Model 1020 Manual

Model 1020 Tube-Input Taper

User Manual

Version 3.0October 5, 2010

Exatron, Inc.2842 Aiello Drive

San Jose, California 95111(408) 629-7600 Tel(800) exa-tron Tel

(408) 629-2832 Faxwww.exatron.com

Copyright NoticeCopyright © 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 ContentsChapter 1: Safety and Support

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Exatron Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Facilities Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Vacuum/Pneumatic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Uncrating the Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Customer In-House Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Offshore Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Exatron Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6End-of-Life Taper Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Significance of This Manual’s Version Number. . . . . . . . . . . . . . . . . . . . . . . 1-7Typographical Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . 1-8Terms Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Chapter 2: System DescriptionChapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Key Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2How the Model 1020 Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Identifying Major Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Three Reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Taper Input Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Motors and Drive Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13Index and Stack Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18Seal Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18Swing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

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

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10/2010 Copyright © Exatron, 2010 Contents-1

Model 1020 Manual

Chapter 3: Taper Setup and RAM Listing — continuedLoading the Carrier Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Loading the Sealing Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Adjusting Heat Seal Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Adjusting Lateral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Adjusting Downward Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Adjusting Pressure Seal Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Loading Tubes into the Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16Power-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19Aligning the Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20Setting Temperature for Heat Seal Heads . . . . . . . . . . . . . . . . . . . . . . . . . 3-21Calibrating Device Position in Tape Pocket . . . . . . . . . . . . . . . . . . . . . . . . 3-26Inspection at Beginning of Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27Beginning a Production Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Homing the Octoloader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29Understanding the Control Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30Using the <SET UP> Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30Modifying Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Understanding the Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32Selecting Type of Tape Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34Selecting Number of Devices to Be Put in Tape. . . . . . . . . . . . . . . . . . . 3-34Setting Tape Pocket Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34Selecting Manual Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Resetting the Count of Devices in Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35Displaying the Count of Devices in Tape . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36Using Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37Changing RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44Notes About the RAM Address Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Warning About Motor Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46Updating Your EPROM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46Separate Settings for Changeover Kits . . . . . . . . . . . . . . . . . . . . . . . . . 3-46Suggested Values for Various Taper Models . . . . . . . . . . . . . . . . . . . . . 3-46

RAM Address Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47Hex-Binary Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52Decimal-Hex-ASCII Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Contents-2 Copyright © Exatron, 2010 10/2010

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

Chapter 5: Dictionary of Displayed MessagesChapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Model 1050 Handler Status and Error Messages . . . . . . . . . . . . . . . . . . . . . 5-4

00## DATA ## . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51 LEFT STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51 RIGHT STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 LEFT STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 RIGHT STEPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54 TUBE INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 TUBE INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6ADD LEADER DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6ADD LEADER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6ALIGN OCTOLOADER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6ALL MODES OFF ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6ALL MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7ALL MOTORS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7CHANGE RAM ? NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7CHANGE RAM ? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7COUNT SET TO 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7CPU ERROR [1-6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8DRIVE MOTOR CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8EMPTY/LOAD PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8EMPTY POCKET ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8EXATRON TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8FIND MOTOR HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8FULL T = ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8GAP STEPS = #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9HANDLER OUT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9



Model 1020 Manual

Chapter 5: Dictionary of Displayed Messages — continuedHOME SENSOR ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9HOME SWING HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9INDEX/STACK JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9IN-SEN 01234567. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10INSPECT YES/NO ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10INSPECTION FAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10INSPECTION OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10INSPECTION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11INSPECTION PASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11INTERFACE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11ISSUE NEW START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11JOG LEFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11JOG OCTOLOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11JOG RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11LOAD DEFAULT NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11LOAD DEFAULT YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11LOAD EPROM>RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12LOADER JAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12LOOP MODE ON ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12MANUAL ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12MOD SET UP ? NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12MOD SET UP ? YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12MOTOR [A, B, or C] BUSY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13MOTOR <A, B, or C> ERROR ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13MOTOR A OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13MOTOR B OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14MOTOR C OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14MOTOR HOME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14MOVE TAPE LEFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14MOVE TAPE RIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14NEW JOB–EMPTY OK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14NEW TAPE SET UP?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14NO POCKET? ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15NOT UP TO TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15OCTO MOTOR CHK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15OCTOLOADER OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15OFFSET = #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15OFFSET>GAP ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15OK TO RUN ? 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15OUT OF POCKET ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15OUTPUT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15PASSWORD ABC? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16PAUSED ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16



Chapter 5: Dictionary of Displayed Messages — continuedPART AT PICK UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16PART DROPPED ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16PICK UP AT HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16PICK UP DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16PICK UP NOT HOME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16PLACE PART ERR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17POCKETS = ###### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17RAM AUTO RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17READY TO RUN ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17RESET COUNT NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17RESET COUNT YES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17RETURN ERROR ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18ROTATE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18ROTATE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18RS-232 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18RUN 4 X 4 MLF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18RUN 5 X 5 MLF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18RUN DEFAULT 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18RUN SSOIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18RUN UNTIL 1 PASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18SEN0-7 01234567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19SEN8-F 89ABCDEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19SENSOR CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19SET # INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19SET GAP ? NO/YES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19SET OFFSET = #### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19SOL TOGGLE CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20SOLENOID CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20SORT = 12345678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20STOP MODE ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20STOP MODE ON ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20SWING HEAD CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21SWING HOME = ### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21SWING STEP = ### . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21TAKE UP MOTOR CK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21TAKE UP REEL ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21TAPE GAP LOST ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21TAPE IS FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22TAPE OUT ERROR ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22TAPE STACK EMPTY ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22TEST TAPE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22THANK YOU #. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22THERMAL OR PSA ?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23



Model 1020 Manual

Chapter 5: Dictionary of Displayed Messages — continuedUART OUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23USE PSA TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23USE THERMAL TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23VAC NOT ADJUSTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23ZERO COUNT ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Chapter 6: Servicing and TroubleshootingChapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Seal Head Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Pressure-Sensitive Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Heat Seal Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Air Regulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Checking Incoming Air from the House Supply . . . . . . . . . . . . . . . . . . . . 6-3Checking Air Regulator Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Adjusting Air Pressure on the Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Adjusting Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Checking the Moisture/Dirt Trap in the Air Regulator . . . . . . . . . . . . . . . . 6-6

Solenoid Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Fiberoptic Photoelectric Sensor Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Chapter 7: Parts ListGuide to the Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Exatron (Part Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Part Quantity Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Lists of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

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

Index


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

Figure 2-4: Other Features of Taper (Model 201) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Figure 2-5: Index Pin Retracted (Left), Extended (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Figure 2-6: Cover Foot Retracted From Pickup Site and Stack Pin Extended (Left); Cover Foot

Extended Over Pickup Site and Stack Pin Retracted (Right) . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Figure 2-7: Motor with Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Figure 2-8: Drive Chain Tension Adjuster for Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 2-9: Tape Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Figure 2-10: Takeup Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Figure 2-11: Octoloader at Home Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Figure 2-12: Octoloader Back with Snap-On Pins (Left); Octo Car Block with Holes for

Snap-On Pins (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10Figure 2-13: Octoloader Front with Two Tubes Attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Figure 2-14: Octoloader Gate Depressed by Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11Figure 2-15: Devices Stopped by Octoloader Gate (Left); Devices Released by Octoloader

Gate (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12Figure 2-16: Octoloader Gate Pin Blocking Exit (Left); Device Exiting Octoloader Chute

(Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12Figure 2-17: Octoloader Gate Closed (Left); Octoloader Gate Opened (Right) . . . . . . . . . . . . . 2-13Figure 2-18: Device at Stack Sensor (A, Top); Device at Pickup Site Sensor (B, Bottom) . . . . 2-14

Figure 2-19: Device at Stack Sensor (A, Left); Device at Pickup Site Sensor (B, Right) . . . . . 2-14Figure 2-20: Taper Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15Figure 2-21: Empty Pocket Sensor (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15Figure 2-22: Out-of-Pocket Sensor (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16Figure 2-23: Gap Sensor (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Figure 2-24: Carrier Tape Out Sensor (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17Figure 2-25: Takeup Arm Sensor (3) Closed (Left), Open (Right). . . . . . . . . . . . . . . . . . . . . . . 2-17Figure 2-26: Swing Arm Home Sensor (9, Left); Swing Arm at Home (Right) . . . . . . . . . . . . . 2-18Figure 2-27: Heat Seal Heads with Counterbalance Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19Figure 2-28: Pressure-Sensitive (PSA) Seal Heads with Counterbalance Weight . . . . . . . . . . . 2-19

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

10/2010 Copyright © Exatron, 2010 Figures-1

Model 1020 Manual

Figure 3-2: Supply Reel Tape Unwound from Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Figure 3-3: Carrier Tape Track at Different Widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Figure 3-4: Track Width Locking Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Figure 3-5: Carrier Tape Under Guide At Top Supply End of Track . . . . . . . . . . . . . . . . . . . . . . 3-5Figure 3-6: Lifting Pressure Roller Arm and Pushing In Keeper Pin—Two Styles . . . . . . . . . . . 3-6Figure 3-7: Takeup Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Figure 3-8: Tape Drive Gear Adjustment Knob with Blue Locking Knob Unscrewed . . . . . . . . 3-7Figure 3-9: Gear Adjustment Narrowed (Left); Widened (Right). . . . . . . . . . . . . . . . . . . . . . . . . 3-7Figure 3-10: Sealing Tape Plates—Outside (Left), Inside (Right) . . . . . . . . . . . . . . . . . . . . . . . . 3-8Figure 3-11: Sealing Tape Threaded to Sealing Tape Guide Assembly for PSA . . . . . . . . . . . . . 3-9Figure 3-12: Sealing Tape Threaded to Sealing Tape Guide Assembly for Heat . . . . . . . . . . . . . 3-9

Figure 3-13: Sealing Tape Threaded Under Guide Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Figure 3-14: Two Widths of Guide Blocks—Top View (Left); Bottom View (Right). . . . . . . . 3-10Figure 3-15: Placement in Grooves of Guide Block—of Sealing Tape (Left) and Carrier Tape

(Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Figure 3-16: Guide Rod Removed from One Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Figure 3-17: Guide Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Figure 3-18: Semicircular Seal Head with Adjustment Screw . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Figure 3-19: Example of Good Tape Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Figure 3-20: Three-Gram and One-Gram Weights (Left); One-Gram Weight on Heat Seal

Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Figure 3-21: Pair of Pressure Seal Heads with Lateral Adjustment Screws . . . . . . . . . . . . . . . . 3-15Figure 3-22: Three-Gram and One-Gram Weights (Left); One-Gram Weight on PSA

Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Figure 3-23: Octoloader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Figure 3-24: Loading a Tube Perpendicular to Octoloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18Figure 3-25: Securing Tube at Bottom of Input Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18Figure 3-26: Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19Figure 3-27: Octo Stop Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Figure 3-28: Heater Controller Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22Figure 3-29: SET Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23Figure 3-30: Up Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23Figure 3-31: Digit in Ones Position Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23Figure 3-32: Left Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Figure 3-33: Digit in Tens Position Selected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24Figure 3-34: Temperature Set Before the SET Button Is Pressed . . . . . . . . . . . . . . . . . . . . . . . . 3-24Figure 3-35: Temperature Set After the SET Button Is Pressed . . . . . . . . . . . . . . . . . . . . . . . . . 3-25Figure 3-36: Down Arrow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25Figure 3-37: Temperature Set to Zero Before the SET Button Is Pressed . . . . . . . . . . . . . . . . . 3-26

Figures-2 Copyright © Exatron, 2010 10/2010

Figure 3-38: Tape Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27Figure 3-39: Swing Arm Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27Figure 3-40: Touching the Blue Dashed ROI Border . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28Figure 3-41: ROI Turns Red and Teach Button Is Visible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28Figure 3-42: <SET UP> Key Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Figure 3-43: Gap Versus Offset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32Figure 3-44: Modify Setup Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33Figure 3-45: Manual Mode Flowchart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38Figure 4-1: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Figure 4-2: Diagnostics Abbreviated Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Figure 4-3: Tape Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Figure 4-4: Swing Arm Calibration Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17Figure 5-1: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Figure 6-1: Brass PSA Rollers (Left); Rubber PSA Rollers (Right) . . . . . . . . . . . . . . . . . . . . . . 6-2Figure 6-2: Heat Seal Head Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Figure 6-3: Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Figure 6-4: Air Valves with Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Figure 6-5: Air Regulator with Small Black Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Figure 6-6: Metal Casing Unscrewed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Figure 6-7: Clear Glass Casing Snapped Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Figure 6-8: Large Black Inner Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Figure 6-9: Solenoid with Plunger on Back Side of Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Figure 6-10: Sensor Controller Set to L-ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10Figure 6-11: Green and Red Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10Figure 6-12: Conditions of Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Figure 7-1: Dimensions Listed From Smallest to Largest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3Figure 8-1: 3000-055-C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3Figure 8-2: 3000-223-2-B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4Figure 8-3: 5000-397-2-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5Figure 8-4: 5000-398-2-C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Figure 8-5: 5000-A89-C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7Figure 8-6: 5000-M08-27-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8Figure 8-7: 5000-M15-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9Figure 8-8: 5000-M22-A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10Figure 8-9: TAPE-190-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Figure 8-10: TAPE-191-3-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12Figure 8-11: TAPE-203-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13Figure 8-12: TAPE-221-A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14Figure 8-13: TAPE-368-1-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

10/2010 Copyright © Exatron, 2010 Figures-3

Model 1020 Manual

Figure 8-14: TAPE-368-2-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Figure 8-15: TAPE-368-3-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17Figure 8-16: TAPE-368-4-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18Figure 8-17: TAPE-419-D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19Figure 8-18: TAPE-917-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20Figure 8-19: TAPE-932-A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

Figure 8-20: TAPE-933-10-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22Figure 8-21: TAPE-933-1-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23Figure 8-22: TAPE-933-2-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24Figure 8-23: TAPE-933-3-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25Figure 8-24: TAPE-933-4-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

Figure 8-25: TAPE-933-5-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27Figure 8-26: TAPE-933-6-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28Figure 8-27: TAPE-933-7-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29Figure 8-28: TAPE-933-8-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30Figure 8-29: TAPE-933-9-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

Figures-4 Copyright © Exatron, 2010 10/2010

Chapter 1: Safety and Support

Chapter OverviewThis chapter discusses the following main topics:

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.

Topic PageExatron Safety Warnings 1-1Facilities Requirements 1-2Installation Overview 1-4Standard Warranty 1-4Exatron Support Services 1-6End-of-Life Taper Disposal 1-6Significance of This Manual’s Version Number 1-7Typographical Conventions Used in This Manual 1-8Terms Used in This Manual 1-8

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.

10/2010 Copyright © Exatron, 2010 1-1

Model 1020 Manual Chapter 1: Safety and Support

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.

Figure 1-1: Emergency Stop Button

Facilities RequirementsEnvironmental Requirements

The Model 1020 taper should be installed in a temperature-controlled, dust-free environment to preclude dust and dirt particles from contaminating its moving parts, especially those parts which come into contact with the devices being tested. The life of your taper is greatly enhanced by keeping it as clean as possible. See Chapter 6 for instructions.

There are no special ventilation requirements.

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

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.

1-2 Copyright © Exatron, 2010 10/2010

Facilities Requirements Vacuum/Pneumatic Requirements

If the taper is to be used in an electrically noisy environment or near large electromechanical equipment, Exatron recommends the use of a reliable surge protector to filter line noise, surges, and spikes that can cause the taper to operate improperly or become damaged.

Electricity supplied to the taper must be within the recommended operating range. If the line voltage drops too low, the taper may not function properly and may be seriously damaged. Verify that correct operating line voltage is present. If it is not, contact Exatron for assistance.

Service calls made to the customer facility to correct problems caused by improper electrical supply are not covered by the Exatron warranty.

Vacuum/Pneumatic RequirementsThe taper system requires a supply of pressurized air at 50 PSI, filtered at 3 CFM for proper operation. The air supply must be clean (containing no particulate matter greater than 5 microns in size), oil-free, and dry (having a dew point of 36 degrees F to 38 degrees F) to operate correctly. Dirty, oily or wet air will cause the vacuum generator to malfunction and will make your system unreliable.

The external air source should be attached to the air regulator mounted on the taper base. Before turning on the air regulator and using the taper, make certain the compressed air line is attached to the air regulator fitting. Check to make sure the air regulator gauge on the external regulator measures the air pressure at 50 PSI, and adjust if necessary.

To maintain these levels of pressurized air quality, replace the air filter (Exatron part #GPA-97-075) in the air regulator of your taper after every 6000 hours or 12 months of operation, which-ever comes first; or if your air regulator registers a pressure drop of 15 PSI.

Moisture of any kind will travel through external and internal air lines. This moisture will coat these air lines and the insides of the taper's cylinders, causing them to stick or to stop func-tioning 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, dam-age to the system will occur. The only corrective action to take at that point is to replace all of the air lines and to completely clean all of the solenoids supplied by those air lines. Taper damage due to improper air supply is not covered by the Exatron warranty.

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

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



Figure 1-2: Air Line Attached to Outlet

Installation OverviewBasic installation of your new Exatron taper will consist of the following major steps:

♦ Unpacking the equipment and assembling its peripheral parts

♦ Powering up the taper ("Power-Up Procedure" on page 3-19) and running Diag-nostics sequences (Chapter 4)

♦ Cycling sample tubes of devices

Uncrating the TaperThe taper will usually come in a wooden crate which will require some disassembly to remove. Please inspect the system when it is removed from the crate for any obvious damage which may be the result of shipping. Contact Exatron and the shipping company immediately if you see any damage.

Standard WarrantyAll 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 main-tenance procedure as defined in this manual.

Exatron does not warrant the following:

♦ Damage caused by improper packaging of equipment returned to Exatron for repair


Standard Warranty Customer In-House Service

♦ Damage caused by the shipping company

♦ Damage caused by natural catastrophes: flood, fire, earthquake, etc.

♦ Damage caused by equipment connected to improper power line voltages

♦ Damage caused by equipment connected to improper air supply: contaminated with oil, water, dirt, etc.

♦ Damage caused by operator abuse or improper practices cautioned against in this manual

♦ Damage caused by interface hardware not manufactured by Exatron

♦ Damage or malfunction caused by customer modifications

♦ Test contactors

Customer In-House Service Except in the case of laser marking systems, Exatron encourages customer in-house equip-ment service and tries to make in-house service as easy as possible to perform. There are no "Void Warranty" warning stickers on Exatron tapers. By using the built-in diagnostic software and diagnostic tools, it is usually possible for the operator to isolate a problem quickly and effect a repair.

The customer is responsible for all cost of in-bound shipping expenses. Standard out-bound shipping expenses will be paid by Exatron. In such cases where the customer requests spe-cific out-bound shipping methods be used, the customer is responsible for all shipping costs and any additional related charges.

Offshore Warranty Service An Exatron taper purchased in the United States and then shipped offshore will be warranted through Exatron in California. Replacement parts are furnished for a period of one year from date of purchase with the exception of replacement contactors. In most cases, it will not be necessary to return the worn part from the offshore user location.

To receive offshore service support, the taper must be purchased through your local Exatron representative, or an extended warranty agreement must be purchased directly from your local Exatron representative.

Please supply the following information when requesting offshore service or replacement parts:

♦ The part number(s) required. If the part number is not known, photocopy or take a photo of the part and fax it to Exatron.

♦ The model number of the taper



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

♦ The taper’s 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 ServicesFor 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 fol-lowing information:

♦ The model number of your taper with all its options

♦ The exact wording of any messages that appeared on your taper display.

