Adjustments and Maintenance SO2000

8/13/2019 Adjustments and Maintenance SO2000

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SO2000

Documentation

Adjustments and Maintenance

Internet: www.rasco.de Email: [email protected]

Rasco Rasco GmbH Rasco Automation Asia PTE LTD3210 Scott Blvd. Geigelsteinstr. 6 25 International Business ParkSanta Clara, CA 95054 83059 Kolbermoor #03-20 German CentreUSA Germany Singapore, 609916Tel. (408)727 7110 Tel. +49 (8031) 2337-0 Tel. +65 6562 8836

Copyright by Rasco GmbH / 2008


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sco Adjustments and Maintenance

2008.Sep.22 Adjustments And Maintenance SO2000.Doc page 2 of 286

1 Common adjustments .................................................................................................................101.1 Fiber optic amplifier ........................................................................................................... 101.2 Connection of the fiber optic ............................................................................................. 101.3 Vacuum Sensor Adjustment ............................................................................................. 111.4 Cylinder reed sensor adjustment ...................................................................................... 121.5 Singulator Tapper Adjustment .......................................................................................... 121.6 Stroke Limitation of Singulator Holder .............................................................................. 131.7 Unloader to Sorter Distance Level Compensation............................................................ 14

2 Manu Tube Loader ....................................................................................................................... 162.1 Gripper ............................................................................................................................. 16

2.1.1 Gripper tilt angle .......................................................................................................... 162.1.2 Tube Centering Gripper ............................................................................................... 172.1.3 Gripper placement ...................................................................................................... 17

2.1.3.1 Right/Left placement Tube to Track ...................................................................... 172.1.3.2 Front/back placement Tube to Track ..................................................................... 18

2.2 Singulator .......................................................................................................................... 182.2.1 Stroke Limitation of Singulator Holder ......................................................................... 20

3 Auto Tube Loader ..........................................................................................................................213.1 Input Stack ....................................................................................................................... 21

3.1.1 Stack width ................................................................................................................... 213.1.2 Stack length ................................................................................................................ 213.1.3 Tube support ............................................................................................................... 223.1.4 Tube centering ............................................................................................................ 23

3.2 Transport ........................................................................................................................... 233.2.1 Transport adjustments ................................................................................................. 233.2.2 Detection of tube in Transport ..................................................................................... 24

3.3 Gripper ............................................................................................................................. 253.3.1 Gripper tilt angle .......................................................................................................... 253.3.2 Loader-Gripper level .................................................................................................... 263.3.3 Tube Centering Gripper .............................................................................................. 273.3.4 Gripper Placement ...................................................................................................... 27

3.3.4.1 Right/left placement Track(Gripper) to Track(Singulator) ....................................... 283.3.4.2 Front/back placement Tube to Track ...................................................................... 293.3.4.3 Side placement Tube to Track ................................................................................ 30

3.3.5 Tube docked sensor adjustment .................................................................................. 303.4 Singulator ......................................................................................................................... 31

3.4.1 Air Jet Singulator .......................................................................................................... 343.4.2 Stroke Limitation of Singulator Holder ......................................................................... 34

3.5 Transport and Gripper speed ........................................................................................... 343.5.1 Transport to stack/track ............................................................................................... 343.5.2 Gripper in/out .............................................................................................................. 353.5.3 Gripper up/down .......................................................................................................... 36

3.6 Tube Pusher Adjustment .................................................................................................. 363.7

Long Tube Handling .......................................................................................................... 37

3.7.1 Middle Stack ................................................................................................................ 373.7.2 Middle Transport .......................................................................................................... 38

3.8 Auto Tube Loader Stopper Blade Adjustments ................................................................ 383.8.1 Tube to Track Adjustments .......................................................................................... 383.8.2 Side Alignment ............................................................................................................. 383.8.3 High Alignment ............................................................................................................. 393.8.4 High Level Stopper Blade ............................................................................................ 39

3.8.4.1 Light Sensor Stopper Blade .................................................................................... 403.8.4.2 Tube in Centering Position ..................................................................................... 413.8.4.3 Tube Docked Sensor .............................................................................................. 41

3.8.5 Gripper & Stopper Blade Speed .................................................................................. 433.8.5.1 Grippershifter to out position .................................................................................. 433.8.5.2

Grippershifter to in position (Gripper down)............................................................ 44

3.8.5.3 Grippershifter to in position (Gripper up) ................................................................ 453.8.5.4 Stopper Blade Speed Adjustment .......................................................................... 46

4 Bowl Loader (SOT) ....................................................................................................................... 48


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4.1 Level compensation ......................................................................................................... 484.1.1 Nominal Turn dimension ............................................................................................. 484.1.2 Height level to Singulator track ................................................................................... 484.1.3 Transit Bowl to Track .................................................................................................. 49

4.2 Bowl Adjustments ............................................................................................................ 504.2.1 Gap to Singulator track ............................................................................................... 504.2.2 Displacement of Bowl and Singulator track ................................................................. 514.2.3 Bowl output (vibration) ................................................................................................. 514.2.4 Frequency Adjustments Bowl Controller ..................................................................... 52

4.2.4.1 Internal limitation of bowl vibrator speed ................................................................ 534.2.5 Air ejectors in bowl ....................................................................................................... 544.2.6 Air Ejectors Adjustment on Base Track Bowl .............................................................. 55

4.2.6.1 Air Ejector #1 .......................................................................................................... 554.2.6.2 Air Ejector #2 .......................................................................................................... 564.2.6.3 Air Ejector #3 .......................................................................................................... 564.2.6.4 Air Ejector #4 .......................................................................................................... 57

4.2.7 Air Jet Bowl (Top guiding) ............................................................................................ 574.2.8 Air Transport Singulator .............................................................................................. 584.2.9 Air Jet Singulator ......................................................................................................... 594.2.10 Air Jet Vision Buffer and Turn 180 ............................................................................... 60

