Adjustments and Maintenance SO2000

SO2000
Documentation
Adjustments and Maintenance
Internet: www.rasco.de Rasco 3210 Scott Blvd. Santa Clara, CA 95054 USA Tel. (408)727 7110 Copyright by Rasco GmbH / 2008
Email: info@rasco.de Rasco Automation Asia PTE LTD 25 International Business Park #03-20 German Centre Singapore, 609916 Tel. +65 6562 8836
Rasco GmbH Geigelsteinstr. 6 83059 Kolbermoor Germany Tel. +49 (8031) 2337-0
Rasco
1
Common adjustments .................................................................................................................10 1.1 Fiber optic amplifier ........................................................................................................... 10 1.2 Connection of the fiber optic ............................................................................................. 10 1.3 Vacuum Sensor Adjustment ............................................................................................. 11 1.4 Cylinder reed sensor adjustment ...................................................................................... 12 1.5 Singulator Tapper Adjustment .......................................................................................... 12 1.6 Stroke Limitation of Singulator Holder .............................................................................. 13 1.7 Unloader to Sorter Distance Level Compensation............................................................ 14 Manu Tube Loader .......................................................................................................................16 2.1 Gripper ............................................................................................................................. 16 2.1.1 Gripper tilt angle .......................................................................................................... 16 2.1.2 Tube Centering Gripper ............................................................................................... 17 2.1.3 Gripper placement ...................................................................................................... 17 2.1.3.1 Right/Left placement Tube to Track ...................................................................... 17 2.1.3.2 Front/back placement Tube to Track ..................................................................... 18 2.2 Singulator .......................................................................................................................... 18 2.2.1 Stroke Limitation of Singulator Holder ......................................................................... 20 Auto Tube Loader..........................................................................................................................21 3.1 Input Stack ....................................................................................................................... 21 3.1.1 Stack width................................................................................................................... 21 3.1.2 Stack length ................................................................................................................ 21 3.1.3 Tube support ............................................................................................................... 22 3.1.4 Tube centering ............................................................................................................ 23 3.2 Transport ........................................................................................................................... 23 3.2.1 Transport adjustments ................................................................................................. 23 3.2.2 Detection of tube in Transport ..................................................................................... 24 3.3 Gripper ............................................................................................................................. 25 3.3.1 Gripper tilt angle .......................................................................................................... 25 3.3.2 Loader-Gripper level .................................................................................................... 26 3.3.3 Tube Centering Gripper .............................................................................................. 27 3.3.4 Gripper Placement ...................................................................................................... 27 3.3.4.1 Right/left placement Track(Gripper) to Track(Singulator) ....................................... 28 3.3.4.2 Front/back placement Tube to Track ...................................................................... 29 3.3.4.3 Side placement Tube to Track ................................................................................ 30 3.3.5 Tube docked sensor adjustment.................................................................................. 30 3.4 Singulator ......................................................................................................................... 31 3.4.1 Air Jet Singulator.......................................................................................................... 34 3.4.2 Stroke Limitation of Singulator Holder ......................................................................... 34 3.5 Transport and Gripper speed ........................................................................................... 34 3.5.1 Transport to stack/track ............................................................................................... 34 3.5.2 Gripper in/out .............................................................................................................. 35 3.5.3 Gripper up/down .......................................................................................................... 36 3.6 Tube Pusher Adjustment .................................................................................................. 36 3.7 Long Tube Handling .......................................................................................................... 37 3.7.1 Middle Stack ................................................................................................................ 37 3.7.2 Middle Transport .......................................................................................................... 38 3.8 Auto Tube Loader Stopper Blade Adjustments ................................................................ 38 3.8.1 Tube to Track Adjustments .......................................................................................... 38 3.8.2 Side Alignment ............................................................................................................. 38 3.8.3 High Alignment............................................................................................................. 39 3.8.4 High Level Stopper Blade ............................................................................................ 39 3.8.4.1 Light Sensor Stopper Blade .................................................................................... 40 3.8.4.2 Tube in Centering Position ..................................................................................... 41 3.8.4.3 Tube Docked Sensor .............................................................................................. 41 3.8.5 Gripper & Stopper Blade Speed .................................................................................. 43 3.8.5.1 Grippershifter to out position .................................................................................. 43 3.8.5.2 Grippershifter to in position (Gripper down)............................................................ 44 3.8.5.3 Grippershifter to in position (Gripper up) ................................................................ 45 3.8.5.4 Stopper Blade Speed Adjustment .......................................................................... 46 Bowl Loader (SOT) .......................................................................................................................48
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4.1 Level compensation ......................................................................................................... 48 4.1.1 Nominal Turn dimension ............................................................................................. 48 4.1.2 Height level to Singulator track ................................................................................... 48 4.1.3 Transit Bowl to Track .................................................................................................. 49 4.2 Bowl Adjustments ............................................................................................................ 50 4.2.1 Gap to Singulator track ............................................................................................... 50 4.2.2 Displacement of Bowl and Singulator track ................................................................. 51 4.2.3 Bowl output (vibration) ................................................................................................. 51 4.2.4 Frequency Adjustments Bowl Controller ..................................................................... 52 4.2.4.1 Internal limitation of bowl vibrator speed ................................................................ 53 4.2.5 Air ejectors in bowl ....................................................................................................... 54 4.2.6 Air Ejectors Adjustment on Base Track Bowl .............................................................. 55 4.2.6.1 Air Ejector #1 .......................................................................................................... 55 4.2.6.2 Air Ejector #2 .......................................................................................................... 56 4.2.6.3 Air Ejector #3 .......................................................................................................... 56 4.2.6.4 Air Ejector #4 .......................................................................................................... 57 4.2.7 Air Jet Bowl (Top guiding) ............................................................................................ 57 4.2.8 Air Transport Singulator .............................................................................................. 58 4.2.9 Air Jet Singulator ......................................................................................................... 59 4.2.10 Air Jet Vision Buffer and Turn 180 ............................................................................... 60 4.3 Bowl Singulator ................................................................................................................ 60 4.3.1 Singulator Scale ........................................................................................................... 60 4.3.2 Device length ............................................................................................................... 61 4.3.3 Stopper shaft ............................................................................................................... 61 4.3.4 Stroke Limitation of Singulator Holder ......................................................................... 62 4.4 Turn 180 ............................................................................................................................ 62 4.4.1 Turning end positions .................................................................................................. 62 4.4.2 Stopper Cylinder .......................................................................................................... 63 4.5 Air Ionizer Adjustments ..................................................................................................... 64 4.6 Vision System Programming ............................................................................................ 65 5 Bowl Loader (QFN) ........................................................................................................................65 5.1 Level compensation ......................................................................................................... 65 5.1.1 Nominal Turn dimension .............................................................................................. 65 5.1.2 Height level to Singulator track ................................................................................... 66 5.1.3 Transit Bowl to Track .................................................................................................. 67 5.2 Bowl Adjustments ............................................................................................................. 68 5.2.1 Gap to Singulator track ............................................................................................... 68 5.2.2 Displacement of Bowl and Singulator track ................................................................. 68 5.2.3 Bowl output (vibration ) ................................................................................................ 69 5.2.4 Air ejectors on bowl .................................................................................................... 69 5.2.5 Flip Check Adjustment ................................................................................................ 70 5.2.5.1 Adjust sensor point diameter .................................................................................. 70 5.2.5.2 Adjust sensor position............................................................................................. 71 5.2.5.3 Initial Reset (SET Mode)......................................................................................... 72 5.2.5.4 Amplifier Adjustment ............................................................................................... 72 5.2.6 Air Transport Singulator .............................................................................................. 74 5.2.7 Air Jet Singulator.......................................................................................................... 75 5.2.8 Air Jet Vision Buffer, Turn 90 and Turn 180 ................................................................ 76 5.3 Bowl Singulator ................................................................................................................ 76 5.3.1 Singulator Scale ........................................................................................................... 76 5.3.2 Device length .............................................................................................................. 77 5.3.3 Stopper shaft ............................................................................................................... 77 5.3.4 Stroke Limitation of Singulator Holder ......................................................................... 78 5.4 Turn 90 ............................................................................................................................. 78 5.4.1 Turning end positions ................................................................................................. 78 5.5 Turn 180 ........................................................................................................................... 79 5.5.1 Turning end positions ................................................................................................. 79 5.5.2 Stopper Cylinder ......................................................................................................... 80 5.6 Flipper .............................................................................................................................. 81 5.7 Flipper Side Adjustment .................................................................................................... 81 5.8 Air Ionizer Adjustments ..................................................................................................... 82 5.9 Vision System Programming............................................................................................. 82
2008.Sep.22
Rasco
5.10 Camera Adjustments ....................................................................................................... 82 5.10.1 Horizontal Camera Alignment ..................................................................................... 82 5.10.2 Sharpness adjustment ................................................................................................ 83 5.10.3 Lens Adjustment ......................................................................................................... 84 5.10.4 Exposure Adjustment .................................................................................................. 85 6 Auto Magazine Loader ..................................................................................................................86 6.1 Magazine Dimensions Adjustments .................................................................................. 86 6.1.1 Stack width................................................................................................................... 86 6.1.2 Stack length ................................................................................................................. 86 6.2 Centering Adjustment ....................................................................................................... 87 6.2.1 Magazine width Adjustment ......................................................................................... 87 6.3 Gripper Adjustment ........................................................................................................... 88 6.3.1 Gripper distance........................................................................................................... 88 6.3.2 Gripper Speed.............................................................................................................. 88 6.3.3 Transport width Adjustment ......................................................................................... 89 6.3.4 Transport Endstop Adjustment .................................................................................... 89 6.3.5 Transport Speed .......................................................................................................... 90 6.4 Swing Adjustment ............................................................................................................. 90 6.4.1 Swing up/down Speed Adjustment .............................................................................. 91 6.5 Turn Unit .......................................................................................................................... 93 6.5.1 Turn End Position ....................................................................................................... 93 6.6 Centering Adjustment ....................................................................................................... 93 6.6.1 Stopper Pin Height Level ............................................................................................. 94 6.7 Shuttle Adjustment ............................................................................................................ 95 6.7.1 Shuttle L & R position .................................................................................................. 95 6.7.2 Shuttle High Level Adjustment..................................................................................... 96 6.7.3 Air Jet Shuttle............................................................................................................... 98 6.7.4 Speed Adjustment Shuttle ........................................................................................... 98 6.7.5 Air Jet Debounce ......................................................................................................... 99 6.8 Flipper Adjustment .......................................................................................................... 100 6.8.1 Endstop Adjustment ................................................................................................... 100 6.8.2 Side Level Compensation .......................................................................................... 101 6.8.3 Air Jet Adjustment ...................................................................................................... 102 6.9 Singulator Adjustments ................................................................................................... 103 6.9.1 Air Jet Singulator Holder ............................................................................................ 104 6.9.2 Stroke Limitation of Singulator Holder ....................................................................... 105 6.10 Magazine Drive Adjustment ............................................................................................ 105 6.10.1 Speed Magazine Drive Adjustment ........................................................................... 105 6.11 Lift stack inner/stack outer ............................................................................................. 106 6.12 Air Vibrator Adjustment ................................................................................................... 106 Chamber .......................................................................................................................................108 7.1 Singulator adjustment ..................................................................................................... 108 7.1.1 Stroke Limitation Upper Lever ................................................................................... 109 7.2 Adjusting Holder and Opener Cylinder .......................................................................... 109 7.3 Exchanging Fans ........................................................................................................... 111 7.3.1 Cover removal............................................................................................................ 111 7.3.2 Fan removal ............................................................................................................... 113 7.4 LN2 Pressure .................................................................................................................. 115 7.5 Fan installation ............................................................................................................... 116 7.5.1 Fan speed control ...................................................................................................... 117 7.6 Temperature calibration .................................................................................................. 118 7.6.1 Calibration kit ............................................................................................................ 118 7.6.2 Sensor placement ...................................................................................................... 118 7.6.2.1 PTB Temperature Sensor Holder ........................................................................ 118 7.6.2.2 RPTB Temperature Sensor Holder ...................................................................... 119 7.6.3 Insulation Plate .......................................................................................................... 120 7.6.4 Calibration Table ........................................................................................................ 121 Plunger (Belly Bar) ......................................................................................................................123 8.1 Level compensation ........................................................................................................ 123 8.1.1 Lead Support ............................................................................................................ 123 8.2 Change of stroke-depth .................................................................................................. 124
2008.Sep.22
Rasco
8.2.1 Exchange of plunger guidings .................................................................................. 124 8.2.2 Activating stroke limitation ......................................................................................... 125 8.2.3 Adjusting the reed sensors for load and test position ................................................ 125 8.2.3.1 Load Position Adjustment ..................................................................................... 125 8.2.3.2 Test Position Adjustment ...................................................................................... 127 8.3 Lead support width adjustment ...................................................................................... 127 8.4 Stopper cylinder .............................................................................................................. 130 8.5 Plunger Speed Control Adjustments ............................................................................... 132 9 Plunger (RPTB) ............................................................................................................................134 9.1 Level compensation ........................................................................................................ 134 9.1.1 Base Track ................................................................................................................. 134 9.1.2 Guiding Opener.......................................................................................................... 135 9.1.3 Pin 1 position adjustment........................................................................................... 135 9.1.3.1 CS1 and CS2 ........................................................................................................ 135 9.1.3.2 Opener Cylinder Adjustment ................................................................................ 137 9.1.3.3 CS3 and CS4 ........................................................................................................ 138 9.2 Guiding Opener ............................................................................................................... 139 9.3 Vacuum Sensor adjustment ............................................................................................ 140 9.4 Adjusting the reed sensors for load and test position ..................................................... 141 9.4.1 Load Position Adjustments ........................................................................................ 142 9.4.2 Test Position Adjustment ........................................................................................... 143 9.5 Plunger Speed Control Adjustments ............................................................................... 143
10 Contactor .....................................................................................................................................144 10.1 Kelvin .............................................................................................................................. 144 10.1.1 Standard .................................................................................................................... 144 10.1.1.1 Level Compensation Stop Dog ............................................................................. 144 10.1.1.2 Spring adjustment ................................................................................................. 144 10.1.2 ESX-Series ................................................................................................................ 146 10.2 Plunge to Board (PTB) .................................................................................................... 146 10.2.1 Johnstech (JTI) .......................................................................................................... 146 10.2.1.1 Level Compensation ............................................................................................. 146 10.2.2 Over Travel compensation ......................................................................................... 147 10.3 Real Plunge to Board (RPTB) ......................................................................................... 148 10.3.1 Rasco Pogo ............................................................................................................... 148 10.3.1.1 Level Compensation ............................................................................................. 148 10.3.2 Over Travel compensation ......................................................................................... 148 11 Sorter ...........................................................................................................................................150 11.1 Level compensation ........................................................................................................ 150 11.1.1 Sorter Turn Base Plate ............................................................................................. 150 11.1.2 Turn 180..................................................................................................................... 151 11.2 Turn Unit ........................................................................................................................ 151 11.2.1 Turn End Position ..................................................................................................... 151 11.2.2 Stopper Cylinder Adjustment ..................................................................................... 152 11.3 Sorter Base Unit ............................................................................................................. 154 11.3.1 Shuttle Belt Tension .................................................................................................. 154 11.3.2 Sorter Belt - new design - Tension ............................................................................ 156 11.3.3 Shuttle belt gear track adjustment .......................................................................... 157 11.3.3.1 Pulley Position Adjustment ................................................................................... 158 11.3.4 Sorter Front Plate Removing ..................................................................................... 158 11.3.5 Sorter Teaching ........................................................................................................ 159 11.3.6 Double Drop light sensor adjustment ........................................................................ 162 11.3.6.1 Focus-size adjustment .......................................................................................... 162 11.3.6.2 Focus adjustment in longitudinal direction............................................................ 163 11.3.6.3 Focus adjustment in longitudinal direction with scale (new sensor holder).......... 163 11.3.6.4 Horizontal focus adjustment ................................................................................ 164 11.3.6.5 Focus intensity adjustment .................................................................................. 164 12 Tape & Reel ..................................................................................................................................165 12.1 Basic Adjustments ......................................................................................................... 165 12.1.1 Reel Clutch Adjustment ............................................................................................ 165 12.1.1.1 Function Reel Clutch ........................................................................................... 165 12.1.1.2 Adjusting Reel Clutch Torque ............................................................................... 165
2008.Sep.22 Adjustments And Maintenance SO2000.Doc page 5 of 286
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12.2 Level compensation ....................................................................................................... 165 12.2.1 Turn 180..................................................................................................................... 165 12.2.2 Handling Area ........................................................................................................... 167 12.2.3 Lead Buffer ................................................................................................................ 167 12.2.4 Taper Turn ................................................................................................................ 167 12.3 Handling Area Adjustments ............................................................................................ 167 12.3.1 Adjustments Mark Buffer ........................................................................................... 167 12.3.1.1 Option Mark Inspection ......................................................................................... 167 12.3.1.2 Laser Marking ....................................................................................................... 167 12.3.2 Adjustments Lead Buffer ........................................................................................... 168 12.3.2.1 Option 3D Lead inspection .................................................................................. 168 12.3.2.2 Option Scratch Inspection ................................................................................... 168 12.3.3 Adjustments Turn ...................................................................................................... 168 12.3.3.1 Adjust the Turn to Entry position: ....................................................................... 168 12.3.3.2 Adjust the Turn to Exit position: ......................................................................... 168 12.3.3.3 Stopper Cylinder .................................................................................................. 169 12.3.4 Adjustment Centering ............................................................................................... 169 12.3.4.1 Function of the Centering .................................................................................... 169 12.3.4.2 Side Guiding width at the Centering ..................................................................... 170 12.3.5 Adjusting Manual Exits .............................................................................................. 170 12.3.5.1 Function of the Manual Exits ............................................................................... 171 12.3.5.2 Position Exit 1 ....................................................................................................... 171 12.3.5.3 Reed sensor at Exit 1 ........................................................................................... 172 12.3.5.4 Position Exit 2 ....................................................................................................... 172 12.3.5.5 Reed sensor at Exit 2 ........................................................................................... 172 12.3.5.6 Position Exit 3 ....................................................................................................... 173 12.3.5.7 Reed sensor at Exit 3 ........................................................................................... 173 12.3.5.8 Position Exit 4 ....................................................................................................... 173 12.3.5.9 Reed sensor at Exit 4 ........................................................................................... 173 12.3.5.10 Manual Exit driving speed .................................................................................... 173 12.4 Taping Area Adjustments ............................................................................................... 174 12.4.1 Pickup Adjustments ................................................................................................... 174 12.4.1.1 Pick Up Stop Position Adjustment ........................................................................ 174 12.4.1.2 Vacuum Head Adjustment .................................................................................... 177 12.4.1.3 90 Turn Position Adjustment ............................................................................... 177 12.4.1.4 Pick Up Head Position .......................................................................................... 178 12.4.1.5 Centering Stopper Adjustments ............................................................................ 179 12.4.1.6 Tape Stopper Adjustment ..................................................................................... 180 12.4.1.6.1 Shock Absorber Tape ...................................................................................... 181 12.4.1.7 Pick Up Speed Adjustments ................................................................................. 182 12.4.2 Pick & Place Unit (Belt System)................................................................................. 183 12.4.2.1 Basic OPI Setup Configuration ............................................................................. 183 12.4.2.2 Turn Cylinder- Synchronisation with Belt and Pickup Head position ................... 183 12.4.2.3 Adjustment of the Belt tension .............................................................................. 185 12.4.2.4 Adjustment of Pickup at Centering Position ......................................................... 186 12.4.2.4.1 Horizontal Position (Center of Centering)........................................................ 186 12.4.2.4.2 Height Adjustment Pick Up Centering (IC Height Adjustment) ....................... 186 12.4.2.5 Adjustment of Pickup at Tape Position ................................................................. 187 12.4.2.5.1 X-Y Position Adjustment .................................................................................. 187 12.4.2.5.2 Height Adjustment ........................................................................................... 187 12.4.2.6 Adjustment of De-Taping Mode ............................................................................ 188 12.4.2.7 Adjustment of Pick Up Axle Bearing ..................................................................... 189 12.4.2.8 Device height compensation ................................................................................ 189 12.4.3 Carrier Tape Roller Adjustments ............................................................................... 190 12.4.4 Tape Guiding Adjustments ........................................................................................ 191 12.4.4.1 Tape Guiding Width .............................................................................................. 191 12.4.4.2 Taper Line height .................................................................................................. 192 12.4.4.3 Sealer Inserts ........................................................................................................ 192 12.4.4.4 Vertical Tape position ........................................................................................... 193 12.4.4.5 Adjusting Indexer belt tensions ............................................................................ 194 12.4.4.6 Synchronizing Indexer Wheels ............................................................................. 195 12.4.4.7 Driving only with one Index Wheel ....................................................................... 195 12.4.4.8 Horizontal Tape Position (Indexer teach procedure ) ........................................... 196
Rasco
12.4.5 Adjusting Free Pocket Sensor .................................................................................. 198 12.4.6 Cover Tape adjustments ........................................................................................... 198 12.4.6.1 Width of Cover Tape ............................................................................................ 199 12.4.6.2 Centering Cover Tape ......................................................................................... 199 12.4.7 Optional In Tape inspection ...................................................................................... 199 12.4.8 Sealer Adjustments ................................................................................................... 199 12.4.8.1 Sealer function ..................................................................................................... 199 12.4.8.2 Adjusting sealing time .......................................................................................... 200 12.4.8.3 Adjusting sealing force ......................................................................................... 200 12.4.8.4 Adjusting sealing temperature ............................................................................. 200 12.4.8.5 Sealer position adjustment ................................................................................... 200 12.4.8.5.1 Basic Adjustments of Position and Angle with Sealer Gauge ......................... 200 12.4.8.5.2 Basic Adjustment of Rotation Angle ................................................................ 202 12.4.8.5.3 Level compensation (Fine Tuning) .................................................................. 203 12.5 Adjustment of Motor revolution ....................................................................................... 205 12.6 Detaping .......................................................................................................................... 206 12.7 Option Dead Bug Sensor (Intape) .................................................................................. 208 12.8 Taper Chassis Configuration ......................................................................................... 208 12.8.1 Basis Configuration ................................................................................................... 208 12.8.2 Additional Vision Configuration ................................................................................. 208 12.8.2.1 Asentics ................................................................................................................ 208 12.8.2.2 ICOS ..................................................................................................................... 209 12.9 Basic Vision Setup .......................................................................................................... 209 13 Auto Tube Unloader ...................................................................................................................210 13.1 Load Stack / Back Stack ................................................................................................ 210 13.1.1 Stack width ................................................................................................................ 210 13.1.2 Stack length .............................................................................................................. 210 13.1.3 Tube Centering / Support Transport ......................................................................... 211 13.2 Transport ........................................................................................................................ 212 13.2.1 Transport adjustment ................................................................................................ 212 13.2.2 Sensor adjustment Tube in Transport .................................................................... 212 13.3 Gripper ........................................................................................................................... 213 13.3.1 Tube Centering Gripper ............................................................................................. 213 13.3.2 Sensor adjustment Tube in Centering ..................................................................... 214 13.3.3 Tube Gripper level adjustment .................................................................................. 214 13.4 Buffer Adjustments .......................................................................................................... 216 13.5 Unloader Sorter .............................................................................................................. 217 13.5.1 Unloader to Sorter adjustment .................................................................................. 217 13.5.1.1 High level adjustments.......................................................................................... 217 13.5.1.2 Side level adjustments .......................................................................................... 219 13.6 Transport and Gripper speed ......................................................................................... 220 13.6.1 Transport to load stack/back stack ........................................................................... 220 13.6.2 Gripper in/out ............................................................................................................ 221 13.6.3 Lift up upper side/lower side ..................................................................................... 221 14 Manu Magazine Unloader ...........................................................................................................222 14.1 High level adjustments .................................................................................................... 222 14.1.1 Base Track to Sorter Shuttle...................................................................................... 222 14.1.2 Magazine to Base Track ............................................................................................ 223 14.2 Magazine Width Adjustment ........................................................................................... 224 14.2.1 Lower Center Part Adjustment ................................................................................... 224 14.2.2 Magazine Centering Adjustment................................................................................ 224 15 Auto Magazine Unloader ............................................................................................................225 15.1 Load Stack / Back Stack ................................................................................................. 225 15.1.1 Stack width ................................................................................................................ 225 15.2 Magazine Centering ........................................................................................................ 226 15.2.1 High Level adjustment ............................................................................................... 226 15.2.2 Side Level adjustment ............................................................................................... 226 15.3 Transport ......................................................................................................................... 227 15.3.1 Endstop Adjustment ................................................................................................... 227 15.3.2 Transport Width Adjustment ...................................................................................... 227 15.3.3 Transport Speed Adjustment ..................................................................................... 228
Rasco
15.4 15.4.1 15.5 15.6 15.7
Unloader to Sorter ........................................................................................................... 228 High Level adjustment ............................................................................................... 228 Lift back stack up / down................................................................................................. 228 Lift load stack up / down ................................................................................................. 229 Pusher Adjustments ........................................................................................................ 229
16 Chassis Adjustments .................................................................................................................230 16.1 Adjusting Air-Pressure ................................................................................................... 230 16.2 Adjusting Pressure Switches ......................................................................................... 231 16.3 Basic Adjustment New Sensor........................................................................................ 233 16.3.1 Display Color Setting ................................................................................................. 233 16.3.2 Operation Mode Setting ............................................................................................. 234 16.3.3 Output type setting ..................................................................................................... 234 16.3.4 Response time setting ............................................................................................... 234 16.3.5 Adjusting Pressure Switches ..................................................................................... 235 16.3.5.1 How to Set Value .................................................................................................. 235 16.3.6 Zero out (Zero ADJ) function ..................................................................................... 236 16.3.7 Key lock function ........................................................................................................ 236 17 Kit and Module exchange ...........................................................................................................237 17.1 Manu Tube Loader ......................................................................................................... 237 17.1.1 Mounting the Manu Tube Loader to the Handler ....................................................... 237 17.1.2 Kit exchange ............................................................................................................. 238 17.1.2.1 Remove Track ...................................................................................................... 238 17.1.2.2 Install the new Track ............................................................................................. 241 17.2 Auto Tube Loader ........................................................................................................... 242 17.2.1 Mounting the Auto Tube Loader to the Handler ........................................................ 242 17.2.1.1 Fixing Points ......................................................................................................... 242 17.2.1.2 Power Supply ........................................................................................................ 243 17.2.2 Kit exchange ............................................................................................................. 244 17.2.3 Auto Tube Loader Stopper Blade .............................................................................. 244 17.2.3.1 Kit remove ............................................................................................................. 244 17.2.3.2 Kit install ............................................................................................................... 246 17.3 Bowl Loader (SOT) ........................................................................................................ 247 17.3.1 Mounting the Bowl Loader (SOT) to the Handler ...................................................... 247 17.3.1.1 Fixing Points ......................................................................................................... 247 17.3.1.2 Power Supply ........................................................................................................ 248 17.3.2 Kit exchange ............................................................................................................. 249 17.3.2.1 Remove Track ...................................................................................................... 249 17.3.2.2 Install the new Track ............................................................................................ 250 17.4 Bowl Loader (QFN) ......................................................................................................... 250 17.4.1 Mounting the Bowl Loader (QFN) to the Handler ...................................................... 250 17.4.2 Kit exchange ............................................................................................................. 251 17.4.2.1 Remove track ....................................................................................................... 251 17.4.2.2 Install the new Kit ................................................................................................. 253 17.5 Auto Magazine Loader .................................................................................................... 254 17.5.1 Mounting the Magazine Loader to the Handler ......................................................... 254 17.5.1.1 Fixing Points ......................................................................................................... 254 17.5.1.2 Power Supply ........................................................................................................ 255 17.5.2 Kit exchange .............................................................................................................. 256 17.5.2.1 Remove Kit ........................................................................................................... 256 17.5.2.1.1 Singulator Kit ................................................................................................... 256 17.5.2.1.2 Shuttle Kit ........................................................................................................ 257 17.5.2.2 Flipper Kit .............................................................................................................. 257 17.5.2.2.1 Flipper Exit Kit.................................................................................................. 257 17.5.2.2.2 Turn and Turn exit Kit ...................................................................................... 258 17.5.2.3 Install new Kit ........................................................................................................ 258 17.6 Chamber ......................................................................................................................... 259 17.6.1 Kit exchange ............................................................................................................. 259 17.6.1.1 Remove Track ..................................................................................................... 259 17.6.1.2 Install the new Track ............................................................................................. 261 17.7 Plunger (Belly Bar) .......................................................................................................... 262 17.7.1.1 Exchange of plunger guidings ............................................................................. 262 17.7.2 Exchange of plunger .................................................................................................. 262
Rasco
17.8 Plunger (RPTB) ............................................................................................................... 264 17.8.1 Plunger Exchange...................................................................................................... 264 17.9 Sorter ............................................................................................................................. 265 17.9.1 Kit exchange ............................................................................................................. 265 17.9.1.1 Remove Track ..................................................................................................... 265 17.9.1.2 Install new Track .................................................................................................. 266 17.10 Tape & Reel .................................................................................................................... 268 17.10.1 Basic Adjustments .................................................................................................... 268 17.10.1.1 Mounting the Taper to the Handler ...................................................................... 268 17.10.1.1.1 Screws to mount the taper .............................................................................. 268 17.10.1.1.2 Track Adjustment Taper to Sorter .................................................................. 269 17.10.1.1.3 Connecting the I/O Cables ............................................................................. 270 17.10.2 Kit exchange .............................................................................................................. 270 17.10.2.1 Remove Kit ........................................................................................................... 270 17.10.2.2 Install Kit ............................................................................................................... 273 17.11 Auto Tube Unloader ....................................................................................................... 274 17.11.1 Mounting the Auto Tube Unloader to the Handler ..................................................... 274 17.11.1.1 Fixing Points ......................................................................................................... 275 17.11.2 Kit Exchange .............................................................................................................. 275 17.12 Manu Magazine Unloader ............................................................................................... 277 17.12.1 Kit Exchange .............................................................................................................. 277 17.13 Auto Magazine Unloader ................................................................................................ 278 17.13.1 Mounting the Auto Magazine Unloader to the Handler.............................................. 278 17.13.2 Kit Exchange .............................................................................................................. 279 18 Preventive Maintenance Checklist ............................................................................................281 18.1 Maintenance Activities .................................................................................................... 281 18.1.1 Common .................................................................................................................... 281 18.1.2 Tube Loader............................................................................................................... 281 18.1.2.1 Loader Tube Singulator ........................................................................................ 281 18.1.2.2 Gripper .................................................................................................................. 281 18.1.2.3 Loader Transport .................................................................................................. 281 18.1.3 Magazine Loader ....................................................................................................... 282 18.1.4 Bowl Loader (SOT/QFN) ........................................................................................... 282 18.1.4.1 Handling Section................................................................................................... 282 18.1.4.2 Vision and Lightning ............................................................................................. 282 18.1.4.3 Bowl Feeder .......................................................................................................... 282 18.1.5 Handler Base ............................................................................................................. 282 18.1.5.1 Chamber Track ..................................................................................................... 282 18.1.5.2 Temperature System ............................................................................................ 283 18.1.5.3 Singulator .............................................................................................................. 283 18.1.5.4 Plunger.................................................................................................................. 283 18.1.5.5 Contactor .............................................................................................................. 283 18.1.5.6 Front...................................................................................................................... 283 18.1.6 Sorter ......................................................................................................................... 283 18.1.6.1 Turn....................................................................................................................... 283 18.1.6.2 Shuttle ................................................................................................................... 283 18.1.7 Unloader .................................................................................................................... 284 18.1.7.1 Tube Unloader ...................................................................................................... 284 18.1.7.2 Stack ..................................................................................................................... 284 18.1.7.3 Transport .............................................................................................................. 284 18.1.8 Manu Tube Unloader ................................................................................................. 284 18.1.9 Manu Magazine Unloader .......................................................................................... 284 18.1.10 Unloader General....................................................................................................... 284 18.1.11 Tape & Reel ............................................................................................................... 284 18.1.11.1 Handling Section................................................................................................... 284 18.1.11.2 Taping section ...................................................................................................... 285 18.1.11.3 Pick up .................................................................................................................. 285 18.1.11.4 Sealer Unit ............................................................................................................ 285 18.1.11.5 Vision System ....................................................................................................... 285 18.1.12 General ...................................................................................................................... 285 18.1.13 Complete ESD Checks, Measure and Record Data.................................................. 286
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Adjustments And Maintenance SO2000.Doc
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Common adjustments
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)
1.1 Fiber optic amplifier
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)
Sensitivity should be lower than 6!
1.2 Connection of the fiber optic

