Accessing DIAGNOSTICS Mode
Figure 4-2: Diagnostics Abbreviated Flowchart
NOTE: Depending on the exact configuration of your handler and taper, the functions accessed by one or more keys may be somewhat different.
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Model 1050 Manual
Diagnostics Quick Reference

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

<1> key = "SOLENOID CHECK" causes continual, intermittent action, then: NOTE: The action produced by each number key corresponds with the action produced by the override button with the same number. See "Tape-and-Reel Override Buttons" on page 2-15. <1> key activates sealing head
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<2> key activates pickup head vacuum <3> key activates knock cylinder (only for tapers thus equipped) <4> key activates index solenoid <5> key activates stack solenoid and cover foot cylinder <6> key activates blow-off from pickup head (to break vacuum seal with device) <7> key activates pickup head on swing arm <8> key activates takeup reel motor <9> key n/a <0> key turns all solenoids OFF <2> key = "SOL TOGGLE CHECK" causes continuous, steady action, then: <Clear> key homes the swing arm <1> key lowers sealing head to tape; press again to raise <2> key turns on pickup head vacuum; press again to turn off <3> key activates knock cylinder; press again to turn off <4> key activates index solenoid; press again to turn off <5> key activates stack solenoid and cover foot cylinder; press again to turn off <6> key turns on blow-off from pickup head; press again to turn off <7> key extends pickup head on swing arm; press again to retract <8> key turns on takeup reel motor; press again to turn off <9> key n/a <0> key turns all solenoids OFF <3> - <9> keys n/a <3> key = "ALL MOTOR CHECK", then: <1> key = "DRIVE MOTOR CHK" (tape drive motor check), then:
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<1> key = "MOVE TAPE LEFT"advances carrier tape several motor steps to the left <2> key = "R235 F30 S235"briefly displays current tape drive motor settings in RAM; helpful when trying to increase the motor's speed <3> key = "MOVE TAPE RIGHT"moves carrier tape several motor steps to the right <4> key = "2 LEFT STEPS"jogs tape drive motor to the left until sensor detects gap between pockets <5> key = "TEST TAPE MOTOR"advances tape to next pocket <6> key n/a <7> key = "JOG LEFT"moves tape drive motor 1 motor step to the left <8> key n/a <9> key = "JOG RIGHT"moves tape drive motor 1 motor step to the right <0> key = "MOTOR A OFF"turns off tape drive motor <2> key = "SWING HEAD CHECK", then: <1> key = "ROTATE DOWN"rotates swing arm down to tape position <2> key = "R160 F10 S160"briefly displays current swing arm motor settings in RAM; helpful when trying to increase the motor's speed <3> key = "ROTATE UP"rotates swing arm up to pickup position <4> key = "SET GAP ? NO", then: <ENTER> key = accept; dont set gap. Followed by display: "GAP STEPS = " and "OFFSET = " <SET UP> key = "SET GAP ? YES"tape advances, distance between leading pocket edges is found <5> key = "1 LEFT STEP"one full pick and place cycle <6> key = "POCKETS = ######."tape drive motor advances and activates seal heads; the number of pockets increments by the same number. However, the swing arm is not activated to get a device from the pickup site. <7> key = "SWING = ###" or "SWING HOME = ###." The result of pressing this key depends on the current position of the swing arm.
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When the swing arm is over the tape: "SWING = ###." The number gets smaller and the swing arm jogs up one motor step. When the swing arm is over the pickup site: "SWING HOME = ###." The number gets larger and the swing arm jogs up one motor step. <8> key = "FIND MOTOR HOME", then "HOME SWING HEAD", then "MOTOR HOME"jogs, rotates, and returns swing arm to home position. <9> key = "SWING = ###" or "SWING HOME = ###." The result of pressing this key depends on the current position of the swing arm. When the swing arm is over the tape: "SWING = ###." The number gets larger and the swing arm jogs down one motor step. When the swing arm is over the pickup site: "SWING HOME = ###." The number gets smaller and the swing arm jogs down one motor step. <0> key = "MOTOR B OFF"turns off swing arm motor <SPACE> key = Toggles pickup head to extend or retract. <DELETE> key = Toggles pickup heads vacuum on or off. <3> - <0> keys n/a <4> key n/a <5> key = "TAKE UP MOTOR ON"turns on takeup reel motor. Lift takeup arm to stop motor. <6> 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 <DIAGNOSTICS> key sends signal "F" from control panel to tester <2> key = "HANDLER OUT CHK", then:
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<1> - <8> keys cause corresponding light ot flash, on LED and on Simulator <9> key activates all ON <0> key activates all OFF <3> key = "SORT = ___" <1> key = "ISSUE NEW START" The taper has been instructed to send a new start-test pulse to the tester/PC; then it waits for an end-of-test sort signal from the tester. If none is received, the message "SORT INPUT" is displayed. <4> - <0> keys n/a <7> - <0> keys n/a <ENTER> key = Exit DIAGNOSTICS.
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SENSOR CHECK: Tape Sensors 0-7
SENSOR CHECK: Tape Sensors 0-7

This diagnostic tests the sensors related to the tape. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <1> key. > Control panel displays "SENSOR CHECK". 3. Press the <1> key again. > Control panel displays all or part of "SEN0-7 01234567". Specifically, the alphanumeric characters indicate:
Tape Sensors
Control Panel Display
0, 1, 2 3 4 5 6 7
Sensor
N/a, no sensor Takeup Arm Gap Empty Pocket Carrier Tape Out Out-of-Pocket
Alphanumeric Character Displayed When...
Red Controller Light
Arm raised; signal open Tape not centered at pocket divider; signal blocked No device in pocket; signal open No tape present; signal open Device not seated fully in pocket; signal blocked
n/a * Off On n/a * Off
* Sensor is of type photo rather than fiberoptic, and hence has no controller. Pressing the <CLEAR> key will flash the control panel's displayed message to confirm the taper is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check. If you suspect that you have a bad sensor/LED pair, use the EXATRON LED checker #3000052 (small blue plastic box). This diagnostic tool is equipped with a transistor (blue/white wires) and an IR LED (orange/blue wires). Direct the transistor at any of the taper's IR LEDs. The LED on the checker should turn off. Direct the checker's LED at any of the taper's transistors. The corresponding number should turn OFF on the taper's display.
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SENSOR CHECK: Pickup Site Sensors 8-F

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

Control Panel Display
8 9 A B C, D, E, F
Sensor
Pickup Head Vacuum Swing Arm Home Device at Stack Device at Pickup Site N/a, no sensor
Alphanumeric Character Displayed When...

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

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

This diagnostic tests various solenoids. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <2> key. > Control panel displays "OUTPUT CHECK". 3. Press the <1> key. > Control panel displays "SOLENOID CHECK". 4. Press each of the handler terminal's keypad keys 0 through 9. Each key turns on the handler's output cover LEDs and sets the corresponding taper solenoid into a continual, intermittent on/off test cycle. For example, the vacuum is activated in intermittent bursts, or the pickup head moves up and down until you stop the action. Key 1 2 3 4 5 6 7 8 9 0 All OFF All solenoids turned off Output Cover LED 1 2 3 4 5 6 7 8 Index pin extends Stack pin retracts; cover foot extends Positive air pressure emitted from suction cup on pickup head to break vacuum between device and suction cup Pickup head extends Takeup reel motor turned on, winding tape and tightening tape slack Taper Solenoid Action Seal heads lowered to tape Pickup head vacuum on
Pressing the <CLEAR> key will flash the terminal'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. > Control panel displays "DIAGNOSTICS". 2. Press the <2> key. > Control panel displays "OUTPUT CHECK". 3. Press the <2> key again. > Control panel displays "SOL TOGGLE CHECK". 4. Press each of the control panel's keypad keys 0 through 9. Each key will turn on/off the 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 <0> key. For example, the vacuum is activated in a steady force until you toggle it off, or the pickup head stays down until you toggle it up. Key Clear 1 2 3 4 5 6 7 8 9 0 All OFF All solenoids turned off 1 2 3 4 5 6 7 8 Index pin extends Stack pin retracts; cover foot extends Positive air pressure emitted from suction cup on pickup head to break vacuum between device and suction cup Pickup head extends Takeup reel motor turned on, winding tape and tightening tape slack Output Cover LED Taper Solenoid Action Swing arm homed to position over pickup site Seal heads lowered to tape Pickup head vacuum on
Press the <ENTER> key to EXIT this diagnostic check and return to the "DIAGNOSTICS" message.
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ALL MOTOR CHECK: Drive Motor Check
ALL MOTOR CHECK: Drive Motor Check

This diagnostic tests and calibrates the positions of the tape drive motor. If a device placed in the tape pocket is misaligned to the left or right as shown in Figure 4-3, use this diagnostic.
Figure 4-3: Tape Calibration Needed
To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <3> key. > Control panel displays "ALL MOTOR CHECK". 3. Press the <1> key. > Control panel displays "DRIVE MOTOR CHK". <1> key = "MOVE TAPE LEFT." The drive motor moves the tape one pocket to the left. <2> key = "R235 F30 S235." The current motor settings in RAM ARE displayed. <3> key = "MOVE TAPE RIGHT." The drive motor moves the tape one pocket to the right. <4> key = "JOG LEFT." The drive motor moves the tape one motor step to the left. <5> key = "TEST TAPE MOTOR." The drive motor advances the tape two pockets to the left. <6> key = "JOG RIGHT." The drive motor moves the tape one motor step to the right. <0> key = "MOTOR A OFF." The drive motor is turned off. Pressing the <CLEAR> key flashes the terminal's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check.
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ALL MOTOR CHECK: Swing Arm Check