♦ A description of what happened and what you were doing when the problem occurred.

♦ A description of how you tried to solve the problem.

End-of-Life Taper DisposalExatron 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 pur-chase. 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.


Significance of This Manual’s Version Number Offshore Warranty Service

We will service our products even when the product is not purchased directly from Exatron. This makes the resale value of Exatron products high as compared to many of our competi-tors. 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 customer’s expense, and we will quote the cost to dismantle and recycle the taper. In many cases, there is no charge for this service other than any third-party disposal fees as required. Whenever possible, reusable components will be offered as a donation to local schools.

Please note that in many cases, Exatron builds systems using major third-party pieces of equipment. These include lasers, printers, camera inspection, chillers, fume extractors, and other large OEM (original equipment manufacturer) subsystems. Exatron will attempt to pro-vide the same support as best we can for these subsystems. Exact details cannot be deter-mined 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 Manual’s Version Number The version number on the cover page of this manual indicates two levels of revision.

♦ The first number is incremented for brand new manuals or complete overhauls, including addition or deletion of chapters.

♦ The second number is incremented for small section changes and additions.

For example, version 2.0 would refer to a completely redone manual or one that has had chapters moved, added, or deleted. The jump from 2.0 to 2.1 might include new or updated procedures, new screens or photos, or updated sections.



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 ManualBlow-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.

Device A generic term that refers to the chip, package, or other part processed by the Exatron taper.

Gap 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".

Gap offset, or Offset

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 arm’s 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.

Gap steps The distance, measured in tape drive motor steps, between the leading edge of adjacent tape pockets.

Home position The location that each motor returns to each time the taper is reset.

Sum check The total of the parameter values for all the RAM addresses displayed in hex.


Chapter 2: System Description

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

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 pres-ence of the system to facilitate reference to the actual system. The parts of the system are identified as shown in this chapter.

Topic PageKey Positions 2-2How the Model 1020 Works 2-2Identifying Major Parts 2-3


Model 1020 Manual Chapter 2: System Description

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

Figure 2-1: Key Device Positions

How the Model 1020 WorksEmpty carrier tape is fed on to the tape track from the supply reel, and the tape drive motor advances the tape.

The octoloader holds up to 8 tubes of devices. Devices in each tube are stopped by an octo-loader gate. The octoloader moves right and left, positioning one tube at a time over the input track. It opens the gate to allow devices to fall down the taper input track. When a tube is emp-tied of devices, the octoloader moves laterally until another tube with devices is located and placed over the input track.

On the input track, the stack pin is by default extended, stopping each device. When a signal is received, the index pin extends to hold the line of waiting devices, the stack pin retracts, and the device drops to the taper’s 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.

Top of index pin

Pickup site w/ cover foot

Top of stack pin

Tape

Swing arm

Taper input track

Top of octo-loader gate


Identifying Major Parts Three Reels

A few inches to the left, a group of sensors ensure that each pocket is filled, and that each device lies flat in the pocket. To the left of these sensors, the sealing heads, either thermal or pressure-sensitive, seal the cover tape onto the edges of the carrier tape.

At regular intervals set by the user, the takeup reel motor is activated and the filled tape is wound onto the takeup reel.

Identifying Major Parts Three Reels

The supply reel (sometimes made of cardboard) containing the carrier tape is at the right end of the taper. The takeup reel (usually made of plastic) is at the left end.

The supply reel containing the sealing tape is above the sealing area.

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.

Supply reel with carrier tape

Output or takeup reel

Supply reel with sealing tape

Tape track—right-to-left direction

Swing arm with pickup head

Control panel



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

After receiving devices from the swing arm, the filled carrier tape is sealed, either with pres-sure-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.


Identifying Major Parts Taper Input Track

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

Taper Input TrackThe taper input track is below the octoloader, at the swing arm. This track has solenoids that control an index pin, a stack pin, and a cover foot.

During a production run, the stack pin is by default extended, restraining the waiting line of devices. When the swing arm on the tape-and-reel assembly is ready to move another device, the index pin is extended between the lowest device in line and the device just above it. Then the stack pin is retracted, allowing the lowest device to fall.

The stack pin and cover foot are activated simultaneously to prevent the device from jumping the stop block. Thus, when the stack pin retracts to release a device, the cover foot is extended to hold the device at the pickup site momentarily until any bouncing action stops.

Heater controller displays

Empty pocket sensor

Track width locking knob

Pressure seal headsHeater fuse

Sensor lights

Override but-ton lights

EMO (emergency stop) button

Pressure roller block

Takeup arm



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

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

Emergency Stop ButtonThe EMO (emergency stop) button on the taper control box shuts down everything on the taper, including the heat seal. Pressing the taper’s EMO button causes a taper error message to be displayed on the control panel. The operator then has the option of aborting the job run, or making any necessary adjustments and then selecting the option to continue the run.


Identifying Major Parts Motors and Drive Chains

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

Figure 2-7: Motor with Drive Chain

Figure 2-8: Drive Chain Tension Adjuster for Octoloader



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

Figure 2-9: Tape Drive Motor

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

Figure 2-10: Takeup Reel Motor

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

Tape drive gear adjustment knob

Tape drive motor


Identifying Major Parts Octoloader

OctoloaderExatron's octoloader is an ambient automatic eight-tube loader. The standard Model 1020 comes equipped with this octoloader which is a moving metal plate holding up to eight tubes of devices, controlled by the taper’s EPROM by means of a stepper motor. The plate automat-ically moves both left and right, positioning each tube of devices over the handler input track. When the input track is emptied, the octoloader automatically searches for tubes with devices. The octoloader has a sensor mounted at its junction with the input track. The octoloader can "see" a device jam and stop its own movement to prevent breaking the jammed device. The octoloader also has an automatic "wiggle" jam-clearing operation which it will implement immediately in an effort to remove the jam without operator assistance.

Model 1020 octoloaders use a snap-on plate which is specifically fitted with tube holders for a given device application. It can be snapped on and unsnapped to clear device jams.

When the octoloader is at its home position, it is pressing the sensor on the red octoloader stop.

Figure 2-11: Octoloader at Home Position



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

Figure 2-13: Octoloader Front with Two Tubes Attached

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


Identifying Major Parts Octoloader

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

Figure 2-14: Octoloader Gate Depressed by Roller



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

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


Identifying Major Parts Sensors

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

SensorsThe sensors for the Model 1020 taper have descriptive names.

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

Sensor Name Sensor ID Figure Sensor

Controller Comment

Device at Stack Sensor A Figure 2-18, Figure 2-19 yes

Device at Pickup Site Sensor B Figure 2-18, Figure 2-19 yes

Swing Arm Home Sensor 9 Figure 2-26 no

Pickup Head Vacuum Sensor 8 no

Carrier Tape Out Sensor 6 Figure 2-24 no

Empty Pocket Sensor 5 Figure 2-21 yes If an image sensor (camera) is attached, it replaces this sensor

Out-of-Pocket Sensor 7 Figure 2-22 yes If an image sensor (camera) is attached, it replaces this sensor

Gap Sensor 4 Figure 2-23 yes

Takeup Arm Sensor 3 Figure 2-25 no



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

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



Figure 2-20: Taper Sensors

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

Figure 2-21: Empty Pocket Sensor (5)



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

Figure 2-23: Gap Sensor (4)

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



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

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



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

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

Index and Stack PinsDuring 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 HeadsThe seal heads are pneumatic; they do not use sensors.


Identifying Major Parts Swing Arm

Figure 2-27: Heat Seal Heads with Counterbalance Weight

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

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



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

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

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


Identifying Major Parts Swing Arm

Figure 2-31: Path and Limits of Swing Arm

SWING = 355maximum

Pickup site SWING HOME = 34maximum

Taper input track

Tape output

SWING = c. 122 from pickup site

Swing arm positions

SWING HOME = c. 12at pickup site




Chapter 3: Taper Setup and RAM Listing

Chapter OverviewThis chapter discusses the following main topics:

Topic PageMounting the Takeup Reel 3-2Mounting the Supply Reel 3-2Adjusting the Carrier Tape Track Width 3-3Loading the Carrier Tape 3-5Loading the Sealing Tape 3-8Adjusting Heat Seal Heads 3-12Adjusting Pressure Seal Heads 3-15Loading Tubes into the Octoloader 3-16Power-Up Procedure 3-19Aligning the Octoloader 3-20Setting Temperature for Heat Seal Heads 3-21Calibrating Device Position in Tape Pocket 3-26Inspection at Beginning of Tape 3-27Beginning a Production Run 3-28Power-Down Procedure 3-29Understanding the Control Panel Keys 3-30Using the <SET UP> Key 3-30Modifying Setup 3-31Resetting the Count of Devices in Tape 3-35Displaying the Count of Devices in Tape 3-36Using Manual Mode 3-37Changing RAM 3-44Notes About the RAM Address Listing 3-45RAM Address Listing 3-47Hex-Binary Conversion Table 3-52Decimal-Hex-ASCII Conversion Table 3-53


Model 1020 Manual Chapter 3: Taper Setup and RAM Listing

Mounting the 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).

To mount an empty takeup reel:


Adjusting the Carrier Tape Track Width

Figure 3-2: Supply Reel Tape Unwound from Top

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

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.

Track width adjustment knobs



♦ 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.

Figure 3-4: Track Width Locking Knob

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 follow-ing 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.

CAUTION: Loosen the track width locking knob before turning the adjustment knobs to prevent bending and damage to the aluminum parts.

To adjust the width of the carrier tape track:


Loading 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.

To load the carrier tape:



Figure 3-6: Lifting Pressure Roller Arm and Pushing In Keeper Pin—Two 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 thumb-screw section of the gear assembly. This should cause the carrier tape to advance freely towards the takeup reel.



> 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)



Loading 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 3-10).

Figure 3-10: Sealing Tape Plates—Outside (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 car-rier 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 posi-tion 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.

To load the sealing tape:



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

> For a heat sealing tape, feed the sealing tape to the right under the lower, smaller projecting pin, then over the upper, larger projecting pin of the seal-ing 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



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 Blocks—Top View (Left); Bottom View (Right)



Figure 3-15: Placement in Grooves of Guide Block—of 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.



> 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.

Figure 3-17: Guide Block Assembly

8. Use light pressure or heat to attach the sealing tape to 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 PositionIf your Model 1010 taper is equipped with heat seal heads, use this procedure to align the lat-eral position of each head separately.

1. Make sure the heaters are off and the thermal heads are cool. There are two

CAUTION: Do not use adhesive tape on the carrier tape, as it contains static elec-tricity and can ruin the static-free condition of the carrier tape.

To align lateral position of heat seal heads:

Guide block adjustment screws


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 3-21 for instructions), and wait until the sealing head is at ambient room temperature.

2. Remove the seal head closest to you (the front seal head). Use a #10 size hex wrench and remove the seal head adjustment screw. Remove the seal head and lay it aside.

3. Loosen the adjustment screw on the back seal head. Adjust the head laterally so that it is directly over the back edge of the sealing tape.

4. Manually engage the back seal head and confirm that the edge of the seal head is aligned with the back of the sealing tape. Make sure that the track holes on the carrier tape are not blocked by the sealing tape.

5. With the seal head engaged, tighten the adjustment screw.

6. Repeat this process with the front sealing head.

Figure 3-18: Semicircular Seal Head with Adjustment Screw

7. Once both heads are aligned, turn the heat to the sealing heads on. Note that you must power on the taper in order to do this. (See "Power-Up Procedure" on page 3-19.) Set the bottom line (the Set Value) on both heaters to 350 degrees. (For instructions on changing the Set Value, see "Setting Temperature for Heat Seal Heads" on page 3-21.) Wait until the top line (the Present Value) reads 350.

8. After the sealing heads have warmed up, check the seal on the sealing tape.

WARNING: Do not touch the heat seal heads directly when the heat is turned on.

Adjustment screw



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.

Figure 3-19: Example of Good Tape Seal

Adjusting Downward PressureTo balance the heat temperature with the pressure applied, you may want to adjust the pres-sure of the 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).

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.

To adjust pressure of heat seal heads:


Adjusting Pressure Seal Heads Adjusting Downward Pressure

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

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

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.

Lateral adjustment screws



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

If the PSA is not applying enough pressure for a good seal, you can adjust the weight for more pressure.

◊ To increase pressure, switch to a heavier weight.◊ To decrease pressure, switch to a lighter weight.

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


Loading Tubes into the Octoloader Adjusting Downward Pressure

Figure 3-23: Octoloader

The octoloader is a moving plate that holds tubes of devices and is controlled by a stepper motor. During production, the plate automatically moves from side to side, positioning each tube above the input track. When the input track becomes empty, the octoloader automatically searches for tubes with devices. A sensor mounted at the junction of the input track allows the octoloader to "see" a device jam, if one occurs. The octoloader then stops moving to prevent damage to the jammed device. In addition, the octoloader has an automatic "wiggle" cycle that will attempt to clear the jam automatically, without operator assistance. (This feature can be turned off at the control panel if necessary.)

1. If your model comes with blue anodized tube gates, turn them so that they are in the open or vertical position.

2. Remove the stopper from the top of a full tube of devices. Keeping the open end higher than the closed end, hold the lower half of the tube in one hand and guide the top of the tube to the octoloader with the other hand.

3. Keeping the open end higher than the closed end, press the open end of the tube firmly against the octoloader main plate at the bottom end of the track.

NOTE: Tubes are installed upside down into the octoloader.

To install full tubes into the octoloader:



Figure 3-24: Loading a Tube Perpendicular to Octoloader

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

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

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


Power-Up Procedure Adjusting Downward Pressure

Power-Up Procedure

1. Connect the taper power cord to the power supply, and plug the power supply only into a 120/100-volt AC 50/60 Hz grounded power outlet.

2. Make sure the air regulator is turned off before connecting the taper to a clean, dry air pressure supply. Air supply should be free from moisture and oil. After connecting to the air supply, turn on the air regulator.

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

3. Move the octoloader plate so that it is flush against the octoloader home switch.

4. Place tubes of devices into the octoloader.

You are now ready to power up the Model 1020 taper.

1. Turn on the taper’s power supply by twisting the red EMO (emergency stop)

Before powering up the taper, do the following:

NOTE: For thermal tape systems, powering on the Model 1020 also turns on the heaters in the sealing heads.

To power up the taper:

On/off switch in ON position

Adjustment valve

On/off switch in OFF position



button clockwise on the power supply until it pops out.

> As the taper powers up, it displays a list of messages like the following, with its model and current control program with revision date. (Please give this revision date to Exatron's Customer Service Department when calling for assistance or software updates. Exatron offers free firmware updates on request for the life of the equipment.)

V02.14 Test Ok EXATRON TAPE TAPE-2 11-16-05 MOD SET UP ? NO FIND MOTOR HOME HOME SWING HEAD MOTOR HOME TAKE UP MOTOR ON READY TO RUN ?

Aligning the OctoloaderEach day on power-up, you may need to align the octoloader. Vibrations from a long run may have gotten it slightly out of alignment.

1. With the taper on, press the <DIAGNOSTICS> key.

> Taper displays "DIAGNOSTICS".

2. Press the <4> key.

> Taper displays "ALL MOTOR CHECK".


> Taper displays "OCTO MOTOR CHK".

4. Press the <1> key to move the octoloader one input tube to the left, or any posi-tion such that the octoloader tube 1 is left of the test rail.

5. Loosen the two screws on the octo stop block.

To align the octoloader:


Setting Temperature for Heat Seal Heads Adjusting Downward Pressure

Figure 3-27: Octo Stop Block

6. Press the <3> key to move the octoloader tube 1 approximately over the test rail.

7. Press the <7> or <9> key as needed to jog the octoloader tube 1 directly above the track.

8. When tube 1 is precisely aligned with the track, gently push the octo stop block flush against the right side of the octoloader, and tighten the lower screw.

9. Press the <1> key to move the octoloader one input tube to the left.

10. Carefully tighten the upper screw on the octo stop block, being sure not to move it.

11. Test your alignment: Press the <8> key to move the octoloader a predefined number of motor steps to the left, then back to the home sensor. It should still be flush with the octo stop block. You can change this number of motor steps by changing the RAM address 009E. See "Changing RAM" on page 3-44.

Setting Temperature for Heat Seal HeadsThe red/orange temperature readouts in the lower SV (Set Value) display are the desired tem-peratures. 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.



Figure 3-28: Heater Controller Display

In Figure 3-28, the back heat seal head has been set to 350 degrees, and the current temper-ature 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.

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 (Fig-ure 3-29).

> The lower display blinks rapidly, indicating it is ready to be set.

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:

Present Value temperature

Set Value temperature



Figure 3-29: SET Button

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

Figure 3-30: Up Arrow Button

Figure 3-31: Digit in Ones Position Selected

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



Figure 3-32: Left Arrow Button

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

Figure 3-33: Digit in Tens Position Selected

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

6. Press the Up arrow button repeatedly until the 0 changes to 2 (Figure 3-34).

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

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



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

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

8. Repeat the procedure for the other seal head.

1. Press the SET button on the lower left of the temperature control display.

> The lower display blinks rapidly, indicating it is ready to be set.

2. Press the Down arrow button until the ones value is 0 (Figure 3-36).

Figure 3-36: Down Arrow Button

3. Press the Left arrow button to shift the digit that lights up to the tens digit.

4. Press the Down arrow button until the tens value is 0.

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

6. Press the Down arrow button until the hundreds value is 0 (Figure 3-37).

To turn off the heat seal heads:



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

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

8. Repeat the procedure for the other seal head.

Calibrating Device Position in Tape Pocket

1. Turn on the taper. (If it was already on, turn it off and back on.)

> The swing arm moves to its home position over the pickup site.

2. Drop a device into the track.

> The device falls to the pickup site.

3. Press the <SET UP> key on the control panel.

4. Follow the instructions in "Modifying Setup" on page 3-31 and especially "Selecting Manual Cycling" on page 3-35 to set the taper to Stop mode.

5. In Stop mode, press the <ENTER> key repeatedly until the swing arm has dropped a device in the tape pocket.

6. Examine the position of the device in the pocket.

To calibrate the optimal placement of the devices in the tape pockets:


Inspection at Beginning of Tape Adjusting Downward Pressure

Figure 3-38: Tape Calibration Needed

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

Figure 3-39: Swing Arm Calibration Needed

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

Inspection at Beginning of TapeWhen you run the leader of a new tape, the first pockets will necessarily be empty. If camera inspection is turned on, you will get the message "INSPECTION FAIL."

First press the <1> key. The message reads "NEW JOB–EMPTY OK". If the fail-ure is because a new tape has been mounted with empty leader pockets, press the <2> key to confirm. The message reads "RUN UNTIL 1 PASS". Empty pock-ets will be advanced until a good device is inspected. Then the inspection routine will inspect each pocket.

For information on using the camera or image sensor, see the camera manufacturer’s docu-mentation.

The only thing that is not evident from that documentation is how to enter the camera’s Teach mode. This is accomplished by touching with the stylus the blue dashed line or ROI (Figure 3-40). After touching, the ROI becomes a solid red line and the Teach button is visible (Figure 3-41).



Figure 3-40: Touching the Blue Dashed ROI Border

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

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


Power-Down Procedure Homing the Octoloader

Homing the OctoloaderThere is no single command that homes the octoloader.