The best performance of a fiber optic amplifier 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 <MODE> Button into normal sensing mode for at least 4 sec. The reading on the Display should be off. If the reading is on, repeat the procedure!
In the sensing mode the Zero-point can be adjusted by pressing both UP key and DOWN key simultaneously
Initial settings: Press both UP key and <MODE> key simultaneously to change from sensing mode to the initial setting 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 P for 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 supplementary setting mode U-1 and no (Normal open) or nc (Normal closed) is displayed alternately and can be changed with the DOWN key to no (U-2 and U-3 should remain on the lowest possible setting) 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 until the 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 with the manual control after the adjustment 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 following 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 Level Compensation

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 do the following : Check the gap between Base Track Unloader and Base Track Sorter (the recommended gap 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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Manu Tube Loader
2.1 Gripper
2.1.1 Gripper tilt angle
Picture 9: Gripper tilt angle
Tilt angle of the Gripper should be the same as the one of the Auto Tube Loader! wich means ~5. (see picture above)
To adjust the tilt angle of the Gripper do the following: Loosen counter nut of tilt angle adjustment screw Turn in/out tilt angle adjustment screw (see picture below) After finishing adjustment lock counter nut again (see picture below)
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2.1.2 Tube Centering Gripper

To 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 picture below)
Picture 11: Tube Centering adjustment Gripper
2.1.3 Gripper placement

Under 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 Singulator
For 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 Guidings of 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 Holder

Please refer to Common Adjustments chapter.
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Auto Tube Loader
3.1 Input Stack

3.1.1 Stack width
To 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 length

To 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 support

To 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!! After adjustment tighten fixing screws again!
3.1.4 Tube centering

To achieve smooth movement from stack into centering, the centering has to be inline with the stack. For adjustment do the following: Loosen centering fixing screws (see picture below) For adjustment use the eccentric screw (see picture below)
Picture 21: Tube centering After adjustment tighten fixing screws again!
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 might become necessary to readjust the tube in transport 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 Gripper
3.3.1 Gripper tilt angle
Tilt angle of the gripper should be the same as the one of the stack chassis (means ~5)! (see picture above)
To adjust the tilt angle of the gripper do the following: Loosen counter nut of tilt angle adjustment screw Turn in/out tilt angle adjustment screw (see picture below)
Picture 26: Gripper tilt angle adjustment screw After finishing adjustment lock counter nut 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 linear thermal 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!

To 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 rod should 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 Placement

Under certain circumstances it might be necessary to readjust the gripper Placement. 2008.Sep.22 Adjustments And Maintenance SO2000.Doc page 27 of 286
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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 Tighten fixing screws again
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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3.3.4.3 Side placement Tube to Track
To readjust the side position of the gripper, do the following: Remove the three screws (see picture above)
Insert or remove shims under the plate (nominal shimming is 0.5mm) After finishing adjustment tighten fixing screws again!
Picture 35: right/left positioning schematic
3.3.5 Tube docked sensor adjustment

For a correct adjustment of the Tube detection sensor do the following: Adjust the tube as shown in the <Front/back placement Tube to Track> chapter. Loosen the fixing screws of the sensor holder. Move sensor back. Turn down the gripper. Move the sensor to the gripper plates until a gap of 0.5mm is reached. Tighten the fixing screws of the sensor holder.
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Picture 36: Tube detection sensor schematic
Picture 37: Tube detection sensor
3.4 Singulator
For 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 Guiding of the Track (see picture and schematic below)
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Picture 40: Adjustment mark
Picture 41: Adjustment schematic
After adjustment remember to tighten fixing screws!
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3.4.1 Air Jet Singulator
Picture 42: Air Jet Singulator

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 350/350ms are 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 Select Auto Tube Loader Push Gripper in/out (yellow Background) Adjust throttle until 250/350ms are reached Lock counter nut after successful adjustment
Picture 44: Gripper in/out throttles
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3.5.3 Gripper up/down

Press the Service button in the main screen Select Auto Tube Loader Push Gripper up/down (yellow background) Adjust throttle until 700/700ms are reached Lock counter nut after successful adjustment The Values always have to be equal
Picture 45: Gripper up/down throttles
3.6 Tube Pusher Adjustment

To 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. Tighten fixing screws again
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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 Blade Adjustments

It is highly recommended to do the adjustments in following order !
3.8.1 Tube to Track Adjustments 3.8.2 Side Alignment

To 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 Alignment

To 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 Blade

To 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 base track. After successful adjustment tighten fixing screws again.
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. After successful adjustment tighten fixing screws again.
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:
2008.Sep.22
Put a tube in and turn up the gripper. Loosen the fixing screws of the sensor holder.
Rasco
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 positions 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 Grippershifter to out position
Press the Service button in the main screen Select Auto Tube Loader Push Grippershifter (yellow background) Adjust throttle until 350ms are reached Lock counter nut after successful adjustment
Picture 62: Throttle Grippershifter
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Picture 63: Grippershifter out position
3.8.5.2 Grippershifter 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 Grippershifter 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 Lock counter nut after successful adjustment
Picture 68: Throttle Stopper Blade Speed
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Picture 69: Stopper Blade Speed
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Bowl Loader (SOT)
4.1 Level compensation

4.1.1 Nominal Turn dimension
The nominal dimension (to be measured like shown in picture below!) is 10mm. In case of deviation use shimming plates.
The turn connector is shimmed with 1/10 mm by factory default!
Picture 70: Nominal dimension measurement
4.1.2 Height level to Singulator track