4.3 Bowl Singulator ................................................................................................................ 604.3.1 Singulator Scale ........................................................................................................... 604.3.2 Device length ............................................................................................................... 614.3.3 Stopper shaft ............................................................................................................... 614.3.4 Stroke Limitation of Singulator Holder ......................................................................... 62

4.4 Turn 180 ............................................................................................................................ 624.4.1 Turning end positions .................................................................................................. 624.4.2 Stopper Cylinder .......................................................................................................... 63

4.5 Air Ionizer Adjustments ..................................................................................................... 644.6 Vision System Programming ............................................................................................ 65

5 Bowl Loader (QFN) ........................................................................................................................ 655.1 Level compensation ......................................................................................................... 65

5.1.1 Nominal Turn dimension .............................................................................................. 655.1.2 Height level to Singulator track ................................................................................... 665.1.3 Transit Bowl to Track .................................................................................................. 67

5.2 Bowl Adjustments ............................................................................................................. 685.2.1 Gap to Singulator track ............................................................................................... 685.2.2 Displacement of Bowl and Singulator track ................................................................. 685.2.3 Bowl output (vibration ) ................................................................................................ 695.2.4 Air ejectors on bowl .................................................................................................... 695.2.5 Flip Check Adjustment ................................................................................................ 70

5.2.5.1 Adjust sensor point diameter .................................................................................. 705.2.5.2 Adjust sensor position ............................................................................................. 715.2.5.3 Initial Reset (SET Mode)......................................................................................... 725.2.5.4 Amplifier Adjustment ............................................................................................... 72

5.2.6 Air Transport Singulator .............................................................................................. 745.2.7 Air Jet Singulator .......................................................................................................... 755.2.8 Air Jet Vision Buffer, Turn 90 and Turn 180 ................................................................ 76

5.3 Bowl Singulator ................................................................................................................ 765.3.1 Singulator Scale ........................................................................................................... 765.3.2 Device length .............................................................................................................. 775.3.3 Stopper shaft ............................................................................................................... 775.3.4 Stroke Limitation of Singulator Holder ......................................................................... 78

5.4 Turn 90 ............................................................................................................................. 785.4.1 Turning end positions ................................................................................................. 78

5.5 Turn 180 ........................................................................................................................... 795.5.1 Turning end positions ................................................................................................. 795.5.2 Stopper Cylinder ......................................................................................................... 80

5.6

Flipper .............................................................................................................................. 81

5.7 Flipper Side Adjustment .................................................................................................... 815.8 Air Ionizer Adjustments ..................................................................................................... 825.9 Vision System Programming ............................................................................................. 82


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5.10 Camera Adjustments ....................................................................................................... 825.10.1 Horizontal Camera Alignment ..................................................................................... 825.10.2 Sharpness adjustment ................................................................................................ 835.10.3 Lens Adjustment ......................................................................................................... 845.10.4 Exposure Adjustment .................................................................................................. 85

6 Auto Magazine Loader .................................................................................................................. 866.1 Magazine Dimensions Adjustments .................................................................................. 86

6.1.1 Stack width ................................................................................................................... 866.1.2 Stack length ................................................................................................................. 86

6.2 Centering Adjustment ....................................................................................................... 876.2.1 Magazine width Adjustment ......................................................................................... 87

6.3 Gripper Adjustment ........................................................................................................... 886.3.1 Gripper distance ........................................................................................................... 886.3.2 Gripper Speed .............................................................................................................. 886.3.3 Transport width Adjustment ......................................................................................... 896.3.4 Transport Endstop Adjustment .................................................................................... 896.3.5 Transport Speed .......................................................................................................... 90

6.4 Swing Adjustment ............................................................................................................. 906.4.1 Swing up/down Speed Adjustment .............................................................................. 91

6.5 Turn Unit .......................................................................................................................... 936.5.1 Turn End Position ....................................................................................................... 93

6.6 Centering Adjustment ....................................................................................................... 936.6.1 Stopper Pin Height Level ............................................................................................. 94

6.7 Shuttle Adjustment ............................................................................................................ 956.7.1 Shuttle L & R position .................................................................................................. 956.7.2 Shuttle High Level Adjustment ..................................................................................... 966.7.3 Air Jet Shuttle ............................................................................................................... 986.7.4 Speed Adjustment Shuttle ........................................................................................... 986.7.5 Air Jet Debounce ......................................................................................................... 99

6.8 Flipper Adjustment .......................................................................................................... 1006.8.1 Endstop Adjustment ................................................................................................... 1006.8.2 Side Level Compensation .......................................................................................... 1016.8.3 Air Jet Adjustment ...................................................................................................... 102

6.9 Singulator Adjustments ................................................................................................... 1036.9.1 Air Jet Singulator Holder ............................................................................................ 1046.9.2 Stroke Limitation of Singulator Holder ....................................................................... 105

6.10 Magazine Drive Adjustment ............................................................................................ 1056.10.1 Speed Magazine Drive Adjustment ........................................................................... 105

6.11 Lift stack inner/stack outer ............................................................................................. 1066.12 Air Vibrator Adjustment ................................................................................................... 106

7 Chamber .......................................................................................................................................1087.1 Singulator adjustment ..................................................................................................... 108

7.1.1 Stroke Limitation Upper Lever ................................................................................... 1097.2 Adjusting Holder and Opener Cylinder .......................................................................... 1097.3 Exchanging Fans ........................................................................................................... 111

7.3.1 Cover removal ............................................................................................................ 1117.3.2 Fan removal ............................................................................................................... 1137.4 LN2 Pressure .................................................................................................................. 1157.5 Fan installation ............................................................................................................... 116

7.5.1 Fan speed control ...................................................................................................... 1177.6 Temperature calibration .................................................................................................. 118

7.6.1 Calibration kit ............................................................................................................ 1187.6.2 Sensor placement ...................................................................................................... 118