This diagnostic tests and calibrates the positions of the swing arm. If a device placed in the tape pocket is misaligned to the front or back as shown in Figure 4-4, use this diagnostic.
Figure 4-4: Swing Arm Calibration Needed
To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <3> key. > Control panel displays "ALL MOTOR CHECK". 3. Press the <2> key. > Control panel displays "SWING HEAD CHECK". <1> key = "ROTATE DOWN." The swing arm rotates down to a position above the tape. <2> key = "R160 F10 S160." The current motor settings in RAM are displayed. <3> key = "ROTATE UP." The swing arm rotates up to a position above the pickup site. <4> key = "SET GAP ? NO." If the pickup head is centering devices in each tape pocket, press <ENTER> to move on. But if devices are being placed improperly as shown in Figure 3-36 on page 3-25, press <SET UP> and then <ENTER> to set the gap. You then have the opportunity to visually check the pickup head position and change the offset. See "Understanding the Gap" on page 3-29 and "Setting Tape Pocket Gap" on page 3-31. <5> key = "1 LEFT STEP". The taper does one full pick-and-place cycle. <6> key = "POCKETS = ######." The drive motor advances and activates the seal heads; the number of pockets increments by the same number. <7> key = "SWING = ###" or "SWING HOME = ###." The result of pressing this key depends on the current position of the swing arm. > When the swing arm is over the tape: "SWING = ###." The number gets smaller and the swing arm jogs up one motor step. 1
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ALL MOTOR CHECK: Swing Arm Check
> When the swing arm is over the pickup site: "SWING HOME = 0##." The number gets larger and the swing arm jogs up one motor step. 1 <8> key = "FIND MOTOR HOME"; "HOME SWING HEAD." The swing arm moves to its home position at the Swing Arm Home sensor, then moves the specified number of motor steps farther up to the pickup site. 2 <9> key = "SWING = ###" or "SWING HOME = ###." The result of pressing this key depends on the current position of the swing arm. > When the swing arm is over the tape: "SWING = ###." The number gets larger and the swing arm jogs down one motor step. 3 > When the swing arm is over the pickup site: "SWING HOME = 0##." The number gets smaller and the swing arm jogs down one motor step. 4 <0> key = "MOTOR B OFF." The swing arm motor is turned off. Pressing the <CLEAR> key will flash the terminal's displayed message to confirm the handler is still in this specific diagnostic check. Press the <ENTER> key to EXIT this diagnostic check.
1 1
2 3 4
Any change made with the <7> key here at "SWING = " is saved in RAM addresses 00FC, 00FD, and 00FE and kept until default values are loaded from the EPROM. Any change made with the <7> key here at "SWING HOME = " is saved in RAM addresses 00E0 and 00E1 and kept until default values are loaded from the EPROM. This change also affects the number of motor steps the swing arm rotates up past its home sensor when the <8> key is pressed. The number of motor steps that the swing arm moves beyond the sensor is taken from the values in RAM addresses 00E0 and 00E1, which are changed by use of the <7> and <9> keys. Any change made with the <9> key here at "SWING = " is saved in RAM addresses 00FC, 00FD, and 00FE and kept until default values are loaded from the EPROM. Any change made with the <9> key here at "SWING HOME = " is saved in RAM addresses 00E0 and 00E1 and kept until default values are loaded from the EPROM. This change also affects the number of motor steps the swing arm rotates up past its home sensor when the <8> key is pressed.
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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 serial 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: 009B 0C 9600 BAUD RAM address: 009C 03 1 STOP, 8 BITS, NO PARITY
To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <6> key. > Control panel displays "INTERFACE CHECK". 3. Press the <1> key. > Control panel displays "RS-232 CHECK". 4. Press each of the following handler terminal's keypad keys to send a signal from the handler to the tester. Terminal Key 1 2 3 4 5 6 7 8 9 RUN 1 2 3 4 5 6 7 8 9 A Signal Sent
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INTERFACE CHECK: RS-232 Port Check
Terminal Key MANUAL SET UP PAUSE TOTALS DIAGNOSTICS B C D E F
Signal Sent
Press each of the handler terminal'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 as more characters are received. Press the <ENTER> key to EXIT this diagnostic check.
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INTERFACE CHECK: Handler Port Output Check

This diagnostic tests the output signals using TTL through the handler port. To access this diagnostic check: 1. Press the <DIAGNOSTICS> key. > Control panel displays "DIAGNOSTICS". 2. Press the <6> key. > Control panel displays "INTERFACE CHECK". 3. Press the <2> key. > Control panel displays "HANDLER OUT CHK". 4. Press each of the handler terminal's keypad keys 1 through 9, then 0 last. Each key turns on/off the handler's output cover LEDs and will set the corresponding handler interface output low. Normally, all handler outputs are at 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 used 21 not used 20 not used 19 not used 18 not used 17 not 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 may 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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Checking Communication Between 5000 Handler and 1050 Taper
Setting Up HyperTerminal for 1050 Taper

You can use a PC or laptop with Windows.

You can hook up a PC or laptop to the 1050 taper and set up HyperTerminal in MS Windows as a way of testing communication to the taper. HyperTerminal emulates the communication protocol used by the system it is connected to, and displays the results of checking this communication. Each message is in uppercase ASCII characters, followed by a carriage return. This ensures that the incoming port and connections on the 1050 are functioning normally.
Configuring a Connection Session

To set up a new connection session in HyperTerminal: 1. Click the Windows Start button, and select Programs Accessories Communications HyperTerminal.
Figure 4-5: Getting to HyperTerminal
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> A brief splash screen is displayed. Wait a second for the window to appear. > On some systems, an intermediate window may appear. If so, double-click the HYPERTRM.EXE program icon to open the program. If not, go to the next step.
Figure 4-6: Opening the HyperTerminal Program
2. In the Connection Description dialog box, type a name for your new connection, and click an icon to identify it. Click OK.
Figure 4-7: Naming a New Connection
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3. In the Connect To dialog box, click the drop-down arrow by the Connect Using box. Select the COM port you want to use. Click OK.
Figure 4-8: Selecting the Connection
4. In the Properties dialog box, make the selections as shown in Figure 4-9. Click OK.
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Figure 4-9: Selecting the Port Settings
If your typed commands are not reflected onscreen, you can change the settings to display them. To display commands typed in HyperTerminal: 1. In the main window, click the Properties button.
Figure 4-10: Getting to Connection Properties
2. In the Properties dialog box, under the Settings tab, click the ASCII Setup button.
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Figure 4-11: Getting to ASCII Setup
3. In the ASCII Setup dialog box, check the Echo typed characters locally box to display what you type onscreen. 4. Check Send line ends with line feeds and Append line feeds to incoming line ends to continue displaying what was typed previously. (Thus you can scroll up to view the record, or history, of commands.)
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Figure 4-12: Displaying Typed Commands Onscreen
5. Click OK. 6. Click OK in the other dialog box. 7. Save your session configurations.
Testing Communication from PC to Taper

HyperTerminal displays communication from the PC (as simulated commands sent from the handler) to the taper. To test communication to the taper: 1. Ensure the taper is turned on and ready. 2. Open HyperTerminal on the PC. 3. Click the Call button to ensure they are connected.
Figure 4-13: Using Call to Connect
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4. Press any of the following keys on the PC keyboard. In each case, the key pressed is reflected on the PC, in the HyperTerminal window. Key 0 1 2 3 4 5 6 COUNT SET TO 0 JOG LEFT 1050 Display Action 0 is sent back to the PC to confirm that the taper is present. Tape advances one pocket; seal heads activate to seal. Taper resets tape output count to zero. Advances tape to align gap between pockets with the gap sensor.
TAKE UP MOTOR ON Turns on takeup reel motor for a specified length of time. ADD LEADER DOWN Runs takeup and drive motors for a specified number of pockets (RAM addresses 00F0, 00F1) with sealing heads down, in active position. ADD LEADER UP Runs takeup and drive motors for a specified number of pockets (RAM addresses 00F2, 00F3) with sealing heads up, in inactive position.
NOTE: These functions do not correspond with the same keystrokes as in Manual mode. 5. To disconnect, click the Disconnect button in the HyperTerminal window.
Figure 4-14: Disconnecting
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Setting Up HyperTerminal for 5000 Handler

After you have ascertained that communication on the 1050 side is functioning, you can hook up the PC or laptop to the 5000 handler and set up HyperTerminal in MS Windows as a way of testing communication to the handler. Each message is in uppercase ASCII characters, followed by a carriage return. This ensures that the incoming port and connections on the 5000 are functioning normally. After you have set up HyperTerminal as described in the previous section, use the PC keyboard to enter numeric commands to the handler. The handler should carry out the commands the same as if you had entered them on the handlers control panel. If the commands for both handler and taper work correctly, but you are still experiencing a communication problem, you know it must be in the cable itself. Replace the cable.
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Chapter Overview
This reference chapter discusses the following status and error messages displayed on the control panel:
Topic #### OLDNEW #### 00## DATA ## ADD LEADER DOWN ADD LEADER UP ALIGN MOTORS ? ALL MODES OFF ? ALL MOTOR CHECK ALL MOTORS OFF CHANGE RAM ? NO CHANGE RAM ? YES CHECK SUM ERROR CHK VAC ADJ COUNT SET TO 0 CPU ERROR <1-5> DIAGNOSTICS DRIVE MOTOR CHK EMPTY POCKET ? EXATRON TAPE FIND MOTOR HOME FULL T = ###### GAP STEPS = #### HANDLER OUT CHK HOME SENSOR ERR HOME SWING HEAD INTERFACE CHECK JOG LEFT JOG RIGHT LOAD DEFAULT NO
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Topic LOAD DEFAULT YES LOAD EPROM>RAM LOAD REMOTE RAM LOOP MODE ON ? MANUAL ###### MEMORY ERROR MOD SET UP ? NO MOD SET UP ? YES MOTOR <A or B> BUSY ? MOTOR <A or B> ERROR ? MOTOR A OFF MOTOR B OFF MOTOR HOME MOVE TAPE LEFT MOVE TAPE RIGHT NO POCKET? ERROR NOT UP TO TEMP OFFSET = #### OFFSET>GAP ERROR PASSWORD ABC? PAUSED ###### POCKETS = ###### RAM AUTO RESET RESET COUNT NO RESET COUNT YES ROTATE DOWN ROTATE UP RS-232 CHECK SEN0-7 01234567 SEN8-F 89ABCDEF SENSOR CHECK SET GAP ? NO/YES SET OFFSET = #### SOLENOID CHECK STOP MODE ON/OFF STOP MODE ON ? SUM CHECK = SUM CHECK ERROR TAKE UP MOTOR ON
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Model 1050 Handler Status and Error Messages
#### OLDNEW ####
Topic TAKE UP REEL ERR TAPE GAP LOST ? TAPE IS FULL TEST TAPE MOTOR THANK YOU THERMAL OR PSA ? TRANSFER ERROR TURN ON REMOTE UART OUT ERROR UPSIDE DOWN ERR ? ZERO COUNT ERR
Page 5-16 5-16 5-16 5-16 5-17 5-17 5-17 5-17 5-17 5-17 5-17

Messages that are displayed on the control panel are alphabetically listed below. Symbols and numbers appear first. Each entry in this section explains why the message is displayed and, when necessary, how to resolve the condition. If further explanation is required, the operator is referred to the appropriate section elsewhere in this manual for details. We are constantly adding messages to the handler's operating code. If a message you need is not listed here, please contact Exatron's Customer Service Department for prompt assistance. For free updates to the firmware, please contact the Exatron Sales Department.
#### 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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00## DATA ##
This is the Change RAM routine. Current RAM address data will be displayed where each pound sign (#) is shown above. Review the following keys for options allowed: <ENTER> Exits routine; saves parameter into RAM. <SET UP> Each time you press the <SET UP> key, the next address is displayed, as from 0090 to 0091. <TOTALS> Each time you press the <TOTALS> key, the previous address is displayed, as from 0091 to 0090 or from 0090 to 00FF. <SPACE> Increments the upper data nibble (the left digit in the parameter at the right end of the displayed address) in the current address. For example, if the current parameter is "EF", press the <SPACE> key to change the parameter to "FF". <DELETE> Increments the lower data nibble (the right digit in the parameter at the right end of the displayed address) in the current address. For example, if the current parameter is "04", press the <DELETE> key to change the parameter to "05". <-> Sets the parameter for the current address to FF. <0> Sets the parameter for the current address to 00. <CLEAR> key = Loads the default parameter for the current address from the EPROM into the RAM.
ADD LEADER DOWN