1. Press the <MANUAL> key to enter Manual mode.

2. Press <0> to turn off all motors. The octoloader will now move freely.

3. Slide the octoloader all the way to the left.

4. Press <ENTER>. The message ALIGN MOTORS ? is displayed.

5. Press <ENTER> again to turn the motors back on.

6. Press the <RUN> key on the taper’s control panel.

> The taper’s control panel message changes from "READY TO RUN ?" to "WAITING." When enough devices are stacked in the taper’s input track, the taper will begin transferring the devices to the tape automatically. No further action is needed by you.

Power-Down ProcedureIn case of unexpected events, you can push in the EMO button to turn off the power to the taper at any time.

1. Run the taper until empty of all devices. Finish the current job.

2. Empty all output tubes, or replace with empty tubes.

3. Turn the taper power off by pushing in the EMO button on the right side of the taper’s control panel.

To home the octoloader:

To begin a production run:

CAUTION: Allow at least 30 seconds before turning the taper's power back on. Avoid rapid OFF/ON cycles.

To power down the system:



Understanding the Control Panel KeysIn Ready To Run mode or after you press the <PAUSE> key, the taper's control panel keys have the following functions:

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

Using the <SET UP> KeyA number of options are available from the <SET UP> key.

You will be stepping through several options, as shown in Figure 3-44. Step-by-step instruc-tions continue on page 3-34. As a reference, you can skip to the desired subtopic:

Key Function

<ENTER> Starts operations; enters your selections into the systemIf you don’t make any selections before pressing <ENTER>, the selection that was last in effect will be used.

<SPACE> ADD LEADER UP—Advances tape drive motor and takeup reel motor, with seal heads up in inactive position.

<DELETE> ADD LEADER DOWN—Advances tape drive motor and takeup reel motor, with seal heads down in active position.

<CLEAR> Erases changes just made to current setting.<RUN> POCKETS = ######—Displays number of devices already placed in tape.

<MANUAL> Puts taper in Manual mode.<SET UP> CHANGE RAM ? YES/NO—Enables you to change RAM settings.

RESET COUNT NO—Enables you to reset the count of devices in tape to zero.MOD SET UP ? YES/NO—Enables you to modify setup parameters.

<PAUSE> Pauses taper operation.<TOTALS> Displays total devices placed in tape.

<DIAGNOSTICS> Puts taper in Diagnostics mode.<0>-<9> Function of numeric keys depends on the mode. See "Using Manual Mode" on page

3-37 or "Diagnostics Quick Reference" on page 4-4.< For long display messages, scrolls to left end of message 1 character at a time.> For long display messages, scrolls to right end of message 1 character at a time.

Topic PageChanging RAM 3-44Resetting the Count of Devices in Tape 3-35Modifying Setup 3-31


Modifying Setup Homing the Octoloader

Figure 3-42: <SET UP> Key Flowchart

Modifying Setup During the taper's powering up message sequence, you can set the taper to go immediately to "DIAGNOSTICS" or "CHANGE RAM". Always select "CHANGE RAM ? YES" when installing new taper update EPROMs into the taper.

At the end of the taper's powering up message sequence, the first option given to you is "MOD SET UP ? NO" (modify setup).

◊ If you do not wish to make any changes to the taper's setup, press the <ENTER> key. The taper will then scroll through the current settings for:

> THERMAL OR PSA (heat seal tape or pressure-sensitive seal tape)> FULL T = ###### (number of devices to be placed in tape)> SET GAP ? NO (find distance between two adjacent pocket gaps)



> 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" (mod-ify setup). Now press the <ENTER> key to make changes.

You will be stepping through several options, as shown in Figure 3-44. Step-by-step instruc-tions continue on page 3-34. As a reference, you can skip to the desired subtopic:

Understanding the GapA 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 dis-tance 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 arm’s 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.

Figure 3-43: Gap Versus Offset

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

Topic PageSelecting Type of Tape Seal 3-34Selecting Number of Devices to Be Put in Tape 3-34Setting Tape Pocket Gap 3-34Selecting Manual Cycling 3-35

Gap Offset


Modifying Setup Understanding the Gap

Figure 3-44: Modify Setup Flowchart



Selecting Type of Tape Seal The taper control panel displays "THERMAL OR PSA ?" Select one of the following keypad choices:

<1> key = "USE THERMAL TAPE"—Use a heat seal.

<1> key = "USE PSA TAPE"—Use a pressure-sensitive adhesive seal.

<CLEAR> = Redisplays the message "THERMAL OR PSA ?" and gives you a chance to change your selection.

<ENTER> key = Press to confirm your selection.

Selecting Number of Devices to Be Put in Tape The taper displays "FULL T = ######" showing a number up to 999,999. This is the number of devices the taper will place into the tape.

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 GapThe taper displays "SET GAP ? NO." The gap is the ridge between adjacent tape pockets.

<ENTER> key = Press to display current settings. The display reads "GAP STEPS = ####", then "OFFSET = ####".

<SET UP> key = "SET GAP ? YES"—This proposes to re-find the gap between the leading edges of two adjacent tape pockets.

CAUTION: Be careful not to set the count for more devices than will fit into the reel of tape.


Resetting the Count of Devices in Tape Selecting Manual Cycling

<ENTER> key = Press to advance the tape and have the taper reset the distance between the gaps at either end of a tape pocket.

<CLEAR> key = Redisplays the message "SET GAP ? NO" and gives you a chance to change your selection.


The taper displays "SET OFFSET = ####". Use Polish notation to change the offset if neces-sary. See "Understanding the Gap" on page 3-32.


Selecting Manual Cycling The taper displays "ALL MODES OFF ?" or "STOP MODE ON/OFF." Stop and loop modes are for testing and troubleshooting of the taper. Select one of the following keypad choices:

<1> key = "STOP MODE ON ?" The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring.

<2> key = "LOOP MODE ON ?" The taper will stop after a complete cycle for one device.

<3> key = "ALL MODES OFF ?" The taper will cycle multiple devices in a normal run. This is the default.

<CLEAR> key = Redisplays the message "STOP MODE ON/OFF" and gives you a chance to change your selection.

<ENTER> key = Enters your selection into the taper.

The taper will now display "READY TO RUN ?."

Resetting the Count of Devices in TapeThe taper keeps a running count of total devices placed in the tape. These counts are pre-served 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.

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.

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 ?"



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.

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 TapeBefore, 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.

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.

To reset the count:

To display the totals:


Using Manual Mode Selecting Manual Cycling

Using Manual ModeManual mode allows you to:

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

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


Model 1020 M

anual C

hapter 3: Taper Setup and R

AM

Listing

3-38C

opyright © E

xatron, 2010 10/2010 Figure 3-45: Manual Mode Flowchart


1. Press the <MANUAL> key. If the taper is processing devices, it is paused.

> If the password security is turned on, the display reads "PASSWORD ABC ?" Enter a 3-digit password using the numeric keys. The factory-set password is 123, or <1>, <2>, <3>.

> The message "MANUAL ######" is displayed, with each pound sign repre-senting a digit of the tape output count.

2. Select one or more of the following keypad choices:

<1> key = "NEW TAPE SET UP?"—Select the tape setup corresponding to the device type you want to run.

<1> key = "RUN 5 X 5 MLF"—Use the tape configuration for this device size.

<2> key = "RUN 4 X 4 MLF"—Use the tape configuration for this device size.

<3> key = "RUN SSOIC"—Use the tape configuration for this device size.

<4> key = "RUN DEFAULT 4"—Use another configuration that you have set up.

<ENTER> key = Press to confirm your selection. The settings for the setup type selected are displayed. Then the taper returns to the previous mode.

<2> key = "FULL T = ######"—This is the number of devices that will make up a full reel of tape. It can be any number up to 999,999.

You can change this number by using the number keys on the control panel. Work from right to left: Start with the smallest (ones) digit, then the tens digit, and work up to the largest digit. For example, to enter the number 001248, press <8>, <4>, <2>, <1>, <0>, <0>.

<ENTER> key = Press to confirm your selection. Next, "RESET COUNT NO" is displayed.

<ENTER> key = Press to leave the tape output count as it is and return to the previous mode.

To use Manual 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 = "THERMAL OR PSA ?"—Select the type of seal you want to use.

<1> key = "USE THERMAL TAPE"—Use a heat seal.

<2> key = "USE PSA TAPE"—Use a pressure-sensitive adhesive seal.

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

<4> key = "SET GAP ? NO"

<ENTER> key = Press to display current settings. The display reads "GAP STEPS = ####", then "OFFSET = ####", then "SWING HOME = ##", then "SWING STEP = ###". Each pound sign (#) is replaced by a digit.

<SET UP> key = "SET GAP ? YES"—This proposes to re-find the gap between tape pockets.

<ENTER> key = Press to advance the tape and set the gap. The display reads "JOG LEFT", then "GAP STEPS = ####, then "OFFSET = ####", and stops at "SET OFFSET= ####".

You can change the offset number by using the number keys on the control panel. Work from right to left: Start with the smallest (ones) digit, then the tens digit, and work up to the largest digit. For example, to enter the number 0725, press <5>, <2>, <7>, <0>.

When you finish, press <ENTER> again to redisplay the current settings.

<5> key = "FIND MOTOR HOME", "HOME SWING HEAD", then "MOTOR HOME"—This automatically resets the swing arm at the pickup position.

<6> key = "POCKETS = ######"—The drive motor advances by one pocket and activates seal heads; the count of pockets increments by one. However, the swing arm is not activated to get a device from the pickup site. Because it does not attempt to place a device in a pocket, this feature allows the operator to either (1) check the location and quality of the seal, or (2) place devices in the tape manually without running them through the input tubes.

NOTE: If you get the message "NO POCKET? ERROR", it means it can’t find the gap. Press down lightly on the tape.



<7> key = "SWING HEAD CHECK"

<1> key = "PART AT PICK UP" or "TAPE STACK EMPTY" or no message—One of 3 responses, depending on the situation:

If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, and no message is displayed.

If a device is already at the pickup site, the message "PART AT PICK UP" is displayed.

If no devices are at either the stack or the pickup site, the message "TAPE STACK EMPTY" is displayed.

Note that this action is a subset of <5>, below.

<2> key —Toggles pickup cylinder on/off.

<3> key —Toggles vacuum on/off.

<4> key = "SET GAP ? NO"




You can change the offset number by using the number keys on the con-trol 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>.


<5> key = "PART AT PICK UP" or "TAPE STACK EMPTY" or no message—One of 3 responses, depending on the situation. Note that <1> is a subset of this full cycle:




If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, the swing arm moves the device to the tape, and the tape advances by one pocket and seals one pocket. No message is displayed.



<6> key = "POCKETS = ######"—The drive motor advances by one pocket and activates seal heads; the count of pockets increments by one. However, the swing arm is not activated to get a device from the pickup site. Because it does not attempt to place a device in a pocket, this feature allows the operator to either (1) check the location and quality of the seal, or (2) place devices in the tape manually without running them through the input tubes.

<7> key = "SWING STEP = ###" or "SWING HOME = ###." The result of pressing this key depends on the current position of the swing arm.

When the swing arm is over the tape: "SWING STEP = ###." The num-ber gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs up one motor step.

When the swing arm is over the pickup site: "SWING HOME = ###." The number gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs up one motor step. This is because the swing arm home sensor is just below the pickup site.

<8> key = The result of pressing this key depends on the current posi-tion of the swing arm.

If swing head is down over tape: "FIND MOTOR HOME", then "HOME SWING HEAD", then "MOTOR HOME"—jogs, rotates, and returns swing arm to home position.

If swing head is up at home or pickup position: "ROTATE DOWN"—head rotates down to tape position.


When the swing arm is over the tape: "SWING STEP = ###." The num-ber gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs down one motor step.

When the swing arm is over the pickup site: "SWING HOME = ###." The number gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs down one motor step.



<8> key = "STOP MODE ON/OFF"—Select the mode you want to run.

<1> key = "STOP MODE ON ?"—The taper will stop after every confirmable action and wait for your next command, enabling you to identify exactly where a problem is occurring.

<2> key = "LOOP MODE ON ?"—The taper will stop after a complete cycle for one device.

<3> key = "ALL MODES OFF ?"—The taper will cycle multiple devices in a normal run. This is the default.


<9> key = "TAKE UP MOTOR CK"—This turns on the takeup motor until one of 3 things happens: (1) the takeup arm is raised by the tautness of the tape, or (2) you gently lift the takeup arm to turn the motor off, or (3) the time limit in number of seconds is reached.

If the motor turns for the full time specified without the takeup arm being raised, the message "TAKE UP REEL ERR" is displayed. At this point you can press either of two keys:

<ENTER> key = Press to rotate reel again.

<CLEAR> key = Press to return to Manual mode.

<0> key = "ALL MOTORS OFF"—This turns off the octoloader and swing arm motors, allowing you to move them freely. It does not, however, turn off the takeup and tape drive motors.

Press <ENTER> to turn the motors back on. The message "ALIGN OCTO-LOADER" is displayed.

<DELETE> key = "ADD LEADER DOWN"—Runs the takeup and drive motors for the specified number of pockets (stored in RAM addresses) with the sealing heads down, in the active position. This creates a leader of sealed, empty pockets on a new reel, or a place to cut the tape to separate filled tape from unused tape.

<CLEAR> key = Press to stop the motors and return to the previous mode.

<SPACE> key = "ADD LEADER UP"—Runs the takeup and drive motors for the specified number of pockets (stored in RAM addresses) with the sealing heads up, in the inactive position. This creates a leader of unsealed, empty pockets.

<CLEAR> key = Press to stop the motors and return to the previous mode.




Changing RAMThe Model 1020 system allows you to change the RAM of each taper CPU. You can do this in one of three ways:

♦ You can change individual address values, or settings.

♦ You can reload all the default settings from the EPROM. This will erase any changes that have been made to individual addresses.

♦ You can reload all the default settings from the EPROM, and then change individ-ual address settings.

When you press the <SET UP> key, you have several options, as shown in Figure 3-42.

1. Press the <SET UP> key on the taper’s control panel. The message "CHANGE RAM? NO" is displayed.

2. Press the <SET UP> key again. The message "CHANGE RAM? YES" is dis-played.

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:

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.

To access the Change RAM mode and change RAM settings:


Notes About the RAM Address Listing Selecting Manual Cycling

> Each time you press the <SET UP> key, the next address is displayed, as from 0090 to 0091.

> Each time you press the <TOTALS> key, the previous address is dis-played, 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 set-ting 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.

Notes About the RAM Address ListingA few words of explanation about various listing features follows.

NOTE: Any changes you made take effect immediately. You do not have to power down and back up first.



Warning About Motor Speeds

The step rate is the constant cruising speed. The starting rate is the speed on startup, at the beginning of movement. The acceleration slope rate is the length of time it takes the motor to reach cruising speed.

Updating Your EPROMWrite 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 KitsNotice 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 ModelsA few addresses in the listing should have different default values according to the taper used. These values are repeated in the following table.

CAUTION: Only an engineer experienced with motor speeds should adjust any motor speeds. If unwise changes are made, damage to the machine could result.

Suggested ROM Default Values

Address Display 1010 Value 1020 Value 1050 Value

0097 # Motors 01 07 03009C Octo 8/4 Tubes 00 08 or 04 00009D Wiggle Octoload n/a; not checked 00 or FF n/a; not checked009E P Up Jog Octo n/a; not checked choice n/a; not checked00A2 Foot Count 1E (30) n/a; not checked n/a; not checked00A4 Pickup Vacuum Delay n/a; not checked choice choice00A5 Place Cycle n/a; not checked choice choice


RAM Address Listing Suggested Values for Various Taper Models

RAM Address ListingThe following sample RAM address table describes each firmware address in numerical order. This information is specific for each Model 1020. It may be slightly different for your taper.

For a list of suggested default values that vary according to the taper model, see "Suggested Values for Various Taper Models" on page 3-46.

The ROM Def’lt column shows the factory-set default value for each address. The Com-ments column shows the meaning of each selection. The RAM Options column shows the values you can use. The code below the values shows what type of value into which the taper translates the entry. For further reference, see the "Decimal-Hex-ASCII Conversion Table" on page 3-53.

Code Type of Value

A ASCIIB BitmapC ChoiceH Hex

RAM Address Listing TAPE1020 10-1-10

Add-ress Display ROM

Def’ltRAM

Options Comments

0090 Top of EPROM 00 C Top of EPROM

0091 Tape Out Check 00 B 00 = Use Tape Out sensor. FF = No tape-out check; sensor 6 ignored.

0092 Thermal or PSA P T = Thermal; P = PSA.

0093 Not used.

0094 Baud Rate RS-232

0C C Stores the baud rate for the RS-232 interface between the taper sys-tem and the PC. Contact Exatron before changing the value.

0095 Data Format 03 C Stores the parity/stop/data bits settings for the RS-232 interface.07 = 5000; 03 = 802 / 8000

0096 Not used.

0097 Not used.

0098 Seal Down Delay 05 00 to FFH

Time delay after seal head down and before the tape drive moves. Counts down in hex in 10 millisecond steps.

0099 Not used.

009A Not used.

009B Temperature Alarm

00 C Check the default value in replacement from manufacturer; for thermal seal heads only. 00 = Normally open. FF = Normally closed.

009C Octo 8/4 Tubes 08 C 00 = 1050, no octoloader. 04 = 4-tube input. 08 = 8-tube input.



009D Wiggle Octoload 00 00, FFC

00 = Wiggles the octoloader if a jam is detected. FF = Octoloader will not wiggle.

009E P Up Jog Octo 00 00 to FFC

For calibration of mechanical placement of octoloader—in-house only! Jogs octoloader right and left upon power-up if desired, to possi-bly 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.

009F Out of Pocket FF 00, FFC

00 = Use Out of Pocket sensor. FF = No out-of-pocket check; sensor 7 ignored or replaced by image sensor (camera).

00A0 Empty Pocket Check

FF 00, FFC

00 = Use Empty Pocket sensor. FF = No empty-pocket check; sensor 5 ignored or replaced by image sensor (camera).

00A1 Check Tempera-ture Alarm

FF 00, FFC

00 = Check temperature alarm. For thermal seal heads only. FF = Skip check of temperature alarm.

00A2 Not used.

00A3 Inspect Yes/No 00 C Used only when camera is installed to inspect placement of devices in tape pockets. 00 = On/Yes. FF = Off/No. AA = No option.

00A4 Pickup Vacuum Delay

05 H At pickup site; delay after pickup vacuum turns on and before pickup head lifts device. Default is 10 ms.

00A5 Not used.

00A6 Index Delay 05 H Adds extra time for device to pass index mechanism. 10 ms delay

00A7 Pickup Delay 0A H At pickup site; delay after pickup head retracts and before swing arm rotates down. 10 ms steps.

00A8 Drop-off Down Delay

05 H At tape; length of time it takes pickup head to extend into tape pocket. 10 ms steps.

00A9 Drop-off Delay 0A H At tape; delay after vacuum turns off to drop device into tape and before pickup head is retracted. 10 ms steps.

00AA Drop-off Up Delay

05 H At tape; length of time it takes pickup head to retract from tape pocket. 10 ms steps.

00AB Password On/Off FF C 00 = On; FF = Off.

00AC Password A 1 See page 4-2. A

Must be 0-9 ASCII. This is the first of 3 digits in the password if turned on at address 00AB.

00AD Password B 2 A Must be 0-9 ASCII. This is the second of 3 digits in the password.

00AE Password C 3 A Must be 0-9 ASCII. This is the third of 3 digits in the password.