Adjusting height level between bowl track and Singulator track: Loosen screws 1 to 3 (like shown in picture Screws on bottom of Bowl Loader) Take out screws 1 to 3 Put in the needed shims between bowl loader base plate an bowl (see picture below) Put in screws 1 to 3 Tighten screws 1 to 3 and check height level again If needed repeat these steps
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Picture 71: Shim between base plate and bowl
4.1.3 Transit Bowl to Track

Loosen the screws from the Track Fixture (see picture below) Put in the needed shims between bowl loader base plate an Track Fixture (see picture below) Tighten screws and check height level again If needed repeat these steps
Picture 72: Shim between Track Fixture and Base Plate 2008.Sep.22 Loosen the screws from the Track Put in the needed shims between Bowl an Track (see picture below) Tighten screws and check height level again. If needed repeat these steps . Adjustments And Maintenance SO2000.Doc page 49 of 286
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Picture 73: Shim between Bowl and Track
There is no shim necessary in the over-worked version !
Picture 74: New design Transit Bowl to Track
4.2 Bowl Adjustments

4.2.1 Gap to Singulator track
For adjustment loosen center screw and turn until gap is within 0,2 0,4 mm
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Picture 75: Bowl center screw (T-Handle)
4.2.2 Displacement of Bowl and Singulator track

Adjusting displacement of Bowl and Singulator Track: Loosen screws 1 to 3 (see picture: Screws on bottom of Bowl Loader) Use screw 4 for actual adjustment of displacement (see picture: Screws on bottom of Bowl Loader) Adjustment is correct if bowl track and Singulator track are in line (see picture: Displacement Bowl-Singulator) After successful adjustment tighten screws 1 to 3 again
Picture 76: Displacement Bowl-Singulator
Picture 77: Screws on bottom of Bowl Loader
4.2.3 Bowl output (vibration)

For adjusting bowl output (vibration strength) use regulator knob on side of Bowl Loader.
If regulator value is set too high, devices cannot reach the Bowl output!
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Picture 78: Bowl output (vibration strength) adjustment knob
4.2.4 Frequency Adjustments Bowl Controller
The default value is 50Hz (former default value: 56Hz) ! Remove bowl cover. Remove controller cover.
Picture 79: Controller Cover
There a two jumpers to change the frequency of the bowl To readjust the controller, find the resonance frequency and turn 1-2Hz lower (to get an uncritical level).
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Picture 80: Bowl Controller
Picture 81: Frequency adjustment
After successful adjustments mount all covers again.
4.2.4.1 Internal limitation of bowl vibrator speed

It is sometimes necessary to limit the bowl vibration to avoid a too strong amplitude and a high noise emission.
This new type of bowl vibrator needs a frequency of 50Hz !
Picture 82: New type bowl vibrator with 50Hz frequency To adjust the internal potentiometer (see picture below) do following steps : Make sure that the bowl can`t hit any kit part . Turn the internal potentiometer to the minimum position (0% output). Turn the external potentiometer to the maximum position (Scalevalue10) Now adjust the internal potentiometer until a loud noise is hearable and a little bit backwards until the noise is disappeared.
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The adjustment is only possible with complete bowl equipment (Track, Cover ,etc.) !
Picture 83: Internal potentiometer
4.2.5 Air ejectors in bowl

Adjusting Air ejectors air stream: Place a device life bug (with leads down) in front of an air ejector Give air pressure to air ejectors If device is just being shot back into bowl, then adjustment is right If adjustment is needed, try opening or closing pressure regulators for air jets (see right picture below) Check again, for correct settings (like shown above) If adjustment is o.k. close pressure regulator again half a turn clockwise Double-check adjustment with Bowl switched on (vibrating) Repeat these steps for all three Air ejectors Do not forget to tighten screws after successful adjustment
If further Adjustment is needed: Try loosening screw (see picture below), holding the air jet. Adjust air stream height by turning the air jet clock-or counterclockwise.
Picture 84: Bowl Air ejectors
Picture 85: Air ejector pressure regulators
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4.2.6 Air Ejectors Adjustment on Base Track Bowl

The air ejectors throttles of the new designed version are directly on the bowl (see picture below) ! All Air Ejectors have to be equal or 0.2mm lower as the Base Track surface.
Picture 86: Air Ejector
Adjust the Pressure Regulator of the Air Ejectors to 2 bar.
Picture 87: Pressure Regulator
Adjust a medium vibration speed. Turn all ejector holes to the lowest level (every device will be blown out).
4.2.6.1 Air Ejector #1

Lay one device upon the other.
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Turn the hole of the ejector far enough so the upper device gets blown away.
Picture 88: Ejector #1

Lay a device 90 turned into the Track . Turn the hole of the ejector far enough so the turned device gets blown away.

Lay a device live bug into the Track . Turn the hole of the ejector far enough so the turned device gets blown away.
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Turn the hole of the ejector far enough so all other wrong devices gets blown away.
4.2.7 Air Jet Bowl (Top guiding)

Adjusting gap between air jet base track and top guiding: Loosen screws (shown in left picture below) Insert 2 devices into base track (under top guiding) Press down top guiding Measure gap between top guiding and base track (shown in right picture below) Add 0.1mm to the measured gap Tighten screws again
Picture 92: Air Jet Bowl (Top guiding)
Picture 93: Gap between top guiding and base track
New design air jet bowl (top guiding)

Loosen screws. Insert 2 devices into base track (under top guiding). Press down top guiding .
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Add 0.1mm to the measured gap . Add or remove shims. Tighten screws again
Adjustments and Maintenance Measure gap between top guiding and base track (shown in right picture below).
Picture 94: Air Jet Bowl (Top guiding) new design
4.2.8 Air Transport Singulator
Picture 95: Air Jet - Transport Singulator
Reworked Placement of Transport Air Jet Throttle
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Picture 96: Air Jet Throttle - Transport Singulator

For a better adjustment it is well to remove the bowl (see picture below)

When adjusting the air pressure too high, the flexible tube possibly pops off the air jet.
Reworked Placement of Singulator Air Jet Throttle
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Picture 98: Air Jet Singulator Throttle
4.2.10 Air Jet Vision Buffer and Turn 180
Picture 99: Air Jet Vision Buffer and Turn 180
4.3 Bowl Singulator

4.3.1 Singulator Scale
To adjust the singulator with the scale do following steps : Measure the length (in mm) of your device. Loosen the fixing screws of the singulator block (see picture below). Move the singulator block (scale) exactly to the device length position (mark line). After adjustment fix screws again.
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Picture 100: Singulator scale
4.3.2 Device length

Adjusting Singulator on device length: Loosen screws (shown in left picture below) Put two devices into Singulator track Gap between first and second device should be located at marking (shown in right picture below) For adjustment, tighten screws again After finishing adjustment, tighten screws again
Picture 101: singulator Adjustment screws
Picture 102: Singulator marking
4.3.3 Stopper shaft

Adjusting gap between stopper shaft and stopper lever: Loosen two locknuts on stopper shaft Adjust stopper shaft height by turning long nut (between locknuts) After adjustment gap between stopper lever and stopper shaft should be approx. 1mm Tighten locknuts again
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Picture 103: Singulator Stopper Shafts (Opener Singulator and Vision Buffer)
Picture 104: Singulator Stopper Shafts (Holder Singulator)

4.4 Turn 180

4.4.1 Turning end positions
Adjustment must be done with pressured air for moving the turn to the end positions!
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For adjusting the 180 turn: Loosen locknuts at stopper screws (Shown in picture 15) For adjusting clockwise stop use screw 1 For adjusting counterclockwise stop use screw 2
After correct adjustment (Top guiding of 180 turn is inline with neighbored top guiding), tighten locknuts again
Picture 105: Turn 180 End position adjustment
4.4.2 Stopper Cylinder
Distance between Base Plate and Stopper Cylinder should be ~10.5mm
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Picture 106: Stopper Cylinder Adjustment In case of divergence: Loosen and remove base plate fixing screws Take out base plate Adjust stopper cylinder Check for correct measure again If distance is correct Put base plate back in Tighten fixing screws
4.5 Air Ionizer Adjustments

To vary the fan speed turn the adjusting knob. The <ION LEVEL> switch should placed on <L>. The <COND> switch should placed on <L>.
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Picture 107: Air Ionizer
4.6 Vision System Programming

Please refer to Vision Systems SO2000 Keyence chapter.
Bowl Loader (QFN)

5.1.1 Nominal Turn dimension
The nominal dimension (to be measured like shown in picture below!) is 8.8mm. In case of deviation use shimming plates.
The turn connector is shimmed with 2/10mm by factory default!
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Picture 108: Nominal dimension measurement
5.1.2 Height level to Singulator track

Adjusting height level between bowl track and Singulator track: Loosen screws 1 to 3 (like shown below in picture Screws on bottom of Bowl Loader) Remove screws 1 to 3 Place the needed shims between bowl loader base plate an bowl (see picture below) Insert screws 1 to 3 Tighten screws 1 to 3 and check height level again If needed repeat these steps
Picture 109: Shim between base plate and bowl
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Picture 110: Bowl bottom view
5.1.3 Transit Bowl to Track

Loosen screws from track fixture (see picture Screws on bottom of Bowl Loader) Insert needed shims between bowl loader base plate and track fixture (see picture below) Tighten screws and check height level again If needed repeat these steps
Picture 111: Shim between Track Fixture and Base Plate Loosen screws of the track Insert needed shims between Bowl an Track Tighten screws and check height level again If needed repeat these steps
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5.2 Bowl Adjustments

5.2.1 Gap to Singulator track
For adjustment loosen center screw and turn until gap is within 0,2-0,4 mm.
Picture 112: Bowl center screw (T-Handle)
5.2.2 Displacement of Bowl and Singulator track

Adjusting displacement of Bowl and Singulator Track: Loosen screws 1 to 3 (see picture: Screws on bottom of Bowl Loader) Use screw 4 for actual adjustment of displacement (see picture: Bowl center screw (THandle)) Adjustment is correct if bowl track and Singulator track are in line (see picture: Displacement Bowl-singulator) After successful adjustment tighten screws 1 to 3 again
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Picture 113: Displacement Bowl Singulator
Adjustments and Maintenance Picture 114: Screws on bottom of Bowl Loader
5.2.3 Bowl output (vibration )

For adjusting bowl output (vibration strength) use regulator knob on side of Bowl Loader.
If regulator value is set too high, devices cannot reach the Bowl output!
Picture 115: Bowl output (vibration strength) adjustment knob
5.2.4 Air ejectors on bowl

Adjusting Air ejectors air stream: Place two devices on top of each other and after them a device on edge in front of an air ejector.
Picture 116: Schematic of device placement Give air pressure to air ejectors If device is just being shot back into bowl, then adjustment is right If adjustment is needed, try opening or closing pressure regulators for air jets. Check again, for correct settings. If adjustment is o.k. close pressure regulator again half a turn clockwise. Double-check adjustment with Bowl switched on (vibrating)
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Repeat these steps for all three Air ejectors Dont forget to tighten screws after successful adjustment
If further Adjustment is needed: Try loosening screw (see picture below), holding the air jet. Adjust air stream height by turning the air jet clock- or counterclockwise.
Picture 118: Bowl Air ejectors (redesign)
Adjust Air ejectors Pressure Regulator to 2 bar.
Picture 119: Bowl Air ejectors Pressure Regulator
5.2.5 Flip Check Adjustment

This adjustment is necessary to identify the right orientation of the device. The air jet should eject every device which is in life bug orientation (labeling on top).
5.2.5.1 Adjust sensor point diameter

Adjust the sensor point to max. size ( approx. 2mm)
Screw in fiber-optic into lense until hard stop. Unscrew fiber-optic a half rotation. Fix the fiber-optic with the counter nut.
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Picture 120: Flip Check Sensor diameter
For smaller devices (<QFN3) adjust a smaller diameter.
5.2.5.2 Adjust sensor position

Adjust sensor point neighboured to air eject hole.
Picture 121: Flip Check Sensor
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Picture 122: Sensor placement
5.2.5.3 Initial Reset (SET Mode)

Its recommended to reset the amplifier before adjustment. Set the mode selector to <SET>. Press and hold down <TEACH> and <MODE> button synchronous for 5 sec. No appears on the display. Press <TEACH> button. YES appears on the display. Press <MODE> button to execute initial reset.
5.2.5.4 Amplifier Adjustment

To adjust the flip check amplifier (see picture below) do following steps: Switch off the main pressure.
Picture 123: Flip Check Sensor Amplifier Move the switches to default position: left switch to <RUN> position; right switch to <L> position. Put a device in life bug orientation under the flip check sensor (see picture below) and note max. light value.
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Picture 124: Device Life Bug Put a device in dead bug orientation (see picture below) and note min. light value.
Picture 125: Device Dead Bug Calculate threshold (middle between max. light value and min. light value). Move the left switch to <ADJ> position. Set threshold with teach / mode buttons (teach button decrease the value; mode button increase the value). Move the switch in <RUN> mode. If you move the switch in the adjustment position <ADJ> you can see threshold value ! Switch main pressure on.
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5.2.6 Air Transport Singulator
Picture 126: Air Jet Transport Singulator
Reworked placement of Air Transport Singulator throttle
Picture 127: Air Jet Transport Singulator throttle
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When adjusting the air pressure too high, the flexible tube possibly pops off the air jet
Reworked placement of Air Jet Singulator throttle
Picture 129: Air Jet Singulator throttle
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5.2.8 Air Jet Vision Buffer, Turn 90 and Turn 180
Picture 130: Air Jet Vision Buffer, Turn 90 and Turn 180
5.3 Bowl Singulator

5.3.1 Singulator Scale
To adjust the singulator with the scale do following steps : Measure the length (in mm) of your device. Loosen the fixing screws of the singulator block (see picture below). Move the singulator block (scale) exactly to the device length position (mark line). After adjustment fix screws again.
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Picture 131: Singulator Scale
5.3.2 Device length

Adjusting Singulator on device length: Loosen screws (shown in left picture below) Put two devices into Singulator track Gap between first and second device should be located at marking (shown in right picture below) For adjustment, move stopper (the one with the loose screws) After finishing adjustment, tighten screws again
Picture 132: Singulator Adjustment screws
Picture 133: Singulator marking
5.3.3 Stopper shaft

Adjsuting gap between stopper shaft and stopper lever: Loosen two locknuts on stopper shaft Adjust stopper shaft height by turning long nut (between locknuts) After adjustment gap between stopper lever and stopper shaft should be approx. 1 mm Tighten locknuts again
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Picture 134: Singulator Stopper Shafts (Opener Singulator and Vision Buffer)
Picture 135: Singulator Stopper Shafts ( Holder Singulator)

5.4 Turn 90
Adjustment only for square devices necessary

Loosen screws (shown in picture below) Adjust the stopper of the turn 90 with a gap of half a device length to the marking (shown in picture below) in other: the device center should be located at the marking After successful adjustment tighten screws again
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Picture 136: Turn 90 adjustment
Picture 137: Turn 90 marking
5.5 Turn 180

Adjustment must be done with pressured air for moving the turn to the end positions!
For adjusting the 180 turn: Loosen locknuts at stopper screws (Shown in picture below) For adjusting clockwise stop use screw 1 For adjusting counterclockwise stop use screw 2 After correct adjustment (Top guiding of 180 turn is inline with neighbored top guiding), tighten locknuts again.
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Picture 138: Turn 180 End position adjustment
5.5.2 Stopper Cylinder
Distance between Base Plate and Stopper Cylinder should be 9.5mm
Picture 139: Stopper Cylinder Adjustment In case of divergence: Loosen and remove base plate fixing screw Take out base plate Adjust stopper cylinder Check for correct measure again If distance is correct Put base plate back in Tighten fixing screws
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5.6 Flipper
To adjust the track of the flipper Bring the flipper in horizontal position Remove fixing screws (shown in picture below) Pull out the flipper Put in the needed shims between cylinder disc and flipper housing Install the flipper and tighten screws again
Picture 140: Flipper fixing screw
Picture 141: Flipper fixing screws down
5.7 Flipper Side Adjustment

To adjust the track of the flipper Bring the flipper in horizontal position Loosen the four fixing screws. Move the flipper in needed position. After successful adjustment fix screws again.
Picture 142: Flipper side adjustment
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5.8 Air Ionizer Adjustments

See Bowl Loader (SOT) Adjustments chapter.
5.9
Vision System Programming
Please refer to Vision Systems SO2000 Matsushita chapter.
5.10 Camera Adjustments

5.10.1 Horizontal Camera Alignment
To adjust the horizontal position of the camera do the following Remove the top cover (therefore disconnect ionizer fan) Loosen fixing screws (you can reach the screws through the clearance holes as shown below)
Picture 143: Base Plate Enable live picture on vision system by pressing <B> on keypad The stopper should placed on the left side of the screen as shown below.
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Picture 144: Stopper position
You can adjust the vision screening window by moving the camera horizontally (shown below)
Picture 145: Horizontal Alignment After sucessful adjustment tighten screws again and put on the top cover (do not forget to connect the ionizer fan).
5.10.2 Sharpness adjustment

In case of unsharp images do the following: Loosen fixing screw on camera holder (see picture below)
Picture 146: Camera holder
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Picture 147: Camera fixing screw Turn grub screw until image sharpness is ok (see picture below) After successful adjustment tighten fixing screws again
Picture 148: Camera grub screws
5.10.3 Lens Adjustment

To get access remove the top cover You can fine adjust sharpness by turning the lens Adjust brightness by turning the iris ring (remember to loosen the fixing screw first)
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Picture 149: Lens adjustment
5.10.4 Exposure Adjustment

In case the quality of the images taken from the device is not good enough, you can try to readjust the lighting. By doing so you can minimize the surface reflections and optimize the readability of the labeling. To vary the lighting do following steps: Loosen the fixing screw (see picture below) Move LED holder as needed. Enable live picture on vision system by pressing <B> on keypad After successful adjustment tighten screw again.
Picture 150: LED holder
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6
6.1.1

Auto Magazine Loader

Stack width
Loosen fixing screws at front and back stack (see picture below). Adjust width by turning the adjustment screw. After adjustment tighten fixing screws again.
6.1 Magazine Dimensions Adjustments

To readapt stack width to a new magazine width do the following:
Picture 151: Stack width
6.1.2 Stack length

To readapt stack length for a different magazine do the following: Loosen fixing screws located on the base plate (see picture below). Put Stack plate on the second position and fix screws.
Front holes for 520mm Magazines, back holes for 540mm Magazines !
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Picture 152: Stack plate
6.2 Centering Adjustment

6.2.1 Magazine width Adjustment
To readapt Centering width for a different magazine do the following: Loosen fixing screws located on the ledge (see picture below). Put center part in a fitting position and fix screws.
Picture 153: Centering
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6.3 Gripper Adjustment

6.3.1 Gripper distance
To readapt gripper distance for a different magazine do the following: Loosen fixing screws located on the swing arm (see picture below). Put gripper plate on the second position and fix screws.
Front holes for 520mm Magazines, back holes for 540mm Magazines !
Picture 154: Gripper
6.3.2 Gripper Speed

To adjust the speed of the Gripper use the throttles (see picture below).

Loosen check nut.