This message is displayed when you press the <DELETE> key from RUN mode or WAITING mode. This runs the takeup reel and tape drive motors with the sealing heads engaged to create a tape leader of fifty empty sealed pockets for a new reel. Use this feature when you intend to cut the tape at the leader and separate the full reel from the rest of the tape. Press the <Clear> key to stop the motors and return to the previous mode.
ADD LEADER UP
This message is displayed when you press the <SPACE> key from RUN mode or WAITING mode. This runs the takeup reel and tape drive motors but without the sealing heads engaged to create a tape leader of fifty empty pockets for a new reel. Use this feature when you intend to cut the tape at the leader and separate the full reel from the rest of the tape. Press the <CLEAR> key to stop the motors and return to the previous mode.
ALIGN MOTORS ?
To enter this mode, press the <0> key to turn off all motors; then press <ENTER> to display the message "READY TO RUN ?"
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ALL MODES 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. <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: Drive Motor Check" on page 4-13 and "ALL MOTOR CHECK: Swing Arm Check" on page 4-14.
ALL MOTORS OFF

You have pressed the <0> key. The power to all motors is now OFF. You can realign or move any machine parts driven by the motors manually. Press any control panel key to continue.
CHANGE RAM ? NO
Exits routine without making any changes to the taper's RAM setup parameters. <ENTER> Exits with no changes. <SET UP> Toggles back to CHANGE RAM ? YES.
CHANGE RAM ? YES

Allows the operator to override the taper's setup parameters. <ENTER> Allows changes to the RAM. See "Changing RAM" on page 3-39 for instructions. <SET UP> Toggles back to CHANGE RAM ? NO.
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CHECK SUM ERROR

The PC has sent new RAM data to the taper. The taper 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.
CHK VAC ADJ

The taper has tried to pick up a device and has failed to detect that the device was already suctioned up by the pickup head's vacuum. To resolve this condition: 1. Press the <PAUSE> key: HANDLER PAUSED. Wiggle the pickup head manually to slightly shift the device. Watch the red LED on the vacuum generator. When the LED lights up, stop wiggling the pickup head. Press any key on the taper's control panel. The taper will automatically resume operation if the device is now detected. 2. Verify that the vacuum line is installed from the vacuum generator to the pickup head. Verify that the pickup head fitting is not leaking. 3. Verify that the pickup head is mechanically adjusted correctly. 4. Pressing the <ENTER> key will skip past this error, but be cautious in selecting this option, because pressing the <ENTER> key will cycle the pickup head down which may destroy the device it is holding. 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 4-11.
COUNT SET TO 0
You have pressed the <SET UP> key and then selected RESET COUNT YES. The count of devices placed in tape pockets has been reset to zero.
CPU ERROR <1-5>

Any of these errors (CPU ERROR 1, CPU ERROR 2, CPU ERROR 3, CPU ERROR 4, CPU ERROR 5) are critical. The taper's control program has detected a major problem, and has stopped operation. Use the following procedure to resolve this problem: 1. Write down exactly which CPU ERROR message is displayed. 2. Write down, to the best of your knowledge, what message(s) was/were displayed by the taper just before the error. 3. Write down, to the best of your knowledge, what the taper was doing just before the error.
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DIAGNOSTICS
4. Power down the taper and handler. 5. Power the handler and taper back up and answer all of the MOD SET UP ? YES questions. 6. Resume handler operation. 7. Fax your notes to Exatron as soon as possible. We will answer your fax with an explanation of what occurred, and a free software update to permanently correct the cause of the problem.
DIAGNOSTICS
You have pressed the <DIAGNOSTICS> key. See "Diagnostics Quick Reference" on page 4-4 as well as the sections following it for details.
DRIVE MOTOR CHK

See "ALL MOTOR CHECK: Drive Motor Check" on page 4-13.
EMPTY POCKET ?
This error message is displayed when an empty pocket in the carrier tape is detected. This occurs even at startup. When this message is displayed, and if the user visually confirms that no error condition is present, press <Enter>. This overrides the empty pocket message until such time as a device is seen in a pocket. If another empty pocket is then seen, the "EMPTY POCKET" message is displayed again. If a device is placed in the pocket directly underneath the sensor, the message "OK TO RUN? 2" is displayed. Pressing the <Enter> or <RUN> keys will start the system running again.
EXATRON TAPE
Power-up message; no action required.
FIND MOTOR HOME

This message is part of the routine for automatically resetting the tapers swing arm at its home position at the device pickup location. This routine occurs upon power-up and may also be actuated during various system paused conditions. The complete auto centering sequence consists of: FIND MOTOR HOME HOME SWING HEAD MOTOR HOME
FULL T = ######
Six digits are displayed after the = symbol. This is the number of devices the tape loader will place into a full tape before it stops. The number is adjustable up to 999,999 devices., which would be displayed as 999999.
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Use the keypad to make your selection. The tape loader accepts changes to each digit from lowest to highest, in order. First enter Ones, then Tens, then Hundreds, then Thousands. For example, to place 38 devices in each output tube, press <8>, then <3>. <-> The minus key sets the count to 0000. <CLEAR> Resets to the beginning of the handler's FULL T = ###### loop. This will also reload the handler's EPROM default value for this address. <ENTER> Confirms your selection.
GAP STEPS = ####

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

See "INTERFACE CHECK: Handler Port Output Check" on page 4-18 for details.
HOME SENSOR ERR

The swing arm motor has attempted to move the swing arm into its home position, that is, fully up and seated at the pickup location, but has not succeeded. This error message may be displayed during power-up of the system or during operation. Inspect the path of the swing arm for any jammed device or other blockage. After removing any blockage, press <Clear> to return to the previous condition. If there is no physical obstacle in the path of the swing arm, you may have a worn sensor. Run the Diagnostics/SENSOR CHECK for the swing arm sensor, described in "SENSOR CHECK: Pickup Site Sensors 8-F" on page 4-10. Replace the sensor as necessary.
HOME SWING HEAD

INTERFACE CHECK
See "INTERFACE CHECK: RS-232 Port Check" on page 4-16 and "INTERFACE CHECK: Handler Port Output Check" on page 4-18 for details.
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JOG LEFT
JOG LEFT
The tape drive motor has moved one step left, about .006".
JOG RIGHT
The tape drive motor has moved one step right, about .006".
LOAD DEFAULT NO
Exits routine without reloading the EPROM default settings into the taper's RAM. <ENTER> exits with no changes. < SET UP> toggles back to LOAD DEFAULT YES.
LOAD DEFAULT YES

Allows the operator to reload the taper's RAM with settings stored in the taper's EPROM. <ENTER> loads defaults from EPROM to RAM. <SET UP> toggles back to LOAD DEFAULT NO.
LOAD EPROM>RAM
The taper has reloaded its RAM setup data with default settings stored in EPROM. For your reference only.
LOAD REMOTE RAM

The PC has sent new handler setup 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.
LOOP MODE ON ?
Loop mode is for testing and troubleshooting of the taper. You can alternate between Stop mode and Loop mode by pressing the <1> and <2> keys, respectively. Select one of the following keypad choices. <1> = "STOP MODE ON ?" The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. <2> = "LOOP MODE ON ?" The taper will stop after a complete cycle for one device. <3> = "ALL MODES OFF ?" The taper will cycle multiple devices in a normal run. This is the default.
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<CLEAR> = Resets to the beginning of the taper's "STOP MODE ON/OFF" loop. <ENTER> = Executes the next loop cycle.
MANUAL ######
You have pressed the <MANUAL> button. The numbers signified by the # placeholders show the number of tape pockets that have been run past the swing arm. With the taping system in MANUAL mode, several keys on the controller have unique functions. See "Using Manual Mode" on page 3-34 for details.
MEMORY ERROR
The taper's internal memory has failed a self-test. Replace the CPU PCB. Contact Exatron Customer Service for assistance.
MOD SET UP ? NO
<SET UP> Modifies the taper's setup. <ENTER> No modifications to the handler's setup are required.
MOD SET UP ? YES

Press the <SET UP> key if no changes to the handler's setup are required. Press the <ENTER> key to make changes to the handler's setup. The handler will now scroll through all of the setup routines listed below. See "Modifying Setup" on page 3-28 for details regarding each setup. Seal type (thermal or PSA) Number of devices making a full tape Set number of gap steps Set number of offset steps Stop/loop modes off/on
MOTOR <A or B> BUSY ?

The taper is checking to see if the stepper motor is moving as required for each of the following taper components. A = tape drive B = swing arm If this message does not go away within a few seconds, the taper will not operate. To resolve this condition: 1. Turn the taper power OFF then ON and try again.
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MOTOR <A or B> ERROR ?
2. Check whether the motor setting address for # Motors in RAM matches the number of motors in your handler. Add the values for each motor it is equipped with. For example, the value for the shuttle motor is 01, and the value for the octoloader motor is 04. If you have just those two motors, their sum is 05, and the display should read: 0091 05. 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 or B> ERROR ?

The taper is checking to see if the stepper motor is powering up properly as required for each of the following handler components. A = tape drive B = swing arm 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 for # Motors in RAM matches the number of motors in your handler. Add the values for each motor it is equipped with. For example, the value for the shuttle motor is 01, the value for the Z pickup motor is 02, and the value for the octoloader motor is 04. If you have those three motors, their sum is 07, and the display should read: 0091 07. 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 OFF
You have pressed the <0> key while in DIAGNOSTICS DRIVE MOTOR CHK and turned off the tape drive motor.
MOTOR B OFF
You have pressed the <0> key while in DIAGNOSTICS SWING HEAD CHECK and turned off the swing arm motor. You can now rotate the swing arm freely to clean or replace the suction cup. Press the <CLEAR> key to turn the swing arm motor back on. Then press the <3> key to rotate the swing arm back up.
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MOTOR HOME
MOVE TAPE LEFT

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

The tape drive motor has moved several steps to the right as part of the Drive Motor Check DIAGNOSTICS routine.
NO POCKET? ERROR
No carrier tape was found in the tape track.
NOT UP TO TEMP
The temperature of the heaters in the sealing heads is too low. Check the two temperature control displays on the front of the taping system to verify the temperatures. If necessary, change the set temperature as described in "Setting Temperature for Heat Seal Heads" on page 3-19.
OFFSET = ####
The gap offset is the distance, measured in tape drive motor steps, between the leading edge of a tape pocket and the center of that pocket. This is a display only. See also "SET OFFSET = ####" on page 5-14.
OFFSET>GAP ERROR
The offset has been set larger than the gap. See "Understanding the Gap" on page 3-29 for details.
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>.
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PAUSED ######
PAUSED ######
You have pressed the <PAUSE> button on the front control panel. The display includes the number of filled tape pockets. The taper will not operate until you select another option from the controller keypad. To restart, press the <RUN> key.
POCKETS = ######
This message is displayed after you have pressed the <TOTALS> key. It shows the total number of devices placed in tape pockets, up to 999,999, since the last time the count was reset to zero. After the count is reset to zero, the display reads: POCKETS = 000000. See "RESET COUNT YES" on page 5-13.
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.
RESET COUNT NO
The current tally of devices placed in the tape remains in memory even when the taper is turned off. Press the <TOTALS> key to see the total, in the format POCKETS = ######. Exits routine without resetting the total count to zero. <ENTER> Exits with no changes. <SET UP> Toggles back to RESET COUNT YES.
RESET COUNT YES