7.6.2.1 PTB Temperature Sensor Holder ........................................................................ 1187.6.2.2 RPTB Temperature Sensor Holder ...................................................................... 119

7.6.3 Insulation Plate .......................................................................................................... 1207.6.4 Calibration Table ........................................................................................................ 121

8

Plunger (Belly Bar) ......................................................................................................................123

8.1 Level compensation ........................................................................................................ 1238.1.1 Lead Support ............................................................................................................ 123

8.2 Change of stroke-depth .................................................................................................. 124


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8.2.1 Exchange of plunger guidings .................................................................................. 1248.2.2 Activating stroke limitation ......................................................................................... 1258.2.3 Adjusting the reed sensors for load and test position ................................................ 125

8.2.3.1 Load Position Adjustment ..................................................................................... 1258.2.3.2 Test Position Adjustment ...................................................................................... 127

8.3 Lead support width adjustment ...................................................................................... 1278.4 Stopper cylinder .............................................................................................................. 1308.5 Plunger Speed Control Adjustments ............................................................................... 132

9 Plunger (RPTB) ............................................................................................................................1349.1 Level compensation ........................................................................................................ 134

9.1.1 Base Track ................................................................................................................. 1349.1.2 Guiding Opener .......................................................................................................... 1359.1.3 Pin 1 position adjustment ........................................................................................... 135

9.1.3.1 CS1 and CS2 ........................................................................................................ 1359.1.3.2 Opener Cylinder Adjustment ................................................................................ 1379.1.3.3 CS3 and CS4 ........................................................................................................ 138

9.2 Guiding Opener ............................................................................................................... 1399.3 Vacuum Sensor adjustment ............................................................................................ 1409.4 Adjusting the reed sensors for load and test position ..................................................... 141

9.4.1 Load Position Adjustments ........................................................................................ 1429.4.2 Test Position Adjustment ........................................................................................... 143

9.5 Plunger Speed Control Adjustments ............................................................................... 14310 Contactor .....................................................................................................................................144

10.1 Kelvin .............................................................................................................................. 14410.1.1 Standard .................................................................................................................... 144

10.1.1.1 Level Compensation Stop Dog ............................................................................. 14410.1.1.2 Spring adjustment ................................................................................................. 144

10.1.2 ESX-Series ................................................................................................................ 14610.2 Plunge to Board (PTB) .................................................................................................... 146

10.2.1 Johnstech (JTI) .......................................................................................................... 14610.2.1.1 Level Compensation ............................................................................................. 146

10.2.2 Over Travel compensation ......................................................................................... 14710.3 Real Plunge to Board (RPTB) ......................................................................................... 14810.3.1 Rasco Pogo ............................................................................................................... 148

10.3.1.1 Level Compensation ............................................................................................. 14810.3.2 Over Travel compensation ......................................................................................... 148

11 Sorter ...........................................................................................................................................15011.1 Level compensation ........................................................................................................ 150

11.1.1 Sorter Turn Base Plate ............................................................................................. 15011.1.2 Turn 180 ..................................................................................................................... 151

11.2 Turn Unit ........................................................................................................................ 15111.2.1 Turn End Position ..................................................................................................... 15111.2.2 Stopper Cylinder Adjustment ..................................................................................... 152

11.3 Sorter Base Unit ............................................................................................................. 15411.3.1

Shuttle Belt Tension .................................................................................................. 154

11.3.2 Sorter Belt - new design - Tension ............................................................................ 15611.3.3 Shuttle belt gear track adjustment .......................................................................... 157

11.3.3.1 Pulley Position Adjustment ................................................................................... 15811.3.4 Sorter Front Plate Removing ..................................................................................... 15811.3.5 Sorter Teaching ........................................................................................................ 15911.3.6 Double Drop light sensor adjustment ........................................................................ 162

11.3.6.1 Focus-size adjustment .......................................................................................... 16211.3.6.2 Focus adjustment in longitudinal direction ............................................................ 16311.3.6.3 Focus adjustment in longitudinal direction with scale (new sensor holder) .......... 16311.3.6.4 Horizontal focus adjustment ................................................................................ 16411.3.6.5 Focus intensity adjustment .................................................................................. 164

12 Tape & Reel ..................................................................................................................................16512.1 Basic Adjustments ......................................................................................................... 165

12.1.1 Reel Clutch Adjustment ............................................................................................ 16512.1.1.1 Function Reel Clutch ........................................................................................... 16512.1.1.2 Adjusting Reel Clutch Torque ............................................................................... 165


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12.2 Level compensation ....................................................................................................... 16512.2.1 Turn 180 ..................................................................................................................... 16512.2.2 Handling Area ........................................................................................................... 16712.2.3 Lead Buffer ................................................................................................................ 16712.2.4 Taper Turn ................................................................................................................ 167

12.3 Handling Area Adjustments ............................................................................................ 16712.3.1 Adjustments Mark Buffer ........................................................................................... 167

12.3.1.1 Option Mark Inspection ......................................................................................... 16712.3.1.2 Laser Marking ....................................................................................................... 16712.3.2 Adjustments Lead Buffer ........................................................................................... 168

12.3.2.1 Option 3D Lead inspection .................................................................................. 16812.3.2.2 Option Scratch Inspection ................................................................................... 168

12.3.3 Adjustments Turn ...................................................................................................... 16812.3.3.1 Adjust the Turn to Entry position: ....................................................................... 16812.3.3.2 Adjust the Turn to Exit position: ......................................................................... 16812.3.3.3 Stopper Cylinder .................................................................................................. 169

12.3.4 Adjustment Centering ............................................................................................... 16912.3.4.1 Function of the Centering .................................................................................... 16912.3.4.2 Side Guiding width at the Centering ..................................................................... 170