00AF Full Tape 100000s

0 A Sets the 100,000s digit for number of devices constituting a full tape.

00B0 Full Tape 10000s 0 A Sets the 10,000s digit for number of devices constituting a full tape.

00B1 Full Tape 1000s 1 A Sets the 1,000s digit for number of devices constituting a full tape.



Def’ltRAM

Options Comments



00B2 Full Tape 100s 0 A Sets the 100s digit for number of devices constituting a full tape.



00B5 Leader 10 3 Sets the 10s digit for number of pockets in leader tape.

00B6 Leader 1 0 Sets the 1s digit for number of pockets in leader tape.

00B7 Take Up 10 2 Sets the 10s digit for number of pockets to be advanced between takeup reel runs.

00B8 Take Up 1 0 Sets the 1s digit for number of pockets to be advanced between takeup reel runs.

00B9 Not used.

00BA Not used.

00BB Not used.

00BC Not used.

00BD Not used.

00BE Not used.

00BF Not used.

00C0 Use Default #? 01 Switch changeover kit settings by group. The other group settings will be ignored. 01 = 5x5 (00C1-00CD). 02 = 4x4 (00CE-00DA). 03 = SSOIC (00DB-00E7). 04 = spare option (00E8-00F4).

00C1 Gap Step 1000s 0 A Sets the 1,000s digit for first tape drive move. For 5x5 device

00C2 Gap Step 100s 6 A Sets the 100s digit for first tape drive move.



00C5 Offset 1000s 0 A 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.

00C6 Offset 100s 0 A Sets the 100s digit for the offset distance.



00C9 Swing Home 10 0 A 30, 31, or 32; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing.

00CA Swing Home 1 6 A 30-39; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing.

00CB Swing Step 100s 0 A Sets the 100s digit for the number of motor steps the swing arm rotates down from its pickup position to the tape position.



Def’ltRAM

Options Comments



00CC Swing Step 10s 6 A Sets the 10s digit for the swing arm’s pickup position to tape position.

00CD Swing Step 1s 1 A Sets the 1s digit for the swing arm’s pickup position to tape position.

00CE Gap Step 1000s 1 A Sets the 1,000s digit for first tape drive move. For 4x4 device

00CF Gap Step 100s 0 A Sets the 100s digit for first tape drive move.

00D0 Gap Step 10s 3 A Sets the 10s digit for first tape drive move.

00D1 Gap Step 1s 7 A Sets the 1s digit for first tape drive move.

00D2 Offset 1000s 0 A 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.

00D3 Offset 100s 9 A Sets the 100s digit for the offset distance.



00D6 Swing Home 10 1 A 30, 31, or 32; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing.

00D7 Swing Home 1 2 A 30-39; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing.

00D8 Swing Step 100s 0 A Sets the 100s digit for the number of motor steps the swing arm rotates down from its pickup position to the tape position.

00D9 Swing Step 10s 6 A Sets the 10s digit for the swing arm’s pickup position to tape position.

00DA Swing Step 1s 1 A Sets the 1s digit for the swing arm’s pickup position to tape position.

00DB Gap Step 1000s 1 A Sets the 1,000s digit for first tape drive move. For SSOIC device

00DC Gap Step 100s 0 A Sets the 100s digit for first tape drive move.

00DD Gap Step 10s 3 A Sets the 10s digit for first tape drive move.

00DE Gap Step 1s 7 A Sets the 1s digit for first tape drive move.

00DF Offset 1000s 0 A 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.

00E0 Offset 100s 9 A Sets the 100s digit for the offset distance.



00E3 Swing Home 10 1 A 30, 31, or 32; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing.

00E4 Swing Home 1 2 A 30-39; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing.

00E5 Swing Step 1s 3 A Sets the 1s digit for the swing arm’s pickup position to tape position.



Def’ltRAM

Options Comments





00E8 Gap Step 1000s 1 A Sets the 1,000s digit for first tape drive move.

00E9 Gap Step 100s 0 A Sets the 100s digit for first tape drive move.

00EA Gap Step 10s 3 A Sets the 10s digit for first tape drive move.

00EB Gap Step 1s 7 A Sets the 1s digit for first tape drive move.

00EC Offset 1000s 0 A 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.

0ED Offset 100s 9 A Sets the 100s digit for the offset distance.

00EE Offset 10s 6 A Sets the 10s digit for the offset distance.

00EF Offset 1s 0 A Sets the 1s digit for the offset distance.

00F0 Swing Home 10 1 A 30, 31, or 32; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing.

00F1 Swing Home 1 2 A 30-39; ASCII only. This determines the number of motor steps the swing arm rotates above its home sensor when homing.

00F2 Swing Step 100s 0 A Sets the 100s digit for the number of motor steps the swing arm rotates down from its pickup position to the tape position.

00F3 Swing Step 10s 6 A Sets the 10s digit for the swing arm’s pickup position to tape position.

00F4 Swing Step 1s 1 A Sets the 1s digit for the swing arm’s pickup position to tape position.

00F5 Not used.

00F6 Not used.

00F7 Not used.

00F8 Not used.

00F9 Not used.

00FA Not used.

00FB Not used.

00FC Not used.

00FD Not used.

00FE Not used.

00FF Not used.



Def’ltRAM

Options Comments



Hex-Binary Conversion TableExatron uses hex as an easy way of representing binary. It allows the user to type an instruc-tion of 2 digits rather than an instruction of 8 digits. The taper decodes the hex instructions into a binary map.

In binary notation, 1 = TRUE and 0 = FALSE.

Comparison of Number Systems

Hexadecimal Binary00 0000 000001 0000 000102 0000 001003 0000 001104 0000 010005 0000 010106 0000 011007 0000 011108 0000 100009 0000 10010A 0000 10100B 0000 10110C 0000 11000D 0000 11010E 0000 11100F 0000 111110 0001 000020 0010 000030 0011 000040 0100 0000


Decimal-Hex-ASCII Conversion Table Suggested Values for Various Taper Models

Decimal-Hex-ASCII Conversion Table Decimal Hex ASCII Decimal Hex ASCII

0 00 34 22 "

1 01 35 23 #

2 02 36 24 $

3 03 37 25 %

4 04 38 26 &

5 05 39 27 ’

6 06 40 28 (

7 07 41 29 )

8 08 42 2A *

9 09 43 2B +

10 0A 44 2C ,

11 0B 45 2D -

12 0C 46 2E .

13 0D 47 2F /

14 0E 48 30 0

15 0F 49 31 1

16 10 50 32 2

17 11 51 33 3

18 12 52 34 4

19 13 53 35 5

20 14 54 36 6

21 15 55 37 7

22 16 56 38 8

23 17 57 39 9

24 18 58 3A :

25 19 59 3B ;

26 1A 60 3C <

27 1B 61 3D =

28 1C 62 3E >

29 1D 63 3F ?

30 1E 64 40 @

31 1F 65 41 A

32 20 Space 66 42 B

33 21 ! 67 43 C



68 44 D 104 68 h

69 45 E 105 69 i

70 46 F 106 6A j

71 47 G 107 6B k

72 48 H 108 6C l

73 49 I 109 6D m

74 4A J 110 6E n

75 4B K 111 6F o

76 4C L 112 70 p

77 4D M 113 71 q

78 4E N 114 72 r

79 4F O 115 73 s

80 50 P 116 74 t

81 51 Q 117 75 u

82 52 R 118 76 v

83 53 S 119 77 w

84 54 T 120 78 x

85 55 U 121 79 y

86 56 V 122 7A z

87 57 W 123 7B {

88 58 X 124 7C |

89 59 Y 125 7D }

90 5A Z 126 7E ~

91 5B [ 127 7F

92 5C \ 128 80

93 5D ] 129 81

94 5E ^ 130 82

95 5F _ 131 83

96 60 ‘ 132 84

97 61 a 133 85

98 62 b 134 86

99 63 c 135 87

100 64 d 136 88

101 65 e 137 89

102 66 f 138 8A

103 67 g 139 8B

Decimal Hex ASCII Decimal Hex ASCII


Chapter 4: Diagnostics

Chapter OverviewThis chapter describes the operation of the taper's extensive built-in diagnostics. These diag-nostics allow every sensor, solenoid, switch, motor, and I/O Port in the taper to be individually tested. Use these checks to troubleshoot any problem the taper may have.

This chapter discusses the following main topics:

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


Model 1020 Manual Chapter 4: Diagnostics

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

The display reads: "DIAGNOSTICS." You can access Diagnostics mode whenever the taper powers up, is in Run mode, or is in Manual mode.

Figure 4-1: Control Panel

You can also enter Diagnostics mode during most device jam-clearing cycles, when the output tube cover LEDs are flashing. If using Diagnostics during a jam, the taper will exit its automatic jam clearing cycle and then return to its previous place in the program, upon exiting Diagnos-tics. In most cases, if the jam is cleared during Diagnostics, the taper will also automatically restart after returning from Diagnostics.

An abbreviated flowchart showing the main Diagnostics functions is shown on page 4-3. The "Diagnostics Quick Reference" showing all the functions begins on page 4-4, and detailed explanations of the major ones are in the sections following the quick reference.


Accessing D

IAG

NO

STIC

S M

ode

10/201

r more keys may be

0C

opyright © E

xatron, 20104-3

Figure 4-2: Diagnostics Abbreviated Flowchart

NOTE: Depending on the exact configuration of your taper, the functions accessed by one osomewhat different.


Diagnostics Quick ReferenceThe 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 per-forming the action described in this section.

<1> key = "SENSOR CHECK", then:

<1> key = "SEN0-7 1234567" —tape sensors 0-7

0-2 displays = n/a (not applicable)

3 display = takeup arm sensor

4 display = tape pocket gap sensor

5 display = n/a (not applicable)

6 display = carrier tape out switch


<2> key = "SEN8-F 89ABCDEF" —input and swing arm/pickup head sensors 8-F

8 display = pickup head vacuum sensor

9 display = swing arm at home/pickup position sensor

A display = device at stack pin sensor

B display = device at pickup site sensor

C display = n/a (not applicable)

D display = device at top of input rail sensor

E display = device jammed at octoloader gap sensor

F display = octoloader at home position switch

<3> key = "IN-SEN 01234567" —camera sensor

0-5 displays = n/a (not applicable)

6 display = camera failure sensor



Diagnostics Quick Reference

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

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

<1> key = "SOLENOID CHECK" causes continual, intermittent action, then:

<1> key activates sealing head cylinder

<2> key activates pickup head vacuum

<3> key activates optional cylinder valve

<4> key activates index solenoid

<5> key activates stack cylinder and cover foot cylinder

<6> key activates blow-off from pickup head (to break vacuum seal with device)

<7> key activates pickup head cylinder on swing arm

<8> key activates takeup reel motor

<9> key n/a

<0> key turns all solenoids OFF

<2> key = "SOL TOGGLE CHECK" causes continuous, steady action, then:

<Clear> key homes the swing arm

<1> key lowers sealing head to tape; press again to raise

<2> key turns on pickup head vacuum; press again to turn off

<3> key activates optional cylinder valve; press again to turn off

<4> key activates index solenoid; press again to turn off

<5> key activates stack cylinder and cover foot cylinder; press again to turn off

<6> key turns on blow-off from pickup head; press again to turn off

<7> key extends pickup head on swing arm; press again to retract

<8> key turns on takeup reel motor; press again to turn off

CAUTION: Do not leave the index solenoid on for more than a couple of seconds or the solenoid may be damaged.



<9> key n/a

<0> key turns all solenoids OFF

<3> - <9> keys n/a

<3> key = "ALL MOTOR CHECK", then:

<1> key = "DRIVE MOTOR CHK" (tape drive motor check), then:

<1> key = "MOVE TAPE LEFT"—advances carrier tape one tape pocket to the left

<2> key = "R235 F30 S235"—briefly displays current tape drive motor settings in RAM

<3> key = "MOVE TAPE RIGHT"—moves carrier tape several motor steps to the right

<4> key = n/a

<5> key = "TEST TAPE MOTOR"—advances tape by one pocket

<6> key n/a

<7> key = "JOG LEFT"—moves tape drive motor 1 motor step to the left

<8> key n/a

<9> key = "JOG RIGHT"—moves tape drive motor 1 motor step to the right

<0> key = "MOTOR A OFF"—turns off tape drive motor

<2> key = "SWING HEAD CHECK", then:

<1> key = "PART AT PICK UP" or "TAPE STACK EMPTY" or no message—One of 3 responses, depending on the situation:

If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, and no message is displayed.



CAUTION: Do not do this diagnostic with a tape present. Tape position will be com-promised and/or tape damage may result.



Note that this action is a subset of <5>, below.

<2> key —Toggles pickup cylinder on/off.

<3> key —Toggles vacuum on/off.

<4> key = "SET GAP ? NO", then:




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>.


<5> key = "PART AT PICK UP" or "TAPE STACK EMPTY" or no message—One of 3 responses, depending on the situation. Note that <1> is a subset of this full cycle:

If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, the swing arm moves the device to the tape, and the tape advances by one pocket and seals one pocket. No mes-sage is displayed.



<6> key = "POCKETS = ######."—tape drive motor advances and activates seal heads; the number of pockets increments by the same number. However, the swing arm is not activated to get a device from the pickup site.





When the swing arm is over the tape: "SWING STEP = ###." The number gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs up one motor step.

When the swing arm is over the pickup site: "SWING HOME = ###." The number gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs up one motor step. This is because the swing arm home sensor is just below the pickup site.

<8> key = The result of pressing this key depends on the current position of the swing arm.

If swing head is down over tape: "FIND MOTOR HOME", then "HOME SWING HEAD", then "MOTOR HOME"—jogs, rotates, and returns swing arm to home position.

If swing head is up at home or pickup position: "ROTATE DOWN"—head rotates down to tape position.


When the swing arm is over the tape: "SWING STEP = ###." The number gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs down one motor step.

When the swing arm is over the pickup site: "SWING HOME = ###." The number gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs down one motor step.

<0> key = "MOTOR B OFF"—turns off swing arm motor

<3> key = "OCTO MOTOR CHK", then:

<1> key = "1 LEFT STEP"—moves octoloader one tube to the left

<2> key = "R200 F10 S200"—briefly displays current octoloader motor settings in RAM

<3> key = "1 RIGHT STEP"—moves octoloader one tube to the right

<4> key = "2 LEFT STEPS"—moves octoloader two tubes to the left

<6> key = "2 RIGHT STEPS"—moves octoloader two tubes to the right

<7> key = "JOG LEFT"—moves octoloader motor 1 motor step to the left



<8> key = "SET # INPUTS"—accesses number of input tubes setting

<1> key = "8 TUBE INPUT"—uses all 8 input tubes

<2> key = "4 TUBE INPUT"—uses 4 input tubes; alternating tracks

<3> key = "OCTOLOADER OFF"—allows operator to drop devices down input track, bypassing octoloader

<9> key = "JOG RIGHT"—moves octoloader motor 1 motor step to the right

<0> key = "MOTOR C OFF"—turns off octoloader motor

<4> - <0> keys n/a

<4> key = "INTERFACE CHECK", then:

<1> key = "RS-232 CHECK", then:

<1> - <9> keys send signals "1" - "9" from control panel to tester (these are future option ports)

<RUN> key sends signal "A" from control panel to tester

<MANUAL> key sends signal "B" from control panel to tester

<SET UP> key sends signal "C" from control panel to tester

<PAUSE> key sends signal "D" from control panel to tester

<TOTALS> key sends signal "E" from control panel to tester

<DIAGNOSTICS> key sends signal "F" from control panel to tester

<2> key = "HANDLER OUT CHK", then:

<1> - <8> keys cause corresponding light ot flash, on LED and on Simulator

<9> key activates all ON

<0> key activates all OFF

<3> key = "SORT = "12345678"

<1> key = "ISSUE NEW START" —The taper has been instructed to send a new start-test pulse to the tester/PC; then it waits for an end-of-test sort signal from the tester. If none is received, the message "SORT INPUT" is displayed.

<4> - <0> keys n/a



<5> key = "TAKE UP MOTOR CK"—turns on takeup reel motor. Lift takeup arm to stop motor.

<6> key = "INSPECTION PASS" or "INSPECTION FAIL"—displays current inspection result.

<7> - <0> keys n/a

<ENTER> key = Exit DIAGNOSTICS.


SENSOR CHECK: Tape Sensors 0-7

SENSOR CHECK: Tape Sensors 0-7 This diagnostic tests the sensors related to the tape.

1. Press the <DIAGNOSTICS> key.

> Control panel displays "DIAGNOSTICS".


> 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:

* 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 #3000-052 (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.

To access this diagnostic check:

Tape Sensors

Control PanelDisplay Sensor Alphanumeric Character

Displayed When...Red Controller

Light

0, 1, 2 N/a, no sensor

3 Takeup Arm Arm raised; signal open n/a *

4 Pocket Gap Tape not centered at pocket divider; signal blocked Off

5 N/a, no sensor

6 Carrier Tape Out No tape present; signal open n/a *

7 N/a, no sensor



SENSOR CHECK: Input and Pickup Sensors 8-F This diagnostic tests the sensors related to the octoloader input, the pickup site, and the swing arm.






> Control panel displays all or part of "SEN8-F 89ABCDEF".


* Sensor is of type photo rather than fiberoptic, and hence has no controller.




Input and Pickup Sensors

Control Panel

DisplaySensor Alphanumeric Character

Displayed When...

Red Controller

Light

8 Pickup Head Vacuum No device attached to pickup head; vacuum open or vacuum turned off

n/a

9 Swing Arm Home Swing arm not home; signal open n/a *

A Device at Stack Device at stack pin; signal blocked On

B Device at Pickup Site Device at pickup site; signal blocked On

C N/a, no sensor

D Device at Top of Input Rail Device at top of input rail; signal blocked

E Device at Octoloader Gap Device jammed at octoloader gap; signal blocked

F Octoloader at Home Octoloader at home position switch


SENSOR CHECK: Image Sensors 0-7

If you suspect that you have a bad sensor/LED pair, use the EXATRON LED checker #3000-052 (small blue plastic box). This diagnostic tool is equipped with a transistor (blue/white wires) and an IR LED (orange/blue wires).

Direct the transistor at any of the taper's IR LEDs. The LED on the checker should turn off. Direct the checker's LED at any of the taper's transistors. The corresponding number should turn OFF on the taper's display.

SENSOR CHECK: Image Sensors 0-7 This diagnostic tests the sensors related to the camera (image sensor).






> Control panel displays all or part of "IN-SEN 01234567".





(Camera) Image Sensor

Control Panel

DisplaySensor Alphanumeric Character

Displayed When...

0, 1, 2, 3, 4, 5 N/a, no sensor

6 Camera Failure Camera failed or not turned on

7 N/a, no sensor



OUTPUT CHECK: Solenoid CheckThis diagnostic tests various solenoids.




> Control panel displays "OUTPUT CHECK".


> Control panel displays "SOLENOID CHECK".

4. Press each of the taper terminal's keypad keys 0 through 9.

Each key turns on the taper's output cover LEDs and sets the corresponding taper solenoid into a continual, intermittent on/off test cycle. For example, the vacuum is activated in intermittent bursts, or the pickup head moves up and down until you stop the action.

Pressing the <CLEAR> key will flash the terminal's displayed message to confirm the taper is still in this specific diagnostic check.

Press the <ENTER> key to exit this diagnostic check and return to the "DIAGNOSTICS" mes-sage.