The current tally of devices placed in the tape remains in memory even when the taper is turned off. Press the <TOTALS> key to see the total, in the format POCKETS = ######. <ENTER> Resets the total to zero. Display reads: COUNT SET TO 0. <SET UP> Toggles back to RESET COUNT NO.
ROTATE DOWN
The swing arm has moved down one step, about .003".
ROTATE UP
The swing arm has moved up one step, about .003"
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Model 1050 Manual
RS-232 CHECK
See "INTERFACE CHECK: RS-232 Port Check" on page 4-16.
SEN0-7 01234567
One or more of the numbers shown above is displayed following SEN0-7. This group of sensors applies to the tape. See "SENSOR CHECK: Tape Sensors 0-7" on page 4-9.
SEN8-F 89ABCDEF
One or more of the numbers/letters shown above is displayed following the phrase SEN8-F. This group of sensors applies to the pickup site. See "SENSOR CHECK: Pickup Site Sensors 8-F" on page 4-10.
SENSOR CHECK
See the sections "SENSOR CHECK: Tape Sensors 0-7" on page 4-9 and "SENSOR CHECK: Pickup Site Sensors 8-F" on page 4-10.
SET GAP ? NO/YES

This proposes to re-find the gap between the leading edges of two adjacent tape pockets. See "Understanding the Gap" on page 3-29 and "Setting Tape Pocket Gap" on page 3-31 for details. <ENTER> key = Press to display current settings. The display reads "GAP STEPS = ####", then "OFFSET = ####". <SET UP> key = "SET GAP ? YES" then press <ENTER> to set the gap.
SET OFFSET = ####

You can type a different offset number if necessary, to get the tape pocket center under the swing arms pickup head. Use Polish notation (right-to-left) to change the number. Then press <ENTER>. The tape advances by the offset you have entered, and SET OFFSET = #### is redisplayed. Again you can look to see if the pocket center is under the pickup head. If not, you can change the number again. Press <ENTER> again to confirm the value.
SOLENOID CHECK
See "OUTPUT CHECK: Solenoid Check" on page 4-11.
STOP MODE ON/OFF

You have pressed the <9> key while in RUN mode or a waiting mode. Stop and loop modes are for testing and troubleshooting of the taper. Select one of the following keypad choices.
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STOP MODE ON ?
<1> = "STOP MODE ON ?" The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. <2> = "LOOP MODE ON ?" The taper will stop after a complete cycle for one device. <3> = "ALL MODES OFF ?" The taper will cycle multiple devices in a normal run. This is the default. <CLEAR> = Resets to the beginning of the taper's "STOP MODE ON/OFF" loop. <ENTER> Confirms your selection.
STOP MODE ON ?
You are in Stop mode. Stop and loop modes are for testing and troubleshooting of the taper. Select one of the following keypad choices. <1> = "STOP MODE ON ?" The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring. Press <ENTER> or <RUN> when you are ready to execute the next action. <2> = "LOOP MODE ON ?" The taper will stop after a complete cycle for one device. <3> = "ALL MODES OFF ?" The taper will cycle multiple devices in a normal run. This is the default. <ENTER> = Executes the next Stop mode action.
SUM CHECK =
Four alphanumeric characters (in hex) are displayed following this message. 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 setup. You can press <ENTER> to skip past this error and try again. Or you can press <CLEAR> to flush the handler of all devices.
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Model 1050 Manual
TAKE UP MOTOR ON
You have activated the takeup motor check feature by pressing the <5> key on the front control panel when the taper was either in RUN mode or a paused condition. Pressing the <5> key turns the takeup motor for five seconds or until the takeup arm switch is thrown, while the above status message is displayed. If the motor turns a full five seconds the error message: "TAKE UP REEL ERR" will be displayed. You may: Press <ENTER> to rotate the takeup motor another five seconds. Press <CLEAR> to return to RUN mode or other previous condition.
TAKE UP REEL ERR

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

This error condition is caused when the carrier tape is in an incorrect position. The gap between tape pockets is not lined up opposite the tape gap sensor. It is possible to move the tape in single-step moves until it is again properly aligned: Press the <7> key to move the tape one step to the left. Press the <9> key to move the tape one step to the right. TIP: To quickly move the tape to the left until the gap between tape pockets is aligned directly opposite the sensor, press the <4> key. The taping system will then be ready to resume operation.
TAPE IS FULL
This message advises that the current taping job is complete, that is, the full tape count has been reached. You can press <ENTER> to reset the count to zero and begin operation again. Or, you may create a tape leader of fifty empty sealed pockets by pressing <DELETE> first. This will run the takeup reel and tape drive motors with the sealing heads engaged to create a tape leader of fifty empty sealed pockets for a new reel. Use this feature when you intend to cut the tape at the leader and separate the full reel from the rest of the tape.
TEST TAPE MOTOR

You have pressed the <5> key while in the Drive Motor Check DIAGNOSTIC.
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THANK YOU
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.
THERMAL OR PSA ?
Select the type of seal tape to apply to the carrier tape. Press the <1> key to "USE THERMAL TAPE" or press <2> to "USE PSA TAPE."
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.
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 has detected an error. Turn the handler OFF, then ON and try again. If the problem continues, replace the handler's CPU PCB.
UPSIDE DOWN ERR ?

The sensor has detected a device that is upside down in the tape pocket; i.e., dead bug when it should be live bug.
ZERO COUNT ERR

The operator has set the tape full quantity to 000000.
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Model 1050 Manual
Set the count for more than 0000. See "FULL T = ######" on page 5-7.
Figure 5-1
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Chapter Overview
This chapter discusses the following maintenance tasks and their frequency: Task Seal Head Maintenance Air Regulator Maintenance Checking Air Regulator Shutoff Valve Adjusting Air Pressure on the Regulator Checking the Moisture/Dirt Trap in the Air Regulator Solenoid Maintenance Fiberoptic Photoelectric Sensor Guidelines Recommended Frequency As needed As needed Monthly As needed Weekly As needed As needed Page 6-1 6-3 6-3 6-4 6-4 6-7 6-8
Preventive maintenance on the Model 1050 is fairly simple. Following this schedule will help to assure your Model 1050 handler will continue to perform properly. CAUTION: Do not lubricate any lead screws! Lubricating the screws will void the warranty. CAUTION: Do not use any cleaners or solvents on any bearings or lead screws! CAUTION: Always power off the system before disconnecting any cables or doing any maintenance.
Seal Head Maintenance

If one of a pair of thermal seal heads is heating but the other is not, it is likely because it has become slightly unplugged. You may get wildly erratic readings or a display of all zeros (0000). Make sure each seal head is firmly plugged in. The front seal head is color-coded red; the back seal head is color-coded blue. Residue from the carrier tape and sealing tape gradually builds up on the sealing heads, whether you use thermal or PSA (pressure-sensitive) heads. In time, this residue prevents a good tape seal. So when you notice any lowered quality of tape seal, clean the heads.
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Model 1050 Manual
Pressure-Sensitive Heads
If the PSA rollers on your taper are brass (Figure 6-1, left), you can clean them with alcohol. Apply alcohol to a Q-tip and rub the Q-tip around the PSA rollers until the edges are shiny. However, if the PSA rollers on your taper are rubber (Figure 6-1, right), do not use alcohol or other cleaning fluids on them. Just replace them with new ones.
Figure 6-1: Brass PSA Rollers (Left); Rubber PSA Rollers (Right)
Heat Seal Heads

Disassemble the blades and clean them with very fine (320) sandpaper. First rub the blade edge on the flat sandpaper in the direction of the blade ends. When the edge is shiny, lay the blade flat on the sandpaper and rub it till each side is shiny, as well.
Figure 6-2: Heat Seal Head Blade
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Air Regulator Maintenance
Checking Air Regulator Shutoff Valve

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

Check the operation of the shutoff valve once a month. To check the operation of the shutoff valve: 1. Turn the valve OFF and verify that the air is indeed off. Turn the valve back ON. 2. Check the PSI setting. > Set the air regulator to 50 PSI. Adjustment valve On/off switch in OFF position On/off switch in ON position
Figure 6-3: Air Regulator Turned Off (Left), On (Right)
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Model 1050 Manual
If the air regulator is turned off, turn it on by turning the on/off knob one quarter-turn counterclockwise. You can leave this knob turned on except when you are checking its operation.
Adjusting Air Pressure on the Regulator

You can increase air pressure at the air regulator. To adjust the air pressure: 1. Pull up on the adjustment valve (the black knob above the display), and turn it. > Turn it clockwise to increase the pressure. > Turn it counterclockwise to decrease the pressure. 2. Push the knob back down to lock it when you have finished the adjustment.
Checking the Moisture/Dirt Trap in the Air Regulator

Check the moisture/dirt trap on the air regulator and the filter chamber. Verify that they are clean, empty and dry. There should be no oil and no water in either chamber. If they are dirty, physically disconnect the incoming air pressure supply from the air regulator and clean the trap and filter as needed. Excessive moisture and or particulate buildup in the filter traps suggest the air supply to the system is too wet and/or dirty. CAUTION: Excessive moisture in the system can damage the air valves. Various models of air regulators differ. Here is one procedure. To check or replace the air filter: 1. Unscrew the small black screw at the bottom of the filter chamber and remove. If water is present, there is water in the air lines and you have a problem that you must correct.
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Figure 6-4: Air Regulator with Small Black Screw Removed
2. Unscrew the metal casing.
Figure 6-5: Metal Casing Unscrewed
3. Snap off the clear glass casing.
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Model 1050 Manual
Large black screw

Figure 6-6: Clear Glass Casing Snapped Off
4. Unscrew the black inner screw that has edges like propeller blades.
Filter
Figure 6-7: Large Black Inner Screw Removed
5. Remove the white filter and clean or replace if necessary, and reassemble in reverse order. If you find it necessary to clean the trap and/or filter more often than once a month, you should correct the problem at your in-house air compressor. Check your manufacturers manual for the exact procedure necessary.
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Solenoid Maintenance
Solenoid Maintenance
CAUTION: NEVER use oil or lubricant of any kind on solenoids.
Figure 6-8: Solenoid with Plunger on Back Side of Taper
Keep the solenoids as clean as possible. If the taper is used with devices that have excessive mold flash, the solenoids will require cleaning regularly. The frequency is dependent upon how much mold flash gets into the solenoids. When cleaning solenoids, do not put excessive stress on solenoid wiring. Check all wiring for signs of wear, exposed conditions, or broken connections. Replace as needed with identical type of wire: standard or flex, same gauge, insulation, color, etc. When cleaning solenoids, check the plungers to be sure there are no burrs of any kind on their shafts. Solenoid life is proportional to the handler environment and how often the solenoids are cleaned. We recommend that all solenoids be replaced every two million cycles as part of a good preventive maintenance program. Replace any bent or damaged solenoid return springs with new parts from the Exatron factory. Refer to the hardware specifications in the Parts List for the part numbers of all solenoids and springs in your handler.
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Model 1050 Manual
Fiberoptic Photoelectric Sensor Guidelines