12.3.5 Adjusting Manual Exits .............................................................................................. 17012.3.5.1 Function of the Manual Exits ............................................................................... 17112.3.5.2 Position Exit 1 ....................................................................................................... 17112.3.5.3 Reed sensor at Exit 1 ........................................................................................... 17212.3.5.4 Position Exit 2 ....................................................................................................... 17212.3.5.5 Reed sensor at Exit 2 ........................................................................................... 17212.3.5.6 Position Exit 3 ....................................................................................................... 17312.3.5.7 Reed sensor at Exit 3 ........................................................................................... 17312.3.5.8 Position Exit 4 ....................................................................................................... 17312.3.5.9 Reed sensor at Exit 4 ........................................................................................... 17312.3.5.10 Manual Exit driving speed .................................................................................... 173

12.4 Taping Area Adjustments ............................................................................................... 17412.4.1 Pickup Adjustments ................................................................................................... 174

12.4.1.1 Pick Up Stop Position Adjustment ........................................................................ 17412.4.1.2 Vacuum Head Adjustment .................................................................................... 17712.4.1.3 90 Turn Position Adjustment ............................................................................... 17712.4.1.4 Pick Up Head Position .......................................................................................... 17812.4.1.5 Centering Stopper Adjustments ............................................................................ 17912.4.1.6 Tape Stopper Adjustment ..................................................................................... 180

12.4.1.6.1 Shock Absorber Tape ...................................................................................... 18112.4.1.7 Pick Up Speed Adjustments ................................................................................. 182

12.4.2 Pick & Place Unit (Belt System) ................................................................................. 18312.4.2.1 Basic OPI Setup Configuration ............................................................................. 18312.4.2.2 Turn Cylinder- Synchronisation with Belt and Pickup Head position ................... 18312.4.2.3 Adjustment of the Belt tension .............................................................................. 18512.4.2.4 Adjustment of Pickup at Centering Position ......................................................... 186

12.4.2.4.1 Horizontal Position (Center of Centering) ........................................................ 18612.4.2.4.2 Height Adjustment Pick Up Centering (IC Height Adjustment) ....................... 18612.4.2.5 Adjustment of Pickup at Tape Position ................................................................. 18712.4.2.5.1 X-Y Position Adjustment .................................................................................. 18712.4.2.5.2 Height Adjustment ........................................................................................... 187

12.4.2.6 Adjustment of De-Taping Mode ............................................................................ 18812.4.2.7 Adjustment of Pick Up Axle Bearing ..................................................................... 18912.4.2.8 Device height compensation ................................................................................ 189

12.4.3 Carrier Tape Roller Adjustments ............................................................................... 19012.4.4 Tape Guiding Adjustments ........................................................................................ 191

12.4.4.1 Tape Guiding Width .............................................................................................. 19112.4.4.2 Taper Line height .................................................................................................. 19212.4.4.3 Sealer Inserts ........................................................................................................ 19212.4.4.4 Vertical Tape position ........................................................................................... 19312.4.4.5 Adjusting Indexer belt tensions ............................................................................ 19412.4.4.6 Synchronizing Indexer Wheels ............................................................................. 19512.4.4.7 Driving only with one Index Wheel ....................................................................... 19512.4.4.8 Horizontal Tape Position (Indexer teach procedure ) ........................................... 196


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12.4.5 Adjusting Free Pocket Sensor .................................................................................. 19812.4.6 Cover Tape adjustments ........................................................................................... 198

12.4.6.1 Width of Cover Tape ............................................................................................ 19912.4.6.2 Centering Cover Tape ......................................................................................... 199

12.4.7 Optional In Tape inspection ...................................................................................... 19912.4.8 Sealer Adjustments ................................................................................................... 199

12.4.8.1 Sealer function ..................................................................................................... 19912.4.8.2 Adjusting sealing time .......................................................................................... 20012.4.8.3 Adjusting sealing force ......................................................................................... 20012.4.8.4 Adjusting sealing temperature ............................................................................. 20012.4.8.5 Sealer position adjustment ................................................................................... 200

12.4.8.5.1 Basic Adjustments of Position and Angle with Sealer Gauge ......................... 20012.4.8.5.2 Basic Adjustment of Rotation Angle ................................................................ 20212.4.8.5.3 Level compensation (Fine Tuning) .................................................................. 203

12.5 Adjustment of Motor revolution ....................................................................................... 20512.6 Detaping .......................................................................................................................... 20612.7 Option Dead Bug Sensor (Intape) .................................................................................. 20812.8 Taper Chassis Configuration ......................................................................................... 208

12.8.1 Basis Configuration ................................................................................................... 20812.8.2 Additional Vision Configuration ................................................................................. 208

12.8.2.1 Asentics ................................................................................................................ 20812.8.2.2 ICOS ..................................................................................................................... 20912.9 Basic Vision Setup .......................................................................................................... 209

13 Auto Tube Unloader ...................................................................................................................21013.1 Load Stack / Back Stack ................................................................................................ 210

13.1.1 Stack width ................................................................................................................ 21013.1.2 Stack length .............................................................................................................. 21013.1.3 Tube Centering / Support Transport ......................................................................... 211

13.2 Transport ........................................................................................................................ 21213.2.1 Transport adjustment ................................................................................................ 21213.2.2 Sensor adjustment Tube in Transport .................................................................... 212

13.3 Gripper ........................................................................................................................... 21313.3.1 Tube Centering Gripper ............................................................................................. 21313.3.2 Sensor adjustment Tube in Centering ..................................................................... 21413.3.3 Tube Gripper level adjustment .................................................................................. 214

13.4 Buffer Adjustments .......................................................................................................... 21613.5 Unloader Sorter .............................................................................................................. 217

13.5.1 Unloader to Sorter adjustment .................................................................................. 21713.5.1.1 High level adjustments.......................................................................................... 21713.5.1.2 Side level adjustments .......................................................................................... 219