Press the Service button in the main screen . Select Auto Magazine Loader. Push <Gripper in/out >(yellow background). Adjust throttles until 500/500 (ms) are reached.
Tighten check nut.
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Picture 155: Gripper Throttles
6.3.3 Transport width Adjustment

For correct Transport width adjustment do the following : Loosen fixing screws. Turn Adjustment screw as far as required. Tighten fixing screws. For very small magazines remove center parts and use the inner fixing holes (see picture below).
Picture 156: Transport width
6.3.4 Transport Endstop Adjustment

For the correct position of the transport do following :
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Remove fixing screws of the transport cover Remove cover
Picture 157: Transport cover
Loosen check nut and adjust hard stop screw. After successful adjustment tighten check nut again. Put on cover.
Picture 158: Hard stop right
Picture 159: Hard stop left
6.3.5 Transport Speed

Press the Service button in the main screen . Select Auto Magazine Loader. Push <Transport to loadstack/backstack >(yellow background). Adjust throttles until 1200/900 (ms) are reached.
6.4 Swing Adjustment
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For the ideal angle of the swing and correct alignment of Magazine and singulator base track adjust the hard stop as following : Remove hard stop screw. Add or remove shims. After successful adjustment tighten hard stop screw.
Picture 160: Hard stop Swing detail
6.4.1 Swing up/down Speed Adjustment

To adjust the speed of the swing do following:
Press the Service button in the main screen . Select Auto Magazine Loader. Push <Swing up/down >(yellow background). The value should be approx. 1800/1800 (ms).
If not, adjust the throttle of the swing up cylinder until the value is reached Remove Transport Cover
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Picture 161: Transport Cover
Remove Transport Plate
Picture 162: Transport Plate
Remove lower Cover
Picture 163: Lower Cover
Adjust the throttle until the value is reached
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Picture 164: Swing up throttle
After successful adjustment check the counter nut of the throttle and mount all covers again
6.5 Turn Unit

6.5.1 Turn End Position
For adjusting end positions of 180 turns: Loosen check nut . Use socket screw for adjusting position (see pictures below) After adjustment track of 180 turn should be inline with flipper base track. Tighten lock nut again!
Picture 165: Turn 180
6.6 Centering Adjustment

For a proper alignment of the Magazine and the Base Track do following steps :
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Put a Magazine into the Centering Move Swing up Loosen the fixing screws of the Centering
Picture 166: Centering fixing screws Turn the adjustment screws right or left until the alignment is ok
Picture 167: Adjustment screw Tighten fixing screws again
6.6.1 Stopper Pin Height Level

For a proper height adjustment of the Stopper pins see picture below :
The nominal shim height is 0.5mm !
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Picture 168: Stopper Block Shims Schematic
Picture 169: Stopper Block Shims
6.7 Shuttle Adjustment

6.7.1 Shuttle L & R position
Loosen the fixing screws of the shuttle plate
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Picture 170: Shuttle left side
Picture 171: Shuttle right side
Move shuttle Track in correct position to the Singulator Buffer Track
Picture 172: Shuttle position After successful adjustment tighten fixing screws again
6.7.2 Shuttle High Level Adjustment

Remove both Stopper Blocks on top of the Shuttle careful do not lose the drill ledges below the shuttle plate.
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Picture 173: Shuttle Stopper Block Remove the Shuttle plate fixing screws on both sides
Picture 174: Shuttle plate Add or remove shims between the shuttle plate and linear guiding
Add or remove always the same quantity of shims on the left and right side , to have an equal level ! After successful level compensation put the shuttle plate back on the guiding and fix the stopper blocks again
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6.7.3 Air Jet Shuttle
Picture 175: Shuttle Air Jet left and right
Picture 176: Air Jet L
Picture 177: Air Jet R
6.7.4 Speed Adjustment Shuttle

To adjust the speed of the Shuttle adjust throttles (see picture below).
Press the Service button in the main screen . Select Auto Magazine Loader. Push <Shuttle left/right >(yellow background). Adjust throttles until approx. 200/200 (ms) are reached.
The values have to be equal !

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Picture 178: Throttles Shuttle
6.7.5 Air Jet Debounce
Picture 179: Debounce Air Jet
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Picture 180: Debounce Air Jet Throttle
6.8 Flipper Adjustment

6.8.1 Endstop Adjustment
For correct alignment of base track shuttle and flipper base track do the following : Loosen check nut. Turn hard stop screw. After successful adjustment tighten check nut.
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Picture 181: Flipper Hard Stop
Picture 182: Flipper Hard Stop detail
6.8.2 Side Level Compensation

For a correct side level adjustment of the flipper do following : Remove fixing screws (see picture below)
Picture 183: Flipper screws Add or remove shims
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Picture 184: Flipper level compensation Check alignment After successful compensation put on flipper and fix screws.
6.8.3 Air Jet Adjustment
Picture 185: Air Jet Flipper Air jet Flipper to Turn 180
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Picture 186: Air Jet Flipper to Turn 180
Picture 187: Air Jet Throttles Flipper to Turn 180
6.9 Singulator Adjustments

To adjust the singulator do the following : Loosen fixing screws. Move Stopper block as far as the device length is align with the shuttle base track (see picture and scematic below). After successful adjustment tighten fixing screws.
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Picture 188: Singulator
Picture 189: Singulator schematic
6.9.1 Air Jet Singulator Holder

Open check nut and adjust throttle. After successful adjustment tighten check nut again.
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Picture 190: Singulator Air Jet

6.10 Magazine Drive Adjustment

6.10.1 Speed Magazine Drive Adjustment
Picture 191: Magazine Drive Throttle

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6.11 Lift stack inner/stack outer

Remove fixing screws and covers.
Picture 192: Top Cover

Press the Service button in the main screen . Select Auto Magazine Loader.
Picture 193: Top Cover front
Push <Lift back stack inner/stack outer >(yellow background). Adjust throttles until 200/200 (ms) are reached. Push <Lift load stack inner/stack outer> (yellow background). Adjust throttles until 170/170 (ms) are reached. The Values always have to be equal!
Picture 194: Throttles Lift up left
Picture 195: Throttles Lift up right
After successful adjustment lock the counter nut and put on all covers
6.12 Air Vibrator Adjustment

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Adjust throttles until the devices are get loosen in the magazine.
Picture 196: Throttles Air Vibrator You can change the value in the <Settings> Press the <Settings> button in the main screen .
Select Auto Magazine Loader.
Insert values as needed.
Picture 197: Settings Air Vibrator
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Chamber
7.1 Singulator adjustment

After changing device-size readjustment of chamber singulator may be necessary For chamber singulator adjustment: Open chamber door (see picture below)
Picture 198: Chamber door Find the opener adjustment marking for the left and the right track (see picture below)
Picture 199: Singulator adjustment marking Insert two devices
Picture 200: Adjustment markings
Open loop holes (see picture Chamber door)
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Adjustments and Maintenance Adjust opener height by turning the opener adjustment wheel (see picture below)
Picture 201: Opener adjustment wheels Track adjustment marking should be located between the two devices (see schematic below)
Picture 202: Adjustment Remember to adjust both left and right side! After adjustment, close loop holes and chamber door
7.1.1 Stroke Limitation Upper Lever

7.2 Adjusting Holder and Opener Cylinder

The pneumatic cylinders are located at the chamber front (see picture below)
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Picture 203: Opener and holder pneumatic cylinder The gap between cylinder cap and lever should be approx. 5/10mm (See pictures below)
Picture 204: Holder cylinder gap
Picture 205: Opener cylinder gap
To adjust gap between cylinder cap and lever: Unplug pneumatic tube (of concerning cylinder) Loosen cylinder fixing screws (see picture below)
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Picture 206: Pneumatic cylinder fixing screws Take out pneumatic cylinder Loosen lock nut (see picture below) Turn shaft in or out as far as needed (see picture below)
Picture 207: Pneumatic cylinder After successful adjustment tighten lock nut and put pneumatic cylinder back in again Tighten cylinder fixing screws Check the gap again and readjust if necessary
7.3 Exchanging Fans

7.3.1 Cover removal
Loosen fixing screws of upper backplane and remove backplane (see picture below)
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Picture 208: Backplanes Loosen fixing screws of center backplane and remove backplane (see pictures below)
Picture 209 and 210: Center Backplane (left and right side) Loosen and remove Plunger (see picture below) Open chamber door (see picture below)
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Picture 211: Chamber door and plunger Unplug pneumatic tubes from pneumatic cylinders (see picture below) Note correct assignment of pneumatic tubes! Loosen cover fixing screws (see picture below)
Picture 212: Pneumatic cylinders and fixing screws Remove cover
7.3.2 Fan removal

Make sure that heater power is switched off!! Unplug heater cables (see picture below)
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Picture 213: Heater plugs Loosen manifold fixing screws of upper and lower manifold (see picture below)
Picture 214: Upper and lower manifold within chamber
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Picture 215: Upper manifold
Picture 216: Lower manifold
Loosen heater fixing screws (see picture below)
Picture 217: Fan fixing screws Take out Fan
7.4 LN2 Pressure

Switch on temperature and select 60C Wait for a steady state of temperature function Wait 1h more Adjust LN2 regulator, the temperature channel No.1 (Chamber Circulation) have to power with approximately 30% Clockwise turning of pressure regulator adjustment screw increases LN2 pressure.
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Picture 218: LN2 regulator and LN2 valves of LN2 Input
7.5 Fan installation

Always exchange the silicone o-ring seals on the upper manifold! (see picture below)
Picture 219: Silicone O-Rings Always exchange the Teflon o-ring seals on the lower manifold! ( seal is located at heater)
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Picture 220: Teflon O-Ring (located at heater) Insert Fan Tighten upper and lower heater fixing screws a little (just a few turns!!) (see picture: Heater fixing screws) Tighten upper and lower manifold (see pictures: Upper manifold and Lower manifold) Tighten heater fixing screws all the way now Plug in heater cables again (see picture: Heater plugs) Put all covers back on and tighten fixing screws Put plunger back in Turn on heater power again Turn on heater power again
7.5.1 Fan speed control

To control the Fan speed do the following: Loosen fixing screws of Reflective Sensor holder (see picture below) Move sensor holder for or backward until the sensor switches to ON when it hits the radial surface of Sensor Flag and OUT when the sensor hits the cutout of Sensor Flag Tighten fixing screws again
Picture 221: Fan speed control
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7.6 Temperature calibration Its recommended to calibrate all used set-points after following changes :
Readjustment of the Heater pressure. Exchange of Temperature Sensors. Using a different Contactor type. Modification which regarding the LN2 or Heater pressure supply. Readjustment of the LN2 pressure.

For Setpoints less than 41C LN2 is necessary Its recommended to calibrate all used set-points.
7.6.1 Calibration kit

The temperature controller of the SO2000 models can be calibrated to values of external sensors. Its recommended to use the Rasco Temperature Calibration Kits. 4 PTB and 4 RPTB sensor holder to fix the sensors in the Contact Site. 5 temperature sensors (PT100, class A) placed in metal bodies, which have the outside dimensions of the devices corresponding to the used conversion kit . Temperature hand measurement equipment Insulation Plate Sensor Holder (Chamber Sensor)
7.6.2 Sensor placement

There are five external sensors to be placed. See pictures below for correct locations:
Picture 222: Locations for contactor sensors
7.6.2.1 PTB Temperature Sensor Holder
The sensor position should be equal on all 4 holder !
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Picture 223: Clip with temperature sensor
Picture 224: temperature sensor (backside)
7.6.2.2 RPTB Temperature Sensor Holder
The sensor position should be equal on all 4 holder !
Picture 225: Clip with temperature sensor
Picture 226: temperature sensor (backside)
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Picture 227: Cable routing
Chamber circulation sensor must be placed on the plunger ! (see picture below) Fix the sensor as shown below.
Picture 228: Location of Chamber circulation sensor
7.6.3 Insulation Plate

Fix the Insulation Plate on the backside of the Contactor (Screws contained in Calibration Kit)
Use only UNC screws to fix the Plate (e.g. UNC 8-32 5/8)
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Picture 229: Insulation Plate
7.6.4 Calibration Table
First make sure that all external sensors are correctly placed! In the main Operator Interface screen, select SETTINGS In the following screen select Temperature In this screen insert the desired temperature value in the appropriate field (see picture below)
Picture 230: Temperature setpoint Make sure that the ON/OFF Button is switched ON (yellow background)
Now allow approximately 30 minutes for the system to reach a stable condition. Select CALIBRATION on the left side.
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Picture 231: Calibration screen Insert actual setpoint value in the first field. Insert previously hand-measured average value of the four CS temperatures. Now activate the calibration by pressing the ON/OFF button in the lower right corner (yellow background) Allow approximately 30 minutes again for temperature stabilization. Now you can see the value difference to the setpoint, subtract this difference from the further measured and inserted values. Make sure that the calibration ON/OFF Button is switched on NOW! (yellow background) Allow again 30 minutes for temperature stabilization and check all external sensors If measured temperatures are ok, go on to the next setpoint and repeat the complete calibration procedure. JUST make sure that you dont overwrite your new settings! Choose a different table row! Measure actual temperature with the installed external chamber circulation sensor
ONLY if the previously inserted temperature setpoint deviates from measured chamber circulation temperature for more than 2 C the chamber circulation sensor has to be calibrated separately:
If you want to calibrate another setpoint, make sure the calibration button is off!
If measured temperatures are not quite ok yet, repeat above steps and tweak settings just a little After finishing all adjustments make sure to remove all inserted external temperature sensors!
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Plunger (Belly Bar)

8.1.1 Lead Support
Gap between lead support and top guiding should be just enough to enable smooth movement of the device the device should be stopped by the lead support notches though. (see picture below). If gap is too big lead support notches can not stop device, if gap is too small device cannot move smoothly.
Picture 232: Correct gap between lead support and top guiding To increase or to decrease gap: Remove top guiding fixing screws (see picture below)
Picture 233: Top guiding fixing screws 2008.Sep.22 Remove top guiding Remove lead support fixing screws (see picture below) Adjustments And Maintenance SO2000.Doc page 123 of 286
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Picture 234: Lead support fixing screws Remove lead support Insert or remove shims as necessary Insert lead support and tighten fixing screws Insert top guiding and tighten fixing screws Check for correct measure and repeat above steps if necessary
8.2 Change of stroke-depth

After changing Plunger head from Kelvin to PTB (plunger to board) or vise versa following steps have to be done: Exchange of plunger guiding Activation of stroke limitation End-switch re-adjustment (reed contact)
8.2.1 Exchange of plunger guidings

Remove old guidings, using an allen wrench
Picture 235: Plunger guiding 2008.Sep.22 Adjustments And Maintenance SO2000.Doc page 124 of 286
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Insert new guiding
8.2.2 Activating stroke limitation

After replacing long plunger guiding with shorter ones, it is necessary to activate stroke limitation: Tighten Stroke limitation fixing screws (shown in picture below) For de-activating stroke limitation (necessary after replacing short plunger guiding with longer ones: Loosen Stroke limitation fixing screws (shown in picture below)
Picture 236: Stroke limitation fixing screws
8.2.3 Adjusting the reed sensors for load and test position
8.2.3.1 Load Position Adjustment
Remove housing, by loosening the housing fixing screws (see picture below)
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Picture 237: Plunger housing, and fixing screws Find the reed sensors located upon the big air cylinder (see picture below)
Picture 238: Reed sensors and air cylinder Move plunger head into load position (see picture below)

The upper holder clips (CS3,CS4) are not necessary on a short stroke (Kelvin) plunger. The sensors will be fixed with grub screws ! Note that for correct adjustment of load-switch there should be a small gap between plunger head and base plate! (approx. 5/10mm)
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Picture 239: Load and Test position
Picture 240: Load Position
Loosen load-switch fixing screw and shift reed sensor until LED (red light) lightens up (see picture: Reed sensors and air cylinder) After correct adjustment, tighten reed switch fixing screw again and (if necessary) proceed to adjustment of end-switch
8.2.3.2 Test Position Adjustment

The test-position can adjusted with Contactor only !
To find the exact end position you have to mount the plunger to the chamber and push the plunger head into the testing position. Move plunger head into test position (see picture Load and Test Position) Remove holder clip and shift reed sensor until LED (red light) lightens up and turns off again, now move (just a few millimeters) the sensor back as far as the light turns on again (see picture Reed sensors and air cylinder). After successful adjustment put on the holder clip again. Put on plunger housing and tighten fixing screws
8.3 Lead support width adjustment

For integrated plunger head use following gauge :
Used gauge width depends on device width
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Picture 241: Adjustment gauge
Open the lead support fixing screws. Put the gauge(slotted hole in front) in the plunger head. Move the sapphire bed notches careful on the gauge. Fix screws and put out the gauge.
Picture 242: Integrated head For lead support adjustment on plunger heads with top guiding: Loosen fixing screws and remove top guiding (see picture below)
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Picture 243: Top guiding and fixing screws Loosen lead support fixing screws (not too much!!)
Insert adjustment gauge (width of gauge should match actual device width! See picture below) Dont let the gauge be clamped by sapphire bed notches!! (see picture: Lead support fixing screws)
Used gauge width depends on device width (see schematic below)
Picture 244: Device free play depending on used gauge width
Be careful with sapphire bed notches since they are very fragile!!
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Picture 245: Lead support and fixing screws
Picture 246: Sapphire bed notches Tighten lead support fixing screws Check for correct measure and repeat above steps if necessary
8.4 Stopper cylinder

Desired gap between stopper cylinder cap and lever is approx. 5/10mm (see picture below)
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Picture 247: Gap between stopper cylinder cap and lever For adjustment: Remove Plunger cover (see 1.1.3) Loosen air cylinder fixing screws and take out air cylinder (see picture below)
Picture 248: Air cylinder fixing screws Loosen counter nut and turn in or out stopper shaft until desired value is reached (see picture below)
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Picture 249: Stopper shaft and counter nut
After successful adjustment put air cylinder back in and tighten fixing screws, put cover back on.
8.5 Plunger Speed Control Adjustments

Choose the correct plunger setting in the configuration screen.
Picture 250: Plunger settings Choose the speed control version Controlled throttles. Choose the correct plunger and stroke length: Belly Bar long, Belly Bar short or RPTB (Real Plunge to Board).
Adjust the throttles to TestPos in the plunger service screen.
Picture 251: Plunger speed service screen
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Picture 252: Plunger Speed Throttles
Activate CS1-4 separately and adjust the throttles until you have following (recommended) plunge times:
520ms to 570ms for Belly Bar long and RPTB (recommended: about 530ms). 230ms to 240ms for Belly Bar short. Adjust the reed sensors from plunger cylinders as described above !

There is no Speed Adjustment to Load Position necessary/possible. It is controlled via fix throttles !
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Plunger (RPTB)

9.1.1 Base Track
After level compensation the Base Track has the same level as bordering guiding (see pictures below)
Picture 253: Base Track
After level compensation Exit, Middle and Input Guiding have the same level.
Picture 254: Exit, Middle and Input Guiding
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9.1.2 Guiding Opener
Device has to be stopped at Lead Frame
Picture 255: Guiding Opener
Picture 256: Schematic View
9.1.3 Pin 1 position adjustment

9.1.3.1 CS1 and CS2
To adjust the Pin1 position it is helpful to put the Plunger vertical Remove Top Guiding Plunger Exit Be careful , shims inlaid
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Picture 257: CS1 CS2
Remove Guiding Opener Open Lead Stopper by pushing Opener up
Picture 258: Open Lead Stopper
Remove Lead Stopper and add/remove shims
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Picture 259: Lead Stopper CS1 CS2
Mount Lead Stopper Control Pin 1 position Mount Guiding Opener and Top Guiding Plunger Exit (insert removed shims!) The Lead Stopper needs to get opened without scratching the Guiding Openers !