Key Output Cover LED Taper Solenoid Action

1 1 Seal heads lowered to tape2 2 Pickup head vacuum on3 3 Optional cylinder valve on4 4 Index pin extends5 5 Stack pin retracts; cover foot extends6 6 Positive air pressure emitted from suction cup on pickup head to

break vacuum between device and suction cup7 7 Pickup head extends on swing arm8 8 Takeup reel motor turned on, winding tape and tightening tape slack9 n/a0 All OFF All solenoids turned off


OUTPUT CHECK: Solenoid Toggle Check

OUTPUT CHECK: Solenoid Toggle CheckThis diagnostic tests various solenoids.




> Control panel displays "OUTPUT CHECK".

3. Press the <2> key again.

> Control panel displays "SOL TOGGLE CHECK".

4. Press each of the control panel's keypad keys 0 through 9.

Each key will turn on/off the taper's output cover LEDs and will set the corresponding taper solenoid into continuous, steady action that can be stopped or toggled by pressing the <0> key. For example, the vacuum is activated in a steady force until you toggle it off, or the pickup head stays down until you toggle it up.

Press the <ENTER> key to exit this diagnostic check and return to the "DIAGNOSTICS" mes-sage.


Key Output Cover LED Taper Solenoid Action

Clear Swing arm homed to position over pickup site1 1 Seal heads lowered to tape2 2 Pickup head vacuum on3 3 Optional cylinder valve on4 4 Index pin extends *5 5 Stack pin retracts; cover foot extends6 6 Positive air pressure emitted from suction cup on pickup head to

break vacuum between device and suction cup7 7 Pickup head extends on swing arm8 8 Takeup reel motor turned on, winding tape and tightening tape slack90 All OFF All solenoids turned off

* CAUTION: Do not leave the index solenoid on for more than a couple of seconds or the solenoid may be damaged.



ALL MOTOR CHECK: Drive Motor CheckThis 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




> Control panel displays "ALL MOTOR CHECK".


> Control panel displays "DRIVE MOTOR CHK".

<1> key = "MOVE TAPE LEFT." The drive motor moves the tape one pocket to the left.<2> key = "R235 F30 S235." The current motor settings are displayed.<3> key = "MOVE TAPE RIGHT." The drive motor moves the tape one pocket to the right.

<5> key = "TEST TAPE MOTOR." The drive motor advances the tape two pockets to the left.<7> key = "JOG LEFT." The drive motor moves the tape one motor step to the left.<9> key = "JOG RIGHT." The drive motor moves the tape one motor step to the right.<0> key = "MOTOR A OFF." The drive motor is turned off.

Pressing the <CLEAR> key flashes the terminal's displayed message to confirm the taper is still in this specific diagnostic check.



CAUTION: Do not do this diagnostic with a tape present. Tape position will be com-promised and/or tape damage may result.


ALL MOTOR CHECK: Swing Arm Check

ALL MOTOR CHECK: Swing Arm CheckThis 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




> Control panel displays "ALL MOTOR CHECK".


> Control panel displays "SWING HEAD CHECK".

<1> key — Indexes device: If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, and no message is displayed.

> If a device is already at the pickup site, the message "PART AT PICK UP" is displayed.

> If no devices are at either the stack or the pickup site, the message "TAPE STACK EMPTY" is displayed.Note that this action is a subset of <5>, below.

<2> key — Toggles pickup cylinder on/off.

<3> key — Toggles vacuum on/off.

<4> key = "SET GAP ? NO." If the pickup head is centering devices in each tape pocket, press <ENTER> to move on. But if devices are being placed improperly as shown in Figure 3-38 on page 3-27, press <SET UP> and then <ENTER> to set the gap. You then have the opportunity to visually check the pickup head position and change the offset. See "Understanding the Gap" on page 3-32 and "Setting Tape Pocket Gap" on page 3-34.




<5> key — The taper does one full pick-and-place cycle: If a device is at the stack but not at the pickup site, the device is indexed from the stack to the pickup site, the swing arm moves the device to the tape, and the tape advances by one pocket and seals one pocket. No message is displayed.

> If a device is already at the pickup site, the message "PART AT PICK UP" is displayed.

> If no devices are at either the stack or the pickup site, the message "TAPE STACK EMPTY" is displayed.Note that <1> is a subset of this full cycle.

<6> key = "POCKETS = ######." The drive motor advances and activates the seal heads; the number of pockets increments by the same number. However, the swing arm is not activated to get a device from the pickup site.


> When the swing arm is over the tape: "SWING STEP = ###." The number gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs up one motor step. 1

> When the swing arm is over the pickup site: "SWING HOME = ##." The number gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs up one motor step. 2

<8> key = The result of pressing this key depends on the current position of the swing arm.

> If swing head is down over tape: "FIND MOTOR HOME", then "HOME SWING HEAD", then "MOTOR HOME"—The swing arm moves to its home position at the Swing Arm Home sensor, then moves the specified number of motor steps farther up to the pickup site. 3

> If swing head is up at home or pickup position: "ROTATE DOWN"—head rotates down to tape position.


> When the swing arm is over the tape: "SWING STEP = ###." The number gets larger (because the swing arm is getting farther from its home position) and the swing arm jogs down one motor step. 4

1 Any change made with the <7> key here at "SWING STEP = " is saved in the RAM addresses for "SWING STEP" and kept until default values are loaded from the EPROM.

2 Any change made with the <7> key here at "SWING HOME = " is saved in the RAM addresses for "SWING HOME" and kept until default values are loaded from the EPROM. This change also affects the number of motor steps the swing arm rotates up past its home sensor when the <8> key is pressed.

3 The number of motor steps that the swing arm moves beyond the sensor is taken from the values in the RAM addresses for "SWING HOME", which are changed by use of the <7> and <9> keys.

4 Any change made with the <9> key here at "SWING STEP = " is saved in the RAM addresses for "SWING STEP" and kept until default values are loaded from the EPROM.


ALL MOTOR CHECK: Swing Arm Check

> When the swing arm is over the pickup site: "SWING HOME = 0##." The number gets smaller (because the swing arm is getting closer to its home position) and the swing arm jogs down one motor step. 1

<0> key = "MOTOR B OFF." The swing arm motor is turned off.

Pressing the <CLEAR> key will flash the terminal's displayed message to confirm the taper is still in this specific diagnostic check.


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



ALL MOTOR CHECK: Octoloader Motor CheckThis diagnostic tests the positions of the octoloader motor.


> Taper displays "DIAGNOSTICS".


> Taper displays "ALL MOTOR CHECK".


> Taper displays "OCTO MOTOR CHK".

<1> key = "1 LEFT STEP." The octoloader moves one tube to the left.<2> key = "R200 F10 S200." The taper displays the current motor settings in RAM. This display is helpful when trying to increase the motor's speed.<3> key = "1 RIGHT STEP." The octoloader moves one tube to the right.<4> key = "2 LEFT STEPS." The octoloader moves two tubes to the left.<6> key = "2 RIGHT STEPS." The octoloader moves two tubes to the right.<7> key = "JOG LEFT." The octoloader moves one motor step to the left, about .006".<8> key = "SET # INPUTS"—accesses number of input tubes setting

<1> key = "8 TUBE INPUT"—uses all 8 input tubes<2> key = "4 TUBE INPUT"—uses 4 input tubes; alternating tracks<3> key = "OCTOLOADER OFF"—allows operator to drop devices down input track, bypassing octoloader

<9> key = "JOG RIGHT." The octoloader moves one motor step to the right, about .006".<0> key = "MOTOR C OFF." The octoloader motor is turned off.

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


CAUTION: Verify that the octoloader is empty of all devices before using this diag-nostic.



Chapter 5: Dictionary of Displayed Messages

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

Figure 5-1: Control Panel

Topic Page00## DATA ## 5-51 LEFT STEP 5-51 RIGHT STEP 5-52 LEFT STEPS 5-52 RIGHT STEPS 5-54 TUBE INPUT 5-68 TUBE INPUT 5-6ADD LEADER DOWN 5-6ADD LEADER UP 5-6ALIGN OCTOLOADER 5-6ALL MODES OFF ? 5-6ALL MOTOR CHECK 5-7ALL MOTORS OFF 5-7CHANGE RAM ? NO 5-7


Model 1020 Manual Chapter 5: Dictionary of Displayed Messages

CHANGE RAM ? YES 5-7COUNT SET TO 0 5-7CPU ERROR [1-6] 5-7DIAGNOSTICS 5-8DRIVE MOTOR CHK 5-8EMPTY/LOAD PARTS 5-8EMPTY POCKET ? 5-8EXATRON TAPE 5-8FIND MOTOR HOME 5-8FULL T = ###### 5-8GAP STEPS = #### 5-9HANDLER OUT CHECK 5-9HOME SENSOR ERR 5-9HOME SWING HEAD 5-9INDEX/STACK JAM 5-9IN-SEN 01234567 5-10INSPECT YES/NO ? 5-10INSPECTION FAIL 5-10INSPECTION OFF 5-10INSPECTION ON 5-11INSPECTION PASS 5-11INTERFACE CHECK 5-11ISSUE NEW START 5-11JOG LEFT 5-11JOG OCTOLOADER 5-11JOG RIGHT 5-11LOAD DEFAULT NO 5-11LOAD DEFAULT YES 5-11LOAD EPROM>RAM 5-12LOADER JAM 5-12LOOP MODE ON ? 5-12MANUAL ###### 5-12MOD SET UP ? NO 5-12MOD SET UP ? YES 5-12MOTOR [A, B, or C] BUSY ? 5-13MOTOR <A, B, or C> ERROR ? 5-13MOTOR A OFF 5-13MOTOR B OFF 5-13MOTOR C OFF 5-14

Topic Page


Chapter Overview

MOTOR HOME 5-14MOVE TAPE LEFT 5-14MOVE TAPE RIGHT 5-14NEW JOB–EMPTY OK 5-14NEW TAPE SET UP? 5-14NO POCKET? ERROR 5-15NOT UP TO TEMP 5-15OCTO MOTOR CHK 5-15OCTOLOADER OFF 5-15OFFSET = #### 5-15OFFSET>GAP ERROR 5-15OK TO RUN ? 6 5-15OUT OF POCKET ? 5-15OUTPUT CHECK 5-15PASSWORD ABC? 5-16PAUSED ###### 5-16PART AT PICK UP 5-16PART DROPPED ? 5-16PICK UP AT HOME 5-16PICK UP DOWN 5-16PICK UP NOT HOME 5-16PLACE PART ERR 5-17POCKETS = ###### 5-17RAM AUTO RESET 5-17READY TO RUN ? 5-17RESET COUNT NO 5-17RESET COUNT YES 5-17RETURN ERROR ? 5-18ROTATE DOWN 5-18ROTATE UP 5-18RS-232 CHECK 5-18RUN 4 X 4 MLF 5-18RUN 5 X 5 MLF 5-18RUN DEFAULT 4 5-18RUN SSOIC 5-18RUN UNTIL 1 PASS 5-18SEN0-7 01234567 5-19SEN8-F 89ABCDEF 5-19SENSOR CHECK 5-19

Topic Page



Model 1050 Handler Status and Error MessagesMessages 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 assis-tance. For free updates to the firmware, please contact the Exatron Sales Department.

SET # INPUTS 5-19SET GAP ? NO/YES 5-19SET OFFSET = #### 5-19SOL TOGGLE CHECK 5-20SOLENOID CHECK 5-20SORT = 12345678 5-20STOP MODE ON/OFF 5-20STOP MODE ON ? 5-20SWING HEAD CHECK 5-21SWING HOME = ### 5-21SWING STEP = ### 5-21TAKE UP MOTOR CK 5-21TAKE UP REEL ERR 5-21TAPE GAP LOST ? 5-21TAPE IS FULL 5-22TAPE OUT ERROR ? 5-22TAPE STACK EMPTY ? 5-22TEST TAPE MOTOR 5-22THANK YOU # 5-22THERMAL OR PSA ? 5-23UART OUT ERROR 5-23USE PSA TAPE 5-23USE THERMAL TAPE 5-23VAC NOT ADJUSTED 5-23ZERO COUNT ERR 5-24

Topic Page


Model 1050 Handler Status and Error Messages 00## DATA ##

00## DATA ##This is the Change RAM routine. Current RAM address data will be displayed where each pound sign (#) is shown above. Review the following keys for options allowed:

<ENTER> Exits routine; saves parameter into RAM.

<SET UP> Each time you press the <SET UP> key, the next address is dis-played, as from 0090 to 0091.

<TOTALS> Each time you press the <TOTALS> key, the previous address is dis-played, 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 cur-rent parameter is "EF", press the <SPACE> key to change the parameter to "FF".

<DELETE> Increments the lower data nibble (the right digit in the parameter at the right end of the displayed address) in the current address. For example, if the current parameter is "04", press the <DELETE> key to change the parameter to "05".

<-> Sets the parameter for the current address to FF.

<0> Sets the parameter for the current address to 00.

<CLEAR> key = Loads the default parameter for the current address from the EPROM into the RAM.

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

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

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

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



4 TUBE INPUTThe octoloader is set to deliver devices from 4 tubes.

8 TUBE INPUTThe octoloader is set to deliver devices from 8 tubes.

ADD LEADER DOWNThis 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 UPThis 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 OCTOLOADERYou have pressed the <0> key to turn off the octoloader motor; then pressed <ENTER> to turn it back on.

ALL MODES OFF ?You have pressed the <9> key during RUN mode or a waiting mode.

Stop and loop modes are for testing and troubleshooting of the taper. Select one of the follow-ing 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.


Model 1050 Handler Status and Error Messages ALL MOTOR CHECK

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

ALL MOTORS OFFYou 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 ? NOExits 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 ? YESAllows the operator to override the taper's setup parameters.

<ENTER> Allows changes to the RAM. See "Changing RAM" on page 3-44 for instructions.

<SET UP> Toggles back to CHANGE RAM ? NO.

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

CPU ERROR [1-6]Any of these errors are critical. The taper's control program has detected a major problem, and has stopped operation. Use the following procedure to resolve this problem:

1. Write down exactly which CPU ERROR message is displayed.

2. Write down, to the best of your knowledge, what message(s) was/were dis-played by the taper just before the error.

3. Write down, to the best of your knowledge, what the taper was doing just before the error.

4. Power down the taper and handler.

5. Power the handler and taper back up and answer all of the MOD SET UP ? YES questions.

6. Resume taper operation.



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.

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

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

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

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

EXATRON TAPEPower-up machine identification message; no action required.

FIND MOTOR HOMEThis message is part of the routine for automatically resetting the taper’s 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.


Model 1050 Handler Status and Error Messages GAP STEPS = ####

Use the keypad to make your selection. The tape loader accepts changes to each digit from lowest to highest, in order. First enter Ones, then Tens, then Hundreds, then Thousands. For example, to place 38 devices in each output tube, press <8>, then <3>.

<-> The minus key sets the count to 0000.

<CLEAR> Resets to the beginning of the handler's FULL T = ###### loop. This will also reload the handler's EPROM default value for this address.


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 arm’s pickup head.

HANDLER OUT CHECKYou have pressed <DIAGNOSTICS>, <4>, <2>. This is a future option port.

HOME SENSOR ERRThe 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 dis-played during power-up of the system or during operation.

Inspect the path of the swing arm for any jammed device or other blockage. After removing any blockage, press <Clear> to return to the previous condition.

If there is no physical obstacle in the path of the swing arm, you may have a worn sensor. Run the Diagnostics/SENSOR CHECK for the swing arm sensor, described in "SENSOR CHECK: Input and Pickup Sensors 8-F" on page 4-12. Replace the sensor as necessary.

HOME SWING HEADThis message is part of the routine for automatically resetting the taper’s 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:


INDEX/STACK JAMA device is jammed at the index site just above the swing head.

<ENTER> fires the index and stack solenoids again to try to dislodge the device.



<RUN> retries the cycle again to try to dislodge the device.

<MANUAL> or <CLEAR> exits Run mode and goes to Manual mode.

IN-SEN 01234567One or more of the numbers shown above is displayed following IN-SEN.

The only significant number is 6, the camera failure sensor. If this number is displayed, there is a problem with the camera. See the camera manufacturer’s documentation for more infor-mation.

INSPECT YES/NO ?This allows you to turn on or off the camera inspection.

<1> = "INSPECTION ON". Press to turn on inspection.

<2> = "INSPECTION OFF". Press to turn off inspection.

<ENTER> confirms your selection.

INSPECTION FAILInspection is turned on and inspection of a pocket has failed. This may be because a device has failed inspection or because of an empty pocket. It also occurs at the beginning of a new tape, which necessarily has several empty pockets in the leader.

<RUN> ignores the error, advances the tape, and continues inspection until the next failure.

<ENTER> reinspects the same pocket.

<.> = "INSPECT YES/NO ?" accesses the option to toggle the inspection on or off.

<1> = "INSPECTION ON" toggles inspection on.

<2> = "INSPECTION OFF" toggles inspection off.

<ENTER> confirms your selection.

<DIAGNOSTICS> exits Run mode and enters Diagnostics mode.

<MANUAL> exits Run mode and enters Manual mode.

INSPECTION OFFCamera inspection of devices in pockets is turned off.


Model 1050 Handler Status and Error Messages INSPECTION ON

INSPECTION ONCamera inspection of devices in pockets is turned on.

INSPECTION PASSInspection is turned on and inspection of a pocket has passed. You have pressed <DIAGNOS-TICS>, <6>, to view this message.

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

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

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

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

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

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

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

LOOP MODE ON ?Loop mode is for testing and troubleshooting of the taper. You can alternate between Stop mode and Loop mode by pressing the <1> and <2> keys, respectively. Select one of the fol-lowing keypad choices.





<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 func-tions. See "Using Manual Mode" on page 3-37 for details.

MOD SET UP ? NO<SET UP> Modifies the taper's setup.

<ENTER> No modifications to the handler's setup are required.

MOD SET UP ? YESPress the <SET UP> key if no changes to the handler's setup are required.

Press the <ENTER> key to make changes to the handler's setup. The handler will now scroll through all of the setup routines listed below. See "Modifying Setup" on page 3-31 for details regarding each setup.


Model 1050 Handler Status and Error Messages MOTOR [A, B, or C] BUSY ?

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

MOTOR [A, B, or C] BUSY ?The taper is checking to see if the stepper motor is moving as required for each of the follow-ing taper components.

♦ A = tape drive♦ B = swing arm♦ C = octoloader

If this message does not go away within a few seconds, the taper will not operate. To resolve this condition:

1. Turn the taper power OFF then ON and try again.

2. Verify that the motor control cable is plugged in and is not broken.

3. Replace the motor driver module and/or the motor control PCB.

4. Contact Exatron for assistance and replacement parts.

MOTOR <A, B, or C> ERROR ?The taper is checking to see if the stepper motor is powering up properly as required for each of the following handler components.

♦ A = tape drive♦ B = swing arm♦ C = octoloader

If this message does not go away within a few seconds, the taper will not operate. To resolve this condition:

1. Turn the taper power OFF then ON and try again.

2. Verify that the motor control cable is plugged in and is not broken.

3. Replace the motor driver module and/or the motor control PCB.

4. Contact Exatron for assistance and replacement parts.

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



MOTOR B OFFYou 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 suc-tion cup.

Press the <CLEAR> key to turn the swing arm motor back on. Then press the <3> key to rotate the swing arm back up.

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

MOTOR HOMEThis message is part of the routine for automatically resetting the taper’s 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:


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

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

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

NEW TAPE SET UP?In Manual mode, you have pressed the <1> key. You can now select the tape size to use.