13.6 Transport and Gripper speed ......................................................................................... 22013.6.1 Transport to load stack/back stack ........................................................................... 22013.6.2 Gripper in/out ............................................................................................................ 22113.6.3 Lift up upper side/lower side ..................................................................................... 221

14 Manu Magazine Unloader ...........................................................................................................22214.1 High level adjustments .................................................................................................... 22214.1.1 Base Track to Sorter Shuttle ...................................................................................... 222

14.1.2 Magazine to Base Track ............................................................................................ 22314.2 Magazine Width Adjustment ........................................................................................... 224

14.2.1 Lower Center Part Adjustment ................................................................................... 22414.2.2 Magazine Centering Adjustment ................................................................................ 224

15 Auto Magazine Unloader ............................................................................................................22515.1 Load Stack / Back Stack ................................................................................................. 225

15.1.1 Stack width ................................................................................................................ 22515.2 Magazine Centering ........................................................................................................ 226

15.2.1 High Level adjustment ............................................................................................... 22615.2.2 Side Level adjustment ............................................................................................... 226

15.3

Transport ......................................................................................................................... 227

15.3.1 Endstop Adjustment ................................................................................................... 22715.3.2 Transport Width Adjustment ...................................................................................... 22715.3.3 Transport Speed Adjustment ..................................................................................... 228


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15.4 Unloader to Sorter ........................................................................................................... 22815.4.1 High Level adjustment ............................................................................................... 228

15.5 Lift back stack up / down ................................................................................................. 22815.6 Lift load stack up / down ................................................................................................. 22915.7 Pusher Adjustments ........................................................................................................ 229

16 Chassis Adjustments .................................................................................................................23016.1 Adjusting Air-Pressure ................................................................................................... 23016.2 Adjusting Pressure Switches ......................................................................................... 23116.3 Basic Adjustment New Sensor ........................................................................................ 233

16.3.1 Display Color Setting ................................................................................................. 23316.3.2 Operation Mode Setting ............................................................................................. 23416.3.3 Output type setting ..................................................................................................... 23416.3.4 Response time setting ............................................................................................... 23416.3.5 Adjusting Pressure Switches ..................................................................................... 235

16.3.5.1 How to Set Value .................................................................................................. 23516.3.6 Zero out (Zero ADJ) function ..................................................................................... 23616.3.7 Key lock function ........................................................................................................ 236

17 Kit and Module exchange ...........................................................................................................23717.1 Manu Tube Loader ......................................................................................................... 237

17.1.1 Mounting the Manu Tube Loader to the Handler ....................................................... 23717.1.2 Kit exchange ............................................................................................................. 23817.1.2.1 Remove Track ...................................................................................................... 23817.1.2.2 Install the new Track ............................................................................................. 241

17.2 Auto Tube Loader ........................................................................................................... 24217.2.1 Mounting the Auto Tube Loader to the Handler ........................................................ 242

17.2.1.1 Fixing Points ......................................................................................................... 24217.2.1.2 Power Supply ........................................................................................................ 243

17.2.2 Kit exchange ............................................................................................................. 24417.2.3 Auto Tube Loader Stopper Blade .............................................................................. 244

17.2.3.1 Kit remove ............................................................................................................. 24417.2.3.2 Kit install ............................................................................................................... 246

17.3 Bowl Loader (SOT) ........................................................................................................ 24717.3.1 Mounting the Bowl Loader (SOT) to the Handler ...................................................... 24717.3.1.1 Fixing Points ......................................................................................................... 247

17.3.1.2 Power Supply ........................................................................................................ 24817.3.2 Kit exchange ............................................................................................................. 249

17.3.2.1 Remove Track ...................................................................................................... 24917.3.2.2 Install the new Track ............................................................................................ 250

17.4 Bowl Loader (QFN) ......................................................................................................... 25017.4.1 Mounting the Bowl Loader (QFN) to the Handler ...................................................... 25017.4.2 Kit exchange ............................................................................................................. 251

17.4.2.1 Remove track ....................................................................................................... 25117.4.2.2 Install the new Kit ................................................................................................. 253

17.5 Auto Magazine Loader .................................................................................................... 25417.5.1 Mounting the Magazine Loader to the Handler ......................................................... 254

17.5.1.1 Fixing Points ......................................................................................................... 25417.5.1.2 Power Supply ........................................................................................................ 25517.5.2 Kit exchange .............................................................................................................. 256

17.5.2.1 Remove Kit ........................................................................................................... 25617.5.2.1.1 Singulator Kit ................................................................................................... 25617.5.2.1.2 Shuttle Kit ........................................................................................................ 257

17.5.2.2 Flipper Kit .............................................................................................................. 25717.5.2.2.1 Flipper Exit Kit.................................................................................................. 25717.5.2.2.2 Turn and Turn exit Kit ...................................................................................... 258

17.5.2.3 Install new Kit ........................................................................................................ 25817.6 Chamber ......................................................................................................................... 259

17.6.1 Kit exchange ............................................................................................................. 25917.6.1.1 Remove Track ..................................................................................................... 25917.6.1.2 Install the new Track ............................................................................................. 261

17.7 Plunger (Belly Bar) .......................................................................................................... 26217.7.1.1 Exchange of plunger guidings ............................................................................. 262

17.7.2 Exchange of plunger .................................................................................................. 262


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17.8 Plunger (RPTB) ............................................................................................................... 26417.8.1 Plunger Exchange...................................................................................................... 264

17.9 Sorter ............................................................................................................................. 26517.9.1 Kit exchange ............................................................................................................. 265

17.9.1.1 Remove Track ..................................................................................................... 26517.9.1.2 Install new Track .................................................................................................. 266

17.10 Tape & Reel .................................................................................................................... 26817.10.1 Basic Adjustments .................................................................................................... 26817.10.1.1 Mounting the Taper to the Handler ...................................................................... 268