9.1.3.2 Opener Cylinder Adjustment

It must be a gap of 0.05 - 0.1mm between the opener and the plunger housing. If not, readjust the opener cylinder as following shown. Activate the opener cylinder. Check the gap of the opener.
Picture 260: Opener Gap
Remove the Plunger cover. Remove the Opener cylinder.
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Picture 304: Opener Cylinder Loosen the check nut and turn the cylinder as needed. After successful adjustment fix the check nut again and mount the cylinder. Mount the Plunger cover.
9.1.3.3 CS3 and CS4
To adjust the Pin1 position it is helpful to put the Plunger vertical Remove Top Guiding Plunger Mid and Guiding Opener
Picture 261: Top Guiding Mid
Remove LS Be careful of avoid damage of LS or LS cable
Open Guiding Opener and remove Mid Guiding Dont lose shims or springs
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Picture 262: Lead Stopper CS3/CS4
Remove Lead Stopper and add/remove shims Mount Lead Stopper Control Pin1 position Mount Mid Guiding (insert removed shims and springs) Mount LS Mount Top Guiding Plunger Mid and Guiding Opener The Lead Stopper needs to get opened without scratching the Guiding Openers !
9.2 Guiding Opener

For Guiding Opener adjustment use the supplied gauge (see picture below) Loosen fixing screws Put in gauge careful Press the guiding opener smooth against the gauge and tighten fixing screws Pull out gauge
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Picture 263: Guiding Opener Gauge
9.3 Vacuum Sensor adjustment
Picture 264: Vacuum Sensors

To check the Basic Adjustments it may be necessary to release the Key-Protect Function: Press the Mode Button in the normal sensing mode for at least 4 sec. The reading on the Display should be off. If the reading is on , repeat the procedure! In the sensing mode the Zero-point can be adjusted by pressing both UP key and DOWN key simultaneously
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1.
Initial settings : Press both UP key and MODE key simultaneously to change from sensing mode to the initial setting 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
2.
Press the MODE key and the Sensor returns to sensing mode. Supplementary settings : Press the DOWN key and the MODE key simultaneously to change to the supplementary setting mode U-1 and no (Normal open) or nc (Normal closed) is displayed alternately and can be changed with the DOWN key to no (U-2 and U-3 should remain on the lowest possible setting)
3.
Press the MODE key and the Sensor returns to sensing mode Adjustment of Vacuum : Activate the Vacuum for Manual Control CS 1 (2,3,4) with and without a device an write down the values The reading without a device at ambient temperature should be < then -40 kPa, the reading with a device should be > then -70 kPa. If the reading is different, check the Vacuum System for correct function Press the MODE key: P-1 and the present Set Value 1 is displayed alternately. Set the value of P-1 to the max. possible value (-101,3) Press the MODE key again: P-2 and the present Set Value 2 is displayed alternately. Set the value for P-2 to a value between the measured value with and without a device Press the MODE key and the Sensor returns to the sensing mode Repeat the procedure for Vacuum sensor CS 2, CS 3, CS 4
It is recommended to activate the Key-Protect Function after adjusting the Sensor by pressing the MODE key for at least 4 sec.
9.4 Adjusting the reed sensors for load and test position
Remove housing, by loosening the housing fixing screws (see picture below)
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Picture 265: Plunger Housing
9.4.1 Load Position Adjustments

Find the reed sensors located upon the big air cylinder (see picture below)
Picture 266: Reed Sensor Move plunger head into load position (see picture below)
Note that for correct adjustment of load-switch there should be a small gap between plunger head and base plate! (approx. 5/10mm)
Picture 267: load / Test position
Picture 268: Gap plunger head
Loosen load-switch fixing screw and shift reed sensor until LED (red light) lightens up (see picture: Reed sensors and air cylinder) After correct adjustment, tighten reed switch fixing screw again and (if necessary) proceed to adjustment of end-switch
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9.4.2 Test Position Adjustment

The test-position can adjusted with Contactor only !
To find the exact end position you have to mount the plunger to the chamber and push the plunger head into the testing position. Move plunger head into test position (see picture Load and Test Position) Remove holder clip and shift reed sensor until LED (red light) lightens up and turns off again, now move (just a few millimeters) the sensor back as far as the light turns on again (see picture Reed sensors and air cylinder). After successful adjustment put on the holder clip again. Put on plunger housing and tighten fixing screws
9.5 Plunger Speed Control Adjustments

For adjustment instructions see Plunger Belly Bar chapter.
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10 Contactor
10.1 Kelvin
10.1.1 Standard
10.1.1.1 Level Compensation Stop Dog
Remove Stop Dog fixing screws Add or remove shims and tighten screws.
10.1.1.2 Spring adjustment
To adjust Contactor springs a microscope is very helpful
Picture 269: Kelvin Contactor
Loosen screws (fixing Kelvin Contact) and tighten them very softly. Put gauge into holes of Centering Parts (mark at top side) and slide down the gauge to the level of Kelvin Contactor springs.
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Picture 270: Kelvin Gauge
Center Kelvin Contact springs to semicircle openings of gauge
Picture 271: Kelvin Contactors centered to openings of gauge
Carefully slide down the gauge to the end position. If there is a bad centering of springs to the openings the Kelvin Contactor have to be moved careful until all springs are inside the gauge openings. Exact centering of springs
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Picture 272: Spring position
Control correct position of Kelvin Contactor by sliding up and down the gauge. The springs should not move (correct centered without contact to the opening surface). If there is no movement and a good centering the alignment of the Contactor springs is ok. Tighten screws to fix Kelvin Contactor.
To prevent loosening of new Kelvin Contacts, all screws have to be tighten again after heating up to 130C for 5 minutes !
10.1.2 ESX-Series
Adjust Contactor by changing the Alignment Plate Remove Contactor Remove Centering Part Loosen screws Remove Middle Ledge Disconnect Contactor Socket Contactor Plate Remove Holder Change Alignment Gauge Mount Contactor in reverse order
10.2 Plunge to Board (PTB)

10.2.1 Johnstech (JTI)
10.2.1.1 Level Compensation

2008.Sep.22
Remove the screws of the Centering parts. Put out Centering parts. Add or remove shims Nominal is 0.2mm. Put in Centering parts. After successful shimming tighten screws.
Rasco
Picture 273: Centering parts Picture 274: Shim (Centering part)
10.2.2 Over Travel compensation
Picture 275: Over Travel PTB
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10.3 Real Plunge to Board (RPTB)

10.3.1 Rasco Pogo
10.3.1.1 Level Compensation
Remove the screws of the Centering parts. Put out Centering parts. Add or remove shims Nominal is 0.5mm. Put in Centering parts. After successful shimming tighten screws.
Picture 276: RPTB Contactor
10.3.2 Over Travel compensation
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Picture 277: Over Travel pogo contactor
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11 Sorter
11.1.1 Sorter Turn Base Plate
Base Plate should be leveled with shuttle (see picture below)
Picture 278: Level base plate shuttle In case of divergence: Remove fixing screws (see picture below) Insert or remove shimming plates below turn base plate Check level again When base plate is leveled, insert and tighten fixing screws again
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Picture 279: Base Plate screws
11.1.2 Turn 180

Measure distance of turn connection plate and base plate Desired value is 5mm
Picture 280: Turn measurement point In case of divergence, remove fixing screws (see picture below)
Picture 281: Turn fixing screws Remove turn connection plate Insert or remove shimming plates below for correct measure Tighten fixing screw again
11.2 Turn Unit

11.2.1 Turn End Position
For adjusting end positions of 180 turns: Loosen locknut 2008.Sep.22 Adjustments And Maintenance SO2000.Doc page 151 of 286
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Use socket screw for adjusting position (see pictures below)
After adjustment track of 180 turn should be inline with track of Post CS Tighten lock nut again!
Picture 282: Turn end-positions left side
Picture 283: Turn end-positions right side
11.2.2 Stopper Cylinder Adjustment
Distance between Base Plate and stopper cylinder should be ~5.5 mm
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Picture 284: Stopper pin measurement point In case of divergence: Loosen and remove base plate fixing screws Take out base plate Adjust stopper cylinder
Picture 285: Stopper Cylinder Adjustment Check for correct measure again If distance is correct Put base plate back in Tighten fixing screws Caution: Do not lose the shims under the connection plate
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11.3 Sorter Base Unit

11.3.1 Shuttle Belt Tension
Its recommended to remove the cover on the chamber side plate if you want to change or readjust the belt.
(That design change was implemented in January 2004)
Picture 286: Chamber side plate For adjusting belt tension:

Use belt tension adjustment tool!
Move shuttle in the right end position!

Place adjustment tool into corresponding mounting (see picture below)
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Picture 287: Belt tension adjustment tool Loosen counter nut of eccentric belt bearing (on the backside) For tension adjustment turn socket screw
Picture 288: Eccentric bearing for belt tension adjustment
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Picture 289: Belt tension adjustment screw Correct tension adjustment is reached, when adjustment tool shows green marking (see picture below)
Picture 290: Correct belt tension After successful adjustment, tighten lock nut and remove adjustment tool
11.3.2 Sorter Belt - new design - Tension

The new belt is recognizable on the white color!
The pin should be 2mm above the marking (see picture below)!
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Picture 291: Correct belt tension for a new belt
11.3.3 Shuttle belt gear track adjustment
For track adjustment shuttle should be located in left max. position Loosen and take out socket head adjustment screw Take off cover plate Loosen belt gear
Picture 292: Belt gear fixing screws For correct adjustment see picture below
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Picture 293: Correct belt-to-gear adjustment After adjustment belt should be parallel to gear and distance A should be equal to B Put on cover plate and tighten socket head screws again
11.3.3.1 Pulley Position Adjustment

To fix the pulley in the correct position pay attention to the distance between the sorter plate (sink) and the outer pulley disc. It should be 8.5mm (see picture below).
It is recommended to use a caliper for measurement !
Picture 294: Correct Pulley position
11.3.4 Sorter Front Plate Removing

The Sorter Front Plate can be removed as a unit (including Amplifiers and Cables) by removing 2 Covers (each cover is mounted with 3 screws) opening 10xM3 Screws and unplugging 3 Connectors. Remove right and left sorter cover.
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Picture 295: Sorter cover
Remove the fixing screws of the sorter front plate.
Picture 296: Sorter front plate
Picture 297: Sorter front plate removed
11.3.5 Sorter Teaching

2008.Sep.22 Do not open sorter cover while shuttle is moving! Moving parts can harm fingers For (re-) teaching sorter positions: Stop running machine Adjustments And Maintenance SO2000.Doc page 159 of 286
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Select SERVICE on the operator interface main screen
Picture 298: Operator Interface Main screen Select SORTER page Select Teach Sorter Exits
Picture 299: Sorter Screen Now youre asked Please check and save Home position!
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Picture 300: Initialization screen

-
Check if shuttle is in left most position if so press SAVE HOME POSITION In case shuttle is not in left most position move shuttle manually and then press SAVE HOME POSITION Now teach each the positions you need: Select Left or Right side of the Shuttle (seen in picture below) Select one of the 16 Exits The shuttle should be moving to desired exit Check if actual position is correct (e.g. if guiding are inline) If not correct shuttle position by pressing <> for small steps left/right or pressing <<>> for big steps left/right (see picture below) After adjustment for actual position is finished, press SAVE POSITION
Picture 301: Shuttle adjustment
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11.3.6 Double Drop light sensor adjustment

11.3.6.1 Focus-size adjustment
Picture 302: focus size adjustment To adjust focus-size, turn lens housing (unmounted) around screw from Double Drop LS carefully! As far as possible (see picture below)
The sensor point should not be sharp but diffuse !

Lock check nut to lens housing Fix Lens housing to Optic Holder 1 again.
Picture 303: focus size adjustment
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11.3.6.2 Focus adjustment in longitudinal direction
Picture 304: longitudinal direction adjustment Bring Sorter Track to compatibility with Turn Track Place 2 devices after another, the first one close to the Stopper Pin (see picture below) Loosen fixing screws of Optic Holder 1 Place focus dot to the middle of 2nd device (see picture below) Bolt on fixing screws from Optic Holder 1
Picture 305: Longitudinal direction adjustment
11.3.6.3 Focus adjustment in longitudinal direction with scale (new sensor holder)
To adjust the double drop sensor with the scale do following steps : Measure the length (in mm) of your device.
2008.Sep.22
Loosen the fixing screws of the Sensor holder (see picture below). Move the sensor holder (Mark arrow) exactly to the device length position on the scale. After adjustment fix screws again.
Rasco
Picture 306: Longitudinal direction adjustment with scale
11.3.6.4 Horizontal focus adjustment
Picture 307: horizontal focus adjustment Loosen fixing screws of Lens Housing Move Lens Housing until focus dot is in the horizontal middle of device Bolt on fixing screws of Lens Housing
11.3.6.5 Focus intensity adjustment

Turn amplifier adjustment screw in this way, that when the focus dot hits the track-bottom the signal is on, an when it hits the device the signal is off
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12 Tape & Reel

12.1 Basic Adjustments
After every adjustment in which actors are moved by the manual control it must be guaranteed that the actors are returned to their original position. The easiest way to avoid damage to the system is to use the implemented RESTART option to setup the system again.
12.1.1 Reel Clutch Adjustment

12.1.1.1 Function Reel Clutch
The integrated clutch is needed to provide a constant tension to the Taper. For use at the de-taping option the clutch for the Cover Reel must be strong enough to pull off the cover tape from the tape.
12.1.1.2 Adjusting Reel Clutch Torque
Picture 308: Reel Clutch By opening the screws you can move each side of the clutch. Moving both sides to the middle will increase the torque (max. 0,2 Nm), moving both sides apart (as shown on the picture) will decrease the torque.
The used clutch works on magnetic basis that means there is no wear and the adjusted torque will not change

12.2.1 Turn 180
Nominal Turn dimension. The nominal dimension (to be measured like shown in picture below!) is 5mm. In case of deviation use shimming plates. Measure distance of turn connection plate and base plate Desired value is 5 mm In case of divergence, remove fixing screws (see picture below)
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Picture 309: Turn measurement point
Picture 310: Turn measurement point
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12.2.2 Handling Area
Picture 311: level compensation taper handling area
12.2.3 Lead Buffer

Use Shims to equalize the sliding level from the Mark Buffer into the Lead Buffer and out into the Mark Buffer Exit. The nominal value is 0.1mm. For the Optional 3D lead inspection additional shims are used to eliminate tolerances of the center prisms. The nominal values for this option is 0.1mm.
12.2.4 Taper Turn

Use Shims to equalize the sliding level from the Lead Buffer Exit into the Taper Turn out into the Centering. The nominal value is 0.1mm.
The Centering shims are part of the conversion kit, therefore the shim thickness is according to the nominal kit shimming.
12.3 Handling Area Adjustments

12.3.1 Adjustments Mark Buffer
12.3.1.1 Option Mark Inspection
For detailed information about the Vision System refer to the corresponding Vision Manual.
12.3.1.2 Laser Marking

After dismounting the camera or the camera system it has to be verified that the camera picture still is on the same position and has the same quality. 2008.Sep.22 Adjustments And Maintenance SO2000.Doc page 167 of 286
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For detail information refer to the corresponding Vision Manual.
12.3.2 Adjustments Lead Buffer

12.3.2.1 Option 3D Lead inspection
For proper co-planarity measurement it is important that the device pusher is pressing the device against the center prism and that no shadow is on the Vision monitor during taking the picture.
12.3.2.2 Option Scratch Inspection

12.3.3 Adjustments Turn
Picture 312: Taper Turn
12.3.3.1 Adjust the Turn to Entry position:

Move the turn to the <Turn to Entry> position (use manual control) Open the counter nut Turn the adjustment screw until the turn is in line with the above guiding Take care that the Mark on the Turn shows in direction turn entry Fix the counter nut
12.3.3.2 Adjust the Turn to Exit position:

Move the turn to the <Turn to Exit> position (use manual control) Open the counter nut Turn the adjustment screw until the turn is in line with the beyond guiding Take care that the Mark on the Turn shows in direction turn exit Fix the counter nut
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12.3.3.3 Stopper Cylinder
Distance between Base Plate and stopper cylinder should be ~ 6mm
Picture 313: Stopper Cylinder measurement In case of divergence: Loosen and remove base plate fixing screws Take out base plate Adjust stopper cylinder Check for correct measure again If distance is correct Put base plate back in Tighten fixing screws
12.3.4 Adjustment Centering

12.3.4.1 Function of the Centering
The Taper centering places the device in such a position that the pickup lifts the device exactly from its center, and guarantees, that the device is placed properly into the tape pocket.
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12.3.4.2 Side Guiding width at the Centering
Picture 314: centering side guiding: width adjustment
The side guiding Centering have to be closed (see manual control) and the kit depending shimming has to be done before correctly! Loosen all screws until you can move the side guiding slightly. Insert 4 guide pins and press (only by hand) them through the side guiding into the base track until you touch the ground. So the width of the side guiding are adjusted properly to the holes on the Base Track. Fix the screws, and remove all guide pins.
12.3.5 Adjusting Manual Exits
Picture 315: Manual Exits adjustment
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12.3.5.1 Function of the Manual Exits
The manual exit always provides 4 output sort categories. The exits can either be tubes or boxes. Due to the 3 cylinders it is possible to drive to 4 different positions, each of these single positions can be adjusted in X direction.
Dont forget to tighten the counter nuts after the adjustment procedure.
Picture 316: Manual Exits Reed sensors
12.3.5.2 Position Exit 1

The adjustment for Exit 1 has to be done at the floating joint (see picture above) First loosen the counter nut and move the Manual Exits to the left or right side (by turning the screw in or out) until the track Exit 1 is in line with the centering track.
Picture 317: Centering Track 2008.Sep.22 Adjustments And Maintenance SO2000.Doc page 171 of 286
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Picture 318: Centering Track and Exits
Picture 319: Inline Adjustment of Centering Track and Exit
12.3.5.3 Reed sensor at Exit 1

The corresponding sensor to detect the Position Taper Exits at Exit 1? is C50i09. (see Reed sensor adjustment on cylinders)

The adjustment for Exit 2 has to be done at the Stopper cylinder for Exit 2(see picture: Manual Exits adjustment) First loosen the counter nut and move the Manual Exits to the left or right side (by turning the screw in or out) until the track Exit 2 is in line with the centering track. (shown in picture: Inline Adjustment of Centering Track and Exit)

The corresponding sensor to detect the Position Taper Exits at Exit 2 ? is C50i10 (see Reed sensor adjustment on cylinders)
Because this sensor is activated from both sides the sensor switch field has to be adjusted symmetrically to the detect position
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The adjustment for Exit 3 has to be done at the Stopper cylinder for Exit 3 (see picture: Manual Exits adjustment) First loosen the counter nut and move the Manual Exits to the left or right side (by turning in or out the screw) until the track Exit 3 is in line with the centering track. (shown in picture: Inline Adjustment of Centering Track and Exit)

The corresponding sensor to detect the Position Exit 3 is C50i11 (see Reed sensor adjustment on cylinders)
Because this sensor is activated from both sides the sensor switch field has to be adjusted systemically to the detect position

The adjustment for Exit 4 has to be done at the Stopper screw (see picture: Manual Exits adjustment). First loosen the counter nut and move the Manual Exits to the left or right side (by turning the screw in or out) until the track Exit 4 is in line with the centering track. (shown in picture: Inline Adjustment of Centering Track and Exit)

The corresponding sensor to detect the Position Exit 4 is C50i12 (see Reed sensor adjustment on cylinders)
12.3.5.10
Manual Exit driving speed
Picture 320: Manual Exits speed To adjust the driving speed it is recommended to use the Manual Control. The movement of the Exit Boxes should be a smooth movement.