Clean dust off the sensor optics with a very low blast of air. Each sensor on your handler is connected to a sensor controller, which displays whether the sensor is "seeing" any object. Most fiberoptic sensor controllers are set to L-ON (light on) by Exatron. This causes the output transistor to turn on when light is received by the sensor.
Figure 6-9: Sensor Controller Set to L-ON
Figure 6-10: Green and Red Indicator Lights
The green light is the Stable Operation Indicator. When the sensor is operating normally under stable conditions, the green light should be ON.
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Fiberoptic Photoelectric Sensor Guidelines
The red light is the Light Reception Indicator. When the sensor is receiving light, the red light should be ON.
Figure 6-11: 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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Model 1050 Manual
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04/2010

This chapter contains the following main sections:
Topic Guide to the Parts List Lists of Parts
Page 7-1 7-4
Spare parts can be obtained from Exatron. It has always been Exatron policy to support all the equipment we have ever manufactured. If the part is still available, or can be made, we will get it for you. In most cases, faxed requests and shipment of replacement parts orders are processed within twenty-four hours of receipt by Exatron. Each parts list is specific to each machine, so the parts list is included in the manual that is shipped with each custom Exatron handler.
Guide to the Parts List

This guide shows how to use the parts list to determine the exact part number of any custom part in your machine in order to replace it if necessary. The parts list contains those items which Exatron has custom manufactured. They include machined parts, sheet metal, printed circuit boards, cables, and standard vendor parts which have been modified by Exatron. A limited number of standard vendor parts are also listed here. The title at the top of the list indicates the type of parts list. This should match your system's hardware. The parts list may change as Exatron improves each model with each new generation. If you have different generations of the same model, the parts list will vary. Whenever possible, Exatron makes design improvements capable of being retrofitted to older versions of the same model. The date on the parts list indicates the date of the last revision of the list, not necessarily the last revision of the system hardware. An explanation of the column categories in the parts list follows.
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Model 1050 Manual
Exatron (Part Number)

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

The next two or three columns indicate the quantity of the specific part used in the manufacture of this system. This information may be useful in determining the correct part number and was used to build an assembly kit when your system was originally built.
Manual
Each row that has a 1 in this column has a corresponding wiring print in this manual. The print is identified by the part number.
Description
This is the name assigned to the part. In most cases, this description will clearly designate the part you wish to locate. Please include this description when ordering replacement parts.
Assembly
This column indicates which major system sub-assembly the part belongs to. In most cases, the "Assembly" can be ordered as a complete replacement part.
Size
These are dimensions in inches. The dimesions are listed left to right from smallest to largest: A x B x C. This is the starting size of the part prior to being machined.
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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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Model 1050 Manual
Lists of Parts
This chapter contains the following parts lists:
Parts List TAPE 1050 7X7 MLF QUICK CHANGE CO KIT TAPE 1050 9X9 MLF QUICK CHANGE CO KIT TAPE MODEL 1050 TAPE OUTPUT
Page 7-4 7-5 7-6
TAPE 1050 7X7 MLF QUICK CHANGE CO KIT

IN HOUSE PART NUMBER SAME SAME 1050 7X7 MAN MLF UAL CO KIT 1 1 1 SAME 1 1 1 1 2 1 SAME SAME 1 1 1 2 1 ? 1 1 1 1 1 WIDT H
PART NUMBER
DESCRIPTION
ASSEMBLY
SIZE
MATERIAL
FINISH
APE
TAPE MASTER PARTS LIST TAPE TYPE B SWING HEAD ASSEMBLY MODIFIED SOLENOID PLUNGER INDEX PLUNGER MOD FITTING KNOCK AIR CYLINDER 1/4 BORE, 1/4 STROKE BLACK BUMP ON SIZE 75 SOLENIOD SWING HEAD ASSEMBLY CA OUT GATE OUT CYLINDER MOUNT TYPE B SWING HEAD DETAIL UNDER SOL TAPE OUT TOP GUIDE UNDER SOL MOUNT COVER TAPE GUIDE BLOCK 16 MM TAPE EXIT STACK PIN BLOCK SOLENOID BUMPER PAD PICK UP BUMPER MOUNT
TAPE SWING HEAD INDEX INDEX INDEX TAPE OUT DANCER ARM 1050 INDEX SWING HEAD OUT GATE OUT GATE SWING HEAD UNDER SOL UNDER SOL TAPE GUIDE INDEX INDEX
TAPE SEE PARTS LIST SP-75 SEE PRINT .250 DIA., .625 L EM EM BRASS HUMPHREY SMITH SEE PART SEE PRINT .312-.375-.942 .875-.987-1.765 SEE PRINT .020-.375-8.936 SS NONE NICKEL HCR RED NONE BLACK 6061 6061 NEDOX NEDOX EM NONE NONE SOIC NONE NONE NONE
-06
00-101-75-A
00-192-A1
00-194-A
NSA-6-1/4
-5012
75-12VDC
PE-475-B
PE-540-B
PE-541-A
PE-700-1-C SAME SAME SAME SAME SAME SAME SAME
PE-705-A
PE-706-A
1.115-1.899-3.800 6061 .500-.885-1.290 .250-.750-.850 ,06-.250-.500 6061 6061 FELT 6061
PE-723-C
PE-733-A
PE-733D
PE-736-B
OUTPUT RAIL .125-.540-.937
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PART NUMBER IN HOUSE PART NUMBER SAME SAME 1050 7X7 MAN MLF UAL CO KIT 1 1 1 1 WIDT H
04/2010
Lists of Parts
DESCRIPTION
ASSEMBLY
SIZE
MATERIAL
FINISH
KIT
TAPE-737-A TAPE-745-A VP6RSE
TAPE OUT UNDER RAIL INDEX ASSEMBLY TAPE OUT BOTTOM RAIL 7 X 7 MLF 6 MM VACUUM CUP
ASSEMBLY 1050 TAPE OUT SWING HEAD
SEE PRINT .300-1.500-9.949 6 MM 6061 PISCO NEDOX 7X7 1

IN HOUSE PART NUMBER 1050 9X9 MLF CO KIT 1 1 1 SAME 1 1 1 1 2 1 SAME 1 1 1
PART NUMBER
MAN UAL
DESCRIPTION
ASSEMBLY
SIZE
MATERIAL
FINISH
WIDTH KIT
TAPE 00-06 2500-101-75-A 2500-192-A1 2500-194-A HNSA-6-1/4 SJ-5012 SP75-12VDC TAPE-475-B TAPE-541-A
SAME SAME
TAPE MASTER PARTS LIST TAPE TYPE B SWING HEAD ASSEMBLY MODIFIED SOLENOID PLUNGER INDEX PLUNGER MOD FITTING
TAPE SWING HEAD INDEX INDEX INDEX
TAPE SEE PARTS LIST SP-75 SEE PRINT .250 DIA., .625 L EM EM BRASS HUMPHREY SMITH SEE PART SEE PRINT .875-.987-1.765 SEE PRINT 6061 NEDOX EM NONE NONE SOIC 2 NONE NONE NONE 1 1
KNOCK AIR CYLINDER 1/4 BORE, TAPE OUT 1/4 STROKE BLACK BUMP ON SIZE 75 SOLENIOD SWING HEAD ASSEMBLY OUT CYLINDER MOUNT TYPE B SWING HEAD DETAIL DANCER ARM 1050 INDEX SWING HEAD OUT GATE SWING HEAD
TAPE-700-1-C SAME
Finish
7-5

IN HOUSE PART NUMBER 1050 9X9 MLF CO KIT 2 1 ? 1 1 1 1 1 1 1 1
7-6
PART NUMBER MAN UAL TAPE-705-A TAPE-706-A TAPE-723-C TAPE-733-A TAPE-733PAD TAPE-736-B TAPE-737-A TAPE-746-A VP6RSE
Copyright Exatron, 2010 04/2010
Model 1050 Manual
DESCRIPTION
ASSEMBLY
SIZE
MATERIAL
FINISH
WIDTH KIT
SAME SAME SAME SAME SAME SAME SAME SAME
UNDER SOL TAPE OUT TOP GUIDE UNDER SOL MOUNT COVER TAPE GUIDE BLOCK 16 MM TAPE EXIT STACK PIN BLOCK SOLENOID BUMPER PAD PICK UP BUMPER MOUNT TAPE OUT UNDER RAIL INDEX ASSEMBLY TAPE OUT BOTTOM RAIL 9 X 9 MLF 6 MM VACUUM CUP
UNDER SOL UNDER SOL TAPE GUIDE INDEX INDEX OUTPUT RAIL ASSEMBLY 1050 TAPE OUT SWING HEAD
.020-.375-8.936
SS
NONE NICKEL HCR RED NONE BLACK 2
1.115-1.899-3.800 6061 .500-.885-1.290 .250-.750-.850 ,06-.250-.500 .125-.540-.937 SEE PRINT .300-1.500-9.949 6 MM 6061 PISCO 6061 6061 FELT 6061
NEDOX
9X9
TAPE MODEL 1050 TAPE OUTPUT

PART NUMBER TAPE ?-2 ?-5 IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE SAME 1 1 1 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
TAPE MASTER PARTS LIST TAPE FUSE HOLDER 2 AMP FUSE POWER SUPPLY POWER SUPPLY
TAPE LITTLE FUSE NONE

PART NUMBER 00-01 00-03 08-03-2784109 1/4" ID WRAP 1L466 1W364 2400-441-A1 2416-061-B1 2500-048-B1 2500-074-C2 3000-055-C3 3000-202-B 3000-204-A1 SAME SAME SAME SAME SAME SAME MOT10011 IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE SAME SAME HOT06183 1 1? 2 5FT OPT 1 2 1 1 10 1 1 4 1 1 1 5 1 1 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
Lists of Parts
TAPE SWING HEAD FOR MODEL 1050, NO CO KIT FRAME AMBIENT 35/W TAPE OUTPUT SNAP SWITCH 120VAC OPEN AT 450 F SPRIAL WRAP 25 RPM SHADED POLE MOTOR, MAG BRAKE, FAN POWER CORD CLAMP BLOCK RS-232 PORT CABLE INTERNAL COVER AIR VENT SPRING TUBE CLAMP 8085 CPU CARD 3000B BUS BOARD CARD CAGE STAND OFF CARD CAGE - LEFT CARD CAGE - RIGHT 3000B I/O PORT PCB
SWING HEAD 5000 FRAME SEAL HEAD SEAL HEAD TAKE UP MOTOR POWER SUPPLY OUTPUT TUBE ELECTRONICS ELECTRONICS OUTPUT TUBE ELECTRONICS ELECTRONICS ELECTRONICS ELECTRONICS ELECTRONICS ELECTRONICS
1050
SEE PARTS 35 LIST DEGREE SEE PARTS LIST FENWAL CARR
220 VAC 50Hz
GRAINGER GRAIN GER .500 DIA., .875 L 6061 T&B 5052 STEEL FR-4 FR-4 6061 5052 5052 FR-4 SS BLUE NONE NEDOX NONE FAB FAB BLACK NEDOX NEDOX FAB NONE
RS-232
SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT .375-1.0005.125 SEE PRINT SEE PRINT SEE PRINT SEE PRINT
3000-205-L-C SAME 3000-205-RC 3000-223-2B2 3044-544-B1 SAME SAME
SWITCH COVER .250 WIDE OUTPUT TUBE
Finish
7-7