17.10.1.1.1 Screws to mount the taper .............................................................................. 26817.10.1.1.2 Track Adjustment Taper to Sorter .................................................................. 26917.10.1.1.3 Connecting the I/O Cables ............................................................................. 270

17.10.2 Kit exchange .............................................................................................................. 27017.10.2.1 Remove Kit ........................................................................................................... 27017.10.2.2 Install Kit ............................................................................................................... 273

17.11 Auto Tube Unloader ....................................................................................................... 27417.11.1 Mounting the Auto Tube Unloader to the Handler ..................................................... 274

17.11.1.1 Fixing Points ......................................................................................................... 27517.11.2 Kit Exchange .............................................................................................................. 275

17.12 Manu Magazine Unloader ............................................................................................... 27717.12.1 Kit Exchange .............................................................................................................. 27717.13 Auto Magazine Unloader ................................................................................................ 27817.13.1 Mounting the Auto Magazine Unloader to the Handler.............................................. 27817.13.2 Kit Exchange .............................................................................................................. 279

18 Preventive Maintenance Checklist ............................................................................................28118.1 Maintenance Activities .................................................................................................... 281

18.1.1 Common .................................................................................................................... 28118.1.2 Tube Loader ............................................................................................................... 281

18.1.2.1 Loader Tube Singulator ........................................................................................ 28118.1.2.2 Gripper .................................................................................................................. 28118.1.2.3 Loader Transport .................................................................................................. 281

18.1.3 Magazine Loader ....................................................................................................... 28218.1.4 Bowl Loader (SOT/QFN) ........................................................................................... 282

18.1.4.1 Handling Section ................................................................................................... 28218.1.4.2 Vision and Lightning ............................................................................................. 28218.1.4.3 Bowl Feeder .......................................................................................................... 282

18.1.5 Handler Base ............................................................................................................. 28218.1.5.1 Chamber Track ..................................................................................................... 28218.1.5.2 Temperature System ............................................................................................ 28318.1.5.3 Singulator .............................................................................................................. 28318.1.5.4 Plunger.................................................................................................................. 28318.1.5.5 Contactor .............................................................................................................. 28318.1.5.6 Front ...................................................................................................................... 283

18.1.6 Sorter ......................................................................................................................... 28318.1.6.1 Turn ....................................................................................................................... 28318.1.6.2 Shuttle ................................................................................................................... 283

18.1.7 Unloader .................................................................................................................... 28418.1.7.1 Tube Unloader ...................................................................................................... 28418.1.7.2 Stack ..................................................................................................................... 28418.1.7.3 Transport .............................................................................................................. 284

18.1.8 Manu Tube Unloader ................................................................................................. 28418.1.9 Manu Magazine Unloader .......................................................................................... 28418.1.10 Unloader General....................................................................................................... 28418.1.11 Tape & Reel ............................................................................................................... 284

18.1.11.1 Handling Section ................................................................................................... 28418.1.11.2 Taping section ...................................................................................................... 28518.1.11.3 Pick up .................................................................................................................. 28518.1.11.4 Sealer Unit ............................................................................................................ 28518.1.11.5

Vision System ....................................................................................................... 285

18.1.12 General ...................................................................................................................... 28518.1.13 Complete ESD Checks, Measure and Record Data .................................................. 286


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1 Common adjustments

1.1 Fiber optic amplifier Set the Operation Mode to L (Output is activated at light detection) Set Timer switch to ON (means OFF-delay timer is activated; 20ms fixed)

Picture 1: Fiber optic amplifier Type E3X-NA41-1

Create situation where the amplifier is receiving light (transition free, tube inserted,...)

Decrease sensitivity until all LEDs are off

Increase sensitivity until all LEDs are on

Increase sensitivity approx. turn (180)

Sensiti vity should be lower than 6!

1.2 Connection of the fiber optic

The best performance of a fiber optic ampli fier requires proper connection of the fiber optic.Cut the plastic fiber optics only with the recommenced tool!

Open clamping lever

Plug in the fiber optic until the O-Ring has been reached feeling resistance.

Slide it through the O-Ring

Close clamping lever


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1.3 Vacuum Sensor Adjustment

Picture 2: Vacuum Sensor

To check the Basic Adjustment it may be necessary to release the Key-Protect Function: Press

the Button into normal sensing mode for at least 4 sec. The reading on the Display shouldbe off . If the reading is on , repeat the procedure!

In the sensing mode the Zero-point can be adjusted by pressing bo th UP key and DOWN keysimultaneously

Initial settings:

Press both UP key and key simultaneously to change from sensing mode to the initialsetting mode

The 3. digit blinks and can be changed with the DOWN key to d for digital display

By pressing the UP key the 2. digit starts to blink and can be changed with the DOWN key to

C for Window comparator mode

By pressing the UP key the 1. digit starts to blink and can be changed with the DOWN key to Pfor kPa (kiloPascal)

Press the MODE key and the Sensor returns to sensing mode.

Supplementary setting:

Press the DOWN key and the MODE key simultaneously to change to the supplementarysetting mode

U-1 and no (Normal open) or nc (Normal closed) is displayed alternately and can bechanged with the DOWN key to no (U-2 and U-3 should remain on the lowest possiblesetting)

Press the MODE key and the Senor returns to sensing mode


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1.4 Cylinder reed sensor adjustment

Picture 3: Reed sensor cylinder

Loosen fixing screws.

Bring cylinder pistol to the position the sensor should detect.

Move the reed sensor from the opposite direction the cylinder pistol was moved to before untilthe red light on the sensor turns on.

Move the reed sensor max. 1mm more in the same direction and tighten the screws.

It is recommended to verify every adjusted Reed sensor w ith the manual cont rol after theadjustment was done.

1.5 Singulator Tapper Adjustment

For the correct working of the singulator tapper are following items important :

The nut has to be fix.

The pogo pin has to be free from play.