Dont forget to tighten the counter nuts of the speed controllers after the adjustment Height of Exit Ledge (only Manual Tube Exits) (TBD)
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12.4 Taping Area Adjustments

12.4.1 Pickup Adjustments

Attention ! Fast pneumatic cylinder! Make sure that the pickup is not activated while doing the adjustments at the PICK UP area!
12.4.1.1 Pick Up Stop Position Adjustment

To adjust the correct position of the pick up head do following: Select <Manual Control>in your OPI. Select <Tape & Reel> and <Handling Area>(see screen below). Open the centering and actuate the stopper
. Picture 321: Handling area screen Insert a device close to the stopper. Close the centering. Check the close placement of the device to the stopper. Select <Taping Area> Switch the vacuum head in <Neutral> state (see picture below).
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Picture 322: Taping area screen
Picture 323: Taping area screen Place about 2mm shims underneath the adjustment screw. Switch on the vacuum head (C51o24) .
Fast moving Cylinder! Keep Hands off Handling Area!
Activate <Move to Centering> on the screen. Check the changing of the vacuum head pressure value (C50i19). Activate <Neutral> and remove Pick Up Head by hand. Reduce the shimming by 0.2mm. Repeat the last 4 steps until the vacuum pressure (C50i19) has reached approx. -60kPa Now reduce the shimming again by 0.2mm and counter adjustment screw with the nut.
When you use rubber tips, reduce the shimming by 0.3mm on the last step.
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Check the adjustment:

Move Pick up to Centering (<Move to Centering>). Open each side of the centering guiding by hand: If the IC is moving (touches the centering), reduce the shimming (~0.1mm) and check again. Open centering <C51oi06> and deactivate stopper <C51o05>. Try to move the IC with tweezers: If the IC is touching the base track, increase shimming (~0.1mm) and check again.

Check if the Bearing Arm Head hits the Stopper rectangular. If not, adjust the angle of the Stopper Holder!
Attention : If you change the stopper position it is always necessary to adjust the shock absorber position new ! Sometimes it is necessary to readjust also the tape stopper.
Picture 324: Pick Up Centering Hard Stop
Picture 325: Vacuum head value
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12.4.1.2 Vacuum Head Adjustment

1.
To check the Basic Adjustments it may be necessary to release the Key-Protect Function: Press the Mode Button in the normal sensing mode for at least 4 sec. The reading on the Display should be off. If the reading is on , repeat the procedure! In the sensing mode the Zero-point can be adjusted by pressing both UP key and DOWN key simultaneously Initial settings : Press both UP key and MODE key simultaneously to change from sensing mode to the initial setting 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
2.
Press the MODE key and the Sensor returns to sensing mode. Supplementary settings : Press the DOWN key and the MODE key simultaneously to change to the supplementary setting mode U-1 and no (Normal open) or nc (Normal closed) is displayed alternately and can be changed with the DOWN key to no (U-2 and U-3 should remain on the lowest possible setting)
3.
Press the MODE key and the Sensor returns to sensing mode Adjustment of Vacuum : Activate the Vacuum for Manual Control with and without a device an write down the values. The reading without a device should be < then -40 kPa, the reading with a device should be > then -70 kPa. If the reading is different, check the Vacuum System for correct function Press the MODE key: P-1 and the present Set Value 1 is displayed alternately. Set the value of P-1 to the max. possible value (-101,3) Press the MODE key again: P-2 and the present Set Value 2 is displayed alternately. Set the value for P-2 to a value between the measured value with and without a device Press the MODE key and the Sensor returns to the sensing mode
It is recommended to activate the Key-Protect Function after adjusting the Sensor by pressing the MODE key for at least 4 sec.
12.4.1.3 90 Turn Position Adjustment

For the correct position of the turn cylinder do following steps : Turn cylinder in completely. Turn cylinder back until fitting is on the left side (see picture below). Now adjust the brass part until the gap of 3.5mm is reached. After adjustment check counter nut.
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Picture 326: Turn Position
12.4.1.4 Pick Up Head Position

Open centering again and move pick up in tape direction to have a good view on the device. Check device position (see picture below). The device has to be exact in the middle of the vacuum chuck.
Picture 327: Centrically device position Should the device not exact in the middle do following : Remove fixing screws and take off arm (see picture below). Insert or remove shims. After shimming put the pick up arm on and tighten fixing screws. Repeat all steps .
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Picture 328: Pick up shims
12.4.1.5 Centering Stopper Adjustments

This adjustment is necessary for a correct lengthwise centric position of the device. Put a device in the centering like described above. Pick up the device. Move pick up arm back. Select <Manual Control>. Select <Tape & Reel> and <Taping Area>.
Picture 329: Neutral turn head Switch the 90 turn neutral and turn vacuum head (see screen below). Check the lengthwise centric position of the device the device must placed in the middle of the head (see picture below).
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Picture 330: Length position If the position is not correct loosen fixing screws and check nut and turn the adjustment screw left or right. The stopper will then move up (left turn) or down (right turn).
Tighten fixing screws.
Picture 331: Stopper position centering Repeat all steps and check position again. After successful adjustment tighten check nut again
12.4.1.6 Tape Stopper Adjustment

The adjustment should guarantee the correct distance between vacuum head and tape. Switch the pick up to neutral and move them by hand to the tape (see picture below) For the first trials the gap between device and tape should be approx. 0.5mm. If you can see the device fit exact into the pocket you can adjust the stopper lower .
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Picture 332: Distance vacuum head and tape If the position deviates adjust the stopper. Loosen counter nut and turn adjustment screw left or right.
Picture 333: Stopper adjustment After successful adjustment tighten counter nut again.

Attention : If you change the stopper position it is always necessary to adjust the shock absorber position new ! Sometimes it is necessary to readjust also the centering.
Check if the Bearing Arm Head hits the Stopper rectangular. If not, adjust the angle of the Stopper Holder!
12.4.1.6.1 Shock Absorber Tape Adjust each damper holder that the gap between Damper Holder and Cylinder arm is approx. 2mm if Pick up is at stop dog.
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Picture 334: Shock absorber adjustment
Picture 335: Shock absorber gap
12.4.1.7 Pick Up Speed Adjustments

To teach the pick up speed do following :
First : Remove vacuum chuck because danger of damaging ! Loose fixing screws and move back the shock absorber . Select <Service> <Tape & Reel> <Pick Up> (you will see a screen similar to the one below). Enter for the first trials in <Decelerate time> 23 two times (see picture below). In <Decelerate offset> 0 and 5 (see picture below). Push teaching <On>. Vary the values until the sound of the stopper is acceptable.
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Picture 336: Teaching screen After successful adjustment fix the shock absorber again.
Adjust the travel of the Dampers by threads. The total travel should be about 2-3mm. Be aware that the travel of the damper effects the index time of the pick up process!
12.4.2 Pick & Place Unit (Belt System)

12.4.2.1 Basic OPI Setup Configuration
Open Configuration Screen and choose Controlled Throttles mode at Speed Control.
Picture 337: Configuration screen
12.4.2.2 Turn Cylinder- Synchronisation with Belt and Pickup Head position
The pointer of the Turn Cylinder must show to specific directions when the Pickup Head has reached the end positions, this depends on the synchronisation of the tooth belt. To check the correct synchronisation, open the Manual Control Screen at OPI and move Pickup Head to Centering. The sticker on the Cylinder marks the black colored area the lever of the Cylinder must now cover, as shown at the picture.
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Picture 338: Lever at Centering position
Now activate Head to Tape. The Lever must also cover the black area Head at Tape
Picture 339: Lever at Tape position
In case the lever does not match the black colored areas a re-synchronisation of the tooth belt is necessary: Set Pick Up to Neutral at Manual Control Screen. The Pick Up Head must now be moved by hand! Loosen 3 screws at the belt wheel, the wheel should now glide on the axle of the cylinder.
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Picture 340: Axle fixing screws
Move Pickup Head by hand to the centering position and press it down, while pressing, turn the lever of the cylinder to the black colored area, then tighten 3 screws at belt wheel again.
The synchronisation is important for the correct function of the speed control. The accuracy of the lever position should not exceed more than 1mm to the black area center !
12.4.2.3 Adjustment of the Belt tension

Loosen four fixing screws of the cylinder plate. Turn tension belt as necessary direction. A play (by finger pressing) of the belt should be around 5mm ! Fix screws again.
Picture 341: Belt tension adjustment
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12.4.2.4 Adjustment of Pickup at Centering Position
12.4.2.4.1 Horizontal Position (Center of Centering)
Picture 342: Pick up center gauge
Remove Rubber Tip and activate vacuum, then put on Pickup Center Gauge to the Pickup Head. Open Centering by Manual Control Screen and move the Pickup Head by hand to the centering. Now check that the peak of the gauge shows to the center of the Centering. If it does not fit, insert or take away shims beneath the lever arm.
Picture 343: Lever Shim
12.4.2.4.2 Height Adjustment Pick Up Centering (IC Height Adjustment) Put on Rubber Tip.
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Open Screw at Hardstop Nut and remove Fixing Plate.
Set Service Stop: Stop when Head is at Centering at Service Screen.
Picture 344: Hardstop Nut
Watch the Vacuum Sensor and turn Harstop Nut clockwise until the vacuum drops below 70, then start to turn counterclockwise.(If already below 70 start with turning Nut counterclockwise.) At the point when the vacuum does not increase anymore while turning counterclockwise, add 3-5 more Clicks clockwise again. 1 Click of the Nut equals about 0.06mm of height change!

Turning the Hardstop Nut is only the adjustment procedure for the Centering Side! The Tape side has a different method of adjustment (see Adjustment of Pickup at Tape Position chapter).
12.4.2.5 Adjustment of Pickup at Tape Position

12.4.2.5.1 X-Y Position Adjustment For X-Y position adjustment see rules in the existing chapter above .
12.4.2.5.2 Height Adjustment
The height adjustment at the Head at Tape side is a once- in- a- time adjustment and is to do with shims.
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Picture 345: Height adjustment shims
12.4.2.6 Adjustment of De-Taping Mode
Picture 346: De-Taping disc
The correct height needs to be shimmed
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Picture 347: De-Taping disc shim
12.4.2.7 Adjustment of Pick Up Axle Bearing

Only in case the Pick Up Axle has a noticeable play, the axial bearing of the Pick Up Head can be shimmed to minimize the play. Shim only +0.02mm and check play again. The 90 Turn must still move easily.
Picture 348: Axle shim
12.4.2.8 Device height compensation
Only for ICs thicker than 2.5mm a different Compensation Plate needs to be installed on the Lever Arm for correct Damper compensation (Engraving: 2.5mm-4mm IC)
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Picture 349: Compensation Track
12.4.3

Carrier Tape Roller Adjustments

Loose the grub fixing screws and move the sensor holder 8mm under the top end of the linear guiding. Tighten screws again. To adjust the hardstop screw loosen the check nut and turn the screw until a gap of 35mm is reached. After successful adjustment tighten check nut again.
Picture 350: Carrier Tape Roller
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12.4.4 Tape Guiding Adjustments

12.4.4.1 Tape Guiding Width
Picture 351: fixing screws taperline width Loosen the fixing screw as shown on the picture above and below
Picture 352: Fixing screws at front
Picture 353: Fixing screws at Exit
To adjust the Width of closed 8mm Taper Lines (UPG), you need to loosen all screws of the Cover Sheets!
Move up the gauge to the needed tape width (The gauge can be used for standard tape width 8, 12, 16, 20, 24mm) Adjustments And Maintenance SO2000.Doc page 191 of 286
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Move down the gauge on both sides and fix the rest of the screws
Adjustments and Maintenance Press the tape guiding against the gauge and fix the 2 screws, do this on both sides
Do not forget to move gauge down this could cause damage to the tape! Mount the safety cover again!
To verify if the adjustment was done correctly, take a piece of the tape and insert it into the taper until you can hold it on both sides, now move the tape vice versa (by hand) The tape should slide smoothly into the guiding!
12.4.4.2 Taper Line height

Only for new Taper Lines! (after 04/2005)
The new Taperline design allows to use Shims for adjusting the vertical play of the tape. Always shim as less as possible. The nominal shimming is 0.05mm. The Exit sheets must always be shimmed 0.05mm higher than the front sheets!
12.4.4.3 Sealer Inserts

To adjust the inserts at the Sealing position, remove the Cover Sheets.
Picture 354: Cover Sheets
The Sealer Inserts should support the carrier tape as narrow as possible, but should never clamp the tape. Take a strip of the carrier tape to check if the tape is going smooth through the inserts, but without side movement.
Also take care that the tape builds one straight line between the sealer inserts and the front and back end of the taper line.
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Picture 355: Sealer Inserts
12.4.4.4 Vertical Tape position

The center of Tape Pocket must be placed exactly in line with the Pick Up Head at Tape Position.
Picture 356: Vertical Tape Position
Loosen locknut (shown in picture below)
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Picture 357: Adjusting vertical Tape Position Now you can adjust the vertical displacement by turning the socket screw carefully! Check adjusted displacement Tighten locknut after successful adjustment
12.4.4.5 Adjusting Indexer belt tensions

To achieve an accurate belt tension, install the Gauge Jig (Taper Belt) (Order# 04.7000.1015) at the shown position. Loosen the lower screw and use this for temporarily fixing of the Gauge Jig. Adjust the eccentric wheel (see pic next page) of the belt bearing until the axle of the Jig covers the marking line. Be aware that the eccentric wheel is countered with a 10mm nut from the backside!
Picture 358: Gauge Jig (Taper Belt)

Remove Gauge Jig and mount the safety cover again! Never move the belt (either manual or electric) while Gauge Jig is mounted!
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12.4.4.6 Synchronizing Indexer Wheels
Picture 359: indexer / wheel Loosen all fixing screws at both wheels and check if each index wheel can be turned easily Insert a piece of tape until you can hold it on both sides, now move the tape vice versa (by hand). The tape should slide smoothly into the guiding! So the indexer wheels are synchronized with the tape Tighten the screws carefully! Take care not to bring any force onto the tape. This will misalign the synchronization!
Mount the safety cover again!
12.4.4.7 Driving only with one Index Wheel

For small devices ( 100mil, QFN 5x5) it is recommended to run only with the left Index Wheel. To remove the unused right Index Wheel, tighten the hand screw above the Wheel. The Index Wheel moves down and is no longer in contact with the tape.
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Picture 360: Driving one Index Wheel
12.4.4.8 Horizontal Tape Position (Indexer teach procedure )

For fine adjustment of horizontal shifting:
Picture 361: Horizontal Tape Position
Teaching is only possible in Stop Status of the handler! Select Tape & Reel Indexer menu
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Picture 362: Indexer Teaching Interface Here you can adjust the steps, the tape should move further to the right or to the left side After adjusting the desired value by pressing << <> >>, save selected values by pressing Save Offset Carefully check position again, if needed readjust.
Picture 363: indexer teaching
For reliable insertion of the devices it is necessary to adjust the indexer so that the device is not touching any side of the tape pocket.
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12.4.5 Adjusting Free Pocket Sensor
Picture 364: empty pocket sensor Depending on the pocket depth the empty pocket sensor has to be slightly adjusted to optimize the function.
It is recommend to adjust the empty pocket sensor after the indexer-teaching procedure
12.4.6 Cover Tape adjustments
Picture 365: cover tape adjustments
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12.4.6.1 Width of Cover Tape
(see picture cover tape adjustments) loosen the counter nut
carefully turn the adjustment ring until you feel the resistance of the Cover tape then turn the ring back approx. 10 tighten the counter nut
12.4.6.2 Centering Cover Tape

Loosen the fixing screws With the micrometer gauge you can adjust the center of the Cover tape very accurately to the tape
During the sealing process you will not immediately see the result of the adjustment. It is recommenced to seal approx. 0.3 to 0.5 m before you readjust again. Tighten the screws again
12.4.7 Optional In Tape inspection

12.4.8 Sealer Adjustments

If the sealer is working there might be danger due to hot surfaces
Picture 366: sealer settings
12.4.8.1 Sealer function

Depending on the Tape and the Cover Tape, different sealing temperature, sealing time and sealing force might be required to guarantee a proper sealing. To increase the peel off force it is recommended to select higher values for temperature, time or force.
Sealing times greater than 200ms could influence the UPH
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12.4.8.2 Adjusting sealing time
The sealing time can be adjusted in settings/taper/timing/sealing time (see user interface)
12.4.8.3 Adjusting sealing force

(see picture: Sealer settings) The sealing force can be adjusted via air pressure for the sealing cylinder Open the counter nut Adjust the proper sealing pressure The pressure can only be adjusted if the sealer is activated (see manual control) Tighten the count nut
12.4.8.4 Adjusting sealing temperature

(see picture: Sealer settings) The sealing temperature can be adjusted on the sealing temperature controller Press the UP key to increase the sealing temperature Press the DOWN key to decrease the sealing temperature
The AL icon will be OFF until the controller reaches the adjusted temperature. The sealer will not work until the AL icon will be ON again
12.4.8.5 Sealer position adjustment

Any adjustment at the sealer can influence other adjustments, so it is very necessary to follow this procedure step by step ! Before you start adjusting the sealer shoe, make sure that all shims and set screws are removed !
12.4.8.5.1 Basic Adjustments of Position and Angle with Sealer Gauge Position
Picture 367: Sealer position
Could be caused by : Readjustment of taper line widths !
Angle
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Picture 368: Sealer angle
Could be caused by : Adjustment of the Pick Down position ! Loosen the four Torx Screws, each about one complete turn.
Pull out knob and turn to hold outer position.
Picture 369: Sealer Torx Screws
Now push down sealer in between the Sealer Gauges. Tighten the four Torx screws again while pressing down!
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Picture 370: Sealer Torx Screws
12.4.8.5.2 Basic Adjustment of Rotation Angle
Picture 371: Sealer Rotation Angle Remount Sheet(s) again.
Loosen the six screws for about one complete turn.
Picture 372: Sealer Screws
Take a precision angle or something similar parallel and place it onto the taper line. Press down the sealer in the center (see pic) and fix the screws crosswise while pressing down.
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Picture 373: Precision Angle
12.4.8.5.3 Level compensation (Fine Tuning)
Picture 374: Level Compensation
Open four screws to remove lower part of sealer. Insert Shims in the countersink as explained in following steps.
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Picture 375: Shim Level Compensation
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Picture 376: Compensation Examples