<1> = "RUN 5 X 5 MLF"

<2> = "RUN 4 X 4 MLF"

<3> = "RUN SSOIC"


Model 1050 Handler Status and Error Messages NO POCKET? ERROR

<4> = "RUN DEFAULT 4"


NO POCKET? ERRORNo carrier tape was found in the tape track.

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

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

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

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

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

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

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

OUTPUT CHECKYou have pressed <DIAGNOSTICS>, <2>. From here you can test the cylinders and sole-noids.



Press the <1> key to test outputs by using intermittent action.

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

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

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

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

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

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

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

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


Model 1050 Handler Status and Error Messages PLACE PART ERR

Press the <3> key on the front panel controller to activate the Automatic Centering feature. The following sequence of messages will be displayed while the rotation motor moves the pickup head into proper operating alignment:

FIND MOTOR HOME JOG ROTATE JOG UP MOTOR HOME

Press <ENTER> or <RUN> to start the system running again.

PLACE PART ERRThe device failed to be picked up at the pickup site.

POCKETS = ######This message is displayed after you have pressed the <TOTALS> key. It shows the total num-ber of devices placed in tape pockets, up to 999,999, since the last time the count was reset to zero.

After the count is reset to zero, the display reads: POCKETS = 000000. See "RESET COUNT YES" on page 5-17.

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

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

RESET COUNT NOThe 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 YESThe 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.

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

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

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

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

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

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

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

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

RUN UNTIL 1 PASSInspection has failed at the beginning of a new tape because of empty leader pockets. You have pressed the <2> key. Now the empty pockets will be advanced until the camera inspects a good device; then the inspection routine will begin.


Model 1050 Handler Status and Error Messages SEN0-7 01234567

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

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

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

SET # INPUTSYou have pressed <DIAGNOSTICS>, <3., <3>, <8>. This message refers to the number of input tubes used, as stored in RAM address 009C: "Octo 8/4 Tubes".

<1> key = "8 TUBE INPUT"—uses all 8 input tubes.

<2> key = "4 TUBE INPUT"—uses 4 input tubes; alternating tracks.

<3> key = "OCTOLOADER OFF"—allows operator to drop devices down input track, bypassing octoloader.

<CLEAR> = Resets to the beginning of the taper's "SET # INPUTS" loop.


SET GAP ? NO/YESThis proposes to re-find the gap between the leading edges of two adjacent tape pockets. See "Understanding the Gap" on page 3-32 and "Setting Tape Pocket Gap" on page 3-34 for details.

<ENTER> key = Press to display current settings. The display reads "GAP STEPS = ####", then "OFFSET = ####".

<SET UP> key = "SET GAP ? YES" then press <ENTER> to set the gap.

SET OFFSET = ####You can type a different offset number if necessary, to get the tape pocket center under the swing arm’s 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.



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

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

SORT = 12345678This is a future option port.

STOP MODE ON/OFF You have pressed the <9> key while in RUN mode or a waiting mode.

Stop and loop modes are for testing and troubleshooting of the taper. Select one of the follow-ing keypad choices.






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.




Model 1050 Handler Status and Error Messages SWING HEAD CHECK

<ENTER> = Executes the next Stop mode action.

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

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

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

TAKE UP MOTOR CKYou have activated the takeup motor check feature by pressing the <5> key on the front con-trol panel when the taper was in RUN mode. Pressing the <5> key turns the takeup motor for five seconds or until the takeup arm switch is thrown, while the above status message is dis-played. 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 ERRYou have activated the takeup motor check feature by pressing the <5> key on the front con-trol 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 FULLThis message advises that the current taping job is complete, that is, the full tape count has been reached. You can press <ENTER> to reset the count to zero and begin operation again.

Or, you may create a tape leader of fifty empty sealed pockets by pressing <DELETE> first. This will run the takeup reel and tape drive motors with the sealing heads engaged to create a tape leader of fifty empty sealed pockets for a new reel. Use this feature when you intend to cut the tape at the leader and separate the full reel from the rest of the tape.

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

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

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

THANK YOU #One or more identifier numbers are displayed following the words THANK YOU. The handler is exiting a jam routine correctly. The handler will resume operation at the end of the two-sec-ond THANK YOU delay.

If your handler is displaying excessive THANK YOU messages, contact Exatron and report the number displayed with the THANK YOU message. This number indicates the source of the former error and what part of the program the handler was in just prior to displaying THANK YOU.

0 = shown after an index jam, "INDEX/STACK JAM," has been cleared

1 = shown after a swing arm homing error, "RETURN ERROR," has been cleared

2 = shown after a loader jam, "LOADER JAM," has been cleared by dropping devices down to the stack pin


Model 1050 Handler Status and Error Messages THERMAL OR PSA ?

3 = shown after an optional temperature alarm check has been cleared

4 = shown after a tape gap error, "TAPE GAP LOST," has been cleared and the gap sensor has found the tape gap again

5 = shown after a loader jam, "LOADER JAM," has been cleared by removing devices so that none are at the stack pin

6 = shown after the <PAUSE> key has been pressed and then unpaused

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

UART OUT ERRORThe handler's UART has detected an error. Turn the handler OFF, then ON and try again.

If the problem continues, replace the handler's CPU PCB.

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

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

VAC NOT ADJUSTEDThe 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 manu-ally 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 select-ing 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 4-14.

ZERO COUNT ERRThe operator has set the tape full quantity to 000000.

Set the count for more than 0000. See "FULL T = ######" on page 5-8.


Chapter 6: Servicing and Troubleshooting

Chapter OverviewThis chapter discusses the following maintenance tasks and their frequency:

Preventive maintenance on the Model 1020 is fairly simple. Following this schedule will help to assure your Model 1020 handler will continue to perform properly.

Seal Head MaintenanceIf 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.

Task Recommended Frequency

Page

Seal Head Maintenance As needed 6-1Air Regulator Maintenance As needed 6-3 Checking Air Regulator Shutoff Valve Monthly 6-3 Adjusting Air Pressure on the Regulator As needed 6-4 Adjusting Air Valves As needed 6-5 Checking the Moisture/Dirt Trap in the Air Regulator Weekly 6-6Solenoid Maintenance As needed 6-9Fiberoptic Photoelectric Sensor Guidelines As needed 6-10

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.


Model 1020 Manual Chapter 6: Servicing and Troubleshooting

Pressure-Sensitive HeadsIf 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 HeadsDisassemble 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


Air Regulator Maintenance Checking Incoming Air from the House Supply

Air Regulator MaintenanceYour 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.

The air regulator assembly includes an oil/water particulate trap which should be visually inspected on occasion. This regulator should be set at factory air pressure of 50 PSI.

Checking Incoming Air from the House SupplyThe first step in ensuring a trouble-free air supply is to ensure the incoming air is adequate.

◊ Make sure the incoming air supply is at least 3 CFMs (cubic feet per minute).

◊ Make sure the needle on the taper’s air regulator is not spiking or pulsing. If it is, the house air supply is inadequate.

Checking Air Regulator Shutoff ValveCheck the operation of the shutoff valve once a month.

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.

CAUTION: Never operate any Exatron equipment that requires compressed air without an approved air regulator and shutoff valve.

To check the operation of the shutoff valve:



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

If the air regulator is turned off, turn it on by turning the on/off knob one quarter-turn counter-clockwise. 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.

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.

To adjust the air pressure:

On/off switch in ON position

Adjustment valve

On/off switch in OFF position


Air Regulator Maintenance Adjusting Air Valves

Adjusting Air ValvesPressurized air for the air cylinders at the test sites is controlled by a series of 24-volt DC air valves mounted on a manifold block. Each air valve is wired through an override button which will turn the valve on while it is pressed (Figure 6-4).

Figure 6-4: Air Valves with Control Adjustment

1. Turn the lock nut counterclockwise to unlock the adjustment knob.

2. Turn the air flow control adjustment knob:

> Turn the knob clockwise to lessen the air flow, or...

> Turn the knob counterclockwise to increase air flow.

3. When air flow is appropriate, turn the lock nut clockwise to tighten it.

To adjust the air flow at the air valve:

Air flow control adjustment knob

Lock nut



Checking the Moisture/Dirt Trap in the Air RegulatorCheck 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 sug-gest the air supply to the system is too wet and/or dirty.

Various models of air regulators differ. Here is one procedure.

1. Unscrew the small black screw at the bottom of the filter chamber and remove. If water is present, there is water in the air lines and you have a problem that you must correct.

Figure 6-5: Air Regulator with Small Black Screw Removed

2. Unscrew the metal casing.

CAUTION: Excessive moisture in the system can damage the air valves.

To check or replace the air filter:


Air Regulator Maintenance Checking the Moisture/Dirt Trap in the Air Regulator

Figure 6-6: Metal Casing Unscrewed

3. Snap off the clear glass casing.

Figure 6-7: Clear Glass Casing Snapped Off

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

Large black screw



Figure 6-8: Large Black Inner Screw Removed

5. Remove the white filter and clean or replace if necessary, and reassemble in reverse order.

If you find it necessary to clean the trap and/or filter more often than once a month, you should correct the problem at your in-house air compressor. Check your manufacturer’s manual for the exact procedure necessary.

Filter


Solenoid Maintenance Checking the Moisture/Dirt Trap in the Air Regulator

Solenoid Maintenance

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

♦ Keep the solenoids as clean as possible.

♦ If the taper is used with devices that have excessive mold flash, the solenoids will require cleaning regularly. The frequency is dependent upon how much mold flash gets into the solenoids.

♦ When cleaning solenoids, do not put excessive stress on solenoid wiring. Check all wiring for signs of wear, exposed conditions, or broken connections. Replace as needed with identical type of wire: standard or flex, same gauge, insulation, color, etc.

♦ When cleaning solenoids, check the plungers to be sure there are no burrs of any kind on their shafts.

♦ Solenoid life is proportional to the handler environment and how often the sole-noids are cleaned. We recommend that all solenoids be replaced every two mil-lion 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.

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



Fiberoptic Photoelectric Sensor GuidelinesClean dust off the sensor optics with a very low blast of air.

Each sensor on your handler is connected to a sensor controller, which displays whether the sensor is "seeing" any object. Most fiberoptic sensor controllers are set to L-ON (light on) by Exatron. This causes the output transistor to turn on when light is received by the sensor.

Figure 6-10: Sensor Controller Set to L-ON

Figure 6-11: Green and Red Indicator Lights

The green light is the Stable Operation Indicator. When the sensor is operating normally under stable conditions, the green light should be ON.


Fiberoptic Photoelectric Sensor Guidelines Checking the Moisture/Dirt Trap in the Air Regulator

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

Figure 6-12: Conditions of Indicator Lights

For both types of sensor (through-beam and reflective), the red light on means nothing is there; nothing is blocking or reflecting the sensor beam. If the red light is off, something is there, interfering with the sensor beam.

For information on fine-tuning the fiberoptic photoelectric sensor and controller, see the ven-dor’s manual.




Chapter 7: Parts List

This chapter contains the following main sections:

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 ListThis 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 genera-tion. 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.

Topic PageGuide to the Parts List 7-1Lists of Parts 7-4


Model 1020 Manual Chapter 7: Parts List

Exatron (Part Number)The first column contains the number assigned by Exatron to a specific part; for example, 8000-D14 or PET-R44. The part number usually has two sections or number/letter sets.

The first set of alphanumeric characters (e.g. 1900, 8000, PET, TAPE) indicates the model number of the system for which the part was originally designed. We use designs of parts from different models to lower inventory costs and to speed the design of custom handlers.

The next three alphanumeric characters (e.g. 906, C06, P14) are simply the numerical count of the part as it was designed. These are the three characters that are stamped or laser marked onto most machined parts.

Exatron occasionally uses additional letters or numbers to indicate special features. We use R and L to specify right and left hand parts. AM or HR will indicate parts for Ambient Machines or Hot Rails. We use 62 or 75 to indicate specific sizes of solenoid plungers. There are other special notations that may be used as part of our numbering system and that may change with time. Please contact the Exatron factory for assistance with any questions regarding special letters or numbers attached to part numbers.

Part Quantity ColumnsThe next two or three columns indicate the quantity of the specific part used in the manufac-ture 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.

ManualEach row that has a 1 in this column has a corresponding wiring print in this manual. The print is identified by the part number.

DescriptionThis 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.

AssemblyThis column indicates which major system sub-assembly the part belongs to.

In most cases, the "Assembly" can be ordered as a complete replacement part.

SizeThese 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.


Guide to the Parts List Finish

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.

FinishThis 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-lubri-cated, 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.

C

A

B


Model 1020 M

anual C

hapter 7: Parts List

7-4 Lists of Partse base machine.

Page7-47-6

ZE FINISH WIDTH

NONE

2-8.250 NEDOX .316 CPT

-.937 BLUE

-.984 HCR

-.984 HCR

-1.000 BLUE

0-8.000 NEDOX .170 TSSOP

2-8.250 NEDOX

0-8.000 NEDOX

8-2.550 NONE

2-8.250 NEDOX

0-8.000 NEDOX

0-10.750 NICKEL

-1.127 NICKEL

Copyright ©

Exatron, 2010

10/2010

Two parts lists are on the following pages. The first is for the changeover kits; the second is for th

List ForTAPE 1020 170 SSOIC 4X4 5X5 MLF AXSEM 9-28-2010 Changeover kitsTAPE MODEL 1020 BASE MACHINE 8-24-2010 Base machine

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

EXATRON1020 170

037 SSOIC CO KIT

1020 4X4 MLF CO

KIT

1020 5X5 MLF CO

KIT

MAN-UAL DESCRIPTION ASSEMBLY SI

1 1 1 TAPE MASTER PARTS LIST TAPE TAPE

2500-101-75-A 1 1 1 MODIFIED SOLENOID PLUNGER

INDEX SP-75

2710-060-G 1 INPUT TUBE HOLDER OCTOLOADER .245-1.86

2710-061-B 8 8 8 TUBE CLAMP OCTOLOADER .250-.500

2710-150-L-D1 4 4 4 LEFT CHAMBER STOP OCTOLOADER .500-.632

2710-150-R-D1 4 4 4 RIGHT CHAMBER STOP OCTOLOADER .500-.632

2710-432-B2 4 4 4 PIVOT BLOCK OCTOLOADER .468-.694

2710-B46-A 1 .170 TSSOP OCTO TRAY OCTOLOADER .237-2.55

2710-J32-B 1 INPUT HOLDER 4X4 LCC CP-.230

OCTOLOADER .245-1.86

2710-J33-B 1 4X4 LCC OCTO TRAY OCTOLOADER .232-2.55

2710-J34-A 4 4 4 CLEAR OCTO TRAY GUIDE OCTOLOADER .125-1.25

2710-J57-A 1 INPUT HOLDER 5 X 5 LCC CP-.268


2710-J58-A 1 5 X 5 LCC OCTO TRAY OCTOLOADER .232-2.55

5000-717-V 1 1 1 OCTO INPUT BASE PLATE OCTOLOADER .250-8.00

5000-D02-C 2 2 2 OCTO PLATE ROLLER OCTOLOADER .312-.500

Lists of Parts

Finish

10/201

0-8.000 NEDOX

375 OD, BRONZE

NONE

T NONE SOIC

-.942 NEDOX

-1.765 NICKEL

0-9.949 NEDOX 5 X 5

0-9.949 NEDOX 4 X 4

-9.098 NONE

-.937 BLACK

9-2.637 NICKEL

-7.50 NONE

0-9.949 NEDOX .170 TSSOP

T

-.438 NICKEL

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

ZE FINISH WIDTH

0C

opyright © E

xatron, 20107-5

5000-N11-A 1 1 1 OCTOLOADER TUBE PUSH UP BAR


BEA16-213 2 2 2 BALL BEARING BALL BEARING .125 ID, ..16 THK

HRD03-100 1 1 1 BLACK BUMP ON DANCER ARM

PNE024-001 1 1 1 KNOCK AIR CYLINDER 1/4 BORE, 1/4 STROKE

TAPE OUT

PNE042-414 1 1 1 4 MM VACUUM CUP SWING HEAD 4 MM

SOL1-002 1 1 1 SIZE 75 SOLENIOD 1050 INDEX SEE PAR

TAPE-540-B 1 1 1 CA OUT GATE OUT GATE .312-.375

TAPE-541-B 1 1 1 OUT CYLINDER MOUNT OUT GATE .875-.987

TAPE-702-E 1 TAPE OUT BOTTOM RAIL 5 X 5 MLF

TAPE OUT .300-1.50

TAPE-703-E 1 TAPE OUT BOTTOM RAIL 4 X 4 MLF

TAPE OUT .300-1.50

TAPE-705-C 2 2 2 UNDER SOL TAPE OUT TOP GUIDE

UNDER SOL .020-.375

TAPE-736-B 1 1 1 PICK UP BUMPER MOUNT OUTPUT RAIL .125-.540

TAPE-929-B 1 1 1 STACK SOLENOID MOUNT INDEX .250-1.89

TAPE-930-B 1 1 1 STOP PIN BLOCK INDEX .437-.585

TAPE-931-B 1 TAPE OUT BOTTOM RAIL .170 TSSOP

BOTTOM RAIL .300-1.50

TAPE-932-A 1 1 1 1 1020 BOTTOM RAIL ASSEMBLY ASSEMBLY SEE PRIN

TAPE-950-A 2 2 2 DECELERATOR MOUNT BLOCK

CO KIT RAIL .207-.250

EXATRON1020 170

037 SSOIC CO KIT

1020 4X4 MLF CO

KIT

1020 5X5 MLF CO

KIT

MAN-UAL DESCRIPTION ASSEMBLY SI

Model 1020 M

anual C


7-6 TAPE MODEL 1020 BASE MACHINE 8-24-2010

FINISH WIDTH

NEDOX

FAB

FAB

NICKEL

NEDOX

NEDOX

FAB

50 RED

33 NICKEL

3 NICKEL

5 NEDOX

0 BLACK

628 RED

FAB

FAB

486 NICKEL

280 NICKEL

21 NEDOX

NONE

5 NONE

5 NONE

NONE

4 NICKEL

Copyright ©

Exatron, 2010

10/2010

EXATRON1020

TAPING MACHINE

MAN-UAL DESCRIPTION ASSEMBLY SIZE

1 TAPE MASTER PARTS LIST TAPE TAPE

2500-048-B1 1 COVER AIR VENT MAIN RAIL SEE PRINT

3000-055-C3 1 1 8085 CPU CARD ELECTRONICS SEE PRINT

3000-202-B 1 3000B BUS BOARD ELECTRONICS SEE PRINT

3000-203-C1 1 OCTO MOTOR COVER OCTOLOADER SEE PRINT

3000-205-L-C 1 CARD CAGE - LEFT MAIN RAIL SEE PRINT

3000-205-R-C 1 CARD CAGE - RIGHT MAIN RAIL SEE PRINT

3000-223-2-B2 1 1 3000B I/O PORT PCB ELECTRONICS SEE PRINT

3000-224-G1 1 OCTO STOP BLOCK OCTOLOADER .687-1.500-1.7

3000-227-B 1 OCTO STOP BLOCK OCTOLOADER .500-1.124-1.3

3000-907-D 1 OCTO SWITCH COVER OCTOLOADER .562-.673-1.03

3044-344-H 1 PIVOT OCTOLOADER .437-.750-1.37

5000-369-B2 1 MOTOR MOUNT OCTOLOADER .375-.834-2.36

5000-370-A2 1 RETURN BLOCK OCTOLOADER 1.093-1.418-1.