PART NUMBER 311SM6-T 3CCF-300-E 3CCF-70-E 3M257 3MP28A-20 3MP28A-40 3MP32A-20 3W160-5DRA3C6 4000-075-A1 4000-106-A1 44D28 44D31 5000-397-2A1 5000-398-2C1 5000-957-A IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE SWT13015 BEA12022 BEA12003 MOT10010 BEA07002 BEA07040 BEA07120 PNE020350 SAME SAME BEA11018 BEA11021 SAME SAME LAB04020 1 1 1 1 2 1 1 1 5 2 1 1 1 1 1 1 1 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
7-8
Model 1050 Manual
MICRO SWITCH SUB MINI SWITCH W/ROLLER ARM MINI-E-PITCH CABLE CHAIN 70 PITCH CHAIN .157 25 RPM SHADED POLE MOTOR, MAG BRAKE, FAN SPROCKET 1.000 DIA., .25 I.D. 2" CHAIN SPROCKET, .250 BORE 1" CHAIN SPROCKET .312 BORE AIR VALVE SWITCH COVER EXTENSION OUTPUT HOLDER PIN 10-32 X 1/4" SHOULDER SCREW 10-32 X 1/2" SHOULDER SCREW QUAD STEPPER DRIVER PCB TEST SITE DRIVER PCB EXATRON NAME PLATE
DANCER ARM CRANK TAKE UP MOTOR TAKE UP MOTOR 110 VAC 60Hz 300 PITCH .157 BERG BERG GRAINGER
NEWARK NONE
BERG TAKE UP MOTOR TAKE UP MOTOR PIVOT CYLINDER OUTPUT TUBE OUTPUT TUBE PRESSURE ROLLER PRESSURE ROLLER ELECTRONICS ELECTRONICS MAIN PLATE SEE PRINT SEE PRINT SEE PRINT FR-4 FR-4 METAL 24 VDC 100W SEE PRINT .250-.500.750 BERG BERG SNAP-TITE FOAM 6061 NONE RED ALLIED ALLIED FAB FAB PAINT 5

PART NUMBER IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE 1 1 1 1 1 1 1 OPT 1 1 SAME HRD02500 1 2 1 1 1 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
04/2010
Lists of Parts
5000-A89-C1 SAME 5000-K01-A 5000-L46-D 5000-M0827-A1 5000-M15-A LAB04028 SAME SAME SAME
FRONT PANEL DRIVER PCB EARTH GROUND PLATE
ELECTRONICS MAIN PLATE 1050
SEE PRINT SEE PRINT .250-1.5005.000 SEE PRINT SEE PRINT SEE PRINT SEE PRINT SEE PRINT .430-3.5009.750 .500-.6256.860 .062-.7502.226
FR-4 METAL 6061 T&B T&B T&B POLY POLY 6061 6061 5052
FAB PAINT BLACK NONE NONE NONE 5000
CHAMBER INTERNAL FUSE 5000 FRAME PANEL TEST SITE DRIVER CABLE FRONT PANEL CABLE MOTOR DRIVER CABLE ELECTRONICS ELECTRONICS ELECTRONICS
5000-M22-A2 SAME
5000-M54120-A1 5000-M54240-A1 5000-M65-G1 5000-M66-A 5000-P05-A 5993K35
SAME SAME
INPUT POWER LABEL 100- POWER SUPPLY 100/120 120 VAC VAC INPUT POWER LABEL 220- POWER SUPPLY 220/240 240 VAC VAC 5 SORT TUBE HOLDER CLAMP BAR, 5 POS. PLUG I/O CONNECTOR (COVER) CLAMP KNOB OUTPUT TUBE OUTPUT TUBE ELECTRONICS
NEDOX BLUE NEDOX McMAS TER CARR
6000-233-8-C 61EA1 6479K25 POW17003 HRD02505
5 1 1
TUBE HOLD DOWN POWER LINE FILTER HAND CRANK KNOB
OUTPUT TUBE POWER SUPPLY ADJUST SCREW
.500-.500.937 6 AMP
6061 CORCOM
NEDOX
McMAS TER CARR
Finish
7-9

PART NUMBER 704.074.2 704.9002 BB-50 CG1-9 IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE SWT05100 SWT05111 BEA18050 BEA09014 1 2 2 2 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
7-10
Model 1050 Manual
PUSH BUTTON MUSHROOM CAP ASSEMBLY SNAP ON SWITCH ASSEMBLY, 2 RED SWITCHES BALL BEARING, PRESS FIT SS SPLIT HUB CLAMP
POWER SUPPLY POWER SUPPLY TAKE UP MOTOR ADJUST SCREW .500 ID, 1.125 OD .25 ID. .875 OD, 6-32 TAP
E.A.O. E.A.O.
NONE
BERG
NONE
CSD5814N-P MOT05000-P CTM150B-00 CY545B DE2D13 E1A-700 BEA16222 HOT03240-100THIN SEM03400 PNE0310.5R PNE002001
2 1 2 4 2
5 PHASE MOTOR DRIVER OEM MICROTERMINAL MOTOR CONTROL CHIP FLANGED BALL BEARING CARTRIDGE HEATERS, 50 WATT FIBER OPTIC AMPLIFIER BIMBA CYLINDER, SPRING OUT RIGHT ANGLE 1/8" TUBE 10-32 FITTING
ELECTRONICS ELECTRONICS ELECTRONICS SEAL HEAD HOT HEAD .25 ID, .50 OD .250 DIA., 1.18 LONG
VEXTA BURRBROWN
ALLIED
NONE WATLOW
E3X-A11 FOR-040-.5 KJL01-32 KQL07-34S MPJ-J-F PB1/8U10MU
3 2 2 1
P&P MOTOR PIVOT CYLINDER PIVOT CYLINDER
OMRON NEWARK SMC SMC THERMX PISCO NONE
RIGHT ANGLE 1/4' TUBE 1/8 PIVOT CYLINDER PIPE FITTING THERMALCOUPLE CONNECTOR FEMALE J TYPE ELECTRONICS
NONE BLACK NONE
HOT-07002-F
2 1
"T" 1/8" TUBE 10-32 FITTING PIVOT CYLINDER

PART NUMBER PK564ANTG30 Q1-50 REXC100FJA3MAN SJ-5012 SMJ-J-M HOT07102-M NRET0480 SEM02301 IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE 1 1 2 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
04/2010
Lists of Parts
STEPPER MOTOR 500 STEP WITH 30 : 1 GEAR E RING TEMPERATURE CONTROL J TYPE TC WITH ALARM
DRIVE MOTOR TAKE UP MOTOR ELECTRONICS WITH ALARM
VEXTA .500 SHAFT BERG PHX AUTOMATION SMITH THERMX SEE PRINT SEE PRINT SEE PRINT EMED EMED EMED NONE BLACK
1 2
BLACK BUMP ON THERMALCOUPLE CONNECTOR MALE J TYPE DANDER ELECTRICAL HAZRAD LABEL DANGER WATCH YOUR FINGERS CAUTION DO NOT OPERATE WITHOUT GUARDS IN PLACE BALL BEARING
DANCER ARM ELECTRONICS ELECTRONICS ELECTRONICS ELECTRONICS
SQS24 SQS3 SQS66
LAB03-011 1 LAB03007 LAB03014 1 1
SR2BEA16ZZRA3P25L0 213 1 DE1D3 OR B1-5 TAPE-102-V1 SAME TAPE-112-B SAME
BALL BEARING
.125 ID, .375 BERG OD, .16 THK
BRONZ E
1 1 3 1
BACK PLATE SUPPLY REEL HUB BRACKET SUPPLY REEL FINGER SUPPLY REEL HUB
BASE SUPPLY REEL SUPPLY REEL SUPPLY REEL
.500-3.50030.000 .250-4.000 DIA. 2.875-.750 DIA. 1.250-1.500 DIA.
6061 6061 6061 6061
PAINT NEDOX NEDOX NEDOX
TAPE-114-A1 SAME TAPE-115-C SAME
7-11
Finish

PART NUMBER TAPE-116-A IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE SAME 1 2 1 1 1 1 1 1 6 2 2? 2 1 1 1 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
7-12
TAPE-126-B TAPE-127-D TAPE-129-C TAPE-130-C TAPE-134-B TAPE-135-C
Model 1050 Manual
SUPPLY REEL GUIDE BRACKET SENSOR BRACKET PRESSURE ROLLER ARM PRESSURE ROLLER BLOCK DANCER ARM SWITCH ACTUATOR DANCER ARM PIVOT KNOB (LG) KNOB (SM) GUIDE ROD SMALL PRESSURE WEIGHT LARGE PRESSURE WEIGHT WEIGHT ROD KEEPER PIN END PLATE LOCATOR SUPPLY REEL ROD SPACER
SUPPLY REEL BASE BASE PINCH ROLLER BASE BASE BASE BASE BASE SEAL HEAD SEAL HEAD SEAL HEAD PINCH ROLLER BASE SUPPLY REEL
.500-.5002.500 .500-.5001.356 .480-.3803.750
6061 6061 6061
RED BLACK NEDOX NEDOX NEDOX NEDOX RED BLUE NONE NONE NONE NONE NONE NEDOX BLACK
TAPE-119-E1 SAME SAME SAME SAME SAME SAME SAME
1.000-1.500- 6061 3.310 .235-.5003.000 .250-.5001.500 .250-.750 DIA. .750-.500 DIA. .500 DIA.3.630 L .500 -1.000 DIA. 1.00 DIA., 1.25 L 3.375-.250 DIA. 1.250-.230 DIA. .475-1.0002.000 .780-1.000 DIA. 6061 6061 6061 6061 SS SS SS SS SS 6061 6061
TAPE-137-A2 SAME TAPE-140-1C TAPE-140-2A TAPE-141-F TAPE-142-A SAME SAME SAME SAME
TAPE-147-C1 SAME TAPE-149-B SAME