The right shim sizes can only be figured out by trial ! Only for special case: One sealing line is similar lighter than the other one.
Picture 377: Compensation Fine Tuning
Picture 378: Compensation Shim
Shim only lighter side under the sealing insert of the tape line.
Picture 379: Insert Shim
12.5 Adjustment of Motor revolution

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To adjust the revolution of the motor do following steps : Remove the white cap. Turn the adjustment screw as far as needed.
Picture 380: Motor adjustment
12.6 Detaping
To use the De-taping function, it is necessary to modify some settings and adjustments as following: Modify the Cover tape guiding as shown in the picture (skip the adjustable pulley) Insert the Distance Piece beneath the head of the screw, so that the slide moves up Lower the Pick Up Hard Stop at the Tape side until the Vacuum Chuck reaches the IC in the tape.
In some cases it is necessary to lower also the hard stop at the centering!
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Picture 381: Cover Tape Guiding
Picture 382: Distance Part
The strength of the Cover Tape Motor Clutch needs to be increased: Move motor with <Manual Control>; <Tape and Reel>; <Taping Area>; <C53o03>, until the fixing screw at the motor side can be reached. Then move Cover Tape Reel by hand until second fixing screw can be reached. Loosen both screws carefully. The magnetic force will pull both sides of the clutch together. Tighten both screws again.
Picture 383: Clutch adjustment. Activate the Detaping Check Box at <Settings>; <Tape and Reel>; <Taper Exit>
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After finishing the De-Taping process reset all setting and adjustments!
12.7 Option Dead Bug Sensor (Intape)

This sensor detect flipped QFN devices in Tape Setting : Teach Amplifier by using dead and live bug device in tape (Dead bug = High Signal)
Picture 384: Dead bug sensor
12.8 Taper Chassis Configuration

12.8.1 Basis Configuration
For detailed information (e.g. baud rate, node ID of CAN Modules ) refer to Electric and pneumatic.
12.8.2 Additional Vision Configuration

12.8.2.1 Asentics
For detailed information refer to Electric and pneumatic.
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Picture 385: Vision Pulso Chassis
12.8.2.2 ICOS
For detailed information refer to Electric and pneumatic.
12.9 Basic Vision Setup

Please refer to Vision Systems SO2000 chapter.
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13 Auto Tube Unloader

13.1 Load Stack / Back Stack
13.1.1 Stack width
To readapt Stack width to a new tube width do following: Loosen fixing screws at Upper and Lower Stacks (see picture below) Adjust width by turning the adjustment screws After adjustment tighten fixing screws again!
Picture 386: Unloader Stack width adjustment
13.1.2 Stack length

To adapt Stack length for a different tube length do the following: Loosen grub screw located on the left side of the Stack assembly (see picture below)
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Picture 387: Unloader Stack length adjustment Now you can shift the Stack front to fit the tube length After adjustment tighten the fixing screw again!
After assembling Unloader to the Handler it could be necessary to adjust the Stack length again.
13.1.3 Tube Centering / Support Transport

To achieve smooth movement from Stack into Centering, the tube Centering Transport has to be inline with the Stack. For adjustment do the following: Loosen Centering / Support fixing screws (see picture below) For adjustment use the eccentric screw (see picture below) Now adjust the Support height by lifting the tube Support (see picture below) Make sure that upper side of tube and upper side of tube Centering have the same level After adjustment tighten fixing screws again Repeat the same procedure with the Lower Stacks
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Picture 388: Centering/Support Transport adjustment
13.2 Transport
13.2.1 Transport adjustment
To adjust Centering of Transport equal with the Stacks do the following: Loosen check nut of Stopper Transport Load (see picture below) Turn Stopper in or out until Centering Transport is in alignment with Upper Load Stacks (see picture below) Lock check nut of Stopper Transport Load again! Repeat the same procedure with the Stopper Transport Back Now repeat the procedure with the Lower Transport
Picture 389: Transport position adjustment
13.2.2 Sensor adjustment Tube in Transport

To adjust sensors Tube in Transport do the following: Move Transport to the Back position (see picture below) Insert tube (see picture below) Loosen fixing screws of Sensor Holder (see picture below)
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Adjustments and Maintenance Move Sensor Holder up or down until Reflective Sensor Tube in Transport will be in the middle of the tube (see picture below) After adjustment tighten fixing screws again! Repeat the same procedure with the Lower Back Stacks
Picture 390: tube in Transport sensors adjustment
13.3 Gripper
To adjust the tube Centering do the following: Insert tube into Gripper Turn Centering adjustment nut in or out as needed (see picture below) During adjustment it might be necessary to loosen the Plastic nut and Sensor Holder. The gap between Centering adjustment nut to Guiding Block and Plastic nut to Cylinder rod should have 1 to 2mm. (see picture below) To adjust the Plastic nut/Cylinder rod is equal to the gap Centering nut/Guiding Block Make sure that the gap Plastic nut/Cylinder rod is equal to the gap Centering nut/Guiding Block Lock check nut from Plastic nut
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Picture 391: tube Centering Gripper adjustment
13.3.2 Sensor adjustment Tube in Centering

To adjust transmissive Sensor tube in Centering do the following: Loosen fixing screws of the Sensor Holder (see picture below) Move Sensor Holder up or down until the beam of transmissive Sensor is able to look through the slot in the Sheet Gripper ( see picture below) After adjustment tighten fixing screws again!
Picture 392: tube in Gripper sensor adjustment
13.3.3 Tube Gripper level adjustment

To adjust the level from the Gripper to the tube do the following: Put a tube in Transport Move Transport to Load position
Picture 393: Gripper tube level fixing screws Loosen fixing screws on Plate below Plate Gripper Shifter (see picture above) Shift Gripper up or down until distance between Plate Gripper and tube amounts to 0-1mm (see picture below) Tighten fixing screws again
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Picture 394: Gripper tube level adjustment
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13.4 Buffer Adjustments

Air Jet Transit Buffer Track to Tube.
Picture 395: Air Jet Throttle
The Side adjustment of the Buffer is only for the right Unloader on the <Exit 8> position necessary ! Loosen the fixing screws of the Buffer plate.
Picture 396: Buffer fixing screws
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Picture 397: Side Adjustment screw
After successful adjustment tighten fixing screws again.
13.5 Unloader Sorter

13.5.1 Unloader to Sorter adjustment
13.5.1.1 High level adjustments
To adjust the Auto Unloader to the Sorter do the following: Insert tube into Gripper Bring Transport in Load position. Loosen check nut and check screw (see picture below). Loosen fixing screws (see picture below). Turn Adjustment Axles (use hexagonal spanner 7mm) left or right until Base Track Sorter Exit is in line with the tube and the device slides smoothly into the tube (see picture below)
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Picture 398: High level adjustment Lock check nut, check screw and tighten fixing screws again
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13.5.1.2 Side level adjustments
To adjust the side gap do following : Move back gripper. Loosen fixing screws (see picture below).
Turn adjustment screw left or right (approx. 1mm) until the position is ok. Tighten fixing screws again.
Picture 399: Side level adjustment
The Plate Gripper Shifter have to be in line with the Sorter (see picture below)
Picture 400: Unloader to Sorter parallel
After assembling Unloader to the Handler it could be necessary to adjust the Stack length again.
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Picture 401: Unloader Sorter adjustment
13.6 Transport and Gripper speed

13.6.1 Transport to load stack/back stack
Press the Service button in the main screen Select Auto Tube Unloader Push Transport to load stack/back stack (yellow background) Adjust throttles until 350/350 (ms) are reached After successful adjustment lock the counter nut The Values always have to be equal!
Picture 402: Transport to load stack/back stack
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13.6.2 Gripper in/out

Press the Service button in the main screen Select Auto Tube Unloader Push Gripper in/out (yellow background) Adjust throttles until 250/350 (ms) are reached After successful adjustment lock the counter nut
Picture 403: Gripper in/out
13.6.3 Lift up upper side/lower side

Press the Service button in the main screen Select Auto Tube Unloader Push Lift up upper side/lower side (yellow background) Adjust throttles until 600/600 (ms) are reached After successful adjustment lock the counter nut The Values always have to be equal!
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Picture 404: Lift up upper side/lower side
14 Manu Magazine Unloader

14.1 High level adjustments
14.1.1 Base Track to Sorter Shuttle
To adjust the Manu Magazine Unloader to the Sorter Shuttle do the following: Loosen check nut and check screw (see picture below). Loosen fixing screws (see picture below). Turn Adjustment Axles (use hexagonal spanner 7mm) left or right until Base Track Sorter Shuttle is in line with the Magazine Base Track and the device slides smoothly into the tube (see picture below).
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Picture 405: High level adjustment
14.1.2 Magazine to Base Track

To adjust the high level from magazine to the Base Track do the following: Remove fixing screws and support plate (see picture below). Add or remove shims . Put back support plate and fix screws.
Picture 406: Support plate
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14.2 Magazine Width Adjustment

14.2.1 Lower Center Part Adjustment
To adjust the Center parts to the Magazine do following : Loosen fixing screws Turn the adjustment screw right respectively left the center parts move closer respectively wider (see picture below). After successful adjustment tighten fixing screws. For very small Magazines remove Center parts and fix them on the inner position.
Picture 407: Center parts
14.2.2 Magazine Centering Adjustment

The position of the Center parts depends on the width of the magazine Remove fixing screw Put Center part in position as required and fix screw
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Picture 408: Centering
15 Auto Magazine Unloader

15.1 Load Stack / Back Stack
15.1.1 Stack width
To readapt Stack width to a new magazine width do following: Loosen fixing screws at Upper and Lower Stacks (see picture below) Adjust width by turning the adjustment screws After adjustment tighten fixing screws again!
Picture 409: Stack width adjustment
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15.2 Magazine Centering

15.2.1 High Level adjustment
To adjust the high level from Magazine to the Base Track do it the same way as shown in the Manu Magazine Unloader chapter.
15.2.2 Side Level adjustment

To adjust the correct alignment of magazine and Base Track do the following : Put in a magazine Loosen the four fixing screws (see picture below). Turn spring loaded adjustment screw until centering is in a correct position. Tighten fixing screws again.
Picture 410: Adjustable Centering schematic
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Picture 411: Adjustable Centering
15.3 Transport
15.3.1 Endstop Adjustment
To adjust the correct position of the Transport do following : Loosen Check Nut. Move Transport in required position. Adjust Stopper screw. After successful adjustment on load and back stack side tighten check nut.
Picture 412: Stopper left
Picture 413: Stopper right
15.3.2 Transport Width Adjustment

To adjust the width of the Center parts do it the same way as shown in the Manu Magazine Unloader chapter.
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15.3.3 Transport Speed Adjustment

To adjust the speed of the transport do the following :
Press the Service button in the main screen Select Auto Magazine Unloader Push <Transport to loadstack/backstack> (yellow background) Adjust all throttles until 800/600 (ms) are reached After successful adjustment lock the counter nut
Picture 414: Transport speed
15.4 Unloader to Sorter

15.4.1 High Level adjustment
To adjust the high level from the Base Track to the Sorter Shuttle Base Track do it the same way as shown in the Manu Magazine Unloader chapter.
15.5 Lift back stack up / down

Press the Service button in the main screen Select Auto Magazine Unloader Push <Lift back stack up/down> (yellow background) Adjust all throttles until 400/400 (ms) are reached After successful adjustment lock the counter nut
The Values always have to be equal!
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Picture 415: Lift up cylinder
15.6 Lift load stack up / down

Press the Service button in the main screen Select Auto Magazine Unloader Push <Lift load stack up/down> (yellow background) Adjust all throttles until 450/450 (ms) are reached After successful adjustment lock the counter nut The Values always have to be equal!
15.7 Pusher Adjustments

Remove Pusher Cover
Picture 416: Cover Pusher
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Picture 417: Pusher throttles Press the Service button in the main screen Select Auto Magazine Unloader Push <Pusher in/out> (yellow background) Adjust throttles until 0/230 (ms) are reached After successful adjustment lock the counter nut and mount the cover.
16 Chassis Adjustments
16.1 Adjusting Air-Pressure
Before adjusting any pressure setting, make sure that system is in STOP-status and that the HEATER is switched off! Otherwise the adjusted air pressure is not correct!
Picture 418: Pressure sensors
Picture 419: Pressure regulators
Adjusting air pressure: Pressure regulators and pressure values are used as follows:
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No: 1 2 3 Name De-Icing Heater Main-pressure Desired Values 0,2 MPa 0,2 MPa 0,5 MPa
Pull out regulator knob (see right picture above) Read adjusted pressure on corresponding pressure sensor (see left picture above) After adjustment push regulator knob back in again
The recommended Heater Pressure is 0.2 MPa. In several cases it is necessary to increase to 0.3 MPa ! Dont forget to adjust the switches (see chapter below).
16.2 Adjusting Pressure Switches

Change into SET-MODE by pressing the SET key for more than 1s On the lower display end the unit plane will be flashing
Picture 420: Pressure Switch flashing unit plane Push until the unit plane shows MPa Push SET to save selected value
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Picture 421: Pressure Switch Output mode setting Push until display shows P for positive output mode (see picture above) Push SET to save selected value Push SET for s
Picture 422: P1 set display You should see a screen similar to picture above Set P1 value by pressing (for correct values see table below)
Pressure Switch (No.) De-Ice (1) Heater (2) Main Pressure (3)
P1 Value 0,10 0,10 0,40
P2 Value 0,25 0,25 0,60
Push SET to save selected value
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Picture 423: P2 set display Set P2 value by pressing (for correct values see table above) Push SET to save selected value
Data settings are completed Repeat these steps if needed for all three pressure switches
16.3 Basic Adjustment New Sensor

16.3.1 Display Color Setting
Press and hold the SET button for 2 seconds or longer Display monitor will appear as seen in the picture below Press the up down button to choose the display color.
Picture 424: Display Color setting Press the SET button to set the color and proceed to the operating mode setting.
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16.3.2 Operation Mode Setting

This mode will let you select the switch operating mode. Press up or down button .
Select Windows mode.
Picture 425: Mode setting Press the SET button to set the mode and proceed to the output type setting.
16.3.3 Output type setting

Select the normally open (no) mode by pressing up down.
Picture 426: Switch output setting Press the SET button to set the mode and proceed to the response time setting.
16.3.4 Response time setting

Select the 1280(ms) by pressing up or down button.
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Picture 427: Response time Press the SET button to set the response time to return to the measuring mode.
16.3.5 Adjusting Pressure Switches

Press the SET button in the measuring mode to display the set value. P_1 and the current set value blink alternately.
16.3.5.1 How to Set Value

To enter a value such as the one for pressure setting : Press the up and down button to change the set value. The first digit blinks.
Picture 428: 1st digit
With every push of the SET button , the next (higher) digit blinks. Press the up and down button to set the value as shown in the table below.
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Picture 429: 2nd digit Pressure Switch (No.) De-Ice (1) Heater (2) Main Pressure (3) P1 Value ,100 ,100 ,400 P2 Value ,250 ,250 ,600
Press and hold the SET button for 1 second or longer to return to the set value display. Press the SET button to display P_2 value Change values as shown in the table above
Next, H and the set value for hysteresis will be displayed alternately. Press the SET button to return to the normal measuring mode.
Press and hold the SET button for 1 second or longer to return to the set value display.
Repeat these steps if needed for all three pressure switches
16.3.6 Zero out (Zero ADJ) function

This function clears and resets the displayed value as long as the measuring pressure is within 70 digits of the atmospheric pressure. This function is effective in detecting pressure fluctuations that exceed a certain amount without being affected by the supply pressure. Press and hold the up and down buttons simultaneously to reset the display.
Release the buttons to return to the measuring mode.
16.3.7 Key lock function

This function prevents incorrect operations such as changing the set value accidentally. Press the SET button and hold for 4 seconds or longer to display the current Loc or UnL setting. Press the up and down button to select the setting and set this function with the SET button. Use the Loc mode to avoid accidental button operation. To release a key lock function, press the SET button and hold for 4 seconds or longer to display the current setting, and select the UnL mode.
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17 Kit and Module exchange

17.1 Manu Tube Loader
17.1.1 Mounting the Manu Tube Loader to the Handler
Switch off Handler Power ! Loose fixing screws and remove cover.
Picture 430: Cover front
Picture 431: Cover back
Fix the Loader on the Top plate
Picture 432: Fixing screw outer
Picture 433: Fixing screw inner
Fix the Loader on the Chamber block
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Picture 434: Fixing screw chamber block (view from backside)
Connect Air pressure hose and Power supply cable. Mount cover again.
17.1.2
Kit exchange
17.1.2.1 Remove Track
Use the screws as described in the pictures !
If you want to change the present Kit proceed like shown (see pictures below). Loosen the screws at the backside. Remove the Cylinder Block just a little bit (~5mm). Remove the Track Clearer.
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Picture 435: backside screws
Remove the tube holder.
Picture 436: Tube Holder
Remove both singulator blocks.
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Picture 437: Singulator remove
Remove all track holder screws and remove the track.
Picture 438: Lower Track screws
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Picture 439: Upper Track screws
17.1.2.2 Install the new Track

To install the new Kit go the remove steps in same order back.
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17.2 Auto Tube Loader

17.2.1 Mounting the Auto Tube Loader to the Handler

To mount or dismount the Loader Module it is recommended that 2 people work together
Switch off Handler Power !
17.2.1.1 Fixing Points

Use the screws as described in the pictures ! Remove the cover from the Auto Tube Loader.
Picture 440: Cover screws
Picture 441: Cover screws backside
Fix the loader on the top plate of the Handler.
Picture 442: Outer fixing screw
Picture 443: Inner fixing screw
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Picture 444: Outer front fixing screw
View from backside Fix the loader on the Chamber Block
Picture 445: Chamber Block fixing
17.2.1.2 Power Supply

Plug on the violet CAN- Cable from Handler to Loader and reverse. Connect 24V Cable. Connect air pressure hose.
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Picture 446: Supply Interface
Mount the cover on the loader again.
17.2.2
Kit exchange
Proceed the same way as shown in the Manu Tube Loader chapter.
17.2.3
Auto Tube Loader Stopper Blade
17.2.3.1 Kit remove

If you want to change the present Kit proceed like shown (see pictures below)
Remove the Track clearer.
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Picture 447: Trackclearer
Remove both Singulator blocks.
Picture 448: Singulator stopper block
Picture 449: Singulator stopper block
Remove tapper pin holder (view from backside)
Picture 450: Tapper pin holder
To remove the track loosen the fixing screws of the track clamps and move them to side.
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Picture 451: Track Clamps
Picture 452: Lower screws
17.2.3.2 Kit install

To install the new Track, go the remove steps in the same order back.
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17.3 Bowl Loader (SOT)

17.3.1 Mounting the Bowl Loader (SOT) to the Handler

To mount or dismount the Bowl Loader it is recommended that 2 people work together !
Switch Handler Power off !