5000-397-2-A1 1 1 QUAD STEPPER DRIVER PCB ELECTRONICS SEE PRINT

5000-398-2-C1 1 1 TEST SITE DRIVER PCB ELECTRONICS SEE PRINT

5000-716-D 1 OCTO BEARING SUPPORT OCTOLOADER .500-2.538-15.

5000-718-D 1 OCTO GUIDE BAR OCTOLOADER .375-2.500-16.

5000-720-E1 1 OCTO CAR BLOCK OCTOLOADER .505-1.086-4.4

5000-721-A2 1 OCTO LOADER BEARING OCTOLOADER RSR12MX-320

5000-725-BOT-B 1 INPUT SENSOR MOUNT BLOCK - BOTTOM OCTOLOADER .437-.874-1.18

5000-725-TOP-B 1 INPUT SENSOR MOUNT BLOCK - TOP OCTOLOADER .250-.874-1.18

5000-729-C 1 CHAIN GUARD OCTOLOADER SEE PRINT

5000-735-H1 1 LOWER OCTO SENSOR MOUNT OCTOLOADER .640-.686-2.60

Lists of Parts

Finish

10/201

4 NICKEL

00 BLACK

PAINT

FAB

PAINT

NONE

NONE

NONE

FAB

4 BLACK

.06 THK NONE

NONE/SS

BERG

.25 L NONE

, 6-32 TAP NONE

ALLIED

NG NONE

ALLIED

TAPE MODEL 1020 BASE MACHINE 8-24-2010

FINISH WIDTH

0C

opyright © E

xatron, 20107-7

5000-736-F 1 UPPER OCTO SENSOR MOUNT OCTOLOADER .250-.640-2.60

5000-877-C 1 REGULATOR MOUNT FRAME .375-1.500-3.0

5000-957-A 1 EXATRON NAME PLATE MAIN PLATE SEE PRINT

5000-A89-C3 1 1 FRONT PANEL DRIVER PCB ELECTRONICS SEE PRINT

5000-K01-A 1 EARTH GROUND PLATE MAIN PLATE SEE PRINT

5000-M08-27-A1 1 1 TEST SITE DRIVER CABLE CABLE SEE PRINT

5000-M15-A 1 1 FRONT PANEL CABLE CABLE SEE PRINT

5000-M22-A2 1 1 MOTOR DRIVER CABLE CABLE SEE PRINT

5000-M42-1-A1 1 CABLE TERMINATION PCB MAIN PLATE SEE PRINT

5000-M54-120-A1 1 INPUT POWER LABEL 100-120 VAC POWER SUPPLY SEE PRINT

5000-M54-240-A1 OPT INPUT POWER LABEL 220-240 VAC POWER SUPPLY SEE PRINT

8000-G74-D 1 VAC ATTACH BLOCK SWING HEAD .312-.592-1.24

BEA01-100 4 TEFLON THRUST WASHER CRANK .25 ID,.62 OD,

BEA03-028 1 10 GROVE TIMING BELT PULLEY TAKE UP MOTOR 1/5 PITCH

BEA03-030 1 30 GROVE TIMING BELT PULLEY TAKE UP MOTOR 1/5 PITCH

BEA04-050 1 50 TEETH SPROCKET WHEEL TAPE DRIVE 50 X 4mm

BEA07-002 2 SPROCKET 1.000 DIA., .25 I.D.

BEA09-004 2 SPLIT HUB CLAMPS COVER TAPE GUIDE

.25 ID, .50 OD,

BEA09-014 2 SS SPLIT HUB CLAMP ADJUST SCREW .25 ID. .875 OD

BEA11-018 1 10-32 X 1/4" SHOULDER SCREW PRESSURE ROLLER

BEA11-020 1 10-32 X .37 L SHOULDER BOLT OCTOLOADER #10-32-.37 LO

BEA11-021 1 10-32 X 1/2" SHOULDER SCREW PRESSURE ROLLER

EXATRON1020

TAPING MACHINE


Model 1020 M

anual C


7-8

NONE

7 NONE

D, .16 THK BRONZE

NONE

, .25 L

OD

NONE

LONG

FENWAL

BLACK

BLACK


FINISH WIDTH

Copyright ©

Exatron, 2010

10/2010

BEA12-018 1 MIN-E-PITCH CHAIN OCTOLOADER

BEA12-022 1 MINI-E-PITCH CABLE CHAIN CRANK 300 PITCH .15

BEA12-155 1 55 GROVE TIMING BELT TAKE UP MOTOR 1/5 PITCH

BEA16-213 2 BALL BEARING BALL BEARING .125 ID, .375 O

BEA16-222 4 FLANGED BALL BEARING SEAL HEAD .25 ID, .50 OD

BEA17-070 1 BRONZE SLEEVE BEARING PINCH ROLLER .25 ID, .312 OD

BEA18-050 2 BALL BEARING, PRESS FIT TAKE UP MOTOR .500 ID, 1.125

FUS1-020 1 FUSE HOLDER POWER SUPPLY

FUS2-002 1 2 AMP FUSE POWER SUPPLY

HOT03-240-100-THIN

2 CARTRIDGE HEATERS, 100 WATT SEAL HEAD .250 DIA., 1.18

HOT05-044-J 2 J TYPE THERMACOUPLE SEAL HEAD

HOT06-183 2 SNAP SWITCH 120VAC OPEN AT 170V SEAL HEAD

HOT-07-002-F 2 THERMALCOUPLE CONNECTOR FEMALE J TYPE

HEATER

HOT07-102-M 2 THERMALCOUPLE CONNECTOR MALE J TYPE

HEATER

HRD02-500 1 CLAMP KNOB

HRD02-505 2 HAND CRANK KNOB ADJUST SCREW

ICOS-CY545 3 MOTOR CONTROL CHIP ELECTRONICS

LAB03-007 1 DANGER WATCH YOUR FINGERS LABEL SEE PRINT

LAB03-011 1 DANGER ELECTRICAL HAZARD LABEL LABEL SEE PRINT

LAB03-014 1 CAUTION DO NOT OPERATE WITHOUT GUARDS IN PLACE

LABEL SEE PRINT

MOT05-000-P 3 5 PHASE MOTOR DRIVER ELECTRONICS

MOT05-001 2 STEPPER MOTOR 500 STEP P&P MOTOR

EXATRON1020

TAPING MACHINE


Lists of Parts

Finish

10/201

NONE

NONE

NONE

NONE

NONE

NONE

NONE

"

NONE


FINISH WIDTH

0C

opyright © E

xatron, 20107-9

MOT05-010 1 STEPPER MOTOR 500 STEP WITH 30 : 1 GEAR

DRIVE MOTOR

MOT10-010 1 25 RPM SHADED POLE MOTOR, MAG BRAKE, FAN

TAKE UP MOTOR 110 VAC ONLY

MOT10-011 OPT 25 RPM SHADED POLE MOTOR, MAG BRAKE, FAN

TAKE UP MOTOR 220 VAC ONLY

NRET04-53 2 E-RING PEEL TEST .250 SHAFT

NRET04-80 1 E RING TAKE UP MOTOR .500 SHAFT

PNE002-001 2 RIGHT ANGLE 1/8" TUBE 10-32 FITTING PIVOT CYLINDER

PNE002-005 1 RIGHT ANGLE 1/4' TUBE 1/8 PIPE FITTING PIVOT CYLINDER

PNE004-001 1 "T" 1/8" TUBE 10-32 FITTING PIVOT CYLINDER

PNE013-010 1 MINI REGULATOR M5-.8 THREAD SWING HEAD

PNE015-015-1 1 REGULATOR ASSEMBLY FRAME SEE PART

PNE015-025 1 O-RING .218 ID, .343 OD, .07 DIA. SWING HEAD

PNE015-090 2 O-RING SQUARE PINCH ROLLER 9/16 ID X 1/16

PNE020-350 3 AIR VALVE PIVOT CYLINDER 24 VDC 100W

PNE022-100 1 VAC GENERATOR 2 NC VALVE SWING HEAD

PNE024-002 1 QUICK AIR DISCONNECT MAIN PLATE

PNE025-022 1 AIR CYLINDER INDEX

PNE031-0.5R 2 BIMBA CYLINDER, SPRING OUT PIVOT CYLINDER

PNE042-412 ? 2 MM SUCTION CUP SWING HEAD 2 MM

PNE042-414 ? 4 MM VACUUM CUP SWING HEAD 4 MM

PNE042-416 ? 6 MM VACUUM CUP SWING HEAD 6 MM

PNE042-418 ? 8 MM SUCTION CUP SWING HEAD 8 MM

POW01-070 1 +5 VDC, 13 AMP SWITCHER POWER SUP-PLY

POWER SUPPLY SEE PART

EXATRON1020

TAPING MACHINE


Model 1020 M

anual C


7-1

GRAINGER

STEVEN ENG.

RS-232

NONE

NONE

ONG

NONE

GRAINGER

000 PAINT

000 PAINT


FINISH WIDTH

0C

opyright © E

xatron, 2010 10/2010

POW01-075 1 +24 VDC, 14 AMP SWITCHER POWER SUP-PLY

POWER SUPPLY SEE PART

POW10-025 1 POWER CORD 3 PRONG 8 FT POWER SUPPLY

POW17-003 1 POWER LINE FILTER POWER SUPPLY 6 AMP

REL01-002??? 1 SOLID STATE RELAY DC IN AC OUT

SEM02-305 2 1/32 DIN TEMPERATURE CONTROLLER W/RS-232 110-240 VAC

HEATER 1/32 DIN

SEM02-500 1 OEM MICROTERMINAL ELECTRONICS

SEM02-802 3 SENSOR CONNECTOR ASSEMBLY/PLUG SWING HEAD

SEM02-802 1 THRU BEAM SENSOR ASSEMBLY SWING HEAD

SEM02-803 1 LED/SENSOR PAIR SENSOR SENSOR

SEM03-319 1 KNOCK AIR CYLINDER 1/4 BORE, 3/8 STROKE

P&P MOTOR

SEM03-400 3 FIBER OPTIC AMPLIFIER P&P MOTOR

SEM03-415 2 SCREW IN FIBER OPTIC PROBE P&P MOTOR

SPR240-020-1.00 1 SPRING .020 WIRE .25 DIA. 1.00 L

SPR375-.028-1.50 1 COMPRESSION SPRING PINCH ROLLER

SWT05-100 1 PUSH BUTTON MUSHROOM CAP ASSEM-BLY

POWER SUPPLY

SWT05-111 2 SNAP ON SWITCH ASSEMBLY, 2 RED SWITCHES

POWER SUPPLY

SWT20-020 OPT FOOT SWITCH

TAPE-102-Y 1 BACK PLATE BASE .500-3.500-30.

TAPE-103-W 1 FRONT PLATE BASE .500-3.500-30.

EXATRON1020

TAPING MACHINE


Lists of Parts

Finish

10/201

. NICKEL

. NICKEL

A. NEDOX

0 RED

0 L NONE

. NONE

L NONE

. NONE

. NONE

00 NEDOX

. BLACK

A. RED

A. RED

A. NONE

. NONE

NICKEL

. RED

55 NEDOX

35 NEDOX

5 NEDOX

5 NEDOX

. NICKEL

NONE

500 BLUE


FINISH WIDTH

0C

opyright © E

xatron, 20107-11

TAPE-112-B1 1 SUPPLY REEL HUB BRACKET SUPPLY REEL .250-4.000 DIA

TAPE-114-A2 3 SUPPLY REEL FINGER SUPPLY REEL 2.875-.750 DIA

TAPE-115-C 1 SUPPLY REEL HUB SUPPLY REEL 1.250-1.500 DI

TAPE-116-A 1 SUPPLY REEL GUIDE BRACKET SUPPLY REEL .500-.500-2.50

TAPE-137-A2 6 GUIDE ROD BASE .500 DIA.- 3.63

TAPE-140-1-C 4 SMALL PRESSURE WEIGHT SEAL HEAD .500 -1.000 DIA

TAPE-140-2-A 2 LARGE PRESSURE WEIGHT SEAL HEAD 1.00 DIA., 1.25

TAPE-141-F 2 WEIGHT ROD SEAL HEAD 3.375-.250 DIA

TAPE-142-A 1 KEEPER PIN PINCH ROLLER 1.250-.230 DIA

TAPE-147-C1 1 END PLATE LOCATOR BASE .475-1.000-2.0

TAPE-149-B 1 SUPPLY REEL ROD SPACER SUPPLY REEL .780-1.000 DIA

TAPE-150-C1 1 CLAMP NUT WITH PIN BASE 1.000-1.250 DI

TAPE-150-NP-C1 1 CLAMP NUT WITH NO PIN BASE 1.000-1.250 DI

TAPE-153-B 2 RAIL ADJ. BUSHING ADJUST SCREW 1.125-1.500 DI

TAPE-156-B 2 HEATER ARM STOP HEATER 1.250-.500 DIA

TAPE-157-K2 1 PINCH ROLLER PINCH ROLLER .246-.700 DIA.

TAPE-158-B2 4 TAKE UP & COVER TAPE SPACER BLUE BASE .437-1.000 DIA

TAPE-162-F 1 BACK RIGHT RAIL BASE .062-.750-19.2

TAPE-163-E 1 FRONT RIGHT RAIL BASE .062-.750-19.2

TAPE-164-E1 1 BACK LEFT RAIL BASE .062-.750-9.60

TAPE-165-D 1 FRONT LEFT RAIL BASE .062-.750-9.58

TAPE-173-D1 2 COVER TAPE DISK (LG) COVER TAPE .375-7.500 DIA

TAPE-180-C 2 M16-2 RAIL ADJUSTMENT SCREW ADJUST SCREW .629 DIA. 6.75L

TAPE-181-B 2 M16X2 RAIL ADJ NUT ADJUST SCREW 1.250-1.366-1.

EXATRON1020

TAPING MACHINE


Model 1020 M

anual C


7-1

NONE

65 CLEAR

65 CLEAR

59 CLEAR

. NONE

. NONE

. NONE

0 L NONE

75 BLACK

68 BLACK

880 NICKEL

32 NICKEL

NONE

232 NICKEL

656 BLACK

1020

.000 NEDOX 1020


FINISH WIDTH

2C

opyright © E

xatron, 2010 10/2010

TAPE-187-A 2 CYLINDER BUMPER PIVOT CYLINDER .650-.750 DIA.

TAPE-188-L-B 1 LEFT CYLINDER MOUNT PIVOT CYLINDER .750-1.750-2.1

TAPE-188-R-B 1 RIGHT CYLINDER MOUNT PIVOT CYLINDER .750-1.750-2.1

TAPE-189-C 1 VALVE MOUNT BLOCK PIVOT CYLINDER .750-1.224-1.3

TAPE-190-B 1 1 CYLINDER ASSEMBLIES PIVOT CYLINDER SEE PRINT

TAPE-191-3-A 2 1 SEAL HEAD ASSEMBLY ASSEMBLY SEE PRINT

TAPE-192-B 2 HOT HEAD LABEL SEAL HEAD SEE PRINT

TAPE-195-C1 1 LEFT HEAD PLATE SEAL HEAD .250-2.000 DIA

TAPE-196-C1 1 RIGHT HEAD PLATE SEAL HEAD .250-2.000 DIA

TAPE-198-G 2 HOT SHOE COVER SEAL HEAD .875-2.000 DIA

TAPE-203-B ? 1 ADJUST SCREW ASSEMBLY ASSEMBLY SEE PRINT

TAPE-218-C 1 TAKE UP REEL SHAFT TAKE UP MOTOR .500 DIA., 9.00

TAPE-219-B 2 TAKE UP MOTOR STAND OFF TAKE UP MOTOR .374-2.750-2.8

TAPE-220-D 1 TAKE UP MOTOR MOUNT PLATE TAKE UP MOTOR .375-2.750-5.9

TAPE-221-A 1 1 TAKE UP MOTOR ASSEMBLY ASSEMBLY SEE PRINT

TAPE-222-G 1 ELECTRONICS MAIN PLATE MAIN RAIL .375-9.880-23.

TAPE-223-K 1 ELECTRONICS SIDE PLATE MAIN RAIL .500-5.095-9.7

TAPE-224-K1 1-MOD ELECTRONICS BACK COVER MAIN RAIL SEE PRINT

TAPE-225-B 1 1020 ELECTRONICS SIDE PANEL MAIN RAIL .125-5.187-12.

TAPE-256-C 1 1020 INPUT POWER WIRING POWER SUPPLY SEE PRINT

TAPE-299-C 1 TAPE OUT SWITCH MOUNT BLOCK MAIN RAIL 1.000-1.450-1.

TAPE-303 ENG 1 1020 TAPE MACHINE ASSEMBLY ASSEMBLY SEE PRINT

TAPE-304-B 1 1020 BASE PLATE OCTOLOADER BASE

.250-12.500-36

EXATRON1020

TAPING MACHINE


Lists of Parts

Finish

10/201

.817 PAINT 1020

.817 PAINT 1020

PAINT 1020

89 NEDOX 1020

99 NEDOX 1020

3 NEDOX 1020

NEDOX 1020

0 L BLUE

98 RED 1020

.000 NEDOX 1020

NONE

NONE

0 NEDOX

0 NEDOX

0 NEDOX

NONE

70 NEDOX

50 NICKEL

152 BLUE

PAINT


FINISH WIDTH

0C

opyright © E

xatron, 20107-13

TAPE-305-L-F1 1 1020OCTO LOADER SUPPORT PLATE -LEFT

OCTOLOADER BASE

.375-10.321-14

TAPE-305-R-F1 1 1020 OCTO LOADER SUPPORT PLATE -RIGHT

OCTOLOADER BASE

.375-10.321-14

TAPE-306-A1 1 1020 BACK COVER OCTOLOADER BASE

SEE PRINT

TAPE-307-A 1 SWING HEAD ATTACH BLOCK SWING HEAD .687-1.217-2.6

TAPE-308-G 1 1020 SWING HEAD SWING HEAD .600-1.813-1.9

TAPE-309-C 1 SWING HEAD ATTACH BLOCK SWING HEAD .375-.600-1.02

TAPE-310-1-L 1 ADJUSTABLE PICK UP PLUNGER SWING HEAD .312 DIA. 1.347

TAPE-310-2-L 1 PLUNGER ADJUST SWING HEAD .217 DIA., - .75

TAPE-311-A 1 CO KIT TO OCTO PLATE ATTACH OCTOLOADER BASE

.500-1.500-1.5

TAPE-312-H 1 1020 OCTO MAIN PLATE OCTOLOADER BASE

.250-14.000-22

TAPE-328-B 1 1020 CONTROL - OCTO - SWING HEAD CABLE

CABLE SEE PRINT

TAPE-329-B 1 1020 INTERNAL DRIVER CABLE CABLE SEE PRINT

TAPE-334-F 2 .024" SEAL BLADE SEAL HEAD .024-.539-1.50

TAPE-335-A 1 HOT HEAD BLOCK RIGHT SEAL HEAD .718-.875-1.50

TAPE-336-A 1 HOT HEAD BLOCK LEFT SEAL HEAD .718-.875-1.50

TAPE-339-A 3 WHEEL FELT PAD COVER TAPE .06-1.00 DIA.

TAPE-353-G 1 SWING HEAD PLATE SWING HEAD .375-6.500-7.4

TAPE-355-F 1 CO KIT RAIL MOUNT BLOCK SWING HEAD .375-2.206-2.7

TAPE-356-C 1 VALVE BLOCK SWING HEAD 1.125-1.172-3.