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Picture 4: Singulator Tapper

1.6 Stroke Limitation of Singulator Holder

This Adjustment regards this fol lowing modules : Manu / Auto Tube Loader , Bowl Loader(QFN) and Chamber !

The Adjustment should prevent the damage to the device.

The Holder Pin should fixed with a gap about 0.5mm to the device. Loosen Counter Nut

Adjust Stopper

Fix Counter Nut

Picture 5: Stroke Limitation


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Picture 6: Stroke Limitation scematic

1.7 Unloader to Sorter Distance LevelCompensation

This Adjustment regards this following modules : Manu / Auto Tube Unloader , Manu /Auto Magazine Unloader with Buffer and the Tape & Reel !

For a correct adjustment of the distance between Sorter Shuttle Base Track and Unloader Base Track dothe following :

Check the gap between Base Track Unloader and Base Track Sorter (the recommendedgap is 0.2mm).

Remove the Unloader.

Remove fixing screws of Unloader ledge.

Add or remove docking shims (see picture and schematic below).

The nominal value is 0.5mm !

Put on the Unloader ledge and tighten screws.

Mount the Unloader..

Picture 7: Docking Shim Schematic


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Picture 8: Docking Shim


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Picture 10: Gripper tilt angle

2.1.2 Tube Centering GripperTo adjust the Tube Centering do the following:

Insert Tube into Gripper

Turn Centering adjustment nut in or out as needed

The gap between Centering adjustment nut to Guiding Block should habe 1 to 2mm (see picturebelow)

Picture 11: Tube Centering adjustment Gripper

2.1.3 Gripper placementUnder certain circumstances it might be necessary to readjust the gripper placement.

2.1.3.1 Right/Left placement Tube to Track

The right/left positioning can be adjusted by inserting or removing Shims (nominal measure = 0.2mm)

Loosen fixing screws (see picture below)

Insert or remove Shims

Tighten fixing screws again


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Picture 12: right/ left positioning Gripper

2.1.3.2 Front/back placement Tube to Track

To readjust the front/back position of the Gripper, do the following:

Loosen fixing screw (see picture below)

Nesting gripper as needed and tighten fixing screw again

Picture 13: front/back positioning Gripper

2.2 SingulatorFor different device dimensions it is necessary to readjust the singulator:


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Loosen singulator fixing screws (see picture below)

Picture 14: Singulator fixing screws

Reworked Singulator Design

For different device dimensions it is necessary to readjust the singulator:

Loosen lever block fixing screws (see picture below).

Picture 15: Singulator (reworked design) fixing screws

Insert a device

If adjusted correctly, the upper device edge has to be inline with the mark on the Side Guidingsof the Track (see Picture and Schematic below)

For a better adjustment fix the front screw first.

After successful adjustment fix the backside screw.


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Picture 16: Adjustment mark

Picture 17: adjustment schematic

2.2.1 Stroke Limitation of Singulator HolderPlease refer to Common Adjustments chapter.


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3 Auto Tube Loader

3.1 Input Stack3.1.1 Stack widthTo readapt stack width to a new tube width do the following:

Loosen fixing screws at front and back stack (see picture below)

Adjust width by turning the adjustment screw

After adjustment tighten fixing screws again!

Picture 18: Stack width adjustment

3.1.2 Stack lengthTo readapt stack length for a different tube length do the following:

Loosen grub screw located on the right side of the stack assembly (see picture below)


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Picture 19: Grub screw for length adjustment

Now you can shift the stack front to fit the tube length

After adjustment tighten the fixing screw again!

3.1.3 Tube supportTo readapt tube support height for different tube heights do the following:

Loosen tube support fixing screws (see picture below)

Picture 20: Tube support


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Adjust support height

Upper side of Tube Centering and upper side of tube must have the same level!!


3.1.4 Tube centeringTo achieve smooth movement from stack into centering, the centering has to be inline with the stack. Foradjustment do the following:

Loosen centering fixing screws (see picture below)

For adjustment use the eccentric screw (see picture below)

Picture 21: Tube centering


3.2 Transport

3.2.1 Transport adjustments

To adjust Centering of Transport equal with the Stacks and gripper do the following:

Loosen check nut of End Stop screws (see picture below). Turn Stopper in or out until Centering Transport is in alignment with Load Stacks

Lock check nut of end stop stack again!

Repeat the same procedure with the end stop of the gripper position.

Now repeat the procedure with the lower transport .


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Picture 22: Transport position adjustment

3.2.2 Detection of tube in Transport

Since some tubes could be a little bended it migh t become necessary to readjust the tubein t ransport sensor, to assure proper operation.

Picture 23: Sensor fixing screws (back) Picture 24: Sensor fixing screws (front)

Adjust sensor and tighten fixing screws again!


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3.3.2 Loader-Gripper level

During hot or cold running it is possible that the level is changing because of the linearthermal expansion of the chamber base track !

Picture 27: Loader Gripper level

The gap between Plate Gripper and Tube has to be 0 to max. 1mm!! (see picture above)

To adjust the Loader-to the Gripper level do the following:

Loosen Loader fixing screws (see picture below)

Picture 28: Loader fixing screws

Adjust level by turning the adjustment screw (see Picture below)


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Picture 29: Loader-Gripper level adjustment screw

After finishing adjustment tighten fixing screws again!

3.3.3 Tube Centering GripperTo adjust the Tube Centering do the following:

Insert Tube into Gripper

Turn Centering adjustment nut in or out as needed

During adjustment it might be necessary to loosen the Plastic nut.