PART NUMBER TAPE-150-C TAPE-153-B TAPE-156-B TAPE-157-G TAPE-158-BB1 TAPE-162-F TAPE-163-D IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE SAME SAME SAME SAME SAME SAME SAME 2 2 2 1 3 1 1 1 1 2 2 2 1 1 2 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
Lists of Parts
CLAMP NUT WITH PIN RAIL ADJ. BUSHING HEATER ARM STOP PINCH ROLLER TAKE UP & COVER TAPE SPACER BLUE BACK RIGHT RAIL FRONT RIGHT RAIL BACK LEFT RAIL FRONT LEFT RAIL COVER TAPE DISK (LG) M16-2 RAIL ADJUSTMENT SCREW M16X2 RAIL ADJ NUT CRANK CRANK HANDLE CYLINDER BUMPER
BASE ADJUST SCREW HEATER PINCH ROLLER BASE BASE BASE BASE BASE COVER TAPE ADJUST SCREW ADJUST SCREW ADJUST SCREW ADJUST SCREW PIVOT CYLINDER
1.000-1.250 DIA. 1.125-1.500 DIA. 1.250-.500 DIA. .250-.750 DIA. .437-1.000 DIA. .062-.75019.255 .062-.75019.235 .062-.7509.605 .062-.7509.585 .375-7.500 DIA. .629 DIA. 6.75L
6061 BLK DEL BLK DEL BLK DEL 6061 STEEL STEEL STEEL STEEL 6061 SS
RED NONE NONE NONE BLUE NEDOX NEDOX NEDOX NEDOX NEDOX NONE BLUE BLUE BLUE NONE
TAPE-164-E1 SAME TAPE-165-D TAPE-173-D TAPE-180-C TAPE-181-B TAPE-182-B TAPE-183-B TAPE-187-A SAME SAME SAME SAME SAME SAME SAME
1.250-1.366- 6061 1.500 .750-1.0002.250 .500 DIA., 1.00 LONG .650-.750 DIA. 6061 6061 BLK DEL
7-13
Finish

PART NUMBER TAPE-188-LB IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE SAME 1 1 1 1 2 2 1 1 2 2 1 1 1 2 1 1 1 1 1 1 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
7-14
TAPE-189-C TAPE-190-B TAPE-191-3A TAPE-192-A
Model 1050 Manual
LEFT CYLINDER MOUNT RIGHT CYLINDER MOUNT VALVE MOUNT BLOCK CYLINDER ASSEMBLIES SEAL HEAD ASSEMBLY HOT HEAD LABEL LEFT HEAD PLATE RIGHT HEAD PLATE HOT SHOE COVER ADJUST SCREW ASSEMBLY
PIVOT CYLINDER PIVOT CYLINDER PIVOT CYLINDER PIVOT CYLINDER ASSEMBLY SEAL HEAD SEAL HEAD SEAL HEAD SEAL HEAD ASSEMBLY
.750-1.7502.165 .750-1.7502.165 .750-1.2241.359 SEE PRINT SEE PRINT SEE PRINT .250-2.000 DIA. .250-2.000 DIA. .875-2.000 DIA. SEE PRINT SEE PRINT SEE PRINT .500 DIA., 9.000 L .374-2.7502.875 .375-2.7505.968
6061 6061 6061
CLEAR CLEAR CLEAR
TAPE-188-R- SAME B SAME SAME SAME SAME
KAPTON PEAK PEAK PEAK NONE NONE NONE
TAPE-195-C1 SAME TAPE-196-C1 SAME TAPE-198-G TAPE-203-B TAPE-204-4A TAPE-211-E TAPE-218-C TAPE-219-B TAPE-220-D SAME SAME SAME SAME SAME SAME SAME
TAPE SWITCH PCB ASSEM- ASSEMBLY BLY 1020/1050 PRESSURE ROLLER ASSEMBLY TAKE UP REEL SHAFT TAKE UP MOTOR STAND OFF TAKE UP MOTOR MOUNT PLATE ASSEMBLY TAKE UP MOTOR TAKE UP MOTOR TAKE UP MOTOR
FR-4
FAB
SS 6061 6061
NONE
BLACK BLACK

PART NUMBER TAPE-221-A TAPE-222-F TAPE-223-J TAPE-224-K TAPE-227-B TAPE-229-A TAPE-230-B TAPE-247-1E TAPE-253-A TAPE-254-A TAPE-257-1C TAPE-258-A IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE SAME SAME SAME SAME SAME SAME SAME SAME SAME SAME SAME SAME 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
Lists of Parts
TAKE UP MOTOR ASSEMBLY
ASSEMBLY
SEE PRINT .375-9.88023.880 .500-5.0959.732 SEE PRINT .500-2.5005.500 35 .500-4.000DEGREE 5.500 .375-5.00028.000 SEE PRINT 6061 6061 SS 6061 6061 6061 WIRE NICKEL NICKEL NONE CLEAR CLEAR CLEAR NONE
ELECTRONICS MAIN PLATE ELECTRONICS ELECTRONICS SIDE PLATE ELECTRONICS ELECTRONICS BACK COVER 5000 FRAME ATTACH BLOCK TAPE FRAME ADJUST BLOCK ELECTRONICS 5000 FRAME 5000 FRAME
5000 TAPE SUPPORT BASE 5000 FRAME PLATE 1020/50/80 INTERNAL AC WIRING CARRIER TAPE PATH DETAIL TAPE AIR CURCUIT 1020/50 SEALING HEAD HEATER WIRING 1020/50 TAKE UP MOTOR WIRING 1020/50 SENSOR/VALVE WIRING 1020/50 DRIVE MOTOR ASSEMBLY EMPTY POCKET FIBER MOUNT BLOCK POWER SUPPLY 1020/50 ASSEMBLY AIR ELECTRONICS TAKE UP MOTOR WIRING ELECTRONICS EMPTY POCKET EMPTY POCKET
SEE PRINT SEE PRINT SEE PRINT SEE PRINT WIRE
TAPE-259-D1 SAME TAPE-262-B TAPE-284-E SAME SAME
.250-2.2502.600
6061
NEDOX
7-15
Finish

PART NUMBER TAPE-299-C TAPE-334-F TAPE-335-A TAPE-336-A TAPE-338-E TAPE-339-A IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE SAME SAME SAME SAME SAME SAME 1 2 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
7-16
Model 1050 Manual
TAPE OUT SWITCH MOUNT ELECTRONICS BLOCK .024" SEAL BLADE HOT HEAD BLOCK RIGHT HOT HEAD BLOCK LEFT TAPE DRIVE WHEEL WHEEL FELT PAD 1050 INPUT POWER WIRING 5000 SUPPLY WIRING FOR 1050 OPTION 1050 FRONT PLATE SEAL HEAD SEAL HEAD SEAL HEAD DRIVE WHEEL COVER TAPE
1050
1.000-1.450- 6061 1.656 .024-.5391.500 .718-.8751.500 .718-.8751.500 SS 6061 6061 6061 FELT WIRE WIRE 6061 SS SS WIRE 3000-223 SS 6061
BLACK NEDOX NEDOX NEDOX NEDOX NONE NONE NONE PAINT NONE NONE NONE NONE NONE NEDOX 1050/1 020 5000 5000 3
PIN WHEEL
.185-2.248 DIA. .06-1.00 DIA. SEE PRINT SEE PRINT .500-3.50030.000 .062-.7509.525 .062-.7503.690 SEE PRINT
TAPE-346-E1 SAME TAPE-347-C2 SAME TAPE-349-F TAPE-350-A TAPE-351-A TAPE-389-D TAPE-390-B TAPE-391-C TAPE-392-E SAME SAME SAME SAME SAME SAME SAME
POWER SUPPLY 1050 5000 FRAME 1050 1050
1050 FRONT GUIDE RAIL #1 1050 1050 FRONT GUIDE RAIL #2 1050 1050/1020 SWING HEAD WIRING 1050/20 TAPE I/O PORT PCB 1020 BOTTOM COVER 1020/1050 END PLATE SWING HEAD ELECTRONICS ELECTRONICS ELECTRONICS 1050/20
SEE PRINT SEE PRINT .500-2.50010.750

PART NUMBER TAPE-394-A TAPE-395-A TAPE-403-E TAPE-404-E TAPE-405-A TAPE-406-C TAPE-407-A TAPE-408-A TAPE-411-A IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE SAME SAME SAME SAME SAME SAME SAME SAME SAME 1 1 2 1 1 1 1 1 1 1 obs 1 1 1 2 1 1 1 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
Lists of Parts
1050 SUPPLY REEL BRACKET SUPPLY REEL OFFSET BLOCK
SUPPLY REEL SUPPLY REEL
.375-2.00020.269 .625-1.0002.000 .500-.8991.298 .187 DIA, 4.00 L .750 DIA. 1.500 L
6061 6061 6061 SS 6061
PAINT BLACK NICKEL NONE NEDOX BLUE
COVER TAPE STOP BLOCK COVER TAPE GUIDE COVER TAPE ADJUST BAR DRIVE WHEEL ADJUST POST DRIVE WHEEL ADJUST HUB ADJUSTABLE DRIVE WHEEL ASSEMBLY TYPE 2 OUTPUT BASE PLATE TAPE OUT MOD. 3 FIBEROPTIC MOUNT BLOCK OUT OF POCKET SENSOR MOUNT BLOCK 5000/1050 CONTROL CABLE GAP & OUT OF POCKET SENSOR MOUNT EMPTY POCKET MOUNT BLOCK COVER TAPE GUIDE BLOCK TOOLING SEAL HEAD ARM COVER TAPE GUIDE DRIVE WHEEL DRIVE WHEEL DRIVE WHEEL OUTPUT TUBE ELECTRONICS FRONT RAIL CABLE GUIDE RAIL EMPTY POCKET COVER TAPE GUIDE SEAL HEAD 1050 1050
1.000-1.000- 6061 1.500 SEE PRINT 6000-515 .562-1.0452.000 .250-.625.812 SEE PRINT .187-.7501.500 .500-1.1591.371 SEE PRINT .500-1.8803.068 6061 6061 6061 WIRE 6061 6061 6061 6061
NEDOX BLUE BLACK NONE BLACK NEDOX HCR NEDOX
TAPE-412-D1 SAME TAPE-414-A1 SAME TAPE-415-C1 SAME TAPE-416-B TAPE-419-B SAME SAME
TAPE-422-B1 SAME
7-17
Finish