TAPE-360-C 1 SWING HEAD BASE COVER SWING HEAD SEE PRINT

EXATRON1020

TAPING MACHINE


Model 1020 M

anual C


7-1

PAINT

NONE

750 NEDOX

269 PAINT

00 BLACK

8 NICKEL

L NONE

HCR

PAINT

NONE

68 NEDOX

IA. NONE

0 NONE

00 NEDOX

0 NICKEL

20 NEDOX

20 NEDOX

08 NICKEL


FINISH WIDTH

4C

opyright © E

xatron, 2010 10/2010

TAPE-361-C 1 SWING HEAD MAIN COVER SWING HEAD SEE PRINT

TAPE-368-1-A 1 1 1020 FRONT VIEW ASSEMBLY SEE PRINT

TAPE-368-2-A 1 1 1020 SIDE VIEW ASSEMBLY SEE PRINT

TAPE-368-3-A 1 1 TYPE B SWING HEAD ASSEMBLY SEE PRINT

TAPE-368-4-A 1 1 1020 TOP VIEW ASSEMBLY SEE PRINT

TAPE-391-C 1 1020 BOTTOM COVER OCTO STAND SEE PRINT

TAPE-392-F 1 1020/1050 END PLATE MAIN RAIL .500-2.500-10.

TAPE-394-A1 1 1050 SUPPLY REEL BRACKET SUPPLY REEL .375-2.000-20.

TAPE-395-A 1 SUPPLY REEL OFFSET BLOCK SUPPLY REEL .625-1.000-2.0

TAPE-403-F1 2 COVER TAPE STOP BLOCK COVER TAPE GUIDE

.500-.899-1.29

TAPE-404-G 1 COVER TAPE ADJUST BAR COVER TAPE GUIDE

.187 DIA, 4.00

TAPE-419-D 1 1 COVER TAPE GUIDE BLOCK TOOLING COVER TAPE GUIDE

SEE PRINT

TAPE-420-A1 1 1020 POWER SUPPLY BASE POWER SUPPLY SEE PRINT

TAPE-421-A 1 1020 OCTO PLATE CABLE CABLE SEE PRINT

TAPE-422-B1 2 SEAL HEAD ARM SEAL HEAD .500-1.880-3.0

TAPE-423-B 2 SEAL ARM PIVOT POST SEAL HEAD 1.412 L, .750 D

TAPE-424-A 2 SEAL HEAD ADJUST SEAL HEAD .500-.848-1.50

TAPE-426-2-D 1 1020 BACK GUIDE RAIL .093-.750-16.0

TAPE-447-D 2 PSA ROLLER BLOCK PSA ROLLER .500-.500-2.50

TAPE-451-A 1 HEATER PLUG MOUNT BLOCK LEFT SEAL HEADS .625-1.250-1.6

TAPE-452-A 1 HEATER PLUG MOUNT BLOCK RIGHT SEAL HEADS .625-1.250-1.6

TAPE-453-A1 2 HEATER MOUNT COVER SEAL HEADS .625-1.250-1.3

EXATRON1020

TAPING MACHINE


Lists of Parts

Finish

10/201

NICKEL LCC

0 NEDOX

0 L NONE

NONE

L NONE

BLUE

0 HCR 8mm

0 HCR 12mm

5 NICKEL

0 HCR

90 HCR

12 HCR

88 HCR

60 HCR 56mm

BLACK

BLACK

76 NICKEL

5 NICKEL

50 BLACK

L NONE

97 NICKEL

NICKEL


FINISH WIDTH

0C

opyright © E

xatron, 20107-15

TAPE-478-E 1 TOP RAIL SWING HEAD ATTACH BLOCK SWING HEAD .375-.600-1.211

TAPE-482-C1 2 SPOT GUIDE RAIL .155-.937-1.00

TAPE-526-B 1 COVER TAPE ROLLER 1.000 DIA. 3.00

TAPE-670-F2 2 SEAL ROLLER RIM PSA ROLLER .140-.625 DIA.

TAPE-671-F 2 SEAL ROLLER RIM PIN PSA ROLLER .312 DIA. .625

TAPE-677-D 1 TAKE UP SLACK PLATE DANCER SEE PRINT

TAPE-680-C 1? COVER TAPE GUIDE BLOCK 8 MM TAPE GUIDE .500-.575-1.29

TAPE-694-B 1? TRACK COVER TAPE GUIDE BLOCK 12mm 202 TOOLING .500-.735-1.29

TAPE-707-A 1 UNDER SOL INDEX SENSOR MOUNT UNDER SOL .625-.625-1.20

TAPE-723-D 1? COVER TAPE GUIDE BLOCK 16 MM TAPE GUIDE .500-.885-1.29

TAPE-725-B 1? COVER TAPE GUIDE BLOCK 24 MM TAPE GUIDE .500-1.200-1.2

TAPE-726-B 1? COVER TAPE GUIDE BLOCK 32 MM TAPE GUIDE .500-1.290-1.5

TAPE-727-1/2-D 1? COVER TAPE GUIDE BLOCK 44 MM TAPE GUIDE .500-1.290-1.9

TAPE-743-A 1? COVER TAPE GUIDE BLOCK 56mm TAPE GUIDE .500-1.290-2.4

TAPE-748-A 1 FRONT FINE GAP & OUT SENSOR MOUNT RAIL .249-.750-.810

TAPE-749-A 1 BACK FINE GAP & OUT SENSOR MOUNT RAIL .249-.750-.810

TAPE-829-B 1 PINCH ROLLER MOUNT PINCH ROLLER .500-1.000-2.3

TAPE-830-A1 1 PINCH ROLLER SLIDE PINCH ROLLER .437-.437-1.12

TAPE-917-B ??? 1 1010 iVu CAMERA MOUNT ASSEMBLY iVu CAMERA SEE PRINT

TAPE-921-A OPT iVu CAMERA ATTACH iVu CAMERA .375-1.457-1.7

TAPE-926-A 1 MOTOR SHAFT ADAPTOR DRIVE WHEEL .750 DIA. 1.750

TAPE-927-A 1 1020 COVER TAPE SPOOL EXTENSION COVER TAPE .500-1.500-4.4

TAPE-928-A 1 BOTTOM INDEX PIN BLOCK INDEX .250-.375-.403

TAPE-933-10-A 1 1 CAMERA OPTION WIRING WIRING SEE PRINT

EXATRON1020

TAPING MACHINE


Model 1020 M

anual C


7-1

BLACK

0 BLACK

1 BLACK

50 BLACK

NONE

500 BLACK

CARR


FINISH WIDTH

6C

opyright © E

xatron, 2010 10/2010

TAPE-933-1-B 1 1 1020 INPUT POWER WIRING WIRING SEE PRINT

TAPE-933-2-A 1 1 1020 CARD CAGE & MOTOR DRIVER WIR-ING

WIRING SEE PRINT

TAPE-933-3-A 1 1 SEAL HEAD HEATER WIRING WIRING SEE PRINT

TAPE-933-4-A 1 1 1020 TAPE I/O PORT PCB WIRING SEE PRINT

TAPE-933-5-A 1 1 TAKE UP MOTOR WIRING WIRING SEE PRINT

TAPE-933-6-A 1 1 1020 SENSOR/VALVE WIRING WIRING SEE PRINT

TAPE-933-7-A 1 1 TYPE B SWING HEAD WIRING WIRING SEE PRINT

TAPE-933-8-A 1 1 1020 AIR CIRCUIT WIRING SEE PRINT

TAPE-933-9-A 1 1 1020 OCTOLOADER WIRING WIRING SEE PRINT

TAPE-937-A 1 iVu SLIDE BLOCK 1020 MOD 1020 TAPE-919

TAPE-938-A 1 iVu CAMERA POST 1020 MOD CAMER MOUNT .500-.875-6.00

TAPE-939-A 1 1020 CAMERA MOUNT ATTACH BLOCK CAMER MOUNT .375-.500-2.25

TAPE-940-B 1 iVu X SLIDE BLOCK 1020 MOD CAMER MOUNT .500-2.501-3.2

TAPE-941-B 1 ELECTRONICS BACK COVER 1020 MOD COVER SEE PRINT

TAPE-949-A 1?? RING LIGHT MOUNT CAMERA 1.000-1.155-1.

VIS130-070-12 OPT iVu CAMERA iVu CAMERA

VIS130-071-6 OPT iVu CAMERA CABLE iVu CAMERA

WIR01-325 12 "SPRIAL WRAP SEAL HEAD

EXATRON1020

TAPING MACHINE


Chapter 8: PrintsList of Prints

The following prints are included in this chapter:

Part Number Description Page

3000-055-C3 8085 CPU CARD 8-3

3000-223-2-B2 3000B I/O PORT PCB 8-4

5000-397-2-A1 QUAD STEPPER DRIVER PCB 8-5

5000-398-2-C1 TEST SITE DRIVER PCB 8-6

5000-A89-C3 FRONT PANEL DRIVER PCB 8-7

5000-M08-27-A1 TEST SITE DRIVER CABLE 8-8

5000-M15-A FRONT PANEL CABLE 8-9

5000-M22-A2 MOTOR DRIVER CABLE 8-10

TAPE-190-B CYLINDER ASSEMBLIES 8-11

TAPE-191-3-A SEAL HEAD ASSEMBLY 8-12

TAPE-203-B ADJUST SCREW ASSEMBLY 8-13

TAPE-221-A TAKE UP MOTOR ASSEMBLY 8-14

TAPE-368-1-A 1020 FRONT VIEW 8-15

TAPE-368-2-C 1020 SIDE VIEW 8-16

TAPE-368-3-A TYPE B SWING HEAD 8-17

TAPE-368-4-A 1020 TOP VIEW 8-18

TAPE-419-D COVER TAPE GUIDE BLOCK TOOLING 8-19

TAPE-917-B 1010 iVu CAMERA MOUNT ASSEMBLY 8-20

TAPE-932-A 1020 BOTTOM RAIL ASSEMBLY 8-21

TAPE-933-10-A CAMERA OPTION WIRING 8-22

TAPE-933-1-B 1020 INPUT POWER WIRING 8-23

TAPE-933-2-A 1020 CARD CAGE & MOTOR DRIVER WIRING 8-24

TAPE-933-3-A SEAL HEAD HEATER WIRING 8-25

TAPE-933-4-A 1020 TAPE I/O PORT PCB 8-26

TAPE-933-5-A TAKE UP MOTOR WIRING 8-27


Model 1020 Manual Chapter 8: Prints

How to View the PrintsIf you are viewing this chapter online in a PDF viewer, you can enlarge any print so you can see small details. Click on the PDF viewer’s magnification tool, which may have an appear-ance like a magnifying glass.

TAPE-933-6-A 1020 SENSOR/VALVE WIRING 8-28

TAPE-933-7-A TYPE B SWING HEAD WIRING 8-29

TAPE-933-8-A 1020 AIR CIRCUIT 8-30

TAPE-933-9-A 1020 OCTOLOADER WIRING 8-31

Part Number Description Page


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

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IndexAair filter 1-3air pressure 6-4

fittings 1-3air regulator 3-19, 6-3, 6-4air supply 1-3, 6-3air valve adjustment 6-5ASCII values 3-47, 3-53

Bbuttons, EMO (emergency stop) 1-1, 2-6

Ccalibration

carrier tape track width 3-3device placement in tape pocket 3-26heat seal heads 3-12octoloader 3-20pressure seal heads 3-15

camera sensors 4-13carrier tape track 3-3cautions and warnings

avoid turning power off and on in rapid cycles 3-29

changing motor speeds can damage machine 3-46connect power to grounded outlet 1-3don’t do diagnostic "MOVE TAPE RIGHT" with

tape present 4-6, 4-16don’t interfere with moving parts 1-1don’t leave on index solenoid 4-5, 4-15don’t lubricate lead screws 6-1don’t lubricate solenoids 6-9don’t touch adhesive tape to carrier tape 3-12don’t touch hot taper seal heads 3-13don’t unplug air hose when air regulator on 1-2don’t use cleaners on bearings or lead screws 6-1don’t use machine without approved air regulator

1-2keep away from moving parts 1-1loosen track width locking knob before turning

adjustment knobs 3-4power off system before maintenance 6-1prevent excess moisture in air regulator and air

valves 6-6Change RAM mode 3-44changeover kit settings 3-46

control panel 2-3, 4-2, 5-1keys 3-30messages 5-1 to 5-24

countstape full 3-48, 3-49totals 3-35, 3-36

Ddecimal values 3-47, 3-53devices

changeover kit settings 3-46totals 3-35, 3-36

Diagnostics mode 4-2, 4-3displays

control panel 3-30, 5-1 to 5-24heater controller 3-22

drive gear adjustment knob 3-7drive gear. See tape drive

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

Fflowcharts

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

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

Hheat seal heads

adjusting position 3-12adjusting pressure 3-14

— continued on next column —

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heat seal heads — continuedmessages 5-15setting temperature 3-21stopping 2-6

heater controller display 2-5, 3-22heater fuse 2-5hex values 3-47, 3-53home positions

octoloader 2-9swing arm 2-18

Iindex pin 2-2, 2-6, 2-18input reel. See supply reelinstallation 1-4interface, RS-232 3-47

Kkeys

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

LLoop mode 3-35

MManual mode 3-37, 3-38, 3-39, 4-2manual, user’s

typography significance 1-8version number significance 1-7

modesChange RAM 3-44Diagnostics 4-2Loop 3-35Manual 3-37, 3-38, 4-2messages 5-6, 5-12


modes — continuedModify Setup 3-31Run 3-28, 3-29, 4-2Stop 3-26, 3-35

Modify Setup mode 3-31, 3-33motors 2-7

messages 5-6, 5-7, 5-13, 5-14octoloader 2-9, 3-20, 3-29RAM addresses 3-49, 3-50, 3-51speeds 3-46swing arm 4-17takeup reel 2-3, 2-4, 3-43, 3-49, 5-21tape drive 2-4, 3-49, 3-50, 3-51, 4-16

Ooctoloader 2-9

aligning 3-20bypassing 5-15home position 2-9homing 3-29loading input tubes 3-16messages 5-15movement 4-20stop block 3-21tube gates 2-11, 3-17

offset 3-32output reel. See takeup reeloverride button lights 2-5

Ppassword 3-39, 4-2photos, taper parts 2-3 to 2-21pickup head 2-2

RAM addresses 3-48pickup site sensors 4-12pins

index 2-2, 2-6, 2-18octoloader gate 2-11snap-on 2-10stack 2-2, 2-6, 2-18

Polish notation 3-34, 3-35, 3-39, 5-19positions

octoloader home 2-9pickup site 2-2swing arm home 2-18tape pocket 2-2top of index pin 2-2top of stack pin 2-2

power-down 3-29

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power-up 3-19message sequence 3-20, 3-31

pressure roller block 2-4, 2-5pressure seal heads 2-5, 2-19, 3-15procedures. See tasks

RRAM addresses

changing 3-44, 3-45, 5-5list 3-47loading default 3-44, 5-11, 5-12, 5-17types of values 3-47

reels 2-3, 3-2RS-232 interface 3-47Run mode 3-28, 3-29, 4-2

Ssafety 1-1 to 1-4

see also cautions and warningstraining responsibilities 1-1

sealing heads 2-3, 2-8, 2-18adjusting PSA 3-15adjusting thermal 3-12messages 5-6, 5-23RAM addresses 3-47, 3-48

sealing tape 3-8, 3-11, 3-14selecting 3-31, 3-34

sensors 2-3, 2-13 to 2-18camera 4-13Carrier Tape Out 2-13, 2-17cleaning optics 6-10Device at Pickup Site 2-13, 2-14Device at Stack 2-13, 2-14Empty Pocket 2-5, 2-13, 2-15fiberoptic controllers 6-10Gap 2-13, 2-16lights 2-5Out-of-Pocket 2-13, 2-16pickup site 4-12Swing Arm Home 2-13, 2-18Takeup Arm 2-13, 2-17tape 4-11

solenoidsmaintenance 6-9testing 4-14, 4-15

stack pin 2-2, 2-6, 2-18Stop mode 3-26, 3-35supply reel 3-2support services 1-5, 1-6

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

Ttakeup arm 3-6takeup reel 2-3, 3-2

messages 5-21motor 2-3, 2-4, 3-43, 5-21RAM addresses 3-49

tapecalibrating position 4-16carrier

direction of movement 2-3loading 3-5messages 5-8, 5-21, 5-22sensors 4-11

gap 3-32offset 3-32output

full count 3-48output, full count 3-34, 3-48, 3-49sealing 3-8, 3-11, 3-14, 3-34sensors 2-13 to 2-17

tape drivecalibrating position 4-16gear 2-4, 3-6messages 5-6, 5-8, 5-11, 5-14RAM addresses 3-49, 3-50, 3-51

taperend-of-life disposal 1-6facilities requirements 1-2installation 1-4operation overview 2-2powering down 3-29powering up 3-19requirements

electrical 1-2environmental 1-2pressurized air 1-3

taper partssee also individual part namesair pressure fittings 1-3air regulator 6-4carrier tape track 3-3chains 2-7control panel 2-3, 3-30, 4-2, 5-1


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taper parts — continuedcover foot 2-6drive gear adjustment knob 3-7Emergency Stop button 1-1EMO (emergency stop) button 2-6guide block 3-10, 3-12heater controller display 2-5heater fuse 2-5index pin 2-2motors 2-7octo stop block 3-21octoloader 2-9, 3-16, 3-20octoloader gates 2-11override button lights 2-5photos 2-3 to 2-21pickup site 2-2pressure roller block 2-4, 2-5seal heads

heat 2-4, 2-19, 3-12, 3-21pressure 2-19, 3-15

sensor lights 2-5sensors 2-5, 2-13 to 2-18stack pin 2-2swing arm 2-2

pickup head 2-2, 2-20takeup arm 3-6takeup reel 2-3tape drive gear 2-4, 3-6taper input track 2-2, 2-5track width adjustment knobs 3-3track width locking knob 2-5, 3-3tubes 3-16

tasksadjusting air flow 6-5adjusting air pressure 6-4adjusting position of heat seal heads 3-12adjusting position of PSA heads 3-15adjusting pressure of heat seal heads 3-14adjusting PSA pressure 3-16adjusting tape track width 3-4aligning octoloader 3-20calibrating device placement in tape pocket 3-26changing digits in settings 3-34, 3-35, 3-39, 5-19changing RAM settings 3-44checking air filter 6-6checking air regulator 6-3checking air regulator moisture/dirt trap 6-6checking air supply from house generator 6-3displaying totals 3-36homing octoloader 3-29loading carrier tape 3-5loading sealing tape 3-8mounting supply reel 3-2


tasks — continuedmounting takeup reel 3-2powering down system 3-29powering up taper 3-19pre-power-up check 3-19resetting totals 3-36securing input tubes on octoloader 3-17setting temperature for heat seal 3-22starting production run 3-29turning off temperature for heat seal 3-25using Manual mode 3-39

temperatures, setting 3-21thermal seal heads. See heat seal headstotals

displaying 3-36resetting 3-35

track width adjustment knobs 3-3track width locking knob 2-5, 3-3, 3-4tubes, input 2-9, 3-16typography significance 1-8

Wwarnings. See cautions and warningswarranty agreement 1-3, 1-4, 1-5, 6-1

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Documents

Model 1020 Manual