Remove the Cover.
Picture 453: Cover screws top
Picture 454: Cover screws back
Fix the Bowl Loader on the handler top plate
Picture 455: Inner fixing screw
Picture 456: Outer fixing screw
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Picture 457: Outer fixing screw (front)
Chamber Block fixing
Picture 458: Outer fixing screw (front)

Plug on the violet CAN- Cable from Handler to Loader and reverse. Connect 24V Cable. Connect 230V Cable. Connect air pressure hose.
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Picture 459: Supply Interface
Mount the cover on the loader again.
17.3.2
Kit exchange

If you want to change the present Kit proceed like shown (see pictures below) Remove the two throttles first. Take off the Cover. Remove all screws.
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Picture 461: Base Track Turn 180 redesign
Don `t lose the shims under the top guiding ! Remove throttle.
Picture 462: Transit to bowl

To install the new Track go the remove steps in same order back
17.4 Bowl Loader (QFN)

17.4.1
2008.Sep.22
Mounting the Bowl Loader (QFN) to the Handler

Proceed the same way as shown in the <Mounting the Bowl Loader (SOT) on the Handler> chapter.
Rasco
17.4.2
Kit exchange
17.4.2.1 Remove track

If you want to change the present Kit proceed like shown (see pictures below) First remove all air jets, throttles and stoppers.
Picture 463: Air jets and stoppers Pull out the air hose of the throttle. Remove the flip check sensor holder. Remove the three throttles. Remove the track from the bowl.
Picture 464: Track on bowl Remove fixing screws of the track
Picture 465: Track on bowl (redesign)
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Picture 466: Transit Track to Bowl
Picture 467: Stiffening fixing
Picture 468: Turn 90 exit Track
Picture 469: Turn 90 Track
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Picture 470: Turn 180 and Flipper Track
Picture 471: Flipper Exit
17.4.2.2 Install the new Kit

To install the new Tack go the remove steps in same order back
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17.5 Auto Magazine Loader

17.5.1 Mounting the Magazine Loader to the Handler

To mount or dismount the Magazine Loader it is recommended that 2 people work together !
Switch Handler Power off !

Remove both Covers of the Loader
Picture 472: Cover screws backside
Picture 473: Cover screws front
Fix the loader on the handler top plate.
Picture 474: Fixing screws middle
Fix screws on the outer side plates (left and right)
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Picture 475: Outer fixing screws
Picture 476: Outer fixing screws (back)
Fixing on Chamber Blocks. Use a shorted allen key !
Picture 477: Fixing screws Chamber
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Picture 478: Left Interface
Adjustments and Maintenance Picture 479: Right Interface
Mount covers again.
17.5.2
Kit exchange
17.5.2.1 Remove Kit

If you want to change the present Kit proceed like shown.
17.5.2.1.1 Singulator Kit Loosen fixing screws and remove Singulator Holder. Remove Light Sensor Holder Loosen fixing screws and remove Track clearer.
Picture 480: Singulator area Loosen screws and remove kit.
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Picture 481: Singulator kit 17.5.2.1.2 Shuttle Kit
To exchange the shuttle kit remove Stopper (see picture below). Loosen Base Track screws and remove kit.
Picture 482: Shuttle kit
17.5.2.2 Flipper Kit

Loosen Base Track screws and remove kit.
. Picture 483: Flipper kit 17.5.2.2.1 Flipper Exit Kit Remove Air jet. Loosen fixing screws and remove kit.
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Picture 484: Flipper exit kit 17.5.2.2.2 Turn and Turn exit Kit Loosen all fixing screws and remove turn and turn exit kit.
Picture 485: Turn & Turn exit kit
17.5.2.3 Install new Kit

To install the new Kit go the remove steps in the same order back
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17.6 Chamber
17.6.1 Kit exchange

If you want to change the present Kit proceed like shown (see pictures below) The Handler is switched off and the Plunger is removed. Loosen the screws and take off the clamps.
Picture 486: Track (Top)
Remove cylinder hoses. Remove screws. Remove lower Chamber door.
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Picture 487: Lower Chamber door
Remove Centerpart the redesigned centerpart is fixed from the backside.
Picture 488: Centerpart Remove the Singulator Block careful out of the Chamber
Picture 489: Singulator
Remove fixing screws . Remove the tapper plate just a few mm.
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Picture 490: Singulator Tapper Remove Singulator Blocks. Remove the track clamps . Tilt the Track a little bit and pull it out.
Picture 491: Track (Lower)

To install the new Kit go the remove steps in the same order back
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17.7 Plunger (Belly Bar)

17.7.1.1 Exchange of plunger guidings
Remove old guidings, using an allen wrench
Picture 492: Plunger guiding Insert new guiding
17.7.2
Exchange of plunger
For exchanging plunger:
Make sure that air pressure is switched off!! Loosen fixing screws for pneumatic manifold (see picture below)
Picture 493: Pneumatic manifold Take off manifold
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Unplug ribbon cable plug (see picture below)
Picture 494: Ribbon cable plug Pull out plunger upwards Insert new plunger Plug in ribbon cable plug (see picture above) Put on pneumatic manifold and tighten fixing screws (see picture: Pneumatic manifold) Switch on air pressure again!!
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17.8 Plunger (RPTB)

17.8.1 Plunger Exchange
For exchanging instructions see Plunger Belly Bar chapter.
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17.9 Sorter
17.9.1
Kit exchange
Loosen the fixing screws of the track clamps (see picture below)
Picture 495: Track holder screws Remove lower Air Jet and loosen the fixing screw of the holder (see picture below)
Picture 496: Lower Air Jet and Holder screws
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Adjustments and Maintenance Loosen fixing screws of the Track and the Turn (see picture below)
Picture 497: Lower Track and Turn screws Remove the Air Jet Dont lose this special screws Loosen the fixing screws of the Track (see picture below)
Picture 498: Shuttle and Air Jet screws
17.9.1.2 Install new Track

To install the new Track go the remove steps in the same order back
For fixing the new exit track press first the lower pin in and after them the upper pin (chamber) !
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The gaps of the turn guiding should be 1mm to the exit guiding and 1.5mm to the shuttle guiding.
Picture 499: Guiding gaps
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17.10 Tape & Reel

17.10.1 Basic Adjustments
17.10.1.1 Mounting the Taper to the Handler
17.10.1.1.1 Screws to mount the taper
To mount or dismount the Taper Module it is recommended that 2 people work together (weight ~60kg)
Picture 500: Mounting screw Taper Sorter side Place the taper properly on the chassis, insert the guide pin, and fix it with the screws.
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Picture 501: Mounting screw Taper Chassis side Remove the lower rear cover from the Handler chassis an fix the Taper Insert the screws for the chassis side and tighten the screw
Picture 502: Mounting screw Taper-Chassis front Insert the screws into the chassis step and tighten the screw
17.10.1.1.2 Track Adjustment Taper to Sorter

Turn the adjusting screw as far as the Track from the Sorter fit to the Track from the Tape & Reel After successful adjusting tighten the counter nut.
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Picture 503: Track adjustment Taper to Sorter
17.10.1.1.3 Connecting the I/O Cables
Picture 504: Chassis interface for Unloader modules
Check if all cables are fixes properly and mount the cover again!
17.10.2
17.10.2.1
Kit exchange
Remove Kit
If you want to change your kit do following steps : Pull the knob and lift the camera up until the knob snap in again.
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Picture 505: Lift camera Put the fixing screws out and remove the air jet and stopper holder.
Picture 506: Air jet holder
Picture 507: Stopper holder
Remove all fixing screws and put out the lead inspection track
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Picture 508: Track lead inspection Remove all fixing screws and put out mark inspection track.
Picture 509: Track mark inspection Remove fixing screws and put out the base track.
Picture 510: Base track SI First remove screws of the side guiding centering and after the put out the side guiding. Remove screws of the base track centering and put them out. Do not lose the shims under the side guiding centering !
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Picture 511: Centering Remove fixing screws and put out the turn 180 base track
17.10.2.2
Install Kit
To install the new kit go the remove steps in same order back.
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17.11 Auto Tube Unloader

17.11.1 Mounting the Auto Tube Unloader to the Handler
Switch off Handler Power ! Fix the Exit ledge on the Sorter
See chapter <Unloader to Sorter Distance level compensation> in the Common Adjustments !
Picture 513: Sorter side
Remove I/O Cover of the Chassis. Connect air hose and I/O cables.
Picture 514: Chassis Interface
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After connecting replace cover
17.11.1.1
Fixing Points
Picture 515: Fixing points
Picture 516: Fixing screw high level
Picture 517: Support block
17.11.2 Kit Exchange

To exchange the Kit of the Buffered Auto Tube Unloader do the following steps : Remove the Air Jet. Remove the Track clearer.
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Picture 518: Track clearer and Air jet
Remove screws (see picture below).
Picture 519: Base Track fixing screws
Install new Kit in reverse order.
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17.12 Manu Magazine Unloader

Remove screws as shown in picture below Remove Kit Put in new Kit and fix screws
Picture 520: Base Track
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17.13 Auto Magazine Unloader

17.13.1 Mounting the Auto Magazine Unloader to the Handler
Switch off Handler power ! Connect Cables and air hose
Picture 521: I/O Interface
Fix the Magazine Unloader on the Sorter and on the Chassis plate.
Picture 522: Fixing points
Fix the Stiffening left and right
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Picture 523: Fixing screws

To exchange the Kit do the following steps : Remove fixing screws. Remove Centering. Remove Track clearer.
Picture 524: Track clearer
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Picture 525: Fixing screws
Install the new Kit in reverse order.
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18 Preventive Maintenance Checklist

18.1 Maintenance Activities
Highlighted Tasks are also included in the OPI software !
18.1.1 Common
Device Count Interval (mill.)
Time Interval (Month)
Check all stopper pins for wear and tear. Empty and clean all vacuum cleaner.
3 3
18.1.2 Tube Loader

18.1.2.1 Loader Tube Singulator

Check for wear and tear on tube singulator assembly.
Check and adjust tube singulator and cylinder speed. Check and adjust tube detection sensor. Check and adjust tube in transport sensor.
3 3 3 3
18.1.2.2 Gripper
Check for wear and tear on gripper assembly. Check for wear and tear on stopper blade assembly. Check and adjust gripper horizontal stop position ,cyl. speed Check and adjust gripper vertical stop position ,cyl. speed Check and adjust gripper assembly sensor. Check and clean input chamber track sensor. Check and adjust tube detection sensor. Check and adjust transit ->tube track. Operate loader/gripper with 10 empty tubes and check the function. 3 1 6 6 6 6 3 3
18.1.2.3 Loader Transport

Check for wear and tear transport assembly. Check and adjust transport assembly. Check and adjust transport stop position, cyl.speed. Check and adjust transport detection sensor. Check and adjust tube pusher. 3 6 6 6 6
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Who/Date
Remarks
Replace
Repair
Adjust
Rasco
Clean the linear guiding with alcohol Check and adjust tube in transport to tube centering
12 3
18.1.3 Magazine Loader

Check all stack sensor Check for wear and tear on swing damper. Check and adjust shuttle position and speed. Check and adjust flipper endpositions. Check and adjust swing up position and speed. Check and adjust transit light sensor. Check for wear and tear on magazine opener. Check for wear and tear on singulation unit and all hoses. Check wear and tear of all tracks. Check an adjust turn endpositions. 6 3 3 3 3 3 6 6 6 6
18.1.4 Bowl Loader (SOT/QFN)

18.1.4.1 Handling Section
Check wear and tear of all tracks. Check and adjust turn endpositions. Check silicone hose on singulator holder. Check all cylinders in manual control on function. Check level compensation at tracks. Check all stopper pins. Clean bowl dish with alcohol. Check ionizer on function and clean fan with airgun. FOR QFN : Check vacuum at 90 turn. FOR QFN : Check Flipper on function and endpositions. 6 3 3 3 6 6 6 3 3 3
18.1.4.2 Vision and Lightning

Clean bowl dish with alcohol. Check teached setting for SOT and QFN. 3 3
18.1.4.3 Bowl Feeder

Check and adjust speed frequence. Check level compensation to input track. Check and adjust airjets settings. FOR QFN : Check and teach dead bug amplifier settings 6 6 3 3
18.1.5 Handler Base

18.1.5.1 Chamber Track
Check for wear and tear on chamber track. Check and adjust soak track sensor. Check the way of the jamclearers and adjust it if necessary. 3 6 6
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18.1.5.2 Temperature System
Change fan bearing and check fan wheel assembly Jam rate at ambient +25C (1 jam/3k devices). Calibrate at the requested cold temperature. Check Jam rate at cold (1 jam/3k devices). Calibrate at the requested hot temperature. Jam rate at hot +160C (1 jam/3k devices).
After 100 Days 6 12 6 12 6
18.1.5.3 Singulator
Check for wear and tear on holder-,stopper-pin and silicone hose. Check and adjust the `device in singulator` sensor. 3 3
18.1.5.4 Plunger
Check for wear and tear on the plunger tracks. Check for wear and tear on the plunger head assembly. Check level compensation of all plunger device guidings. Check and adjust sensor in plunger assembly. Check and service vacuum assembly. Check and service vacuum sensor. Check and adjust pin 1 position. Check and clean lead support for wear and damage. Check and adjust plunger speed. Check ESD grounding on wear and tear. Check vacuum hoses 3 3 6 3 3 3 3 3 3 6 3
18.1.5.5 Contactor
Verify the contacts. 3
18.1.5.6 Front
Check for wear and tear on the plunger arm plunger centering. Check for wear and tear chamber door sealings and movement. Check movement of singulator cyl. 3 4 3
18.1.6 Sorter
18.1.6.1 Turn
Check for wear and tear on turn track. Check for wear and tear on turn stopper. Check and adjust turn sensor Check and adjust transit post cs > turn, L&R. Check and adjust transit turn > shuttle, L&R. 3 3 6 3 3
18.1.6.2 Shuttle
Check for wear and tear on sort shuttle track. 3
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Check for wear and tear on sort shuttle stopper. Clean the linear bearing with alcohol. Check and adjust transit airjets. Check and adjust belt tension. Check and adjust all sort shuttle stop positions, 16x (teaching). Clean whole area with vacuum cleaner.
3 6 3 3 6 3
18.1.7 Unloader
18.1.7.1 Tube Unloader
Check for wear and tear on auto tube unloader track. Check for wear and tear on auto tube unloader stopper. Check and adjust side guidings. Check and adjust track sensor. Check and adjust transit track > tube. 3 3 3 3 3
18.1.7.2 Stack
Check and adjust stack sensor. 6
18.1.7.3 Transport
Check for wear and tear on transport assembly. Check and adjust transport assembly. Check and adjust transport stop position and cyl. speed. Check and adjust tube pusher. 3 3 3 6
18.1.8 Manu Tube Unloader

Check and adjust sensor. Check for wear and tear on track. 6 6
18.1.9 Manu Magazine Unloader

Check and adjust transport speed and position. Check of wear, tear and movement of the trackclearer. Check for wear and tear of light sensor cables. Check for wear and tear at buffer track. 3 3 3 3
18.1.10 Unloader General

Check and adjust all jam clearer airjets. Check and adjust all accelerator airjets. 12 12
18.1.11 Tape & Reel

18.1.11.1 Handling Section
3 3 Check and adjust sideguiding settings at centering. Check for wear and tear for all stoppers.
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Check and adjust turn endpositions. Check for wear and tear all tracks. Check for wear and tear all ground wires and grounding spring at pick up. Check and adjust all transit sensors. Check and adjust manu exit endpositions.
3 3 3 3 6
18.1.11.2

Taping section
6 6 6 6 6 6 6
Check and adjust belt tension at indexer. Check function of auto tape cutter. Check for a smooth movement of tape in taperline. Check bulb of the servivelamp. Check and adjust speed of carriertape motor. Clean all rollers with alcohol. Clean linear guiding at carrier tape tension roller with alcohol.
18.1.11.3

Pick up
3 1 1 3 3 3 6
Check and adjust stoppers at centering and pick up alignment. Check for wear and tear all damper. Check for wear and tear vacuum chuck and vacuum setting. Check for wear and tear for a smooth 90 turn motion. Clean 90 turn throttles. Clean linear guiding with alcohol. Check for wear and tear pick up hardstops (ppek cups),2x.
18.1.11.4

Sealer Unit
6 6 6 0.3 3
Check and fix sealer knob. Check for wear and tear at cabeling of sealer Check for wear and tear of sealer shoe surface. Clean the sealer shoe. Check for wear and tear at damper.
18.1.11.5

Vision System
3 3
Clean all mirrors and windows, use the RASCO Cleaning Set. Clean all filters (camera and PC`s) with air gun. Check and adjust lenses and optics. Delete old vision jobs, like projects and pictures. Check for wear and tear all vision PC fan`s. Check for software updates. Backup all settings on floppydisk.
18.1.12 General
Verify the main pressure regulator during run. Verify the heater pressure regulator during run. Verify the deicing pressure regulator during run. Drain water drop as necessary. Check air filters and clean as necessary.
3 3 3 1 3
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Check all pressure sensor, using manual control screen. Check bin mapping. Check function of the bulbs of the signal tower. Check start/stop led indicator. Check if air hoses are in fittings properly and for loose fittings. Check LS amplifiers for archived sensitivity. Check sealing at front, contactor, chamber plugs and exchange if damaged. Check all wires for wear, kinks and integrity. Clean all sensors with air gun and alcohol. Clean all tracks with air gun and alcohol. Check all air hoses for wear, kinks, and integrity
6 3 6 3 6 3 3 3 6 3 3
18.1.13 Complete ESD Checks, Measure and Record Data

Fix Parts (like : Tracks, Baseplate , e.g.) <10 Ohms
Moving Parts <1K Ohms (like : Turn, Shuttle, Pick up, Plungerhead, e.g.) Check every ground wire Check Banana Plug <1M Ohm
Notes :
2008.Sep.22
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Adjustments and Maintenance SO2000

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SO2000

Adjustments and Maintenance

Adjustments and Maintenance

Adjustments and Maintenance

Adjustments and Maintenance

Adjustments and Maintenance

Adjustments and Maintenance

Adjustments and Maintenance

Adjustments and Maintenance

Adjustments and Maintenance

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

1.1 Fiber optic amplifier

Sensitivity should be lower than 6!

1.2 Connection of the fiber optic

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

1.3 Vacuum Sensor Adjustment

Picture 2: Vacuum Sensor

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

1.4 Cylinder reed sensor adjustment

1.5 Singulator Tapper Adjustment

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

Picture 4: Singulator Tapper

1.6 Stroke Limitation of Singulator Holder

Picture 5: Stroke Limitation

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

Picture 6: Stroke Limitation scematic

1.7 Unloader to Sorter Distance Level Compensation

Picture 7: Docking Shim Schematic

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

Picture 8: Docking Shim

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

Manu Tube Loader

Picture 9: Gripper tilt angle

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

2.1.2 Tube Centering Gripper

Picture 11: Tube Centering adjustment Gripper

2.1.3 Gripper placement

2.1.3.1 Right/Left placement Tube to Track

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

Picture 12: right/ left positioning Gripper

2.1.3.2 Front/back placement Tube to Track

Picture 13: front/back positioning Gripper

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

Picture 14: Singulator fixing screws

Reworked Singulator Design

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

Picture 16: Adjustment mark

Picture 17: adjustment schematic

2.2.1 Stroke Limitation of Singulator Holder

Adjustments And Maintenance SO2000.Doc

Adjustments and Maintenance

Auto Tube Loader

3.1 Input Stack