PART NUMBER TAPE-423-B TAPE-424-A TAPE-426-3D TAPE-429-A TAPE-447-LB1 IN HOUSE 1050 MAN PART TAPING UAL NUMBER MACHINE SAME SAME SAME SAME SAME 2 2 1 1 1 1 2 1 1 2 1 2 1 2 4 1 DESCRIPTION ASSEMBLY OPTIONS SIZE MATERIAL FINISH WIDTH KIT
7-18
Model 1050 Manual
SEAL ARM PIVOT POST SEAL HEAD ADJUST 1050 BACK GUIDE RAIL 1050 ELECTRONICS SIDE PANEL PSA ROLLER BLOCK LEFT PSA ROLLER BLOCK RIGHT PSA PINCH ROLLER HEATER PLUG MOUNT BLOCK LEFT HEATER PLUG MOUNT BLOCK RIGHT HEATER MOUNT COVER 45 DEGREE MAIN PLATE ATTACH SPOT GUIDE RAIL COVER TAPE GUIDE ASSEMBLY J TYPE THERMACOUPLE
SEAL HEAD SEAL HEAD
1.412 L, .750 DIA. .500-.8481.500 .093-.75016.000
SS PEEK 6061 5052 6061 6061 BRASS 6061 6061 6061 6061 6061
NONE NONE NEDOX NICKEL NEDOX NEDOX NONE NEDOX NEDOX NEDOX NEDOX 1020 NEDOX
ELECTRONICS PSA ROLLER PSA ROLLER PSA ROLLER SEAL HEADS SEAL HEADS SEAL HEADS SWING HEAD PSA PSA PSA
SEE PRINT .500-.8482.375 .500-.8482.375 .500 DIA..281 .625-1.2501.620 .625-1.2501.620 .625-1.2501.308 45 .687-1.217DEGREE 2.750 .155-.9371.000
TAPE-447-R- SAME B1 TAPE-448-E TAPE-451-A TAPE-452-A TAPE-453-A TAPE-470-B TAPE-482-C TAPE-649-A TC-GG-J-3044 TP410 SAME SAME SAME SAME SAME SAME SAME HOT05044-J BEA01100
ASSEMBLY SEAL HEAD
SEE PRINT 2 .25 ID,.62 TEFLON OD, .06 THK NONE 4
TEFLON THRUST WASHER HEATER POVOT
Lists of Parts
Finish
04/2010
7-19
Model 1050 Manual
7-20
04/2010
Chapter 8: Prints
A set of wiring prints is included in the manual that is shipped with each custom Exatron handler.
04/2010
8-1
Model 1050 Manual
Chapter 8: Prints
8-2
04/2010
Index
A
air filter 1-3 air pressure 6-4 fittings 1-3 air regulator 3-17, 6-3, 6-4 air supply 1-3 ASCII values 3-42, 3-48, 4-17 control panel 2-4, 4-2 keys 3-26 messages 5-1 to 5-18 counts tape full 3-44 totals 3-33
D
decimal values 3-42, 3-48 devices changeover kit settings 3-41 messages 5-17 totals 3-33 Diagnostics mode 4-2, 4-3 displays control panel 3-26, 5-1 to 5-18 heater controller 3-20 drive gear adjustment knob 3-7 drive gear. See tape drive
B
blow-off 2-15 buttons Emergency Stop override 2-14 1-1, 2-7
C
calibration carrier tape track width 3-3 device placement in tape pocket 3-24 heat seal heads 3-12 pressure seal heads 3-15 carrier tape track 3-3 cautions and warnings avoid turning power off and on in rapid cycles 3-26 changing motor speeds can damage machine 3-41 connect power to grounded outlet 1-3 dont interfere with moving parts 1-1 dont lubricate lead screws 6-1 dont lubricate solenoids 6-7 dont touch adhesive tape to carrier tape 3-12 dont touch hot taper seal heads 3-13 dont unplug air hose when air regulator on 1-2 dont use cleaners on bearings or lead screws 6-1 dont use machine without approved air regulator 1-2 empty output tubes before beginning production run 3-18 keep away from moving parts 1-1 loosen track width locking knob before turning adjustment knobs 3-4 power off system before maintenance 6-1 prevent excess moisture in air regulator and air valves 6-4 Change RAM mode 3-39 changeover kit settings 3-41 checksum 5-3, 5-6, 5-15
E
electrical capability 1-2 Emergency Stop button 1-1, 2-7 end-of-life disposal 1-7 EPROM, updating 3-39, 3-41
F
flowcharts <SET UP> key options 3-28 Diagnostics mode 4-3 Manual mode 3-35 Modify Setup mode 3-30
G
gap 3-28, 3-29, 5-16 gap steps 3-29, 3-46, 5-8 guide block 3-10, 3-12
H
heat seal heads adjusting position 3-12 adjusting pressure 3-14 continued on next column
04/2010
Index-1
Model 1050 Manual
heat seal heads continued messages 5-12 semicircular 3-13 setting temperature 3-19 stopping 2-7 heater controller display 2-5, 3-20 heater fuse 2-5 hex values 3-42, 3-48 home position, swing arm 2-14 HyperTerminal 4-19, 4-26
I
index pin 2-2, 2-3, 2-6, 2-15 input reel. See supply reel installation 1-4 interface, RS-232 3-42
modes continued Loop 3-32 Manual 3-34, 3-35, 4-2 messages 5-5, 5-9 Modify Setup 3-28 Run 3-25, 4-2 Stop 3-24, 3-32 Modify Setup mode 3-28, 3-30 motors messages 5-4, 5-5, 5-10, 5-11, 5-12 overview 2-7 RAM addresses 3-42, 3-45, 3-46 speeds 3-41 swing arm 4-14 takeup reel 2-3, 2-5, 2-15, 3-27, 3-37, 3-44, 5-16 tape drive 2-5, 3-45, 4-13
O
offset 3-29, 3-46 output reel. See takeup reel override button lights 2-5
K
keys <.> (period) 3-27 <-> (minus) 3-27, 3-40 <0> 3-27, 3-40 <CLEAR> 3-26, 3-40 <DELETE> 3-26, 3-38, 3-40 <DIAGNOSTICS> 3-26, 4-2 <ENTER> 3-24, 3-26 <MANUAL> 3-26 <PAUSE> 3-26 <RUN> 3-25, 3-26, 3-40 <SET UP> 3-26, 3-27, 3-28, 3-32 <SPACE> 3-26, 3-38, 3-40 <TOTALS> 3-26, 3-33 numeric 3-27, 4-4 to 4-8
P
password 3-36, 4-2 photos, taper parts 2-3 to 2-20 pickup head 2-3, 2-15 RAM addresses 3-43 pickup site sensors 4-10 pins index 2-2, 2-3, 2-6, 2-15 stack 2-2, 2-3, 2-7, 2-15 Polish notation 3-31, 3-32, 3-36, 5-14 ports 2-19, 4-16, 4-18, 4-19, 4-26 positions pickup site 2-2 swing arm home 2-14 tape pocket 2-2 top of index pin 2-2 top of stack pin 2-2 power-down 3-26 power-up 3-16 message sequence 3-19, 3-28 pressure roller block 2-5 pressure seal heads 2-5, 2-16, 3-15 procedures. See tasks
L
Loop mode 3-32
M
Manual mode 3-34, 3-35, 4-2 accessing 3-36 manual, users typography significance 1-8 version number significance 1-7 modes Change RAM 3-39 Diagnostics 4-2 continued on next column
Index-2
04/2010
Index
R
RAM addresses changing 3-39, 3-40, 5-4 list 3-42 loading default 3-39, 5-9, 5-13 sum check 5-3 types of values 3-42 reels 2-4, 3-2 RS-232 interface 3-42, 4-16 Run mode 3-25, 4-2
T
takeup arm 3-6 takeup reel 2-3, 3-2 messages 5-16 motor 2-3, 2-5, 2-15, 3-27, 3-37, 5-16 RAM addresses 3-44 tape calibrating position 4-13 carrier direction of movement 2-4 loading 3-5 messages 5-7, 5-16, 5-17 sensors 4-9 gap 3-29 offset 3-29 output full count 3-31, 3-44 totals 3-33 sealing 3-8, 3-11, 3-14, 3-31 sensors 2-9 to 2-13 tape drive calibrating position 4-13 gear 2-5, 3-6 messages 5-4, 5-7, 5-9, 5-12 RAM addresses 3-45, 3-46 taper communication with handler 2-19, 4-19, 4-26 end-of-life disposal 1-7 facilities requirements 1-2 installation 1-4 operation overview 2-3 powering down 3-26 powering up 3-16 requirements electrical 1-2 environmental 1-2 pressurized air 1-3 taper parts see also individual part names air pressure fittings 1-3 air regulator 6-4 carrier tape track 3-3 control panel 2-4, 3-26, 4-2 cover foot 2-7 drive gear adjustment knob 3-7 Emergency Stop button 1-1, 2-7 guide block 3-10, 3-12 heater controller display 2-5 heater fuse 2-5 index pin 2-2 override button lights 2-5 continued on next column
S
safety 1-1 to 1-4 see also cautions and warnings training responsibilities 1-1 sealing heads 2-3, 2-9, 2-15 adjusting PSA 3-15 adjusting thermal 3-12 messages 5-4, 5-17 RAM addresses 3-42, 3-43 sealing tape 3-8, 3-11, 3-14 selecting 3-28, 3-31 sensors 2-3, 2-9 to 2-14 Carrier Tape Out 2-9, 2-13 cleaning optics 6-8 Device at Pickup Site 2-9, 2-10 Device at Stack 2-9, 2-10 Empty Pocket 2-5, 2-9, 2-11 fiberoptic controllers 6-8 Gap 2-9, 2-12 lights 2-5 Out-of-Pocket 2-9, 2-12 pickup site 4-10 Swing Arm Home 2-9, 2-14 Takeup Arm 2-9, 2-13 tape 4-9 solenoids maintenance 6-7 testing 4-11, 4-12 stack pin 2-2, 2-3, 2-7, 2-15 Stop mode 3-24, 3-32 supply reel 3-2 support services 1-5, 1-6, 1-7 swing arm 2-3, 2-4, 2-14, 2-16, 3-27 calibrating position 4-14 home position 2-14 messages 5-7, 5-8, 5-13 path diagram 2-18 pickup head 2-3, 2-17 RAM addresses 3-43, 3-45
04/2010
Index-3
Model 1050 Manual
taper parts continued override buttons 2-14 photos 2-3 to 2-20 pickup site 2-2 pressure roller block 2-5 seal heads heat 2-5, 2-16, 3-12, 3-19 pressure 2-16, 3-15 sensor lights 2-5 sensors 2-5, 2-9 to 2-14 stack pin 2-2 swing arm 2-2, 2-3 pickup head 2-3, 2-17 takeup arm 3-6 takeup reel 2-3 tape drive gear 2-5, 3-6 taper input track 2-2, 2-5 track width adjustment knobs 3-3 track width locking knob 2-5, 3-3 tasks adjusting air pressure 6-4 adjusting position of heat seal heads 3-12 adjusting position of PSA heads 3-15 adjusting pressure of heat seal heads 3-14 adjusting PSA pressure 3-16 adjusting tape track width 3-4 calibrating device placement in tape pocket 3-24 changing digits in settings 3-31, 3-32, 3-36, 5-14 changing RAM settings 3-39 checking air filter 6-4 checking air regulator 6-3 checking air regulator moisture/dirt trap 6-4 displaying commands typed in HyperTerminal 4-22, 4-24 displaying totals 3-33 loading carrier tape 3-5 loading sealing tape 3-8 mounting supply reel 3-2 mounting takeup reel 3-2 powering down system 3-26 powering up handler 3-18 powering up taper 3-18 pre-power-up check 3-16 resetting totals 3-33 setting temperature for heat seal 3-20 setting up HyperTerminal 4-19 starting production run 3-25 turning off temperature for heat seal 3-23 using Manual mode 3-36 temperatures, setting 3-19 thermal seal heads. See heat seal heads
totals displaying 3-33 resetting 3-33 track width adjustment knobs 3-3 track width locking knob 2-5, 3-3, 3-4 typography significance 1-8
W
warnings. See cautions and warnings warranty agreement 1-3, 1-5, 1-6, 6-1
Index-4
04/2010

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Model 1050 Automated Taper Used with Model 5000 Handler User Manual

Version 3.2 April 1, 2010

Chapter 2: System Description

Chapter 3: Taper Setup and RAM Listing

Copyright Exatron, 2010