The gap between Centering adjustment nut to Guiding Block and Plastic nut to Cylinder rodshould have 1 to 2mm. (see picture below)

To adjust the Plastic nut loosen check nut from centering. (see picture below)

Make sure that the gap Plastic nut /Cylinder rod is equal to the gap Centering nut/Guiding Block

Lock check nut from Centering

Picture 30: Tube Centering Gripper adjustment

3.3.4 Gripper PlacementUnder certain circumstances it might be necessary to readjust the gripper Placement.


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3.3.4.1 Right/left placement Track(Gripper) to Track(Singulator)

The right/left positioning can be adjusted by inserting or removing Shims (nominal measure = 0.2mm)

Loosen fixing screws (see picture below)

Insert or remove Shims


Picture 31: right/left positioning


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Picture 32: right/left positioning schematic

3.3.4.2 Front/back placement Tube to Track

To readjust the front/back position of the gripper, do the following:

Loosen the four fixing screws (see picture below)

Picture 33: Front/back positioning

Picture 34: Front/back positioning side view

Position Gripper as needed with the adjustment nut and tighten fixing screws again

After finishing adjustment tighten fixing screws again


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Picture 36: Tube detection sensor schematic

Picture 37: Tube detection sensor

3.4 SingulatorFor different device dimensions it is necessary to readjust the singulator:

Loosen singulator fixing screws (see picture below)


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Picture 38: Singulator fixing screws

Reworked Singulator Design

For a better adjustment tighten front screw first

Picture 39: Reworked Singulator fixing screws

Insert a device

If adjusted correctly, the upper device edge has to be inline with the mark on the Side Guidingof the Track (see picture and schematic below)


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Picture 40: Adjustment mark

Picture 41: Adjustment schematic

Af ter adjustment remember to tighten fixing screws!


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3.4.1 Air Jet Singulator

Picture 42: Air Jet Singulator

3.4.2 Stroke Limitation of Singulator HolderPlease refer to Common Adjustments chapter.

3.5 Transport and Gripper speed

3.5.1 Transport to stack/track Press the Service button in the main screen

Select Auto Tube Loader

Push Transport to stack/track (yellow background)

Adjust throttle until 350/350msare reached

Lock counter nut after successful adjustment

The Values always have to be equal!


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Picture 43: Transport throttles

3.5.2 Gripper in/out Press the Service button in the main screen


Push Gripper in/out (yellow Background) Adjust throttle until 250/350msare reached


Picture 44: Gripper in/out throttles


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3.5.3 Gripper up/down Press the Service button in the main screen


Push Gripper up/down (yellow background)

Adjust throttle until 700/700msare reached


The Values always have to be equal

Picture 45: Gripper up/down throttles

3.6 Tube Pusher AdjustmentTo adjust the tube pusher correct do following steps:

Loosen fixing screws of the cylinder holder (see picture below)

Move the cylinder in a distance of approx. 2mm at least.



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Picture 46: Tube Pusher

3.7 Long Tube Handling

3.7.1 Middle Stack

For long tubes use the tube supports (see picture below)

Picture 47: Middle Stack and Middle Transport

It should be a gap of 0.2mm between the black tube support and the middle hard stop.

Picture 48: Middle Stack Gap


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3.7.2 Middle Transport

Picture 49: Alignment Transport

3.8 Auto Tube Loader Stopper BladeAdjustments

It is highly recommended to do the adjustments in following order !

3.8.1 Tube to Track Adjustments

3.8.2 Side AlignmentTo adjust the side alignment of the tube do following :

Loosen the fixing screws.

Add or remove shims.

After successful adjustment tighten fixing screws again.


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Picture 50: Side Adjustment Picture 51: Side Adjustment schematic

3.8.3 High AlignmentTo adjust the high alignment of the tube do following :

Loosen the fixing screws.

Turn adjustment screw left or right. After successful adjustment tighten fixing screws again.

Picture 52: High Adjustment Picture 53: High Adjustment schematic

3.8.4 High Level Stopper BladeTo adjust the high alignment of the stopper blade do following :

Loosen fixing screws.


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Move the stopper blade until it is around 0.2mm under the contact surface of the basetrack.


Picture 54: Stopper Blade High Adjustment Picture 55: Stopper Blade Adjustment schematic

3.8.4.1 Light Sensor Stopper Blade

To adjust the high alignment of the stopper blade do following :

Loosen fixing grub screws.

Move the sensor until the hole of the sensor flag is coaxial to the marking on the sensor.


Picture 56: Stopper Blade Sensor


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Picture 57: Alignment marking

3.8.4.2 Tube in Centering Position

The tube is in the correct position if there is a gap about 2mm and the sensor is in off status.To adjust the input depth of the tube move the stack plate.

Picture 58: Tube in Centering

3.8.4.3 Tube Docked Sensor

For a correct adjustment of the Tube detection sensor do the following:

Put a tube in and turn up the gripper.

Loosen the fixing screws of the sensor holder.


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Move the sensor to the tube until a gap of 1.5mm is reached.

Tighten the fixing screws of the sensor holder.

Picture 59: Tube Docked Sensor

Picture 60: Tube Docked Sensor schematic

It is possible to choose between three different posi tions for the tube docked sensor, in

cases of a cut out in the front area of the tube (e.g. poka yoke tubes) !


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Picture 61: Three sensor positions

3.8.5 Gripper & Stopper Blade Speed

3.8.5.1 Grippersh ifter to out posi tion

Press the Service button in the main screen


Push Grippershifter (yellow background)

Adjust throttle until 350msare reached


Picture 62: Throttle Grippershifter


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Picture 63: Grippershifter out position

3.8.5.2 Grippersh ifter to in position (Gripper down)






Picture 64: Throttle Grippershifter to in position (down)


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Picture 65: Grippershifter to in position (down)

3.8.5.3 Grippersh ifter to in position (Gripper up)






Picture 66: Throttle Grippershifter to in position (up)


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Picture 67: Grippershifter to in position (up)

3.8.5.4 Stopper Blade Speed Adjustment

Adjust Throttle until a proper speed is reached


Picture 68: Throttle Stopper Blade Speed


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Picture 69: Stopper Blade Speed


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2008.Sep.22 Adjustment

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Adjustments and Maintenance SO2000